MTU 8 V 4000 M40A, Operating Instructions Manual

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Table of Contents
1 Safety
1.1 General conditions
5
1.2 Personnel and organizational requirements 6
1.3 Transportation 7
1.4 Crankshaft transport locking device 8
1.5 Safety regulations for startup and operation 11
1.6 Explosion hazard when removing
inspection port cover on engine 12
1.7 Safety regulations for maintenance and
repair work 13
1.8 Auxiliary materials, fire prevention and
environmental protection 16
1.9 Conventions for safety instructions in the
text 19
2 General Information
2.1 Engine side and cylinder designations
20
2.2 Product description 21
2.3 Engine – Overview 28
2.4 Sensors, actuators and injectors –
Overview 29
3 Technical Data
3.1 8 V 4000 M40A engine data
34
3.2 8 V 4000 M40A engine data 37
3.3 8 V 4000 M40A engine data 40
3.4 8 V 4000 M40B engine data 43
3.5 8 V 4000 M40B engine data 46
3.6 8 V 4000 M40B engine data 49
3.7 Firing order 52
3.8 Engine – Main dimensions 53
4 Operation
4.1 LOP – Controls
54
4.2 Engine – Preparations for putting into
operation after extended out-of-service
periods (>3 months) 56
4.3 Putting the engine into operation after
scheduled out-of-service-period 57
4.4 Tasks after 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 Operational checks 64
4.10 Stopping the engine at the LOP 65
4.11 Emergency stop from LOP 66
4.12 After stopping the engine 67
4.13 Fuel treatment system – Shutdown 68
4.14 Plant – Cleaning 69
5 Maintenance
5.1 Maintenance task reference table [QL1]
70
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting
71
6.2 Troubleshooting 72
6.3 LOP fault messages 75
7 Task Description
7.1 Engine
80
7.1.1 Engine – Barring manually 80
7.1.2 Engine cranking on starter 81
7.2 Cylinder Liner 82
7.2.1 Cylinder liner – Endoscopic examination 82
7.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 84
7.3 Crankcase Breather 86
7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement
86
7.3.2 Crankcase breather – oil separator
replacement 88
7.4 Valve Drive 89
7.4.1 Valve gear - Lubrication 89
7.4.2 Valve clearance – Check and adjustment 90
7.4.3 Cylinder head cover – Removal and
installation 95
7.5 Injection Pump / HP Pump 96
7.5.1 HP pump – Relief bore check 96
7.6 Injection Valve / Injector 97
7.6.1 Injector – Replacement 97
MS15021/01E 2012-02 | Table of Contents | 3
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