MTU 12 V 2000 M72 Operating Instructions Manual
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MTU 12 V 2000 M72 Operating Instructions Manual

Diesel engine
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Operating Instructions

Diesel engine
12 V 2000 M72
16V 2000 M72
M015650/03E

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angelito ranches
February 22, 2025

is it safe to run the engine with the bank b flap closed at reduced speed while the ferry boat is experiencing rough sea or bad weather? how long can we run it at reduce speed without putting the engine at risk?

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Summary of Contents for MTU 12 V 2000 M72

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 2000 M72 16V 2000 M72 M015650/03E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services.
  • Page 3 Commissioning Note Important Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ ranty, spare parts, etc.).

  • Page 5: Table Of Contents

    7.2 Engine mounted heat exchanger, EPA stage 2 7.2.1 Engine – Barring manually 3.2 12 V 2000 M72 engine data: remote heat 7.2.2 Engine – Barring with starting system exchanger, EPA stage 2 3.3 16V 2000 M72 engine data: Engine- 7.3 Cylinder Liner...
  • Page 6 7.15.3 Engine coolant – Change 7.15.4 Engine coolant – Draining 8.1 Abbreviations 7.15.5 Engine coolant – Filling 8.2 MTU contacts/service partners 7.15.6 HT coolant pump — Relief bore check 7.15.7 Engine coolant – Sample extraction and analysis 7.15.8 Coolant filter – Replacement 9 Appendix B 7.16 Raw Water Pump with Connections...

  • Page 7: Safety

    Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

  • Page 8: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company.

  • Page 9: Transport

    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 an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis.

  • Page 10: Safety Regulations For Startup And Operation

    Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: •...

  • Page 11: Safety Precautions When Working On The Engine

    Do not use the assembly or plant as a ground terminal. Never place the welding cable across or near wiring harnesses of MTU plants. The welding current may otherwise induce an interference voltage in the wiring harnesses which could damage the electrical sys‐...
  • Page 12 If welding has to be carried out on components (e.g. exhaust manifold), these components must first be removed from the engine. Hydraulic installation and removal Check the tools and devices to be used for perfect operation and safe condition. Only use the specified devices for force-fitting/removing parts.

  • Page 13: Auxiliary Materials, Fire Prevention And Environmental Protection

    MTU will provide assistance and advice if emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliability and performance of MTU engines and must be complied with over the entire life cycle of the engine.
  • Page 14 Lead • When working with lead or lead-containing pastes, avoid direct contact with the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust! • Switch on fume extraction system. • After coming into contact with lead or lead-containing materials, wash hands! Acids and alkaline solutions •...
  • Page 15 Used oil Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil. M015650/03E 2011-10 | Safety | 15...

  • Page 16: Conventions For Safety Instructions In The Text

    1.7 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 17: General Information

    2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).

  • Page 18: Product Description

    2.2 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection, sequential turbocharging and charge-air cooling. An electronic management system provides engine control and monitoring. Fuel system with common rail injection Controlled by the engine electronics, the common rail injection system determines injection pressure, in‐...
  • Page 19 Open-loop control: • Injection (fuel pressure, injection timing, injection duration, operating status) • Sequential turbocharging (cutting-in and out) with secondary turbocharger • Engine protection with multi-stage safety systems: • Power reduction • Power limitation • Emergency stop Monitoring: • Exhaust gas temperature, A-side •...
  • Page 20 SOLAS – Fire protection specifications Special connections In case of leakage, the above-mentioned connection types are spray-protected even without a cover and have been confirmed compliant with SOLAS by GL and DNV. Plug-in pipe connection The sleeve (4) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐...
  • Page 21 The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under pressure. HP line between fuel injector and HP accumulator 1 Support ring 4 Union nut 7 Thrust ring 2 V-ring 5 HP line 8 V-ring 3 Thrust ring...
  • Page 22 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 22 | General Information | M015650/03E 2011-10...
  • Page 23 HP line between distributor and HP accumulator 1 Jacket pipe 5 Thrust screw 9 Pressure pipe 2 O-ring 6 Thrust ring 10 O-ring 3 O-ring 7 O-ring 4 Thrust ring 8 HP line Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from where it is routed at atmospheric pressure into a level-monitored leak fuel tank.

  • Page 24: Engine Layout

    2.3 Engine layout Engine layout 1 Engine oil heat exchang‐ 13 Carrier housing 26 Raw-water connection for 14 Exhaust turbocharger gearbox cooling 2 Engine oil filter (primary turbocharger) 27 Gearcase 3 Engine coolant filter 15 Exhaust turbocharger, left 28 Raw water pump 4 Change-over lever for en‐...
  • Page 25 1 Exhaust turbocharger, left 9 Engine coolant filter 20 Oil dipstick (secondary turbocharger) 10 Engine oil filter 21 Drive flange 2 Exhaust turbocharger 11 Fuel filter 22 Flywheel housing (primary turbocharger) 12 Engine oil heat exchang‐ 23 Engine mounting 3 Air intake 24 Carrier housing core 4 Engine hoisting lug (driv‐...

  • Page 26: Sensors, Actuators And Injectors - Overview

    2.4 Sensors, actuators and injectors – Overview Engine plan view Deviations from illustrations are insignificant. Also applies similarly to 12V. Item Description Monitoring of Lube oil temperature Charge-air pressure Turbocharger speed Intake air temperature Charge-air temperature 26 | General Information | M015650/03E 2011-10...
  • Page 27 Engine free end Item Description Monitoring of Fuel pressure after filter B5.3 (option) Lube oil pressure before filter B5.1 Lube oil pressure after filter B5.2 (option) Lube oil pressure after filter Engine coolant level, expansion tank B21 (option) Raw water pressure B6.2 (option) Coolant temperature B6.1...
  • Page 28 Engine driving end Item Description Monitoring of B1 (ECU) Camshaft speed B13.2 (optional EMU) Crankshaft speed B13 (ECU) Crankshaft speed 28 | General Information | M015650/03E 2011-10...
  • Page 29 Engine, right side Item Description Monitoring of YB33 Fuel temperature Fuel pressure (in rail) B16 (option) Coolant pressure Leak fuel level Y27.2 4-2-directional control valve, B-side B4.22 Exhaust temperature, B-side 2-2-directional control valve M015650/03E 2011-10 | General Information | 29...
  • Page 30 Engine, left side Item Description Monitoring of B4.21 Exhaust gas temperature, A-side Y27.1 4-2-directional control valve, A-side B54 (option) Lube oil pressure, replenishment pump System sensors These sensors are fitted outside the engine. Description Monitoring of Starting-air pressure Fuel prefilter water level Exhaust back pressure Start interlock, switching status 30 | General Information | M015650/03E 2011-10...

  • Page 31: Technical Data

    3 Technical Data 3.1 12V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 32 Number of cylinders Inlet valves per cylinder Exhaust valves per cylinder 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...
  • Page 33 INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline) Number of cylinders Longitudinal inclination, continuous max., driving end down (Option: max. degrees operating inclinations) Longitudinal inclination, temporary max., driving end down (Option: max. degrees 22.5 operating inclinations) Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ degrees ating inclinations) Transverse inclination, continuous max.

  • Page 34: 2000 M72 Engine Data: Remote Heat Exchanger, Epa Stage

    3.2 12 V 2000 M72 engine data: remote heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
  • Page 35 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) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine inlet connection, min.
  • Page 36 CAPACITIES Number of cylinders Engine oil capacity, initial filling (standard oil system) (option: max. operat‐ Liters ing inclinations) Oil change quantity, max. (standard oil system) (option: max. operating in‐ Liters clinations) Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. Liters operating inclinations) Oil pan capacity at dipstick mark “max.”...

  • Page 37: 2000 M72 Engine Data: Engine-Mounted Heat Exchanger, Epa Stage

    3.3 16V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 38 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 39 CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler) liters Total engine oil capacity at initial filling (standard oil system) (Option: max. liters operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liters clinations) Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. liters operating inclinations) Oil pan capacity at dipstick mark "max."...

  • Page 40: 2000 M72 Engine Data: Separate Heat Exchanger, Epa Stage

    3.4 16V 2000 M72 engine data: Separate heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 41 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 (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine inlet connection, min.
  • Page 42 CAPACITIES Number of cylinders Total engine oil capacity at initial filling (standard oil system) (Option: max. liters operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liters clinations) Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. liters operating inclinations) Oil pan capacity at dipstick mark "max."...

  • Page 43: Firing Order

    3.5 Firing order Firing order A1-B4-A4-A2-B3-A3-B2-B1 10 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 M015650/03E 2011-10 | Technical Data | 43...

  • Page 44: Engine - Main Dimensions

    3.6 Engine – Main dimensions Main dimensions Engine model Length (A) Width (B) Height (C) 8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M92 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M93 approx.

  • Page 45: Operation

    4.1 Engine – Putting the engine into operation (out of service > 3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting the engine into operation (out-of-service period > 3 months) Item Measure Engine Depreserve (→...

  • Page 46: Putting The Engine Into Operation After Scheduled Out-Of-Service Period

    4.2 Putting the engine into operation after scheduled out-of- service period Preconditions ☑ Engine is stopped and starting disabled. Startup Item Task Lube oil system Check oil level (→ Page 102). Coolant system Check coolant level (→ Page 115). Coolant system Preheat coolant with preheating unit.

  • Page 47: 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 49). Shut down fuel treatment system (→ Page 57). M015650/03E 2011-10 | Operation | 47...

  • Page 48: 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 49: Fuel Treatment System - Start-Up

    4.5 Fuel treatment system – Start-up Fuel treatment system – Overview Switch on fuel treatment system (→ Page 52). 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 50 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 52). Start engine (→ Page 53). 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 51: Operational Checks

    4.6 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 52: Fuel Treatment System - Switching On

    4.7 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant is ready for operation. • Before switching on, ensure that all housings are closed. •...

  • Page 53: Starting The Engine

    4.8 Starting the engine Preconditions ☑ External start interlock is not activated. ☑ Emergency air shut-off flaps (if fitted) are open. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 54: Stopping The Engine

    4.9 Stopping the engine Preconditions ☑ Engine is running in local mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed.

  • Page 55: Emergency Stop

    4.10 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. An emergency stop of the engine can be initiated from the following points : (→...

  • Page 56: After Stopping The Engine

    4.11 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Action Coolant circuit Drain coolant (→ Page 117) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze additive;...

  • Page 57: Fuel Treatment System - Shutdown

    4.12 Fuel treatment system – Shutdown Fuel treatment system – Shutdown Press the illuminated pushbutton "Water drain" on the switchgear cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.

  • Page 58: Plant - Cleaning

    4.13 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 59: 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 60: 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 elec‐ 2. In addition to the automatic water drain function, water can also trode opens the water drain be drained manually.

  • Page 61: Troubleshooting

    6.2 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine wiring or starter defective Check if cable connections are proper‐...
  • Page 62 Engine speed not steady Component Probable Cause Task Fuel injection equip‐ Injector defective Replace (→ Page 85). ment Speed sensor Defective Replace. Fuel system Not vented Vent fuel system (→ Page 88). Defective Contact Service. Charge-air temperature too high Component Probable Cause Task Engine coolant...
  • Page 63 Exhaust gas white Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Drain fuel prefilter (→ Page 92). Intercooler Leaking Contact Service. M015650/03E 2011-10 | Troubleshooting | 63...

  • Page 64: 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 65: Solas Shielding - Installation

    7.1.2 SOLAS shielding - Installation Preconditions ☑ Engine shut down and starting disabled. ☑ Engine 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 filter and fuel filter Pinpoint installation location (→...

  • Page 66: Installation Locations For Solas Shielding

    7.1.3 Installation locations for SOLAS shielding General Primarily fit SOLAS shielding as per MTN 5233 (→ Page 64). Free end B-side Item Type of shielding Comments Shield (A7) On fuel delivery pump Free end B-side Shield (A7) On HP fuel pump Free end B-side Free end...
  • Page 67 Item Type of shielding Comments Shield (A8) On fuel filter Free end Shield (A7) Above fuel priming pump Free end Shield (A7) Below fuel priming pump Free end Driving end A-side Item Type of shielding Comments Shield (A5) On air flap Driving end A-side Shield (A4)
  • Page 68 Driving end A-side Item Type of shielding Comments Shield (A5) To turbocharger relubrication Driving end A-side Shield (A5) On valve plate Driving end A-side Driving end 68 | Task Description | M015650/03E 2011-10...
  • Page 69 Item Type of shielding Comments Shield (A4) Turbocharger lubrication, left side Driving Shield (A4) Turbocharger lunrivation, center Driving Driving end Item Type of shielding Comments Shield (A4) Turbocharger lubrication, right side Driving Driving end B-side M015650/03E 2011-10 | Task Description | 69...
  • Page 70 Item Type of shielding Comments Shield (A5) Turbocharger flap Driving end B-side Shield (A5) Turbocharger flap Driving end B-side Shield (A4) On brazed-on union Driving end B-side Shield (A5) On air flap Driving end B-side Shield (A4) To turbocharger relubrication Driving end B-side Driving end B-side...
  • Page 71 Driving end A-side Item Type of shielding Comments Shield (A5) To flap control Driving end A-side Driving end B-side Item Type of shielding Comments Shield (A5) To flap control Driving end B-side M015650/03E 2011-10 | Task Description | 71...

  • Page 72: 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. Barring tool F6783914 Ratchet F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...

  • Page 73: Engine - Barring With Starting System

    7.2.2 Engine – Barring with starting system Preconditions ☑ Clutch is disengaged. ☑ Engine start is disabled. ☑ LOP is accessible and open. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone. •...

  • Page 74: 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. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 84). Remove injector (→...
  • Page 75 Final steps Install injector (→ Page 86). Install cylinder head cover (→ Page 84). M015650/03E 2011-10 | Task Description | 75...

  • Page 76: 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 exami‐ nation report. Finding Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 77 Finding Action Discolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring onwards and less pro‐ nounced from TDC-ring 1.

  • Page 78: 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. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. WARNING Compressed air Risk of injury!

  • Page 79: 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 Filter element (→...
  • Page 80 Checking diaphragm Remove cover (4). Take off spring (5), seal (2) and diaphragm (3). Check diaphragm (3) for damage. Fit new diaphragm if used one is damaged. Mount diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 81: 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.

  • Page 82: Adjusting Valve Clearance

    10V2000 Position Cylinder Firing TDC in cylinder A1 Bank A Bank B Overlap TDC in cylinder A1 Bank A Bank B “E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted 12V2000 Position Cylinder Firing TDC in cylinder A1 Bank A Bank B Overlap TDC in cylinder A1...
  • Page 83 Final steps Install sensor B13. Connect cable to sensor B13. Remove barring tool. Install cylinder head cover (→ Page 84). Install air filter (→ Page 99). M015650/03E 2011-10 | Task Description | 83...

  • Page 84: 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 device F6783025 Gasket (→ Spare Parts Catalog) Preparatory steps Remove air filter (→ Page 99). Remove intake housing.

  • Page 85: 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) Remove injector and install new one. (→ Page 86) M015650/03E 2011-10 | Task Description | 85...

  • Page 86: 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 box wrench F30011450 Open end wrench bit F30025897 Box wrench adapter F30451199 Alignment device F6790507...

  • Page 87: Installing Injector

    Installing injector Remove all plugs before installation. Fit new O-rings onto injector and coat with grease. Fit new sealing ring with grease on injector, ensuring correct installation position of sealing ring. Clean sealing surface on cylinder head and protective sleeve. Insert injector (1) in cylinder head, ensuring that it is correctly aligned with the HP line connection.

  • Page 88: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Venting fuel system Unlock fuel priming pump, unscrew handle.

  • Page 89: 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 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...
  • Page 90 Easy-change fuel filter replacement with the engine stopped Stop engine and disable engine start. Cut out the filter to be replaced. B Left filter cut out C Right filter cut out Remove cut-out easy-change filter using the oil filter wrench. Clean sealing surface on filter head.
  • Page 91 7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 92: Fuel Prefilter – Draining

    7.8.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Seal (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 93: Fuel Prefilter – Flushing

    7.8.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Seal (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 94 Open threaded vent plug (5) of the filter to be flushed. Unlock drain valve (6) by pressing toggle, open it 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 (5) and drain valve (6).

  • Page 95: 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) Seal (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 96 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the fil‐ ter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐...

  • Page 97: Charge-Air Cooling

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 98: 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) Remove old air filter and install new air filter . (→ Page 99) Reset signal ring of service indicator . (→...

  • Page 99: Air Filter – Removal And Installation

    7.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it.

  • Page 100: 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 98). After installation of new filter, press reset button (1).

  • Page 101: 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 131). M015650/03E 2011-10 | Task Description | 101...

  • Page 102: Lube Oil System, Lube Oil Circuit

    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 103: Engine Oil – Change

    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 104: Oil Filtration / Cooling

    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) DANGER Unguarded rotating and moving engine components. Risk of serious injury –...
  • Page 105 Remove cut-out oil filter using the oil filter wrench. Clean the sealing surface at the connecting piece. Check condition of the new sealing ring and coat it with oil. Fit the protective cover acc. to SOLAS re‐ quirements (→ Page 18). Install and tighten new oil filter by hand.
  • Page 106 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. Strap wrench F30379104 Cold cleaner (Hakutex 50) 50622 Filter sleeve (→ Spare Parts Catalog) O-ring (→...
  • Page 107 Centrifugal oil filter – Cleaning and filter-sleeve replacement Remove nut, holding the rotor with a strap wrench. Remove nut (1), washer (2), rotor cap (3) and sealing ring (4). Remove sleeve (1). Measure the layer thickness of the oil resi‐ due.
  • Page 108 Fit new sealing ring (4). Set on rotor cap (3), observe marks. Fit washer (2). Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard M18 x 1.5 Tightening torque 10 Nm Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.

  • Page 109: Coolant Circuit, General, High Temperature Circuit

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Drain and venting points 8 V, 10 V 1 Overflow line, expansion 2 Filler neck tank M015650/03E 2011-10 | Task Description | 109...
  • Page 110 12 V, 16 V 1 Overflow line, expansion 2 Filler neck tank 110 | Task Description | M015650/03E 2011-10...
  • Page 111 Free end (KGS) 1 Fuel filter vent screws 4 Measuring point, pres‐ 5 Raw water pump drain 2 Engine coolant drain plug sure before raw water plug 3 Raw water pump filling pump 6 Connection for oil extrac‐ plug tion M015650/03E 2011-10 | Task Description | 111...
  • Page 112 Left side 1 Engine coolant drain plug 2 Engine coolant drain plug (M14x1.5) 112 | Task Description | M015650/03E 2011-10...
  • Page 113 Right side 1 Engine coolant drain plug 3 Oil dipstick (connection (M14x1.5) left or right engine side 2 Oil filler neck (connection optional) left or right engine side 4 Leak-off-fuel tank optional) M015650/03E 2011-10 | Task Description | 113...
  • Page 114 Driving end (KS) 1 Engine coolant drain plug 2 Connection for oil extrac‐ tion 114 | Task Description | M015650/03E 2011-10...

  • Page 115: Engine Coolant – Level Check

    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.

  • Page 116: Engine Coolant – Change

    7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Drain engine coolant. (→ Page 117) Fill with engine coolant. (→ Page 118) 116 | Task Description | M015650/03E 2011-10...

  • Page 117: Engine Coolant – Draining

    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 118: Engine Coolant – Filling

    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 119: Ht Coolant Pump — Relief Bore Check

    7.15.6 HT coolant pump — Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 120 • corrosion inhibitor concentration; • pH value. Fit breather valve and close it. Change engine coolant according to the coolant operating times specified in the (→ MTU Fluids and Lu‐ bricants Specifications A001061/..)(→ Page 117). 120 | Task Description | M015650/03E 2011-10...

  • Page 121: Coolant Filter – Replacement

    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 122: Raw Water Pump With Connections

    7.16 Raw Water Pump with Connections 7.16.1 Raw water pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 123: 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 Belt is oily, shows signs of over‐ Replace(→...
  • Page 124 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 125: Fuel Treatment System

    7.19 Fuel Treatment 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. M015650/03E 2011-10 | Task Description | 125...

  • Page 126: Differential Pressure Gauge – Check

    7.19.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Differential pressure gauge – Check Switch on fuel treatment system (→ Page 52). Set the alarm points at the differential pressure gauge to zero.
  • Page 127 7.19.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking water level probe (3-in-1 rod electrode) Disconnect plug from water level probe.

  • Page 128: Pump Capacity – Check

    7.19.4 Pump capacity – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking pump capacity Install suitable pressure gauge in the intake connection of the pump. Check pump pressure.

  • Page 129: Coalescer Filter Element – Replacement

    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 F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 130 Tighten nut (3) to specified tightening 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 screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system.

  • Page 131: Wiring (General) For Engine/Gearbox/Unit

    7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 132: Accessories For (Electronic) Engine Governor / Control System

    7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.
  • Page 133 7.21.2 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating.

  • Page 134: Emu – Checking Plug-In Connections

    7.21.3 EMU – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. EMU – checking plug-in connections Verify that all plug-in connections are securely seated. Secure loose connectors and latch. 134 | Task Description | M015650/03E 2011-10...

  • Page 135: Engine Governor – Carry Out Self-Test

    7.21.4 Engine governor – Carry out self-test DANGER Electrical voltage. Risk of serious injury - danger to life! • Make certain that the power supply to the engine is switched off before starting to work. Ensure that the power supply cannot be switched on unintentionally! Carrying out self-test Switch off power supply to system.

  • Page 136: Emu And Connectors – Cleaning

    7.21.5 EMU and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol EMU and connectors – Cleaning Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol.
  • Page 137 7.21.6 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.
  • Page 138 7.21.7 Engine monitoring unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 139: Appendix A 8.1 Abbreviations

    American National Standards Institute Association of American standardization organiza‐ tions Abgasturbolader Exhaust turbocharger (ETC) Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica‐ tion No. A01061/.. Controller Area Network Data bus system, bus standard Cross Connection Gear Transfer gearbox CODAG...
  • Page 140 Abbrevia‐ Meaning Explanation tion Interface Data Module 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 Device...
  • Page 141 Abbrevia‐ Meaning Explanation tion Transmitter Deviation Alarm: Deviation in transmitter values Unterer Totpunkt Bottom Dead Center (BDC) Voith Schneider Voith Schneider drive Water jet Water jet drive Werkzeugkatalog Tool Catalog (TC) Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for signals from the ADEC engine governor M015650/03E 2011-10 | Appendix A | 141...

  • Page 142: Mtu Contacts/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 the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply.

  • Page 143: Appendix B 9.1 Special Tools

    9 Appendix B 9.1 Special Tools Alignment device Part No.: F6790507 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 86) Angular screw driver Part No.: F30002816 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 81) Barring tool Part No.: F6783914...
  • Page 144 Mandrel Part No.: 8205892861/08 Qty.: Used in: 7.18.1 Battery-charging generator drive – Drive belt replacement (→ Page 124) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.15.7 Engine coolant – Sample extraction and analysis (→ Page 120) Oil filter wrench Part No.:...
  • Page 145 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page 74) Socket wrench Part No.: F30030450 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 81) Socket wrench Part No.: 0005896803/00 Qty.: Used in: 7.6.2 Injector –...

  • Page 146: Index

    9.2 Index 12 V 2000 M72 engine data: remote heat exchanger, EPA stage 2 34 ECU 7 engine governor 12V 2000 M72 engine data: Engine-mounted heat ex‐ – Removal and installation  137 changer, EPA stage 2  31 Emergency stop 55 16V 2000 M72 engine data: Engine-mounted heat ex‐...
  • Page 147 Installation locations for SOLAS shielding 66 – Check  131 Intercooler – Checking condensate drain line for coolant discharge and obstruction 97 Maintenance and repair work – Safety requirements  11 MTU contact persons 142 Operational checks 51 Personnel and organizational requirements 8 Plant – Cleaning  58 Product description 18...

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