MTU 16V2000M72 Operating Instructions Manual
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MTU 16V2000M72 Operating Instructions Manual

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Operating Instructions
Diesel engine
12V2000M72
16V2000M72
M015650/06E

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Summary of Contents for MTU 16V2000M72

  • Page 1 Operating Instructions Diesel engine 12V2000M72 16V2000M72 M015650/06E...
  • 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

    4.3 16V2000M72 engine data, engine-mounted 8.3 Cylinder Liner heat exchanger, EPA stage 2 8.3.1 Cylinder liner – Endoscopic examination 4.4 16V2000M72 engine data, remote heat 8.3.2 Cylinder liner – Instructions and comments on exchanger, EPA stage 2 endoscopic and visual examination 4.5 Firing order...
  • Page 4 8.16.3 Engine coolant – Change 8.16.4 Engine coolant – Draining 9.1 List of abbreviations 8.16.5 Engine coolant – Filling 9.2 MTU Contact/Service Partners 8.16.6 HT coolant pump — Relief bore check 8.16.7 Engine coolant – Sample extraction and 10 Appendix B analysis 8.16.8 Coolant filter –...

  • Page 5: Safety

    Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life. M015650/06E 2018-05 | Safety | 5...
  • Page 6 Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies. Please note the following when replacing components with emission labels: • The relevant emission labels must be affixed to the spare part. • Emission labels shall not be transferred from the replaced part to the spare part. •...

  • Page 7: Correct Use Of All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...

  • Page 8: Personnel And Organizational Requirements

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

  • Page 9: Initial Start-Up And Operation - Safety Regulations

    1.4 Initial start-up and operation – Safety regulations Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications 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 10 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.

  • Page 11: Assembly, Maintenance, And Repair Work - Safety Regulations

    1.5 Assembly, maintenance, and repair work – Safety regulations Safety regulations for work prior to assembly, maintenance, and repair Have assembly, 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 from oil vapors, fluids and lubricants, risk of burning).
  • Page 12 When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing. Removing, installing and cleanliness Pay particular attention to cleanliness at all times. Completely wipe up escaped fluids and lubricants due to the risk of slipping.
  • Page 13 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
  • Page 14 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.

  • Page 15: Fire And Environmental Protection, Fluids And Lubricants

    Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
  • Page 16 Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion.

  • Page 17: Standards For Warning Notices In The Text And Highlighted Information

    1.7 Standards for warning notices in the text and highlighted information 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: Transport

    Setting the engine down after transport • Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. • Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

  • Page 19: General Information

    3 General Information 3.1 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)

  • Page 20: Product Description

    3.2 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, se- quential 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 injec- tion pressure, injection timing and injection quantity independently of the engine speed.
  • Page 21 • 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 22 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 23 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 24 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 24 | General Information | M015650/06E 2018-05...
  • Page 25 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 26: Engine - Overview

    3.3 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 27 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 housing 23 Flywheel housing mary turbocharger) with integrated expansion 24 Engine mounting 3 Air intake tank 25 Carrier housing middle sec- 4 Engine lifting equipment...

  • Page 28: Sensors And Actuators - Overview

    3.4 Sensors and actuators – Overview Engine plan view Deviations from illustrations are insignificant. Also applies similarly to 12V. Item Designation Monitoring of Intake air temperature Charge-air temperature Lube oil temperature Charge-air pressure Turbocharger speed 28 | General Information | M015650/06E 2018-05...
  • Page 29 Engine free end Item Designation Monitoring of 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 30 Engine driving end Item Designation Monitoring of B1 (ECU) Camshaft speed B13.2 (optional EMU) Crankshaft speed B13 (ECU) Crankshaft speed 30 | General Information | M015650/06E 2018-05...
  • Page 31 Engine, right side Item Designation Monitoring of 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 M015650/06E 2018-05 | General Information | 31...
  • Page 32 Engine, left side Item Designation Monitoring of 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. Designation Monitoring of Starting-air pressure Fuel prefilter water level Exhaust back pressure Start interlock, switching status 32 | General Information | M015650/06E 2018-05...

  • Page 33: Technical Data

    4 Technical Data 4.1 12V2000M72 engine data, engine-mounted heat exchanger, EPA stage 2 Explanation: DL Reference value: Continuous power BL Reference 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 34 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 engine-external 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 35 Capacities Number of cylinders Engine coolant, engine side (with cooling system) 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 at dipstick mark “min.” (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “max.”...

  • Page 36: 12V2000M72 Engine Data, Remote Heat Exchanger, Epa Stage

    4.2 12V2000M72 engine data, remote heat exchanger, EPA stage Explanation: DL Reference value: Continuous power BL Reference 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 37 Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (measuring point: before engine) Fuel system Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 38 Number of cylinders Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max. Liters operating inclinations) Weights / main dimensions Number of cylinders Engine dry weight (with standard accessories installed, without coupling) 2770 Acoustics...

  • Page 39: 16V2000M72 Engine Data, Engine-Mounted Heat Exchanger, Epa Stage

    4.3 16V2000M72 engine data, engine-mounted heat exchanger, EPA stage 2 Explanation: DL Reference value: Continuous power BL Reference 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 40 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 engine-external 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 41 Capacities Number of cylinders Engine coolant, engine side (with cooling system) 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 at dipstick mark “min.” (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “max.”...

  • Page 42: 16V2000M72 Engine Data, Remote Heat Exchanger, Epa Stage

    4.4 16V2000M72 engine data, remote heat exchanger, EPA stage Explanation: DL Reference value: Continuous power BL Reference 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 43 Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (measuring point: before engine) Fuel system Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 44 Number of cylinders Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max. Liters operating inclinations) Weights / main dimensions Number of cylinders Engine dry weight (with standard accessories installed, without coupling) 3337 Acoustics...

  • Page 45: Firing Order

    4.5 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 M015650/06E 2018-05 | Technical Data | 45...

  • Page 46: Engine - Main Dimensions

    4.6 Engine – Main dimensions Main dimensions Engine model Length (A) Width (B) Height (C) 12V2000M72 approx. 2078 mm approx. 1295 mm approx. 1390 mm 16V2000M72 approx. 2486 mm approx. 1295 mm approx. 1390 mm 46 | Technical Data | M015650/06E 2018-05...

  • Page 47: Operation

    5.1 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 48: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    5.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Measure Lube oil system Check engine oil level (→ Page 134). Coolant circuit Check coolant level (→ Page 145). Coolant circuit If necessary, heat up coolant with coolant preheating unit if T<5 °C.

  • Page 49: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    5.3 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 51). Shut down fuel treatment system (→ Page 60). M015650/06E 2018-05 | Operation | 49...

  • Page 50: 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 51: Fuel Treatment System - Putting Into Operation

    5.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 54). 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 52 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 54). Start engine (→ Page 55). 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 53: Operational Checks

    5.6 Operational checks DANGER Rotating, moving engine components. Engine operation at high load/speed. Risk of crushing, danger of parts of the body being caught or pulled in! • Personnel must only stay in the operating room of the engine/engine-generator set as long as neces- sary and only if on-site attendance is expressly required in the descriptions.

  • Page 54: Fuel Treatment System - Switching On

    5.7 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. •...

  • Page 55: Starting The Engine

    5.8 Starting the engine Preconditions ☑ External start interlock is not activated. ☑ Emergency air-shutoff flaps (if applicable) 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 engine's danger zone.

  • Page 56: Re-Starting The Engine Following An Automatic Safety Shutdown

    5.9 Re-starting the engine following an automatic safety shutdown NOTICE Re-starting the engine following an automatic safety shutdown. Risk of severe engine damage! • Before starting the engine, make sure the root cause of the safety shutdown was eliminated. • If the root cause cannot be identified or eliminated, contact Service. Note: •...

  • Page 57: Engine - Shutdown

    5.10 Engine – Shutdown Preconditions ☑ Engine is running in Local mode CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE Stopping the engine when it is running at full load causes extreme stress to the engine.

  • Page 58: Emergency Engine Shutdown

    5.11 Emergency engine shutdown CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE An emergency stop subjects the engine system to an extremely high load.

  • Page 59: After Shutting Down 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: • Carry out engine preservation (→ MTU Preservation and Represervation Specifications A001070/..) M015650/06E 2018-05 | Operation | 59...

  • Page 60: Fuel Treatment System - Shutdown

    5.13 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 61: Plant - Cleaning

    5.14 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaner (→ Tools Catalog) 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 62: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 63: Troubleshooting

    7 Troubleshooting 7.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (see manufacturer's documentation). Battery: Cable connections faulty u Check if cable connections are properly secured (see manufacturer's documentation). u Check firm seating of cable connections, contact Service.
  • Page 64 Vent fuel system (→ Page 115). u Contact Service. Engine Control Unit defective Charge-air temperature too high Cause Corrective action u Check (MTU test kit). Incorrect coolant concentration u Contact Service. Charge-air cooler clogged u Check fans and air supply/ventilation ducts. Engine room: Air-intake...
  • Page 65 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 135). Too much engine oil in the engine Oil separator or oil pre-separator 1. Clean preseparator (→ Page 104). of crankcase breather clogged 2. Replace oil separator element (→ Page 105). Exhaust turbocharger, cylinder u Contact Service.

  • Page 66: Fault Messages On The Ecu7 Engine Governor For Series 2000 Cr Marine Engines

    7.2 Fault messages on the ECU7 engine governor for Series 2000 CR marine engines Possible engine responses to yellow alarm: Warning, power limitation/reduction, speed limitation, engine shutdown Possible engine responses to red alarm: Engine shutdown, power limitation/reduction, speed limitation, warning Procedure following an automatic safety shutdown (→...
  • Page 67 6 – SS T-Charge Air PV-Number: Cause Corrective action The charge-air temperature at 1. Observe any other messages. sensor B9.1 exceeded limit value 2. Check engine room or acoustic enclosure temperature. 2. Charge-air temperature is too 3. Check charge-air cooler coolant discharge (→ Page 129). high.
  • Page 68 20 – SS T-Exhaust A PV-Number: Cause Corrective action The exhaust temperature at 1. Observe any other messages. sensor B4.21 has violated upper 2. Check individual exhaust gas temperatures of bank A at LOP . limit value 2. The exhaust gas 3.
  • Page 69 25 – HI P-Diff-Lube Oil PV-Number: Cause Corrective action The differential oil pressure at 1. Observe any other messages. sensors B5.1 and B5.3 has 2. Replace engine oil filter (→ Page 136). violated upper limit value 1. The 3. Check engine wiring (→ Page 160). differential oil pressure is too 4.
  • Page 70 51 – HI T-Lube Oil PV-Number: Cause Corrective action The lube oil temperature at sensor 1. Reduce power. B7.1 exceeded limit value 1. Lube 2. Observe any other messages. oil temperature is too high. 3. Check operation of cooler and fan (plant). 4.
  • Page 71 65 – LO P-Fuel PV-Number: Cause Corrective action The fuel pressure at sensor B34.1 1. Observe any other messages. has violated limit value 1. Fuel 2. Check fuel reserves and fuel supply. pressure is too low. 3. Replace fuel filter (→ Page 116). 4.
  • Page 72 81 – AL Rail Leakage PV-Number: Cause Corrective action During engine start: The pressure 1. Observe any other messages. increase in the HP fuel system is 2. Check HP fuel system for leak-tightness. too low. 3. Vent fuel system (→ Page 115). During engine stop: The pressure 4.
  • Page 73 104 – AL Eng Hours Counter Defect PV-Number: Cause Corrective action The operating hours calculated by 1. Observe any other messages. the ECU and stored on stopping 2. Contact Service. the engine cannot be read out properly on restarting the engine. 118 –...
  • Page 74 122 – HI T-ECU PV-Number: Cause Corrective action The temperature at the sensor 1. Disconnect power supply. inside the ECU has violated the 2. Check power supply (plant). upper limit value. The temperature 3. Check plug connections for engine governor ECU (→ Page 163). inside the housing is too high.
  • Page 75 Corrective action CAN bus 2 to plant automation 1. Observe any other messages. system (e.g. Murphy display) 2. Check connection between plant automation system and MTU disrupted or defective. automation system. 3. Contact Service. 189 – AL CAN2 Error Passive...
  • Page 76 201 – SD T-Coolant PV-Number: Cause Corrective action The signal from the coolant 1. Check engine wiring (→ Page 160). temperature sensor B6.1 on 2. Contact Service. coolant distribution housing is faulty or missing. 202 – SD T-Fuel PV-Number: Cause Corrective action The signal from the fuel 1.
  • Page 77 215 – SD P-HD PV-Number: Cause Corrective action The signal from the HP fuel 1. Check engine wiring (→ Page 160). pressure sensor B48.1 is faulty or 2. Contact Service. missing. 216 – SD T-Lube Oil PV-Number: Cause Corrective action The signal from the lube-oil 1.
  • Page 78 230 – SD Crankshaft Speed PV-Number: Cause Corrective action The signal from the crankshaft 1. Check engine wiring (→ Page 160). speed sensor B13.1 is faulty or 2. Contact Service. missing. 231 – SD Camshaft Speed PV-Number: Cause Corrective action The signal from the camshaft 1.
  • Page 79 322 – AL Wiring Cylinder A2 PV-Number: Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 160). wiring for cylinder A2 or injector 2. Check injector. defective. 3. Replace injector (→ Page 112). 4.
  • Page 80 326 – AL Wiring Cylinder A7 PV-Number: Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 160). wiring for cylinder A7 or injector 2. Check injector. defective. 3. Replace injector (→ Page 112). 4.
  • Page 81 334 – AL Wiring Cylinder B4 PV-Number: Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 160). wiring for cylinder B4 or injector 2. Check injector. defective. 3. Replace injector (→ Page 112). 4.
  • Page 82 341 – AL Open Load Cylinder A1 PV-Number: Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 160). to cylinder A1. 2. Check injector. 3. Replace injector (→ Page 112). 4. Contact Service. 342 –...
  • Page 83 346 – AL Open Load Cylinder A6 PV-Number: Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 160). for cylinder A6. 2. Check injector. 3. Replace injector (→ Page 112). 4. Contact Service. 346 –...
  • Page 84 353 – AL Open Load Cylinder B3 PV-Number: Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 160). to cylinder B3. 2. Check injector. 3. Replace injector (→ Page 112). 4. Contact Service. 354 –...
  • Page 85 356 – AL Open Load Cylinder B8 PV-Number: Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 160). to cylinder B8. 2. Check injector. 3. Replace injector (→ Page 112). 4. Contact Service. 361 –...
  • Page 86 372 – AL Wiring TO 2 PV-Number: Cause Corrective action Short circuit or wire break on 1. Check engine wiring (→ Page 160). transistor output 2 (TO 2). 2. Contact Service. 373 – AL Wiring TO 3 PV-Number: Cause Corrective action Short circuit or wire break on 1.
  • Page 87 384 – AL Wiring TOP 4 PV-Number: Cause Corrective action Short circuit or wire break at 1. Check engine wiring (→ Page 160). transistor output 4 plant-side 2. Contact Service. (TOP 4). 390 – AL MCR exceeded PV-Number: Cause Corrective action The current engine power exceeds 1.
  • Page 88 404 – AL Open Load Digital Input 5 PV-Number: Cause Corrective action Open load detected at digital 1. Check engine wiring (→ Page 160). input 5 of the ECU. 2. Check plug connections for engine governor ECU (→ Page 163). 3.
  • Page 89 411 – LOLO U-PDU PV-Number: Cause Corrective action The ECU voltage to control the 1. Check power supply (plant). injectors has violated lower limit 2. Check engine wiring (→ Page 160). value 2. 3. Check plug connections for engine governor ECU (→ Page 163). 4.

  • Page 90: Control Cabinet Of Fuel Treatment System - Troubleshooting

    7.3 Control cabinet of fuel treatment system – Troubleshooting Water alarm Cause Corrective action When the maximum water level is 1. Press illuminated pushbutton 'Water alarm' for acknowledgment. reached, the water level electrode 2. In addition to the automatic water drain function, water can also be opens the water drain valve and drained manually: Press illuminated pushbutton 'Water drain'.

  • Page 91: Task Description

    8 Task Description 8.1 SOLAS 8.1.1 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 92: Solas Shielding - Installation

    8.1.2 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 93: Installation Locations For Solas Shielding

    8.1.3 Installation locations for SOLAS shielding General information Install SOLAS shielding as per MTN 5233 as a matter of priority (→ Page 91). Free end, B side Item Type of shielding Comments Shield (A7) On fuel delivery pump Shield (A7) On HP fuel pump Free end M015650/06E 2018-05 | SOLAS | 93...
  • Page 94 Item Type of shielding Comments Shield (A8) On fuel filter Shield (A7) Above fuel priming pump Shield (A7) Below fuel priming pump Driving end, A-side Item Type of shielding Comments Shield (A5) On air flap Shield (A4) On brazed-on union Shield (A5) On exhaust turbocharger flap Shield (A5)
  • Page 95 Item Type of shielding Comments Shield (A5) To exhaust turbocharger lubrication Shield (A5) On valve plate Driving end Item Type of shielding Comments Shield (A4) Turbocharger lubrication, left side Shield (A4) Exhaust turbocharger lubrication, center Driving end Item Type of shielding Comments Shield (A4) Turbocharger lubrication, right side...
  • Page 96 Driving end, B-side Item Type of shielding Comments Shield (A5) Turbocharger flap Shield (A5) Turbocharger flap Shield (A4) On brazed-on union Shield (A5) On air flap Shield (A4) To exhaust turbocharger lubrication Driving end, B-side Item Type of shielding Comments Shield (A5) On valve plate 96 | SOLAS | M015650/06E 2018-05...
  • Page 97 Driving end, A-side Item Type of shielding Comments Shield (A5) To flap control Driving end, B-side Item Type of shielding Comments Shield (A5) To flap control M015650/06E 2018-05 | SOLAS | 97...

  • Page 98: Engine

    8.2 Engine 8.2.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine barring device 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 99: Engine - Cranking On Starting System

    8.2.2 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 100: Cylinder Liner

    8.3 Cylinder Liner 8.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 111). Remove injector (→...
  • Page 101 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 102). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 102: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    8.3.2 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 examina- tion 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 103 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and burn marks 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 104: Crankcase Breather

    8.4 Crankcase Breather 8.4.1 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 105: Crankcase Breather - Oil Separator Replacement, Diaphragm Check And Replacement

    8.4.2 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, 8–40 Nm F30043446 Ratchet adapter F30027340 Engine oil Filter element (→...
  • Page 106 Checking diaphragm Remove cover (4). Remove spring (5), seal (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new dia- phragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 107: Belt Drive

    8.5 Belt Drive 8.5.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. WARNING Exposed rotating parts can eject drawn-in components or draw in body parts. Risk of crushing, limbs or extremities may be pinched, trapped or entangled! Risk of injury due to flying parts! •...

  • Page 108: Valve Drive

    8.6 Valve Drive 8.6.1 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.
  • Page 109 Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder 1 bank A: • 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 110 Final steps Remove barring device. Install cylinder head cover (→ Page 111). Install air filter (→ Page 131). 110 | Valve Drive | M015650/06E 2018-05...

  • Page 111: Cylinder Head Cover - Removal And Installation

    8.6.2 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F30043446 Centering device F6783025 Gasket (→ Spare Parts Catalog) Preparatory steps Remove air filter (→...

  • Page 112: Injection Valve / Injector

    8.7 Injection Valve / Injector 8.7.1 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 113). 112 | Injection Valve / Injector | M015650/06E 2018-05...

  • Page 113: Injector - Removal And Installation

    8.7.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Socket wrench F30451502 Puller F6790629 Double-head box wrench F30011450 Open-end wrench bit F30025897 Box wrench F30451199 Alignment device F6790507...
  • Page 114 Installing injector Prior to installation, remove all blanking plugs. Fit new O-rings on injector and coat with as- sembly compound. Secure new sealing ring with assembly com- pound on injector, observing installation posi- tion of sealing ring. Clean sealing surface on cylinder head and protective sleeve.
  • Page 115 8.8 Fuel System 8.8.1 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. •...
  • Page 116 8.9 Fuel Filter 8.9.1 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 Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 117 Easy-change fuel filter replace- ment with the engine running Cut out filter to be replaced, e.g. turn three- way cock to position (B) to switch off the fil- ter (2) to be replaced. Open threaded vent plug (1) of switched-off filter at filter head and check that fuel filter is not under pressure.

  • Page 118: Fuel Prefilter – Differential Pressure Gage

    8.9.2 Fuel prefilter – Differential pressure gage check and adjustment Preconditions ☑ Both filters are cut in DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
  • Page 119 8.9.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. (only with single-stage fuel prefilter) Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 120 Connect filling pump to filling connection (1) on intake side of filter. Loosen threaded vent plugs (2) and fill with fuel until fuel emerges from vent pipe (3). Close threaded vent plugs (2). Fuel prefilter with reversible du- plex filter – Draining Switch off filter which is to be drained (A or 1 Filter A switched off 2 Filter B switched off...
  • Page 121 Connect filling pump to filling connection (1) on intake side of filter. Open vent valve (2) and fill with fuel until fuel emerges from vent pipe (3). Close vent valve (2). Open rotary slide valve (4) a little (by approx. 30°) and open vent valve(s) (2), until fuel emerges from vent pipe (3).
  • Page 122 8.9.4 Fuel prefilter – Flushing Preconditions ☑ Engine is stopped and starting disabled. (only with single-stage fuel prefilter) Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 123 Fuel prefilter with single-stage filter – Flushing Close fuel shutoff valve. Loosen threaded vent plugs (1). Open drain valve (2) and drain fuel. Result: Fuel flows from filtered side back to unfil- tered side, flushing filter deposits downwards out of the filter. Close threaded vent plugs (1) and drain valve (2).
  • Page 124 Fuel prefilter with switchable duplex filter – Flushing Cut out contaminated filter (A or B): 1 Filter A switched off 2 Filter B switched off Open threaded vent plug (1) of filter to be flushed. Remove drain valve (2) and drain fuel. Result: Fuel flows from filtered side back to unfil- tered side, flushing filter deposits downwards...
  • Page 125 Connect filling pump to filling connection (1) on intake side of filter. Open vent valve (2) and fill with fuel until fuel emerges from vent pipe (3). Close vent valve (2). Open rotary slide valve (4) a little (by approx. 30°) and open vent valve(s) (2), until fuel emerges from the vent pipe (3).
  • Page 126 8.9.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. (only with single-stage fuel prefilter) Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→...
  • Page 127 Filter element with single-stage filter – Replacement Close fuel shutoff valve. Loosen threaded vent plugs (1) of contami- nated filter. Unlock drain valve (5) by pressing toggle and open it. Drain fuel from filter. Close drain valve (5). Remove screws securing cover (2) and open filter cartridge housing.
  • Page 128 Release threaded vent plug (1) of contaminat- ed filter. Unlock drain valve (5) by pressing toggle and open it. Drain water and contaminants from filter. Close drain valve (5). Remove screws securing cover (2) and take off cover. Remove spring housing (3) and filter element (4).

  • Page 129: Charge-Air Cooling

    8.10 Charge-Air Cooling 8.10.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 130: Air Filter

    8.11 Air Filter 8.11.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing air filter Remove old air filter and install new air filter (→ Page 131). Reset signal ring of contamination indicator (→...
  • Page 131 8.11.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms. •...

  • Page 132: Air Intake

    8.12 Air Intake 8.12.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. WARNING The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac- uum. Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door can be prevented! •...

  • Page 133: Starting System

    8.13 Starting System 8.13.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter and nut on cable connection for secure seating and tighten if required. Check cabling (→ Page 160). M015650/06E 2018-05 | Starting System | 133...

  • Page 134: Engine Oil System

    8.14 Engine Oil System 8.14.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. Checking oil level prior to en- gine start Pull out dipstick from guide tube and wipe it. Insert dipstick into guide tube up to the stop, pull it out after approx.
  • Page 135 8.14.2 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 Oil is hot.

  • Page 136: Oil Filtration / Cooling

    8.15 Oil Filtration / Cooling 8.15.1 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) Shield for SOLAS (→ Spare Parts Catalog) DANGER Components are moving or rotating.
  • Page 137 Oil filter replacement with the engine stopped Stop engine (→ Page 57) and disable engine start. Cut out the filter to be replaced. A Right filter cut out B Both filters cut in (normal operating position) C Left filter is cut out. Use oil filter wrench to unscrew cut-out oil fil- ter.

  • Page 138: Centrifugal Oil Filter – Cleaning And Filter

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet F30027340 Cold cleaner (Hakutex 60 MTU) X00070585 Filter sleeve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Oil is hot.
  • Page 139 Use torque wrench to tighten nut (2) to specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque 8 Nm + 1 Nm Fit housing cover (1). Screw on nuts (4). Use torque wrench to tighten nuts (4) crosswise to specified tightening torque. Name Size Type...

  • Page 140: Coolant Circuit, General, High-Temperature

    8.16 Coolant Circuit, General, High-Temperature Circuit 8.16.1 Draining and venting points Figures also apply similarly to 12V and 16V. Plan view 1 Overflow line, expansion 2 Filler neck tank 140 | Coolant Circuit, General, High-Temperature Circuit | M015650/06E 2018-05...
  • Page 141 Free end (KGS) 1 Fuel filter vent screws 3 Raw water pump filling plug 5 Raw water pump drain plug 2 Engine coolant drain plug 4 Measuring point, pressure 6 Connection: Oil extraction before raw water pump M015650/06E 2018-05 | Coolant Circuit, General, High-Temperature Circuit | 141...
  • Page 142 Left side 1 Engine coolant drain plug 2 Engine coolant drain plug (M14x1.5) 142 | Coolant Circuit, General, High-Temperature Circuit | M015650/06E 2018-05...
  • Page 143 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) M015650/06E 2018-05 | Coolant Circuit, General, High-Temperature Circuit | 143...
  • Page 144 Driving end (KS) 1 Engine coolant drain plug 2 Connection: Oil extraction 144 | Coolant Circuit, General, High-Temperature Circuit | M015650/06E 2018-05...
  • Page 145 8.16.2 Engine coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 146 8.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 147). Fill with engine coolant (→ Page 148). 146 | Coolant Circuit, General, High-Temperature Circuit | M015650/06E 2018-05...
  • Page 147 8.16.4 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 148 8.16.5 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 149 8.16.6 HT coolant pump — Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 150: Engine Coolant – Sample Extraction And

    • pH value. Fit breather valve and close it. Change engine coolant according to the coolant operating times specified in (→ MTU Fluids and Lubricants Specifications A001061/..) (→ Page 147). 150 | Coolant Circuit, General, High-Temperature Circuit | M015650/06E 2018-05...
  • Page 151 8.16.8 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 152: Raw Water Pump With Connections

    8.17 Raw Water Pump with Connections 8.17.1 Raw water pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 153: Battery-Charging Generator

    8.18 Battery-Charging Generator 8.18.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Preparatory steps Remove safety equipment (if fitted). Remove screws of protective cover (engine free end).

  • Page 154: Fuel Supply System

    8.19 Fuel Supply System 8.19.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 154 | Fuel Supply System | M015650/06E 2018-05...

  • Page 155: Differential Pressure Gage – Alarm Function

    8.19.2 Differential pressure gage – Alarm function 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 gage alarm function Switch on fuel treatment system (→...

  • Page 156: Water Level Probe (3-In-1 Rod Electrode

    8.19.3 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 157: Check

    8.19.4 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 158: Coalescer Filter Element ‒ Replacement

    8.19.5 Coalescer filter element ‒ Replacement Preconditions ☑ System is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet adapter F30027340 Fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→...
  • Page 159 Tighten nut (3) to specified torque using a torque wrench. 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. Result: The fuel treatment system is ready for operation.

  • Page 160: Wiring (General) For Engine/Gearbox/Unit

    8.20 Wiring (General) for Engine/Gearbox/Unit 8.20.1 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 161: Accessories For (Electronic) Engine

    8.21 Accessories for (Electronic) Engine Governor / Control System 8.21.1 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.

  • Page 162: Governor / Control System

    8.21.2 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 163: Engine Governor Plug Connections – Check

    8.21.3 Engine governor plug connections – Check Preconditions ☑ Engine stopped and starting disabled. ☑ Electronic engine management system is de-energized. 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 164: Engine Monitoring Unit Emu 7 – Plug

    8.21.4 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 165: Interface Module Eim Plug Connections – Check

    8.21.5 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 en- gaged. Check screws (1) of cable clamps on EIM for firm seating.

  • Page 166: Engine Control Unit – Self-Test

    8.21.6 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 167: Engine Governor Ecu 7 – Removal And

    8.21.7 Engine governor ECU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine electronics is powered off. 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 168: Installation

    8.21.8 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.

  • Page 169: Engine Interface Module Eim 2 – Removal And

    8.21.9 Engine Interface Module EIM 2 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing Engine Interface Mod- ule from engine Note or mark assignment of cables and con- nectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors.

  • Page 170: Engine Interface Module Eim 2 – Diagnostic

    8.21.10 Engine Interface Module EIM 2 – Diagnostic features Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM 2). It indicates the operating status of the EIM 2. Functions of diagnostic lamp DILA DILA glows Engine Interface Module (EIM 2) is OK.
  • Page 171 1 Preamble 6 VSP current path failed (S5) 11 ES pushbutton current path 2 Engine Control Unit current 7 SLD current path failed (S6) failed – 24 V external (S10) path failed (S1) 8 DDV current path failed (S7) 12 Key switch current path 3 MCS current path failed 9 Gear monitoring current failed (S11)
  • Page 172 Sample flashing sequences A Fuse S5 failure (1/2 second B Fuse S1 and fuse S4 failure steps) (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 2.

  • Page 173: Appendix A

    Association of American standardization organiza- tions Abgasturbulader 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 Con- trol Unit...
  • Page 174 Abbrevia- Meaning Explanation tion Initial Injector Equalization Entering of injector code with DiaSys in engine gover- International Maritime Organization International Organization for Stand- International umbrella organization for all national ardization standardization institutes Kraftgegenseite Engine free end in accordance with DIN ISO 1204 Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal...

  • Page 175: Mtu Contact/Service Partners

    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 high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.

  • Page 176: Appendix B

    10 Appendix B 10.1 Special Tools Alignment device Part No.: F6790507 Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 113) Angular screw driver Part No.: F30453001 Qty.: Used in: 8.6.1 Valve clearance – Check and adjustment (→ Page 108) Barring tool Part No.: F6555766...
  • Page 177 Box wrench Part No.: F30451199 Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 113) Centering device Part No.: F6783025 Qty.: Used in: 8.6.2 Cylinder head cover – Removal and installation (→ Page 111) Double-head box wrench Part No.: F30002800 Qty.: Used in:...
  • Page 178 Endoscope Part No.: Y20097353 Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 100) Engine barring device Part No.: F6783914 Qty.: Used in: 8.2.1 Engine – Barring manually (→ Page 98) Qty.: Used in: 8.6.1 Valve clearance – Check and adjustment (→...
  • Page 179 MTU test kit Part No.: F6798833 Qty.: Used in: 8.16.7 Engine coolant – Sample extraction and analysis (→ Page 150) Oil filter wrench Part No.: F30379104 Qty.: Used in: 8.9.1 Fuel filter – Replacement (→ Page 116) Qty.: Used in: 8.15.1 Engine oil filter –...
  • Page 180 Ratchet Part No.: F30027340 Qty.: Used in: 8.15.2 Centrifugal oil filter – Cleaning and filter-sleeve re- placement (→ Page 138) Ratchet adapter Part No.: F30027340 Qty.: Used in: 8.4.2 Crankcase breather – Oil separator replacement, di- aphragm check and replacement (→ Page 105) Qty.: Used in: 8.19.5 Coalescer filter element ‒...
  • Page 181 Socket wrench Part No.: F30451502 Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 113) Torque wrench, 20–100 Nm Part No.: F30026582 Qty.: Used in: 8.6.1 Valve clearance – Check and adjustment (→ Page 108) Torque wrench, 8-40 Nm Part No.: F30043446 Qty.:...
  • Page 182 Valve clearance gage Part No.: Y4345893 Qty.: Used in: 8.6.1 Valve clearance – Check and adjustment (→ Page 108) 182 | Special Tools | M015650/06E 2018-05...
  • Page 183 2 36 Cylinder  16V2000M72 engine data, engine-mounted heat exchang- – Designation  19 er, EPA stage 2 39 Cylinder head cover  16V2000M72 engine data, remote heat exchanger, EPA – Installation  111 stage 2 42 – Removal  111 Cylinder liner  – Endoscopic examination  100 Actuators ...
  • Page 184 Engine oil filter  – Replacement  136 Engine oil level  Maintenance Schedule  – Check  134 – Maintenance task reference table [QL1]  62 Engine sides  MTU contact persons 175 – Designation  19 Oil filter  Filter sleeve  – Replacement  136 – Replacement  138 Operational checks  53...
  • Page 185 Safety regulations  – Assembly work  11 – Auxiliary materials  15 – Environmental protection  15 – Fire prevention  15 – Fluids and lubricants  15 – Important provisions  5, 7 – Initial start-up  9 – Maintenance work  11 – Operation  9 – Organizational requirements  8 –...

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