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MTU_ValueService

Technical Documentation

Diesel Engine
12 V 2000 M72
16 V 2000 M72

Operating Instructions
M015650/01E
Printed in Germany
© 2007 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, microfilming 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.
Wichtig – Important – Importante

Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH
zurücksenden.
Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik-
Support (Gewährleistung, Ersatzteile etc.).

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
(warranty, spare parts, etc.).

Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen


GmbH.
Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en
exploitation contractuelle (garantie, rechanges, etc.).

Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU


Friedrichshafen GmbH.
Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico
contractual (garantía, piezas de repuesto, etc.).

Ritagliare “Avviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen
GmbH.
Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).

É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU


Friedrichshafen.
Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças
sobressalentes, etc.) estabelecido contratualmente.

Postcard

MTU Friedrichshafen GmbH


Department MST
88040 Friedrichshafen
GERMANY

Bitte in Blockschrift ausfüllen!
Please use block capitals!
Prière de remplir en lettres capitales!
¡A rellenar en letras de imprenta!
Scrivere in stampatello!
Favor preencher com letras de forma!

Motornr.: Auftragsnr.: Inbetriebnahme-


Engine No.: MTU works order No.:
o
No du moteur: N° de commande: meldung
N de motor: N° de pedido:
Motore N.: N. commessa: Commissioning
No. do motor: No. do pedido:
Note
Motortyp: Inbetriebnahmedatum:
Engine model: Date put into operation: Notice de mise
Type du moteur: Mise en service le: en service
Tipo de motor: Fecha de puesta en servicio:
Motore tipo: Messa in servizio il:
Tipo do motor: Data da colocação em serviço: Aviso de puesta
en servicio
Eingebaut in: Schiffstyp / Schiffshersteller:
Installation site: Vessel/type/class / Shipyard:
Lieu de montage: Type du bateau / Constructeur: Avviso di messa
Lugar de montaje: Tipo de buque / Constructor: in servizio
Installato: Tipo di barca / Costruttore
Incorporado em: Tipo de embarcação/estaleiro naval:
Participação da
Endabnehmer/Anschrift: colocação em
End user`s address: serviço
Adresse du client final:
Dirección del cliente final:
Indirizzo del cliente finale:
Usuário final/endereço:

Bemerkung:
Remarks:
Remarques:
Observaciones:
Commento:
Observações:
Table of Contents 01

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
1.1 General conditions ....................................................... 05
1.2 Personnel and organizational requirements .................................. 06
1.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
1.4 Safety requirements when working on the engine ............................. 08
1.5 Expedients, fluids and lubricants, fire safety and environmental protection ........ 11
1.6 Standards for warning notices in the publication .............................. 13
2 Product Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.1 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.2 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Engine Side and Cylinder Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.1 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3.1 12V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 ... 25
2.3.2 12V 2000 M72 engine data: Separate heat exchanger, EPA stage 2 . . . . . . . . . . 29
2.3.3 16V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 ... 32
2.3.4 16V 2000 M72 engine data: Separate heat exchanger, EPA stage 2 . . . . . . . . . . 36
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Putting the engine into operation (out-of-service period > 3 months) .............. 39
3.2 Putting the engine into operation after scheduled out-of-service period ........... 40
3.3 Tasks after extended out-of-service periods (>3 weeks) . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Checks prior to startup ................................................... 42
3.5 Fuel treatment system – Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.6 Starting the engine ....................................................... 45
3.7 Fuel treatment system – Switching on ....................................... 46
3.8 Operational checks ...................................................... 47
3.9 Stopping the engine ...................................................... 48
3.10 Emergency stop ......................................................... 49
3.11 After stopping the engine ................................................. 50
3.12 Fuel treatment system – Putting out of service ................................ 51
3.13 Plant – Cleaning ......................................................... 52
4 Maintenance .................................................................. 53
4.1 Preface ................................................................ 53
4.2 Maintenance schedule matrix .............................................. 55
4.3 Maintenance tasks ....................................................... 58

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02 Table of Contents

5 Troubleshooting ............................................................... 61
5.1 Fuel treatment system – Troubleshooting .................................... 61
5.2 Troubleshooting ......................................................... 62
6 Task Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1 Engine ................................................................. 65
6.1.1 Engine – Barring manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1.2 Engine – Barring with starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.2 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.2.1 Cylinder liner – Endoscopic examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners
............................................................... 69
6.3 Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.3.1 Crankcase breather – Cleaning oil pre-separator element . . . . . . . . . . . . . . . . . . 71
6.3.2 Crankcase breather – Oil separator replacement, diaphragm check and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.4 Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.4.1 Valve clearance – Check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.4.2 Cylinder-head cover – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.5 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.5.1 Injector – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.5.2 Injector – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.6.1 Fuel system – Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.7 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.7.1 Fuel filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.7.2 Fuel prefilter, differential pressure gauge – Inspection and adjustment . . . . . . . . 84
6.7.3 Fuel prefilter - Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.7.4 Fuel prefilter – Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.7.5 Fuel prefilter – Filter element replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.8 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.8.1 Air filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.8.2 Air filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.9 Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.9.1 Service indicator – Signal ring position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.10 Staring Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.10.1 Starter – Condition check .......................................... 94
6.11 Lube-oil System, Lube-oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.11.1 Engine oil – Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.11.2 Engine oil – Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.12 Oil Filtration/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.12.1 Engine oil filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.12.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement . . . . . . . . . . . . . . . . 99
6.13 General Cooling Circuit, High Temperature Circuit ............................. 102

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Table of Contents 03

6.13.1 Drain and venting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102


6.13.2 Engine coolant – Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.13.3 Engine coolant – Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.13.4 Engine coolant – Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.13.5 Engine coolant system – Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.13.6 HT coolant pump – Relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.13.7 Engine coolant – Sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . 113
6.13.8 Coolant filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.14 Raw Water Pump with Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.14.1 Raw water pump – Relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.15 Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.15.1 Drive belt – Condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.16 Battery-Charging Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.16.1 Battery-charging generator drive – Drive belt check and adjustment . . . . . . . . . . 117
6.16.2 Battery-charging generator drive – Drive belt replacement . . . . . . . . . . . . . . . . . . 118
6.17 Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.17.1 Water drain valve – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.17.2 Differential pressure gauge – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.17.3 3-in-1 bar electrode – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.17.4 Pump capacity – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.17.5 Coalescer filter element – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.18 General Cabling for Engine / Gearbox / Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.18.1 Engine wiring – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.18.2 Sensors, actuators and injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.19 Accessories for Engine Governor (Electronic) / Control System ................. 131
6.19.1 Engine governor and connectors – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.19.2 EMU and connectors – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.19.3 Engine governor plug-in connections – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.19.4 EMU – Checking plug-in connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.19.5 ECU – Self-test implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.19.6 Engine governor – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6.19.7 EMU – Installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.1 Special tools ............................................................ 139
7.2 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
8 Annex ....................................................................... 153
8.1 Manufacturer’s documentation ............................................. 153
8.2 MTU contact person/service partner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
8.3 Index .................................................................. 155

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04 Table of Contents

M015650/01E 2007-10 © MTU


Safety 05

1 Safety

1.1 General conditions


General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions
Modifications made by the customer to the engine may affect safety.
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. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.

M015650/01E 2007-10 © MTU


06 Safety

1.2 Personnel and organizational requirements


Personnel
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organization
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).

M015650/01E 2007-10 © MTU


Safety 07

1.3 Transport
Transport
Lift the engine only with the lifting eyes provided.
Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the
transport pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking
devices for crankshaft and engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured
against slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

M015650/01E 2007-10 © MTU


08 Safety

1.4 Safety requirements when working on the engine


Safety precautions when putting the equipment into operation
Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Immediately after putting the device or system into operation, make sure that all control and display
instruments as well as the signaling and alarm systems work properly.
Safety requirements for operators
Procedures for cases of emergency must be practised regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard 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 is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Strict adherence to the maintenance and repair schedule is an essential safety factor.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed air line when air starters are fitted. Post
the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Have maintenance and repair work carried out by qualified and authorized personnel only.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane. Always support by
suitable means which conform with the applicable regulations before commencing maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After completing
work on the engine, check that all protective devices/safety guards have been installed and that
all tools and loose parts have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage fuel lines during maintenance and repair work. To tighten the connections when installing
the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.

M015650/01E 2007-10 © MTU


Safety 09

Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes
when exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this
case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals
if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Observe special cleanness when conducting maintenance and repair work on the engine plant. After completion
of maintenance and repair work, make sure that no loose objects are in/on the engine plant.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise
induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.

M015650/01E 2007-10 © MTU


10 Safety

Before use, the tools must be checked at regular intervals (crack test).
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies. Any measures requiring a power
supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be 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 surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.

M015650/01E 2007-10 © MTU


Safety 11

1.5 Expedients, fluids and lubricants, fire safety and


environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave rags soaked with fluids and lubricants
lying around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
SOLAS classification
On engines/plants with SOLAS classification, operational checks must include the following tasks:
• Check all protective covers (according to SOLAS) of lube-oil and fuel connections (>1.8
bar) for damage, replace if necessary (→ Page 15)
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 wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
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 applicable, which
means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).
Fluids and lubricants
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, lubricants 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.
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!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
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.

M015650/01E 2007-10 © MTU


12 Safety

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 numbing.
• 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 suffocation.
• Avoid all knocks and jars to the containers, valves and fittings or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
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.
When working with compressed air, safety precautions must be constantly observed:
• 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
pressure 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 workpieces 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. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of explosion!
• Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.

M015650/01E 2007-10 © MTU


Safety 13

1.6 Standards for warning notices in the publication


In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures

Note: This Publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:

Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

M015650/01E 2007-10 © MTU


14 Safety

M015650/01E 2007-10 © MTU


Product Summary 15

2 Product Summary

2.1 Engine Overview

2.1.1 Product description

Description of the engine


Engine
The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct
injection, sequential turbocharging and charge-air cooling.
An electronic management system provides engine control and monitoring.

Fuel system with Common Rail injection


Controlled by the electronic engine management system, the Common Rail injection system determines
injection pressure, commencement and amount of injection independently of engine speed.
Injection pressures up to 1800 bar provide optimum injection and combustion conditions.
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.
Lube oil system
Wet-sump forced-feed lubrication system
The following components are supplied with lube oil:
• Bearings
• Piston cooling
• Control and actuating elements of the sequential turbocharging system
Cooling system
• Two separate circuits:
• Engine coolant
• Raw water
• Coolant cooled by raw-water cooled plate-core heat exchangers
• Thermostat-controlled coolant circuit
• Charge air cooled or heated by coolant
• Return fuel cooled by coolant
Electronic system
Electronic control and monitoring system with integrated security and test system with interfaces to
remote control system (RCS) and to monitoring system (MCS).
Electronic engine governor (ECU)
Closed-loop control:
• Speed
• High-pressure fuel
Open-loop control:
• Fuel injection (fuel pressure, commencement of injection, injection duration, operating status)
• Sequential turbocharging (cut-in/cut-out) of the secondary turbocharger
• Engine protection by multistage safety systems:
• Power reduction

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16 Product Summary

• Power limitation
• Emergency stop
Monitoring:
• Exhaust temperature, A side
• Exhaust temperature, B side
• Engine speed
• Oil pressure
• Differential oil pressure
• Coolant temperature
• Coolant level
• Turbocharger speed
• Leak-off 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 VDC power supply

SOLAS – Fire protection specifications


Protective covers on pressure lines >1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown.
Actuating cylinders (on left and right sides), oil supply

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Product Summary 17

Fuel filter, oil filter

HP fuel pump

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18 Product Summary

Special connections
In case of leakage, the following connection types are spray-protected even without a cover and
have been confirmed compliant with SOLAS by GL and DNV.

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Product Summary 19

Plug-in pipe connection


The sleeve (4) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (3) defect occurs.
The connection is confirmed as compliant with SOLAS by DNV and GL.
Plug 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 loose thread or a defective sealing ring (2), the liquid first has to pass the thread.
Because of the defective sealing ring (2), the pressure is so reduced, that the leak runs off without pressure.

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20 Product Summary

HP connections

1 Jacketed barrel 7 Leakage-overflow bore 13 Thrust ring


2 HP fuel line 8 Thrust ring 14 Shims
3 O-ring 9 Union nut 15 Union nut
4 Union nut 10 Union nut 16 Thrust ring
5 Groove for O-ring 11 Connecting piece 17 O-ring
6 Thrust ring 12 Circlip

The HP fuel line is sealed by the thrust ring (8).


If leakage in the area of the thrust ring (8) or the HP line (5) occurs, the emerging fuel is routed to the leakage chamber.
The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage
chamber is sealed toward the outside by the O-rings (3).
This prevents the leak from escaping.
The connection is confirmed as compliant with SOLAS by DNV and GL.

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Product Summary 21

Protective cover of fuel filters and lube oil filters


Protective cover with a plastic ring

The plastic ring (1) prevents lateral spray.


The liquid is routed into the collector bowl and the pressure is greatly reduced.
Protective cover with lip

The lip (1) prevents lateral spray.


The liquid is routed into the collector bowl and the pressure is greatly reduced.

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22 Product Summary

2.1.2 Engine layout

Engine layout

1 Engine oil heat exchanger 12 Exhaust turbocharger, right 23 Electric starter


2 Engine oil filter (secondary turbocharger) 24 Oil pan
3 Engine coolant filter 13 Carrier housing 25 Battery-charging generator
4 Change-over lever for engine 14 Exhaust turbocharger (primary 26 Raw-water connection for
oil filter turbocharger) gearbox cooling
5 Fuel cooler 15 Exhaust turbocharger, left 27 Gearcase
6 Coolant distribution housing with (secondary turbocharger) 28 Raw water pump
integral expansion tank 16 Exhaust outlet (horizontal) 29 Raw-water connection from sea
7 Engine hoisting lug (free end) 17 Actuating cylinder for exhaust flap 30 Raw water connection to sea
8 Electronic engine management 18 Actuating cylinder for air flap 31 Plate-core heat exchanger
system 19 Control valve for flap control 32 Thermostat housing
9 Air filter 20 Cylinder head cover 33 Fuel priming pump
10 Air intake 21 Exhaust manifold 34 Fuel duplex filter (switchable)
11 Air collector housing (shroud) 22 Engine mounting KGS = free end

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Product Summary 23

1 Exhaust turbocharger, left 9 Engine coolant filter 20 Oil dipstick


(secondary turbocharger) 10 Engine oil filter 21 Drive flange
2 Exhaust turbocharger (primary 11 Fuel filter 22 Flywheel housing
turbocharger) 12 Engine oil heat exchanger 23 Engine mounting
3 Air intake 13 Coolant distribution housing with 24 Carrier housing core
4 Engine hoisting lug (driving end) integral expansion tank 25 Carrier housing lower part
5 Exhaust turbocharger, right 14 Thermostat housing 26 Exhaust outlet
(secondary turbocharger) 15 Exhaust manifold 27 Carrier housing upper part
6 Engine coolant filler neck 16 Coolant pump KS = driving end
7 Crankcase breather 17 HP fuel pump
8 Change-over lever for engine 18 Fuel delivery pump
oil filter 19 Oil filler neck

Engine model designation


Key to the model designation 12V/16V 2000 Mxy
• 12/16 = Number of cylinders
• V = Cylinder arrangement
• 2000 = Series
• Mx = application segment
• y = design index

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24 Product Summary

2.2 Engine Side and Cylinder Designations

2.2.1 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.
The numbering of engine components is also from the driving end, starting with No. 1.

1 KGS = Free end 3 KS = Driving end


2 Right side 4 Left side

M015650/01E 2007-10 © MTU


Product Summary 25

2.3 Technical Data

2.3.1 12V 2000 M72 engine data: Engine-mounted heat


exchanger, EPA stage 2
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS

Engine model 12V 2000


M72

Application group 1B

Intake air temperature °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 12

Rated engine speed A rpm 2250

Fuel stop power ISO 3046 A kW 1080

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12

Intake air depression (new filter) A mbar 15

Intake air depression, max. L mbar 30

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26 Product Summary

MODEL RELATED DATA (basic design)

Number of cylinders 12

Cylinder arrangement: V angle degrees 90

Bore mm 135

Stroke mm 156

Cylinder displacement liters 2.23

Total displacement liters 26.76

Inlet valves per cylinder 2

Exhaust valves per cylinder 2

RAW-WATER CIRCUIT (open circuit)

Number of cylinders 12

Raw water pump: Inlet pressure, min. L bar -0.4

Raw water pump: Inlet pressure, max. L bar +0.5

Pressure loss in off-engine raw-water system, max. L bar 0.7

LUBE OIL SYSTEM

Number of cylinders 12

Lube oil operating temperature before engine, from R °C 78

Lube oil operating temperature before engine, to R °C 88

Lube oil operating pressure before engine, from R bar 7.8

Lube oil operating pressure before engine, to R bar 8.8

Lube oil operating pressure, low idle (meas. point: before engine) R bar 3.0

FUEL SYSTEM

Number of cylinders 12

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at supply connection to engine (when engine is running), min. L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. R liter/min 4.6

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Product Summary 27

GENERAL OPERATING DATA

Number of cylinders 12

Firing speed, from R rpm 100

Firing speed, to R rpm 200

STARTING (electric)

Number of cylinders 12

Rated starter voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Number of cylinders 12

Longitudinal inclination, continuous max., driving end down (Option: max. operating L degrees 15
inclinations)

Longitudinal inclination, temporary max., driving end down (Option: max. operating L degrees 22.5
inclinations)

Longitudinal inclination, temporary max., driving end up (Option: max. operating L degrees 10
inclinations)

Transverse inclination, continuous max. (Option: max. operating inclinations) L degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degrees 32.5

CAPACITIES

Number of cylinders 12

Engine coolant, engine-side (with cooler) R liters 125

Total engine oil capacity at initial filling (standard oil system) (Option: max. R liters 123
operating inclinations)

Oil change quantity, max. (standard oil system) (Option: max. operating R liters 113
inclinations)

Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. L liters 87
operating inclinations)

Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. L liters 105
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 12

Engine dry weight (with attached standard accessories, without coupling) R kg 2780

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28 Product Summary

ACOUSTICS

Number of cylinders 12

Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m distance, R dB(A) 105
ISO 6798)

Engine surface noise with attenuated intake noise (filter), BL, (free-field R dB(A) 102
sound-pressure level Lp, 1m distance, ISO 6798)

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Product Summary 29

2.3.2 12V 2000 M72 engine data: Separate heat exchanger, EPA stage 2
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS

Engine model 12V 2000


M72

Application group 1B

Intake air temperature °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 12

Rated engine speed A rpm 2250

Fuel stop power ISO 3046 A kW 1080

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12

Intake air depression (new filter) A mbar 15

Intake air depression, max. L mbar 30

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30 Product Summary

MODEL RELATED DATA (basic design)

Number of cylinders 12

Cylinder arrangement: V angle degrees 90

Bore mm 135

Stroke mm 156

Cylinder displacement liters 2.23

Total displacement liters 26.76

Inlet valves per cylinder 2

Exhaust valves per cylinder 2

LUBE OIL SYSTEM

Number of cylinders 12

Lube oil operating temperature before engine, from R °C 79

Lube oil operating temperature before engine, to R °C 89

Lube oil operating pressure before engine, from R bar 7.8

Lube oil operating pressure before engine, to R bar 8.8

Lube oil operating pressure, low idle (meas. point: before engine) R bar 3.0

FUEL SYSTEM

Number of cylinders 12

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at supply connection to engine (when engine is running), min. L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. R liter/min 4.6

GENERAL OPERATING DATA

Number of cylinders 12

Firing speed, from R rpm 100

Firing speed, to R rpm 200

STARTING (electric)

Number of cylinders 12

Rated starter voltage (standard design) R V= 24

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Product Summary 31

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Number of cylinders 12

Longitudinal inclination, continuous max., driving end down (Option: max. operating L degrees 15
inclinations)

Longitudinal inclination, temporary max., driving end down (Option: max. operating L degrees 22.5
inclinations)

Longitudinal inclination, temporary max., driving end up (Option: max. operating L degrees 10
inclinations)

Transverse inclination, continuous max. (Option: max. operating inclinations) L degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degrees 32.5

CAPACITIES

Number of cylinders 12

Total engine oil capacity at initial filling (standard oil system) (Option: max. R liters 123
operating inclinations)

Oil change quantity, max. (standard oil system) (Option: max. operating R liters 113
inclinations)

Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. L liters 87
operating inclinations)

Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. L liters 105
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 12

Engine dry weight (with attached standard accessories, without coupling) R kg 2770

ACOUSTICS

Number of cylinders 12

Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m distance, R dB(A) 105
ISO 6798)

Engine surface noise with attenuated intake noise (filter), BL, (free-field R dB(A) 102
sound-pressure level Lp, 1m distance, ISO 6798)

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32 Product Summary

2.3.3 16V 2000 M72 engine data: Engine-mounted heat


exchanger, EPA stage 2
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS

Engine model 16V 2000


M72

Application group 1B

Intake air temperature °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 16

Rated engine speed A rpm 2250

Fuel stop power ISO 3046 A kW 1440

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16

Intake air depression (new filter) A mbar 15

Intake air depression, max. L mbar 30

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Product Summary 33

MODEL RELATED DATA (basic design)

Number of cylinders 16

Cylinder arrangement: V angle degrees 90

Bore mm 135

Stroke mm 156

Cylinder displacement liters 2.23

Total displacement liters 35.68

Inlet valves per cylinder 2

Exhaust valves per cylinder 2

RAW-WATER CIRCUIT (open circuit)

Number of cylinders 16

Raw water pump: Inlet pressure, min. L bar -0.4

Raw water pump: Inlet pressure, max. L bar +0.5

Pressure loss in off-engine raw-water system, max. L bar 0.7

LUBE OIL SYSTEM

Number of cylinders 16

Lube oil operating temperature before engine, from R °C 77

Lube oil operating temperature before engine, to R °C 87

Lube oil operating pressure before engine, from R bar 6.0

Lube oil operating pressure before engine, to R bar 7.0

Lube oil operating pressure, low idle (meas. point: before engine) R bar 2.5

FUEL SYSTEM

Number of cylinders 16

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at supply connection to engine (when engine is running), min. L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. R liter/min 6.2

M015650/01E 2007-10 © MTU


34 Product Summary

GENERAL OPERATING DATA

Number of cylinders 16

Firing speed, from R rpm 100

Firing speed, to R rpm 120

STARTING (electric)

Number of cylinders 16

Rated starter voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Number of cylinders 16

Longitudinal inclination, continuous max., driving end down (Option: max. operating L degrees 15
inclinations)

Longitudinal inclination, temporary max., driving end down (Option: max. operating L degrees 22.5
inclinations)

Longitudinal inclination, temporary max., driving end up (Option: max. operating L degrees 10
inclinations)

Transverse inclination, continuous max. (Option: max. operating inclinations) L degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degrees 32.5

CAPACITIES

Number of cylinders 16

Engine coolant, engine-side (with cooler) R liters 135

Total engine oil capacity at initial filling (standard oil system) (Option: max. R liters 168
operating inclinations)

Oil change quantity, max. (standard oil system) (Option: max. operating R liters 155
inclinations)

Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. L liters 115
operating inclinations)

Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. L liters 138
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 16

Engine dry weight (with attached standard accessories, without coupling) R kg 3337

M015650/01E 2007-10 © MTU


Product Summary 35

ACOUSTICS

Number of cylinders 16

Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m distance, R dB(A) 108
ISO 6798)

Engine surface noise with attenuated intake noise (filter), BL, (free-field R dB(A) 105
sound-pressure level Lp, 1m distance, ISO 6798)

M015650/01E 2007-10 © MTU


36 Product Summary

2.3.4 16V 2000 M72 engine data: Separate heat exchanger, EPA stage 2
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS

Engine model 16V 2000


M72

Application group 1B

Intake air temperature °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 16

Rated engine speed A rpm 2250

Fuel stop power ISO 3046 A kW 1440

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16

Intake air depression (new filter) A mbar 15

Intake air depression, max. L mbar 30

M015650/01E 2007-10 © MTU


Product Summary 37

MODEL RELATED DATA (basic design)

Number of cylinders 16

Cylinder arrangement: V angle degrees 90

Bore mm 135

Stroke mm 156

Cylinder displacement liters 2.23

Total displacement liters 35.68

Inlet valves per cylinder 2

Exhaust valves per cylinder 2

LUBE OIL SYSTEM

Number of cylinders 16

Lube oil operating temperature before engine, from R °C 78

Lube oil operating temperature before engine, to R °C 88

Lube oil operating pressure before engine, from R bar 6.0

Lube oil operating pressure before engine, to R bar 7.0

Lube oil operating pressure, low idle (meas. point: before engine) R bar 2.5

FUEL SYSTEM

Number of cylinders 16

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at supply connection to engine (when engine is running), min. L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. R liter/min 6.2

GENERAL OPERATING DATA

Number of cylinders 16

Firing speed, from R rpm 100

Firing speed, to R rpm 120

STARTING (electric)

Number of cylinders 16

Rated starter voltage (standard design) R V= 24

M015650/01E 2007-10 © MTU


38 Product Summary

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Number of cylinders 16

Longitudinal inclination, continuous max., driving end down (Option: max. operating L degrees 15
inclinations)

Longitudinal inclination, temporary max., driving end down (Option: max. operating L degrees 22.5
inclinations)

Longitudinal inclination, temporary max., driving end up (Option: max. operating L degrees 10
inclinations)

Transverse inclination, continuous max. (Option: max. operating inclinations) L degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degrees 32.5

CAPACITIES

Number of cylinders 16

Total engine oil capacity at initial filling (standard oil system) (Option: max. R liters 168
operating inclinations)

Oil change quantity, max. (standard oil system) (Option: max. operating R liters 155
inclinations)

Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. L liters 115
operating inclinations)

Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. L liters 138
operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 16

Engine dry weight (with attached standard accessories, without coupling) R kg 3337

ACOUSTICS

Number of cylinders 16

Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m distance, R dB(A) 108
ISO 6798)

Engine surface noise with attenuated intake noise (filter), BL, (free-field R dB(A) 105
sound-pressure level Lp, 1m distance, ISO 6798)

M015650/01E 2007-10 © MTU


Operation 39

3 Operation

3.1 Putting the engine into operation (out-of-service


period > 3 months)
Preconditions
• Engine is stopped and starting disabled.
• MTU Fluids and Lubricants Specification (A001061/..) is available.
Putting the engine into operation (out-of-service period > 3 months)

Item Task

Engine Depreserve (→MTU Fluids and Lubricants Specifications A001061/..).

Lube oil system Check oil level (→ Page 95).

Fuel prefilter Prime (→ Page 89).

Fuel prefilter, pressure gauge Align adjustable pointer with position of pressure indicator (→ Page 84).

Fuel system Vent (→ Page 81).

Raw-water pump (if located Prime (approx. 3 to 4 liters).


above waterline) Filling point (→ Page 102)

Coolant system If engine is out of service for more than one year, change coolant (→ Page 109).

Coolant system Check coolant level (→ Page 108).

Coolant system Preheat coolant with preheating unit.

Engine control system Switch on (→Operating instructions BlueVision )

Engine Start (→Operating instructions BlueVision ).

M015650/01E 2007-10 © MTU


40 Operation

3.2 Putting the engine into operation after scheduled


out-of-service period
Preconditions
• Engine is stopped and starting disabled.
Startup

Item Task

Lube oil system Check oil level (→ Page 95).

Coolant system Check coolant level (→ Page 108).

Coolant system Preheat coolant with preheating unit.

Fuel prefilter Drain (→ Page 85).

Battery-charging generator Check condition of drive belt (→ Page 116).


drive

Engine control system Switch on (→Operating instructions BlueVision ).

Engine Start (→Operating instructions BlueVision ).

M015650/01E 2007-10 © MTU


Operation 41

3.3 Tasks after extended out-of-service periods (>3 weeks)


Tasks after extended out-of-service periods (>3 weeks)
Note: Operate fuel treatment system for at least 5 minutes.

1. Put fuel treatment system into operation (→ Page 43).


2. Put fuel treatment system out of service (→ Page 51).

M015650/01E 2007-10 © MTU


42 Operation

3.4 Checks prior to startup


Checks prior to startup
1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
1.1. Clean affected components.
1.2. Disinfect affected components with biocides (→MTU Fluids and Lubricants Specifications A001061/..).
2. Close drain valves on housing.
3. Open all supply and discharge valves.
4. Switch on fuel treatment system (→ Page 46).
5. Check direction of rotation of pump.
6. Vent bypass and fuel lines of the system.
6.1. Open ball valve for pressure tank.
6.2. Open ball valve for overflow tank.
6.3. Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
6.4. Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: If no leaks are detected, the fuel treatment system is ready for operation.

M015650/01E 2007-10 © MTU


Operation 43

3.5 Fuel treatment system – Putting into operation


Fuel treatment system – Overview

1. Switch on fuel treatment system (→ Page 46).


2. Check the differential pressure at the differential-pressure gauge (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
1. Remove coalescer filter element (→ Page 123).
2. Check sealing faces on coalescer filter element and in the pressure tank.

Initial operation: Harbor Acceptance Tests


1. Replace fuel filter on engine (→ Page 82).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.

2. Install a pressure gauge in the fuel supply line from the shipside fuel system to the engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 46).
Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is
delivered via the overflow tank back to the tank. Water which has settled in the tank is separated.
4. Start engine (→ Page 45).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.

M015650/01E 2007-10 © MTU


44 Operation

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:

7. Increase engine speed to 1000 rpm and monitor suction pressure.


8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter
replacement simulation with the engine running as part of the Harbor Acceptance Tests.

Simulation of filter replacement with the engine running: Harbor Acceptance Tests
1. Switch on fuel treatment system (→ Page 46).
2. Start engine (→ Page 45).
3. Run engine at idling speed.
4. Close ball valve (5) at the inlet to the fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball valve (19) .
Result: Fuel emerges. If no fuel emerges:
• Open ball valve (5) at the inlet to the fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:

7. Increase engine speed to 1000 rpm and monitor suction pressure.


Result: If all engine operating values are within the specified limits, open ball valve (5) at the inlet to the
fuel treatment system.

Simulation of power failure (emergency): Harbor Acceptance Tests


1. Switch on fuel treatment system (→ Page 46).
2. Start engine (→ Page 45).
3. Run engine at idling speed.
4. Switch off pump (21) on switchgear cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:

6. Increase engine speed to 1000 rpm and monitor suction pressure.


Result: If the suction pressure is within the specified limits, simulation was successful.

Simulation of power failure (emergency): Sea Acceptance Tests


1. Switch on fuel treatment system (→ Page 46).
2. Start engine (→ Page 45).
3. Run engine at idling speed.
4. Switch off pump (21) on switchgear cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:

6. Operate engine at full load and monitor suction pressure.


Result: If the suction pressure is within the specified limits, simulation was successful.

M015650/01E 2007-10 © MTU


Operation 45

3.6 Starting the engine


Preconditions
• External start interlock is not activated.
• Emergency air shut-off flaps (if fitted) are open.

Unguarded rotating and moving engine components.


Risk of serious injury — danger to life!
DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone.

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

The engine can be started from the following points (→Operating instructions for electronic system):
1. Commanding control stand (→Operating instructions for electronic system);
2. Local operating panel LOP (→Operating instructions for electronic system);
3. Local Operation Station LOS (→Operating instructions for electronic system);
4. CCU (→Operating instructions for electronic system).

M015650/01E 2007-10 © MTU


46 Operation

3.7 Fuel treatment system – Switching on


Preconditions
• The onboard power supply is switched on.

Damage to engine/plant.
Major material damage!
CAUTION • 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.

Fuel treatment system – Switching on


1. Carry out checks prior to start-up (→ Page 42).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.

M015650/01E 2007-10 © MTU


Operation 47

3.8 Operational checks


Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Operational checks

Item Task

Engine under load Visually inspect the engine for leaks and general condition;
Engine at nominal speed Check for abnormal noises and vibrations;
Check exhaust color (→ Page 62).
Check overflow line on expansion tank for coolant discharge (→ Page 102),
contact Service in case of severe coolant discharge.

Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter pressure gauge is
within the limit (→ Page 84).
Drain water and contaminants (→ Page 85)

Air filter Check signal ring position of service indicator (→ Page 93);
Replace air filter (→ Page 91), if the signal ring is completely visible in the service
indicator control window.

HT coolant pump Check relief bore for oil and coolant discharge and contaminations (→ Page 112).

Raw water pump Check relief bore for oil and water discharge and contaminations. (→ Page 115)

Hydraulic pack (for Maritune Check hydraulic system visually for leaks.
only)

M015650/01E 2007-10 © MTU


48 Operation

3.9 Stopping the engine


Preconditions
• Engine is running in local mode.

Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
CAUTION • 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.

The engine can be stopped from the following points (→Operating instructions for electronic system):
1. Commanding control stand (→Operating instructions for electronic system);
2. Local operating panel LOP (→Operating instructions for electronic system);
3. Local Operation Station LOS (→Operating instructions for electronic system);
4. CCU (→Operating instructions for electronic system).

M015650/01E 2007-10 © MTU


Operation 49

3.10 Emergency stop


An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
CAUTION • Initiate emergency stop only in emergency situations.

An emergency stop of the engine can be initiated from the following points (→Operating instructions
for electronic system):
1. Commanding control stand (→Operating instructions for electronic system);
2. Local operating panel LOP (→Operating instructions for electronic system);
3. Local Operation Station LOS (→Operating instructions for electronic system);
4. CCU (→Operating instructions for electronic system).

M015650/01E 2007-10 © MTU


50 Operation

3.11 After stopping the engine


Preconditions
• MTU Fluids and Lubricants Specification (A001061/..) is available.
After stopping the engine

Item Task

Cooling system Drain coolant (→ Page 110) if:


• freezing temperatures are expected and the engine is to remain out of
service for an extended period and engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not maintained at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room
temperature;
• antifreeze concentration is 50% and engine-room temperature is
below -40 °C.

Raw water Drain


• if freezing temperatures are expected and the engine is to remain out
of service for an extended period.

Engine control system Switch OFF.

Air intake and exhaust system Out-of-service-period > 1 week


• Seal engine’s air and exhaust sides.
Out-of-service-period > 1 month
• Preserve engine (→MTU Fluids and Lubricants Specification
A001061/.. ).

M015650/01E 2007-10 © MTU


Operation 51

3.12 Fuel treatment system – Putting out of service


Fuel treatment system – Putting out of service
1. Press the illuminated pushbutton “Water drain” on the switchgear cabinet 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 system.
5. Open drain valve until pressure has escaped from fuel treatment system.

M015650/01E 2007-10 © MTU


52 Operation

3.13 Plant – Cleaning


Preconditions
• Engine is stopped and starting disabled.
• Operating voltage is not applied.

Special tools

Designation / Use Part No. Qty.


Steam-jet cleaning unit

Material

Designation / Use Part No. Qty.


Cleaner (Hakupur 312) 30390 1

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Water jet.
Risk of injury and scalding!
WARNING • 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!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
4. Carry out external cleaning as follows:
4.1. Remove coarse dirt.
4.2. Spray on cleaner sparingly and leave it for 1 to 5 minutes.
4.3. Use the high-pressure jet to remove the loosened dirt.
4.4. 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 80 °C.

M015650/01E 2007-10 © MTU


Maintenance 53

4 Maintenance

4.1 Preface

MTU maintenance concept


The maintenance system for MTU products is based on a preventive maintenance concept. Preventive
maintenance facilitates advance planning and ensures a high level of equipment availability.
The maintenance schedule is based on the load profile / load factor specified below. The time intervals at which
the maintenance work is to be carried out and the relevant checks and tasks involved are average values based
on operational experience and are therefore to be regarded as guidelines only. Special operating conditions and
technical requirements may require additional maintenance work and/or modification of the maintenance intervals.
In order to be authorized to carry out the individual maintenance jobs, maintenance personnel must have achieved a
level of training and qualification appropriate to the complexity of the task in hand. The various Qualification Levels
QL1 to QL4 reflect the levels of training offered in MTU courses and the contents of the tool kits required.
QL1: Operational monitoring and maintenance which can be carried out during a break
in operation without disassembling the engine.
QL2: Component replacement (only corrective).
QL3: Maintenance work which requires partial disassembly of the engine.
QL4: Maintenance work which requires complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. Following
this, maintenance work is to be continued at the intervals indicated.
The "Task" numbers stated in the list of jobs to be done/action to be taken indicate the relevant
maintenance item. They serve as a reference for the required scope of parts and are also
listed on the labels of the corresponding spare parts.

Notes on maintenance
Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and lists of
recommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001061 and in
the fluids and lubricants specifications produced by the component manufacturers. They are therefore not included
in the maintenance schedule (exception: deviations from the Fluids and Lubricants Specifications). All fluids and
lubricants used must meet MTU specifications and be approved by the relevant component manufacturer.
Amongst other items, the operator/customer must carry out the following additional maintenance work:
• Protect components made of rubber or synthetic material from oil. Never treat them
with organic detergents. Wipe with a dry cloth only.
• Fuel prefilter:
Maintenance depends on how dirty fuel is. The paper inserts in fuel prefilters must be
changed every two years at the latest (Task 9998).
• Battery:
Battery maintenance depends on the level of use and the ambient conditions. The battery
manufacturer’s instructions must be observed.
The relevant manufacturer’s instructions apply with respect to the maintenance of any components
which do not appear in this maintenance schedule.
Items that are listed in this maintenance schedule but that do not refer to the respective engine model, can be ignored.

Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures in
accordance with the Fluids and Lubricants Specifications, MTU Publication No. A001061.

Application group
1B Fast vessels with high load factors

M015650/01E 2007-10 © MTU


54 Maintenance

Load factor
Load factor

Load profile
Load-profile table

Load factor 100% <15%

Corresponding operating time 75% 25%

Changes from/to full load

M015650/01E 2007-10 © MTU


Maintenance 55

4.2 Maintenance schedule matrix

0-5,250 operating hours


Item Operating hours [h]

Limit years

1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
4,250
4,500
4,750
5,000
5,250
daily
250
500
750
Fuel treatment system 1

Fuel treatment system 2

Engine oil filter 2

Engine operation - X

Crankcase breather - X X X X X X X X X X X X X X X X X X X X X

Crankcase breather - X X X X X X X X X X

Centrifugal oil filter - X X X X X X X X X X

Fuel filter 2 X X X X X X X X X X

Valve gear - X X X X X

Belt drive 2 X

Air filter 3 X

Fuel injectors -

Cylinder chambers -

Component maintenance -

Cylinder head -

Extended component maintenance 18

M015650/01E 2007-10 © MTU


56 Maintenance

5,500-10,750 operating hours


Item Operating hours [h]

Limit years

10,000
10,250
10,500
10,750
5,500
5,750
6,000
6,250
6,500
6,750
7,000
7,250
7,500
7,750
8,000
8,250
8,500
8,750
9,000
9,250
9,500
9,750
Fuel treatment system 1

Fuel treatment system 2

Engine oil filter 2

Engine operation -

Crankcase breather - X X X X X X X X X X X X X X X X X X X X X X

Crankcase breather - X X X X X X X X X X X

Centrifugal oil filter - X X X X X X X X X X X

Fuel filter 2 X X X X X X X X X X X

Valve gear - X X X X X

Belt drive 2 X X

Air filter 3 X X

Fuel injectors - X

Cylinder chambers - X

Component maintenance - X

Cylinder head -

Extended component maintenance 18

M015650/01E 2007-10 © MTU


Maintenance 57

11,000-12,000 operating hours


Item Operating hours [h]

Limit years

12,000
11,000
11,250
11,500
11,750
Fuel treatment system 1

Fuel treatment system 2

Engine oil filter 2

Engine operation -

Crankcase breather - X X X X X

Crankcase breather - X X X

Centrifugal oil filter - X X X

Fuel filter 2 X X X

Valve gear - X X

Belt drive 2 X

Air filter 3 X

Fuel injectors - X

Cylinder chambers - X

Component maintenance - X

Cylinder head - X

Extended component maintenance 18 X

M015650/01E 2007-10 © MTU


58 Maintenance

4.3 Maintenance tasks


Qual- Interval Item Maintenance tasks Task
ifica-
tion [h] [a]

QL1 - 1 Fuel treatment system Fuel treatment system (if installed): check differential pressure gauge W1245
alarm function (→ Page 120)

Fuel treatment system (if installed): check pump capacity W1246


(→ Page 122).

QL1 - 2 Fuel treatment system Fuel treatment system (if installed): check operation of rod electrode W1244
(→ Page 121).

QL1 - 2 Engine oil filter Replace engine oil filter with each engine oil change, at the latest after W1008
limit value years (→ Page 97).

QL1 daily - Engine operation Check engine oil level (→ Page 47). W0500

Visually inspect engine for leaks and general condition (→ Page 47). W0501

Check intercooler drain (if installed) (→ Page 47). W0502

Check service indicator of air filter (→ Page 47). W0503

Check relief bores on coolant pump(s) (→ Page 47). W0505

Check for abnormal running noises, exhaust gas discoloration and W0506
vibrations (→ Page 47).

Drain water and contaminants from fuel prefilter (if fitted) (→ Page 47). W0507

Check vacuum gauge reading on fuel prefilter (if installed) W0508


(→ Page 47).

QL1 250 - Crankcase breather Replace paper or knitted fabric insert (if installed) of oil mist separator. W1139

QL1 500 - Crankcase breather Clean wire meshes of crankcase breather. W1140

QL1 500 - Centrifugal oil filter Centrifugal oil filter (if installed): check layer thickness of oil residue, W1009
clean and replace filter sleeve (→ Page 99).

QL1 500 2 Fuel filter Replace fuel filter or fuel filter element (→ Page 82). W1001

QL1 1,000 - Valve gear Check valve clearance (→ Page 74). W1002

QL1 3,000 2 Belt drive Check drive belt condition and tension, replace if necessary W1003
(→ Page 116).

QL1 3,000 3 Air filter Replace air filter (→ Page 91). W1005

QL1 6,000 - Fuel injectors Replace fuel injectors (→ Page 78). W1006

QL1 6,000 - Cylinder chambers Endoscope cylinder chambers (→ Page 67). W1011

QL3 6,000 - Component maintenance Before starting maintenance work, drain coolant and flush coolant W2000
circuits (→MTU Fluids and Lubricants Specifications A001061/.. )

Clean air pipework (→Maintenance Manual). W2002

Clean intercooler and check for leaks (→Maintenance Manual). W2003

Check engine coolant thermostat and replace thermostat insert W2006


(→Maintenance Manual).

Check centrifugal oil filter for wear (if installed) (→Maintenance W2009
Manual).

Check vibration damper (→Maintenance Manual). W2011

Replace diaphragms of crankcase breather (→Maintenance Manual). W2014

M015650/01E 2007-10 © MTU


Maintenance 59

Qual- Interval Item Maintenance tasks Task


ifica-
tion [h] [a]

Clean engine coolant cooler, and, if possible, check for leaks W2017
(→Maintenance Manual).

Clean engine oil heat exchanger and check for leaks (→Maintenance W2018
Manual).

Check engine alignment. W2036

Clean fuel cooler (→Maintenance Manual). W2059

Overhaul charge-air coolant pump. W2070

Check rocker, valve bridge, pushrods and ball joints for wear W2074
(→Maintenance Manual) (→Maintenance Manual)

Overhaul exhaust turbocharger (→Maintenance Manual). W2075

Replace sealing material of all disassembled components. W2062

Overhaul engine coolant pump (→Maintenance Manual) W2110

Overhaul raw water pump (→Maintenance Manual) W2111

QL3 12,000 - Cylinder head Overhaul cylinder heads and piston crowns and visually inspect W1063
running pattern of cylinder liners (→Maintenance Manual).

QL4 12,000 18 Extended component Disassemble engine completely. Check engine components W3000
maintenance according to assembly instructions, if necessary recondition or
replace (→Workshop Manual).

Replace all elastomer components and seals (→Workshop Manual). W3001

Replace piston rings (→Workshop Manual). W3002

Replace conrod bearings (→Workshop Manual). W3003

Replace crankshaft bearings (→Workshop Manual). W3004

Replace cylinder liners (→Workshop Manual). W3005

Replace auxiliary PTO antifriction bearings (→Workshop Manual). W3006

Replace high-pressure fuel pump (→Workshop Manual). W3007

Replace actuating cylinders for air flaps. W3011

Replace actuating cylinders for exhaust flaps (→Workshop Manual). W3012

Replace exhaust flap bearing (→Workshop Manual). W3013

Overhaul starter (→Workshop Manual). W3041

Overhaul battery-charging generator. W3042

Replace fuel pressure relief valve (→Workshop Manual). W3043

Replace high-pressure fuel sensor (→Workshop Manual). W3057

Replace water filter (→Workshop Manual). W3058

Replace wire meshes of crankcase breather (→Workshop Manual). W3056

M015650/01E 2007-10 © MTU


60 Maintenance

M015650/01E 2007-10 © MTU


Troubleshooting 61

5 Troubleshooting

5.1 Fuel treatment system – Troubleshooting

Symptom Meaning Task

Illuminated pushbutton When the maximum water level is reached, A Press illuminated pushbutton
“water alarm” is lit. the water level electrode opens the water “Water alarm” for
drain valve and water is discharged. If the acknowledgement.
opening period of the valve exceeds a preset B In addition to the automatic
limit (4 minutes), the pump will switch off and water drain function,
an alarm is initiated. water can also be drained
manually. To do so, press
the illuminated pushbutton
“Water drain” to open the
drain valve.

Signal lamp The drive motor is equipped with an overload Reset motor protection relay.
“Pump fault” is lit. protection. If the maximum permissible
current consumption is exceeded, e.g. in
case of a blockage or dry-running, the motor
protection relay triggers and the pump is
switched off.

Signal lamp “Warning filter” The differential pressure exceeded 1.3 bar. Replace coalescer filter element
is lit. (→ Page 123).

Illuminated pushbutton The max. permissible differential pressure 1. Replace coalescer filter
“Replace filter element” is of 1.5 bar was exceeded. If the coalescer element (→ Page 123).
lit. filter element is not replaced, pressure will 2. Press illuminated pushbutton
increase further and the safety valve will “Replace filter element” for
open. Fuel will be led via the bypass directly acknowledgement.
into the overflow tank.

M015650/01E 2007-10 © MTU


62 Troubleshooting

5.2 Troubleshooting
Engine does not turn when starter is actuated

Component Probable Cause Task

Battery Low or defective Charge or replace (see manufacturer’s


documentation).

Cable connections defective Check if cable connections are


properly secured (see manufacturer’s
documentation).

Starter Engine wiring or starter defective Check if cable connections are properly
secured, contact Service.

Engine wiring Defective Check (→ Page 125).

ECU Plug-in connections are loose Check plug-in connections for secure
seating

Engine Running gear blocked (engine Contact Service.


cannot be barred manually)

Engine turns but does not fire

Component Probable Cause Task

Starter Poor rotation by starter: Battery Charge or replace battery (see


low or defective manufacturer’s documentation).

Engine wiring Defective Check (→ Page 125).

Fuel system Not vented Vent fuel system (→ Page 81).

ECU Defective Contact Service.

Engine fires unevenly

Component Probable Cause Task

Fuel injection equipment Injector defective Replace (→ Page 78).

Engine wiring Defective Check (→ Page 125).

Fuel system Not vented Vent fuel system (→ Page 81).

ECU Defective Contact Service.

M015650/01E 2007-10 © MTU


Troubleshooting 63

Engine does not reach nominal speed

Component Probable Cause Task

Fuel supply Fuel prefilter clogged Replace (→ Page 89).

Fuel filter clogged Replace (→ Page 82).

Air supply Air filter clogged Check signal ring position of service indicator
(→ Page 93).

Fuel injection equipment Injector defective Replace (→ Page 78).

Engine wiring Defective Check (→ Page 125).

Engine Overloaded Contact Service.

Engine speed not steady

Component Probable Cause Task

Fuel injection equipment Injector defective Replace (→ Page 78).

Speed sensor Defective Replace.

Fuel system Not vented Vent fuel system (→ Page 81).

ECU Defective Contact Service.

Charge-air temperature too high

Component Probable Cause Task

Engine coolant Incorrect coolant concentration Check.

Intercooler Contaminated Contact Service.

Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts.

Charge air pressure too low

Component Probable Cause Task

Air supply Air filter clogged Check signal ring position of service
indicator (→ Page 93).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercooler

Component Probable Cause Task

Intercooler Leaking, major coolant discharge Contact Service.

M015650/01E 2007-10 © MTU


64 Troubleshooting

Exhaust gas black

Component Probable Cause Task

Air supply Air filter clogged Check signal ring position of service
indicator (→ Page 93).

Fuel injection equipment Injector defective Replace (→ Page 78).

Engine Overloaded Contact Service.

Exhaust gas blue

Component Probable Cause Task

Engine oil Too much oil in engine Drain engine oil (→ Page 96).

Oil separator or oil-preseparator • Clean oil separator (→ Page 71);


of crankcase breather clogged • Replace filter element of oil separator
(→ Page 72).

Exhaust turbocharger, cylinder Defective Contact Service.


head, piston rings, cylinder
liner

Exhaust gas white

Component Probable Cause Task

Engine Not at operating temperature Run engine to reach operating temperature.

Fuel system Water in fuel Drain fuel prefilter (→ Page 85).

Intercooler Leaking Contact Service.

M015650/01E 2007-10 © MTU


Task Description 65

6 Task Description

6.1 Engine

6.1.1 Engine – Barring manually

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Barring tool F6783914 1
Ratchet F30006212 1

Unguarded rotating and moving engine components.


Risk of serious injury - danger to life!
DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled
and all tools removed from the engine.

Engine – Barring manually


1. Fit ratchet with barring tool on barring tool connection at the vibration damper on engine free end.
2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there should
be no abnormal resistance.
Result: If the resistance exceeds compression resistance, contact Service.

M015650/01E 2007-10 © MTU


66 Task Description

6.1.2 Engine – Barring with starting system

Preconditions
• Clutch is disengaged.
• Engine start is disabled.
• LOP is accessible and open.

Unguarded rotating and moving engine components.


Risk of serious injury - danger to life!
DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled
and all tools removed from the engine.

Barring
1. Press barring button on the LMB motherboard of
the LOP and keep it depressed.
Result: Engine is barred by starter for max. 20
seconds.
2. Release barring button.

M015650/01E 2007-10 © MTU


Task Description 67

6.2 Cylinder Liner

6.2.1 Cylinder liner – Endoscopic examination

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Rigid endoscope Y20097353 1

Preparatory steps
1. Remove cylinder-head cover (→ Page 77).
2. Remove injector (→ Page 79).

Positioning crankshaft at BDC


1. Using barring device, turn crankshaft until crankpin of the cylinder to be tested has reached BDC.
2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner - Endoscopic examination

Findings Task

• Thin carbon coating on carbon scraper ring No actions required


• Slight localized additive deposits at top edge
• Localized smooth areas at lower edge
• Carbon deposits on entire circumference between top piston ring and
lower edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker

• Darker areas of even or varying color intensity Further endoscopic examination


• Beginning and end of the discoloration are not sharply defined and do required as part of maintenance
not cover the entire stroke area work
• Dark areas in the upper section of the cooling bore, remaining
circumference cannot be faulted
• Piston rings cannot be faulted

• On the entire circumference not only bright discoloration (not critical for Cylinder liner must be replaced;
operation) clearly visible darker stripes that begin at the top piston ring Service must be contacted
• Heat discoloration in the direction of stroke and honing pattern damage
• Heat discoloration of piston rings

1. Compile endoscopy report using the table.


2. Use technical terms for description of the liner surface (→ Page 69).
3. Depending on findings:
• Do not take any action or
• carry out further endoscopic examination as part of maintenance work or
• contact Service: cylinder liner must be replaced.

M015650/01E 2007-10 © MTU


68 Task Description

Final steps
1. Install injector (→ Page 79).
2. Install cylinder-head cover (→ Page 77).

M015650/01E 2007-10 © MTU


Task Description 69

6.2.2 Instructions and comments on endoscopic and visual


examination of cylinder liners

Terms used for endoscopic examination


Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report.

Minor dirt scores Light scoring can take place during the assembly of a new engine (honing products,
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 another. In
most cases, they are found at the 6-o’clock and 12-o’clock positions (inlet/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 honing
pattern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and temperature
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 interrupted.
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 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.

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 pronounced from TDC-ring
1. The honing pattern is usually no longer visible and displays a clearly defined
(straight) edge to the undisturbed surface. The damaged 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 by either the piston skirt
or the piston crown. Material deposits on the liner (smear), heavy discoloration.
Severe, visible scoring.
Replace liner.

M015650/01E 2007-10 © MTU


70 Task Description

Evaluation of findings and further measures


The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough investigation
and compliance with the above evaluation criteria allows a definite evaluation. To avoid unnecessary disassembly
work, it is recommended that another inspection be carried out after further operation of the engine.

M015650/01E 2007-10 © MTU


Task Description 71

6.3 Crankcase Ventilation

6.3.1 Crankcase breather – Cleaning oil pre-separator element

Preconditions
• Engine is stopped and starting disabled.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Crankcase breather – Cleaning oil pre-separator


element
1. Remove cover (1) from housing (4).
2. Remove oil separator (2) and gasket (3).
3. Clean oil separator (2) in fuel and blow dry with
compressed air.
4. Moisten oil separator (2) with engine oil.
5. Place oil separator (2) with new gasket (3) onto
housing (4) and install cover (1).
6. Clean further oil pre-separator element in the
same way.

M015650/01E 2007-10 © MTU


72 Task Description

6.3.2 Crankcase breather – Oil separator replacement, diaphragm


check and replacement

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Torque wrench 6-50 Nm F30027336 1
Ratchet adapter F30027340 1

Spare parts

Designation / Use Part No. Qty.


Filter element
Diaphragm
O-ring

Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Replacing filter element of oil separator


1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element into housing (4) ensuring
correct installation position, and fit cover (2)
with new O-ring.
4. Tighten screws of cover (2) to specified tightening
torque of 6 Nm + 2 Nm.
5. Replace filter elements of further oil separators in
the same way.

M015650/01E 2007-10 © MTU


Task Description 73

Checking diaphragm
1. Remove cover (4).
2. Take off spring (5), seal (2) and diaphragm (3).
3. Check diaphragm (3) for damage.
4. Fit new diaphragm if used one is damaged.
5. Mount diaphragm (3) on housing (1).
6. Install new seal (2) and spring (5) together with
cover (4).
7. Tighten screws of cover (4) to specified tightening
torque of 6 Nm + 2 Nm.
8. Check diaphragms in further oil separators in
the same way.

M015650/01E 2007-10 © MTU


74 Task Description

6.4 Valve Drive

6.4.1 Valve clearance – Check and adjustment

Preconditions
• Engine is stopped and starting disabled.
• Engine coolant temperature is max. 40 °C.
• Valves are closed.

Special tools

Designation / Use Part No. Qty.


Feeler gauge Y4345893 1
Barring tool F6783914 1
Ratchet F30006212 1
Double box wrench F30002800 1
Allen key F30002816 1
Socket wrench F30030450 1
Torque wrench, 10-60 Nm F30510423 1

Preparatory steps
1. Remove air filter (→ Page 92).
2. Remove cylinder head cover (→ Page 77).

Positioning A1 piston at TDC


1. Remove cable from sensor B13 (→ Page 126).
2. Remove sensor B13.
3. Using ratchet and barring tool, rotate crankshaft in engine direction of rotation until the marking on the flywheel
is aligned with the center of the sensor seat.

Checking valve clearance at two crankshaft positions


1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet (E) = 0.3 mm;
• Exhaust (A) = 0.4 mm.

M015650/01E 2007-10 © MTU


Task Description 75

3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table
below.

8V 2000

Position Cylinder 1 2 3 4 5 6 7 8

Firing TDC in cylinder A1 Bank A EA -A E- -A

Bank B E- E- -- -A

Overlap TDC in cylinder A1 Bank A -- E- -A E-

Bank B -A -A EA E-

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

10 V2000

Position Cylinder 1 2 3 4 5 6 7 8

Firing TDC in cylinder A1 Bank A EA -- -- -A E-

Bank B E- -- -A EA E-

Overlap TDC in cylinder A1 Bank A -- EA EA E- -A

Bank B -A EA E- -- -A

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

12V 2000

Position Cylinder 1 2 3 4 5 6 7 8

Firing TDC in cylinder A1 Bank A EA E- -A E- -A --

Bank B E- -- -A E- EA -A

Overlap TDC in cylinder A1 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

16V 2000

Position Cylinder 1 2 3 4 5 6 7 8

Firing TDC in cylinder A1 Bank A E A - A E A E - -A E - - - - -

Bank B E - - A - - E - E A E - EA -A

Overlap TDC in cylinder A1 Bank A - - E - E - - A E - -A EA EA

Bank B -A E - E A E A - - -A -- E-

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

M015650/01E 2007-10 © MTU


76 Task Description

Adjusting valve clearance


1. Loosen locknut (1) and unscrew adjusting screw
(2) by a few threads.
2. Insert feeler gauge between valve bridge and
rocker arm.
3. Readjust adjusting screw (2) so that the feeler
gauge just passes through the gap.
4. Tighten locknut (1) with torque wrench to the
prescribed tightening torque of 50 Nm while
holding the adjusting screw (2) with screwdriver.
5. Check whether the feeler gauge just passes
through between valve bridge and rocker arm.
Result: If not, adjust valve clearance.

Final steps
1. Install sensor B13.
2. Connect cable to sensor B13.
3. Remove barring tool.
4. Install cylinder head cover (→ Page 77).
5. Install air filter (→ Page 92).

M015650/01E 2007-10 © MTU


Task Description 77

6.4.2 Cylinder-head cover – Removal and installation

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Centering device F6783025 1

Spare parts

Designation / Use Part No. Qty.


Gasket

Preparatory steps
1. Remove air filter (→ Page 92).
2. Remove intake housing.

Cylinder-head cover – Removal and installation


1. Remove screws (1).
2. Remove cylinder-head cover (2) with gasket
from cylinder head.
3. Clean mating faces.
4. Check condition of gasket of cylinder-head cover.
Result: Replace damaged gasket(s).
5. Center cylinder-head cover (2) with centering
device.
6. Use torque wrench to tighten screws (1) to
specified torque 20 Nm.

Final steps
1. Install air filter (→ Page 92).
2. Install intake housing.
3. Check cylinder-head covers for leaks.

M015650/01E 2007-10 © MTU


78 Task Description

6.5 Injector

6.5.1 Injector – Replacement

Spare parts

Designation / Use Part No. Qty.


Injector

Remove injector and install new one (→ Page 79).

M015650/01E 2007-10 © MTU


Task Description 79

6.5.2 Injector – Removal and installation

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Socket wrench 0005896803/00 1
Assembly device F6784160 1
Double box wrench F30011450 1
Open end wrench bit F30025897 1
Box wrench adapter F30451199 1

Material

Designation / Use Part No. Qty.


Petroleum jelly, white 40317 1
Engine oil

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Preparatory steps
1. Close fuel supply to engine.
2. Remove cylinder head cover (→ Page 77).

Removing injector
1. Remove HP line (5) using socket wrench.
2. Disconnect injector cable (4).
3. Remove screw (2).
4. Take off hold-down clamp (3).
5. Remove injector (1) with assembly device.
6. Remove O-rings from injector.
7. Mask all connections and bores or seal with
suitable plugs.

M015650/01E 2007-10 © MTU


80 Task Description

Installing injector
1. Remove all plugs before installation.
2. Fit new O-rings (supplied with the injector) on the injector and coat with petroleum jelly.
3. Fit new sealing ring with petroleum jelly on injector, ensuring correct installation position of sealing ring.
4. Clean sealing surface on cylinder head and protective sleeve.
5. Use assembly device to insert injector (1) in cylinder head, ensuring that it is correctly aligned with the HP
line connection.
6. Fit hold-down clamp (3) in correct installation position, coat screw (2) with engine oil.
7. Screw in screw (2) and tighten by hand.
8. Coat thread and sealing cone of HP line (5) and injector (1) with engine oil.
9. Connect HP line (5) to HP fuel accumulator and tighten by hand.
10. Connect HP line (5) to injector (1) and tighten by hand.
11. Tighten screw of hold-down clamp (3) to specified tightening torque of 40 Nm + 4 Nm using a box wrench
adapter and a torque wrench.
12. Use socket wrench and torque wrench to tighten HP line (5) to the specified torque:
• Thrust screw on injector to 20 Nm + 5 Nm
• Thrust screw on rail to 30 Nm + 5 Nm
13. Attach cable (4).

Final steps
1. Install cylinder head cover (→ Page 77).
2. Open fuel supply to engine.

M015650/01E 2007-10 © MTU


Task Description 81

6.6 Fuel System

6.6.1 Fuel system – Venting

Preconditions
• Engine is stopped and starting disabled.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel system – Venting


1. Unlock fuel priming pump, unscrew handle.

2. Open vent plugs on filter head.


3. Operate the pump with the handle until fuel
without bubbles comes out of the vent plugs
and the nipples.
4. Close vent plugs on filter head.
5. Operate the pump with the handle until fuel without
bubbles comes out of the nipple.
6. Lock fuel priming pump, screw in handle.

M015650/01E 2007-10 © MTU


82 Task Description

6.7 Fuel Filter

6.7.1 Fuel filter – Replacement

Special tools

Designation / Use Part No. Qty.


Oil filter wrench F30379104 1

Material

Designation / Use Part No. Qty.


Diesel fuel

Spare parts

Designation / Use Part No. Qty.


Easy-change filter

Unguarded rotating and moving engine components.


Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Engine noise above 85 dB (A).
Risk of damage to hearing!
WARNING • Wear ear protectors.

Damage to component.
Serious damage to plant!
CAUTION • 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.

M015650/01E 2007-10 © MTU


Task Description 83

Fuel filter replacement with the engine stopped


1. Stop engine and disable starting
2. Cut out the filter to be replaced.
3. Remove cut-out filter using the oil filter wrench.
4. Clean the sealing surface of the filter head.
5. Check sealing ring of the new easy-change filter
and coat it with fuel.
6. Fit the protective cover acc. to SOLAS
requirements (→ Page 15).
7. Install and tighten new filter by hand.
8. Set three-way cock to operating position (both
filters cut in).
9. Replace further fuel filters in the same way.
10. Vent fuel system (→ Page 81).

A Both filters cut in (operating position)


B Left filter cut out
C Right filter cut out

Fuel filter replacement with the engine running


1. Cut out the filter to be replaced.
2. Open vent plug of the cut-out filter and make
sure that the pressure is completely released
from the filter.
3. Close vent plugs.
4. Remove cut-out filter using the oil filter wrench.
5. Clean the sealing surface of the filter head.
6. Check sealing ring of the new easy-change filter
and coat it with fuel.
7. Fit the protective cover acc. to SOLAS
requirements (→ Page 15).
8. Install and tighten new filter by hand.
9. Set three-way cock to operating position (both
filters cut in).
10. Replace further fuel filters in the same way.

M015650/01E 2007-10 © MTU


84 Task Description

6.7.2 Fuel prefilter, differential pressure gauge – Inspection and adjustment


Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Differential pressure – Adjustment of indicator


1. When commissioning the new filter element: Align
adjustable pointer (2) with pressure indicator (3) on
pressure gauge (1).
2. Check the differential pressure.

Fuel prefilter – Differential pressure check


1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of pressure
gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 87).

M015650/01E 2007-10 © MTU


Task Description 85

6.7.3 Fuel prefilter - Draining

Preconditions
• Engine is stopped and starting disabled.

Material

Designation / Use Part No. Qty.


Diesel fuel

Spare parts

Designation / Use Part No. Qty.


Seal

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

M015650/01E 2007-10 © MTU


86 Task Description

Fuel prefilter, water draining


1. Shut off the filter to be drained.

I Left filter cut in


II Right filter cut in

2. Open vent plug (5) of the filter to be drained.


3. Unlock drain cock (6) by pressing toggle and
open it.
4. Drain water and contaminants from the filter until
pure fuel emerges.
5. Close drain cock (6).
6. Remove screws securing the cover and take
off cover (2).
7. Fill filter housing with clean fuel.
8. Place new gasket in cover (2).
9. Fit cover with gasket and secure it with screws.
10. Turn the cut-off filter on again.
11. When fuel emerges from system, close vent
plug (5).

M015650/01E 2007-10 © MTU


Task Description 87

6.7.4 Fuel prefilter – Flushing

Material

Designation / Use Part No. Qty.


Diesel fuel

Spare parts

Designation / Use Part No. Qty.


Gasket

Unguarded rotating and moving engine components.


Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Engine noise above 85 dB (A).
Risk of damage to hearing!
WARNING • Wear ear protectors.

M015650/01E 2007-10 © MTU


88 Task Description

Fuel prefilter – Flushing


1. Cut out the contaminated filter.

I Left filter cut in


II Right filter cut in

2. Open vent plug (5) of the filter to be flushed.


3. Unlock drain cock (6) by pressing toggle, open it
and drain fuel.
Result: Fuel flows from filtered side back to
the unfiltered side, flushing the filter deposits
downwards out of the filter.
4. Close vent plug (5) and drain cock (6).

Fuel prefilter – Filling with fuel


1. Stop the engine (→Operating instructions for electronic system) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
3. Fill filter housing with clean fuel.
4. Place new gasket in cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 84).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 89).

M015650/01E 2007-10 © MTU


Task Description 89

6.7.5 Fuel prefilter – Filter element replacement

Preconditions
• Engine is stopped and starting disabled.

Material

Designation / Use Part No. Qty.


Diesel fuel

Spare parts

Designation / Use Part No. Qty.


Filter element
Seal

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

M015650/01E 2007-10 © MTU


90 Task Description

Replace filter element


1. Shut off the contaminated filter.

I Left filter cut in


II Right filter cut in

2. Open vent plug (5) of the contaminated filter.


3. Unlock drain cock (6) by pressing toggle and
open it.
4. Drain water and contaminants from the filter.
5. Close drain cock (6).
6. Remove screws securing the cover and take
off cover (2).
7. Remove spring (4) and filter element (3).
8. Insert new filter element (3) and spring (4).
9. Fill filter housing with clean fuel.
10. Place new gasket in cover (2).
11. Fit cover with gasket and secure it with screws.
12. Turn the cut-off filter on again.
13. Close vent plug (5) when fuel emerges.
14. Adjust the differential pressure gauge.
(→ Page 84).

M015650/01E 2007-10 © MTU


Task Description 91

6.8 Air Filter

6.8.1 Air filter replacement

Spare parts

Designation / Use Part No. Qty.


Air filter

Remove air filter and install new one (→ Page 92).

Reset signal ring of service indicator (→ Page 93).

M015650/01E 2007-10 © MTU


92 Task Description

6.8.2 Air filter removal and installation

Preconditions
• Engine is stopped and starting disabled.
Air filter removal and installation
1. Loosen 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 filter (3) with clamp (2) onto intake
housing (1).
5. Tighten clamp (2).

M015650/01E 2007-10 © MTU


Task Description 93

6.9 Air Intake

6.9.1 Service indicator – Signal ring position check

Preconditions
• Engine is stopped and starting disabled.
Signal ring position check
1. If the signal ring is completely visible in the control
window (2), replace air filter (→ Page 91).
2. After installation of new filter, press reset button (1).
Result: Engaged piston with signal ring moves
back to initial position.

M015650/01E 2007-10 © MTU


94 Task Description

6.10 Staring Equipment

6.10.1 Starter – Condition check

Preconditions
• Engine is stopped and starting disabled.
Starter – Condition check
1. Check starter securing screws for secure seating.
2. Tighten loose screw connections.
3. Check wiring (→ Page 125).

M015650/01E 2007-10 © MTU


Task Description 95

6.11 Lube-oil System, Lube-oil Circuit

6.11.1 Engine oil – Level check

Preconditions
• Engine is stopped and starting disabled.
Oil level check prior to engine start
1. Withdraw dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop,
withdraw after approx. 10 seconds and check
oil level.
3. Oil level must be between "min." and "max." marks.
4. Top up to "max." if required (→ Page 96).
5. Insert dipstick into guide tube up to the stop.

Oil level check after the engine is stopped


1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between "min." and "max." marks.
4. Top up to "max." if required (→ Page 96).
5. Insert dipstick into guide tube up to the stop.

M015650/01E 2007-10 © MTU


96 Task Description

6.11.2 Engine oil – Change

Preconditions
• Engine is stopped and starting disabled.
• Engine is at operating temperature.
• MTU Fluids and Lubricants Specifications (A001061/..) are available.

Material

Designation / Use Part No. Qty.


Engine oil

Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Version with extraction equipment: Oil extraction


1. Position a suitable container to drain the engine oil into.
2. Extract all oil from oil pan using the extraction equipment.

Filling with new oil


1. Determine filling capacity for oil change (→
Product Summary - Technical Data).
2. Open cover of filler neck.
3. Fill engine oil through filler neck until “max.” mark
on oil dipstick is reached.
4. Close cover of filler neck.
5. Check engine oil level (→ Page 95).
6. After oil change, bar engine with starting system.

M015650/01E 2007-10 © MTU


Task Description 97

6.12 Oil Filtration/Cooling

6.12.1 Engine oil filter – Replacement

Special tools

Designation / Use Part No. Qty.


Oil filter wrench F30379104 1

Material

Designation / Use Part No. Qty.


Engine oil

Spare parts

Designation / Use Part No. Qty.


Oil filter

Unguarded rotating and moving engine components.


Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING 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!
CAUTION • 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.

M015650/01E 2007-10 © MTU


98 Task Description

Oil filter replacement with the engine stopped


1. Stop engine and disable starting
2. Cut out the filter to be replaced.

A Right filter cut out


B Both filters cut in (operating position)
C Left filter cut out

3. Remove cut-out oil filter using the oil filter wrench.


4. Clean the sealing surface at the connecting piece.
5. Check condition of the new sealing ring and
coat it with oil.
6. Fit the protective cover acc. to SOLAS
requirements (→ Page 15).
7. Install and tighten new oil filter by hand.
8. Replace further oil filters in the same way.
9. After each oil change and filter replacement, bar
engine with starting system (→ Page 66).
10. Check oil level (→ Page 95).

Oil filter replacement with the engine running


1. Cut out the filter to be replaced.
2. Remove cut-out oil filter using the oil filter wrench.
3. Clean the sealing surface at the connecting piece.
4. Check condition of the new sealing ring and coat it with oil.
5. Fit the protective cover acc. to SOLAS requirements (→ Page 15).
6. Install and tighten new oil filter by hand.
7. Replace further oil filters in the same way.
8. Check oil level (→ Page 95).

M015650/01E 2007-10 © MTU


Task Description 99

6.12.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Strap wrench F30379104 1

Material

Designation / Use Part No. Qty.


Cold cleaner (Hakutex 50) 50622 1

Spare parts

Designation / Use Part No. Qty.


Filter sleeve
O-ring
O-ring

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Centrifugal oil filter – Rotor removal


1. Release nuts (3).
2. Remove housing cover (1).
3. Remove complete rotor (2) from housing.

M015650/01E 2007-10 © MTU


100 Task Description

Centrifugal oil filter – Cleaning and filter-sleeve


replacement
1. Remove nut, holding the rotor with a strap wrench.

2. Remove nut (1), washer (2), rotor cap (3) and


sealing ring (4).

3. Remove sleeve (1).


4. Measure the layer thickness of the oil residue.
5. If maximum layer thickness (25 mm) is exceeded,
shorten maintenance interval.
6. Clean rotor components and remove strainers (2).
7. Wash standpipes (3) and nozzles (4) with cleaner,
blow out with compressed air.
8. Insert the new filter sleeve with the smooth surface
facing the rotor cap.

M015650/01E 2007-10 © MTU


Task Description 101

9. Fit new sealing ring (4).


10. Set on rotor cap (3), observe marks.
11. Fit washer (2).
12. Hold rotor with strap wrench and tighten nut
(1) with torque wrench to the specified torque:
40 to 50 Nm.

13. Insert complete rotor (2) into the housing and


check for ease-of-movement.
14. Set housing cover (1) with new sealing ring onto
lower section, observe marks.
15. Tighten nuts (3) crosswise and evenly.

M015650/01E 2007-10 © MTU


102 Task Description

6.13 General Cooling Circuit, High Temperature Circuit

6.13.1 Drain and venting points

8 V, 10 V

1 Overflow line, expansion tank 2 Filler neck

M015650/01E 2007-10 © MTU


Task Description 103

12 V, 16 V

1 Overflow line, expansion tank 2 Filler neck

M015650/01E 2007-10 © MTU


104 Task Description

Free end (KGS)

1 Fuel filter vent screws 4 Measuring point, pressure before 6 Connection for oil extraction
2 Engine coolant drain plug raw water pump
3 Raw water pump filling plug 5 Raw water pump drain plug

M015650/01E 2007-10 © MTU


Task Description 105

Left side

1 Engine coolant drain plug


2 Engine coolant drain plug
(M14x1.5)

M015650/01E 2007-10 © MTU


106 Task Description

Right side

1 Engine coolant drain plug 3 Oil dipstick (connection left or


(M14x1.5) right engine side optional)
2 Oil filler neck (connection left or 4 Leak-off-fuel tank
right engine side optional)

M015650/01E 2007-10 © MTU


Task Description 107

Driving end (KS)

1 Engine coolant drain plug 2 Connection for oil extraction

M015650/01E 2007-10 © MTU


108 Task Description

6.13.2 Engine coolant – Level check

Preconditions
• Engine is stopped and starting disabled.
• MTU Fluids and Lubricants Specification (A001061/..) is available.

Coolant is hot and under pressure.


Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Coolant-level check at filler neck:


1. Turn breather valve on coolant expansion tank
(→ Page 22) counterclockwise until first 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).

Coolant-level check by means of level sensor:


1. Switch engine control system on and check display (coolant level is automatically monitored by the engine
control system).
2. If required, top up with treated engine coolant (→ Page 111).

M015650/01E 2007-10 © MTU


Task Description 109

6.13.3 Engine coolant – Change

Material

Designation / Use Part No. Qty.


Engine coolant

Drain engine coolant (→ Page 110).

Fill engine coolant system (→ Page 111).

M015650/01E 2007-10 © MTU


110 Task Description

6.13.4 Engine coolant – Draining

Preconditions
• Engine is stopped and starting disabled.

Coolant is hot and under pressure.


Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Preparatory steps
1. Provide an appropriate container to collect the coolant or
2. switch on the extraction device.
3. Switch off preheating unit.

Engine coolant – Draining


1. Turn breather valve on coolant expansion tank (→ Page 102)counterclockwise to the first stop and release
pressure.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
4. Open drain valves or drain plugs (→ Page 102) and drain or pump off coolant.
5. Close all open drain points.
6. Set breather valve onto filler neck and close it.

M015650/01E 2007-10 © MTU


Task Description 111

6.13.5 Engine coolant system – Filling

Preconditions
• Engine is stopped and starting disabled.
• MTU Fluids and Lubricants Specification (A001061/..) is available.

Material

Designation / Use Part No. Qty.


Engine coolant

Coolant is hot and under pressure.


Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Cold coolant in hot engine can cause thermal stress.


Formation of cracks in components!
CAUTION • Fill / top up coolant only into cold engine.

Engine coolant system – Filling


1. Turn breather valve on coolant expansion tank (→ Page 22)counterclockwise to first stop and allow pressure
to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Pour coolant into engine until coolant level reaches lower edge of cast-in eye of filler neck.
4. Check proper condition of breather valve and clean sealing faces.
5. Set breather valve onto filler neck and close it.
6. Start the engine and operate it at idle speed for some minutes.
7. Check coolant level (→ Page 108) .

M015650/01E 2007-10 © MTU


112 Task Description

6.13.6 HT coolant pump – Relief bore check


Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

HT coolant pump – Relief bore check


1. Check relief bore for oil and coolant discharge.
2. Stop the engine (→Operating instructions for
electronic system)and disable engine start.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to 10 drops
per hour;
• Permissible oil discharge: up to 5 drops per
hour.
4. If discharge exceeds the specified limits, contact
Service.

M015650/01E 2007-10 © MTU


Task Description 113

6.13.7 Engine coolant – Sample extraction and analysis

Preconditions
• Engine is stopped and starting disabled.
• MTU Fluids and Lubricants Specification (A001061/..) is available.

Special tools

Designation / Use Part No. Qty.


MTU test kit 5605892099/00 1

Coolant is hot and under pressure.


Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Engine coolant – Sample extraction and analysis


1. Turn breather valve on coolant expansion tank (→ Page 102)counterclockwise until first stop and allow
pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
4. Draw off approx. 1 liter coolant and drain into a clean container.
5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Fit breather valve and close it.
7. Change engine coolant according to the coolant operating times specified in the (→MTU Fluids and Lubricants
Specifications A001061/..) (→ Page 110).

M015650/01E 2007-10 © MTU


114 Task Description

6.13.8 Coolant filter – Replacement

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Oil filter wrench F30379104 1

Spare parts

Designation / Use Part No. Qty.


Engine coolant filter

Coolant is hot and under pressure.


Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Coolant filter – Replacement


1. Turn breather valve on coolant expansion tank
(→ Page 22)counterclockwise until first stop and
allow pressure to escape.
2. Continue to turn breather valve counterclockwise
and remove.
3. Remove coolant filter using the oil filter wrench.
4. Clean the sealing surface at the connecting piece.
5. Moisten sealing ring of the new coolant filter
with engine oil.
6. Install and tighten coolant filter by hand.
7. Close breather valve.
8. Check coolant level (→ Page 108).

M015650/01E 2007-10 © MTU


Task Description 115

6.14 Raw Water Pump with Connections

6.14.1 Raw water pump – Relief bore check


Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.

Engine noise above 85 dB (A).


Risk of damage to hearing!
WARNING • Wear ear protectors.

Raw water pump – Relief bore check


1. Check relief bore for oil and coolant discharge.
2. Stop the engine (→Operating instructions for
electronic system) and disable engine start.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to 10 drops
per hour;
• Permissible oil discharge: up to 5 drops per
hour.
4. If discharge exceeds the specified limits, contact
Service.

M015650/01E 2007-10 © MTU


116 Task Description

6.15 Belt Drive

6.15.1 Drive belt – Condition check

Preconditions
• Engine is stopped and starting disabled.
• Guard is removed.

Item Findings Task

Drive belt A Breaks in a few individual places None

Drive belt Belt is oily, shows signs of Replace (→ Page 118)


overheating

Drive belt B Breaks around the entire


circumference

Drive belt C Areas of belt material missing

M015650/01E 2007-10 © MTU


Task Description 117

6.16 Battery-Charging Generator

6.16.1 Battery-charging generator drive – Drive belt check and adjustment

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Assembly device F6559691 1

Check drive belt condition (→ Page 116).

Drive belt – Checking distance


1. Measure distance (A) with assembly device.
2. If measured value of distance (A) is not within the
tolerance of 98 mm ± 1.5 mm, readjust belt tension.

Adjusting belt tension


1. Counterhold adjustment lever (2) at square (5).
2. Rotate adjusting lever until drive belt (4) is detensioned.
3. Loosen screws (1) and (3).
4. Use assembly device to adjust distance (A) by turning adjustment lever (2).
5. Tighten screws (1) and (3).
6. Measure distance (A) with assembly device.

M015650/01E 2007-10 © MTU


118 Task Description

6.16.2 Battery-charging generator drive – Drive belt replacement

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Mandrel 8205892861/08 1

Preparatory steps
1. Remove safety equipment (if fitted).
2. Remove screws of protective cover (engine free end).
3. Take off protective cover.

Replacing drive belt


1. Counterhold adjusting lever at square.
2. Rotate adjusting lever until drive belt is detensioned.
3. Use mandrel to lock adjusting lever in position.
4. Remove drive belt.
5. Check cleanness of belt pulleys.
6. Insert new drive belt.
7. Remove mandrel.

Final steps
1. Check distance dimension of belt drive (→ Page 117).
2. Install guard.
3. Install screws of protective cover.
4. Install safety equipment (if fitted).
5. Check function of safety equipment (if fitted).

M015650/01E 2007-10 © MTU


Task Description 119

6.17 Fuel Supply System

6.17.1 Water drain valve – Check


Water drain valve – Check
1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.

M015650/01E 2007-10 © MTU


120 Task Description

6.17.2 Differential pressure gauge – Check


Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Differential pressure gauge – Check


1. Switch on fuel treatment system (→ Page 46).
2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is initiated with preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.

M015650/01E 2007-10 © MTU


Task Description 121

6.17.3 3-in-1 bar electrode – Check

Preconditions
• System is put out of service and emptied.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

3-in-1 bar electrode – Check


1. Remove connector from 3-in-1 bar electrode.
2. Unscrew 3-in-1 bar electrode.
3. Plug connector into 3-in-1 bar electrode.
4. Immerse 3-in-1 bar electrode into a tank filled with water up to the thread.
Result: Water drain valve opens.
5. Keep 3-in-1 bar electrode in the tank.
Result: Alarm must be initiated with the preset delay.
6. Remove connector from 3-in-1 bar electrode.
7. Remove 3-in-1 bar electrode from tank.
8. Screw in 3-in-1 bar electrode.
9. Plug connector into 3-in-1 bar electrode.
10. Put the fuel treatment system into operation.

M015650/01E 2007-10 © MTU


122 Task Description

6.17.4 Pump capacity – Check

Special tools

Designation / Use Part No. Qty.


Pressure gauge

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Pump capacity – Check


1. Install pressure gauge in the intake connection of the pump.
2. Check pump pressure.
2.1. Switch on fuel treatment system (→ Page 46).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused
by overflowing fuel and can be disregarded.

2.2. Close ball valve at the outlet of the fuel treatment system.
2.3. Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Checking pump pressure with reduced suction
3.1. Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.
3.2. Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3.3. Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.

Example:

Measured value (normal condition). 3 bar

Measured value (reduced suction condition). 2.6 bar

If the measured value (reduced suction condition) is 10% lower than the measured value (normal condition), the
wear limit is reached. Repair pump (contact Service).

M015650/01E 2007-10 © MTU


Task Description 123

6.17.5 Coalescer filter element – Replacement

Preconditions
• System is switched off and starting disabled.

Special tools

Designation / Use Part No. Qty.


Torque wrench, 6-50 Nm F30027336 1
Ratchet adapter F30027339 1

Material

Designation / Use Part No. Qty.


Diesel fuel

Spare parts

Designation / Use Part No. Qty.


Coalescer filter element
Seal

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

M015650/01E 2007-10 © MTU


124 Task Description

Coalescer filter element – Replacement


1. Close ball valve at inlet and outlet of fuel treatment
system.
2. Open drain valve.
3. Drain fuel.
4. Close drain valve.
5. Remove nut (9) with washer (2).
6. Remove screws (1).
7. Remove cover with seal (10).
8. Remove nut (3), washer (8) and end plate (7).
9. Remove coalescer filter element (4).
10. Collect emerging fuel.
11. Clean housing with a non-linting cloth, rinse
with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element.
15. Install end plate (7), washer (8) and nut (3).
16. Use torque wrench to tighten nut (3) to the
specified tightening torque. Tightening torque:
30 Nm
17. Fit seal (10).
18. Install cover.
19. Install screw (1), washer (2) and nut (9).
20. Tighten nut (9).
21. Open ball valve at inlet and outlet of fuel treatment
system.
Result: The fuel treatment system is ready for
operation.

M015650/01E 2007-10 © MTU


Task Description 125

6.18 General Cabling for Engine / Gearbox / Genset

6.18.1 Engine wiring – Check

Preconditions
• Engine is stopped and starting disabled.

Material

Designation / Use Part No. Qty.


Isopropyl alcohol 46181 1

Engine wiring – Check


1. Check securing screws of cable clamps on the engine and tighten loose screw connections.
2. Make certain that cables are securely seated in clamps and cannot move freely.
3. Check cable binders for secure seating, tighten loose cable binders.
4. Replace defective cable binders.
5. Inspect electrical components visually for damage:
• connector housings;
• contacts;
• connector sockets;
• cables and terminals;
• plug-in contacts.
6. If conductors are damaged (→Contact Service)
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Make certain that all sensor connectors are securely latched.

M015650/01E 2007-10 © MTU


126 Task Description

6.18.2 Sensors, actuators and injectors - Overview

Pos. Designation Monitors

1 B3 Intake air temperature

2 B44 Turbocharger speed

3 B9 Charge-air temperature

4 B10 Charge-air pressure

5 B7 Lube-oil temperature

M015650/01E 2007-10 © MTU


Task Description 127

V 2000CR, free end (KGS)

Pos. Designation Monitors

1 B34 Fuel line: pressure downstream of filter

2 B5.3 Lube oil pressure upstream of filter

3 B5.2 Lube oil pressure

4 B5 Lube oil pressure

5 F33 Coolant pressure

6 B21 Raw water pressure

7 B16 Coolant pressure

8 B6.2 Coolant temperature

9 B6 Coolant temperature

M015650/01E 2007-10 © MTU


128 Task Description

V 2000CR, driving end (KS)

Pos. Designation Monitors

1 B4.22 Exhaust temperature

2 B1 Camshaft speed

M015650/01E 2007-10 © MTU


Task Description 129

V 2000CR, right engine side

Pos. Designation Monitors

1 Y39.x Injector (illustration shows 16V, for 12V two


sensors less)

2 B33 Fuel temperature

3 B48 Fuel pressure in Common Rail

4 M8 H.P. pump

5 B13.2 Crankshaft speed

6 B13 Crankshaft speed

7 F46 Leak-off fuel level

M015650/01E 2007-10 © MTU


130 Task Description

V 2000CR, left engine side

Pos. Designation Monitors

1 Y39.x Injector (illustration shows 16V, for 12V two


sensors less)

2 B4.21 Exhaust temperature, A bank

3 Y27 Exhaust temperature, B bank

System sensors
These sensors are fitted outside the engine.

Designation Monitors

B19 Intake air depression

B70 Water level in fuel prefilter

B41 Exhaust back pressure

S37 Start interlock, switching status

M015650/01E 2007-10 © MTU


Task Description 131

6.19 Accessories for Engine Governor (Electronic) / Control


System

6.19.1 Engine governor and connectors – Cleaning

Preconditions
• Engine is stopped and starting disabled.

Material

Designation / Use Part No. Qty.


Isopropyl alcohol

Engine governor and connectors – Cleaning


1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.
2. Remove dirt from connector and cable surfaces with isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning heavily contaminated connectors on engine governor


1. Release latches of connectors and withdraw connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches.

M015650/01E 2007-10 © MTU


132 Task Description

6.19.2 EMU and connectors – Cleaning

Preconditions
• Engine is stopped and starting disabled.

Material

Designation / Use Part No. Qty.


Isopropyl alcohol

EMU and connectors – Cleaning


1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.
2. Remove dirt from connector and cable surfaces with isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated EMU connectors


1. Release latches of connectors and withdraw connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches.

M015650/01E 2007-10 © MTU


Task Description 133

6.19.3 Engine governor plug-in connections – Check

Preconditions
• Engine is stopped and starting disabled.
Checking plug-in connections on engine governor
1. Verify that all plug-in connections are securely seated.
2. Secure loose connectors and latch.

M015650/01E 2007-10 © MTU


134 Task Description

6.19.4 EMU – Checking plug-in connections

Preconditions
• Engine is stopped and starting disabled.
EMU – checking plug-in connections
1. Verify that all plug-in connections are securely seated.
2. Secure loose connectors and latch.

M015650/01E 2007-10 © MTU


Task Description 135

6.19.5 ECU – Self-test implementation


Electrical voltage.
Risk of serious injury - danger to life!
DANGER • Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!

Self-test implementation
1. Switch off power supply to system.
2. Remove connectors X1, X2 and X4 from the
engine governor.
2.1. Release lock (3) of connectors (2).
2.2. Withdraw connectors (2).
3. Switch on power supply.
Result:
• The engine governor is operable if the
diagnostic lamp (1) changes to continuous
illumination within 30 seconds after power has
been switched on.
• If the diagnostic lamp (1) flashes after 30
seconds, replace engine governor (→Contact
Service).
• If the diagnostic lamp stays dark, check power
supply.
4. Switch off power supply.
5. Refit connectors X1, X2 and X4 on engine
governor.
5.1. Plug in connector (2).
5.2. Lock connectors.

M015650/01E 2007-10 © MTU


136 Task Description

6.19.6 Engine governor – Removal and installation

Preconditions
• Engine is stopped and starting disabled.
Removing engine governor from engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (2).
3. Release lock (3) of connectors.
4. Withdraw all connectors.
5. Remove screws (1).
6. Take off engine governor.

Installing engine governor on engine


1. For installation follow reverse sequence of working steps. Ensure that connectors are plugged in the correct
socket.
2. Check rubber bearing before installation.
Result: If the rubber bearing is porous or defective, fit a new one.

M015650/01E 2007-10 © MTU


Task Description 137

6.19.7 EMU – Installation and removal

Preconditions
• Engine is stopped and starting disabled.
Removing ECU with EMU from the engine
1. Mark or note down cable to connection
assignment.
2. Remove all screws (2).
3. Undo latches (3) of the connectors.
4. Withdraw all connectors.
5. Remove screws (1).
6. Take off ECU (1) with EMU (4).

Removing EMU
1. Remove screws from the lower side of EMU (4).
2. Take off EMU (4) from ECU (1).

Installing EMU
1. Place EMU (4) on ECU (1).
2. Install screws on the lower side of EMU (4) and tighten.

Installing ECU with EMU on engine


1. For installation, follow the reverse sequence of work steps as described for removal. Ensure that the cables
are correctly assigned to the connections.
2. Check rubber mount before installation.
Result: If the rubber mount is porous or defective, fit a new one.

M015650/01E 2007-10 © MTU


138 Task Description

M015650/01E 2007-10 © MTU


Special Tools 139

7 Special Tools

7.1 Special tools

Part No. Designation / Use Qty.

Steam-jet cleaning unit

F6783914 Barring tool 1

F30006212 Ratchet 1

M015650/01E 2007-10 © MTU


140 Special Tools

Part No. Designation / Use Qty.

Y20097353 Rigid endoscope 1

F30027336 Torque wrench 6-50 Nm 1

M015650/01E 2007-10 © MTU


Special Tools 141

Part No. Designation / Use Qty.

F30027340 Ratchet adapter 1

Y4345893 Feeler gauge 1

M015650/01E 2007-10 © MTU


142 Special Tools

Part No. Designation / Use Qty.

F6783914 Barring tool 1

F30002800 Double box wrench 1

M015650/01E 2007-10 © MTU


Special Tools 143

Part No. Designation / Use Qty.

F30002816 Allen key 1

F30030450 Socket wrench 1

M015650/01E 2007-10 © MTU


144 Special Tools

Part No. Designation / Use Qty.

F30510423 Torque wrench, 10-60 Nm 1

F6783025 Centering device 1

0005896803/00 Socket wrench 1

M015650/01E 2007-10 © MTU


Special Tools 145

Part No. Designation / Use Qty.

F6784160 Assembly device 1

F30011450 Double box wrench 1

M015650/01E 2007-10 © MTU


146 Special Tools

Part No. Designation / Use Qty.

F30025897 Open end wrench bit 1

F30451199 Box wrench adapter 1

M015650/01E 2007-10 © MTU


Special Tools 147

Part No. Designation / Use Qty.

F30379104 Oil filter wrench 1

F30379104 Strap wrench 1

M015650/01E 2007-10 © MTU


148 Special Tools

Part No. Designation / Use Qty.

5605892099/00 MTU test kit 1

F6559691 Assembly device 1

M015650/01E 2007-10 © MTU


Special Tools 149

Part No. Designation / Use Qty.

8205892861/08 Mandrel 1

F30027336 Torque wrench, 6-50 Nm 1

M015650/01E 2007-10 © MTU


150 Special Tools

Part No. Designation / Use Qty.

F30027339 Ratchet adapter 1

Pressure gauge

M015650/01E 2007-10 © MTU


Special Tools 151

7.2 Standard tools – Overview

Part No. Designation Qty.


Use

8205891159/00 General tools kit 1

M015650/01E 2007-10 © MTU


152 Special Tools

M015650/01E 2007-10 © MTU


Annex 153

8 Annex

8.1 Manufacturer’s documentation


See Manufacturer’s documentation.

M015650/01E 2007-10 © MTU


154 Annex

8.2 MTU contact person/service partner


You will find the MTU contact person/service partner for your region at www.mtu-online.com,
worldwide, in the left-hand navigation margin.

M015650/01E 2007-10 © MTU


Annex 155

8.3 Index
12V 2000 M72 engine data: Engine-mounted Coolant filter – Replacement . . . . . . . . . . . . . . 114
heat exchanger, EPA stage 2 . . . . . . . . . . . . . 25 Crankcase breather – Cleaning oil pre-separator
12V 2000 M72 engine data: Separate heat element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
exchanger, EPA stage 2 . . . . . . . . . . . . . . . . . 29 Crankcase breather – Oil separator replacement,
16V 2000 M72 engine data: Engine-mounted diaphragm check and replacement . . . . . . . . . 72
heat exchanger, EPA stage 2 . . . . . . . . . . . . . 32 Crankcase Ventilation . . . . . . . . . . . . . . . . . . . 71
16V 2000 M72 engine data: Separate heat Crankcase breather – Cleaning oil
exchanger, EPA stage 2 . . . . . . . . . . . . . . . . . 36 pre-separator element . . . . . . . . . . . . . 71
3-in-1 bar electrode – Check . . . . . . . . . . . . . . 121 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement . . . . . . . . . . . . . . . . . . . . . 72
A Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . 67
Accessories for Engine Governor (Electronic) / Cylinder liner – Endoscopic
Control System . . . . . . . . . . . . . . . . . . . . . . . . 131 examination . . . . . . . . . . . . . . . . . . . . . 67
ECU – Self-test implementation . . . . . . 135 Instructions and comments on endoscopic
EMU – Checking plug-in and visual examination of cylinder
connections . . . . . . . . . . . . . . . . . . . . . 134 liners . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
EMU – Installation and removal . . . . . . 137 Cylinder liner – Endoscopic examination . . . . 67
EMU and connectors – Cleaning . . . . . 132
Engine governor – Removal and Cylinder-head cover – Removal and
installation . . . . . . . . . . . . . . . . . . . . . . . 136 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Engine governor and connectors –
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 131 D
Engine governor plug-in connections –
Differential pressure gauge – Check . . . . . . . . 120
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Drain and venting points . . . . . . . . . . . . . . . . . 102
After stopping the engine . . . . . . . . . . . . . . . . 50
Drive belt – Condition check . . . . . . . . . . . . . . 116
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Air filter removal and installation . . . . . . 92
Air filter replacement . . . . . . . . . . . . . . . 91 E
Air filter removal and installation . . . . . . . . . . . 92 ECU – Self-test implementation . . . . . . . . . . . 135
Air filter replacement . . . . . . . . . . . . . . . . . . . . 91 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . 49
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 EMU – Checking plug-in connections . . . . . . . 134
Service indicator – Signal ring position EMU – Installation and removal . . . . . . . . . . . 137
check . . . . . . . . . . . . . . . . . . . . . . . . . . 93
EMU and connectors – Cleaning . . . . . . . . . . 132
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
B Engine – Barring manually . . . . . . . . . . 65
Battery-Charging Generator . . . . . . . . . . . . . . 117 Engine – Barring with starting
Battery-charging generator drive – Drive system . . . . . . . . . . . . . . . . . . . . . . . . . 66
belt check and adjustment . . . . . . . . . . 117 Engine – Barring manually . . . . . . . . . . . . . . . 65
Battery-charging generator drive – Drive
Engine – Barring with starting system . . . . . . . 66
belt replacement . . . . . . . . . . . . . . . . . . 118
Engine coolant – Change . . . . . . . . . . . . . . . . 109
Battery-charging generator drive – Drive belt
check and adjustment . . . . . . . . . . . . . . . . . . . 117 Engine coolant – Draining . . . . . . . . . . . . . . . . 110
Battery-charging generator drive – Drive belt Engine coolant – Level check . . . . . . . . . . . . . 108
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Engine coolant – Sample extraction and
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Drive belt – Condition check . . . . . . . . . 116 Engine coolant system – Filling . . . . . . . . . . . . 111
Engine governor – Removal and
C installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Centrifugal oil filter – Cleaning and filter-sleeve Engine governor and connectors –
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Checks prior to startup . . . . . . . . . . . . . . . . . . 42 Engine governor plug-in connections –
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Coalescer filter element – Replacement . . . . . 123

M015650/01E 2007-10 © MTU


156 Annex

Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . 22 General conditions . . . . . . . . . . . . . . . . . . . . . 05


Engine oil – Change . . . . . . . . . . . . . . . . . . . . 96 General Cooling Circuit, High Temperature
Engine oil – Level check . . . . . . . . . . . . . . . . . 95 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Coolant filter – Replacement . . . . . . . . . 114
Engine oil filter – Replacement . . . . . . . . . . . . 97
Drain and venting points . . . . . . . . . . . . 102
Engine Overview . . . . . . . . . . . . . . . . . . . . . . . 15 Engine coolant – Change . . . . . . . . . . . 109
Engine layout . . . . . . . . . . . . . . . . . . . . 22 Engine coolant – Draining . . . . . . . . . . . 110
Product description . . . . . . . . . . . . . . . . 15 Engine coolant – Level check . . . . . . . . 108
Engine side and cylinder designations . . . . . . 24 Engine coolant – Sample extraction and
Engine Side and Cylinder Designations . . . . . 24 analysis . . . . . . . . . . . . . . . . . . . . . . . . . 113
Engine side and cylinder Engine coolant system – Filling . . . . . . 111
designations . . . . . . . . . . . . . . . . . . . . . 24 HT coolant pump – Relief bore
check . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Engine wiring – Check . . . . . . . . . . . . . . . . . . 125
Expedients, fluids and lubricants, fire safety and
environmental protection . . . . . . . . . . . . . . . . . 11 H
HT coolant pump – Relief bore check ....... 112
F
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 I
Fuel filter – Replacement . . . . . . . . . . . 82 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Fuel prefilter – Filter element Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
replacement . . . . . . . . . . . . . . . . . . . . . 89 Injector – Removal and installation . . . . 79
Fuel prefilter – Flushing . . . . . . . . . . . . 87 Injector – Replacement . . . . . . . . . . . . . 78
Fuel prefilter - Draining . . . . . . . . . . . . . 85
Fuel prefilter, differential pressure gauge Injector – Removal and installation . . . . . . . . . 79
– Inspection and adjustment . . . . . . . . . 84 Injector – Replacement . . . . . . . . . . . . . . . . . . 78
Fuel filter – Replacement . . . . . . . . . . . . . . . . 82 Instructions and comments on endoscopic and
Fuel prefilter – Filter element replacement . . . 89 visual examination of cylinder liners . . . . . . . . 69
Fuel prefilter – Flushing . . . . . . . . . . . . . . . . . 87
Fuel prefilter - Draining . . . . . . . . . . . . . . . . . . 85 L
Fuel prefilter, differential pressure gauge – Lube-oil System, Lube-oil Circuit . . . . . . . . . . 95
Inspection and adjustment . . . . . . . . . . . . . . . 84 Engine oil – Change . . . . . . . . . . . . . . . 96
Engine oil – Level check . . . . . . . . . . . . 95
Fuel Supply System . . . . . . . . . . . . . . . . . . . . 119
3-in-1 bar electrode – Check . . . . . . . . . 121
Coalescer filter element – M
Replacement . . . . . . . . . . . . . . . . . . . . 123 Maintenance schedule matrix . . . . . . . . . . . . . 55
Differential pressure gauge – Check . . . 120
Pump capacity – Check . . . . . . . . . . . . 122 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . 58
Water drain valve – Check . . . . . . . . . . 119 Manufacturer’s documentation . . . . . . . . . . . . 153
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 81 MTU contact person/service partner . . . . . . . . 154
Fuel system – Venting . . . . . . . . . . . . . 81
Fuel system – Venting . . . . . . . . . . . . . . . . . . . 81 O
Fuel treatment system – Putting into Oil Filtration/Cooling . . . . . . . . . . . . . . . . . . . . 97
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Centrifugal oil filter – Cleaning and
Fuel treatment system – Putting out of filter-sleeve replacement . . . . . . . . . . . . 99
service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Engine oil filter – Replacement . . . . . . . 97
Fuel treatment system – Switching on . . . . . . 46 Operational checks . . . . . . . . . . . . . . . . . . . . . 47
Fuel treatment system – Troubleshooting . . . . 61
P
G Personnel and organizational require-
General Cabling for Engine / Gearbox / ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06
Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Plant – Cleaning . . . . . . . . . . . . . . . . . . . . . . . 52
Engine wiring – Check . . . . . . . . . . . . . 125 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sensors, actuators and injectors -
Product description . . . . . . . . . . . . . . . . . . . . . 15
Overview . . . . . . . . . . . . . . . . . . . . . . . . 126
Pump capacity – Check . . . . . . . . . . . . . . . . . 122

M015650/01E 2007-10 © MTU


Annex 157

Putting the engine into operation (out-of-service T


period > 3 months) . . . . . . . . . . . . . . . . . . . . . 39 Tasks after extended out-of-service periods (>3
Putting the engine into operation after scheduled weeks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
out-of-service period . . . . . . . . . . . . . . . . . . . . 40 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 25
12V 2000 M72 engine data:
R Engine-mounted heat exchanger, EPA
stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . 25
Raw water pump – Relief bore check . . . . . . . 115 12V 2000 M72 engine data: Separate
Raw Water Pump with Connections . . . . . . . . 115 heat exchanger, EPA stage 2 . . . . . . . . 29
Raw water pump – Relief bore 16V 2000 M72 engine data:
check . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Engine-mounted heat exchanger, EPA
stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . 32
16V 2000 M72 engine data: Separate
S heat exchanger, EPA stage 2 . . . . . . . . 36
Safety requirements when working on the
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 62
Sensors, actuators and injectors -
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Service indicator – Signal ring position V
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Valve clearance – Check and adjustment . . . . 74
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Standard tools – Overview . . . . . . . . . . . . . . . 151 Cylinder-head cover – Removal and
Standards for warning notices in the installation . . . . . . . . . . . . . . . . . . . . . . . 77
publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Valve clearance – Check and
adjustment . . . . . . . . . . . . . . . . . . . . . . 74
Staring Equipment . . . . . . . . . . . . . . . . . . . . . 94
Starter – Condition check . . . . . . . . . . . 94
Starter – Condition check . . . . . . . . . . . . . . . . 94 W
Starting the engine . . . . . . . . . . . . . . . . . . . . . 45 Water drain valve – Check ............... 119
Stopping the engine . . . . . . . . . . . . . . . . . . . . 48

M015650/01E 2007-10 © MTU

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