MTU 8V2000Mx4x, 10V2000Mx4 Operating Instructions Manual

Operating Instructions

Diesel engine

8V2000Mx4x
10V2000Mx4

MS150060/04E

Engine model kW/cyl. Application group

8V2000M84L 112 kW/cyl. 1Continuous operation, variable, medium load

factors

8V2000M94 116.5 kW/cyl. 1DS, continuous operation, variable, low load

factors

10V2000M94 119.3 kW/cyl. 1DS, continuous operation, variable, low load

factors

Table 1: Applicability

© 2016 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ­ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro­filming and storage or processing in electronic systems including databases and online services.

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.

Table of Contents

1 Safety

1.1 Important provisions for all products 5

1.2 Personnel and organizational requirements 6

1.3 Correct use for all products 7

1.4 Safety regulations for startup and operation 8

1.5 Safety precautions when working on the
engine 10

1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13

1.7 Standards for safety notices in the text 15

2 Transport

2.1 Transportation 16

2.2 Lifting requirements 17

2.3 Transport locking device for resilient
mounts 18

3 General Information

3.1 Engine side and cylinder designations 20

3.2 Product description 21

3.3 Engine – Overview 27

3.4 Sensors and actuators – Overview 29

4 Technical Data

4.1 Engine data 8V2000M84L – European
Recreational Craft Directive 34

4.2 Engine data 8V2000M94 37

4.3 Engine data 10V2000M94 40

4.4 Firing order 43

4.5 Engine – Main dimensions 44

5 Operation

5.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 45

5.2 Engine – Putting into operation after
scheduled out-of-service-period 46

5.3 Tasks after extended out-of-service periods
(>3 weeks) 47

5.4 Checks prior to start-up 48

5.5 Fuel treatment system – Putting into
operation 49

5.6 Operational checks 51

5.7 Fuel treatment system – Switching on 52

5.8 Starting the engine 53

5.9 Engine – Shutdown 54

5.10 Emergency engine shutdown 55

5.11 After stopping the engine 56

5.12 Fuel treatment system – Shutdown 57

5.13 Plant – Cleaning 58

6 Maintenance

6.1 Maintenance task reference table [QL1] 59

7 Troubleshooting

7.1 Control cabinet of fuel treatment system –
Troubleshooting 60

7.2 Troubleshooting 61

8 Task Description

8.1 SOLAS 64

8.1.1 SOLAS shielding – Installation as per MTN
5233 64

8.1.2 SOLAS shielding – Installation 65

8.1.3 Installation locations for SOLAS shielding 66

8.2 Engine 71

8.2.1 Engine – Barring manually 71

8.2.2 Engine – Cranking on starting system 72

8.3 Cylinder Liner 73

8.3.1 Cylinder liner – Endoscopic examination 73

8.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 75

8.4 Crankcase Breather 77

8.4.1 Crankcase breather – Cleaning oil pre­separator element 77

8.4.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 78

8.5 Valve Drive 80

8.5.1 Valve clearance – Check and adjustment 80

8.5.2 Cylinder head cover – Removal and
installation 83

8.6 Injector 84

8.6.1 Injector – Replacement 84

8.6.2 Injector – Removal and installation 85

8.7 Fuel System 87

8.7.1 Fuel system – Venting 87

8.8 Fuel Filter 88

8.8.1 Fuel filter – Replacement 88

8.8.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 91

8.8.3 Fuel prefilter – Draining 92

8.8.4 Fuel prefilter – Flushing 94

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8.8.5 Fuel prefilter – Filter element replacement 96

8.9 Charge-Air Cooling 98

8.9.1 Charge-air cooler – Checking condensate drain
line for coolant discharge and obstruction 98

8.10 Air Filter 99

8.10.1 Air filter – Replacement 99

8.10.2 Air filter – Removal and installation 100

8.11 Air Intake 101

8.11.1 Service indicator – Signal ring position check 101

8.12 Starting Equipment 102

8.12.1 Starter – Condition check 102

8.13 Lube Oil System, Lube Oil Circuit 103

8.13.1 Engine oil – Level check 103

8.13.2 Engine oil – Change 104

8.14 Oil Filtration / Cooling 105

8.14.1 Engine oil filter – Replacement 105

8.14.2 Centrifugal oil filter and filter sleeve –
Cleaning and replacement 107

8.15 Coolant Circuit, General, High-Temperature
Circuit 110

8.15.1 Drain and venting points 110

8.15.2 Engine coolant level – Check 115

8.15.3 Engine coolant – Change 116

8.15.4 Engine coolant – Draining 117

8.15.5 Engine coolant – Filling 118

8.15.6 HT coolant pump – Relief bore check 119

8.15.7 Engine coolant sample extraction and analysis 120

8.15.8 Coolant filter – Replacement 121

8.16 Raw Water Pump with Connections 122

8.16.1 Raw water pump – Relief bore check 122

8.17 Belt Drive 123

8.17.1 Drive belt – Condition check 123

8.18 Battery-Charging Generator 124

8.18.1 Battery-charging generator drive – Drive belt
replacement 124

8.19 Fuel Supply System 125

8.19.1 Water drain valve – Check 125

8.19.2 Differential pressure gauge – Check 126

8.19.3 Water level probe (3-in-1 rod electrode) –
Check 127

8.19.4 Pump capacity – Check 128

8.19.5 Coalescer filter element – Replacement 129

8.20 Wiring (General) for Engine/Gearbox/Unit 131

8.20.1 Engine cabling – Check 131

8.21 Accessories for (Electronic) Engine
Governor / Control System 132

8.21.1 Engine governor and connector – Cleaning 132

8.21.2 EMU and connectors – Cleaning 133

8.21.3 Engine governor plug connections – Check 134

8.21.4 Engine Monitoring Unit EMU 7 – Plug
connection check 135

8.21.5 Interface module EIM plug connections –
Check 136

8.21.6 Engine Control Unit – Self-test 137

8.21.7 Engine governor ECU 7 – Removal and
installation 138

8.21.8 Engine Monitoring Unit – Removal and
installation 139

8.21.9 Engine Interface Module EIM – Removal and
installation 140

8.21.10 Diagnostic features on EIM 141

9 Appendix A

9.1 Abbreviations 144

9.2 MTU Contact/Service Partners 146

10 Appendix B

10.1 Special Tools 147

10.2 Index 154

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1 Safety

1.1 Important provisions for all products

Nameplate

The product is identified by nameplate, model designation or serial number and must match with the infor­mation on the title page of this manual.

Nameplate, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi­cations.

General information

This product may pose a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Noncompliance with the safety instructions and warning notices

Emission regulations and emission labels

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional compo­nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex­changed or repaired if the components used for this purpose are approved by the manufacturer.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu­lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera­tional life.

Engines used exclusively in land-based, military applications other than by US government agencies are ex­cepted from this proviso.

Please note the following when replacing components with emission labels:

• The relevant emission labels must be affixed to the spare part.

• Do not transfer the emission labels from the replaced part to the spare part.

• Remove the emission labels from the replaced part and destroy them.

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1.2 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa­tion, or transportation.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.

Personnel must receive instruction on product handling and maintenance based on this manual with a spe­cial emphasis on safety requirements and warnings.

This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.

Personnel requirements

All work on the product shall be carried out by trained and qualified personnel only:

• Training at the Training Center of the manufacturer

• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as­sembly, installation, and transport in writing.

Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip­tions of the individual activities.

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1.3 Correct use for all products

Correct use

The product is intended for use in accordance with its contractually-defined purpose as described in the rele­vant technical documents only.

Intended use entails operation:

• Within the permissible operating parameters in accordance with the (→ Technical data)

• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)

• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva­tion Specifications of the manufacturer)

• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con­tact/Service partner)

• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in­cluding engine control/parameters)

• In compliance with all safety regulations and in adherence with all warning notices in this manual

• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product

• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques

• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re­pair

• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul

The product shall not be operated in explosive atmospheres unless the necessary approval has been grant­ed.

Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.

The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:

• For drive systems: http://www.mtu-online.com

• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversions

Unauthorized changes to the product represent a contravention of its intended use and compromise safety.

Changes or modifications shall only be considered to comply with the intended use when expressly author­ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor­ized changes or modifications.

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1.4 Safety regulations for startup and operation

Safety regulations for startup

Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.

Whenever the product is subsequently taken into operation ensure that:

• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.

• All maintenance and repair work has been completed.

• All loose parts have been removed from rotating machine components.

• All safety equipment is in place.

• No persons wearing pacemakers or any other technical body aids are present.

• The service room is adequately ventilated.

• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.

• Protect battery terminals, generator terminals or cables against accidental contact.

• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).

Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.

Smoking is prohibited in the area of the product.

Safety regulations during operation

The operator must be familiar with the control and display elements.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.

The following steps must be taken if a malfunction of the system is detected or reported by the system:

• Inform supervisor(s) in charge.

• Analyze the message.

• Respond by taking any necessary emergency action, e.g. emergency stop.

Operation

Do not remain in the operating room when the product is running for any longer than absolutely necessary.

Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.

Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:

• Wear ear protection.

• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.

Operation of electrical equipment

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.

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Follow the applicable warning instructions pertaining to such devices.

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1.5 Safety precautions when working on the engine

Safety regulations prior to 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).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita­ble collecting vessels of adequate capacity to catch fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.

Never carry out maintenance and repair work with the product in operation, unless:

• It is expressly permitted to do so following a written procedure.

• The product is running in the low load range and only for as long as absolutely necessary.

Lock-out the product to preclude undesired starting, e.g.

• Start interlock

• Key switch

• With hydraulic starting system: shut off supply line.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers.

Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start­ers are fitted.

Disconnect the control equipment from the product.

Use the recommended special tools or suitable equivalents when instructed to do so.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.

The following applies to starters with copper-beryllium alloy pinions:

• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.

• Observe the safety data sheet.

Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product.

Release residual pressure before removing or replacing a component in the supply line. To depressurize pres­surized lines, shut off the lines first, then release the residual pressure.

Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem­bly.

Carry out work only on assemblies or plants which are properly secured.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.

Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en­gines or components that are held in place by lifting equipment.

Keep fuel injection lines and connections clean.

Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

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Never bend lines and avoid damaging lines, particularly the fuel lines.

Ensure that all retainers and dampers are installed correctly.

Ensure that O-rings are not installed in a slanted/twisted condition.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.

Note cooling time for components which are heated for installation or removal (risk of burning).

Pay particular attention to cleanliness at all times.

Remove any condensate from components which were chilled before assembly. If necessary, coat the com­ponents with a suitable corrosion inhibitor.

Safety regulations following maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.

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 removed
(especially the barring gear).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Ensure that the grounding system is properly connected.

Welding work

Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery cables or actuate the battery isolating switch.

• Separate the electrical ground of electronic equipment from the ground of the unit.

No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv­ably damage the electrical system.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.

Observe the max. permissible force-on pressure specified for the jig/fixture.

Do not attempt to bend or exert force on H.P. lines.

Before starting work, pay attention to the following:

• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.

• During the installation procedure, screw on device with pushed-in plunger.

• During the removal procedure, screw on device with retracted plunger.

For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.

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During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the
component being pressed.

Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow battery acids to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.

Do not place objects on the battery.

Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in­jury through the sudden discharge of acid or bursting of the battery body.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and 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.

Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable straps to secure cables.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to a functional testing on completion of all repair work. Check cor­rect execution of the emergency stop function in particular.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil if necessary.

Work with laser devices

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in­structions in the manufacturer's user manual when working with laser equipment.

Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).

Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur­ing safe operation.

Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem­perature of 20 °C.

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1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials

Fire prevention

Flames, naked light and smoking are prohibited.

When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.

Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.

Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.

When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.

Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its
handling.

Noise

Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan­ger are drowned.

Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal

Dispose of used fluids, lubricants and filters in accordance with local regulations.

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy­cled.

Auxiliary materials

Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.

Take special care when using hot, chilled or caustic materials.

Used oil

Used oil contains combustion residues that are harmful to health.

Wear protective gloves!

Wash relevant areas after contact with used oil.

Lead

• Adopt suitable measures to avoid the formation of lead dust.

• Switch on extraction system.

• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale

lead vapors.

• Wash relevant areas after contact with lead or lead-containing substances.

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Compressed air

Observe special safety precautions when working with compressed air:

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con­tainers, risks causing an explosion.

• Wear goggles when blowing dirt off workpieces or blowing away swarf.

• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.

• Pay special attention to the pressure in the compressed air system or pressure vessel.

• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.

• Hose couplings and connections must be securely attached.

• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).

• Release residual pressure before removing or replacing pneumatic equipment in the supply line. To de­pressurize compressed-air lines, shut off the lines first, then release the residual pressure.

• Carry out leak test in accordance with the specifications.

Painting

• Observe the relevant safety data sheet for all materials.

• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.

• There must be no naked flames in the vicinity.

• No smoking.

• Observe fire-prevention regulations.

• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen

• Observe the relevant safety data sheet for all materials.

• Work with liquid nitrogen may be carried out only by qualified personnel.

• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and safety goggles.

• Make sure that working area is well ventilated.

• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkaline solutions/urea (AdBlue®, DEF)

• Observe the relevant safety data sheet for all materials.

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth­ing.

• Do not inhale vapors.

• If urea solution is swallowed, rinse out mouth and drink plenty of water.

• Remove any wet clothing immediately.

• After contact skin, wash body areas with plenty of water.

• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.

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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!

• Remedial action.

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!

• Remedial action.

NOTICE

In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!

• Remedial action.

• Additional product information.

Warning notices

1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera­tion, maintenance, repair, assembly, installation, or transportation.

2. 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.

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2 Transport

2.1 Transportation

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Crossbeam

T80091731 1

Crossbeam

T80092210 1

DANGER

Suspended load.

Danger to life!

• Use appropriate lifting devices and appliances.

• Never stand beneath a suspended load.

Transportation

1. Prior to transportation, install the transport locking device for the resilient mounts (→ Page 18).

2. Use lifting eyes provided for transporting the engine (→ Page 17).

3. Only use suitable transportation and lifting equipment.

4. The engine must only be transported in installation position (→ Page 17).

5. Remove any loose parts on engine.

6. Always raise/lower engine slowly. The lifting ropes or chains must not rub against the engine or its compo­nents during the lifting procedure. Readjust lifting equipment as necessary.

7. For special packaging with aluminum foil: Attach engine to lifting eyes of bearing pedestal or transport with
means of transportation device suitable for the load (forklift truck).

8. Secure engine against tilting during transportation. Secure such as to preclude slipping and tipping when
driving up or down inclines and ramps.

Placement after transportation

1. Only set down engine on a firm, level surface.

2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.

3. Never set engine down on oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

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2.2 Lifting requirements

Lifting requirements

DANGER

Suspended load.

Danger to life!

• Use appropriate lifting devices and appliances.

• Never stand beneath a suspended load.

1 Max. admissible diagonal

pull 35°

2 Max. admissible diagonal

pull 10°

3 Center of gravity

Take note of the engine center of gravity

For details on engine center of gravity, see Installation/Arrangement drawings.

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2.3 Transport locking device for resilient mounts

Transport locking device

Note: The locking device protects the resilient mounts from shocks and vibration damage during engine transport.

1. The transport locking device must be removed before initial operation of the engine.

2. Prior to every engine transport, the transport locking device must be installed according to the instructions.

Removing transport locking de­vice - version A

1. On all bearing outer races of the resilient
mount (1) release nut (4) and unscrew and
remove locking screw (2) together with wash­ers (3) and nut (4) (4 x per bearing element).

2. The removed parts (2, 3, 4) of the transport
locking device must be stored carefully for
possible reuse.

Installing transport locking de­vice - version A

1. Screw in locking screw (2) together with
washers (3) and nut (4) (4 x per bearing ele­ment) until screw head with washers is flush
against the bearing element.

2. Lock locking screw (2) with nut (4).

3. Mark the engine as "Fitted with transporta­tion locking device".

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Removing transport locking de­vice - version B

1. On all bearing outer races of the resilient
mount (1) release nuts (3, 4) and unscrew
and remove together with locking screw (2)
(4 x per bearing element).

2. The removed parts (2, 3, 4) of the transport
locking device must be stored carefully for
possible reuse.

Installing transport locking de­vice - version B

1. Screw in locking screw (2) together with nut
(3) and nut (4) (4 x per bearing element).

2. Place nut (3) in position on resilient mount
(1).

3. Lock locking screw (2) with nut (4).

4. Mark the engine as "Fitted with transporta­tion locking device".

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3 General Information

3.1 Engine side and cylinder designations

1 Left engine side (A-side)
2 Engine free end in accord-

ance with DIN ISO 1204
(KGS = Kupplungsgegen­seite)

3 Right engine side (B-side)
4 Engine driving end in ac-

cordance with
DIN ISO 1204 (KS = Kup­plungsseite)

Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left­hand side of the engine (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).

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3.2 Product description

Description of the engine

Engine

The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection, 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.

Injection pressures up to 1800 bar ensure optimum fuel injection and combustion conditions.

Turbocharging system

The charging system comprises charge-air system, exhaust system and sequential turbocharging.

The exhaust system is equipped with triple-walled, water-cooled exhaust lines.

The triple-walled design permits

• low surface temperature,

• reduced thermal load,

• absolute gas-tightness

Lube oil system

Wet-sump forced-feed lubrication system

Components supplied with oil:

• Bearings

• Piston cooling

• Control and actuating elements of the sequential turbocharging system

Cooling system

• Two separate circuits:

– Engine coolant
– Raw water

• Coolant cooling by raw water-cooled plate-core heat exchanger

• Thermostat-controlled coolant system

• Coolant-cooled / preheated charge-air

• Coolant-cooled fuel return

Electronic system

Electronic control and monitoring system with integrated safety and test system with interfaces to the Re­mote Control System (RCS) and to the Monitoring and Control System (MCS).

Connection box EIM (Engine Interface Module)

The Engine Interface Module (EIM) is the central connection box on the engine. It covers the entire minimum
scope of a Series marine engine. It has no controls or parts requiring maintenance.

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Functions:

• Starter control (start repetition, tooth alignment, starter protection)

• Generator monitoring

• Open bus interface to the plant (SAE J1939)

• Emergency stop function with line break monitoring

• Redundant power supply

• Optional control of emergency-air shutoff flaps

• Key switch logic

• 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. The first part is integrated in the engine wiring harness via the
62-pole Tyco connector X52. The second part is formed by those signals involving a higher current. Such
signals are routed out via M threaded pins and are also integrated in the engine wiring harness.

Functions

• ECU supply

• EMU supply

• Plant signals (ECU7 connector X1)

• Bus interface (2x MCS5 CAN)

• CAN dialog output (1x MCS5 CAN)

• ECU and EMU emergency stop

• Electric starter

• Terminal 45 starter A/B (engaged)

• Pneumatic starter

• Starting air pressure valve

• Starting air pressure sensor

• Barring device (Barring Gear 1 and 2)

• Generator (with exciter control)

• Optional emergency-air shutoff flaps

• Activation of SDAF 1+2

• Feedback from SDAF 1+2

Electronic engine control unit (ECU)

Closed-loop control:

• Engine speed

• High-pressure fuel

Valve gear:

• Injection (fuel pressure, injection timing, injection duration, operating status)

• Sequential turbocharging (cutting-in and out) with secondary turbocharger

• Engine protection with multi-stage safety systems:
– Power reduction
– Power limitation
– Emergency stop

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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

• Fuel pressure after filter

Monitoring in engine room

Engine control and monitoring unit (LOP)

Functions:

• Engine speed, oil pressure and coolant temperature are monitored and displayed

• Integrated safety system

• Integrated Test System

• Redundant CAN bus interface to governor and higher-level control and monitoring system

• 24 V DC supply

SOLAS – Fire safety requirements

Special connections

In case of leakage, the connection types shown above are spray-protected even without a cover and have
been confirmed compliant with SOLAS by GL and DNV.

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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).

In case of a loose thread or a faulty sealing ring (1), the liquid first has to pass the thread.

The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under pres­sure.

HP line between injector and HP accumulator

1 Support ring
2 V-ring
3 Thrust ring

4 HP line
5 Thrust screw
6 Support ring

7 Thrust ring
8 V-ring
9 Union nut

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HP line between distributor and HP accumulator

1 Union nut
2 O-ring
3 Thrust ring

4 Thrust screw
5 O-ring
6 O-ring

7 Thrust ring
8 Pressure pipe
9 Jacket pipe

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HP line between distributor and HP accumulator

1 Jacket pipe
2 O-ring
3 O-ring
4 Thrust ring

5 O-ring
6 Thrust screw
7 Thrust ring
8 O-ring

9 HP line

10 Pressure pipe

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.

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3.3 Engine – Overview

View on free end

Illustrations are also applicable to 10V.

1 Raw water pump
2 Auxiliary PTOs
3 Coolant pump

4 HP fuel pump
5 Oil filler neck
6 Cylinder head

KGS Free end

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View on driving end

1 Centrifugal oil filter
2 Raw water coolant pipework
3 Lube oil filter
4 Coolant filter
5 Lube oil cooler
6 Engine governor
7 Charge-air cooler

8 Air filter (air intake)

9 Air supply
10 Exhaust turbocharger
11 Gear train
12 Mounting/support
13 Starter
14 Oil pan

15 Exhaust pipework
16 Battery-charging generator
17 Plate-core heat exchanger
18 Coolant distribution housing

with integrated expansion
tank

KS Driving end

Engine model designation

Key to the engine model designation 8V/10V2000Mxyz

8/10 Number of cylinders

V Cylinder arrangement: V engine

2000 Series

M Application

x Application segment (4, 5, 6, 7, 9)

y Design status (0, 1, 2, ...)

z Special characteristics

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3.4 Sensors and actuators – Overview

Top view

Deviations from illustrations are insignificant.

Also valid for 8V engines.

No. Description Monitoring of

1 B10 Charge-air pressure

2 B9 Charge-air temperature

3 B7 Lube oil temperature

4 B3 Intake air temperature

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Engine free end

No. Description Monitoring of

1 B34 Fuel line pressure after filter

2 B5.3 (optional) Lube oil pressure before filter

3 B5.1 Lube oil pressure

4 B5.2 (optional) Lube oil pressure

5 F33 Coolant level

6 B21 (optional) Raw water pressure

7 B6.2 (optional) Coolant pressure

8 B6.1 Coolant temperature

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Engine driving end

No. Description Monitoring of

1 B4.21 Exhaust gas temperature, A side

2 B4.22 Exhaust temperature, B-side

3 B1 Camshaft speed

4 B13 Crankshaft speed

5 B13.2 (optional) Crankshaft speed

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Engine right side

No. Description Monitoring of

1 B44 Turbocharger speed

2 B33 Fuel temperature

3 B48 Fuel pressure in Common Rail

4 B16 (optional) Coolant pressure

5 F46 Leak fuel level

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Engine left side

No. Description Monitoring of

1 Y41 Solenoid valvesWastegate

2 Y27 Solenoid valves for turbocharger control

3 B54 (optional) Oil replenishment pump pressure

System sensors

The sensors are fitted on the off-engine system.

Description Monitoring of

B19 Starting-air pressure

B70 Water level in fuel prefilter

B41 Exhaust backpressure

S37 Start interlock, switching status

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4 Technical Data

4.1 Engine data 8V2000M84L – European Recreational Craft
Directive

Explanation

Index (I) Meaning

DL Ref. value: Continuous power

BL Ref. value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

L Limit up to which the engine can be operated without changes such as load setting

N Not yet defined value

- Not applicable

X Applicable

Reference conditions

Engine model 8V2000

M84L

Application group 1D

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)

Number of cylinders 8

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 895

General conditions (for maximum power)

Number of cylinders 8

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

Model related data (basic design)

Number of cylinders 8

Cylinder arrangement: V angle Degrees

(°)

90

Bore mm 135

Stroke mm 156

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Number of cylinders 8

Cylinder displacement Liters 2.23

Total displacement Liters 17.84

Number of inlet valves per cylinder 2

Number of exhaust valves per cylinder 2

Raw water circuit (open circuit)

Number of cylinders 8

Raw water pump: Inlet pressure, min. L bar -0.4

Raw water pump: inlet pressure, max. L bar +0.5

Pressure loss in engine-external raw water system, max. L bar 1.2

Lube oil system

Number of cylinders 8

Lube oil operating temperature before engine, from R °C 74

Lube-oil operating temperature before engine, to R °C 83

Lube oil operating pressure before engine, from R bar 9.0

Lube oil operating pressure before engine, to R bar 10.0

Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.5

Fuel system

Number of cylinders 8

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. A liters/min 4.8

General operating data

Number of cylinders 8

Firing speed, from R rpm 100

Firing speed, to R rpm 120

Starter (electric)

Number of cylinders 8

Rated starter voltage (standard design) R V= 24

Inclinations - standard oil system (reference: waterline)

Number of cylinders 8

Longitudinal inclination, continuous max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

15

Longitudinal inclination, temporary max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

20

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Number of cylinders 8

Longitudinal inclination, continuous max. driving end up (option: max. operat­ing inclinations)

L Degrees

(°)

0

Longitudinal inclination, temporary max., driving end up (option: max. operat­ing inclinations)

L Degrees

(°)

10

Transverse inclination, continuous max. (option: max. operating inclinations) L Degrees

(°)

22.5

Transverse inclination, temporary max. (option: max. operating inclinations) L Degrees

(°)

40

Capacities

Number of cylinders 8

Engine coolant, engine side (with cooling system) R Liters 100

Engine oil capacity, initial filling (standard oil system) (option: max. operating
inclinations)

R Liters 73

Oil change quantity, max. (standard oil system) (option: max. operating inclina­tions)

R Liters 67

Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op­erating inclinations)

L Liters 54

Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max.
operating inclinations)

L Liters 62

Weights / main dimensions

Number of cylinders 8

Engine dry weight (with attached standard accessories, without coupling) R kg 1970

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4.2 Engine data 8V2000M94

Explanation

Index (I) Meaning

DL Ref. value: Continuous power

BL Ref. value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

L Limit up to which the engine can be operated without changes such as load setting

N Not yet defined value

- Not applicable

X Applicable

Reference conditions

Engine model 8V2000

M94

Application group 1DS

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)

Number of cylinders 8

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 932

General conditions (for maximum power)

Number of cylinders 8

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

Model related data (basic design)

Number of cylinders 8

Cylinder arrangement: V angle Degrees

(°)

90

Bore mm 135

Stroke mm 156

Cylinder displacement Liters 2.23

Total displacement Liters 17.84

Number of inlet valves per cylinder 2

Number of exhaust valves per cylinder 2

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Raw water circuit (open circuit)

Number of cylinders 8

Raw water pump: Inlet pressure, min. L bar -0.4

Raw water pump: inlet pressure, max. L bar +0.5

Pressure loss in engine-external raw water system, max. L bar 1.2

Lube oil system

Number of cylinders 8

Lube oil operating temperature before engine, from R °C 74

Lube oil operating temperature before engine, to R °C 83

Lube oil operating pressure before engine, from R bar 9.0

Lube oil operating pressure before engine, to R bar 10.0

Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.5

Fuel system

Number of cylinders 8

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. R liters/min 5.2

General operating data

Number of cylinders 8

Firing speed, from R rpm 100

Firing speed, to R rpm 120

Starter (electric)

Number of cylinders 8

Rated starter voltage (standard design) R V= 24

Inclinations - standard oil system (reference: waterline)

Number of cylinders 8

Longitudinal inclination, continuous max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

15

Longitudinal inclination, temporary max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

20

Longitudinal inclination, continuous max. driving end up (option: max. operat­ing inclinations)

L Degrees

(°)

0

Longitudinal inclination, temporary max., driving end up (option: max. operat­ing inclinations)

L Degrees

(°)

10

Transverse inclination, continuous max. (option: max. operating inclinations) L Degrees

(°)

22.5

Transverse inclination, temporary max. (option: max. operating inclinations) L Degrees

(°)

40

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Capacities

Number of cylinders 8

Engine coolant, engine side (with cooling system) R Liters 100

Engine oil capacity, initial filling (standard oil system) (option: max. operating
inclinations)

R Liters 73

Oil change quantity, max. (standard oil system) (option: max. operating inclina­tions)

R Liters 67

Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op­erating inclinations)

L Liters 54

Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max.
operating inclinations)

L Liters 62

Weights / main dimensions

Number of cylinders 8

Engine dry weight (with attached standard accessories, without coupling) R kg 1970

Acoustics

Number of cylinders 8

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1 m dis­tance, ISO 6798, +3 dB(A) tolerance)

R dB(A) 106

Engine surface noise with attenuated intake noise (filter) - BL (free-field sound
power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)

R dB(A) 106

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4.3 Engine data 10V2000M94

Explanation

Index (I) Meaning

DL Ref. value: Continuous power

BL Ref. value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

L Limit up to which the engine can be operated without changes such as load setting

N Not yet defined value

- Not applicable

X Applicable

Reference conditions

Engine model 10V2000

M94

Application group 1DS

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)

Number of cylinders 10

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 1193

General conditions (for maximum power)

Number of cylinders 10

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

Model related data (basic design)

Number of cylinders 10

Cylinder arrangement: V angle Degrees

(°)

90

Bore mm 135

Stroke mm 156

Cylinder displacement Liters 2.23

Total displacement Liters 22.30

Number of inlet valves per cylinder 2

Number of exhaust valves per cylinder 2

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Raw water circuit (open circuit)

Number of cylinders 10

Raw water pump: Inlet pressure, min. L bar -0.4

Raw water pump: inlet pressure, max. L bar +0.5

Pressure loss in engine-external raw water system, max. L bar 1.2

Lube oil system

Number of cylinders 10

Lube oil operating temperature before engine, from R °C 75

Lube oil operating temperature before engine, to R °C 83

Lube oil operating pressure before engine, from R bar 8.0

Lube oil operating pressure before engine, to R bar 9.0

Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.5

Fuel system

Number of cylinders 10

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. R liters/min 5.9

General operating data

Number of cylinders 10

Firing speed, from R rpm 100

Firing speed, to R rpm 120

Starter (electric)

Number of cylinders 10

Rated starter voltage (standard design) R V= 24

Inclinations - standard oil system (reference: waterline)

Number of cylinders 10

Longitudinal inclination, continuous max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

15

Longitudinal inclination, temporary max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

20

Longitudinal inclination, continuous max. driving end up (option: max. operat­ing inclinations)

L Degrees

(°)

5

Longitudinal inclination, temporary max., driving end up (option: max. operat­ing inclinations)

L Degrees

(°)

10

Transverse inclination, continuous max. (option: max. operating inclinations) L Degrees

(°)

22.5

Transverse inclination, temporary max. (option: max. operating inclinations) L Degrees

(°)

35

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Capacities

Number of cylinders 10

Engine coolant, engine side (with cooling system) R Liters 114

Engine oil capacity, initial filling (standard oil system) (option: max. operating
inclinations)

R Liters 81

Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op­erating inclinations)

L Liters 64

Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max.
operating inclinations)

L Liters 70

Weights / main dimensions

Number of cylinders 10

Engine dry weight (with attached standard accessories, without coupling) R kg 2230

Acoustics

Number of cylinders 10

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1 m dis­tance, ISO 6798, +3 dB(A) tolerance)

R dB(A) 106

Engine surface noise with attenuated intake noise (filter) - BL (free-field sound
power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)

R dB(A) 106

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4.4 Firing order

Firing order

8V A1-B4-A4-A2-B3-A3-B2-B1

10 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1

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4.5 Engine – Main dimensions

Main dimensions

Engine model Length (A) Width (B) Height (C)

8V2000M84L approx. 1693 mm approx. 1130 mm approx. 1200 mm

8V2000M94 approx. 1693 mm approx. 1130 mm approx. 1200 mm

10V2000M94 approx. 1888 mm approx. 1130 mm approx. 1237 mm

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5 Operation

5.1 Putting the engine into operation after extended out-of-service
periods (>3 months)

Preconditions

☑ Engine is stopped and starting disabled.

☑ MTU Preservation and Represervation Instructions (A001070/..) available.

Putting the engine into operation (out-of-service period > 3 months)

Item Action

Engine Depreserve (→ MTU Preservation and Represervation Instructions

A001070/..).

Lube oil system Check engine oil level (→ Page 103).

Fuel prefilter Fill with fuel (→ Page 96).

Fuel prefilter, pressure gage Align adjustable pointer with position of pressure indicator (→ Page 91).

Fuel system Vent (→ Page 87).

Raw water pump (if located
above waterline)

Prime (approx. 3 to 4 liters).
Filling point (→ Page 110).

Coolant circuit If engine is out of service for more than one year, change engine coolant

(→ Page 116).

Coolant circuit Check coolant level (→ Page 115).

Coolant circuit Heat engine coolant with coolant preheating unit.

Engine Control Unit ECU Check plug connections (→ Page 134).

Engine Interface Module EIM Check plug connections (→ Page 136).

Engine Monitoring Unit EMU Check plug connections (→ Page 135).

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5.2 Engine – Putting into operation after scheduled out-of-service­period

Preconditions

☑ Engine is stopped and starting disabled.

Putting into operation

Item Action

Lube oil system Check engine oil level (→ Page 103).

Coolant circuit Check coolant level (→ Page 115).

Coolant circuit Heat engine coolant with coolant preheating unit.

Fuel prefilter Drain water and contaminants (→ Page 92).

Battery-charging generator
drive

Check condition of drive belt (→ Page 123).

Engine Control Unit ECU Check plug connections (→ Page 134).

Engine Interface Module EIM Check plug connections (→ Page 136).

Engine Monitoring Unit EMU Check plug connections (→ Page 135).

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5.3 Tasks after extended out-of-service periods (>3 weeks)

Tasks after extended out-of-service periods (>3 weeks)

Note: Operate fuel treatment system for at least 5 minutes.

1. Start up fuel treatment system (→ Page 49).

2. Shut down fuel treatment system (→ Page 57).

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5.4 Checks prior to start-up

Checks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.

b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..).

2. Close drain valves on housing.

3. Open all supply and discharge valves.

4. Switch on fuel treatment system (→ Page 52).

5. Check direction of rotation of pump.

6. Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.

b) Open ball valve for overflow tank.

c) Close ball valve at the inlet to the fuel treatment system.

Result: Bypass line is vented via the overflow tank.

d) Open ball valve at the inlet to the fuel treatment system.

7. Check the fuel treatment system for leaks.

Result: The fuel treatment system is ready for operation.

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5.5 Fuel treatment system – Putting into operation

Fuel treatment system – Overview

1. Switch on fuel treatment system (→ Page 52).

2. Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system:

0.1 bar to 0.3 bar.

Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.

1. Remove coalescer filter element (→ Page 129).

2. Check sealing faces on coalescer filter element and in the pressure tank.

Initial operation: HAT

1. Replace fuel filter on engine (→ Page 88).

Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.

2. Install a pressure gauge in the fuel supply line from the shipyard-side fuel system to the engine.

3. Switch on fuel treatment system and operate it for some minutes (→ Page 52).

Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is delivered via

the overflow tank back to the tank. Water which has settled in the tank is separated.

4. Start engine (→ Page 53).

5. Run engine at idling speed.

6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.

7. Increase engine speed to 1000 rpm and monitor suction pressure.

8. Check suction pressure at the engine-mounted fuel delivery pump.

Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replace-

ment simulation with the engine running as part of the Harbor Acceptance Tests.

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Simulation of filter replacement with the engine running: HAT

1. Switch on fuel treatment system (→ Page 52).

2. Start engine (→ Page 53).

3. Run engine at idling speed.

4. Close ball cock (5) at the inlet to the fuel treatment system.

Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit

opens and fuel flows through bypass (3) and bypass (2).

5. Open ball cock (19).

Result: Fuel emerges. If no fuel emerges:

• Open ball cock (5) at the inlet to the fuel treatment system.

• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .

6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.

7. Increase engine speed to 1000 rpm and monitor suction pressure.

Result: If all engine operating values are within the specified limits, open ball cock (5) at the inlet to the fuel treat-

ment system.

Simulation of power failure (emergency): HAT

1. Switch on fuel treatment system (→ Page 52).

2. Start engine (→ Page 53).

3. Run engine at idling speed.

4. Switch off pump (21) on switch cabinet.

Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.

5. Check suction pressure at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.

6. Increase engine speed to 1000 rpm and monitor suction pressure.

Result: If the suction pressure is within the specified limits, simulation was successful.

Simulation of power failure (emergency): SAT

1. Switch on fuel treatment system (→ Page 52).

2. Start engine (→ Page 53).

3. Run engine at idling speed.

4. Switch off pump (21) on switch cabinet.

Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.

5. Check suction pressure at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.

6. Operate engine at full load and monitor suction pressure.

Result: If the suction pressure is within the specified limits, simulation was successful.

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5.6 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!

• Wear ear protectors.

Operational checks

Item Measure

Engine under load
Engine at nominal speed

Visually inspect engine for leaks and general condition;
Check for abnormal running noises and vibration;
Check exhaust color (→ Page 61).

Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter is within the limit

(→ Page 91).
Drain water and contaminants (→ Page 92).

Air filter Check signal ring position of contamination indicator (→ Page 101).

Replace air filter (→ Page 99), if the signal ring is completely visible in the
service indicator observation window.

HT coolant pump Check relief bore for oil and coolant discharge and contamination

(→ Page 119).

Raw water pump Check relief bore for oil and water discharge and contamination

(→ Page 122).

Intercooler Check condensate drain (if applicable) (→ Page 98).

Engine oil Check engine oil level (→ Page 103).

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5.7 Fuel treatment system – Switching on

Preconditions

☑ The on-board power supply is switched on.

NOTICE

Risk of damage to engine/system.

Risk of severe damage to property!

• Before switching on, ensure that the engine/system is ready for operation.

• Before switching on, ensure that all housings are closed.

• Before switching on, ensure that no work is in progress anywhere on the entire system.

Fuel treatment system – Switching on

1. Carry out checks prior to start-up (→ Page 48).

2. Switch on master switch on switchgear cabinet.

Result: Signal lamp “Control voltage present” lights up.

3. Switch on switch for pump.

Result: Signal lamp “Pump running” lights up.

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5.8 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 engine's
danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

The engine can be started from the following points

Item Action

Control stand (→ Operating instructions for electronic system)

Local Operating Panel LOP (→ Operating instructions for electronic system)

Local Operation Station LOS (→ Operating instructions for electronic system)

CCU (→ Operating instructions for electronic system)

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5.9 Engine – Shutdown

Preconditions

☑ Engine is running in Local mode

CAUTION

Shutting down from full-load operation may cause hot water to escape from the expansion tank.

Risk of scalding!

• Allow engine to cool down.

• Wear protective clothing, protective gloves, and safety goggles / safety mask.

NOTICE

Stopping the engine when it is running at full load causes extreme stress to the engine.

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.

The engine can be stopped from the following points

Item Action

Control stand (→ Operating instructions for electronic system)

Local Operating Panel LOP (→ Operating instructions for electronic system)

Local Operation Station LOS (→ Operating instructions for electronic system)

CCU (→ Operating instructions for electronic system)

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5.10 Emergency engine shutdown

CAUTION

Shutting down from full-load operation may cause hot water to escape from the expansion tank.

Risk of scalding!

• Allow engine to cool down.

• Wear protective clothing, protective gloves, and safety goggles / safety mask.

NOTICE

An emergency stop subjects the engine system to an extremely high load.

Risk of overheating, damage to components!

• Trigger an emergency stop only in emergency situations.

The engine can be stopped from the following points in an emergency

Item Action

Control stand (→ Operating instructions for electronic system)

Local Operating Panel LOP (→ Operating instructions for electronic system)

Local Operation Station LOS (→ Operating instructions for electronic system)

CCU (→ Operating instructions for electronic system)

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5.11 After stopping the engine

Preconditions

☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

NOTICE

Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at
temperatures below 0 °C.

Risk of sensor damage!

• Remove pressure sensors and shake off residual water.

After stopping the engine

Item Measure

Coolant circuit Drain coolant (→ Page 117) if:

• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze addi­tive;

• the engine room is not heated;

• the coolant is not kept at a suitable temperature;

• the antifreeze concentration is insufficient for the engine-room tempera­ture;

• antifreeze concentration is 50 % and engine-room temperature is below

-40 °C.

Raw water Drain

• if freezing temperatures are to be expected and the engine is to remain
out of service for an extended period.

Engine Control System Switch off.

Air intake and exhaust sys­tem

Out-of-service-period > 1 week

• Seal engine's air and exhaust sides.

Engine Out-of-service-period > 1 month

• Carry out engine preservation (→ MTU Preservation and Represervation
Specifications A001070/..)

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5.12 Fuel treatment system – Shutdown

Shutting down fuel treatment system

1. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet
stops.

2. Switch off fuel treatment system.

3. Close ball valve at the inlet to the fuel treatment system.

4. Close ball valve at the outlet of the fuel treatment system.

5. Open drain valve until pressure has escaped from fuel treatment system.

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5.13 Plant – Cleaning

Preconditions

☑ Engine is stopped and starting disabled.

☑ No operating voltage is applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

High-pressure cleaning unit

- 1

Cleaner (Hakupur 50/136)

X00056700 1

WARNING

Compressed air gun ejects a jet of pressurized air.

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.

WARNING

Water jet from high-pressure cleaning unit.

Risk of eye injury, risk of scalding!

• Do not direct water jet at persons.

• Wear protective clothing, protective gloves, and goggles/safety mask.

NOTICE

Cleaning agents should not be left to take effect for too long.

Damage to components is possible!

• Observe manufacturer's instructions.

NOTICE

Blowing down product with compressed air.

Entry of dirt and damage to components is possible!

• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.

Plant – Cleaning

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec­tion).

2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.

3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:

• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.

• A minimum distance between spray nozzle and plant of 1 m must be observed.

• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.

Note: Never direct compressed air directly at electronic components.

5. Carry out external cleaning as follows:

a) 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.

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6 Maintenance

6.1 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.

Task

Option

Maintenance tasks

W0500 Check engine oil level. (→ Page 103)

W0501 Visually inspect engine for leaks and general condition. (→ Page 51)

W0502 Check charge-air cooler drain(s). (→ Page 51)

W0503 Check service indicator of air filter. (→ Page 51)

W0505 Check relief bores of water pump(s). (→ Page 51)

W0506 Check engine for abnormal running noises, exhaust color

and vibrations.

(→ Page 51)

W0507 X Drain water and contaminants from fuel prefilter. (→ Page 51)

W0508 X Check reading on contamination indicator of fuel prefilter. (→ Page 51)

W1001 Replace fuel filter or fuel filter element. (→ Page 88)

W1005 Replace air filter. (→ Page 99)

W1006 Replace fuel injectors. (→ Page 84)

W1008 Replace engine oil filter when changing engine oil, or when

the interval (years) is reached, at the latest.

(→ Page 105)

W1009 X Check layer thickness of oil residue, clean and replace filter

sleeve, at every oil change, at the latest.

(→ Page 107)

W1011 Perform endoscopic examination. (→ Page 73)

W1036 Replace coolant filter. (→ Page 121)

W1046 Replace filter or filter element. (→ Page 78)

W1140 Clean wire meshes of crankcase breather. (→ Page 77)

W1207 Check valve clearance and adjust if necessary. IMPORTANT!

Initial setting after 1,000 operating hours and after every
overhaul of the cylinder heads after 1,000 operating hours.

(→ Page 80)

W1244 X Check function of rod electrode. (→ Page 127)

W1245 X Check alarm function of differential pressure gauge. (→ Page 126)

W1246 X Check pump capacity. (→ Page 128)

Table 2: Maintenance task reference table [QL1]

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7 Troubleshooting

7.1 Control cabinet of fuel treatment system – Troubleshooting

Water alarm

Cause Corrective action

When the maximum water level is
reached, the water level electrode
opens the water drain valve and
water is discharged. If the opening
period of the valve exceeds a
preset limit (4 minutes), the pump
will switch off and an alarm is
initiated.

1. Press illuminated pushbutton 'Water alarm' for acknowledgment.

2. In addition to the automatic water drain function, water can also be
drained manually: Press illuminated pushbutton 'Water drain'.
The water drain valve opens.

Pump fault

Cause Corrective action

The drive motor is equipped with
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-running,
the motor protection relay
triggers and the pump is switched
off.

u Reset motor protection relay.

Pre-alarm

Cause Corrective action

The differential pressure
exceeded 1.3 bar.

u Replace coalescer filter element (→ Page 129).

Replace filter element

Cause Corrective action

The max. permissible differential
pressure exceeded 1.5 bar. If the
coalescer filter element is not
replaced, pressure will increase
further and the safety valve will
open. Fuel will be led via the
bypass directly into the overflow
tank.

1. Replace coalescer filter element (→ Page 129).

2. Press illuminated pushbutton 'Water alarm' for acknowledgment.

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7.2 Troubleshooting

Engine does not turn when starter is actuated

Cause Corrective action

Battery low or faulty u Charge or replace (see manufacturer's documentation).

Battery: Cable connections faulty u Check if cable connections are properly secured (see

manufacturer's documentation).

Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.

Engine cabling defective u Check (→ Page 131).

Loose plug connections on Engine
Control Unit

u Check plug connections (→ Page 134).

Loose plug connections on Engine
Interface Module (EIM)

u Check plug connections (→ Page 136).

Fuse F1 in engine wiring harness
defective (fuse lamp on EIM
flashes with relevant flashing
code)

u Check fuse (replace if required) and re-start the system by

actuating the key switch.

Running gear blocked (engine
cannot be barred manually)

u Contact Service.

Engine turns on starting but does not fire

Cause Corrective action

Poor rotation by starter: Battery
low or faulty

u Charge or replace battery (see manufacturer's documentation).

Engine cabling defective u Check (→ Page 131).

Air in fuel system u Vent fuel system (→ Page 87).

Engine Control Unit defective u Contact Service.

Engine fires unevenly

Cause Corrective action

Injector defective u Replace (→ Page 84).

Engine cabling defective u Check (→ Page 131).

Air in fuel system u Vent fuel system (→ Page 87).

Engine Control Unit defective u Contact Service.

Engine does not reach nominal speed

Cause Corrective action

Fuel prefilter clogged u Replace (→ Page 96).

Easy-change fuel filter clogged u Replace (→ Page 88).

Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 101).

Fuel injection: Injector defective u Replace (→ Page 84).

Engine cabling defective u Check (→ Page 131).

Engine: Overload u Contact Service.

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Engine speed not steady

Cause Corrective action

Fuel injection: Injector defective u Replace (→ Page 84).

Speed transmitter defective u Contact Service.

Air in fuel system u Vent fuel system (→ Page 87).

Engine Control Unit defective u Contact Service.

Charge-air temperature too high

Cause Corrective action

Incorrect coolant concentration u Check (MTU test kit).

Charge-air cooler clogged u Contact Service.

Engine room: Air-intake
temperature too high

u Check fans and air supply/ventilation ducts.

Charge-air pressure too low

Cause Corrective action

Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 101).

Charge-air cooler contaminated u Contact Service.

Exhaust turbocharger defective u Contact Service.

Coolant leaks at charge-air cooler

Cause Corrective action

Charge-air cooler leaking, major
coolant discharge

u Contact Service.

Black exhaust gas

Cause Corrective action

Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 101).

Fuel injection: Injector defective u Replace (→ Page 84).

Engine: Overload u Contact Service.

Blue exhaust gas

Cause Corrective action

Too much engine oil in the engine u Drain engine oil (→ Page 104).

Oil separator or oil pre-separator
of crankcase breather clogged

1. Clean preseparator (→ Page 77).

2. Replace oil separator element (→ Page 78).

Exhaust turbocharger, cylinder
head, piston rings, cylinder liner
defective

u Contact Service.

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White exhaust gas

Cause Corrective action

Engine is not at operating
temperature

u Run engine to reach operating temperature.

Water in fuel u Drain fuel prefilter (→ Page 92).

Charge-air cooler leaking u Contact Service.

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8 Task Description

8.1 SOLAS

8.1.1 SOLAS shielding – Installation as per MTN 5233

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Shield A4

735233000100 5

Shield A5

735233000101 7

Shield A7

735233000103 6

Shield A8

735233000104 2

Installing SOLAS shielding

1. Pinpoint installation location (→ Page 66).

2. Install suitable shielding.

3. Press shielding until locked.

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8.1.2 SOLAS shielding – Installation

Preconditions

☑ Engine is stopped and starting disabled.

☑ Engine is cooled down to ambient temperature.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter shield

X00009628

Fuel filter shield

X00009654

Installing SOLAS shield on oil fil­ter and fuel filter

1. Pinpoint installation location (→ Page 66).

2. Install suitable shielding.

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8.1.3 Installation locations for SOLAS shielding

General information

Primarily fit SOLAS shielding as per MTN 5233 (→ Page 64).

On crankcase

Item Type of shielding Remarks

1 Shield (A4) On brazed-on union

2 Shield (A5) On crankcase

Free end B-side

Item Type of shielding Remarks

1
Free end
B-side

Shield (A7) On fuel delivery pump

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Free end B-side

Item Type of shielding Remarks

1
Free end
B-side

Shield (A7) On HP fuel pump

Free end

Item Type of shielding Remarks

1
Free end

Shield (A7) Above fuel priming pump.

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Free end

Item Type of shielding Remarks

1
Free end

Shield (A7) Below fuel priming pump.

Free end

Item Type of shielding Remarks

1
Free end

Shield (A8) On fuel filter housing

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Driving end A-side

Item Type of shielding Remarks

1
Driving end

Shield (A5) On valve plate

Driving end A-side

Item Type of shielding Remarks

1
Driving end

Shield (A5) On air flap control

2
Driving end

Shield (A4) On brazed-on union

3
Driving end

Shield (A5) On exhaust turbocharger flap control.

4
Driving end

Shield (A5) On exhaust turbocharger flap control.

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Driving end

Item Type of shielding Remarks

1
Driving end

Shield (A4) Exhaust turbocharger lubrication.

2
Driving end

Shield (A4) On brazed-on union.

Driving end

Item Type of shielding Remarks

1
Driving end

Shield (A4) Exhaust turbocharger lubrication.

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8.2 Engine

8.2.1 Engine – Barring manually

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine barring device

F6783914 1

Ratchet with extension

F30006212 1

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before barring the engine, make sure that there are no persons in the engine's danger zone.

• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring engine manually

1. Fit ratchet with barring device on barring device connection at the vibration damper on engine free end.

2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.

Result: If the resistance exceeds the normal compression resistance, contact Service.

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8.2.2 Engine – Cranking on starting system

Preconditions

☑ Clutch is disengaged.

☑ Engine start is disabled.

☑ LOP is accessible and open.

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before barring the engine, make sure that there are no persons in the engine's danger zone.

• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Turning

1. Press and hold down TURN pushbutton on
LMB motherboard of LOP.

Result: Engine is cranked on starter for max. 20 sec-

onds.

2. Release TURN button.

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8.3 Cylinder Liner

8.3.1 Cylinder liner – Endoscopic examination

Preconditions

☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring device

F6555766 1

Ratchet with extension

F30006212 1

Endoscope

Y20097353 1

Preparatory steps

1. Remove cylinder head cover (→ Page 83).

2. Remove injector (→ Page 85).

Positioning crankshaft at BDC

1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC.

2. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder liner

Findings Measure

• Thin carbon coating around carbon scraper ring

• Slight localized additive deposits at top edge

• Localized smooth areas at bottom edge

• Carbon deposits on entire circumference between top piston ring and
bottom edge of carbon scraper ring

• First signs of marks left by top piston ring

• Bright mark on entire circumference

• Faultless, even honing pattern

• First signs of marks left by lower cooling bores

• Running pattern seems darker

No actions required.

• Dark areas with even or varying degrees of discoloration

• Beginning and end of the discoloration are not sharply defined and do
not cover the entire stroke area

• Dark areas in the upper section of the cooling bore, remaining circum­ference are faultless

• Piston rings are faultless

Further endoscopic examina­tion required as part of mainte­nance work.

• On the entire circumference, apart from light areas of discoloration (do
not impair operation) clearly darker stripes that start at the top piston
ring

• Heat discoloration in the direction of stroke and honing pattern dam­age

• Heat discoloration of piston rings

Cylinder liner must be replaced,
contact Service.

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1. Compile endoscopic report using the table.

2. Use technical terms to describe the liner surface (→ Page 75).

3. Depending on findings:

• Do not take any action or

• carry out a further endoscopic examination as part of maintenance work or

• contact Service; cylinder liner must be replaced.

Final steps

1. Install injector (→ Page 85).

2. Install cylinder head cover (→ Page 83).

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8.3.2 Instructions and comments on endoscopic and visual examination of cylinder
liners

Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina­tion report.

Findings Explanations/Action

Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,

particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.

Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area

and cross through the hone pattern in the direction of stroke.
Findings not critical.

Scored area These areas consist of scores of different length and depth next to one another. In

most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Findings not critical.

Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern

is still visible. Smoothened areas appear brighter and more brilliant than the sur­rounding running surface.
Findings not critical.

Bright area Bright areas are on the running surface and show local removal of the honing pat-

tern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-

ture differences around the liner. It appears rather darker within the honed struc­ture in contrast to the bright metallic running surface. The honing pattern is undis­turbed. Discolorations extend in stroke direction and may be interrupted.
Findings not critical.

Corrosion fields /
spots

Corrosion fields / spots result from water (condensed water) with the valves in the
overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.

Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-

oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.

Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run

over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be­coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re­placed.

Seizure marks, scuff­ing

Irregular circumference lengths and depths. Can be caused either by the piston
skirt or the piston crown. Material deposits on the liner (smear), heavy discolora­tion. Severe, visible scoring.
Replace liner.

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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.

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8.4 Crankcase Breather

8.4.1 Crankcase breather – Cleaning oil pre-separator element

Preconditions

☑ Engine is stopped and starting disabled.

WARNING

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING

Compressed air gun ejects a jet of pressurized air.

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.

Crankcase breather, cleaning oil
pre-separator element

1. Undo clamp (2).

2. Remove hose (1) and clamp (2) from cov­er (3).

3. Slacken screws (4).

4. Remove screws (4) and washers (5).

5. Remove cover (3), gasket (6), oil pre-separa­tor (7) and gasket (8).

6. Wash oil pre-separator element (7) and cov­er (3) in fuel and blow out with compressed
air.

7. Moisten oil pre-separator element (7) with
engine oil.

8. Insert gasket (8) and oil pre-separator ele­ment (7) with new gasket (6).

9. Place cover (3) in position and tighten screws
(4) and washers (4).

10. Place clamp (2) and hose (1) on cover (3).

11. Tighten clamp (2).

12. Clean other oil pre-separator elements in the
same way.

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8.4.2 Crankcase breather – Oil separator replacement, diaphragm check and
replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 8-40 Nm

F30043446 1

Ratchet adapter

F30027340 1

Engine oil

Filter element

(→ Spare Parts Catalog)

Diaphragms

(→ Spare Parts Catalog)

Gasket

(→ Spare Parts Catalog)

WARNING

Hot oil.
Oil can contain combustion residues which are harmful to health.

Risk of injury and poisoning!

• Wear protective clothing, gloves, and goggles / safety mask.

• Avoid contact with skin.

• Do not inhale oil vapor.

Replacing oil separator filter el­ement

1. Remove cover (2) with O-ring (3).

2. Remove filter element (1) from housing (4).

3. Insert new filter element in housing (4).

4. Install cover (2) with new O-ring.

5. Use torque wrench to tighten the screws of cover (2) to the specified torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm

6. Replace further oil separator elements in the same way.

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Checking diaphragm

1. Remove cover (4).

2. Remove spring (5), gasket (2) and dia­phragm (3).

3. Check diaphragm (3) for damage, fit new dia­phragm if used one is damaged.

4. Install diaphragm (3) on housing (1).

5. Install new gasket (2) and spring (5) together
with cover (4).

6. Use torque wrench to tighten the screws of cover (4) to the specified torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm

7. Check diaphragm in other oil separators in the same manner.

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8.5 Valve Drive

8.5.1 Valve clearance – Check and adjustment

Preconditions

☑ Engine is stopped and starting disabled.

☑ Engine coolant temperature max. 40 °C.

☑ Valves are closed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Valve clearance gauge

Y4345893 1

Engine barring device

F6783914 1

Ratchet with extension

F30006212 1

Double-head box wrench

F30002800 1

Offset screwdriver

F30453001 1

Socket wrench

F30030450 1

Torque wrench, 20–100 Nm

F30026582 1

Measuring device

Y4345888 1

Engine oil

Preparatory steps

1. Remove air filter (→ Page 100).

2. Remove cylinder head cover (→ Page 83).

Positioning A1 piston at TDC

Note: With cylinder head and valve gear installed.

1. Install dial gauge (2) under preload in meas­uring device (4) and clamp with screw (1).

2. Install measuring device (4) in cylinder head
and secure using knurled-head screw (3).

3. Zero dial gauge (2).

4. Turn engine using barring device until piston
A1 reaches firing TDC.

Result: The piston is at firing TDC when both rocker

arms are unloaded, i.e. have clearance.

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Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:

• If the rocker arms are unloaded on cylinder 1, bank A, the piston is in firing TDC.

• If the rocker arms are loaded on cylinder 1, bank A, the piston is in overlap TDC.

2. Check valve clearance with cold engine:

• Inlet (I) = 0.3 mm;

• Exhaust (X) = 0.4 mm.

3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table
below.

Position Cylinder 1 2 3 4 5 6 7 8 9 10

8V

Firing TDC in cylinder A1 Bank A I X – X I – – X

Bank B I – I – – – – X

Overlap TDC in cylinder A1 Bank A – – I – – X I –

Bank B – X – X I X I –

10V

Firing TDC in cylinder A1 Bank A I X – – – – – X I –

Bank B I – – – – X I X I –

Overlap TDC in cylinder A1 Bank A – – I X I X I – – X

Bank B – X I X I – – – – X

I

Inlet: Inlet valve adjustment admissible

X

Exhaust: Exhaust valve adjustment admissible

–

Valve adjustment inadmissible

4. Use valve clearance gauge to determine the distance between valve bridge and rocker arm.

5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.

2. Insert valve clearance gauge (3) between
valve bridge and rocker arm.

3. Readjust adjusting screw (2) so that the valve
clearance gauge (3) just passes through the
gap.

4. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)
with Allen key to prevent it from turning.

Name Size Type Lubricant Value/Standard

Locknut M12x1 Tightening torque (Engine oil) 50 Nm

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5. Check if the valve clearance gauge (3) just passes through between valve bridge and rocker arm.

Result: If not, adjust valve clearance.

Final steps

1. Remove barring device.

2. Install cylinder head cover (→ Page 83).

3. Install air filter (→ Page 100).

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8.5.2 Cylinder head cover – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 8-40 Nm

F30043446 1

Centering device

F6783025 1

Gasket

(→ Spare Parts Catalog)

Preparatory steps

1. Remove air filter (→ Page 100).

2. Remove air guide housing.

Removing and installing cylin­der head cover

1. Remove screws (1).

2. Remove cylinder head cover (2) with gasket
from cylinder head.

3. Clean installation surface.

4. Check condition of gasket of cylinder head
cover.

Result: Replace damaged seals.

5. Align cylinder head cover (2) with centering
device.

6. Insert and tighten screws (1).

Final steps

1. Install air filter (→ Page 100).

2. Install air guide housing.

3. Check cylinder head covers for leaks.

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8.6 Injector

8.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

u Remove injector and install new one (→ Page 85).

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8.6.2 Injector – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Socket wrench

F30451502 1

Puller

F6790629 1

Double-head box wrench

F30011450 1

Open-end wrench bit

F30025897 1

Box wrench

F30451199 1

Alignment device

F6790507 1

Assembly compound (Kluthe Hakuform 30-15)

X00067260 1

Engine oil

Pressure pipe tube

(→ Spare Parts Catalog)

Hold-down clamp screw

(→ Spare Parts Catalog)

Injector

(→ Spare Parts Catalog)

WARNING

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Preparatory steps

1. Close off fuel supply to engine.

2. Remove cylinder head cover (→ Page 83).

Remove injector

1. Remove HP line (5) using socket wrench.

2. Disconnect cable (4) at injector.

3. Remove screw (2).

4. Take off hold-down clamp (3).

5. Remove injector (1) with puller.

6. Remove O-rings from injector.

7. Mask all connections and bores or seal with
suitable plugs.

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Installing injector

1. Prior to installation, remove all blanking
plugs.

2. Fit new O-rings on injector and coat with as­sembly compound.

3. Secure new sealing ring with assembly com­pound on injector, observing installation posi­tion of sealing ring.

4. Clean sealing surface on cylinder head and
protective sleeve.

5. Insert injector (1) in cylinder head, ensuring
that it is correctly aligned with the HP line
connection.

6. Fit hold-down clamp (3) in correct installation
position, coat screw (2) with engine oil.

7. Screw in screw (2) and tighten by hand.

8. Coat thread and sealing cone of HP line (5)
and injector (1) with engine oil.

9. Align injector (1) and HP line (5) with align­ment device.

10. Connect HP line (5) to HP accumulator and
tighten by hand.

11. Connect HP line (5) to injector (1) and tighten
by hand.

12. Tighten screw of hold-down clamp (3) with a box wrench adapter and a torque wrench to specified tightening
torque.

Name Size Type Lubricant Value/Standard

Screw M10 x 85 Tightening torque (Engine oil) 40 Nm + 4 Nm

13. Use socket wrench and torque wrench to tighten HP line (5) to the specified torque.

Name Size Type Lubricant Value/Standard

HP line Tightening torque (Engine oil) 30 Nm + 5 Nm

14. Attach cable (4).

Final steps

1. Install cylinder head cover (→ Page 83).

2. Open fuel supply to engine.

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8.7 Fuel System

8.7.1 Fuel system – Venting

Preconditions

☑ Engine is stopped and starting disabled.

WARNING

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Venting fuel system

1. Unscrew handle (3) at fuel priming pump (2).

2. Open vent plug (1).

3. Operate the pump with the handle (3) until
bubble-free fuel emerges from the vent plug
(1).

4. Close vent plug (1).

5. Unscrew handle (3) at fuel priming pump (2).

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8.8 Fuel Filter

8.8.1 Fuel filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter wrench

F30379104 1

Easy-change filter

(→ Spare Parts Catalog)

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

WARNING

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

NOTICE

Damage to component!

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.

Preparatory step

u Provide a suitable container to collect the fuel.

Replacing fuel filter with the en­gine running

1. Note the three-way cock settings listed be­low:

(A) Both filters are cut in (standard posi-

tion).
(B) Right filter is cut out.
(C) Left filter is cut out.

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Note: Filter replacement on a running engine is per-

missible only with a short-time cutout of the
filter to be replaced.

2. Turn three-way cock to setting (B) to cut out
the filter (2) which is to be replaced:

Result: Fuel filter (2) is cut out of the fuel circuit, but

is still under pressure.

3. Connect venting hose to threaded vent plug
(1) of filter which has been cut out. Lead the
end of the hose to the prepared collecting
container.

4. Carefully turn the threaded vent plug (1) of
the cut out filter to the left. Check that the
fuel filter is depressurized.

5. Close vent plug (1).

6. Unscrew switched off easy-change filter (2)
with oil filter wrench.

7. Clean sealing surface on filter head.

8. Lightly oil sealing ring of new easy-change fil­ter.

9. Screw on easy-change filter (2) by hand until
seal makes contact, then tighten by hand.

Note: Cut the fuel filter back in slowly following re-

placement to return both filters to operation.
The engine may shut down if the filter is cut
back in too quickly.

10. Turn three-way cock slowly to position (A) to
allow fuel to flow through both filters (stand­ard position).

11. Replace other fuel filters in the same way.

Replacing fuel filter with the en­gine at standstill

1. Note the three-way cock settings listed be­low:

(A) Both filters are cut in (standard posi-

tion).
(B) Right filter is cut out.
(C) Left filter is cut out.

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2. Stop engine and disable engine start.

3. Turn three-way cock to setting (B) to cut out
the filter (1) which is to be replaced.

4. Unscrew switched off easy-change filter (1)
with oil filter wrench.

5. Clean sealing surface on filter head.

6. Lightly oil sealing ring of new easy-change fil­ter.

7. Screw on easy-change filter (1) by hand until
gasket makes contact, then tighten by hand.

8. Turn three-way cock to position (A) so both
filters are in use (standard position).

9. Replace other fuel filters in the same way.

10. Vent fuel system (→ Page 87).

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8.8.2 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.

Risk of damage to hearing!

• Wear ear protectors.

Setting adjustable pointer of dif­ferential pressure gauge

1. After installation of a new filter element, align
adjustable pointer (2) with pressure-indicat­ing pointer (3) of pressure gauge (1).

2. Verify that differential pressure is within the
limit.

Fuel prefilter – checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).

2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point­er (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 94).

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8.8.3 Fuel prefilter – Draining

Preconditions

☑ Engine is stopped and starting disabled.

WARNING

Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.

Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!

• Seek medical attention immediately; do not induce vomiting.

• Do not inhale vapors or mist.

• Wear protective clothing, protective gloves, and safety glasses.

• If contact is made with skin, wash off with water and soap.

WARNING

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Draining fuel prefilter

1. Switch off filter which is to be drained (A or
B):

1 Filter A cut out
2 Filter B cut out

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2. Open threaded vent plug (1) of the filter to be
drained.

3. Open drain valve (2).

4. Drain water and contaminants from the filter
until pure fuel emerges.

5. Close drain valve (2).

6. Connect filling pump to filling connection (1)
on the intake side of the filter.

7. Open vent valve (2) and fill with fuel until fuel
emerges from the vent pipe (3).

8. Close vent valve (2).

9. Open rotary slide valve (4) a little (by approx.
30°) and open vent valve(s) (2), until fuel
emerges from the vent pipe (3).

10. Close vent valve(s) (2).

11. Turn rotary slide valve (4) back to locked po­sition.

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8.8.4 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

Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.

Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!

• Seek medical attention immediately; do not induce vomiting.

• Do not inhale vapors or mist.

• Wear protective clothing, protective gloves, and safety glasses.

• If contact is made with skin, wash off with water and soap.

WARNING

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Fuel prefilter – Flushing

1. Cut out contaminated filter (A or B):
1 Filter A cut out
2 Filter B cut out

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2. Open threaded vent plug (1) of filter to be
flushed.

3. Open drain valve (2) and drain fuel.

Result: Fuel flows from filtered side back to the unfil-

tered side, flushing the filter deposits down­wards out of the filter.

4. Close threaded vent plug (1) and drain
valve (2).

Fuel prefilter, filling with fuel

1. Stop engine (→ Page 54) and disable engine start.

2. Connect filling pump to filling connection (1)
on the intake side of the filter.

3. Open vent valve (2) and fill with fuel until fuel
emerges from the vent pipe (3).

4. Close vent valve (2).

5. Open rotary slide valve (4) a little (by approx.
30°) and open vent valve(s) (2), until fuel
emerges from the vent pipe (3).

6. Close vent valve(s) (2).

7. Turn rotary slide valve (4) back to locked po­sition.

8. Check differential pressure (→ Page 91).

Result: If flushing did not improve differential pres-

sure, replace filter element in fuel prefilter
(→ Page 96).

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8.8.5 Fuel prefilter – Filter element replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel

Filter element

(→ Spare Parts Catalog)

Gasket

(→ Spare Parts Catalog)

WARNING

Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.

Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!

• Seek medical attention immediately; do not induce vomiting.

• Do not inhale vapors or mist.

• Wear protective clothing, protective gloves, and safety glasses.

• If contact is made with skin, wash off with water and soap.

WARNING

Fuels are combustible and explosive.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Replacing filter element

1. Cut out the filter to be replaced (A or B).
1 Filter A cut out
2 Filter B cut out

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2. Open threaded vent plug (1) of contaminated
filter.

3. Unlock drain valve (5) by pressing toggle and
open it.

4. Drain water and dirt from filter.

5. Close drain valve (5).

6. Remove screws securing cover (2) and take
off cover.

7. Remove spring cartridge (3) and filter ele­ment (4).

8. Insert new filter element (4) and spring car­tridge (3).

9. Fill filter housing with clean fuel.

10. Place new seal in cover.

11. Fit cover with gasket and secure it with
screws (2).

12. Cut in the cut-out filter again.

13. Close threaded vent plug (1) when fuel
emerges.

14. Set differential pressure display instrument
(→ Page 91).

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8.9 Charge-Air Cooling

8.9.1 Charge-air cooler – 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.

Risk of damage to hearing!

• Wear ear protectors.

WARNING

Compressed air gun ejects a jet of pressurized air.

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.

Charge-air cooler, checking con­densate drain line for coolant
discharge and obstruction

1. Check drain line for water discharge and ob­struction when the engine is running idle.

2. If no air emerges, remove condensate drain
line and blow out with compressed air.

3. Replace obstructed drain line by new one.

4. Install condensate drain line.

5. If a large amount of coolant is continuously
discharged, the charge-air cooler is leaking.
Contact Service.

Emergency measures prior to engine start with a leaking charge-air cooler

1. Remove injectors (→ Page 84).

2. Bar engine manually (→ Page 71).

3. Bar engine on starting system to blow out combustion chambers (→ Page 72).

4. Install injectors (→ Page 85).

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8.10 Air Filter

8.10.1 Air filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Air filter

(→ Spare Parts Catalog)

Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 100).

2. Reset signal ring of contamination indicator (→ Page 101).

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8.10.2 Air filter – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque screwdriver, 1–5 Nm

F30452774 1

Removing and installing air fil­ter

1. Release clamp (2).

2. Remove air filter (1) and clamp (2) from con­necting flange of intake housing (3).

3. Verify that there are no objects in the con­necting flange of the intake housing (3) and
clean it.

4. Place new air filter (1) with clamp (2) onto in­take housing (3).

5. Tighten screw on clamp (2) with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw - Tightening torque 5 Nm

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