Page 1: Operating Instructions
Operating Instructions Diesel engine 8 V 2000 M60/M61 12V 2000 M60/M61 16V 2000 M60/M61 MW15406/17E...
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 Commissioning Note Important Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.).
Page 5: Table Of Contents
45 °C 5 Maintenance intake air temperature 3.10 12V 2000 M61 engine data 5.1 Maintenance schedule reference table [QL1] 120 3.11 12V 2000 M61 engine data 3.12 12V 2000 M61 engine data MW15406/17E 2014-05 | Table of Contents | 5...
Page 6 7.10 Charge-Air Cooling General, Left-Hand Side 7.23.1 Engine governor and connectors – Cleaning 7.23.2 Engine monitoring unit and connectors – 7.10.1 Intercooler ‒ Checking condensate drain line Cleaning for coolant discharge and obstruction 6 | Table of Contents | MW15406/17E 2014-05...
Page 7 8.2 MTU contact persons/service partners 7.24 Emergency Instrumentation (Local Operating Panel) 9 Appendix B 7.24.1 LOP and connectors – Cleaning 9.1 Special Tools 7.24.2 LOP – Visual inspection 7.24.3 LOP – Test procedures 9.2 Index MW15406/17E 2014-05 | Table of Contents | 7...
Page 8: 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 9: Personnel And Organizational Requirements
Wear proper protective clothing for all work. When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec- tive gloves, goggles, breathing protection). Observe the information on personal protective equipment in the respective activity description. MW15406/17E 2014-05 | Safety | 9...
Page 10: Transport
Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis.
Page 11: Safety Requirements For Startup And Operation
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment Some components are live (high voltage) when electrical equipment is in operation. Observe the safety instructions for these appliances. MW15406/17E 2014-05 | Safety | 11...
Page 12: Safety Requirements For Maintenance And Repair Work
Observe the cooling time for components which have been heated for installation or removal (risk of burning!). Always use suitable ladders and work platforms when working above head-height. Ensure that compo- nents or assemblies are placed on stable surfaces. 12 | Safety | MW15406/17E 2014-05...
Page 13 Do not place tools on the battery. Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by the sudden discharge of acid or bursting of the battery unit. MW15406/17E 2014-05 | Safety | 13...
Page 14 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre- vent any risk to the eyes. Measuring component deviations Workpieces, components and measuring instruments are within specified tolerances at a reference temperature of 20°C. 14 | Safety | MW15406/17E 2014-05...
Page 15: 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 16: Compressed Air
• After contact with skin, rinse affected parts of the body with plenty of water. • Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi- ble. 16 | Safety | MW15406/17E 2014-05...
Page 17: Standards For Safety Notices In The Text
The higher level warning notice is used if several hazards apply at the same time. Warnings related to personal injury shall be considered to include a warning of potential damage. MW15406/17E 2014-05 | Safety | 17...
Page 18: General Information
• Centrifugal lube oil filter • Coolant expansion tank Electronic system Electronic control and monitoring system with integrated safety and test system, providing interfaces to Remote Control System (RCS) and Monitoring and Control System (MCS). 18 | General Information | MW15406/17E 2014-05...
Page 19 • Interface to CAN field bus for connected, communicating monitoring system components. SOLAS – Fire protection specifications All fuel lines with fuel pressure >1.8 bar are fitted with SOLAS-compliant covers as per MTU standard MTN5233. All oil lines with oil pressure >1.8 bar are fitted with SOLAS-compliant covers as per MTU standard MTN5233.
Page 20 Fuel system covers 20 | General Information | MW15406/17E 2014-05...
Page 21 MW15406/17E 2014-05 | General Information | 21...
Page 22 Lube oil system covers 22 | General Information | MW15406/17E 2014-05...
Page 23 MW15406/17E 2014-05 | General Information | 23...
Page 24 The fluid must first pass the thread in case of a loose threaded union or faulty sealing ring (2). The pressure is thus greatly reduced by this and the faulty sealing ring (2) that any leakage is not under pressure. 24 | General Information | MW15406/17E 2014-05...
Page 25 Leak fuel is allowed to escape without pressure via the leakage overflow bore (7). The leakage chamber is sealed toward the outside by the O-rings (3). This prevents leaking fuel from escaping. The union is confirmed as being SOLAS-compliant by DNV and GL. MW15406/17E 2014-05 | General Information | 25...
Page 26 The fluid is diverted to the catch basin whereby the pressure is greatly reduced. Shielding by overlapping design The overlap (1) precludes lateral spray. The fluid is diverted to the catch basin whereby the pressure is greatly reduced. 26 | General Information | MW15406/17E 2014-05...
Page 27: Engine Side And Cylinder Designations
(1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4). The numbering of other engine components also starts with 1 at driving end (4). MW15406/17E 2014-05 | General Information | 27...
Page 28: 2000 M40-M91A/B Engines - Overview
Cylinder arrangement: V engine 2000 Series Application: M = Marine 4, ...,9 Application segment 0, 1 Design index (0, ..., 9) Special feature: A = 50 Hz, B = 60 Hz Table 1: Engine model designation 28 | General Information | MW15406/17E 2014-05...
Page 29: Sensors And Actuators - Overview
7 B07 (lube oil temperature) ture) 5 F25 (lube-oil pressure dif- 8 B05 (lube oil pressure) 2 B10 (charge-air pressure) ference over filter) 3 B09 (charge-air tempera- 6 B34 (fuel pressure after fil- ture) ter) MW15406/17E 2014-05 | General Information | 29...
Page 30 Left engine side 12V 2000 M 1 F33 (coolant level) 2 Y27 (turbocharger control 3 B21 (raw water pressure) valve) 30 | General Information | MW15406/17E 2014-05...
Page 31 Engine free end 12V 2000 M 1 B06 (coolant temperature) 2 B6.2 (coolant tempera- ture) MW15406/17E 2014-05 | General Information | 31...
Page 32 Right engine side 12V 2000 M 1 B44 (turbocharger speed) 3 F46 (leak-off fuel level) 2 B16 (coolant pressure) 4 B33 (fuel temperature) 32 | General Information | MW15406/17E 2014-05...
Page 33 Driving end 12V 2000 M 1 B01 (camshaft speed) 3 B13 (crankshaft speed) 5 B4.21 (exhaust bulk tem- 2 B4.22 (exhaust bulk tem- 4 B13.2 (crankshaft speed) perature, A side) perature, B side) MW15406/17E 2014-05 | General Information | 33...
Page 34 7 B07 (lube oil temperature) ture) 5 F25 (lube-oil pressure dif- 8 B05 (lube oil pressure) 2 B10 (charge-air pressure) ference over filter) 3 B09 (charge-air tempera- 6 B34 (fuel pressure after fil- ture) ter) 34 | General Information | MW15406/17E 2014-05...
Page 35 Left engine side 16V 2000 M 1 F33 (coolant level) 2 Y27 (turbocharger control 3 B21 (raw water pressure) valve) MW15406/17E 2014-05 | General Information | 35...
Page 36 Free end 16V 2000 M 1 B06 (coolant temperature) 2 B6.2 (coolant tempera- ture) 36 | General Information | MW15406/17E 2014-05...
Page 37 Right engine side 16V 2000 M 1 B44 (turbocharger speed) 3 F46 (leak-off fuel level) 2 B16 (coolant pressure) 4 B33 (fuel temperature) MW15406/17E 2014-05 | General Information | 37...
Page 38 Driving end 16V 2000 M 1 B01 (camshaft speed) 3 B13 (crankshaft speed) 5 B4.21 (exhaust bulk tem- 2 B4.22 (exhaust bulk tem- 4 B13.2 (crankshaft speed) perature, A side) perature, B side) 38 | General Information | MW15406/17E 2014-05...
Page 39: Technical Data
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 15.92 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder MW15406/17E 2014-05 | Technical Data | 39...
Page 40 Longitudinal inclination continuous max. drive side down (Design: max. operat- degree ing inclinations) Longitudinal inclination temporary max. drive side down (Design: max. operat- degree 22.5 ing inclinations) Longitudinal inclination continuous max. drive side up (Design: max. operating degree inclinations) 40 | Technical Data | MW15406/17E 2014-05...
Page 41 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) MW15406/17E 2014-05 | Technical Data | 41...
Page 42: 2000 M60 Engine Data: Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 15.92 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder 42 | Technical Data | MW15406/17E 2014-05...
Page 43 Longitudinal inclination temporary max. drive side up (Design: max. operating degree inclinations) Transverse inclination continuous max. (Design: max. operating inclinations) degree 22.5 Transverse inclination temporary max. (Design: max. operating inclinations) degree MW15406/17E 2014-05 | Technical Data | 43...
Page 44 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) 44 | Technical Data | MW15406/17E 2014-05...
Page 45: 2000 M60 Engine Data: Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 15.92 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder MW15406/17E 2014-05 | Technical Data | 45...
Page 46 Longitudinal inclination temporary max. drive side up (Design: max. operating degree inclinations) Transverse inclination continuous max. (Design: max. operating inclinations) degree 22.5 Transverse inclination temporary max. (Design: max. operating inclinations) degree 46 | Technical Data | MW15406/17E 2014-05...
Page 47 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) MW15406/17E 2014-05 | Technical Data | 47...
Page 48: 2000 M60 Engine Data: Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 15.92 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder 48 | Technical Data | MW15406/17E 2014-05...
Page 49 Transverse inclination temporary max. (Design: max. operating inclinations) degree CAPACITIES Number of cylinders Engine oil capacity, initial filling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating incli- liter nations) MW15406/17E 2014-05 | Technical Data | 49...
Page 50 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) 50 | Technical Data | MW15406/17E 2014-05...
Page 51: 2000M61 Engina Data
Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 1.99 1.99 1.99 1.99 Displacement, total Liters 15.92 15.92 15.92 15.92 Number of inlet valves per cylinder Number of exhaust valves per cylinder MW15406/17E 2014-05 | Technical Data | 51...
Page 52 Firing speed. to Starting (electric) Number of cylinders Rated starter voltage (standard design) Starting (with compressed air/hydraulic starter) Number of cylinders Starting air pressure before starter motor, min. Starting air pressure before starter motor, max. 52 | Technical Data | MW15406/17E 2014-05...
Page 53 Oil pan capacity at dipstick mark “max.” Liters (standard oil system) (option: max. operat- ing inclinations) Weights / main dimensions Number of cylinders Engine dry weight (with standard accesso- 1790 1790 1790 1790 ries installed, w/o coupling) MW15406/17E 2014-05 | Technical Data | 53...
Page 54 Lp, 1m distance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) 54 | Technical Data | MW15406/17E 2014-05...
Page 55: 2000 M60 Engine Data: Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 23.88 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder MW15406/17E 2014-05 | Technical Data | 55...
Page 56 Longitudinal inclination continuous max. drive side down (Design: max. operat- degree ing inclinations) Longitudinal inclination temporary max. drive side down (Design: max. operat- degree 22.5 ing inclinations) Longitudinal inclination continuous max. drive side up (Design: max. operating degree inclinations) 56 | Technical Data | MW15406/17E 2014-05...
Page 57 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) MW15406/17E 2014-05 | Technical Data | 57...
Page 58: 2000 M60 Engine Data: Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 23.88 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder 58 | Technical Data | MW15406/17E 2014-05...
Page 59 Longitudinal inclination temporary max. drive side up (Design: max. operating degree inclinations) Transverse inclination continuous max. (Design: max. operating inclinations) degree 22.5 Transverse inclination temporary max. (Design: max. operating inclinations) degree MW15406/17E 2014-05 | Technical Data | 59...
Page 60 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) 60 | Technical Data | MW15406/17E 2014-05...
Page 61: 2000 M60 Engine Data: Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 23.88 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder MW15406/17E 2014-05 | Technical Data | 61...
Page 62 Longitudinal inclination temporary max. drive side up (Design: max. operating degree inclinations) Transverse inclination continuous max. (Design: max. operating inclinations) degree 22.5 Transverse inclination temporary max. (Design: max. operating inclinations) degree 62 | Technical Data | MW15406/17E 2014-05...
Page 63 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) MW15406/17E 2014-05 | Technical Data | 63...
Page 64: 2000 M60 Engine Data: Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 23.88 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder 64 | Technical Data | MW15406/17E 2014-05...
Page 65 Transverse inclination temporary max. (Design: max. operating inclinations) degree CAPACITIES Number of cylinders Engine oil capacity, initial filling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating incli- liter nations) MW15406/17E 2014-05 | Technical Data | 65...
Page 66 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) 66 | Technical Data | MW15406/17E 2014-05...
Page 67: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 23.88 Inlet valves per cylinder Exhaust valves per cylinder MW15406/17E 2014-05 | Technical Data | 67...
Page 68 Degrees ating inclinations) (°) Longitudinal inclination, temporary max. driving end down (Option: max. oper- Degrees 22.5 ating inclinations) (°) Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) (°) 68 | Technical Data | MW15406/17E 2014-05...
Page 69 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) MW15406/17E 2014-05 | Technical Data | 69...
Page 70: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 23.88 Inlet valves per cylinder Exhaust valves per cylinder 70 | Technical Data | MW15406/17E 2014-05...
Page 71 Longitudinal inclination, temporary max., driving end up (Option: max. operat- Degrees ing inclinations) (°) Transverse inclination continuous max. (Option: max. operating inclinations) Degrees 22.5 (°) Transverse inclination, temporary max. (Option: max. operating inclinations) Degrees (°) MW15406/17E 2014-05 | Technical Data | 71...
Page 72 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) 72 | Technical Data | MW15406/17E 2014-05...
Page 73: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 23.88 Inlet valves per cylinder Exhaust valves per cylinder MW15406/17E 2014-05 | Technical Data | 73...
Page 74 Degrees ating inclinations) (°) Longitudinal inclination, temporary max. driving end down (Option: max. oper- Degrees 22.5 ating inclinations) (°) Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) (°) 74 | Technical Data | MW15406/17E 2014-05...
Page 75 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) MW15406/17E 2014-05 | Technical Data | 75...
Page 76: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 23.88 Inlet valves per cylinder Exhaust valves per cylinder 76 | Technical Data | MW15406/17E 2014-05...
Page 77 Longitudinal inclination, temporary max., driving end up (Option: max. operat- Degrees ing inclinations) (°) Transverse inclination continuous max. (Option: max. operating inclinations) Degrees 22.5 (°) Transverse inclination, temporary max. (Option: max. operating inclinations) Degrees (°) MW15406/17E 2014-05 | Technical Data | 77...
Page 78 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) 78 | Technical Data | MW15406/17E 2014-05...
Page 79: 2000 M60 Engine Data: Engine-Mounted Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 31.84 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder MW15406/17E 2014-05 | Technical Data | 79...
Page 80 Longitudinal inclination continuous max. drive side down (Design: max. operat- degree ing inclinations) Longitudinal inclination temporary max. drive side down (Design: max. operat- degree 22.5 ing inclinations) Longitudinal inclination continuous max. drive side up (Design: max. operating degree inclinations) 80 | Technical Data | MW15406/17E 2014-05...
Page 81 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) MW15406/17E 2014-05 | Technical Data | 81...
Page 82: 2000 M60 Engine Data: Engine-Mounted Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 31.84 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder 82 | Technical Data | MW15406/17E 2014-05...
Page 83 Longitudinal inclination temporary max. drive side up (Design: max. operating degree inclinations) Transverse inclination continuous max. (Design: max. operating inclinations) degree 22.5 Transverse inclination temporary max. (Design: max. operating inclinations) degree MW15406/17E 2014-05 | Technical Data | 83...
Page 84 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) 84 | Technical Data | MW15406/17E 2014-05...
Page 85: 2000 M60 Engine Data: Separate Heat Exchanger, Reference Condition: 25 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 31.84 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder MW15406/17E 2014-05 | Technical Data | 85...
Page 86 Transverse inclination temporary max. (Design: max. operating inclinations) degree CAPACITIES Number of cylinders Engine oil capacity, initial filling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating incli- liter nations) 86 | Technical Data | MW15406/17E 2014-05...
Page 87 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) MW15406/17E 2014-05 | Technical Data | 87...
Page 88: 2000 M60 Engine Data: Separate Heat Exchanger, Reference Condition: 45 °C Intake Air Temperature
MODEL-RELATED DATA (basic design) Number of cylinders Cylinder configuration: V angle degree Bore Stroke Cylinder displacement liter 1.99 Total displacement liter 31.84 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder 88 | Technical Data | MW15406/17E 2014-05...
Page 89 Transverse inclination temporary max. (Design: max. operating inclinations) degree CAPACITIES Number of cylinders Engine oil capacity, initial filling (standard oil system) (Option: max. operating liter inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating incli- liter nations) MW15406/17E 2014-05 | Technical Data | 89...
Page 90 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- db(A) tance, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- db(A) pressure level Lp, 1m distance, ISO 6798) 90 | Technical Data | MW15406/17E 2014-05...
Page 91: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 31.84 Inlet valves per cylinder Exhaust valves per cylinder MW15406/17E 2014-05 | Technical Data | 91...
Page 92 Degrees ating inclinations) (°) Longitudinal inclination, temporary max. driving end down (Option: max. oper- Degrees 22.5 ating inclinations) (°) Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) (°) 92 | Technical Data | MW15406/17E 2014-05...
Page 93 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) MW15406/17E 2014-05 | Technical Data | 93...
Page 94: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 31.84 Inlet valves per cylinder Exhaust valves per cylinder 94 | Technical Data | MW15406/17E 2014-05...
Page 95 Longitudinal inclination, temporary max., driving end up (Option: max. operat- Degrees ing inclinations) (°) Transverse inclination continuous max. (Option: max. operating inclinations) Degrees 22.5 (°) Transverse inclination, temporary max. (Option: max. operating inclinations) Degrees (°) MW15406/17E 2014-05 | Technical Data | 95...
Page 96 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) 96 | Technical Data | MW15406/17E 2014-05...
Page 97: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 31.84 Inlet valves per cylinder Exhaust valves per cylinder MW15406/17E 2014-05 | Technical Data | 97...
Page 98 Degrees ating inclinations) (°) Longitudinal inclination, temporary max. driving end down (Option: max. oper- Degrees 22.5 ating inclinations) (°) Longitudinal inclination, continuous max. driving end up (Option: max. operat- Degrees ing inclinations) (°) 98 | Technical Data | MW15406/17E 2014-05...
Page 99 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) MW15406/17E 2014-05 | Technical Data | 99...
Page 100: 2000 M61 Engine Data
MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder Liters 1.99 Total displacement Liters 31.84 Inlet valves per cylinder Exhaust valves per cylinder 100 | Technical Data | MW15406/17E 2014-05...
Page 101 Longitudinal inclination, temporary max., driving end up (Option: max. operat- Degrees ing inclinations) (°) Transverse inclination continuous max. (Option: max. operating inclinations) Degrees 22.5 (°) Transverse inclination, temporary max. (Option: max. operating inclinations) Degrees (°) MW15406/17E 2014-05 | Technical Data | 101...
Page 102 Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- dB(A) tance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- dB(A) pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance) 102 | Technical Data | MW15406/17E 2014-05...
Page 103: Firing Order
3.22 Firing order Number of cylin- Firing order ders A1-B4-A4-A2-B3-A3-B2-B1 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 MW15406/17E 2014-05 | Technical Data | 103...
Page 104: Engine - Main Dimensions
2005 mm approx. 1280 mm approx. 1315 mm 12 V 2000 M50-M61 approx. 2350 mm approx. 1400 mm approx. 1475 mm 16 V 2000 M50-M61 approx. 2815 mm approx. 1425 mm approx. 1520 mm 104 | Technical Data | MW15406/17E 2014-05...
Page 105: Operation
LED (spot) lights up when an alarm is active. White DIM ↑ Holding down the button increases LCD background illu- mination. White DIM ↓ Holding down the button decreases LCD background illu- mination. MW15406/17E 2014-05 | Operation | 105...
Page 106 (also if transmitted from RCS). EMERGENCY STOP Pressing the button initiates an immediate emergency en- gine stop. LED (spot) flashes once the emergency stop has been tripped and until the alarm has been acknowledged. 106 | Operation | MW15406/17E 2014-05...
Page 107: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)
4.2 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the engine into operation (out-of-service period > 3 months) Item Measure Engine Depreserve (→...
Page 108: Putting The Engine Into Operation After Scheduled Out-Of-Service Period
Drain (→ Page 176). Battery-charging generator Check condition of drive belt (→ Page 208). drive Engine control system Switch ON. Press READY FOR OPERATION button (→ Page 105). Press LAMP TEST button (→ Page 105). 108 | Operation | MW15406/17E 2014-05...
Page 109: Starting The Engine From Lop
• Automatic starting sequence is performed; • Engine speed display instrument indicates increasing speed; • After completion of the starting sequence, the engine runs at idle speed, and the illuminated pushbutton START changes to basic bright- ness. MW15406/17E 2014-05 | Operation | 109...
Page 110: Starting The Engine With The Blueline Automation System (Control Stand)
Bar with starting system (→ Page 147). Starting the engine at the BlueLine automation system (control stand) Item Measure Engine Start the engine at the BlueLine automation system (control stand) (→ Blue- Line documentation). 110 | Operation | MW15406/17E 2014-05...
Page 111: Engine Emergency Stop At Blueline Automation System (Control Stand)
Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Engine emergency stop at BlueLine automation system Item Measure Engine Emergency stop at BlueLine automation system (→ Operating Instructions for BlueLine). MW15406/17E 2014-05 | Operation | 111...
Page 112: Operational Checks
HT coolant pump Check relief bore for oil and coolant discharge and contamination (→ Page 204). Raw-water pump Check relief bore for escaping oil and water, check for contamination (→ Page 207). 112 | Operation | MW15406/17E 2014-05...
Page 113: Coupling - Disengaging From Lop
Press COUPLING NEUTRAL illuminated pushbutton (→ Page 105). • COUPLING NEUTRAL button flashes. • Gearbox is disengaged (neutral position). • After receiving the feedback signal from coupling, the COUPLING NEU- TRAL button is illuminated brightly. MW15406/17E 2014-05 | Operation | 113...
Page 114: Waterjet - Flushing From Lop (Optional)
Release FLUSH illuminated pushbutton. • FLUSH pushbutton flashes. • Gearbox is disengaged (neutral position). • Illumination of FLUSH pushbutton is switched off as soon as the feed- back signal from coupling is received. 114 | Operation | MW15406/17E 2014-05...
Page 115: Stopping The Engine From Lop
Operate engine at idle speed (→ Page 105). Temperature indications Wait until engine temperatures do not fall any further. Press illuminated pushbutton STOP (→ Page 105). • STOP pushbutton is illuminated; • Engine at a standstill. MW15406/17E 2014-05 | Operation | 115...
Page 116: Stopping The Engine At The Blueline Automation System (Control Stand)
Stopping the engine at the BlueLine automation system (control stand) Item Measure Engine Stop the engine at the BlueLine automation system (control stand) (→ Blue- Line Operating Instructions). 116 | Operation | MW15406/17E 2014-05...
Page 117: Emergency Stop From Lop
• Audible and visual alarm signaling stops. Press ALARM ACKNOWLEDGE button again. • Power supply to ECU is provided; • Alarm has been acknowledged. Engine On engines with emergency air-shutoff flaps: open flaps. • Engine is ready for starting. MW15406/17E 2014-05 | Operation | 117...
Page 118: 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/..) 118 | Operation | MW15406/17E 2014-05...
Page 119: Plant - Cleaning
Seal all openings in a suitable way. b) Remove coarse dirt. c) Spray on cleaner sparingly and leave it for 1 to 5 minutes. d) Use the high-pressure jet to remove the loosened dirt. e) Dry engine with compressed air. MW15406/17E 2014-05 | Operation | 119...
Page 120: Maintenance
Perform endoscopic inspection of combustion chambers (→ Page 148) W1140 Clean wire meshes of crankcase breather (→ Page 154) W1178 Replace pressure pipe neck in cylinder head (→ Page 164) Table 2: Maintenance schedule reference table [QL1] 120 | Maintenance | MW15406/17E 2014-05...
Page 121: Lop Fault Messages
2. Perform LOP test procedures (→ Page 225). 3. Check ECU plug-in connections (→ Page 218). 4. Check engine wiring (→ Page 214). 5. Contact Service. • have ECU checked and replaced, if required. MW15406/17E 2014-05 | Troubleshooting | 121...
Page 122 • have ECU checked and replaced, if required. defective. AL Transistor Output 3/4 Fail Cause Corrective action u Contact Service. One of the ECU 4 transistor outputs (TAA3 or TAA4) • have ECU checked and replaced, if required. defective. 122 | Troubleshooting | MW15406/17E 2014-05...
Page 123 2. Perform LOP test procedures (→ Page 225). CAN bus. 3. Check ECU plug-in connections (→ Page 218). 4. Check engine wiring (→ Page 214). 5. Contact Service. • Have GCU/GMU checked and replaced if required. MW15406/17E 2014-05 | Troubleshooting | 123...
Page 124 2. Perform LOP test procedures (→ Page 225). bus. 3. Check ECU plug-in connections (→ Page 218). 4. Check engine wiring (→ Page 214). 5. Contact Service. • Have PCU checked and replaced, if required. 124 | Troubleshooting | MW15406/17E 2014-05...
Page 125 1. Check LOP visually (→ Page 223). +A001-A010) not detected on 2. Perform LOP test procedures (→ Page 225). redundant CAN bus. 3. Contact Service. • Have MPU 23 of PIM No. 21.X+A001-A010 checked and replaced, if required. MW15406/17E 2014-05 | Troubleshooting | 125...
Page 126 RCS with PIM No. 21.X+A300- 1. Check LOP visually (→ Page 223). A500 not detected on redundant 2. Perform LOP test procedures (→ Page 225). CAN bus. 3. Contact Service. • Have RCS checked and replaced, if required. 126 | Troubleshooting | MW15406/17E 2014-05...
Page 127 SS P-Gear Control Oil (GCU) Cause Corrective action u Check gearbox control-oil level and top up, if required (see Safety system detects that gear control oil pressure is too low. gearbox documentation). MW15406/17E 2014-05 | Troubleshooting | 127...
Page 128 Cause Corrective action u Determine cause for shutoff and rectify. Safety system has triggered engine stop. SS T-Coolant (ECU) Cause Corrective action Safety system detects that u Reduce power. coolant temperature is too high. 128 | Troubleshooting | MW15406/17E 2014-05...
Page 129 Cause Corrective action RCS measuring point. u Status report ("Trolling Active" lamp on). Cylinder cutout Cause Corrective action Measuring point "Cylinder u Status report for "cylinder cutout/number of cylinders halved" cutout active". during idling MW15406/17E 2014-05 | Troubleshooting | 129...
Page 130: Troubleshooting
Injection pump faulty. u Replace (→ Page 160). Engine wiring faulty. u Check (→ Page 214). Air in fuel system. u Vent fuel system (→ Page 171). Engine control unit ECU is u Contact Service. defective. 130 | Troubleshooting | MW15406/17E 2014-05...
Page 131 Charge-air pressure too low Cause Corrective action Air filter clogged. u Check signal ring position of contamination indicator (→ Page 184). u Contact Service. Charge-air cooler is contaminated. Exhaust turbocharger faulty. u Contact Service. MW15406/17E 2014-05 | Troubleshooting | 131...
Page 132 Run engine to reach operating temperature. Engine is not at operating temperature. Water in fuel. u Check fuel system at fuel prefilter. Drain fuel prefilter (→ Page 176). u Contact Service. Charge-air cooler leaky. 132 | Troubleshooting | MW15406/17E 2014-05...
Page 133: Task Description
Designation / Use Part No. Qty. Shield A4 735233000100 Shield A5 735233000101 Shield A7 735233000103 Shield A8 735233000104 SOLAS shielding – Installation Pinpoint installation location (→ Page 136). Install suitable shielding. Press shielding until locked. MW15406/17E 2014-05 | Task Description | 133...
Page 134: Solas Shielding - Installation As Per Mtn 5233
Designation / Use Part No. Qty. Shield A4 735233000100 Shield A5 735233000101 Shield A7 735233000103 Shield A8 735233000104 Installing SOLAS shielding Pinpoint installation location (→ Page 136). Install suitable shielding. Press shielding until locked. 134 | Task Description | MW15406/17E 2014-05...
Page 135: Solas Shielding - Installation
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 136). Install suitable shielding. MW15406/17E 2014-05 | Task Description | 135...
Page 136: Installation Locations For Solas Shielding
On crankcase Item Type of shielding Remarks Shield (A4) On brazed-on union Shield (A5) On crankcase Free end B-side Item Type of shielding Remarks Shield (A7) On fuel delivery pump Free end B-side 136 | Task Description | MW15406/17E 2014-05...
Page 137 Free end B-side Item Type of shielding Remarks Shield (A7) On HP fuel pump Free end B-side Free end Item Type of shielding Remarks Shield (A7) Above fuel priming pump. Free end MW15406/17E 2014-05 | Task Description | 137...
Page 138 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 138 | Task Description | MW15406/17E 2014-05...
Page 139 Shield (A5) On air flap control Driving end Shield (A4) On brazed-on union Driving end Shield (A5) On exhaust turbocharger flap control. Driving end Shield (A5) On exhaust turbocharger flap control. Driving end MW15406/17E 2014-05 | Task Description | 139...
Page 140 Item Type of shielding Remarks Shield (A4) Exhaust turbocharger lubrication. Driving end Shield (A4) On brazed-on union. Driving end Driving end Item Type of shielding Remarks Shield (A4) Exhaust turbocharger lubrication. Driving end 140 | Task Description | MW15406/17E 2014-05...
Page 141: Installation Locations For Solas Shielding
Primarily fit SOLAS shielding as per MTN 5233 (→ Page 133). 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 MW15406/17E 2014-05 | Task Description | 141...
Page 142 On air flap 2 (driving end, A-side) Shield (A4) On brazed-on union 3 (driving end, A-side) Shield (A5) On turbocharger flap 4 (driving end, A-side) Shield (A5) On turbocharger flap Driving end A-side 142 | Task Description | MW15406/17E 2014-05...
Page 143 1 (driving end) Shield (A4) Turbocharger lubrication, left side 2 (driving end) Shield (A4) Turbocharger lubrication, center Driving end Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, right side MW15406/17E 2014-05 | Task Description | 143...
Page 144 4 (driving end, B-side) Shield (A5) On air flap 5 (driving end, B-side) Shield (A4) To turbocharger lubrication Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) On valve plate 144 | Task Description | MW15406/17E 2014-05...
Page 145 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 MW15406/17E 2014-05 | Task Description | 145...
Page 146: Engine
No resistance other than compres- sion resistance may be encountered. Result: If the resistance exceeds the normal com- pression resistance, contact Service. For barring device removal, follow reverse sequence of working steps. 146 | Task Description | MW15406/17E 2014-05...
Page 147: Engine - Barring With Starting System
20 seconds. Plug connector X4 (3) and use connector pliers (2) to secure the bayonet cou- pling (4) by turning it clockwise until it latches into place. MW15406/17E 2014-05 | Task Description | 147...
Page 148: Cylinder Liner
Use technical terms for description of the liner surface (→ Page 150). Depending on findings: • Do not take any action or • Carry out further endoscopic examination as part of maintenance work or • Contact Service; cylinder liner must be replaced. 148 | Task Description | MW15406/17E 2014-05...
Page 149 Final steps Install injector (→ Page 166). Install cylinder head cover (→ Page 158). MW15406/17E 2014-05 | Task Description | 149...
Page 150: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston skirt or the piston crown. Material deposits on the liner (smear), heavy discolora- tion. Severe, visible scoring. Replace liner. 150 | Task Description | MW15406/17E 2014-05...
Page 151 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. MW15406/17E 2014-05 | Task Description | 151...
Page 152: Crankcase Breather
(2) with new O-ring. Tighten screws of cover (2) to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque 6 Nm + 2 Nm Replace further oil separator elements in the same way. 152 | Task Description | MW15406/17E 2014-05...
Page 153 (4). Tighten screws of cover (4) to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque 6 Nm + 2 Nm Check diaphragms in further oil separators in the same way. MW15406/17E 2014-05 | Task Description | 153...
Page 154: Crankcase Breather - Cleaning Oil Separator Element
Moisten oil separator (2) with engine oil. Place oil separator (2) with new gasket (3) onto housing (4) and install cover (1). Clean other oil separator element in the same way. 154 | Task Description | MW15406/17E 2014-05...
Page 155: Valve Drive
Box wrench bit, 17 mm F30030450 Feeler gauge Y4342013 Preparatory steps Remove cover plate (2). Remove cylinder head cover (→ Page 158). Bar engine manually in engine direction of rotation until the markings (1) are aligned. MW15406/17E 2014-05 | Task Description | 155...
Page 156: Adjusting Valve Clearance
Tighten locknut (1) applying the specified tightening torque, holding adjusting screw (2) firmly with screwdriver. Name Size Type Lubricant Value/Standard Locknut M12x1 Tightening torque 50 Nm 156 | Task Description | MW15406/17E 2014-05...
Page 157 Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap. Result: If not, adjust valve clearance. Final steps Remove barring device. For installation of removed parts, follow reverse sequence of working steps. MW15406/17E 2014-05 | Task Description | 157...
Page 158: Cylinder Head Cover - Removal And Installation
Align cylinder head cover (2) with centering jig. Tighten screws (1) to specified torque 20 Nm using a torque wrench. Final steps Install air filter (→ Page 183). Install air guide housing. Check cylinder head covers for leaks. 158 | Task Description | MW15406/17E 2014-05...
Page 159: Injection Pump / Hp Pump
7.6.1 Injection pump – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injection pump (→ Spare Parts Catalog) Injection pump – Replacement Remove injection pump and install new one (→ Page 160). MW15406/17E 2014-05 | Task Description | 159...
Page 160: Injection Pump - Removal And Installation
• Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Preparatory steps Close fuel supply line upstream of fuel filter. Remove engine control system (→ Page 220). Drain fuel (→ Page 170). Remove charge-air pipes and all seals. 160 | Task Description | MW15406/17E 2014-05...
Page 161 Coat roller (arrowed) with engine oil. Clean sealing face and fuel bores in crank- case. Use barring gear (→ Page 146) to position the pump cams on the camshaft at base circle. MW15406/17E 2014-05 | Task Description | 161...
Page 162 Coat gaskets with grease (Kluthe Hakuform 30-10/Emulgier) and place onto cylinder head. Install charge-air pipes. Install engine control system (→ Page 220). Open fuel supply line before fuel filter. Vent fuel system (→ Page 171). 162 | Task Description | MW15406/17E 2014-05...
Page 163: Injection Valve / Injector
7.7 Injection Valve / Injector 7.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 166). MW15406/17E 2014-05 | Task Description | 163...
Page 164: Hp Fuel Line - Pressure Pipe Neck Replacement
Moisten taper of pressure pipe neck with engine oil. Insert pressure pipe neck into cylinder head until it is in contact with the sealing ring. Fully press in pressure pipe neck (1) by hand. 164 | Task Description | MW15406/17E 2014-05...
Page 165 Tighten union nut on pressure pipe neck to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 20 Nm + 5 Nm Final steps Install cylinder head cover (→ Page 158). Vent fuel system (→ Page 171). MW15406/17E 2014-05 | Task Description | 165...
Page 166: Injector - Removal And Installation
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders. Preparatory steps Remove cylinder head cover (→ Page 158). Drain fuel (→ Page 170). 166 | Task Description | MW15406/17E 2014-05...
Page 167 Remove screw (5). Take off clamp (4). Screw puller into injector. Remove injector with puller. Remove injector sealing ring (1) using a self-made hook. After removal, seal all openings with suita- ble covers. MW15406/17E 2014-05 | Task Description | 167...
Page 168: Installing Injector
Tightening torque 50 Nm Install fuel line (3). Tighten union nut on injection pump to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 20 Nm +5 Nm 168 | Task Description | MW15406/17E 2014-05...
Page 169 Tighten union nut on pressure pipe neck to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 20 Nm +5 Nm Install leak-off-fuel lines. Final steps Install cylinder head cover (→ Page 158). Vent fuel system (→ Page 171). MW15406/17E 2014-05 | Task Description | 169...
Page 170: Fuel System
Release threaded vent plugs on filter head. Open nipple on fuel line and drain fuel into appropriate container. When fuel stops emerging from system, close nipple on fuel line. Close threaded vent plugs on filter head. 170 | Task Description | MW15406/17E 2014-05...
Page 171: Fuel System - Venting
Venting fuel system Unlock fuel priming pump, unscrew handle. Open vent plugs on filter head. Operate the pump with the handle until bubble-free fuel emerges at the vent plugs. Close vent plugs on filter head. MW15406/17E 2014-05 | Task Description | 171...
Page 172 Close nipple at fuel heat exchanger. Open nipple at fuel line. Operate the pump with the handle until bubble-free fuel emerges at the nipple. Close nipple at fuel line. Lock fuel priming pump, screw in handle. 172 | Task Description | MW15406/17E 2014-05...
Page 173: Fuel Filter
Severe material damage! • For filter replacement with the engine running, operate the engine at low engine load. • The filter which is to be replaced must be cut out for a brief period only. MW15406/17E 2014-05 | Task Description | 173...
Page 174 Fit SOLAS shield (→ Page 18). Screw on easy-change filter and tighten by hand. Set three-way cock to operating position (both filters cut in). Replace further fuel filters in the same way. 174 | Task Description | MW15406/17E 2014-05...
Page 175: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge
With the engine running at full load or rated power, read off pressure at gauge (1). If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 177). MW15406/17E 2014-05 | Task Description | 175...
Page 176: Fuel Prefilter - Draining
Fill filter housing with clean fuel. Place new seal in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges from system. 176 | Task Description | MW15406/17E 2014-05...
Page 177: Fuel Prefilter - Flushing
High level of engine noise when the engine is running. Risk of damage to hearing! • Wear ear protectors. Fuel prefilter – Flushing Cut out the contaminated filter. 1 Left filter cut in 2 Right filter cut in MW15406/17E 2014-05 | Task Description | 177...
Page 178: Fuel Prefilter – Filling With Fuel
Fit cover with gasket and secure it with screws. Check differential pressure (→ Page 175). Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel pre- filter (→ Page 179). 178 | Task Description | MW15406/17E 2014-05...
Page 179: Fuel Prefilter - Filter Element Replacement
Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing filter element Cut out the contaminated filter. I Left filter cut in II Right filter cut in MW15406/17E 2014-05 | Task Description | 179...
Page 180 Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges. Set adjustable pointer of differential pres- sure gage (→ Page 175). 180 | Task Description | MW15406/17E 2014-05...
Page 181: Charge-Air Cooling General, Left-Hand Side
Emergency measures prior to engine start with a leaking intercooler Remove injectors (→ Page 163). Bar engine manually (→ Page 146). Bar engine with starting system to blow out cylinder chambers (→ Page 147). Install injectors (→ Page 166). MW15406/17E 2014-05 | Task Description | 181...
Page 182: Air Filter
Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 183). Reset signal ring of contamination indicator (→ Page 184). 182 | Task Description | MW15406/17E 2014-05...
Page 183: Air Filter - Removal And Installation
(3). Verify that there are no objects in the flange of the intake housing (3) and clean Place new air filter (1) with clamp (2) onto intake housing (3). Tighten clamp (2). MW15406/17E 2014-05 | Task Description | 183...
Page 184: Air Intake
If the signal ring is completely visible in the control window (2), replace air filter (→ Page 182). After installation of new filter, press reset button (1). Result: Engaged piston with signal ring moves back to initial position. 184 | Task Description | MW15406/17E 2014-05...
Page 185: Air-Flow Control Flap - Ease Of Movement Check
Air-flow control flap – Check for ease of movement Actuate lever several times by hand, mov- ing it between positions “A” and “B” to check for ease of movement. If the lever does not move freely, contact Service. MW15406/17E 2014-05 | Task Description | 185...
Page 186: 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 214). 186 | Task Description | MW15406/17E 2014-05...
Page 187: Lube Oil System, Lube Oil Circuit
Result: If there is no mark, mark the oil dipstick (→ Page 189). If necessary, top up to "max." mark (→ Page 188). Insert oil dipstick into guide tube up to the stop. MW15406/17E 2014-05 | Task Description | 187...
Page 188: Engine Oil - Change
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 Sealing ring (→...
Page 189: Oil Filtration / Cooling
7.15 Oil Filtration / Cooling 7.15.1 Oil dipstick — Marking 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 oil Oil dipstick (→...
Page 190: Engine Oil Filter - Replacement
Stop engine (→ Page 115) 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 190 | Task Description | MW15406/17E 2014-05...
Page 191 Fit SOLAS shield (→ Page 133). Screw on and tighten new oil filter by hand. Replace other oil filters in the same way. Switch filter to normal position. Check oil level (→ Page 187). MW15406/17E 2014-05 | Task Description | 191...
Page 192: Centrifugal Oil Filter And Filter Sleeve - Cleaning And Replacement
• Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders. Removing rotor of centrifugal oil filter Release nuts (3). Remove housing cover (1). Remove complete rotor (2) from housing. 192 | Task Description | MW15406/17E 2014-05...
Page 193 Clean rotor components and remove strain- ers (2). Wash standpipes (3) and nozzles (4) with cleaner, blow out with compressed air. Insert the new filter sleeve with the smooth surface facing the rotor cap. MW15406/17E 2014-05 | Task Description | 193...
Page 194 40 Nm to 50 Nm Insert complete rotor (2) into the housing and check for ease-of-movement. Set housing cover (1) with new O-ring onto lower section, observe marks. Tighten nuts (3) crosswise and evenly. 194 | Task Description | MW15406/17E 2014-05...
Page 195: Coolant Circuit, General, High-Temperature Circuit
7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.1 Drain and venting points Top side 1 Engine coolant vent 3 Overflow line 5 Fuel filter 2 Intercooler 4 Engine coolant expansion 6 Engine oil filter tank MW15406/17E 2014-05 | Task Description | 195...
Page 196 Left side 1 Engine coolant drain plug 2 Engine coolant drain plug 3 Raw water pump drain plug 196 | Task Description | MW15406/17E 2014-05...
Page 197 3 Fuel vent valve 5 Raw water pump drain tional) plug 8 Oil filler neck (connection 6 Connection for oil extrac- left or right engine side op- tion tional) 9 Fuel priming pump MW15406/17E 2014-05 | Task Description | 197...
Page 198 2 Engine coolant drain plug 5 Raw water pump filling left or right engine side op- 3 Engine oil filter plug tional) 6 Oil filler neck (connection 4 Leak-fuel tank left or right engine side op- tional) 198 | Task Description | MW15406/17E 2014-05...
Page 199 5 Oil filler neck (connection 3 Oil dipstick (connection left or right engine side op- left or right engine side op- tional) tional) 6 Engine coolant drain plug MW15406/17E 2014-05 | Task Description | 199...
Page 200: Engine Coolant - Level Check
7.16.2 Engine coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specification (A001061/..) is available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask.
Page 201: Engine Coolant - Change
7.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 202). Fill with engine coolant (→ Page 203). MW15406/17E 2014-05 | Task Description | 201...
Page 202: Engine Coolant Draining
• Crankcase (1) • Intercooler (6) • Exhaust-pipe elbow (5) • Heating connection (3) • Engine oil heat exchanger (2) Close all open drain points. Place breather valve on filler neck and close. 202 | Task Description | MW15406/17E 2014-05...
Page 203: Engine Coolant - Filling
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 204: Ht Coolant Pump - Relief Bore Check
Clean the relief bore (arrow) with a wire if it is dirty. • Permissible coolant discharge: up to 10 drops per hour. • Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits, contact Service. 204 | Task Description | MW15406/17E 2014-05...
Page 205: Engine Coolant - Sample Extraction And Analysis
7.16.7 Engine coolant – Sample extraction and analysis 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. MTU test kit 5605892099/00 WARNING Coolant is hot and under pressure.
Page 206: Raw Water Pump With Connections
Remove plug screw (1) on raw water elbow (3). Fill 3 to 4 liters of water into the system through the opening. Install plug screw (1) with new sealing ring (2) and tighten. 206 | Task Description | MW15406/17E 2014-05...
Page 207: Raw Water Pump - Relief Bore Check
Clean the relief bore with a wire if it is dirty. • Permissible coolant discharge: up to 10 drops per hour. • Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits, contact Service. MW15406/17E 2014-05 | Task Description | 207...
Page 208: Belt Drive
Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→ Page 211) Drive belt C Chunking Drive belt Belt is oily, shows signs of over- heating 208 | Task Description | MW15406/17E 2014-05...
Page 209: Battery-Charging Generator
Check drive belt condition (→ Page 208). Belt drive – Checking distance Measure distance (A) with assembly de- vice. If measured value of distance (A) is not within the tolerance of 98 mm ± 1.5 mm, readjust belt tension. MW15406/17E 2014-05 | Task Description | 209...
Page 210 Use assembly device to adjust distance (A) by turning adjustment lever (2). Tighten screws (1) and (3). Measure distance (A) with assembly device. Final steps Install protective cover (2). Install securing screws (3) of protective cover (2). Install indicator (1). Install limit switch (4). 210 | Task Description | MW15406/17E 2014-05...
Page 211: Battery-Charging Generator Drive - Drive Belt Replacement
Check cleanness of belt pulleys. Fit new drive belt. Remove mandrel. Final steps Install protective cover. Install screws of protective cover. Install safety equipment (if fitted). Check function of safety equipment (if fitted). MW15406/17E 2014-05 | Task Description | 211...
Page 212: Engine Mounting / Support
• When measured height setting (b) = 4 mm, the permissible value of (a) is 143 mm. Replace the resilient mount, if the meas- ured value of dimension (a) is lower than the permissible value. 212 | Task Description | MW15406/17E 2014-05...
Page 213: Universal Shaft
Universal shaft – Greasing Remove guard from universal shaft. Clean the two grease nipples on each joint half. Press grease into all nipples until it emerg- es at the star seals and sealing rings. Reinstall guard. MW15406/17E 2014-05 | Task Description | 213...
Page 214: Wiring (General) For Engine/Gearbox/Unit
Contact Service if cable conductors are damaged. Note: Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts using isopropyl alcohol. Ensure that all sensor connectors are securely engaged. 214 | Task Description | MW15406/17E 2014-05...
Page 215: Accessories For (Electronic) Engine Governor / Control System
(3). Clean connector housings, connector sock- et housings (1) and all contacts with iso- propyl alcohol. When connectors, sockets and all contacts are dry: Fit connectors and check governor connections (→ Page 218). MW15406/17E 2014-05 | Task Description | 215...
Page 216: Engine Monitoring Unit And Connectors - Cleaning
Clean connector housings, connector sock- et housings (1) and all contacts with iso- propyl alcohol. When connectors, sockets and all contacts are dry: Fit connectors and check plug con- nections on EMU (→ Page 219). 216 | Task Description | MW15406/17E 2014-05...
Page 217: Start Interlock Limit Switch – Check
(2) is not distort- • Loosen switch housing (1) and fit it with screws in a position providing that the switch (2) is ON. • If this is not feasible, contact Service. MW15406/17E 2014-05 | Task Description | 217...
Page 218: Ecu – Plug Connections Check
Tighten loose bayonet couplings (2) with connector pliers (3) by turning them clock- wise until they latch into place. Make sure that unassigned sockets are closed off with cover caps. If bayonet couplings are defective, contact Service. 218 | Task Description | MW15406/17E 2014-05...
Page 219 Tighten loose bayonet couplings (2) with connector pliers (3) by turning them clock- wise until they latch into place. Make sure that unassigned sockets are closed off with cover caps. If bayonet couplings are defective, contact Service. MW15406/17E 2014-05 | Task Description | 219...
Page 220: Engine Governor – Removal And Installation
Use connector pliers (2) to disengage the bayonet union nuts (4) of the connec- tors (3) by turning them counterclockwise. Remove all connectors. Close connector sockets with appropriate covering caps (1). 220 | Task Description | MW15406/17E 2014-05...
Page 221 Installing engine governor on engine Install in reverse order. Ensure correct assignment of plugs and sockets. Use connector pliers to turn the bayonet union nuts of the connectors clockwise until they latch into place. MW15406/17E 2014-05 | Task Description | 221...
Page 222 Remove heavy soiling from housing surface with isopropyl alcohol. Cleaning connectors on LOP Remove dirt from connector and socket surfaces using isopropyl alcohol. Check legibility of cable labels. Clean or replace illegible labels. 222 | Task Description | MW15406/17E 2014-05...
Page 223: Lop – Visual Inspection
(3) is held firmly in place in the socket. If this is not the case, press the securing el- ements (1) concerned in the direction of the arrow until they engage noticeably. MW15406/17E 2014-05 | Task Description | 223...
Page 224 Connect battery in accordance with battery manufacturer's instructions. Switch master power switch to ON. Switch on engine control system. Hold down LAMP TEST pushbutton: Result: Indicators and controls light up. Have damaged lamps immediately replaced by Service. 224 | Task Description | MW15406/17E 2014-05...
Page 225: Lop – Test Procedures
Engine Control Unit. • LOCAL OPERATION pushbutton (1) is illuminated at basic brightness: Remote mode active. Press LOCAL OPERATION pushbutton (1) again. Result: LOCAL OPERATION pushbutton (1) is illuminated brightly (Local mode is active);. MW15406/17E 2014-05 | Task Description | 225...
Page 226 Press ALARM ACKNOWLEDGE pushbutton (1). Result: Audible and visual alarm signaling stops. Press ALARM ACKNOWLEDGE pushbutton (1) again. Result: Power supply to Engine Control Unit is pro- vided. On engines with emergency air-shutoff flaps: Open flaps. 226 | Task Description | MW15406/17E 2014-05...
Page 227 Alarm: Measured value exceeds 2nd maximum limit value High Temperature ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO power – Net 3046-7 Interface Data Module International Maritime Organization MW15406/17E 2014-05 | Appendix A | 227...
Page 228 Synchronized Self-Shifting (clutch) STBD Starboard T-xyz Temperature-xyz Temperature measuring point xyz Transmitter Deviation Alarm: Deviation in transmitter values Unterer Totpunkt Bottom Dead Center (BDC) Voith Schneider Voith Schneider drive Water jet Water jet drive 228 | Appendix A | MW15406/17E 2014-05...
Page 229 Abbrevia- Meaning Explanation tion Werkzeugkatalog Tool Catalog (TC) Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for signals from the ADEC engine governor MW15406/17E 2014-05 | Appendix A | 229...
Page 230: 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 231: Special Tools
Used in: 7.6.2 Injection pump – Removal and installation (→ Page 160) Box wrench bit, 17 mm Part No.: F30030450 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 155) MW15406/17E 2014-05 | Appendix B | 231...
Page 232 Double-head box wrench Part No.: F30011450 Qty.: Used in: 7.7.2 HP fuel line – Pressure pipe neck replacement (→ Page 164) Qty.: Used in: 7.7.3 Injector – Removal and installation (→ Page 166) 232 | Appendix B | MW15406/17E 2014-05...
Page 233 Used in: 7.19.2 Battery-charging generator drive – Drive belt re- placement (→ Page 211) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.16.7 Engine coolant – Sample extraction and analysis (→ Page 205) MW15406/17E 2014-05 | Appendix B | 233...
Page 234 7.7.3 Injector – Removal and installation (→ Page 166) Puller Part No.: 3555890163/00 Qty.: Used in: 7.7.3 Injector – Removal and installation (→ Page 166) Ratchet Part No.: F30006212 Qty.: Used in: 7.2.1 Engine ‒ Barring manually (→ Page 146) 234 | Appendix B | MW15406/17E 2014-05...
Page 235 Spider patch spanner Part No.: F30027425 Qty.: Used in: 7.7.2 HP fuel line – Pressure pipe neck replacement (→ Page 164) Qty.: Used in: 7.7.3 Injector – Removal and installation (→ Page 166) MW15406/17E 2014-05 | Appendix B | 235...
Page 236 Spider patch spanner, AF22 Part No.: F30027425 Qty.: Used in: 7.6.2 Injection pump – Removal and installation (→ Page 160) Steam jet cleaner Part No.: Qty.: Used in: 4.14 Plant – Cleaning (→ Page 119) 236 | Appendix B | MW15406/17E 2014-05...
Page 237 7.7.2 HP fuel line – Pressure pipe neck replacement (→ Page 164) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.4.1 Crankcase ventilation – Oil separator element re- placement, diaphragm check and replacement (→ Page 152) MW15406/17E 2014-05 | Appendix B | 237...
Page 238 Vernier caliper, 300 mm Part No.: Y20000275 Qty.: Used in: 7.20.1 Engine mounting – Checking condition of resil- ient mounts (→ Page 212) 238 | Appendix B | MW15406/17E 2014-05...
Page 239 – Sample extraction and analysis 205 – Drive belt Engine coolant – Level check 200 – Replacement 211 Engine driving end – Definition 27 Engine emergency stop – At BlueLine automation system (control stand) 111 MW15406/17E 2014-05 | Appendix B | 239...
Page 240 Resilient mounts – Pressure pipe neck replacement 164 – Condition check 212 HT coolant pump – Relief bore check 204 Safety notices, standards 17 Injection pump – Removal – Installation 160 – Replacement 159 240 | Appendix B | MW15406/17E 2014-05...
Page 241 Stopping the engine from LOP (without Blue Line automa- tion system) 115 Transport 10 Troubleshooting 130 Universal shaft – Greasing 213 Valve clearance – Adjustment 155 – Check 155 Venting points 195 Waterjet – Flushing – From LOP (option) 114 MW15406/17E 2014-05 | Appendix B | 241...

MTU MW15406/17E Operating Instructions Manual

1 Safety

2 General Information

3 Technical Data

4 Operation

5 Maintenance

6 Troubleshooting

7 Task Description

8 Appendix A

9 Appendix B

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