MTU 8 V 2000 M84 Operating Instructions Manual
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MTU 8 V 2000 M84 Operating Instructions Manual

MTU 8 V 2000 M84 Operating Instructions Manual

Mtu 8 v 2000 m84; 10 v 2000 m84 diesel engines
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Operating Instructions

Diesel engine
8 V 2000 M84
10 V 2000 M84
MS150062/01E

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Summary of Contents for MTU 8 V 2000 M84

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 8 V 2000 M84 10 V 2000 M84 MS150062/01E...
  • 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: Table Of Contents

    Table of Contents 1 Safety 4.13 Plant – Cleaning 1.1 General conditions 1.2 Personnel and organizational requirements 5 Maintenance 1.3 Transportation 1.4 Safety regulations for startup and operation 5.1 Maintenance task reference table [QL1] 1.5 Safety regulations for maintenance and repair work 1.6 Auxiliary materials, fire prevention and environmental protection...
  • Page 4 8 Appendix A 7.15.5 Engine coolant – Filling 8.1 Abbreviations 7.15.6 HT coolant pump — Relief bore check 8.2 MTU contacts/service partners 7.15.7 Engine coolant – Sample extraction and analysis 7.15.8 Coolant filter – Replacement 7.16 Raw Water Pump with Connections 9 Appendix B 7.16.1 Raw water pump –...

  • Page 5: Safety

    Correct use also includes observation of and compliance with the maintenance specifications. 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.

  • Page 6: 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 7: Transportation

    1.3 Transportation Transport without flange-mounted gearbox Illustration is essentially valid for 8V 2000 M engines Illustration is essentially valid for 12/16V 2000 M engines Transport with flange-mounted gearbox Illustration is essentially valid for 8V 2000 M engines MS150062/01E 2012-01 | Safety | 7...
  • Page 8 The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plants with flange-mounted gearboxes. Only use transport and lifting devices approved by MTU. Take the engine's center of gravity into account. 8 | Safety | MS150062/01E 2012-01...
  • Page 9 Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set 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 Regulations For Maintenance And Repair Work

    1.5 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
  • Page 12 Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
  • Page 13 For conducting light-beam procedures and measurement work, only the following laser devices must be used: • Laser devices of classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

  • Page 14: Auxiliary Materials, Fire Prevention And Environmental Protection

    Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.
  • Page 15 Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • 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 with "A" and those of the right side with "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 | MS150062/01E 2012-01...
  • 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 View on free end 1 Engine oil heat exchang‐ 8 Oil separator 16 Raw water connection 9 Actuating cylinder from sea 2 Engine oil filter 10 2/2-way solenoid 17 Protective cover (belt pul‐ 3 Coolant filter 11 4/2-way solenoid valve ley) 4 Coolant distribution hous‐...
  • Page 25 View on driving end 1 Vent housing 8 Oil filler neck 15 Carrier housing lower 2 Diverter lever for oil filters 9 Oil dipstick section 3 Cylinder head 10 Preheating pump 16 Carrier housing middle 4 Exhaust housing 11 Oil pan section 5 Coolant pump 12 Flywheel...

  • Page 26: Sensors, Actuators And Injectors - Overview

    2.4 Sensors, actuators and injectors – Overview Top view Description Monitoring of Charge-air pressure Charge-air temperature Lube oil temperature Intake air temperature 26 | General Information | MS150062/01E 2012-01...
  • Page 27 Free end Description Monitoring of Fuel line pressure after filter B5.3 (option) Lube oil pressure before filter B5.1 Lube oil pressure B5.2 (optional) Lube oil pressure Coolant level B21 (optional) Raw water pressure B6.2 (optional) Coolant pressure B6.1 Coolant temperature MS150062/01E 2012-01 | General Information | 27...
  • Page 28 Driving end Description Monitoring of B4.22 Exhaust temperature, B-side Camshaft speed Crankshaft speed B13.2 (option) Crankshaft speed B4.21 Exhaust gas temperature, A side 28 | General Information | MS150062/01E 2012-01...
  • Page 29 Right engine side Description Monitoring of Turbocharger speed Fuel temperature Fuel pressure in Common Rail B16 (optional) Coolant pressure Leak fuel level MS150062/01E 2012-01 | General Information | 29...
  • Page 30 Left engine side Description Monitoring of Wastegate solenoid valves Solenoid valves for turbocharger control B54 (optional) Oil replenishment pump pressure System sensors The sensors are fitted on the off-engine system. Description Monitoring of Starting-air pressure Water level in fuel prefilter Exhaust backpressure Start interlock, switching status 30 | General Information | MS150062/01E 2012-01...

  • Page 31: Technical Data

    3 Technical Data 3.1 8V 2000M84 engine data 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 32 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 33 Capacities Number of cylinders Engine coolant, engine side (with cooling system) Liters 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 34: 2000 M84 Engine Data

    3.2 10V 2000 M84 engine data 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 35 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 36 CAPACITIES Number of cylinders Engine coolant capacity (with cooling equipment) liters Total engine oil capacity at initial filling (standard oil system) (Option: max. liters operating inclinations) Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. liters operating inclinations) Oil pan capacity at dipstick mark "max."...

  • Page 37: Firing Order

    3.3 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 MS150062/01E 2012-01 | Technical Data | 37...

  • Page 38: Engine - Main Dimensions

    3.4 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 39: Operation

    4.1 Putting the engine into operation after extended out-of- service periods (>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 40: Engine - Putting Into Operation After Scheduled Out-Of-Service-Period

    4.2 Engine – Putting into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Measure Lube oil system Check engine oil level (→ Page 96). Coolant circuit Check coolant level (→ Page 109). Coolant circuit Heat engine coolant with coolant preheating unit.

  • Page 41: 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 43). Shut down fuel treatment system (→ Page 51). MS150062/01E 2012-01 | Operation | 41...

  • Page 42: 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 43: Fuel Treatment System - Putting Into Operation

    4.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 46). 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 44 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 46). Start engine (→ Page 47). 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 45: 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 46: 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 47: Starting The Engine

    4.8 Starting the engine Preconditions ☑ External start interlock is not active. ☑ Emergency air shut-off flaps (if fitted) are open. DANGER 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 48: 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 49: 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 50: 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 111) 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 51: Fuel Treatment System - Shutdown

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

  • Page 52: 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 53: 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 54: 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 55: 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 56 Engine speed not steady Component Probable Cause Task Fuel injection equip‐ Injector defective Replace (→ Page 79). ment Speed sensor Defective Replace. Fuel system Not vented Vent fuel system (→ Page 82). Defective Contact Service. Charge-air temperature too high Component Probable Cause Task Engine coolant...
  • Page 57 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 86). Intercooler Leaking Contact Service. MS150062/01E 2012-01 | Troubleshooting | 57...

  • Page 58: Task Description

    7 Task Description 7.1 SOLAS 7.1.1 SOLAS shielding – Installation as per MTN 5233 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 59: Solas Shielding - Installation

    7.1.2 SOLAS shielding – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil filter and fuel filter Pinpoint installation location (→...

  • Page 60: Installation Locations For Solas Shielding

    7.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 58). On crankcase Item Type of shielding Remarks Shield (A4) On brazed-on union Shield (A5) On crankcase Free end B-side 60 | Task Description | MS150062/01E 2012-01...
  • Page 61 Item Type of shielding Remarks Shield (A7) On fuel delivery pump Free end B-side Free end B-side Item Type of shielding Remarks Shield (A7) On HP fuel pump Free end B-side Free end MS150062/01E 2012-01 | Task Description | 61...
  • Page 62 Item Type of shielding Remarks Shield (A7) Above fuel priming pump Free end Free end Item Type of shielding Remarks Shield (A7) Below fuel priming pump Free end Free end Item Type of shielding Remarks Shield (A8) On fuel filter housing Free end 62 | Task Description | MS150062/01E 2012-01...
  • Page 63 Driving end A-side Item Type of shielding Remarks Shield (A5) On valve plate Driving end Driving end A-side MS150062/01E 2012-01 | Task Description | 63...
  • Page 64 Item Type of shielding Remarks Shield (A5) On air flap control Driving Shield (A4) On brazed-on union Driving Shield (A5) On exhaust turbocharger flap control Driving Shield (A5) On exhaust turbocharger flap control Driving Driving end Item Type of shielding Remarks Shield (A4) Exhaust turbocharger lubrication...
  • Page 65 Driving end Item Type of shielding Remarks Shield (A4) Exhaust turbocharger lubrication Driving MS150062/01E 2012-01 | Task Description | 65...

  • Page 66: 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 67: Engine - Barring With Starting Equipment

    7.2.2 Engine – Barring with starting equipment 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 68: 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 78). Remove injector (→...
  • Page 69 Final steps Install injector (→ Page 80). Install cylinder head cover (→ Page 78). MS150062/01E 2012-01 | Task Description | 69...

  • Page 70: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 71 Findings Measure Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1.

  • Page 72: Crankcase Breather

    7.4 Crankcase Breather 7.4.1 Crankcase breather – Cleaning oil separator element Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 73: Crankcase Ventilation - Oil Separator Element Replacement, Diaphragm Check And Replacement

    7.4.2 Crankcase ventilation – Oil separator element 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 74 Checking diaphragms Remove cover (4). Take off spring (5), gasket (2) and dia‐ phragm (3). Check diaphragm (3) for damage. Replace diaphragm if damaged. Install diaphragm (3) on housing (1). Install new gasket (2) and spring (5) togeth‐ er with cover (4). Tighten screws of cover (4) to specified tightening torque.

  • Page 75: 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 76 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 - A - - Bank B...

  • Page 77: Valve Clearance Adjustment

    Valve clearance adjustment Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. Tighten locknut (1) with torque wrench to the prescribed tightening torque of 50 Nm while holding the adjusting screw (2) with screwdriver.

  • Page 78: 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 93). Remove intake housing.

  • Page 79: 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 80) MS150062/01E 2012-01 | Task Description | 79...

  • Page 80: 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 81: 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 82: 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 83: 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 84 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 85: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    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 86: 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 87: Fuel Prefilter ‒ Flushing

    7.8.4 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ 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 88 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve 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 89: 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 90 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 91: 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 92: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 93). Reset signal ring of contamination indicator (→...

  • Page 93: 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 94: Air Intake

    7.11 Air Intake 7.11.1 Contamination 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 92). After installation of new filter, press reset button (1).

  • Page 95: Starting Equipment

    7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 125). MS150062/01E 2012-01 | Task Description | 95...

  • Page 96: 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 97: 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 98: 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) Plastic ring (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components.
  • Page 99 Oil filter replacement with the engine stopped Stop engine (→ Page 48) and disable en‐ gine start. Cut out the filter to be replaced. A Right filter cut out B Both filters cut in (normal operating position) C Left filter cut out Remove cut-out oil filter using the oil filter wrench.

  • Page 100: Centrifugal Oil Filter – Cleaning And Filter Sleeve Replacement

    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 101 Cleaning centrifugal oil filter and replacing filter sleeve 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 102 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 103: 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 MS150062/01E 2012-01 | Task Description | 103...
  • Page 104 12 V, 16 V 1 Overflow line, expansion 2 Filler neck tank 104 | Task Description | MS150062/01E 2012-01...
  • Page 105 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 MS150062/01E 2012-01 | Task Description | 105...
  • Page 106 Left side 1 Engine coolant drain plug 2 Engine coolant drain plug (M14x1.5) 106 | Task Description | MS150062/01E 2012-01...
  • Page 107 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) MS150062/01E 2012-01 | Task Description | 107...
  • Page 108 Driving end (KS) 1 Engine coolant drain plug 2 Connection for oil extrac‐ tion 108 | Task Description | MS150062/01E 2012-01...

  • Page 109: 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 110: Engine Coolant – Change

    7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 111). Fill with engine coolant (→ Page 112). 110 | Task Description | MS150062/01E 2012-01...

  • Page 111: 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 112: 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 113: 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 114: Engine Coolant – Sample Extraction And Analysis

    • 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 111). 114 | Task Description | MS150062/01E 2012-01...

  • Page 115: 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 116: 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 117: 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 118: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Mandrel 8205892861/08 Preparatory steps Remove safety equipment (if fitted). Remove screws of protective cover (engine free end). Remove protective cover.

  • Page 119: Fuel Supply System

    7.19 Fuel Supply System 7.19.1 Water drain valve – Check Checking water drain valve Open water drain valve. Check water outlet for obstructions. Close water drain valve. MS150062/01E 2012-01 | Task Description | 119...

  • Page 120: 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. Checking differential pressure gauge Switch on fuel treatment system (→ Page 46). Set the alarm points at the differential pressure gauge to zero.

  • Page 121: Water Level Probe (3-In-1 Rod Electrode Check

    7.19.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) –...

  • Page 122: 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. Pump capacity – Check Install suitable pressure gauge in the intake connection of the pump. Check pump pressure.

  • Page 123: 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 adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 124 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 gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system.

  • Page 125: 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 126: 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 127: Engine Governor – Checking Plug-In Connections

    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 128: 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. 128 | Task Description | MS150062/01E 2012-01...

  • Page 129: 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 130: 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 131: Ecu 7 Engine Governor – Removal And Installation

    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 132: Engine Monitoring Unit – Removal And Installation

    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 133: 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 134 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 135 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 MS150062/01E 2012-01 | Appendix A | 135...

  • Page 136: 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 137: 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 80) Angular screw driver Part No.: F30002816 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 75) Barring tool Part No.: F6783914...
  • Page 138 Mandrel Part No.: 8205892861/08 Qty.: Used in: 7.18.1 Battery-charging generator drive – Drive belt replacement (→ Page 118) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.15.7 Engine coolant – Sample extraction and analysis (→ Page 114) Oil filter wrench Part No.:...
  • Page 139 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page 68) Socket wrench Part No.: F30030450 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 75) Socket wrench Part No.: 0005896803/00 Qty.: Used in: 7.6.2 Injector –...

  • Page 140: Index

    9.2 Index 10V 2000 M84 engine data 34 Drain and venting points 103 8V 2000M84 engine data 31 Drive belt – Condition check  117 Abbreviations 133 Actuators ECU 7 engine governor – Overview  26 – Removal and installation  131 After stopping the engine 50 Emergency stop 49 Air filter EMU and connectors –...
  • Page 141  54 discharge and obstruction 91 Valve clearance – Check and adjustment 75 Maintenance work – Safety regulations  11 Water drain valve MTU contact persons 136 – Check  119 Water level probe (3-in-1 rod electrode) Oil separator element – Check  121 – Replacement  73...

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