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MTU 8 V 4000 M40A, Operating Instructions Manual

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MTU 8 V 4000 M40A Operating Instructions Manual Download Page 163

Abbrevia‐

tion

Meaning

Explanation

LOLO

Low Low

Alarm: Measured value lower than 2nd minimum

limit value

LOP

Local Operating Panel

Control console, control panel

LOS

Local Operating Station

MCS

Monitoring and Control System

MCU

Management Computer Unit

Computer for control stand, 19"/9.5" unit size

MG

Message

MPU

Microprocessor Unit, Microprocessing

Unit

OT

Oberer Totpunkt

Top Dead Center (TDC)

P-xyz

Pressure-xyz

Pressure measuring point xyz

PAN

Panel

Control panel

PIM

Peripheral Interface Module

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

Safety system alarm

SSK

Schnellschlussklappe(n)

German designation for shutdown air flaps

T-xyz

Temperature-xyz

Temperature measuring point xyz

TD

Transmitter Deviation

Alarm: Deviation in transmitter values

UT

Unterer Totpunkt

Bottom Dead Center (BDC)

WZK

Werkzeugkatalog

Tool Catalog (TC)

MS15021/01E 2012-02 | Appendix A | 163

TIM-ID: 0000002048 - 003

Summary of Contents for 8 V 4000 M40A

Page 1: ...Operating Instructions Diesel engine 8 V 4000 M40A 8 V 4000 M40B Application group 3B MS15021 01E...

Page 2: ...ten 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 on...

Page 3: ...fter extended out of service periods 3 weeks 58 4 5 Checks prior to start up 59 4 6 Fuel treatment system Putting into operation 60 4 7 Engine Starting 62 4 8 Fuel treatment system Switching on 63 4 9...

Page 4: ...gine coolant Filling 132 7 16 6 Engine coolant pump Relief bore check 135 7 16 7 Engine coolant Sample extraction and analysis 136 7 17 Raw Water Pump with Connections 137 7 17 1 Raw water pump Relief...

Page 5: ...it on delivery Any 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 alo...

Page 6: ...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 r...

Page 7: ...l or use a means of transportation which is appropriate for the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans por...

Page 8: ...instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be installed 4 Always use the screws supplied with or installed in the...

Page 9: ...the flywheel only not the ring gear 4 Install screws 4 into the bores of retainers 1 until the retainers 1 are locked in position 5 Tighten screws 4 alternately with torque wrench to the specified tig...

Page 10: ...ays use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine 1 Install engine mounting brackets 2 on both sides with guard plates 1 w...

Page 11: ...ing units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must be taken if a malfunction of the system...

Page 12: ...ry danger to life Allow the engine to cool down before opening the crankcase Avoid open flames electrical sparks and ignition sources Safety instructions u Before starting maintenance work allow the e...

Page 13: ...ions clean Always seal connections with caps or covers if a line is removed or opened Take care not to damage lines in particular fuel lines during maintenance and repair work Ensure that all retainer...

Page 14: ...haft end until correct sealing is established During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working on ele...

Page 15: ...used Laser devices of classes 1 2 or 3A Laser devices of class 3B which have maximum output in the visible wavelength range 400 to 700 nm a maximum output of 5 mW and in which the beam axis and surfac...

Page 16: ...n of additional compo nents as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations Emission control units...

Page 17: ...air is air compressed at excess pressure and is stored in tanks from which it can be extract ed The pressure at which the air is kept can be read off at pressure gauges which must be connected to the...

Page 18: ...Used oil Used oil may contain health threatening combustion residues Rub barrier cream into hands Wash hands after contact with used oil 18 Safety MS15021 01E 2012 02 TIM ID 0000002828 004...

Page 19: ...ion involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety warnings in accordance...

Page 20: ...designated A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end Other components are numbered in the same way...

Page 21: ...oolant absolute gas tightness Turbocharging Sequential turbocharging with internal engine coolant controlled charge air cooling The right hand ex haust turbocharger is cut in and cut out with electron...

Page 22: ...d ship side monitoring Electronic Gear Control Unit GCU ship side wall mounting Functions Data processing logistics for gear coupling control Input output signals as well as data transfer to CAN field...

Page 23: ...ne 2 Fuel line on fuel delivery pump 3 Non return valve 4 Sealing cone 5 Fuel line on HP fuel pump 6 Fuel line on vent line All lines with SOLAS compliant covers for pipe connections according to MTU...

Page 24: ...line on control block 8 Oil line on control block 9 Oil lines on T piece 10 Oil line valve housing 11 Oil line actuating cylinder to control block 12 Oil line actuating cylinder to control block 13 C...

Page 25: ...significantly if an O ring 3 defect oc curs The connection is confirmed as compliant with SOLAS by DNV and GL Plugs and sensors Screw in plugs 4 are sealed toward the outside either with a copper seal...

Page 26: ...connection 19 Union nut 20 Thrust ring The HP fuel line is sealed by the thrust ring 9 If leakage in the area of the thrust ring 9 or the HP line 2 occurs the emerging fuel is routed to the leakage ch...

Page 27: ...synthetic ring Shielding by overhang design The synthetic ring 1 or the overhang 2 prevents lateral spray The fluid is diverted to the catch basin whereby the pressure is significantly reduced MS1502...

Page 28: ...pply en gine related 22 Drive systems driving end and free end cou pling 23 Equipment carrier 24 Engine coolant pump 25 Charge air line 26 Mounting support 27 Starting equipment 28 Flywheel housing 29...

Page 29: ...tempera ture 7 B06 coolant tempera ture 8 Injector Y39 14 cylinder B4 9 Injector Y39 13 cylinder B3 10 Injector Y39 12 cylinder B2 11 Injector Y39 11 cylinder B1 12 B44 2 turbocharger speed B side 13...

Page 30: ...oil tempera ture 5 B05 lube oil pressure 6 B50 crankcase pressure 7 B4 4 exhaust tempera ture cylinder A4 8 B4 3 exhaust tempera ture cylinder A3 9 B4 2 exhaust tempera ture cylinder A2 10 B4 1 exhau...

Page 31: ...oil pressure 2 B01 camshaft speed 3 Sensor B34 fuel pres sure after filter 4 B33 fuel temperature in common rail 5 B48 fuel pressure in common rail MS15021 01E 2012 02 General Information 31 TIM ID 00...

Page 32: ...r B1 2 B4 12 exhaust tempera ture cylinder B2 3 B4 13 exhaust tempera ture cylinder B3 4 B4 14 exhaust tempera ture cylinder B4 5 B16 coolant pressure 6 F33 coolant level 32 General Information MS1502...

Page 33: ...k tem perature A side 2 B49 T charge air air re circulation valve 3 B4 22 exhaust bulk tem perature B side 4 B13 crankshaft speed 5 B13 2 crankshaft speed MS15021 01E 2012 02 General Information 33 TI...

Page 34: ...rature C 25 Raw water inlet temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders...

Page 35: ...o R bar 5 3 Lube oil operating pressure low idle meas point before engine R bar 2 0 FUEL SYSTEM Number of cylinders 8 Fuel pressure at supply connection to engine min when engine is starting L bar 0 1...

Page 36: ...110 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 140 WEIGHTS MAIN DIMENSIONS Number of cylinders 8 Engine dry weight with attached standard acc...

Page 37: ...erature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1500...

Page 38: ...to engine min when engine is run ning L bar 0 3 Fuel pressure at supply connection to engine max when engine is start ing L bar 1 5 Fuel supply flow max R Liters min 13 8 GENERAL OPERATING DATA Number...

Page 39: ...NS Number of cylinders 8 Engine dry weight with attached standard accessories without coupling R kg 4430 ACOUSTICS Number of cylinders 8 Exhaust noise unsilenced BL free field sound pressure level Lp...

Page 40: ...erature C 32 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1500...

Page 41: ...to engine min when engine is run ning L bar 0 3 Fuel pressure at supply connection to engine max when engine is start ing L bar 1 5 Fuel supply flow max R Liters min 13 8 GENERAL OPERATING DATA Number...

Page 42: ...NS Number of cylinders 8 Engine dry weight with attached standard accessories without coupling R kg 4430 ACOUSTICS Number of cylinders 8 Exhaust noise unsilenced BL free field sound pressure level Lp...

Page 43: ...rature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1800 C...

Page 44: ...rating pressure low idle meas point before engine R bar 2 0 FUEL SYSTEM Number of cylinders 8 Fuel pressure at supply connection to engine min when engine is starting L bar 0 1 Fuel pressure at supply...

Page 45: ...110 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 140 WEIGHTS MAIN DIMENSIONS Number of cylinders 8 Engine dry weight with attached standard acc...

Page 46: ...rature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1800 C...

Page 47: ...to engine min when engine is run ning L bar 0 3 Fuel pressure at supply connection to engine max when engine is start ing L bar 1 5 Fuel supply flow max R Liters min 14 8 GENERAL OPERATING DATA Number...

Page 48: ...NS Number of cylinders 8 Engine dry weight with attached standard accessories without coupling R kg 4430 ACOUSTICS Number of cylinders 8 Exhaust noise unsilenced BL free field sound pressure level Lp...

Page 49: ...rature C 32 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1800 C...

Page 50: ...to engine min when engine is run ning L bar 0 3 Fuel pressure at supply connection to engine max when engine is start ing L bar 1 5 Fuel supply flow max R Liters min 14 8 GENERAL OPERATING DATA Number...

Page 51: ...NS Number of cylinders 8 Engine dry weight with attached standard accessories without coupling R kg 4430 ACOUSTICS Number of cylinders 8 Exhaust noise unsilenced BL free field sound pressure level Lp...

Page 52: ...ng order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 52 T...

Page 53: ...idth B Height C 8 V 4000 M40 50 A B approx 2340 mm approx 1380 mm approx 1990 mm 12 V 4000 M40 50 A B approx 3220 mm approx 1520 mm approx 1835 mm 16 V 4000 M40 50 A B approx 3690 mm approx 1520 mm ap...

Page 54: ...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 key a second time acknowledges an active alarm...

Page 55: ...between 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 key switches between local operation an...

Page 56: ...lter Fill with fuel Page 111 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 107 Fuel system Vent Page 103 Raw water pump if raw water pump lies above t...

Page 57: ...lant circuit Check coolant level Page 129 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water Page 108 Check if suction side pressure indicated at the fuel pref...

Page 58: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 60 2 Shut down fuel treatment system Page 68 58...

Page 59: ...ves 4 Switch on fuel treatment system Page 63 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Page 60: ...ine 3 Switch on fuel treatment system and operate it for some minutes Page 63 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 61: ...ency HAT 1 Switch on fuel treatment system Page 63 2 Start engine Page 62 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel vi...

Page 62: ...m LOP Item Measure Engine Start in unloaded condition System Switch on LOP LOCAL OPERATION button is illuminated brightly local operating mode is active Page 54 LOP Press illuminated pushbutton READY...

Page 63: ...hing on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Switching on fuel treatment system 1 Carry out checks prior to start up...

Page 64: ...arge and for dirt Page 96 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter pressure gauge is within the limit Page 107 Drain water and contaminants Page 108 Exhaust system...

Page 65: ...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 spee...

Page 66: ...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 fr...

Page 67: ...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 free...

Page 68: ...binet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 69: ...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...

Page 70: ...fitted Page 64 W0508 Check reading on differential pressure gauge of fuel prefilter if fitted Page 64 W1001 Replace fuel filter or fuel filter element Page 105 W1002 Check valve clearance Page 90 W100...

Page 71: ...d with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry run ning the motor protection relay triggers and the pump is switch ed off u R...

Page 72: ...Measure Starter Poor rotation by starter Battery dis charged or faulty Charge or replace battery see manu facturer s documentation Engine wiring Faulty Check Page 149 Fuel system Air in fuel system V...

Page 73: ...n of contami nation indicator Page 116 Intercooler Contaminated Contact Service Exhaust turbocharger Faulty Contact Service Coolant leaks at intercooler Component Cause Measure Intercooler Leaking maj...

Page 74: ...operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter Page 108 Intercooler Leaking Contact Service 74 Tro...

Page 75: ...3 5 Check engine wiring Page 149 AL Shutdown Expect ed Yellow alarm occurred Red alarm with engine shutdown will probably follow 1 Start other genset as preventive measure 2 Determine cause of yellow...

Page 76: ...ced if required AL Water in Fuel Pre filter Water in fuel prefilter Drain fuel prefilter Page 108 DL 211 A001 A001 DIS not recognized on default bus 1 Check LOP visually Page 157 2 Perform LOP test pr...

Page 77: ...ns and fulfill if nec essary RL 211 A001 A001 DIS not recognized on redundant bus 1 Check LOP visually Page 157 2 Perform LOP test procedures Page 160 3 Contact Service Have DIS checked and re placed...

Page 78: ...CU Safety system detects that engine oil pressure is too low 1 Check lube oil level and top up if required Page 120 2 Contact Service SS P Lube Oil EMU Safety system detects that engine oil pressure i...

Page 79: ...ked and re placed if required TD T Coolant The two coolant temperature sensors provide different values 1 Check LOP visually Page 157 2 Perform LOP test procedures Page 160 3 Check ECU plug in connect...

Page 80: ...ry Danger to life Before barring the engine ensure that nobody is in the danger zone Engine Barring manually 1 Remove guard plate 2 Engage barring device 2 with ring gear 3 and install on flywheel hou...

Page 81: ...ngine Engine cranking on starter 1 Disengage the bayonet union nut 4 of connector X4 with connector pliers 2 and withdraw connector 3 from Engine Control Unit 2 Bar engine in unloaded condition Press...

Page 82: ...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...

Page 83: ...Final steps 1 Install injector Page 98 2 Install cylinder head cover Page 95 MS15021 01E 2012 02 Task Description 83 TIM ID 0000000015 013...

Page 84: ...Smoothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Bright area Bright areas are on the running surface and show local removal of the honing...

Page 85: ...tion starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the pis ton skirt or the piston crown Material deposits on th...

Page 86: ...Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do...

Page 87: ...oil separator elements in the same way Checking diaphragm variant B 1 Remove cover 4 2 Remove spring 5 gasket 2 and dia phragm 3 3 Check diaphragm 3 for damage fit new diaphragm if used one is damage...

Page 88: ...s 5 and spacer sleeves 6 3 Loosen clamp 8 remove guide sleeve 9 from oil separator by turning it 4 Coat O ring in the new oil separator with denatured ethanol 5 Press guide sleeve into new oil separat...

Page 89: ...cylinder head covers Page 95 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjust ing screws with oil 4 Install cylinder head covers Page 95 Lubricating valve g...

Page 90: ...Part No Qty Feeler gauge Y20010128 1 Torque wrench 10 60 Nm F30510423 1 Torque wrench 60 320 Nm F30047446 1 Ring socket wrench F30039518 1 Preparatory steps 1 Remove cylinder head cover Page 95 2 Ins...

Page 91: ...idge Note Not applicable for engines with flying valve bridge 1 Prior to adjusting valve clearance check valve bridge balance on all valve bridges 2 Use feeler gauge to determine distance be tween val...

Page 92: ...with open end wrench and release locknut 2 2 Use feeler gauge to determine distance be tween valve bridge and rocker arm 3 Place one feeler gauge of the determined value each between valve bridge and...

Page 93: ...h open end wrench 8 Recheck valve bridge balance Checking valve clearance at two crankshaft positions Item Explanation 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Ex...

Page 94: ...distance between valve bridge and rocker arm 5 If the deviation from the set value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release locknut 1 2 Insert feeler gauge between va...

Page 95: ...r head cover 1 Clean cylinder head covers prior to removal if they are heavily soiled 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1 Clean...

Page 96: ...ors HP pump Relief bore check 1 Check relief bore for oil and fuel discharge by visual inspection 2 If relief bore is contaminated stop the en gine disable engine start and clean relief bore 3 Note th...

Page 97: ...tor Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 98 MS15021 01E 2012 02 Ta...

Page 98: ...e T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00058060 1 Engine oil WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke...

Page 99: ...ne side is completed 1 Undo cable terminal screws arrow on in jector and remove cable terminals 2 Remove screw 2 and take off hold down clamp 1 3 Remove high pressure fuel line 5 4 Install installatio...

Page 100: ...h assembly paste 3 Fit new O rings on injector and coat with grease 4 Fit new sealing ring on injector with grease ensuring correct installation position of seal ing ring 5 Clean sealing surface on cy...

Page 101: ...nch to the specified initial tightening torque Name Size Type Lubricant Value Standard Screw M12 Preload torque Engine oil 5 Nm to 10 Nm 13 Fit O rings 4 and 6 on high pressure fuel line 5 and coat wi...

Page 102: ...ue wrench Name Size Type Lubricant Value Standard Union nut Tightening torque 120 Nm 10 Nm 18 Twist cable several times 19 Insert cable terminals arrows underneath screws on injector and tighten screw...

Page 103: ...nd explosion Avoid open flames electrical sparks and ignition sources Do not smoke Venting and filling LP fuel system 1 Connect filling device to connection 2 2 Open vent plugs 6 on filter 5 3 Use han...

Page 104: ...must be provided 6 Fill fuel system with hand pump providing 9 bar minimum pressure 7 If no whistling sound is audible pump must be operated faster 8 Filling is completed if Whistling noise is no mor...

Page 105: ...y 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 WARNI...

Page 106: ...uel filters in the same way 9 Vent fuel system Page 103 Replacing fuel filter with the engine running 1 Cut out the filter to be replaced 2 Open threaded vent plugs at filter head of cut out filter an...

Page 107: ...n installing the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Check differential pressure Checking differential pressure of fuel prefilter 1...

Page 108: ...drained I Left filter cut in II Right filter cut in 2 Open threaded vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from filter...

Page 109: ...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...

Page 110: ...alve 6 Fuel prefilter Topping up with fuel 1 Stop engine Page 65 and disable engine start 2 Remove screws for cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cov...

Page 111: ...Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smok...

Page 112: ...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 gasket in cover 2 11 Fit cover with gasket and s...

Page 113: ...line for coolant discharge and obstruction 1 With the engine running verify that air emerges from the condensate drain line at driving end left and right engine side If no air emerges 2 Remove condens...

Page 114: ...re parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 115 2 Reset signal ring of contamination indicator...

Page 115: ...stallation 1 Release 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 fil...

Page 116: ...sabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 114 2 After installation of new filter press reset button 1 Result Engag...

Page 117: ...g disabled Checking air flap for easy movement 1 Actuate lever several times to check ease of movement Result The spring must push back the air flap 2 If spring does not return air flap to initial po...

Page 118: ...ditions Engine is stopped and starting disabled Checking exhaust flap for easy movement 1 Actuate control linkage several times by hand to check for ease of movement 2 Contact Service if the control l...

Page 119: ...check Preconditions Engine is stopped and starting disabled Starter Condition check 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 149 MS15021 01E 20...

Page 120: ...or heat exchanger back to the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 121 5 Insert oil dipstick into guide tube up to the...

Page 121: ...he drain plug s on the oil pan 1 Provide a suitable container in which to collect the engine oil 2 Remove drain plug s and drain engine oil 3 Install drain plug s with new sealing ring Version with se...

Page 122: ...Screw M26 x 1 5 Tightening torque Engine oil 100 Nm 10 Nm Filling with new engine oil 1 Open cover on filler neck 2 Pour engine oil through the filler neck up to the max mark on the oil dipstick 3 Clo...

Page 123: ...ear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine oil sampl...

Page 124: ...ntact 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...

Page 125: ...al po sition Position C Upper filters cut out 2 Unscrew oil filter with oil filter wrench 3 Clean sealing face on connecting piece 4 Check condition of the new sealing ring and coat it with oil 5 Fit...

Page 126: ...mulsifier X00029933 1 Filter sleeve Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to healt...

Page 127: ...12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that smooth surface of filter sleeve 9 faces ro tor cap 8 14 Check sealing ring 11 repl...

Page 128: ...it General High Temperature Circuit 7 16 1 Venting points Coolant lines on ETC 1 Venting point Vent line Cross distributionn expansion tank 1 Venting point 128 Task Description MS15021 01E 2012 02 TIM...

Page 129: ...stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye Checking engine coola...

Page 130: ...ecial tools Material Spare parts Designation Use Part No Qty Engine coolant Changing engine coolant 1 Drain engine coolant Page 131 2 Fill with engine coolant Page 132 130 Task Description MS15021 01E...

Page 131: ...nd 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 an...

Page 132: ...es and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather val...

Page 133: ...ant emerg es from the loosened unions at the two tur bochargers 9 Tighten the coolant line union on both tur bochargers Page 128 10 Start engine Page 62 11 After the engine has run at idling speed for...

Page 134: ...breather valve and clean sealing faces if required 6 Set breather valve onto filler neck and turn until the first stop to close 7 Start engine Page 62 8 After the engine has run at idling speed for 1...

Page 135: ...ne coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 65 and disable en gine start observe general safety instruc tions for maintenance and repair 3 C...

Page 136: ...protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine coolant Sample extraction and analysis 1 With the engine run...

Page 137: ...rotectors Checking relief bore on raw water pump 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 65 and disable en gine start observe general safety instruc tions for maintenan...

Page 138: ...n and starting disabled Checking condition of battery charging generator drive coupling 1 Remove protective cover 2 Check resilient coupling for cracks and de formation arrow 3 Contact Service in case...

Page 139: ...ews for firm seating Preconditions Engine is stopped and starting disabled Engine mounts Checking securing screws for firm seating 1 Check securing screws for firm seating 2 Tighten loose threaded con...

Page 140: ...Wipe rubber surface with dry cloth do not use organic detergents 2 Check resilient elements for crack formation and deformation by visual inspection 3 Have cracked mounts replaced contact Service Engi...

Page 141: ...ent 1 Undo nut 3 2 Adjust buffer clearance by turning the central buffer 1 3 Coat mating face of nut 3 and thread of central buffer 1 with a little engine oil Engine oil must not get in contact with t...

Page 142: ...of damage to hearing Wear ear protectors Bilge pump Relief bore check 1 Check relief bores for oil and water dis charge 2 Stop engine Page 65 and disable en gine start 3 Clean the relief bores with a...

Page 143: ...System 7 21 1 Water drain valve Check Checking water drain valve 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve MS15021 01E 2012 02 Task Description 143 TIM I...

Page 144: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 63 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 145: ...w water level probe 3 Disconnect plug from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread Result Water drain valve opens 5 Leave water...

Page 146: ...heck pressure at the pressure gauge in the inlet to the fuel treatment system and note it 3 Check pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shutoff valve...

Page 147: ...tion of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Replacing...

Page 148: ...ightening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screw 1 washer 2 and nut 9 20 Tighten nut 9 21 Open ball valve at the inlet and outlet of the fuel treatment system...

Page 149: ...nnot 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 contac...

Page 150: ...om 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 Cleani...

Page 151: ...f connectors 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 contaminat...

Page 152: ...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...

Page 153: ...plug connections 1 Use connector pliers 3 to make certain that all plug in connections on engine con trol unit are securely seated 2 Tighten loose bayonet couplings 2 with connector pliers 3 by turnin...

Page 154: ...it 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 turni...

Page 155: ...483 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...

Page 156: ...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 fastening parts 6 as one u...

Page 157: ...master power switch to OFF 3 Disconnect battery in accordance with battery manufacturer s instructions Checking housing and internal assemblies for secure seating 1 Open LOP front door 2 Check securin...

Page 158: ...1 are engaged in the lugs 2 so that the covering cap 3 is held firmly in place in the socket 3 If this is not the case press the securing el ements 1 concerned in the direction of the arrow until they...

Page 159: ...rer s instructions 2 Switch master power switch to ON 3 Switch on Engine Control System 4 Keep LAMP TEST button pressed Result Indicators and controls light up 5 Have damaged lamps immediately replace...

Page 160: ...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...

Page 161: ...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...

Page 162: ...Ersatzteilkatalog Spare Parts Catalog SPC HI High Alarm Measured value exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum lim it value HT High Temperature ICFN ISO Conti...

Page 163: ...measuring point xyz PAN Panel Control panel PIM Peripheral Interface Module RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization organization SD S...

Page 164: ...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 c...

Page 165: ...ectors Cleaning Page 150 Qty Used in 1 7 23 2 Engine monitoring unit and connectors Cleaning Page 151 Qty Used in 1 7 23 4 Checking engine control unit plug connections Page 153 Qty Used in 1 7 23 5 E...

Page 166: ...gine coolant Sample extraction and analysis Page 136 Oil filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter Replacement Page 105 Qty Used in 1 7 15 1 Engine oil filter Replacement Page 12...

Page 167: ...am jet cleaner Part No Qty Used in 1 4 14 Plant Cleaning Page 69 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 90 Torque wrench 60 320 Nm Part...

Page 168: ...30027336 Qty Used in 1 7 3 1 Crankcase breather Oil separator replacement diaphragm check and replace ment Page 86 Qty Used in 1 7 15 2 Centrifugal oil filter Cleaning and filter sleeve replacement Pa...

Page 169: ...82 Instructions and comments on endoscopic and visual examination 84 D Differential pressure gauge Check 144 E Emergency stop from LOP 66 Engine Barring manually 80 Cranking on starter 81 Main dimens...

Page 170: ...Operational checks 64 P Personnel and organizational requirements 6 Plant Cleaning 69 Product description 21 Pump capacity Check 146 Putting into operation Fuel treatment system 60 Putting the engine...

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