MTU 12V2000M93 Operating Instructions Manual
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MTU 12V2000M93 Operating Instructions Manual

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Operating Instructions

Diesel engine
12V2000M93
16V2000M93
M015655/05E

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Summary of Contents for MTU 12V2000M93

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12V2000M93 16V2000M93 M015655/05E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    7.3.1 Cylinder liner – Endoscopic examination 7.3.2 Instructions and comments on endoscopic and visual examination of cylinder liners 3 Technical Data 7.4 Crankcase Breather 3.1 Engine data 12V2000M93 7.4.1 Crankcase breather – Cleaning oil pre- 3.2 Engine data 16V2000M93 separator element 3.3 Firing order 7.4.2 Crankcase breather –...
  • Page 4 8 Appendix A 7.16.1 Raw water pump – Relief bore check 8.1 Abbreviations 7.17 Belt Drive 8.2 MTU contact persons/service partners 7.17.1 Drive belt – Condition check 7.18 Battery-Charging Generator 9 Appendix B 7.18.1 Battery-charging generator drive – Drive belt replacement 9.1 Special Tools...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...
  • Page 6 Replacing components with emission labels Emission labels are attached to all MTU engines. These must remain on the engine throughout its op- erational life. Engines used exclusively in land-based, military applications other than by US government agencies are excepted from this proviso.

  • Page 7: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 8: Transport

    1.3 Transport Transport without flange-mounted gearbox A max. permissible diagonal B max. permissible diagonal pull 70° pull 35° Illustration is also valid for 12V/16V2000Mxx engines 8 | Safety | M015655/05E 2015-06...
  • Page 9 Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set down engines onto the oil pan unless expressly permitted by MTU on an engine-specific base. M015655/05E 2015-06 | Safety | 9...

  • Page 10: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica- tions before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 11 Observe the warning information applicable to the devices. M015655/05E 2015-06 | Safety | 11...

  • Page 12: Safety Regulations For Maintenance And Repair Work

    1.5 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 13 Always seal connections with caps or covers if a line is removed or opened. Fit new seals when re-installing lines. Never bend lines and avoid damaging lines, particularly the fuel lines. Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed ina slanted/twisted condition.
  • Page 14 For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed on. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries.

  • Page 15: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials.

  • Page 16: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale lead vapors. • Wash relevant areas after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 17: Standards For Safety Notices In The Text

    1.7 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 18: General Information

    2 General Information 2.1 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and stud joints to MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 •...
  • Page 19 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350...
  • Page 20 Strength class Material Basic size (Nm) (Nm) A2 / A4 = tightening torques Tightening torque for self-locking hex nuts (Nm) Lubricant Thread 7,5 +1 – 17 +2 – 35 +4 – 59 +6 – 100 +10 – 140 +14 – 290 +29 –...
  • Page 21 Torsion-protected M (Nm) Not torsion-protected M (Nm) Thread M20 x 1.5 M22 x 1.5 M24 x 2 1170 M27 x 2 1000 1230 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques Tightening torques for plug screws to MTN 5183-1 standard This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A (sealed with sealing ring to DIN 7603-Cu).
  • Page 22 Tightening torques M are given for screw plugs made of steel (St) with surface protected by a phos- phate coating and oiled or galvanized. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 23 Screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M64 x 2 = tightening torques Tightening torques for plug screws to DIN 7604C (with long threaded end) Screwed into Thread Steel/gray cast iron M Al alloy M (Nm) (Nm) M8 x 1...
  • Page 24 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface coating and oiled, or galvanized, and to banjo screws made of copper/aluminum alloys. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 25 Tightening torques for male unions to MTN 5183-3 standard This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu). Tightening torques M are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.
  • Page 26 Tightening torques for union nuts to DIN 3859-2 1 Union nut 2 Union body 3 O-ring 4 Ferrule Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point. Tightening torques for spigot unions with O-ring to ISO 6149-2 Torque (Nm) +10% Thread...
  • Page 27 Torque (Nm) +10% Thread M27 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789) Tightening torques for spigot unions with O-ring to ISO 6149-3 Torque (Nm) +10% Thread M8 x 1...
  • Page 28 Tightening torques for plug screws to MTN 5183-6 Screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M10 x 1 10 +2 M12 x 1.5 14 +2 M14 x 1.5 15 +3 M16 x 1.5 18 +3 M18 x 1.5 23 +3 M22 x 1.5...
  • Page 29 Sealing head/sealing cone with metric union nut Metric thread Pipe outer dia. Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...
  • Page 30 ORFS – flat sealing with union nut UNF thread Size Torque (Nm) 9/16–18 –4 14 +2 11/16–16 –6 24 +3 13/16–16 –8 43 +4 1–14 –10 60 +8 1.3/16–12 –12 90 +5 1.3/16–12 –14 90 +5 1.7/16–12 –16 125 +10 1.11/16–12 –20 170 +20...

  • Page 31: Engine Side And Cylinder Designations

    2.2 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

  • Page 32: Product Description

    2.3 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, injection timing and injection quantity independently of the engine speed.
  • Page 33 • Interface to ECU and EMU • MCS5 dialog interface • Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box) • Connection facility for an MTU Local Operating Station (LOS) Serial RS422 interface for diagnosis The engine interface is divided into two parts.
  • Page 34 Monitoring: • Exhaust gas temperature, A side • Exhaust temperature, B-side • Engine speed • Oil pressure • Differential oil pressure • Coolant temperature • Coolant level • Exhaust turbocharger speed • Leak fuel level • Oil temperature • Coolant pressure •...
  • Page 35 Plug-in pipe union The sleeve (3) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure decreases significantly if an O-ring (2) fault occurs. The connection is confirmed as compliant with SOLAS by DNV and GL. Plugs and sensors Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN, or an O-ring (ISO).
  • Page 36 HP line between distributor and HP accumulator 1 Union nut 4 Thrust screw 7 Thrust ring 2 O-ring 5 O-ring 8 Pressure pipe 3 Thrust ring 6 O-ring 9 Jacket pipe 36 | General Information | M015655/05E 2015-06...
  • Page 37 HP line between distributor and HP accumulator 1 Jacket pipe 5 O-ring 9 HP line 2 O-ring 6 Thrust screw 10 Pressure pipe 3 O-ring 7 Thrust ring 4 Thrust ring 8 O-ring Leak-off 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.

  • Page 38: Engine - Overview

    2.4 Engine – Overview Engine overview Also applies similarly to 12V. 1 Engine oil heat exchanger 14 Exhaust turbocharger (pri- 27 Engine Interface Module 2 Engine oil filter mary turbocharger) 3 Coolant filter 15 Exhaust turbocharger, left 28 Gearcase 4 Change-over lever for en- (secondary turbocharger) 29 Raw water pump gine oil filter...
  • Page 39 1 Exhaust turbocharger, left 11 Fuel filter 21 Oil dipstick (secondary turbocharger) 12 Engine oil heat exchanger 22 Drive flange 2 Exhaust turbocharger (pri- 13 Coolant distribution hous- 23 Flywheel housing mary turbocharger) ing with integrated expan- 24 Engine mounting 3 Air intake sion tank 25 Carrier housing middle...

  • Page 40: Sensors And Actuators - Overview

    2.5 Sensors and actuators – Overview Engine plan view Deviations from illustrations are insignificant. Also applies similarly to 12V. Monitoring of Item Designation Intake air temperature Charge-air temperature Lube oil temperature Charge-air pressure Turbocharger speed 40 | General Information | M015655/05E 2015-06...
  • Page 41 Engine free end Monitoring of Item Designation Fuel pressure after filter B5.3 (optional) Lube oil pressure before filter B5.1 Lube oil pressure after filter B5.2 (optional) Lube oil pressure after filter Engine coolant level, expansion tank B21 (optional) Raw water pressure B6.2 (optional) Coolant temperature B6.1...
  • Page 42 Engine driving end Monitoring of Item Designation B1 (ECU) Camshaft speed B13.2 (optional EMU) Crankshaft speed B13 (ECU) Crankshaft speed 42 | General Information | M015655/05E 2015-06...
  • Page 43 Engine, right side Monitoring of Item Designation 2-2-directional control valve YB33 Fuel temperature Fuel pressure (in rail) B16 (optional) Coolant pressure Leak fuel level Y27.2 4-2-directional control valve, B-side B4.22 Exhaust temperature, B-side M015655/05E 2015-06 | General Information | 43...
  • Page 44 Engine, left side Monitoring of Item Designation B4.21 Exhaust gas temperature, A-side Y27.1 4-2-directional control valve, A-side B54 (optional) Lube oil pressure, replenishment pump System sensors These sensors are fitted outside the engine. Monitoring of Designation Starting-air pressure Fuel prefilter water level Exhaust back pressure Start interlock, switching status 44 | General Information | M015655/05E 2015-06...

  • Page 45: Technical Data

    3 Technical Data 3.1 Engine data 12V2000M93 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 setting)
  • Page 46 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.4 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in off-engine raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 47 CAPACITIES Number of cylinders Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (option: max. operating Liters inclinations) Oil change quantity max. (standard oil system) (option: max. operating inclina- Liters tions) Oil pan capacity dipstick mark min. (standard oil system) (option: max. operat- Liters ing inclinations) Oil pan capacity dipstick mark max.

  • Page 48: Engine Data 16V2000M93

    3.2 Engine data 16V2000M93 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 49 RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.4 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in off-engine raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 50 CAPACITIES Number of cylinders Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (option: max. operating Liters inclinations) Oil change quantity max. (standard oil system) (option: max. operating inclina- Liters tions) Oil pan capacity dipstick mark min. (standard oil system) (option: max. operat- Liters ing inclinations) Oil pan capacity dipstick mark max.

  • Page 51: Firing Order

    3.3 Firing order Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 M015655/05E 2015-06 | Technical Data | 51...

  • Page 52: Engine - Main Dimensions

    3.4 Engine – Main dimensions Main dimensions Height (C) Engine model Length (A) Width (B) 12V2000M93 approx. 2069 mm approx. 1295 mm approx. 1350 mm 16V2000M93 approx. 2486 mm approx. 1295 mm approx. 1390 mm 52 | Technical Data | M015655/05E 2015-06...

  • Page 53: Operation

    4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Preservation and Represervation Instructions (A001070/..) available. Putting the engine into operation (out-of-service period > 3 months) Item Action Engine Depreserve (→...

  • Page 54: Engine - Putting Into Operation After Scheduled Out-Of-Service-Period

    4.2 Engine – Putting into operation after scheduled out-of-service- period Preconditions ☑Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 110). Coolant circuit Check coolant level (→ Page 121). Coolant circuit Heat engine coolant with coolant preheating unit.

  • Page 55: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.3 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. Start up fuel treatment system (→ Page 57). Shut down fuel treatment system (→ Page 65). M015655/05E 2015-06 | Operation | 55...

  • Page 56: Checks Prior To Start-Up

    Checks prior to start-up 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.

  • Page 57: Fuel Treatment System - Putting Into Operation

    4.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 60). Check the differential pressure at 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.
  • Page 58 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 60). Start engine (→ Page 61). Run engine at idling speed. Close ball cock (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).

  • Page 59: Operational Checks

    4.6 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 60: Fuel Treatment System - Switching On

    4.7 Fuel treatment system – Switching on Preconditions ☑The on-board power supply is switched on. NOTICE Risk of damage to engine/system. Risk of severe damage to property! • Before switching on, ensure that the engine/system is ready for operation. • Before switching on, ensure that all housings are closed. •...

  • Page 61: Starting The Engine

    4.8 Starting the engine Preconditions ☑External start interlock is not active. ☑Emergency air shut-off flaps (if fitted) are open. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 62: Engine - Shutdown

    4.9 Engine – Shutdown Preconditions ☑Engine is running in Local mode NOTICE 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 minutes until engine temperatures have dropped and constant values are displayed.

  • Page 63: Emergency Engine Stop

    4.10 Emergency engine stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. An emergency engine stop can be initiated from the following points Item Action Control stand...

  • Page 64: After Stopping The Engine

    Switch off. Air intake and exhaust sys- Out-of-service-period > 1 week • Seal engine's air and exhaust sides. Engine Out-of-service-period > 1 month • Depreserve engine (→ MTU Preservation and Represervation Specifica- tions A001070/..) 64 | Operation | M015655/05E 2015-06...

  • Page 65: Fuel Treatment System - Shutdown

    4.12 Fuel treatment system – Shutdown Shutting down fuel treatment system 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.

  • Page 66: Plant - Cleaning

    4.13 Plant – Cleaning Preconditions ☑Engine is stopped and starting disabled. ☑No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaning unit Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 67: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 68: Fuel Treatment System - Troubleshooting

    6 Troubleshooting 6.1 Fuel treatment system – Troubleshooting Illuminated pushbutton “water alarm” is lit. Cause Corrective action When the maximum water level 1. Press illuminated pushbutton “Water alarm” to acknowledge. is reached, the water level 2. In addition to the automatic water drain function, water can also electrode opens the water drain be drained manually.

  • Page 69: Troubleshooting

    6.2 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action u Charge or replace (see manufacturer's documentation). Battery low or faulty Battery: Cable connections u Check if cable connections are properly secured (see faulty manufacturer's documentation). u Check firm seating of cable connections, contact Service. Engine cabling or starter faulty u Check (→...
  • Page 70 Engine Control Unit defective u Contact Service. Charge-air temperature too high Cause Corrective action Incorrect coolant concentration u Check (MTU test kit). u Contact Service. Intercooler dirty u Check fans and air supply/ventilation ducts. Engine room: Air-intake temperature too high...
  • Page 71 White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Water in fuel u Drain fuel prefilter (→ Page 99). u Contact Service. Intercooler leaking M015655/05E 2015-06 | Troubleshooting | 71...

  • Page 72: Task Description

    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 Shield A5 735233000101 Shield A7 735233000103 Shield A8 735233000104...

  • Page 73: Solas Shielding - Installation

    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. Qty. Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil fil- ter and fuel filter Pinpoint installation location (→...

  • Page 74: Installation Locations For Solas Shielding

    7.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 72). Free end B-side Item Type of shielding Comments 1 (free end, B-side) Shield (A7) On fuel delivery pump 2 (free end, B-side) Shield (A7) On HP fuel pump Free end...

  • Page 75: Shield A4

    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 Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) On air flap 2 (driving end, A-side)
  • Page 76 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 Driving end Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, left side 2 (driving end) Shield (A4) Turbocharger lubrication, center Driving end...
  • Page 77 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...
  • Page 78 Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) To flap control Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) To flap control 78 | Task Description | M015655/05E 2015-06...

  • Page 79: Engine

    7.2 Engine 7.2.1 Engine – Barring manually Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine barring gear F6783914 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 80: Engine - Cranking On Starting System

    7.2.2 Engine – Cranking on starting system Preconditions ☑Clutch is disengaged. ☑Engine start is disabled. ☑LOP is accessible and open. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 81: Cylinder Liner

    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. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 91). Remove injector (→...
  • Page 82 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 83). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 83: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.3.2 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 ex- amination report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 84 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 85: Crankcase Breather

    7.4 Crankcase Breather 7.4.1 Crankcase breather – Cleaning oil pre-separator element Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. •...

  • Page 86: Crankcase Breather - Oil Separator Replacement, Diaphragm Check And Replacement

    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 Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Engine oil Filter element (→...
  • Page 87 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 88: Valve Drive

    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 Engine barring device F6783914...

  • Page 89: Adjusting Valve Clearance

    Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If rocker arms on cylinder 1 bank A are unloaded, the piston is in firing TDC. • If rocker arms on cylinder 1 bank A are loaded, the piston is in overlap TDC. Check valve clearance with cold engine: •...
  • Page 90 Check that the feeler gauge (3) just passes through between valve bridge and rocker arm. Result: If not, adjust valve clearance. Final steps Remove barring device. Install cylinder head cover (→ Page 91). Install air filter (→ Page 107). 90 | Task Description | M015655/05E 2015-06...

  • Page 91: Cylinder Head Cover - Removal And Installation

    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 jig F6783025 Sealing (→ Spare Parts Catalog) Preparatory steps Remove air filter (→ Page 107). Remove air guide housing.

  • Page 92: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 93). 92 | Task Description | M015655/05E 2015-06...

  • Page 93: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Socket wrench 0005896803/00 Puller F6790629 Double-head box wrench F30011450 Open-end wrench bit F30025897 Box wrench F30451199 Alignment device F6790507 Assembly compound (Kluthe Hakuform 30-15)
  • Page 94 Installing injector Prior to installation, remove all blanking plugs. Fit new O-rings on injector and coat with assembly compound. Secure new sealing ring with assembly compound on injector, observing 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.

  • Page 95: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Venting fuel system Unscrew handle (3) at fuel priming pump (2).

  • Page 96: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 97 Easy-change fuel filter replace- ment with the engine stopped Stop engine and disable engine start. Cut out the filter to be replaced. A Both filters are cut in (standard posi- tion) B Left filter is cut out C Right filter is cut out Unscrew switched off easy-change filter with oil filter wrench.

  • Page 98: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 99: Fuel Prefilter - Draining

    7.8.3 Fuel prefilter – Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! •...
  • Page 100 Open threaded vent plug (1) of the filter to be drained. Open drain valve (2). Drain water and contaminants from the fil- ter until pure fuel emerges. Close drain valve (2). Connect filling pump to filling connec- tion (1) on the intake side of the filter. Open vent valve (2) and fill with fuel until fuel emerges from the vent pipe (3).

  • Page 101: Fuel Prefilter - Flushing

    7.8.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING Liquid or gaseous media, e.g.
  • Page 102 Open threaded vent plug (1) of filter to be flushed. Open drain valve (2) and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (1) and drain valve (2).

  • Page 103: Fuel Prefilter - Filter Element Replacement

    7.8.5 Fuel prefilter – Filter element replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g.
  • Page 104 Open threaded vent plug (1) of contaminat- ed filter. Unlock drain valve (5) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (5). Remove screws securing cover (2) and take off cover. Remove spring cartridge (3) and filter ele- ment (4).

  • Page 105: Charge-Air Cooling

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 106: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 107). Reset signal ring of contamination indicator (→...
  • Page 107 7.10.2 Air filter – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20 Nm F30044239 Air filter – Removal and installa- tion Release clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3).

  • Page 108: Air Intake

    7.11 Air Intake 7.11.1 Service indicator – Signal ring position check Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 106). After installation of new filter, press reset button (1).

  • Page 109: Starting Equipment

    7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 137). M015655/05E 2015-06 | Task Description | 109...
  • Page 110 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 Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx.
  • Page 111 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.
  • Page 112 7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) SOLAS shield (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.
  • Page 113 Unscrew cut-out oil filter with oil filter wrench. Clean sealing surface on connecting piece. Check condition of new oil filter sealing ring and coat it with oil. Fit SOLAS shield (→ Page 72). Screw on and tighten new oil filter by hand. Replace other oil filters in the same way.
  • Page 114 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 Part No. Qty. Torque wrench, 8-40 Nm F30043446 Ratchet F30027340 Cold cleaner(Hakutex 60) X00056750 Filter sleeve (→...
  • Page 115 Centrifugal oil filter – Cleaning and filter-sleeve replacement Slacken off nuts (4) crosswise. Remove housing cover (1). Carefully remove rotor (3) from lower part of housing (5). Remove nut (2). Carefully remove rotor cap. Remove filter sleeve from rotor cap. Measure thickness of oil residues on filter sleeve.
  • Page 116 7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Drain and venting points 12 V, 16 V 1 Overflow line, expansion 2 Filler neck tank 116 | Task Description | M015655/05E 2015-06...
  • Page 117 Free end (KGS) 1 Fuel filter vent screws 3 Raw water pump filling 5 Raw water pump drain 2 Engine coolant drain plug plug plug 4 Measuring point, pressure 6 Connection for oil extrac- before raw water pump tion M015655/05E 2015-06 | Task Description | 117...
  • Page 118 Left side 1 Engine coolant drain plug 2 Engine coolant drain plug (M14x1.5) 118 | Task Description | M015655/05E 2015-06...
  • Page 119 Right side 1 Engine coolant drain plug 3 Oil dipstick (connection on (M14x1.5) left or right engine selecta- 2 Oil filler neck (connection ble) on left or right engine se- 4 Leak-fuel tank lectable) M015655/05E 2015-06 | Task Description | 119...
  • Page 120 Driving end (KS) 1 Engine coolant drain plug 2 Connection for oil extrac- tion 120 | Task Description | M015655/05E 2015-06...
  • Page 121 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.
  • Page 122 7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 123). Fill with engine coolant (→ Page 124). 122 | Task Description | M015655/05E 2015-06...

  • Page 123: Draining Engine Coolant

    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 Provide an appropriate container to collect the coolant or Switch on the extraction device.
  • Page 124 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 Coolant is hot and under pressure.
  • Page 125 7.15.6 HT coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 126: Engine Coolant – Sample Extraction And

    • corrosion inhibitor concentration; • pH value. Fit breather valve and close it. Change engine coolant according to the coolant operating times specified in the (→ MTU Fluids and Lu- bricants Specifications A001061/..) (→ Page 123). 126 | Task Description | M015655/05E 2015-06...
  • Page 127 7.15.8 Coolant filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 128: Raw Water Pump With Connections

    7.16 Raw Water Pump with Connections 7.16.1 Raw water pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 129: Belt Drive

    7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑Engine is stopped and starting disabled. ☑Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...

  • Page 130: Battery-Charging Generator

    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 Part No. Qty. Mandrel 8205892861/08 Preparatory steps Remove safety equipment (if fitted). Remove screws of protective cover (engine free end). Remove protective cover.

  • Page 131: Fuel Supply System

    7.19 Fuel Supply System 7.19.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. M015655/05E 2015-06 | Task Description | 131...
  • Page 132 7.19.2 Differential pressure gauge – Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking differential pressure gauge Switch on fuel treatment system (→...
  • Page 133 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 and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. •...
  • Page 134 7.19.4 Pump capacity – Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking pump capacity Install suitable pressure gauge in the intake connection of the pump.
  • Page 135 7.19.5 Coalescer filter element – Replacement Preconditions ☑System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 136 Use torque wrench to tighten nut (3) to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit seal (10). Install cover. Install screws (1), washers (2) and nuts (9). Tighten nuts (9). Open ball valve at the inlet and outlet of the fuel treatment system.
  • Page 137 7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine cabling – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
  • Page 138 7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine governor and connector – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! •...
  • Page 139 7.21.2 EMU and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! •...
  • Page 140 7.21.3 Engine governor plug connections – Check Preconditions ☑Engine stopped and starting disabled. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.
  • Page 141 7.21.4 Engine Monitoring Unit EMU 7 – Plug connection check Preconditions ☑Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Ensure that the clips (1) are engag- Check screws (3) of cable clamps on EMU (2) for firm seating.
  • Page 142 7.21.5 Interface module EIM plug connections – Check Preconditions ☑Engine is stopped and starting disabled. Checking EIM plug connections Check both Tyco plugs (62-pole) (2) on EIM for firm seating. Ensure that clips (3) are engaged. Check screws (1) of cable clamps on EIM for firm seating.
  • Page 143 7.21.6 Engine Control Unit – Self-test DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! • Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! ECU7 self-test Switch off power supply to system.
  • Page 144 7.21.7 Engine Control Unit ECU 7 – Removal and installation Preconditions ☑Engine is stopped and starting disabled. NOTICE 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.
  • Page 145 7.21.8 Engine Monitoring Unit – Removal and installation Preconditions ☑Engine is stopped and starting disabled. NOTICE 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 Control Unit with Engine Monitoring Unit from engine...
  • Page 146 7.21.9 Engine Interface Module EIM – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Removing EIM from the engine Note or mark assignment of cables and connectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors. Unscrew power and starter cable.
  • Page 147 7.21.10 Diagnostic features on EIM Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM). It indicates the operating status of the EIM. Functions of diagnostic lamp DILA DILA lights Engine Interface Module (EIM) is OK. DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
  • Page 148 1 Preamble 6 VSP current path failed 11 ES pushbutton current 2 ECU current path failed (S5) path failed – 24 V external (S1) 7 SLD current path failed (S10) 3 MCS current path failed (S6) 12 Key switch current path (S2) 8 DDV current path failed failed (S11)
  • Page 149 Sample flashing sequences A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail- ond steps) ure (1/2 second steps) Note: These bit patterns are continuously transmitted. The CAN message "Status of internal power supply" also contains information on the current path states of the EIM.
  • Page 150 American National Standards Institute Governing body for US American standards Exhaust turbocharger Baureihe (Series) Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-...
  • Page 151 Explanation Abbrevia- Meaning tion Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly Light Emitting Diode Local Monitoring Unit LOP subassembly Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit...
  • Page 152 Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 153: Appendix B

    9 Appendix B 9.1 Special Tools Alignment device Part No.: F6790507 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 93) Angular screw driver Part No.: F30002816 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 88) Barring device Part No.: F6555766...
  • Page 154 Box wrench Part No.: F30451199 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 93) Centering jig Part No.: F6783025 Qty.: Used in: 7.5.2 Cylinder head cover – Removal and installation (→ Page 91) Double-head box wrench Part No.: F30002800 Qty.: Used in:...
  • Page 155 Endoscope Part No.: Y20097353 Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page 81) Engine barring device Part No.: F6783914 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 88) Engine barring gear Part No.: F6783914 Qty.: Used in:...
  • Page 156 Measuring instrument Part No.: Y4345888 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 88) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.15.7 Engine coolant – Sample extraction and analysis (→ Page 126) 156 | Appendix B | M015655/05E 2015-06...
  • Page 157 Oil filter wrench Part No.: F30379104 Qty.: Used in: 7.8.1 Fuel filter – Replacement (→ Page 96) Qty.: Used in: 7.14.1 Engine oil filter – Replacement (→ Page 112) Qty.: Used in: 7.15.8 Coolant filter – Replacement (→ Page 127) Open-end wrench bit Part No.: F30025897...
  • Page 158 Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.4.2 Crankcase breather – Oil separator replacement, diaphragm check and replacement (→ Page 86) Ratchet adapter Part No.: F30027339 Qty.: Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 135) Ratchet with extension Part No.: F30006212 Qty.:...
  • Page 159 Socket wrench Part No.: 0005896803/00 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 93) Torque wrench, 10–60 Nm Part No.: F30510423 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 88) Torque wrench, 4-20 Nm Part No.: F30044239 Qty.:...
  • Page 160 Torque wrench, 8-40 Nm Part No.: F30043446 Qty.: Used in: 7.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 114) 160 | Appendix B | M015655/05E 2015-06...
  • Page 161 – Replacement  127 Engine coolant – Sample extraction and analysis 126 Coolant filter  Engine data  – Replacement  127 – 12V2000M93  45 Crankcase breather  – 16V2000M93  48 – Diaphragm check  86 Engine driving end  – Oil pre-separator element   – Definition  31...
  • Page 162 Engine oil level  – Engine  52 – Check  110 Maintenance schedule  Engine sides  – Maintenance task reference table [QL1]  67 – Designation  31 MTU contact persons 152 Filter  Oil filter  – Coalescer element   – Replacement  112 – Replacement  135 Operational checks  59 –...
  • Page 163 SOLAS shielding  – Installation  73 SOLAS shielding as per MTN 5233 – Installation 72 Spare parts service 152 Starter  – Condition check  109 Startup  – After extended out-of-service periods (>3 months)  53 – Putting into operation after scheduled out-of-service-pe- riod  54 Tasks  –...

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