Operating Instructions Diesel engine 12 V 2000 M72 16V 2000 M72 M015650/04E
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Commissioning Note Important Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ ranty, spare parts, etc.).
Table of Contents 1 Safety 1.1 1.2 1.3 1.4 1.5 General conditions Personnel and organizational requirements Transport Safety regulations for startup and operation Safety regulations for maintenance and repair work 1.6 Auxiliary materials, fire prevention and environmental protection 1.
7.8 Fuel Filter 7.8.1 Fuel filter – Replacement 7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge 7.8.3 Fuel prefilter – Draining 7.8.4 Fuel prefilter – Flushing 7.8.5 Fuel prefilter – Filter element replacement 7.9 Charge-Air Cooling 7.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction 89 89 91 92 93 95 97 97 7.10 Air Filter 98 7.11 Air Intake 100 7.10.1 Air filter – Replacement 7.10.2 Air filter – Removal and installation 7.11.
1 Safety 1.1 General conditions General In addition to the instructions in this publication, the applicable country-specific legislation and other com‐ pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations.
1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company. Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐ tion.
1.3 Transport Transport Only use the lifting eyes provided to lift the engine. Only use transport and lifting devices approved by MTU. Take the engine's center of gravity into account. The engine must only be transported in installation position, max. permissible diagonal pull 10°. If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐ ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
1.4 Safety regulations for startup and operation Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: • that all maintenance and repair work is completed, • that all loose parts have been removed from rotating machine components, • that nobody is in the danger area of moving machine parts.
1.5 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Take special care when removing ventilation or plug screws from the engine.
Welding work Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or system as ground terminal. Do not 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. Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
TIM-ID: 0000000879 - 023 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.
1.6 Auxiliary materials, fire prevention 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 cloths soaked with fluids and lubri‐ cants 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.
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.
Used oil Used oil may contain health-threatening combustion residues. TIM-ID: 0000002828 - 004 Rub barrier cream into hands! Wash hands after contact with used oil.
1.7 Conventions for safety instructions in the text DANGER WARNING CAUTION NOTICE Note: In the event of immediate danger. Consequences: Death or serious injury • Remedial action In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action In the event of dangerous situations. Consequences: Minor injury or material damage • Remedial action In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage.
2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end of the engine. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
2.2 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 engine electronics, the common rail injection system determines injection pressure, in‐ jection timing and injection quantity independently of the engine speed.
Open-loop control: • Injection (fuel pressure, injection timing, injection duration, operating status) • Sequential turbocharging (cutting-in and out) with secondary turbocharger • Engine protection with multi-stage safety systems: • Power reduction • Power limitation • Emergency stop Monitoring: • Exhaust gas temperature, A-side • Exhaust temperature, B-side • Engine speed • Oil pressure • Differential oil pressure • Coolant temperature • Coolant level • Exhaust turbocharger speed • Leak fuel level • Oil t
SOLAS – Fire protection specifications Special connections In case of leakage, the above-mentioned connection types are spray-protected even without a cover and have been confirmed compliant with SOLAS by GL and DNV. Plug-in pipe connection TIM-ID: 0000002177 - 002 The sleeve (4) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐ curs. The connection is confirmed as compliant with SOLAS by DNV and GL.
The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under pressure.
HP line between distributor and HP accumulator 4 Thrust screw 5 O-ring 6 O-ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe TIM-ID: 0000002177 - 002 1 Union nut 2 O-ring 3 Thrust ring M015650/04E 2012-02 | General Information | 23
HP line between distributor and HP accumulator 1 2 3 4 Jacket pipe O-ring O-ring Thrust ring 5 6 7 8 Thrust screw Thrust ring O-ring HP line 9 Pressure pipe 10 O-ring TIM-ID: 0000002177 - 002 Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from where it is routed at atmospheric pressure into a level-monitored leak fuel tank.
2.
1 Exhaust turbocharger, left (secondary turbocharger) 2 Exhaust turbocharger (primary turbocharger) 3 Air intake 4 Engine hoisting lug (driv‐ ing end) 5 Exhaust turbocharger, right (secondary turbo‐ charger) 6 Engine coolant filler neck 7 Crankcase breather 8 Change-over lever for en‐ gine oil filter 9 10 11 12 13 14 15 16 17 18 19 Engine coolant filter Engine oil filter Fuel filter Engine oil heat exchang‐ er Coolant distribution hous‐ ing with integral expan‐ sion tank Thermostat housing Exhaust manifol
2.4 Sensors, actuators and injectors – Overview Engine plan view Deviations from illustrations are insignificant. Also applies similarly to 12V.
Engine free end Description Monitoring of 1 B34 Fuel pressure after filter 2 B5.3 (option) Lube oil pressure before filter 3 B5.1 Lube oil pressure after filter 4 B5.2 (option) Lube oil pressure after filter 5 F33 Engine coolant level, expansion tank 6 B21 (option) Raw water pressure 7 B6.2 (option) Coolant temperature 8 B6.
Engine driving end Description Monitoring of 1 B1 (ECU) Camshaft speed 2 B13.
Engine, right side Description Monitoring of 1 YB33 Fuel temperature 2 B48 Fuel pressure (in rail) 3 B16 (option) Coolant pressure 4 F46 Leak fuel level 5 Y27.2 4-2-directional control valve, B-side 6 B4.
Engine, left side Item Description Monitoring of 1 B4.21 Exhaust gas temperature, A-side 2 Y27.1 4-2-directional control valve, A-side 3 B54 (option) Lube oil pressure, replenishment pump System sensors These sensors are fitted outside the engine.
3 Technical Data 3.1 12V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings).
Number of cylinders 12 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.
INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline) Number of cylinders 12 Longitudinal inclination, continuous max., driving end down (Option: max. operating inclinations) L degrees 15 Longitudinal inclination, temporary max., driving end down (Option: max. operating inclinations) L degrees 22.5 Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ L ating inclinations) degrees 10 Transverse inclination, continuous max. (Option: max.
3.2 12 V 2000 M72 engine data: remote heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g.
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.
CAPACITIES Number of cylinders 12 Engine oil capacity, initial filling (standard oil system) (option: max. operat‐ ing inclinations) R Liters 123 Oil change quantity, max. (standard oil system) (option: max. operating in‐ clinations) R Liters 113 Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. operating inclinations) L Liters 87 Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max.
3.3 16V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings).
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.
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. operating inclinations) R liters 168 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liters 155 Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. operating inclinations) L liters 115 Oil pan capacity at dipstick mark "max.
3.4 16V 2000 M72 engine data: Separate heat exchanger, EPA stage 2 Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings).
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.
CAPACITIES Number of cylinders 16 Total engine oil capacity at initial filling (standard oil system) (Option: max. operating inclinations) R liters 168 Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations) R liters 155 Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. operating inclinations) L liters 115 Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max.
3.
3.6 Engine – Main dimensions TIM-ID: 0000002153 - 002 Main dimensions Engine model Length (A) Width (B) Height (C) 8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M92 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M93 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M84 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M94 approx. 1683 mm approx. 1147 mm approx. 1200 mm 10V 2000 M72 approx. 1860 mm approx. 1147 mm approx.
4 Operation 4.1 Engine – Putting the engine into operation (out of service > 3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting the engine into operation (out-of-service period > 3 months) Item Measure Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..). Lube oil system Check engine oil level (→ Page 102). Fuel prefilter Fill with fuel (→ Page 95).
4.2 Putting the engine into operation after scheduled out-ofservice period Preconditions ☑ Engine is stopped and starting disabled. Startup Item Task Lube oil system Check oil level (→ Page 102). Coolant system Check coolant level (→ Page 115). Coolant system Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 92). Battery-charging generator Check condition of drive belt (→ Page 123). drive Switch on (→ Operating instructions BlueVision ).
4.3 Tasks after extended out-of-service periods (>3 weeks) Tasks after extended out-of-service periods (>3 weeks) Operate fuel treatment system for at least 5 minutes. Start up fuel treatment system (→ Page 50). Shut down fuel treatment system (→ Page 58). TIM-ID: 0000007730 - 005 Note: 1. 2.
4.4 Checks prior to start-up Checks prior to start-up 1. 2. 3. 4. 5. 6. Result: TIM-ID: 0000007736 - 005 7. Result: Check tank and the entire pipework for cleanness. If microorganisms are detected: a) Clean affected components. b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..). Close drain valves on housing. Open all supply and discharge valves. Switch on fuel treatment system (→ Page 53). Check direction of rotation of pump.
4.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview 1. 2. Result: Switch on fuel treatment system (→ Page 53). Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system: 0.1 bar to 0.3 bar. If no differential pressure is measured, the coalescer filter element is probably being bypassed. 1. Remove coalescer filter element (→ Page 129). 2. Check sealing faces on coalescer filter element and in the pressure tank.
Simulation of filter replacement with the engine running: HAT 1. 2. 3. 4. Result: 5. Result: 6. Note: 7. Result: Switch on fuel treatment system (→ Page 53). Start engine (→ Page 54). Run engine at idling speed. Close ball cock (5) at the inlet to the fuel treatment system. 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). Open ball cock (19). Fuel emerges.
4.6 Operational checks DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Operational checks Item Measure Engine under load Visually inspect engine for leaks and general condition; Engine at nominal speed Check for abnormal running noises and vibration; Check exhaust color (→ Page 62).
4.7 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant is ready for operation. • Before switching on, ensure that all housings are closed. • Before switching on, ensure that no work is in progress anywhere on the entire system. Switching on fuel treatment system Carry out checks prior to start-up (→ Page 49). Switch on master switch on switch cabinet.
4.8 Starting the engine Preconditions ☑ External start interlock is not activated. ☑ Emergency air shut-off flaps (if fitted) are open. DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.
4.9 Stopping the engine Preconditions ☑ Engine is running in local mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed.
4.10 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations.
4.11 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
4.12 Fuel treatment system – Shutdown Shutting down fuel treatment system 1. TIM-ID: 0000007732 - 005 2. 3. 4. 5. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system. Open drain valve until pressure has escaped from fuel treatment system.
4.13 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner - 1 30390 1 Cleaner (Hakupur 312) WARNING WARNING CAUTION Note: Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Water jet. Risk of injury and scalding! • Do not direct water jet at persons.
5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication.
6 Troubleshooting 6.1 Fuel treatment system – Troubleshooting Illuminated pushbutton “Water alarm” is lit. Cause Corrective action When the maximum water level is reached, the water level elec‐ trode opens the water drain valve and water is discharged. If the opening period of the valve exceeds a preset limit (4 mi‐ nutes), the pump will switch off and an alarm is initiated. 1. Press illuminated pushbutton “Water alarm” to acknowledge. 2.
6.2 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 proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine wiring or starter defective Check if cable connections are proper‐ ly secured, contact Service. Engine wiring Defective Check (→ Page 131).
Engine speed not steady Component Probable Cause Task Fuel injection equip‐ ment Injector defective Replace (→ Page 85). Speed sensor Defective Replace. Fuel system Not vented Vent fuel system (→ Page 88). 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.
Exhaust gas white Probable Cause Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Drain fuel prefilter (→ Page 92). Intercooler Leaking Contact Service.
7 Task Description 7.1 SOLAS 7.1.1 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A4 735233000100 10 Shield A5 735233000101 14 Shield A7 735233000103 6 Shield A8 735233000104 2 SOLAS shielding – Installation Pinpoint installation location (→ Page 67). Install suitable shielding. Press shielding until locked. TIM-ID: 0000010550 - 003 1. 2. 3.
7.1.2 SOLAS shielding – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Oil filter shield X00009628 Fuel filter shield X00009654 Qty. Installing SOLAS shield on oil filter and fuel filter Pinpoint installation location (→ Page 67). Install suitable shielding. TIM-ID: 0000010702 - 004 1. 2.
7.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 65).
Item Type of shielding Comments 1 (free end) Shield (A8) On fuel filter 2 (free end) Shield (A7) Above fuel priming pump 3 (free end) Shield (A7) Below fuel priming pump Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) On air flap 2 (Driving end, A-side) Shield (A4) On brazed-on union 3 (driving end, A-side) Shield (A5) On turbocharger flap 4 (driving end, A-side) Shield (A5) On turbocharger flap Driving end A-side TIM-ID: 0000010064 - 005 Driving end A-side
Item Type of shielding Comments 1 (driving end, A-side) Shield (A5) To turbocharger lubrication 2 (driving end, A-side) Shield (A5) On valve plate Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, left side 2 (driving end) Shield (A4) Turbocharger lubrication, center Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, right side Driving end TIM-ID: 0000010064 - 005 Driving end M015650/04E 2012-02 | Task Descript
Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) Turbocharger flap 2 (driving end, B-side) Shield (A5) Turbocharger flap 3 (driving end, B-side) Shield (A4) On brazed-on union 4 (driving end, B-side) Shield (A5) On air flap 5 (driving end, B-side) Shield (A4) To turbocharger lubrication Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) On valve plate TIM-ID: 0000010064 - 005 Driving end B-side 70 | Task Description | M015650/
Driving end A-side Item Type of shielding Comments 1 (driving end, A-side) Shield (A5) To flap control Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) To flap control TIM-ID: 0000010064 - 005 Driving end B-side M015650/04E 2012-02 | Task Description | 71
7.2 Engine 7.2.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use DANGER Part No. Qty. Barring tool F6783914 1 Ratchet F30006212 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone.
7.2.2 Engine – Barring with starting system Preconditions ☑ Clutch is disengaged. ☑ Engine start is disabled. ☑ LOP is accessible and open. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • 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. Result: TIM-ID: 0000002788 - 001 2.
7.3 Cylinder Liner 7.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 1 Preparatory steps 1. 2. Remove cylinder head cover (→ Page 84). Remove injector (→ Page 86). Positioning crankshaft at BDC 1. 2. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
Final steps Install injector (→ Page 86). Install cylinder head cover (→ Page 84). TIM-ID: 0000000015 - 013 1. 2.
7.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐ ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring on the running surface under endoscope magnification.
Findings Measure Burn mark This is caused by a malfunction 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 2 onwards and less pro‐ nounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam‐ aged surface is usually discolored. The circumferential length varies.
7.4 Crankcase Breather 7.4.1 Crankcase breather – Cleaning oil pre-separator element Preconditions ☑ Engine is stopped and starting disabled. WARNING WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Crankcase breather – Cleaning oil pre-separator element 1. 2. 3. 4. 5.
7.4.2 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 6-50 Nm F30027336 1 Ratchet adapter F30027340 1 Filter element (→ Spare Parts Catalog) Diaphragm (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Checking diaphragm 1. 2. 3. 4. 5. 6. 7. Remove cover (4). Take off spring (5), seal (2) and diaphragm (3). Check diaphragm (3) for damage. Fit new diaphragm if used one is damaged. Mount diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4). Tighten screws of cover (4) to specified tightening torque. Name Size Screw Tightening torque Lubricant Value/Standard 6 Nm + 2 Nm Check diaphragms in further oil separators in the same way. TIM-ID: 0000003491 - 004 8.
7.5 Valve Drive 7.5.1 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y4345893 1 Barring tool F6783914 1 Ratchet F30006212 1 Double box wrench F30002800 1 Angular screw driver F30002816 1 Socket wrench F30030450 1 Torque wrench, 10-60 Nm F30510423 1 Preparatory steps 1. 2.
10V2000 Position Cylinder 1 2 3 4 5 Firing TDC in cylinder A1 Bank A EA -- -- -A E- Bank B E- -- -A EA E- Bank A -- EA EA E- -A Bank B -A EA E- -- -A Overlap TDC in cylinder A1 6 7 8 9 “E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted 12V2000 Position Cylinder 1 2 3 4 5 Firing TDC in cylinder A1 Bank A EA E- -A E- -A -- Bank B E- -- -A E- E A Bank A -- -A E- -A E- EA Bank B -A EA E- -A --
Valve clearance adjustment 1. 2. 3. 4. 5. Result: Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. Tighten locknut (1) with torque wrench to the prescribed tightening torque of 50 Nm while holding the adjusting screw (2) with screwdriver. Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap.
7.5.2 Cylinder-head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Centering device F6783025 1 Gasket (→ Spare Parts Catalog) Preparatory steps 1. 2. Remove air filter (→ Page 99). Remove intake housing. Cylinder-head cover – Removal and installation 1. 2. 3. 4. Result: 5. 6. Remove screws (1). Remove cylinder-head cover (2) with gas‐ ket from cylinder head. Clean mating faces.
7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Injector Part No. Qty. (→ Spare Parts Catalog) Remove injector and install new one.
7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. 0005896803/00 1 Puller F6790629 1 Double box wrench F30011450 1 Open end wrench bit F30025897 1 Box wrench adapter F30451199 1 Alignment device F6790507 1 Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1 Socket wrench Engine oil WARNING Fuels are combustible.
Installing injector 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove all plugs before installation. Fit new O-rings onto injector and coat with grease. Fit new sealing ring with grease on injector, ensuring correct installation position of sealing ring. Clean sealing surface on cylinder head and protective sleeve. Insert injector (1) in cylinder head, ensuring that it is correctly aligned with the HP line connection. Fit hold-down clamp (3) in correct installation position, coat screw (2) with engine oil.
7.7 Fuel System 7.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Venting fuel system 1. Unlock fuel priming pump, unscrew handle. 2. Open vent plugs on filter head. Note: 3. 4. 5. TIM-ID: 0000004716 - 002 6. New version has two threaded vent plugs, old version has four threaded vent plugs.
7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Special tools, Material, Spare parts Designation / Use Oil filter wrench Diesel fuel Easy-change filter DANGER DANGER WARNING WARNING Qty. F30379104 1 (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Unguarded rotating and moving engine components.
Easy-change fuel filter replacement with the engine stopped 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Stop engine and disable engine start. Cut out the filter to be replaced. B Left filter cut out C Right filter cut out Remove cut-out easy-change filter using the oil filter wrench. Clean sealing surface on filter head. Check sealing ring of the new easy-change filter and coat it with fuel. Fit SOLAS shield (→ Page 65). Screw on easy-change filter and tighten by hand.
7.8.2 DANGER WARNING Fuel prefilter – Differential pressure check and adjustment of gauge Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Differential pressure gauge adjustment 1. 2. When installing the new filter element: align adjustable pointer (2) with pressure-indicat‐ ing pointer (3) of pressure gauge (1).
7.8.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Diesel fuel Seal WARNING Part No. Qty. (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. 1. Cut out the filter to be drained. I Left filter cut in II Right filter cut in 2. Open threaded vent plug (5) of the filter to be drained.
7.8.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Diesel fuel Seal DANGER WARNING WARNING Qty. (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A).
2. 3. Result: 4. Open threaded vent plug (5) of the filter to be flushed. Unlock drain valve (6) by pressing toggle, open it and drain fuel. Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6). Fuel prefilter – Filling with fuel Stop engine (→ Operating Instructions for electronic system ) and disable engine start. Remove screws securing the cover and take off cover (2).
7.8.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Diesel fuel Filter element (→ Spare Parts Catalog) Seal (→ Spare Parts Catalog) Qty. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing filter element Cut out the contaminated filter.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. TIM-ID: 0000004946 - 004 14. Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the fil‐ ter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3). Insert new filter element (3) and spring housing (4). Fill filter housing with clean fuel. Place new seal in cover (2).
7.9 Charge-Air Cooling 7.9.1 DANGER WARNING WARNING Intercooler – Checking condensate drain line for coolant discharge and obstruction Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors.
7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Air filter Part No. Qty. (→ Spare Parts Catalog) Air filter – Replacement Remove old air filter and install new air filter (→ Page 99). Reset signal ring of service indicator (→ Page 100). TIM-ID: 0000005447 - 009 1. 2.
7.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation 1. 2. 3. 4. TIM-ID: 0000005457 - 005 5. Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it. Place new air filter (3) with clamp (2) onto intake housing (1). Tighten clamp (2).
7.11 Air Intake 7.11.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position 1. 2. TIM-ID: 0000005484 - 006 Result: If the signal ring is completely visible in the control window (2), replace air filter (This is not applicable to your system.). After installation of new filter, press reset button (1). Engaged piston with signal ring moves back to initial position.
7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 131). TIM-ID: 0000000905 - 015 1. 2.
7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Oil level check prior to engine start 1. 2. 3. 4. 5. Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between "min." and "max." marks. Top up to "max." if required (→ Page 103). Insert oil dipstick into guide tube up to the stop.
7.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. • Avoid contact with skin. • Do not inhale oil vapor.
7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Oil filter wrench Engine oil Oil filter DANGER WARNING WARNING CAUTION Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Hot oil.
3. 4. 5. 6. 7. 8. 9. 10. Remove cut-out oil filter using the oil filter wrench. Clean the sealing surface at the connecting piece. Check condition of the new sealing ring and coat it with oil. Fit the protective cover acc. to SOLAS re‐ quirements (→ Page 19). Install and tighten new oil filter by hand. Replace further oil filters in the same way. After each oil change and filter replace‐ ment, bar engine with starting system (→ Page 73). Check oil level (→ Page 102).
7.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Strap wrench Cold cleaner (Hakutex 50) WARNING Part No. Qty. F30379104 1 50622 1 Filter sleeve (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) Compressed air Risk of injury! • Do not direct compressed-air jet at persons.
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. 4. Remove sleeve (1). Measure the layer thickness of the oil resi‐ due. If maximum layer thickness (25 mm) is ex‐ ceeded, shorten maintenance interval. Clean rotor components and remove strain‐ ers (2). Wash standpipes (3) and nozzles (4) with cleaner, blow out with compressed air.
9. 10. 11. Fit new sealing ring (4). Set on rotor cap (3), observe marks. Fit washer (2). 12. Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque. 13. 14. 15. Size Type Nut M18 x 1.5 Tightening torque Lubricant Value/Standard 10 Nm Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque. Name Size Type Nut M16 x 1.
7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.
12 V, 16 V 2 Filler neck TIM-ID: 0000006696 - 001 1 Overflow line, expansion tank 110 | Task Description | M015650/04E 2012-02
Free end (KGS) 4 Measuring point, pres‐ sure before raw water pump 5 Raw water pump drain plug 6 Connection for oil extrac‐ tion TIM-ID: 0000006696 - 001 1 Fuel filter vent screws 2 Engine coolant drain plug 3 Raw water pump filling plug M015650/04E 2012-02 | Task Description | 111
Left side 2 Engine coolant drain plug (M14x1.
Right side 3 Oil dipstick (connection left or right engine side optional) 4 Leak-off-fuel tank TIM-ID: 0000006696 - 001 1 Engine coolant drain plug (M14x1.
Driving end (KS) 2 Connection for oil extrac‐ tion TIM-ID: 0000006696 - 001 1 Engine coolant drain plug 114 | Task Description | M015650/04E 2012-02
7.15.2 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Coolant-level check at filler neck: 1. 2. 3. Turn breather valve on coolant expansion tank (→ Page 25) counterclockwise until first stop and allow pressure to escape.
7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Engine coolant – Change Drain engine coolant (→ Page 117). Fill with engine coolant (→ Page 118). TIM-ID: 0000000036 - 028 1. 2.
7.15.4 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps 1. 2. 3. Provide an appropriate container to collect the coolant or switch on the extraction device. Switch off preheating unit. Engine coolant – Draining 1. TIM-ID: 0000006746 - 001 2. 3. 4. 5. 6.
7.15.5 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING CAUTION Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Cold coolant in hot engine can cause thermal stress.
7.15.6 DANGER WARNING HT coolant pump — Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. HT coolant pump — Relief bore check 1. 2. 3. TIM-ID: 0000006803 - 002 4. Check relief bore for oil and coolant dis‐ charge. Stop engine (→ Operating instructions elec‐ tronic system) and disable engine start.
7.15.7 Engine coolant – Sample extraction and analysis Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools, Material, Spare parts Designation / Use MTU test kit WARNING Part No. Qty. 5605892099/00 1 Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Engine coolant – Sample extraction and analysis 1. 2. 3. 4. 5.
7.15.8 Coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Oil filter wrench Coolant filter WARNING Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Coolant filter – Replacement 1. 2. 3. 4. 5. TIM-ID: 0000006921 - 004 6. 7. 8.
7.16 Raw Water Pump with Connections 7.16.1 DANGER WARNING Raw water pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Raw water pump – Relief bore check 1. 2. 3. TIM-ID: 0000007284 - 001 4. Check relief bore for oil and coolant dis‐ charge. Stop engine (→ Page 55) and disable en‐ gine start.
7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed.
7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Mandrel Part No. Qty. 8205892861/08 1 Preparatory steps 1. 2. 3. Remove safety equipment (if fitted). Remove screws of protective cover (engine free end). Remove protective cover. Drive belt – Replacement 1. 2. 3. 4. 5. 6. 7. Hold adjusting lever at square.
7.19 Fuel Treatment System 7.19.1 Water drain valve – Check Checking water drain valve Open water drain valve. Check water outlet for obstructions. Close water drain valve. TIM-ID: 0000007733 - 006 1. 2. 3.
7.19.2 WARNING Differential pressure gauge – Check Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking differential pressure gauge Switch on fuel treatment system (→ Page 53). Set the alarm points at the differential pressure gauge to zero. Alarm is initiated with preset delay. Reset the alarm points at the differential pressure gauge to the specified values. TIM-ID: 0000007737 - 005 1. 2. Result: 3.
7.19.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) – Check Disconnect plug from water level probe. Unscrew water level probe. Disconnect plug from water level probe. Immerse water level probe into a tank filled with water until water level reaches the thread.
7.19.4 WARNING Pump capacity – Check Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking pump capacity 1. 2. Note: 3. 4. Install suitable pressure gauge at the neck of the intake side of the pump. Check pump pressure. a) Switch on fuel treatment system (→ Page 53). The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel and can be disregarded.
7.19.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING CAUTION CAUTION Part No. Qty. Torque wrench, 6-50 Nm F30027336 1 Ratchet adapter F30027339 1 Diesel fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke.
16. Name Size Type Lubricant Value/Standard Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system. The fuel treatment system is ready for operation. TIM-ID: 0000007735 - 006 17. 18. 19. 20. 21. Result: Tighten nut (3) to specified tightening torque using a torque wrench.
7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Engine wiring – Check 1. 2. 3. 4. 5. 6. Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged.
7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Note: Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Engine governor and connectors – Cleaning 1. 2. 3.
7.21.2 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating. Latch connectors if loose. TIM-ID: 0000000048 - 005 1. 2.
7.21.3 EMU – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. EMU – checking plug-in connections Verify that all plug-in connections are securely seated. Secure loose connectors and latch. TIM-ID: 0000008395 - 001 1. 2.
7.21.4 DANGER Engine governor – Carry out self-test Electrical voltage. Risk of serious injury - danger to life! • 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! Carrying out self-test 1. 2. 3. Result: TIM-ID: 0000008482 - 002 4. 5. Switch off power supply to system. Remove connectors X1, X2 and X4 from the engine governor. a) Release lock (3) of connectors (2). b) Unplug connector (2).
7.21.5 EMU and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol EMU and connectors – Cleaning 1. 2. 3. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol. Check legibility of cable labels. Clean or replace illegible labels.
7.21.6 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed. Removing engine governor from engine 1. 2. 3. 4. 5. 6. Note or mark assignment of cables and connectors. Remove all screws (2). Undo latches (3) of the connectors. Remove all connectors. Remove screws (1).
7.21.7 Engine monitoring unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed. Removing engine governor with engine monitoring unit from engine 1. 2. 3. 4. 5. 6. Note or mark assignment of cables and plugs. Remove all screws (2). Release lock (3) of connectors.. Remove all connectors.
8 Appendix A TIM-ID: 0000002049 - 005 8.1 Abbreviations Abbrevia‐ tion Meaning Explanation ADEC Advanced Diesel Engine Control Engine governor AL Alarm Alarm (general) ANSI American National Standards Institute Association of American standardization organiza‐ tions ATL Abgasturbolader Exhaust turbocharger (ETC) BR Baureihe Series BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica‐ tion No. A01061/..
Abbrevia‐ tion Meaning IDM Interface Data Module IMO International Maritime Organization ISO International Organization for Stand‐ ardization International umbrella organization for all national standardization institutes KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LCD Liquid Crystal Display, Liquid Crystal Device LCU Local Control Unit LED Light Emitting Diode LMU Local Monitoring Unit LOP subass
Meaning Explanation TD Transmitter Deviation Alarm: Deviation in transmitter values UT Unterer Totpunkt Bottom Dead Center (BDC) VS Voith Schneider Voith Schneider drive WJ Water jet Water jet drive WZK Werkzeugkatalog Tool Catalog (TC) ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for signals from the ADEC engine governor TIM-ID: 0000002049 - 005 Abbrevia‐ tion M015650/04E 2012-02 | Appendix A | 141
8.2 MTU contacts/service partners Service Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures fast and direct support on site and the high availability of our products. Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU internet site: http://www.mtu-online.
9 Appendix B 9.1 Special Tools Alignment device Part No.: F6790507 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 86) Angular screw driver Part No.: F30002816 Qty.: Used in: 1 7.5.1 Valve clearance – Check and adjustment (→ Page 81) Barring tool Part No.: F6783914 Qty.: Used in: 1 7.2.1 Engine – Barring manually (→ Page 72) Qty.: Used in: 1 7.5.1 Valve clearance – Check and adjustment (→ Page 81) Box wrench adapter Part No.: F30451199 Qty.: Used in: 1 7.6.
Mandrel Part No.: 8205892861/08 Qty.: Used in: 1 7.18.1 Battery-charging generator drive – Drive belt replacement (→ Page 124) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 1 7.15.7 Engine coolant – Sample extraction and analysis (→ Page 120) Oil filter wrench Part No.: F30379104 Qty.: Used in: 1 7.8.1 Fuel filter – Replacement (→ Page 89) Qty.: Used in: 1 7.14.1 Engine oil filter – Replacement (→ Page 104) Qty.: Used in: 1 7.15.
Rigid endoscope Part No.: Y20097353 Qty.: Used in: 1 7.3.1 Cylinder liner – Endoscopic examination (→ Page 74) Socket wrench Part No.: F30030450 Qty.: Used in: 1 7.5.1 Valve clearance – Check and adjustment (→ Page 81) Socket wrench Part No.: 0005896803/00 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 86) Steam jet cleaner Part No.: - Qty.: Used in: 1 4.13 Plant – Cleaning (→ Page 59) Strap wrench Part No.: F30379104 Qty.: Used in: 1 7.14.
9.
Fuel – Prefilter – Differential pressure gauge - Check and adjust‐ ment 91 – Draining 92 – Filter element replacement 95 – Treatment system – Troubleshooting 61 – treatment system – Shutdown 58 – Switching on 53 Fuel filter – Replacement 89 Fuel prefilter – Differential pressure gauge – Check and adjustment 91 – Draining 92 – Filter element – Replacement 95 Fuel prefilter – Flushing 93 Fuel system – Venting 88 Fuel treatment system – Putting into operation 50 – Shutdown 58 – Switching on 53 Putting into op
