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12 V 2000 M40A
MTU 12 V 2000 M40A User Manual
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7.6
Injection Pump / HP Pump
7.6.1
Injection pump – Replacement
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Injection pump
(→ Spare Parts Catalog)
Injection pump – Replacement
u
Remove injection pump and install new one (→ Page 169).
168
|
Task Description
|
MS150031/05E 2013-01
TIM-ID: 0000000020 - 004
167
169
Table of Contents
Default Chapter
1
Operating Instructions
1
Table of Contents
3
MS150031/05E 2013-01 | Table of Contents
5
1 Safety
6
Important Provisions for All Products
6
Personnel and Organizational Requirements
7
Transportation
8
Safety Regulations for Maintenance and Repair Work
11
Fire Prevention and Environmental Protection, Fluids and Lubricants, Auxiliary Materials
14
Compressed Air
15
Standards for Warning Notices in the Text
16
2 General Information
17
Engine Side and Cylinder Designations
17
Product Description
18
Series 2000 M40A/B - M41A/B
27
Sensors, Actuators and Injectors - Overview
28
Sensors, Actuators and Injectors - Overview
32
3 Technical Data
42
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
42
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
45
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions
45
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
48
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
51
2000M41A Engine Data: Engine-Mounted Heat Exchanger
54
2000M41A Engine Data: Remote Heat Exchanger
57
2000M41B Engine Data: Engine-Mounted Heat Exchanger
60
2000M41B Engine Data: Remote Heat Exchanger
63
Number of Cylinders
64
Exhaust Noise, Unsilenced - DL (Free-Field Sound Pressure Level Lp, 1M Dis-R Db(A)
65
Tance, ISO 6798, +3Db(A) Tolerance)
65
Engine Surface Noise with Attenuated Intake Noise (Filter) - DL (Free-Field R Db(A)
65
Sound Power Level Lp, 1 M Distance, ISO 6798, +2Db(A) Tolerance)
65
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
66
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
69
C Intake Air Temperature
72
C Intake Air Temperature
75
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
78
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
81
C Intake Air Temperature
84
C Intake Air Temperature
87
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
90
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
93
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
96
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
99
Engine Data 12V 2000M41A/B
102
Engine Data 16V 2000M41A/B
105
Firing Order
108
Engine - Main Dimensions
109
4 Operation
110
LOP - Controls
110
Putting the Engine into Operation (Out-Of- Service Period > 3 Months)
112
Putting the Engine into Operation after Scheduled Out-Of-Service Period
113
Starting the Engine from LOP
114
Operational Checks
115
Stopping the Engine at the LOP
116
Emergency Stop from LOP
117
After Stopping the Engine
118
Plant Cleaning
119
5 Maintenance
120
Maintenance Task Reference Table [QL1]
120
6 Troubleshooting
121
ECU Alarms
121
Troubleshooting
132
LOP Fault Messages
135
Solas
140
SOLAS Shielding as Per MTN 5233 - Installation
140
SOLAS Shielding - Installation
141
Installation Locations for SOLAS Shielding
142
Installation Locations for SOLAS Shielding
147
7 Task Description
140
Engine
153
Engine - Barring Manually
153
Engine - Barring with Starting System
154
Cylinder Liner
155
Cylinder Liner Endoscopic Examination
155
Instructions and Comments on Endoscopic and Visual Examination of Cylinder Liners
157
Crankcase Breather
159
Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check and Replacement
159
Crankcase Breather - Cleaning Oil Separator Element
161
Crankcase Breather - Oil Separator Replacement, Diaphragm Check and Replacement
162
Valve Drive
164
Valve Clearance - Check and Adjustment
164
Adjusting Valve Clearance
165
Cylinder Head Cover - Removal and Installation
167
Injection Pump / HP Pump
168
Injection Pump - Replacement
168
Injection Pump - Removal and Installation
169
Injection Valve / Injector
172
Injector - Replacement
172
Injector - Removal and Installation
173
Installing Injector
175
Fuel System
177
HP Fuel Line - Pressure Pipe Neck Replacement
177
Fuel - Draining
179
Fuel System - Venting
180
Fuel Filter
182
Fuel Filter - Replacement
182
Fuel Prefilter - Differential Pressure Check and Adjustment of Gauge
184
Fuel Prefilter - Draining
185
Fuel Prefilter - Flushing
186
Fuel Prefilter - Filter Element Replacement
188
Charge-Air Cooling
190
Intercooler - Checking Condensate Drain Line for Coolant Discharge and Obstruction
190
Air Filter
191
Air Filter - Replacement
191
Air Filter - Removal and Installation
192
Air Intake
193
Service Indicator - Signal Ring Position Check
193
(Optional)
193
Starting Equipment
194
Starter - Condition Check
194
Lube Oil System, Lube Oil Circuit
195
Engine Oil - Level Check
195
Engine Oil - Change
196
Oil Filtration / Cooling
197
Oil Dipstick - Marking
197
Engine Oil Filter - Replacement
198
Centrifugal Oil Filter - Cleaning and Filter-Sleeve Replacement
200
Coolant Circuit, General, High-Temperature Circuit
203
Drain and Venting Points
203
Engine Coolant - Level Check
208
Engine Coolant - Change
209
Engine Coolant - Draining
210
Engine Coolant - Filling
211
HT Coolant Pump - Relief Bore Check
212
Engine Coolant - Sample Extraction and Analysis
213
Raw Water Pump with Connections
214
Raw Water Pump - Relief Bore Check
214
Belt Drive
215
Drive Belt - Condition Check
215
Battery-Charging Generator
216
Battery-Charging Generator Drive - Drive Belt Check and Adjustment
216
Battery-Charging Generator Drive - Drive Belt Replacement
218
Engine Mounting / Support
220
Engine Mounting - Checking Condition of Resilient Mounts
220
Wiring (General) for Engine/Gearbox/Unit
221
Engine Wiring - Check
221
Accessories for (Electronic) Engine Governor / Control System
222
Engine Governor and Connectors - Cleaning
222
Engine Monitoring Unit and Connectors - Cleaning
223
Start Interlock Limit Switch - Check
224
ECU - Plug Connections Check
225
Engine Monitoring Unit - Plug Connection Check
226
Engine Control Unit - Removal and Installation
227
Emergency Instrumentation (Local Operating Panel)
229
LOP and Connectors - Cleaning
229
Checking Threaded Connections
230
LOP - Visual Inspection
230
LOP - Test Procedures
232
8 Appendix A
234
Abbreviations
234
Appendix A 8.1 Abbreviations
234
MTU Contact Persons/Service Partners
236
9 Appendix B
237
Special Tools
237
Index
244
5
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MTU 12 V 2000 M40A Specifications
General
Brand
MTU
Model
12 V 2000 M40A
Category
Engine
Language
English
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