Professional Documents
Culture Documents
Diesel engine
12 V 2000 M72
16V 2000 M72
M015650/03E
Printed in Germany
2011 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written 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.
Commissioning Note
Important
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.).
Table of Contents
1 Safety
1.1
1.2
1.3
1.4
1.5
General conditions
Personnel and organizational requirements
Transport
Safety regulations for startup and operation
Safety precautions when working on the
engine
1.6 Auxiliary materials, fire prevention and
environmental protection
1.7 Conventions for safety instructions in the
text
7
8
9
10
11
13
4.9
4.10
4.11
4.12
4.13
54
55
56
57
58
5 Maintenance
5.1 Maintenance task reference table [QL1]
59
16
6 Troubleshooting
2 General Information
2.1
2.2
2.3
2.4
17
18
24
26
31
34
37
40
43
44
4 Operation
4.1 Engine Putting the engine into operation
(out of service > 3 months)
4.2 Putting the engine into operation after
scheduled out-of-service period
4.3 Tasks after extended out-of-service periods
(>3 weeks)
4.4 Checks prior to start-up
4.5 Fuel treatment system Start-up
4.6 Operational checks
4.7 Fuel treatment system Switching on
4.8 Starting the engine
45
46
47
48
49
51
52
53
60
61
7 Task Description
7.1 SOLAS
3 Technical Data
3.1 12V 2000 M72 engine data: Enginemounted heat exchanger, EPA stage 2
3.2 12 V 2000 M72 engine data: remote heat
exchanger, EPA stage 2
3.3 16V 2000 M72 engine data: Enginemounted heat exchanger, EPA stage 2
3.4 16V 2000 M72 engine data: Separate heat
exchanger, EPA stage 2
3.5 Firing order
3.6 Engine Main dimensions
64
64
65
66
7.2 Engine
72
74
72
73
74
76
78
78
79
81
81
84
85
88
85
86
88
89
89
91
92
93
95
97
97
123
124
123
124
125
125
126
127
128
129
98
100
131
101
132
98
99
100
101
102
104
104
106
131
132
133
134
135
136
137
138
109
109
115
116
117
118
119
120
121
122
122
8 Appendix A
8.1 Abbreviations
8.2 MTU contacts/service partners
139
142
9 Appendix B
9.1 Special Tools
9.2 Index
143
146
102
103
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
Incorrect use
Operation, maintenance and repair by unqualified personnel
Modifications or conversions
Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis
aged for 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
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 safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta
tion.
Keep it handy in the vicinity of the engine such that it is 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 the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Depending on the kind of work, use the necessary personal protective equipment.
1.3 Transport
Transport
Only use the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
The engine must only be transported in installation position, max. permissible diagonal pull 10.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear
ing pedestal 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
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.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-tocase basis.
Engine operation
The following conditions must be fulfilled before starting the engine:
Wear ear protection.
Ensure that the engine room is well ventilated.
Do not inhale engine exhaust gases.
Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
Protect battery terminals, battery-charger terminals and cables against accidental contact.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Welding work
Never carry out welding work on the assembly or engine plant or mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or plant as a ground terminal.
Never place the welding cable across or near wiring harnesses of MTU plants. The welding current may
otherwise induce an interference voltage in the wiring harnesses which could damage the electrical sys
tem.
M015650/03E 2011-10 | Safety | 11
If welding has to be carried out on components (e.g. exhaust manifold), these components must first be
removed from the engine.
Laser devices must be equipped, in accordance with their class and usage, with protective devices for
ensuring safe operation.
For conducting light-beam procedures and measurement work, only the following laser devices may be
used:
Laser devices in 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 surface have been designed in
such a way as to prevent any risk to the eyes.
When working with laser equipment, always wear special laser-protection goggles eye injury through
strongly concentrated beam.
SOLAS classification
On engines/plants with SOLAS classification, operational checks must include the following tasks:
Check all covers (fitted in accordance with SOLAS requirements) on lube oil and fuel pipe connections
(>1.8 bar) for damage, replace as necessary. ( Page 18)
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wad
ding, plugs or capsules).
Environmental protection
Modification or removal of mechanical or electronic components or the installation 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/systems may only be main
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and could involve the termination of the operating license by the emission authorities. MTU does not ac
cept any liability for violations of the emission regulations. MTU will provide assistance and advice if
emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure
the reliability and performance of MTU engines and must be complied with over the entire life cycle of the
engine.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applica
ble, which means work must only be carried out by authorized specialist companies (MTU is an author
ized specialist company).
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubri
cants and other chemical substances, follow the safety instructions applicable to the product. Take care
when handling hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do
not smoke.
M015650/03E 2011-10 | Safety | 13
Lead
When working with lead or lead-containing pastes, avoid direct contact with the skin and do not inhale
lead vapors.
Adopt suitable measures to avoid the formation of lead dust!
Switch on fume extraction system.
After coming into contact with lead or lead-containing materials, wash hands!
Painting
When painting in other than spray booths equipped with extractors, ensure good ventilation. Make
sure that adjacent work areas are not affected.
No naked flames!
No smoking.
Observe fire prevention regulations!
It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numb
ing.
Wear protective clothing, gloves, closed shoes and protective goggles!
Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffo
cation.
Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed 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
compressed air tanks and the compressed air lines.
Pay special attention to the pressure level in the compressed air network and pressure vessel!
Connecting devices and equipment must either be designed for this pressure or, if the permitted pres
sure for the connecting elements is lower than the pressure required, a pressure reducing valve and
safety valve (set to permitted pressure) must form an intermediate connection. Hose coupling and
connections must be securely attached!
Always wear protective goggles when blowing off tools or extracting chips!
The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents airborne particles being reflected and thereby prevents injury to eyes.
First shut off compressed air lines before compressed air equipment is disconnected from the supply
line or before equipment or tool is to be replaced!
Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion!
Forcing compressed air into thin-walled containers (e.g. sheet metal, plastic, glass) for drying purpos
es or to check for leaks will result in a risk of bursting!
Do not blow dirty clothing with compressed air when being worn on the body.
When working with compressed air, safety precautions must be constantly observed:
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands! Wash hands after contact with used oil.
WARNING
CAUTION
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
Read and familiarize yourself with all safety notices before starting up or repairing the product.
Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
1.
2.
2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are 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 of
the engine.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
3 KS = Driving end
4 Left engine side
Charging system
The charging system comprises charge-air system, exhaust system and sequential turbocharging.
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
low surface temperature,
reduced thermal load,
absolute gas-tightness.
Cooling system
Two separate cooling circuits:
Engine coolant
Raw water
Coolant cooling by raw water-cooled plate-core heat exchanger
Thermostat-controlled coolant system
Coolant-cooled / preheated charge air
Coolant-cooled fuel return
Electronic control and monitoring system with integrated security and test system with interfaces to re
mote control system (RCS) and to monitoring system (MCS).
Electronic engine control unit (ECU)
Closed-loop control:
Engine speed
Fuel HP
Electronic system
Open-loop control:
Injection (fuel pressure, injection timing, injection duration, operating status)
Sequential turbocharging (cutting-in and out) with secondary turbocharger
Engine protection with multi-stage safety systems:
Power reduction
Power limitation
Emergency stop
Monitoring:
Exhaust gas temperature, A-side
Exhaust temperature, B-side
Engine speed
Oil pressure
Differential oil pressure
Coolant temperature
Coolant level
Exhaust turbocharger speed
Leak fuel level
Oil temperature
Coolant pressure
Fuel pressure after filter
Monitoring in engine room
Engine control and monitoring unit (LOP)
Functions:
Engine speed, oil pressure and coolant temperature are monitored and displayed
Integrated safety system
Integrated test system
Redundant CAN bus interface to governor and higher-level control and monitoring system
24 V DC power supply
In case of leakage, the above-mentioned connection types are spray-protected even without a cover and
have been confirmed compliant with SOLAS by GL and DNV.
Plug-in pipe connection
Only leak-off along the line is possible, the pressure is decreased 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 (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
In case of a loose single-ended union or a defective sealing ring (2), the liquid first has to pass the
thread.
20 | General Information | M015650/03E 2011-10
The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under
pressure.
4 Union nut
5 HP line
6 Thrust screw
7 Thrust ring
8 V-ring
9 Support ring
1 Support ring
2 V-ring
3 Thrust ring
4 Thrust screw
5 O-ring
6 O-ring
7 Thrust ring
8 Pressure pipe
9 Jacket pipe
1 Union nut
2 O-ring
3 Thrust ring
1
2
3
4
Jacket pipe
O-ring
O-ring
Thrust ring
5
6
7
8
Thrust screw
Thrust ring
O-ring
HP line
9 Pressure pipe
10 O-ring
Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from
where it is routed at atmospheric pressure into a level-monitored leak fuel tank.
13 Carrier housing
14 Exhaust turbocharger
(primary turbocharger)
15 Exhaust turbocharger, left
(secondary turbocharger)
16 Exhaust outlet (horizon
tal)
17 Actuating cylinder for ex
haust flap
18 Actuating cylinder for air
flap
19 Control valve for flap con
trol
20 Cylinder head cover
21 Exhaust manifold
22 Engine mounting
23 Electric starter
24 Oil pan
25 Battery-charging genera
tor
Engine layout
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Oil dipstick
Drive flange
Flywheel housing
Engine mounting
Carrier housing core
Carrier housing lower
part
26 Exhaust outlet
27 Carrier housing upper
part
KS = driving end
Description
Monitoring of
B7
B10
Charge-air pressure
B44
Turbocharger speed
B3
B9
Charge-air temperature
Item
Description
Monitoring of
B34
B5.3 (option)
B5.1
B5.2 (option)
F33
B21 (option)
B6.2 (option)
Coolant temperature
B6.1
Coolant temperature
Item
Description
Monitoring of
B1 (ECU)
Camshaft speed
Crankshaft speed
B13 (ECU)
Crankshaft speed
Item
Description
Monitoring of
YB33
Fuel temperature
B48
B16 (option)
Coolant pressure
F46
Y27.2
B4.22
F41
Item
Item
Description
Monitoring of
B4.21
Y27.1
B54 (option)
System sensors
These sensors are fitted outside the engine.
Monitoring of
B19
Starting-air pressure
B70
B41
S37
Description
3 Technical Data
3.1 12V 2000 M72 engine data: Engine-mounted heat
exchanger, EPA stage 2
Explanation:
DL
BL
A
G
R
L
N
X
REFERENCE CONDITIONS
Engine model
12V 2000
M72
Application group
1B
25
25
Barometric pressure
mbar
1000
100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders
12
rpm
2250
kW
1080
Number of cylinders
12
mbar
15
mbar
30
12
degrees
90
Bore
mm
135
Stroke
mm
156
Cylinder displacement
liters
2.23
Total displacement
liters
26.76
Number of cylinders
12
12
bar
-0.4
bar
+0.5
bar
0.7
12
78
88
bar
7.8
bar
8.8
Lube oil operating pressure, low idle (meas. point: before engine)
bar
3.0
FUEL SYSTEM
Number of cylinders
12
bar
-0.3
bar
-0.3
bar
+0.25
liter/min
4.6
12
rpm
100
Firing speed, to
rpm
200
STARTING (electric)
Number of cylinders
R
V=
24
TIM-ID: 0000003110 - 001
12
12
degrees
15
degrees
22.5
degrees
10
degrees
22.5
degrees
32.5
CAPACITIES
Number of cylinders
12
liters
125
Total engine oil capacity at initial filling (standard oil system) (Option: max.
operating inclinations)
liters
123
Oil change quantity, max. (standard oil system) (Option: max. operating in
clinations)
liters
113
Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max.
operating inclinations)
liters
87
Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. L
operating inclinations)
liters
105
12
kg
2780
ACOUSTICS
Number of cylinders
12
R
dB(A)
105
Engine surface noise with attenuated intake noise (filter), BL, (free-field
sound-pressure level Lp, 1m distance, ISO 6798)
dB(A)
102
REFERENCE CONDITIONS
Engine model
12V2000
M72
Application group
1B
25
25
Barometric pressure
mbar
1000
100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders
12
rpm
2250
kW
1080
12
mbar
15
mbar
30
Degrees
90
Bore
mm
135
Stroke
mm
156
Cylinder displacement
Liters
2.23
Total displacement
Liters
26.76
Number of cylinders
12
79
89
bar
7.8
bar
8.8
Lube oil operating pressure (low idle) (meas. point: before engine)
bar
3.0
FUEL SYSTEM
Number of cylinders
12
bar
-0.3
bar
-0.3
bar
+0.25
Liters/min
4.6
12
rpm
100
Firing speed, to
rpm
200
STARTER (electric)
Number of cylinders
12
V=
24
12
L
Degrees
15
Degrees
22.5
Degrees
10
Degrees
22.5
Degrees
32.5
CAPACITIES
Number of cylinders
12
Engine oil capacity, initial filling (standard oil system) (option: max. operat
ing inclinations)
Liters
123
Oil change quantity, max. (standard oil system) (option: max. operating in
clinations)
Liters
113
Oil pan capacity at dipstick mark min. (standard oil system) (option: max.
operating inclinations)
Liters
87
Oil pan capacity at dipstick mark max. (standard oil system) (option: max.
operating inclinations)
Liters
105
12
R
kg
2770
ACOUSTICS
Number of cylinders
12
R
dB(A)
105
dB(A)
102
REFERENCE CONDITIONS
Engine model
16V 2000
M72
Application group
1B
25
25
Barometric pressure
mbar
1000
100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders
16
rpm
2250
kW
1440
16
mbar
15
mbar
30
Number of cylinders
16
degrees
90
Bore
mm
135
Stroke
mm
156
Cylinder displacement
liters
2.23
Total displacement
liters
35.68
16
bar
-0.4
bar
+0.5
bar
0.7
16
77
87
bar
6.0
bar
7.0
Lube oil operating pressure, low idle (meas. point: before engine)
bar
2.5
FUEL SYSTEM
Number of cylinders
16
bar
-0.3
bar
-0.3
bar
+0.25
liter/min
6.2
16
rpm
100
Firing speed, to
rpm
120
STARTING (electric)
Number of cylinders
Rated starter voltage (standard design)
16
R
V=
24
degrees
15
degrees
22.5
degrees
10
degrees
22.5
degrees
32.5
Number of cylinders
CAPACITIES
Number of cylinders
16
liters
135
Total engine oil capacity at initial filling (standard oil system) (Option: max.
operating inclinations)
liters
168
Oil change quantity, max. (standard oil system) (Option: max. operating in
clinations)
liters
155
Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max.
operating inclinations)
liters
115
Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. L
operating inclinations)
liters
138
16
kg
3337
ACOUSTICS
Number of cylinders
16
R
dB(A)
108
Engine surface noise with attenuated intake noise (filter), BL, (free-field
sound-pressure level Lp, 1m distance, ISO 6798)
dB(A)
105
3.4 16V 2000 M72 engine data: Separate heat exchanger, EPA
stage 2
Explanation:
DL
BL
A
G
R
L
N
X
REFERENCE CONDITIONS
Engine model
16V 2000
M72
Application group
1B
25
25
Barometric pressure
mbar
1000
100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders
16
rpm
2250
kW
1440
16
mbar
15
mbar
30
degrees
90
Bore
mm
135
Stroke
mm
156
Cylinder displacement
liters
2.23
Total displacement
liters
35.68
Number of cylinders
16
78
88
bar
6.0
bar
7.0
Lube oil operating pressure, low idle (meas. point: before engine)
bar
2.5
FUEL SYSTEM
Number of cylinders
16
bar
-0.3
bar
-0.3
bar
+0.25
liter/min
6.2
16
rpm
100
Firing speed, to
rpm
120
STARTING (electric)
Number of cylinders
16
V=
24
Number of cylinders
16
degrees
15
degrees
22.5
degrees
10
degrees
22.5
degrees
32.5
CAPACITIES
Number of cylinders
16
Total engine oil capacity at initial filling (standard oil system) (Option: max.
operating inclinations)
liters
168
Oil change quantity, max. (standard oil system) (Option: max. operating in
clinations)
liters
155
Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max.
operating inclinations)
liters
115
Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. L
operating inclinations)
liters
138
16
R
kg
3337
ACOUSTICS
Number of cylinders
16
R
dB(A)
108
Engine surface noise with attenuated intake noise (filter), BL, (free-field
sound-pressure level Lp, 1m distance, ISO 6798)
dB(A)
105
10 V
A1-B4-A4-B3-A3-B2-A2-B5-A5-B1
12 V
A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V
A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7
8V
Engine model
Length (A)
Width (B)
Height (C)
8V 2000 M72
approx. 1683 mm
approx. 1147 mm
approx. 1200 mm
8V 2000 M92
approx. 1683 mm
approx. 1147 mm
approx. 1200 mm
8V 2000 M93
approx. 1683 mm
approx. 1147 mm
approx. 1200 mm
8V 2000 M84
approx. 1683 mm
approx. 1147 mm
approx. 1200 mm
8V 2000 M94
approx. 1683 mm
approx. 1147 mm
approx. 1200 mm
approx. 1860 mm
approx. 1147 mm
approx. 1320 mm
approx. 1860 mm
approx. 1147 mm
approx. 1320 mm
approx. 1860 mm
approx. 1147 mm
approx. 1320 mm
approx. 1860 mm
approx. 1147 mm
approx. 1320 mm
approx. 1860 mm
approx. 1147 mm
approx. 1320 mm
approx. 2069 mm
approx. 1295 mm
approx. 1350 mm
approx. 2069 mm
approx. 1295 mm
approx. 1350 mm
approx. 2094 mm
approx. 1295 mm
approx. 1350 mm
approx. 2094 mm
approx. 1295 mm
approx. 1350 mm
approx. 2486 mm
approx. 1295 mm
approx. 1390 mm
approx. 2486 mm
approx. 1295 mm
approx. 1390 mm
approx. 2511 mm
approx. 1295 mm
approx. 1390 mm
approx. 2511 mm
approx. 1295 mm
approx. 1390 mm
Main dimensions
4 Operation
4.1 Engine Putting the engine into operation (out of service > 3
months)
Preconditions
Engine is stopped and starting disabled.
MTU Fluids and Lubricants Specifications (A001061/..) are available.
Measure
Engine
Fuel prefilter
Fuel system
Raw water pump (if located Fill with water (approx. 3 4 liters).
above waterline)
Filling point ( Page 109).
Coolant circuit
If engine is out of service for more than one year, change engine coolant
( Page 116).
Check coolant level ( Page 115).
Heat engine coolant with coolant preheating unit.
Switch on ( Operating Instructions for BlueVision).
Engine
4.2 Putting the engine into operation after scheduled out-ofservice period
Preconditions
Engine is stopped and starting disabled.
Startup
Item
Task
Coolant system
Coolant system
Fuel prefilter
Engine
Note:
1.
2.
2.
3.
4.
5.
6.
Result:
7.
Result:
Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.
b) Disinfect affected components with biocides ( MTU Fluids and Lubricants Specifications
A001061/..).
Close drain valves on housing.
Open all supply and discharge valves.
Switch on fuel treatment system ( Page 52).
Check direction of rotation of pump.
Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
Check the fuel treatment system for leaks.
The fuel treatment system is ready for operation.
1.
2.
Result:
Note:
2.
3.
Result:
4.
5.
6.
Note:
7.
8.
Result:
Note:
6.
Result:
If the suction pressure is within the permissible limits and engine operation is satisfactory:
Increase engine speed to 1000 rpm and monitor suction pressure.
If the suction pressure is within the specified limits, simulation was successful.
Note:
6.
Result:
If the suction pressure is within the permissible limits and engine operation is satisfactory:
Operate engine at full load and monitor suction pressure.
If the suction pressure is within the specified limits, simulation was successful.
1.
2.
3.
4.
Result:
5.
WARNING
Operational checks
Item
Measure
Fuel prefilter
HT coolant pump
Check relief bore for oil and coolant discharge and contamination
( Page 119).
Check relief bore for oil and water discharge and contamination
( Page 122).
Intercooler
Engine oil
Air filter
Damage to engine/plant.
Major material damage!
Before switching on, ensure that the engine/plant is ready for operation.
Before switching on, ensure that all housings are closed.
Before switching on, ensure that no work is in progress anywhere on the entire system.
1.
2.
Result:
3.
Result:
WARNING
1.
2.
3.
4.
5.
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until
engine temperatures have dropped and constant values are displayed.
1.
2.
3.
4.
5.
An emergency stop of the engine can be initiated from the following points :
( Operating instructions for electronic system)
Commanding control stand ( Operating instructions for electronic system);
Local operating panel LOP ( Operating instructions for electronic system);
Local Operation Station LOS ( Operating instructions for electronic system);
CCU ( Operating instructions for electronic system).
1.
2.
3.
4.
5.
Action
Coolant circuit
Raw water
Drain
If freezing temperatures are to be expected and the engine is to remain
out of service for an extended period.
Switch off.
Engine
2.
3.
4.
5.
Press the illuminated pushbutton "Water drain" on the switchgear cabinet until water discharge from the
outlet stops.
Switch off fuel treatment system.
Close ball valve at the inlet to the fuel treatment system.
Close ball valve at the outlet of the fuel treatment system.
Open drain valve until pressure has escaped from fuel treatment system.
Part No.
Qty.
30390
WARNING
CAUTION
Note:
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Water jet.
Risk of injury and scalding!
Do not direct water jet at persons.
Wear protective clothing, gloves, and goggles / safety mask.
Excessive reaction time of cleaning agents on components.
Damage to component!
Observe manufacturer's instructions.
Wear protective clothing, gloves, and goggles / safety mask.
There is a risk of damaging sensors with compressed air.
1.
2.
3.
4.
Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro
tection).
Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Carry out external cleaning as follows:
a) Remove coarse dirt.
b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
c) Use the high-pressure jet to remove the loosened dirt.
d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m
must be observed. The temperature of the cleaning medium must not exceed 80C.
Plant Cleaning
5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task
Maintenance tasks
W0500
( Page 51)
W0501
( Page 51)
W0502
( Page 51)
W0503
( Page 51)
W0505
( Page 51)
W0506
( Page 51)
W0507
( Page 51)
W0508
( Page 51)
W1001
( Page 89)
W1002
( Page 81)
W1003
Check drive belt condition and tension, replace as necessary ( Page 123)
W1005
( Page 98)
W1006
( Page 85)
W1008
Replace engine oil filter at each oil change or when the time
limit (years) is reached, at the latest
( Page 104)
W1009
( Page 106)
W1011
( Page 74)
W1036
( Page 121)
W1139
Replace paper or knitted fabric insert (if fitted) of oil mist sep ( Page 79)
arator.
W1140
( Page 78)
W1244
( Page 127)
W1245
( Page 126)
W1246
( Page 128)
6 Troubleshooting
6.1 Fuel treatment system Troubleshooting
Illuminated pushbutton Water alarm is lit.
Cause
Corrective action
Corrective action
u Reset motor protection relay.
Corrective action
u Replace coalescer filter element ( Page 129).
Corrective action
1. Replace coalescer filter element ( Page 129).
2. Press illuminated pushbutton Replace filter element to ac
knowledge.
TIM-ID: 0000007734 - 005
Cause
6.2 Troubleshooting
Engine does not turn when starter is actuated
Component
Probable Cause
Task
Battery
Low or defective
Starter
Engine wiring
Defective
ECU
Engine
Contact Service.
Probable Cause
Task
Starter
Engine wiring
Defective
Fuel system
Not vented
ECU
Defective
Contact Service.
Probable Cause
Task
Injector defective
Engine wiring
Defective
Fuel system
Not vented
ECU
Defective
Contact Service.
Probable Cause
Task
Fuel supply
Air supply
Injector defective
Engine wiring
Defective
Engine
Overloaded
Contact Service.
Probable Cause
Task
Injector defective
Speed sensor
Defective
Replace.
Fuel system
Not vented
ECU
Defective
Contact Service.
Probable Cause
Task
Engine coolant
Check.
Intercooler
Contaminated
Contact Service.
Engine room
Probable Cause
Task
Air supply
Intercooler
Contaminated
Contact Service.
Contact Service.
Probable Cause
Task
Intercooler
Contact Service.
Component
Probable Cause
Task
Air supply
Injector defective
Engine
Overloaded
Contact Service.
Component
Probable Cause
Task
Engine oil
Contact Service.
Task
Engine
Fuel system
Water in fuel
Intercooler
Leaking
Contact Service.
Component
7 Task Description
7.1 SOLAS
7.1.1
Part No.
Qty.
Shield A4
735233000100
10
Shield A5
735233000101
14
Shield A7
735233000103
Shield A8
735233000104
1.
2.
3.
7.1.2
Part No.
X00009628
X00009654
Qty.
1.
2.
7.1.3
Item
Type of shielding
Comments
Shield (A7)
Shield (A7)
On HP fuel pump
Free end
B-side
2
Free end
B-side
Free end
Item
Type of shielding
Comments
Shield (A8)
On fuel filter
Shield (A7)
Shield (A7)
Free end
2
Free end
3
Free end
Item
Type of shielding
Comments
Shield (A5)
On air flap
Shield (A4)
On brazed-on union
Shield (A5)
On turbocharger flap
Shield (A5)
On turbocharger flap
Driving end
A-side
2
Driving end
A-side
3
Driving end
A-side
TIM-ID: 0000010064 - 004
4
Driving end
A-side
Item
Type of shielding
Comments
Shield (A5)
To turbocharger relubrication
Shield (A5)
On valve plate
Driving end
A-side
2
Driving end
A-side
Driving end
Item
Type of shielding
Comments
Shield (A4)
Shield (A4)
Driving
end
2
Driving
end
Driving end
Item
Type of shielding
Comments
Shield (A4)
Driving
end
Item
Type of shielding
Comments
Shield (A5)
Turbocharger flap
Shield (A5)
Turbocharger flap
Shield (A4)
On brazed-on union
Shield (A5)
On air flap
Shield (A4)
To turbocharger relubrication
Driving
end B-side
2
Driving
end B-side
3
Driving
end B-side
4
Driving
end B-side
5
Driving
end B-side
Item
Type of shielding
Comments
Shield (A5)
On valve plate
Driving
end B-side
Item
Type of shielding
Comments
Shield (A5)
To flap control
Driving
end A-side
Item
Type of shielding
Comments
Shield (A5)
To flap control
Driving
end B-side
7.2 Engine
7.2.1
DANGER
Part No.
Qty.
Barring tool
F6783914
Ratchet
F30006212
Result:
Fit ratchet with barring tool on barring tool connection at the vibration damper on engine free end.
Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.
If the resistance exceeds the normal compression resistance, contact Service.
7.2.2
DANGER
Barring
1.
Result:
2.
Part No.
Qty.
Rigid endoscope
Y20097353
Preparatory steps
1.
2.
Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached
BDC.
Insert endoscope into cylinder liner through injector seat.
Measure
No action required
Final steps
Install injector ( Page 86).
Install cylinder head cover ( Page 84).
1.
2.
7.3.2
Action
Minor dirt scores can occur during the assembly of a new engine (honing prod
ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring
on the running surface under endoscope magnification. Cannot be felt with the
fingernail.
Findings not critical.
Single scores
Clearly visible scores from hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Findings not critical.
Scored area
These areas consist of scores of different length and depth next to one anoth
er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in
let/exhaust) along the transverse engine axis.
Findings not critical.
Smoothened area
Smoothened areas are on the running surface but almost the whole honing
pattern is still visible. 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 appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern
is undisturbed. Discolorations extend in stroke direction and may be interrupt
ed.
Findings not critical.
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in
the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there are corrosion pittings.
Black lines are a step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
Cylinders with a number of black lines around the running surface have limited
service life and should be replaced.
Black lines
Finding
Action
Discolorations (Heat)
These are caused by a disturbance in the liner / ring tribosystem. Usually they
run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring
and becoming more visible from the second TDC-ring onwards and less pro
nounced from TDC-ring 1. The honing pattern is usually no longer visible and
displays a clearly defined (straight) edge to the undisturbed surface. The dam
aged surface is usually discolored. The circumferential length varies.
Liners with heat discoloration 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.
The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in
vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un
necessary disassembly work, it is recommended that another inspection be carried out after further oper
ation of the engine.
WARNING
WARNING
6.
7.4.2
WARNING
Part No.
Qty.
F30027336
Ratchet adapter
F30027340
Filter element
Diaphragm
O-ring
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.
4.
5.
Size
Type
Lubricant
Tightening torque
Value/Standard
6 Nm + 2 Nm
Checking diaphragm
1.
2.
3.
4.
5.
6.
7.
Size
Screw
Tightening torque
Lubricant
Value/Standard
6 Nm + 2 Nm
8.
Type
Part No.
Qty.
Feeler gauge
Y4345893
Barring tool
F6783914
Ratchet
F30006212
F30002800
F30002816
Socket wrench
F30030450
F30510423
Preparatory steps
1.
2.
3.
Cylinder
Bank A
EA
-A
E-
-A
Bank B
E-
E-
--
-A
Bank A
--
E-
-A
E-
Bank B
-A
-A
EA
E-
E = inlet valve clearance adjustment permitted, A = exhaust valve clearance adjustment permitted
M015650/03E 2011-10 | Task Description | 81
10V2000
Position
Cylinder
Bank A
EA
--
--
-A
E-
Bank B
E-
--
-A
EA
E-
Bank A
--
EA
EA
E-
-A
Bank B
-A
EA
E-
--
-A
E = inlet valve clearance adjustment permitted, A = exhaust valve clearance adjustment permitted
12V2000
Position
Cylinder
Bank A
EA
E-
-A
E-
-A
--
Bank B
E-
--
-A
E-
EA
-A
Bank A
--
-A
E-
-A
E-
EA
Bank B
-A
EA
E-
-A
--
E-
E = inlet valve clearance adjustment permitted, A = exhaust valve clearance adjustment permitted
16V2000
Position
Cylinder
Bank A
E A
- A
E A
E -
-A
E - - -
Bank B
E -
- A
- -
E -
E A E - EA -
Bank A
- -
E -
E -
- A
E -
-A
EA E
A
Bank B
-A
E -
E A
E A
- -
-A
--
8
- A
E-
E = inlet valve clearance adjustment permitted, A = exhaust valve clearance adjustment permitted
4.
5.
Use feeler gauge to determine the distance between valve bridge and rocker arm.
If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.
1.
2.
3.
4.
5.
Result:
Final steps
Install sensor B13.
Connect cable to sensor B13.
Remove barring tool.
Install cylinder head cover ( Page 84).
Install air filter ( Page 99).
1.
2.
3.
4.
5.
7.5.2
Part No.
Qty.
Centering device
F6783025
Gasket
Preparatory steps
1.
2.
Final steps
Install air filter ( Page 99).
Install intake housing.
Check cylinder-head covers for leaks.
1.
2.
3.
Injector Replacement
Special tools, Material, Spare parts
Designation / Use
Injector
Part No.
Qty.
7.6.2
Part No.
Qty.
0005896803/00
Puller
F6790629
F30011450
F30025897
F30451199
Alignment device
F6790507
X00029933
Socket wrench
Engine oil
WARNING
Preparatory steps
1.
2.
Removing injector
Remove HP line (5) using socket wrench.
Disconnect injector cable (4).
Remove screw (2).
Take off hold-down clamp (3).
Remove injector (1) with puller.
Remove O-rings from injector.
Mask all connections and bores or seal with
suitable plugs.
1.
2.
3.
4.
5.
6.
7.
Installing injector
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Tighten screw of hold-down clamp (3) with a box wrench adapter and a torque wrench to specified tight
ening torque.
13.
Name
Size
Type
Lubricant
Value/Standard
Screw
M10 x 85
Tightening torque
(Engine oil)
40 Nm + 4 Nm
Use socket wrench and torque wrench to tighten HP line (5) to the specified torque.
Name
HP fuel line
14.
Size
Type
Lubricant
Value/Standard
Tightening torque
(Engine oil)
30 Nm + 5 Nm
Final steps
Install cylinder head cover ( Page 84).
Open fuel supply to engine.
1.
2.
WARNING
2.
Note:
3.
4.
5.
6.
DANGER
DANGER
WARNING
WARNING
Qty.
F30379104
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 out for a brief period only.
CAUTION
Part No.
Note:
3.
4.
5.
6.
7.
8.
9.
10.
7.8.2
DANGER
WARNING
1.
2.
7.8.3
Part No.
Qty.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
7.8.4
Part No.
Diesel fuel
Seal
DANGER
WARNING
WARNING
Qty.
1.
2.
3.
Result:
4.
1.
2.
3.
4.
5.
6.
Result:
7.8.5
WARNING
Part No.
Diesel fuel
Filter element
Seal
Qty.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
DANGER
WARNING
WARNING
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Part No.
Qty.
( Page 99)
7.10.2
5.
Result:
1.
2.
1.
2.
3.
4.
5.
7.13.2
Part No.
Qty.
Engine oil
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.
4.
5.
6.
DANGER
WARNING
WARNING
CAUTION
Part No.
Qty.
F30379104
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.
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 out for a brief period only.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1.
2.
3.
4.
5.
6.
7.
8.
7.14.2
WARNING
Part No.
Qty.
F30379104
50622
Filter sleeve
O-ring
O-ring
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
1.
2.
3.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.
13.
14.
15.
Size
Type
Nut
Lubricant
Value/Standard
10 Nm
Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.
Name
Size
Type
Nut
Lubricant
Value/Standard
40 Nm to 50 Nm
16.
Name
2 Filler neck
12 V, 16 V
2 Filler neck
Left side
Right side
7.15.2
WARNING
2.
Switch engine control system on and check display (coolant level is automatically monitored by the en
gine control system).
If required, top up with treated engine coolant ( Page 118).
7.15.3
Part No.
Qty.
Engine coolant
( Page 117)
7.15.4
WARNING
Preparatory steps
1.
2.
3.
2.
3.
4.
5.
6.
Turn breather valve on coolant expansion tank ( Page 109)counterclockwise to the first stop and re
lease pressure.
Continue to turn breather valve counterclockwise and remove.
Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
Open drain valves or drain plugs ( Page 109) and drain or pump off coolant.
Close all open drain points.
Set breather valve onto filler neck and close it.
7.15.5
Part No.
Qty.
Engine coolant
WARNING
CAUTION
2.
3.
4.
5.
6.
7.
( Page 24)Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow
pressure to escape.
Continue to turn breather valve counterclockwise and remove.
Pour coolant into engine until coolant level reaches lower edge of cast-in eye of filler neck.
Check proper condition of breather valve and clean sealing faces.
Place breather valve on filler neck and close.
Start the engine and operate it at idle speed for some minutes.
Check coolant level ( Page 115).
7.15.6
DANGER
WARNING
4.
7.15.7
Part No.
Qty.
5605892099/00
6.
7.
Turn breather valve on coolant expansion tank ( Page 109)counterclockwise until first stop and allow
pressure to escape.
Continue to turn breather valve counterclockwise and remove.
Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
Draw off approx. 1 liter coolant and drain into a clean container.
Using the equipment and chemicals from the MTU test kit, examine coolant for:
antifreeze concentration;
corrosion inhibitor concentration;
pH value.
Fit breather valve and close it.
Change engine coolant according to the coolant operating times specified in the ( MTU Fluids and Lu
bricants Specifications A001061/..)( Page 117).
7.15.8
Part No.
Qty.
F30379104
6.
7.
8.
WARNING
4.
Findings
Action
Drive belt A
Singular cracks
None
Drive belt
Drive belt B
Drive belt C
Chunking
Item
Part No.
Qty.
8205892861/08
Preparatory steps
1.
2.
3.
Final steps
Install protective cover.
Install screws of protective cover.
Install safety equipment (if fitted).
Check function of safety equipment (if fitted).
1.
2.
3.
4.
1.
2.
3.
7.19.2
WARNING
1.
2.
Result:
3.
7.19.3
WARNING
1.
2.
3.
4.
Result:
5.
Result:
6.
7.
8.
9.
10.
7.19.4
WARNING
3.
4.
3 bar
2.6 bar
If the measured value (reduced suction condition) is 10% lower than the measured value (normal con
dition), the wear limit is reached. Repair pump (contact Service).
7.19.5
WARNING
CAUTION
CAUTION
Part No.
Qty.
F30027336
Ratchet
F30027339
Diesel fuel
Engine oil
Coalescer filter element
Seal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Name
Size
Type
Lubricant
Value/Standard
Nut
M16
Tightening torque
(Engine oil)
30 Nm +3 Nm
17.
18.
19.
20.
21.
Result:
Part No.
Qty.
Isopropyl alcohol
X00058037
6.
Close male connectors that are not plugged in with the protective cap supplied.
Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
Ensure that all sensor connectors are securely engaged.
Note:
7.
8.
Check securing screws of cable clamps on engine and tighten loose threaded connections.
Ensure that cables are fixed in their clamps and cannot swing freely.
Check that cable ties are firm, tighten loose cable ties.
Replace faulty cable ties.
Visually inspect the following electrical line components for damage:
connector housings;
contacts;
sockets;
cables and terminals;
plug-in contacts.
( Contact Service) if cable conductors are damaged.
Note:
Designation / Use
Part No.
Qty.
Isopropyl alcohol
X00058037
Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
Note:
1.
2.
3.
7.21.2
Note:
Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
1.
2.
7.21.3
1.
2.
7.21.4
DANGER
3.
Result:
4.
5.
7.21.5
Part No.
Qty.
Isopropyl alcohol
Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.
Remove dirt from connector and cable surfaces with isopropyl alcohol.
Check legibility of cable labels. Clean or replace illegible labels.
1.
2.
3.
7.21.6
CAUTION
1.
2.
Result:
7.21.7
CAUTION
1.
2.
Result:
8 Appendix A
8.1 Abbreviations
Abbrevia
tion
Meaning
Explanation
ADEC
Engine governor
AL
Alarm
Alarm (general)
ANSI
ATL
Abgasturbolader
BR
Baureihe
Series
BV
Betriebsstoffvorschrift
CAN
CCG
Transfer gearbox
CODAG
CPP
DAG
DE
Diesel Engine
DIN
DIS
Display unit
DL
Default Lost
ECS
ECS-UNI
ECU
EDM
EMU
ETK
Ersatzteilkatalog
FPP
GCU
GMU
GT
Gas Turbine
HAT
HI
High
HIHI
High High
HT
High Temperature
ICFN
Engine governor
Abbrevia
tion
Meaning
IDM
IMO
ISO
KGS
Kraftgegenseite
KS
Kraftseite
LCD
LCU
LED
LMU
LOP subassembly
LO
Low
LOLO
Low Low
LOP
LOS
MCS
MG
Message
MPU
MRG
OT
Oberer Totpunkt
P-xyz
Pressure-xyz
PAN
Panel
Control panel
PCU
PIM
PT
Power Turbine
RCS
RL
Redundancy Lost
SAE
SAT
SD
Sensor Defect
SDAF
SOLAS
SS
Safety System
SSK
Schnellschlussklappe(n)
SSS
STBD
Starboard
T-xyz
Temperature-xyz
Explanation
LOP subassembly
Meaning
Explanation
TD
Transmitter Deviation
UT
Unterer Totpunkt
VS
Voith Schneider
WJ
Water jet
WZK
Werkzeugkatalog
ZKP
Zugehrigkeit-Kategorie-Parameter
Abbrevia
tion
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
- either 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
9 Appendix B
9.1 Special Tools
Alignment device
Part No.:
F6790507
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 86)
F30002816
Qty.:
Used in:
1
7.5.1 Valve clearance Check and adjustment ( Page 81)
Barring tool
Part No.:
F6783914
Qty.:
Used in:
1
7.2.1 Engine Barring manually ( Page 72)
Qty.:
Used in:
1
7.5.1 Valve clearance Check and adjustment ( Page 81)
F30451199
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 86)
Centering device
Part No.:
F6783025
Qty.:
Used in:
1
7.5.2 Cylinder-head cover Removal and installation ( Page 84)
F30002800
Qty.:
Used in:
1
7.5.1 Valve clearance Check and adjustment ( Page 81)
F30011450
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 86)
Feeler gauge
Part No.:
Y4345893
Qty.:
Used in:
1
7.5.1 Valve clearance Check and adjustment ( Page 81)
M015650/03E 2011-10 | Appendix B | 143
Mandrel
Part No.:
8205892861/08
Qty.:
Used in:
1
7.18.1 Battery-charging generator drive Drive belt replacement ( Page 124)
5605892099/00
Qty.:
Used in:
1
7.15.7 Engine coolant Sample extraction and analysis ( Page 120)
F30379104
Qty.:
Used in:
1
7.8.1 Fuel filter Replacement ( Page 89)
Qty.:
Used in:
1
7.14.1 Engine oil filter Replacement ( Page 104)
Qty.:
Used in:
1
7.15.8 Coolant filter Replacement ( Page 121)
F30025897
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 86)
Puller
Part No.:
F6790629
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 86)
Ratchet
Part No.:
F30006212
Qty.:
Used in:
1
7.2.1 Engine Barring manually ( Page 72)
Qty.:
Used in:
1
7.5.1 Valve clearance Check and adjustment ( Page 81)
Part No.:
F30027339
Qty.:
Used in:
1
7.19.5 Coalescer filter element Replacement ( Page 129)
Ratchet adapter
Part No.:
F30027340
Qty.:
Used in:
1
7.4.2 Crankcase breather Oil separator replacement, diaphragm check and replace
ment ( Page 79)
Ratchet
Rigid endoscope
Part No.:
Y20097353
Qty.:
Used in:
1
7.3.1 Cylinder liner Endoscopic examination ( Page 74)
Socket wrench
Part No.:
F30030450
Qty.:
Used in:
1
7.5.1 Valve clearance Check and adjustment ( Page 81)
Socket wrench
Part No.:
0005896803/00
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 86)
Qty.:
Used in:
1
4.13 Plant Cleaning ( Page 58)
Strap wrench
Part No.:
F30379104
Qty.:
Used in:
1
7.14.2 Centrifugal oil filter Cleaning and filter-sleeve replacement ( Page 106)
F30510423
Qty.:
Used in:
1
7.5.1 Valve clearance Check and adjustment ( Page 81)
Qty.:
Used in:
1
7.4.2 Crankcase breather Oil separator replacement, diaphragm check and replace
ment ( Page 79)
Qty.:
Used in:
1
7.19.5 Coalescer filter element Replacement ( Page 129)
Part No.:
9.2 Index
A
Abbreviations139
After stopping the engine56
Air filter
Removal and installation 99
Replacement 98
Auxiliary materials, fire prevention and environmental
protection13
B
Battery-charging generator drive
Drive belt
Replacement 124
C
Centrifugal oil filter Cleaning and filter-sleeve replace
ment 106
Checks
Prior to start-up 48
Coalescer filter element
Replacement 129
Connectors
Cleaning 132
Contacts142
Coolant
Filter
Replacement 121
Coolant filter
Replacement 121
Crankcase breather Cleaning oil pre-separator ele
ment78
Crankcase breather Oil separator replacement, dia
phragm check and replacement79
Cylinder liner
Endoscopic examination 74
Instructions and comments on endoscopic and visual
examination 76
Cylinder-head cover Removal and installation84
D
Differential pressure gauge
Check 126
Drain and venting points109
Drive belt
Condition check 123
E
ECU 7 engine governor
Removal and installation 137
Emergency stop55
EMU and connectors Cleaning136
EMU Checking plug-in connections134
Engine
Barring manually 72
Main dimensions 44
Putting the engine into operation (out of service > 3
months) 45
Wiring check 131
Engine coolant
Change 116
Filling 118
Engine coolant Draining117
Engine coolant Level check115
Engine coolant Sample extraction and analysis120
Engine governor
Carry out self-test 135
Checking plug-in connections 133
Cleaning 132
Engine layout24
Engine monitoring unit
Removal and installation 138
Engine oil
Change 103
Engine oil filter Replacement104
Engine oil level
Check 102
Engine side and cylinder
designations 17
Engine wiring
Check 131
Engine Barring with starting system73
F
Filter
Coalescer element
Replacement 129
Coolant
Replacement 121
Firing order43
Fuel
Prefilter
Differential pressure gauge - Check and adjust
ment 91
Draining 92
Filter element replacement 95
Treatment system
Shutdown 57
Switching on 52
Troubleshooting 60
Fuel filter
Replacement 89
Fuel prefilter
Differential pressure gauge
Check and adjustment 91
Draining 92
Filter element
Replacement 95
Fuel prefilter Flushing93
Fuel system Venting88
Fuel treatment system
Start-up 49
Fuel treatment system
Shutdown 57
Switching on 52
G
General conditions7
T
Tasks
After extended out-of-service periods 47
Tasks after extended out-of-service periods (>3 weeks)
47
Transport9
Troubleshooting61
Fuel treatment system 60
V
H
HT coolant pump
Relief bore check
Starter
Condition check 101
Starting the engine53
Startup and operation
Safety regulations 10
Stopping the engine54
I
Injector
Removal and installation 86
Injector Replacement85
Installation locations for SOLAS shielding66
Intercooler Checking condensate drain line for coolant
discharge and obstruction97
W
Water drain valve
Check 125
Water level probe (3-in-1 rod electrode)
Check 127
Wiring - engine
Check 131
M
Maintenance and repair work
Safety requirements 11
MTU contact persons142
O
Operational checks51
P