MTU 12 V 2000 M86 Operating Instructions Manual
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MTU 12 V 2000 M86 Operating Instructions Manual

MTU 12 V 2000 M86 Operating Instructions Manual

Diesel engine
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Operating Instructions

Diesel engine
12 V 2000 M86
12 V 2000 M96
12 V 2000 M96L
16 V 2000 M86
16 V 2000 M96
16 V 2000 M96L
MS150119/00E

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Summary of Contents for MTU 12 V 2000 M86

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 2000 M86 12 V 2000 M96 12 V 2000 M96L 16 V 2000 M86 16 V 2000 M96 16 V 2000 M96L MS150119/00E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 7 Task Description 1.1 Important requirements for all products 7.1 SOLAS 1.2 Personnel and organizational requirements 7.1.1 SOLAS shielding as per MTN 5233 – Installation 1.3 Transport 7.1.2 SOLAS shielding – Installation 1.4 Safety requirements for startup and 7.1.3 Installation locations for SOLAS shielding operation 1.5 Safety requirements for maintenance and...
  • Page 4 8 Appendix A 7.19 Engine Mounting / Support 7.19.1 Engine mounting – Checking securing screws 8.1 List of abbreviations for firm seating 8.2 MTU contact persons/service partners 7.19.2 Engine mounting – Checking condition of resilient mounts 9 Appendix B 7.20 Belt Drive 9.1 Special Tools...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...

  • Page 6: Personnel And Organizational Requirements

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

  • Page 7: Transport

    Set the engine down on a firm, level surface only. 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 8: Safety Requirements For Startup And Operation

    1.4 Safety requirements for startup and operation Safety requirements for startup The product must be installed and accepted in accordance with manufacturers' specifications prior to initial startup. All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior to initial startup.

  • Page 9: Safety Requirements For Maintenance And Repair Work

    1.5 Safety requirements for maintenance and repair work Safety requirements before commencing maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 10 Pay particular attention to cleanliness at all times. Safety requirements after completing maintenance and repair work Ensure that all personnel is clear of danger zones before cranking. Check that all access ports/apertures which have been opened to facilitate working are closed again. Check that all safety equipment has been installed and that all tools and loose parts have been re- moved (especially the barring gear).
  • Page 11 Working on electrical/electronic assemblies Always obtain the permission of the duty supervisor before commencing maintenance or repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Avoid damaging cabling during removal.

  • Page 12: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product.

  • Page 13: Compressed Air

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

  • Page 14: Standards For Safety Notices In The Text

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

  • Page 15: General Information

    2 General Information 2.1 Torque specifications for screws and nuts Tightening torques for setscrew and connections as per MTN 5008 standard The standard applies to setscrews and the associated nuts as specified in the following standards when not subjected to dynamic loading: •...
  • Page 16 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M20 x 1.5 M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350 1900 1250...
  • Page 17 Not torsion-protected M (Nm) Torsion-protected M (Nm) Thread M24 x 2 1170 M27 x 2 1000 1230 1250 1575 *Protect screw shaft from torsion when tightening. = Tightening torques. Tightening torques for plug screws as per MTN 5183-1 standard The standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852, model A (sealed by sealing ring DIN 7603-Cu).
  • Page 18 Tightening torques M are given for plug screws made of steel (St) with surface protected by a phos- phate coating and oiled or galvanized. Coat thread and mating faces beneath heads with engine oil prior to assembly. An assembly tolerance of +10% of the table values is admissible for unavoidable deviations during the tightening process.
  • Page 19 = Tightening torques Tightening torque for plug screws DIN 7604C (with long screwed end) inserted in Thread Steel/gray cast iron M Al alloy M (Nm) (Nm) M8 x 1 M22 x 1.5 M26 x 1.5 M30 x 1.5 M38 x 1.5 M45 x 1.5 = Tightening torques Tightening torque for banjo screws as per MTN 5183-2 standard...
  • Page 20 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface and oiled or galvanized and for copper-aluminum alloy. Coat thread and mating faces beneath heads with engine oil prior to assembly. An assembly tolerance of +10% of the table values is admissible for unavoidable deviations during the tightening process.
  • Page 21 Tightening torques for male connectors as per MTN 5183-3 standard The standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852, model A (sealed by sealing ring DIN 7603-Cu). Tightening torques M are given for male connectors made of steel (St) with surface protected by a phosphate coating and oiled or galvanized.
  • Page 22 Tightening torques for union nuts as per DIN 3859-2 1 Union nut 2 Screw fixture 3 O-ring 4 Ball-type union Union nut: When installing the ball-type union, first tighten the union nut firmly by hand (noticeable in- crease in force), then tighten another 1/4 turn (90°) past this point. Tightening torques for threaded journals with O-rings as per ISO 6149-2 Thread Torque (Nm) +10%...

  • Page 23: Installation

    Thread Torque (Nm) +10% M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for closing off installation spaces for screw-in valves (see ISO 7789). Tightening torques for threaded journals with O-rings as per ISO 6149-3 Thread Torque (Nm) +10% M8 x 1 M10 x 1...
  • Page 24 Tightening torques for plug screw joints as per MTN 5183-6 inserted in Thread Steel/gray cast iron M Al alloy M (Nm) (Nm) M10 x 1 10+ 2 M12 x 1.5 14+ 2 M14 x 1.5 15+ 3 M16 x 1.5 18+ 3 M18 x 1.5 23+ 3...
  • Page 25 Sealing head/sealing cone with metric union nut Metric thread Pipe outer Ø Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...

  • Page 26: Engine Side And Cylinder Designations

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

  • Page 27: Product Description

    2.3 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection, sequential turbocharging and charge-air cooling. An electronic management system provides engine control and monitoring. Fuel system with Common Rail injection Controlled by the electronic engine management system, the common rail injection system determines injection pressure, injection timing and injection quantity independently of the engine speed.
  • Page 28 • Interface to ECU and EMU • MCS5 dialog interface • Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box) • Connection facility for an MTU Local Operating Station (LOS) Serial RS422 interface for diagnosis The engine interface is divided into two parts.
  • Page 29 Monitoring: • Exhaust gas temperature, A side • Exhaust temperature, B-side • Engine speed • Oil pressure • Differential oil pressure • Coolant temperature • Coolant level • Exhaust turbocharger speed • Leak fuel level • Oil temperature • Coolant pressure •...
  • Page 30 Plug-in pipe union The sleeve (3) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure decreases significantly if an O-ring (2) fault occurs. The connection is confirmed as compliant with SOLAS by DNV and GL. Plugs and sensors Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN, or an O-ring (ISO).
  • Page 31 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 MS150119/00E 2014-08 | General Information | 31...
  • Page 32 HP line between distributor and HP accumulator 1 Jacket pipe 5 O-ring 9 HP line 2 O-ring 6 Thrust screw 10 Pressure pipe 3 O-ring 7 Thrust ring 4 Thrust ring 8 O-ring Leak-off fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from where it is routed at atmospheric pressure into a level-monitored leak-fuel tank.

  • Page 33: Engine Layout

    2.4 Engine layout Overview of free end Also applies similarly to 12V. 1 Engine oil heat exchanger 12 Exhaust turbocharger, left 23 Battery-charging generator 2 Engine oil filter (secondary turbocharger) 24 Raw water pump 3 Diverter lever for engine 13 Actuating cylinder for ex- 25 Plate-core heat exchanger oil filter haust flap...
  • Page 34 1 Carrier housing upper sec- 7 Fuel delivery pump 12 Carrier housing lower sec- tion 8 Exhaust turbocharger oil tion 2 Air filter (air intake) valve 13 Bleeder valve 3 Thermostat housing 9 Carrier housing middle a Air intake 4 Exhaust housing section b Exhaust outlet 5 Crankcase vent line...

  • Page 35: Sensors And Actuators - Overview

    2.5 Sensors and actuators – Overview Sensors and actuators on engine driving end Item Name Monitoring of B4.21 ETC temperature, A side B4.22 ETC temperature, B side B13.1 Crankshaft speed MS150119/00E 2014-08 | General Information | 35...
  • Page 36 Sensors and actuators on engine free end Item Name Monitoring of B5.3 Lube oil pressure before filter B5.2 Lube oil pressure after filter B5.1 Lube oil pressure after filter Coolant level probe in expansion tank Raw water pressure B6.2 Coolant temperature B6.1 Coolant temperature Fuel pressure after filter...
  • Page 37 Sensors and actuators on left side Item Name Monitoring of Y27.1 4/2 directional control valve, A side Oil replenishment pump pressure EIM Engine Interface Module MS150119/00E 2014-08 | General Information | 37...
  • Page 38 Sensors and actuators on right side Item Name Monitoring of Exhaust gas recirculation (bypass at ETC) HP fuel pressure Y45.1 Pressure regulating valve EIL electronic label Coolant pressure CR pump Leak fuel level Camshaft speed, B side B13.2 Crankshaft speed Y27.2 4/2 directional control valve, B side 38 | General Information | MS150119/00E 2014-08...
  • Page 39 Sensors and actuators on engine top Item Name Monitoring of Intake air temperature 4/2 mixing valve, intercooler 4/2 directional control valve, recirculation EMU Engine Monitoring Unit Lube oil temperature Fuel temperature Y45.2 Pressure regulating valve Charge air temperature Charge air pressure ETC speed MS150119/00E 2014-08 | General Information | 39...

  • Page 40: Technical Data

    3 Technical Data 3.1 12V 2000 M86/M96/M96L 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 41 Model-related data Unit Value Number of inlet valves per cylinder Number of exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Raw water circuit Unit Value Raw water pump: Inlet pressure, min. -0.4 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in engine-external raw water system, max.
  • Page 42 Inclinations, standard oil system Unit Value Transverse inclination continuous max. (option: max. operating inclinations) Degrees (°) Transverse inclination, temporary max. (option: max. operating inclinations) Degrees (°) CAPACITIES Capacities Unit Value Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (design: max. operating Liters inclinations) Oil change quantity max.

  • Page 43: 2000 M86/M86/M96L Engine Data

    3.2 16V 2000 M86/M86/M96L 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 44 RAW WATER CIRCUIT (open circuit) Raw water circuit Unit Value Raw water pump: Inlet pressure, min. -0.4 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in engine-external raw water system, max. LUBE OIL SYSTEM Lube oil system Unit Value Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to...
  • Page 45 CAPACITIES Capacities Unit Value Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (design: max. operating Liters inclinations) Oil change quantity max. (standard oil system) (design: max. operating inclina- Liters tions) Oil pan capacity dipstick mark min. (standard oil system) (design: max. operat- Liters ing inclinations) Oil pan capacity dipstick mark max.

  • Page 46: Firing Order

    3.3 Firing order Firing order 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 46 | Technical Data | MS150119/00E 2014-08...

  • Page 47: Engine - Main Dimensions

    3.4 Engine – Main dimensions Main dimensions Engine model Length (A) Width (B) Height (C) 16V 2000 M86 2495 mm 1318 mm 1455 mm 16V 2000 M96 16V 2000 M96L 12V 2000 M86 2082 mm 1292 mm 1440 mm 12V 2000 M96 12V 2000 M96L MS150119/00E 2014-08 | Technical Data | 47...

  • Page 48: Operation

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

  • Page 49: Engine - Putting Into Operation After Scheduled Out-Of-Service-Period

    4.2 Engine – Putting into operation after scheduled out-of-service- period Preconditions ☑Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 97). Coolant circuit Check coolant level (→ Page 103). Coolant circuit Heat engine coolant with coolant preheating unit.

  • Page 50: Operational Checks

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

  • Page 51: Starting The Engine

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

  • Page 52: Engine - Shutdown

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

  • Page 53: Emergency Engine Stop

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

  • Page 54: After Stopping The Engine

    Switch off. Air intake and exhaust sys- Out-of-service-period > 1 week • Seal engine's air and exhaust sides. Engine Out-of-service-period > 1 month • Depreserve engine (→ MTU Preservation and Represervation Specifica- tions A001070/..) 54 | Operation | MS150119/00E 2014-08...

  • Page 55: Plant - Cleaning

    4.8 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 gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 56: 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 57: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action u Charge or replace (see manufacturer's documentation). Battery flat or defective. u Check if cable connections are properly secured (see Cable connections on battery are defective. manufacturer's documentation).
  • Page 58 Air in fuel system. u Vent fuel system (→ Page 83). Charge-air temperature too high Cause Corrective action Incorrect engine coolant u Check (MTU test kit). concentration. u Contact Service. Charge-air cooler is contaminated. Air inlet temperature in engine u Check fan room is too high.
  • Page 59 Blue exhaust gas Cause Corrective action Too much oil in engine. u Drain engine oil (→ Page 98). Oil separator or oil preseparator u Replace (→ Page 74). of crankcase breather clogged. u Contact Service. Exhaust turbocharger faulty. u Contact Service. Cylinder head is faulty.

  • Page 60: 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 61: Solas Shielding - Installation

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

  • Page 62: Installation Locations For Solas Shielding

    7.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 60). Free end B-side Item Type of shielding Comments 1 (free end, B-side) Shield (A7) On fuel delivery pump 2 (free end, B-side) Shield (A7) On HP fuel pump Free end...
  • Page 63 Item Type of shielding Comments 1 (free end) Shield (A8) On fuel filter 2 (free end) Shield (A7) Above fuel priming pump 3 (free end) Shield (A7) Below fuel priming pump Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) On air flap 2 (driving end, A-side)
  • Page 64 Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) To turbocharger lubrication 2 (driving end, A-side) Shield (A5) On valve plate Driving end Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, left side 2 (driving end) Shield (A4) Turbocharger lubrication, center Driving end...
  • Page 65 Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) Turbocharger flap 2 (driving end, B-side) Shield (A5) Turbocharger flap 3 (driving end, B-side) Shield (A4) On brazed-on union 4 (driving end, B-side) Shield (A5) On air flap 5 (driving end, B-side) Shield (A4) To turbocharger lubrication...
  • Page 66 Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) To flap control Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) To flap control 66 | Task Description | MS150119/00E 2014-08...

  • Page 67: Engine

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

  • Page 68: Engine - Cranking On Starting System

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

  • Page 69: Cylinder Liner

    7.3 Cylinder Liner 7.3.1 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex- amination report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,...
  • Page 70 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 71: Cylinder Liner - Endoscopic Examination

    7.3.2 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 76). Remove injector (→ Page 81). Positioning crankshaft at BDC Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
  • Page 72 Final steps Install injector (→ Page 81). Install cylinder head cover (→ Page 76). 72 | Task Description | MS150119/00E 2014-08...

  • Page 73: 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 gun ejects a jet of pressurized air.

  • Page 74: Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check And Replacement

    7.4.2 Crankcase breather – 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 F30027340 Engine oil Filter element (→...
  • Page 75 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 76: Valve Drive

    7.5 Valve Drive 7.5.1 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Centering jig F6783025 Sealing (→ Spare Parts Catalog) Preparatory steps Remove air filter (→ Page 94). Remove air guide housing.

  • Page 77: Valve Clearance - Check And Adjustment

    7.5.2 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Engine coolant temperature is max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y4345893 Barring gear F6783914 Ratchet F30006212...

  • Page 78: Adjusting Valve Clearance

    Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check valve clearance with the engine cold: •...

  • Page 79: Injection Pump / Hp Pump

    7.6 Injection Pump / HP Pump 7.6.1 HP fuel pump – Filling with engine oil Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 80: Injector

    7.7 Injector 7.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 81). 80 | Task Description | MS150119/00E 2014-08...

  • Page 81: Injector - Removal And Installation

    7.7.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Screwdriver bit T45 F30454548 Assembly sleeve F30454554 Puller F6795554 Puller F6790991 Puller F6790992 Puller F6795777 Torque wrench, 10-60 Nm F30452769 Grease (Kluthe Hakuform 30-10/Emulgier) X00029933...

  • Page 82: Installation

    Installing injector Prior to installation, remove all blanking plugs. Fit new O-rings on injector (2) and coat with grease. Secure new sealing ring on injector (2) with grease observing installation position of sealing ring. Clean sealing surface on cylinder head and protective sleeve. Insert injector (2) in cylinder head, ensuring correct alignment with HP line connection.

  • Page 83: Fuel System

    7.8 Fuel System 7.8.1 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. Fuel system – Venting Unlock fuel priming pump, unscrew handle.

  • Page 84: Fuel Filter

    7.9 Fuel Filter 7.9.1 Fuel filter – Replacement Preconditions ☑Engine is stopped and starting disabled ☑Coolant temperature is below 40 °C Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Fuel Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible.

  • Page 85: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

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

  • Page 86: Fuel Prefilter - Draining

    7.9.3 Fuel prefilter – Draining 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. Draining fuel prefilter Switch off filter which is to be drained (A or 1 Filter A switched off 2 Filter B switched off Open threaded vent plug (1) of the filter to...
  • Page 87 Connect filling pump to filling connection (1) on suction side of filter. Open vent valve (2) and fill with fuel until it emerges from the vent pipe (3). Close vent valve (2). Turn slide (4) a little (approx. 30°) and open vent valve(s) (2) until fuel emerges from the vent pipe (3).

  • Page 88: Fuel Prefilter - Flushing

    7.9.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING Fuels are combustible.
  • Page 89 Open threaded vent plug (1) of filter to be flushed. Open drain valve (2) and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (1) and drain valve (2).

  • Page 90: Fuel Prefilter - Filter Element Replacement

    7.9.5 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) Sealing (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 91 Open threaded vent plug (1) of contaminat- ed filter. Unlock drain valve (5) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (5). Remove screws securing cover (2) and take off cover. Remove spring cartridge (3) and filter ele- ment (4).

  • Page 92: Charge-Air Cooling

    7.10 Charge-Air Cooling 7.10.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 93: Air Filter

    7.11 Air Filter 7.11.1 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 94). Reset signal ring of contamination indicator (→...

  • Page 94: Air Filter - Removal And Installation

    7.11.2 Air filter – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Air filter – Removal and installa- tion Loosen clamp (2). Remove air filter (3) and clamp (2) from connecting flange of intake housing (1). Clean connecting flange (1) of intake hous- ing and check for obstruction.

  • Page 95: Air Intake

    7.12 Air Intake 7.12.1 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 93). After installation of new filter, press reset button (1).

  • Page 96: Starting Equipment

    7.13 Starting Equipment 7.13.1 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 115). 96 | Task Description | MS150119/00E 2014-08...

  • Page 97: Lube Oil System, Lube Oil Circuit

    7.14 Lube Oil System, Lube Oil Circuit 7.14.1 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 98 7.14.2 Engine oil – Change Preconditions ☑Engine is stopped and starting disabled. ☑Engine is at operating temperature. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Hot oil.

  • Page 99: Oil Filtration / Cooling

    7.15 Oil Filtration / Cooling 7.15.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) Cover for SOLAS (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.

  • Page 100: Coolant Circuit, General, High-Temperature

    7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.1 Engine coolant drain and venting points 16V 2000 M96L 1 Engine coolant drain screw 2 Filling screw on seawater 3 Seawater pump drain pump 100 | Task Description | MS150119/00E 2014-08...
  • Page 101 1 Engine coolant drain screw 2 Engine coolant drain screw Preheating line inlet con- nection 1 Engine coolant overflow 2 Engine coolant filler neck 3 Engine coolant drain screw line MS150119/00E 2014-08 | Task Description | 101...
  • Page 102 1 Engine coolant drain screw 102 | Task Description | MS150119/00E 2014-08...
  • Page 103 7.16.2 Engine coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask.
  • Page 104 7.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 105). Fill with engine coolant (→ Page 106). 104 | Task Description | MS150119/00E 2014-08...

  • Page 105: Draining Engine Coolant

    7.16.4 Engine coolant – Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide an appropriate container to collect the coolant or Switch on the extraction device.
  • Page 106 7.16.5 Engine coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 107 7.16.6 HT coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 108: Engine Coolant – Sample Extraction And

    • corrosion inhibitor concentration; • pH value. Fit breather valve and close it. Change engine coolant according to the coolant operating times specified in the (→ MTU Fluids and Lu- bricants Specifications A001061/..) (→ Page 105). 108 | Task Description | MS150119/00E 2014-08...

  • Page 109: Low-Temperature Circuit

    7.17 Low-Temperature Circuit 7.17.1 Charge-air 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. Charge-air coolant –...

  • Page 110: Raw Water Pump With Connections

    7.18 Raw Water Pump with Connections 7.18.1 Raw water pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 111: Engine Mounting / Support

    7.19 Engine Mounting / Support 7.19.1 Engine mounting – Checking securing screws for firm seating Preconditions ☑Engine is stopped and starting disabled. Engine mounting, checking securing screws for firm seating Check securing screws for firm seating. Tighten loose threaded connections. MS150119/00E 2014-08 | Task Description | 111...

  • Page 112: Engine Mounting – Checking Condition Of

    7.19.2 Engine mounting – Checking condition of resilient mounts Preconditions ☑Engine is stopped and starting disabled. Engine mounting – Checking the condition of resilient mounts Wipe rubber surface with dry cloth, do not use organic detergents. Visually inspect resilient mounts for cracking and deformation. Check rubber surfaces for swelling.

  • Page 113: Belt Drive

    7.20 Belt Drive 7.20.1 Drive belt – Condition check Preconditions ☑Engine is stopped and starting disabled. ☑Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...

  • Page 114: Battery-Charging Generator

    7.21 Battery-Charging Generator 7.21.1 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 115: Wiring (General) For Engine/Gearbox/Unit

    7.22 Wiring (General) for Engine/Gearbox/Unit 7.22.1 Еngine wiring ‒ Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Еngine 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 116: Accessories For (Electronic) Engine

    7.23 Accessories for (Electronic) Engine Governor / Control System 7.23.1 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 117: Emu And Connectors – Cleaning

    7.23.2 EMU and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Cleaning EMU and connectors Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from the connector and cable surfaces with isopropyl alcohol.

  • Page 118: Engine Governor Plug Connections – Check

    7.23.3 Engine governor plug connections – Check Preconditions ☑Engine stopped and starting disabled. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.

  • Page 119: Engine Monitoring Unit Emu 8 – Plug

    7.23.4 Engine Monitoring Unit EMU 8 – Plug connections check Preconditions ☑Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Ensure that the clips (1) are engag- Check screws (3) of cable clamps on EMU (2) for firm seating.

  • Page 120: Interface Module Eim Plug Connections

    7.23.5 Interface module EIM plug connections – Check Preconditions ☑Engine is stopped and starting disabled. Checking EIM plug connections Check both Tyco plugs (62-pole) (2) on EIM for firm seating. Ensure that clips (3) are engaged. Check screws (1) of cable clamps on EIM for firm seating.

  • Page 121: Engine Control Unit – Self-Test

    7.23.6 Engine Control Unit – Self-test DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! • Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! ECU7 self-test Switch off power supply to system.

  • Page 122: Engine Governor Ecu 9 – Removal And

    7.23.7 Engine governor ECU 9 – Removal and installation Preconditions ☑Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 123: Engine Monitoring Unit – Removal And

    7.23.8 Engine Monitoring Unit – Removal and installation Preconditions ☑Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed. Removing Engine Control Unit with Engine Monitoring Unit from engine...

  • Page 124: Engine Interface Module Eim – Removal And

    7.23.9 Engine Interface Module EIM – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Removing EIM from the engine Note or mark assignment of cables and connectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors. Unscrew power and starter cable.

  • Page 125: Diagnostic Features Of Eim

    7.23.10 Diagnostic features of EIM Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM). It indicates the operating status of the EIM. Functions of diagnostic lamp DILA DILA lights Engine Interface Module (EIM) is OK. DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
  • Page 126 1 Preamble 6 VSP current path failed 11 ES pushbutton current 2 ECU current path failed (S5) path failed – 24V external (S1) 7 SLD current path failed (S10) 3 MCS current path failed (S6) 12 Key switch current path (S2) 8 DDV current path failed failed (S11)
  • Page 127 Sample flashing sequences A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail- ond steps) ure (1/2 second steps) Note: These bit sequences are transmitted constantly. Information about the status of the current paths of the EIM is also provided in the CAN message “Sta- tus internal power supply”.

  • Page 128: Appendix A

    US standards Abgasturbolader Exhaust turbocharger (ETC) Backup Data Module Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A001061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller Common Rail Deutsches Institut für Normung e. V.
  • Page 129 Abbre- Meaning Explanation viation International Organization for Standardiza- International umbrella organization of all standards tion institutes Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204 Kupplungsseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly Light Emitting Diode...

  • Page 130: Mtu Contact Persons/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 –...

  • Page 131: Appendix B

    9 Appendix B 9.1 Special Tools Assembly sleeve Part No.: F30454554 Qty.: Used in: 7.7.2 Injector – Removal and installation (→ Page 81) Barring gear Part No.: F6783914 Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 77) Centering jig Part No.: F6783025...
  • Page 132 Double-head box wrench Part No.: F30002800 Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 77) Engine barring gear Part No.: F6783914 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 67) Feeler gage Part No.: Y4345893 Qty.: Used in:...
  • Page 133 Measuring instrument Part No.: Y4345888 Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 77) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.16.7 Engine coolant – Sample extraction and analysis (→ Page 108) Offset screwdriver Part No.:...
  • Page 134 Puller Part No.: F6795554 Qty.: Used in: 7.7.2 Injector – Removal and installation (→ Page 81) Puller Part No.: F6790991 Qty.: Used in: 7.7.2 Injector – Removal and installation (→ Page 81) Puller Part No.: F6790992 Qty.: Used in: 7.7.2 Injector – Removal and installation (→ Page 81) Puller Part No.: F6795777...
  • Page 135 Ratchet Part No.: F30006212 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 67) Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 77) Ratchet Part No.: F30027340 Qty.: Used in: 7.4.2 Crankcase breather – Oil separator element re- placement, diaphragm check and replacement (→...
  • Page 136 Socket wrench Part No.: F30030450 Qty.: Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page 77) Steam jet cleaner Part No.: Qty.: Used in: 4.8 Plant – Cleaning (→ Page 55) Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 7.5.2 Valve clearance –...
  • Page 137 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.4.2 Crankcase breather – Oil separator element re- placement, diaphragm check and replacement (→ Page 74) MS150119/00E 2014-08 | Appendix B | 137...

  • Page 138: Index

    9.2 Index Engine Control Unit  – Self-test  121 Actuators  Engine coolant  – Overview  35 – Change  104 After stopping the engine 54 – Draining  105 Air filter  – Filling  106 – Installation  94 – Level check  103 – Removal  94 Engine coolant – Sample extraction and analysis 108 –...
  • Page 139 – Nuts  15 – Screws  15 – Screws and nuts  15 Maintenance schedule  Transport 7 – Maintenance task reference table [QL1]  56 Troubleshooting 57 MTU contact persons 130 Valve clearance  Oil filter  – Adjustment  77 – Replacement  99 – Check  77 Operational checks  50...

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