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8 V 2000 M40A
MTU 8 V 2000 M40A User Manual
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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
2
Table of Contents
Table of Contents
5
Default Chapter
1
Operating Instructions
1
1 Safety
8
General Conditions
8
Personnel and Organizational Requirements
9
Transportation
10
Safety Precautions When Working on the Engine
13
Fluids and Lubricants, Fire Prevention and Environmental Protection
15
Conventions for Safety Instructions in the Text
17
2 Product Summary
18
Product Description
18
Series 2000 M40A/B - M41A/B
27
Engine Side and Cylinder Designations
28
Engine - Main Dimensions
29
Firing Order
30
Technical Data
31
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
31
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
34
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
37
2000 M40B Engine Data, Separate Heat
40
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
43
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
46
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
49
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
52
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
55
2000 M40A Engine Data: Engine-Mounted Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
58
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 25 °C Intake Air Temperature
61
2000 M40A Engine Data: Separate Heat Exchanger, Reference Conditions: 45 °C Intake Air Temperature
64
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
67
2000 M40B Engine Data, Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
70
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
73
2000 M40B Engine Data, Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
76
Engine Data 12V 2000M41A/B
79
Engine Data 16V 2000M41A/B
82
3 Operation
85
LOP - Controls
85
Putting the Engine into Operation
87
Putting the Engine into Operation (Out-Of- Service Period > 3 Months)
87
Putting the Engine into Operation after Scheduled Out-Of-Service Period
88
Starting the Engine from LOP
89
Operational Checks
90
Stopping the Engine at the LOP
91
Emergency Stop from LOP
92
After Stopping the Engine
93
Plant - Cleaning
94
4 Maintenance
95
Maintenance Task Reference Table [QL1]
95
5 Troubleshooting
96
LOP Alarms
99
6 Task Description
104
Engine
104
Engine - Barring Manually
104
Engine - Barring with Starting System
105
Cylinder Liner
106
Cylinder Liner - Endoscopic Examination
106
Instructions and Comments on Endoscopic and Visual Examination of Cylinder Liners
108
Crankcase Breather
110
Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check and Replacement
110
Crankcase Breather - Cleaning Oil Separator Element
112
Crankcase Breather - Oil Separator Replacement, Diaphragm Check and Replacement
113
Valve Clearance - Checking and Adjusting
115
Valve Drive
115
Cylinder Head Cover - Removal and Installation
118
Injection Pump - Replacement
119
Injection Pump / HP Pump
119
Injection Pump - Removal and Installation
120
Injection Valve / Injector
123
Injector - Replacement
123
Injector - Removal and Installation
124
Installing Injector
126
6.7 Fuel System
128
Fuel System
128
HP Fuel Line - Pressure Pipe Union Replacement
128
Fuel - Draining
130
Fuel System Venting
131
Fuel Filter
133
Fuel Filter - Replacement
133
Engine Is Stopped and Starting Disabled
133
Special Tools, Material, Spare Parts
133
Designation / Use Part no
133
WARNING Fuels Are Combustible
133
Risk of Fire and Explosion
133
Avoid Open Flames, Electrical Sparks and Ignition Sources
133
Do Not Smoke
133
Fuel Prefilter - Differential Pressure Check and Adjustment of Gauge
135
Fuel Prefilter - Draining
136
Fuel Prefilter - Flushing
137
Fuel Prefilter - Filter Element Replacement
139
Charge-Air Cooling
141
Intercooler - Checking Condensate Drain Line for Coolant Discharge and Obstruction
141
WARNING Compressed Air Risk of Injury
141
Do Not Direct Compressed-Air Jet at Persons
141
Wear Protective Goggles / Safety Mask and Ear Protectors
141
Air Filter
142
Air Filter - Replacement
142
Air Filter - Removal and Installation
143
Air Intake
144
Service Indicator - Signal Ring Position Check
144
Starting Equipment
145
Starter - Condition Check
145
Lube Oil System, Lube Oil Circuit
146
Engine Oil Level - Check
146
Engine Oil - Change
147
Oil Filtration / Cooling
148
Oil Dipstick - Marking
148
Engine Oil Filter - Replacement
149
Centrifugal Oil Filter - Cleaning and Filter-Sleeve Replacement
151
Coolant Circuit, General, High-Temperature Circuit
154
Drain and Venting Points
154
Engine Coolant - Level Check
159
Engine Coolant - Change
160
Engine Coolant - Draining
161
Preparatory Steps
161
Engine Coolant Filling
162
HT Coolant Pump - Relief Bore Check
163
Engine Coolant - Sample Extraction and Analysis
164
Raw Water Pump with Connections
165
Raw Water Pump - Relief Bore Check
165
Belt Drive
166
Drive Belt - Condition Check
166
Battery-Charging Generator
167
Battery-Charging Generator Drive - Drive Belt Check and Adjustment
167
Battery-Charging Generator Drive - Drive Belt Replacement
169
Engine Mounting / Support
171
Engine Mounting - Checking Condition of Resilient Mounts
171
Wiring (General) for Engine/Gearbox/Unit
172
Engine Wiring - Check
172
Accessories for (Electronic) Engine Governor / Control System
173
Engine Control Unit and Connectors - Cleaning
173
Engine Monitoring Unit and Connectors
174
Cleaning
174
Start Interlock Limit Switch - Check
175
ECU - Checking Plug Connections
176
Engine Monitoring Unit, Plug Connections - Check
177
Engine Control Unit - Removal and Installation
178
Emergency Instrumentation (Local Operating Panel)
180
LOP and Connectors - Cleaning
180
LOP - Visual Inspection
181
LOP - Test Procedures
183
7 Appendix A
185
Abbreviations
185
MTU Contacts/Service Partners
187
Special Tools
188
5
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MTU 8 V 2000 M40A Specifications
General
Brand
MTU
Model
8 V 2000 M40A
Category
Engine
Language
English
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