MTU 12 V 2000 M94, 16 V 2000 M94 Operating Instructions Manual

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Operating Instructions

Diesel engine 12 V 2000 M94 16 V 2000 M94

MS150061/04E

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Printed in Germany

This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services.

This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.

Subject to alterations and amendments.

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Table of Contents

1 Safety

1.1 General conditions 5

1.2 Personnel and organizational requirements 6

1.3 Transport 7

1.4 Safety regulations for startup and operation 9

1.5 Safety regulations for maintenance and repair work 10

1.6 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection 13

1.7 Conventions for safety instructions in the text 15

2 General Information

2.1 Tightening specifications for screws, nuts and bolts 16

2.2 Engine side and cylinder designations 27

2.3 Product description 28

2.4 Engine - Overview 34

2.5 Sensors, actuators and injectors – Overview 36

3 Technical Data

3.1 12V 2000 M94 engine data 41

3.2 16V 2000 M94 engine data 44

3.3 Firing order 47

3.4 Engine – Main dimensions 48

4 Operation

4.1 Putting the engine into operation after extended out-of-service periods (>3 months) 49

4.2 Engine – Putting into operation after scheduled out-of-service-period 50

4.3 Tasks after extended out-of-service periods (>3 weeks) 51

4.4 Checks prior to start-up 52

4.5 Fuel treatment system – Putting into operation 53

4.6 Operational checks 55

4.7 Fuel treatment system – Switching on 56

4.8 Starting the engine 57

4.9 Stopping the engine 58

4.10 Emergency stop 59

4.11 After stopping the engine 60

4.12 Fuel treatment system – Shutdown 61

4.13 Plant cleaning 62

5 Maintenance

5.1 Maintenance task reference table [QL1] 63

6 Troubleshooting

6.1 Fuel treatment system – Troubleshooting 64

6.2 Troubleshooting 65

7 Task Description

7.1 SOLAS 68

7.1.1 SOLAS shielding as per MTN 5233 – Installation 68

7.1.2 SOLAS shielding – Installation 69

7.1.3 Installation locations for SOLAS shielding 70

7.2 Engine 75

7.2.1 Engine – Barring manually 75

7.2.2 Engine – Barring with starting equipment 76

7.3 Cylinder Liner 77

7.3.1 Cylinder liner – Endoscopic examination 77

7.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination 79

7.4 Crankcase Breather 81

7.4.1 Crankcase breather – Cleaning oil preseparator element 81

7.4.2 Crankcase breather – Oil separator element replacement, diaphragm check and replacement 82

7.5 Valve Drive 84

7.5.1 Valve clearance – Check and adjustment 84

7.5.2 Cylinder-head cover – Removal and installation 87

7.6 Injection Valve / Injector 88

7.6.1 Injector – Replacement 88

7.6.2 Injector – Removal and installation 89

7.7 Fuel System 91

7.7.1 Fuel system – Venting 91

7.8 Fuel Filter 92

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7.8.1 Fuel filter – Replacement 92

7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge 94

7.8.3 Fuel prefilter – Draining 95

7.8.4 Fuel prefilter ‒ Flushing 96

7.8.5 Fuel prefilter – Filter element replacement 98

7.9 Charge-Air Cooling 100

7.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction 100

7.10 Air Filter 101

7.10.1 Air filter – Replacement 101

7.10.2 Air filter – Removal and installation 102

7.11 Air Intake 103

7.11.1 Contamination indicator – Signal ring position check (optional) 103

7.12 Starting Equipment 104

7.12.1 Starter – Condition check 104

7.13 Lube Oil System, Lube Oil Circuit 105

7.13.1 Engine oil – Level check 105

7.13.2 Engine oil – Change 106

7.14 Oil Filtration / Cooling 107

7.14.1 Engine oil filter – Replacement 107

7.14.2 Centrifugal oil filter – Cleaning and filtersleeve replacement 109

7.15 Coolant Circuit, General, HighTemperature Circuit 112

7.15.1 Drain and venting points 112

7.15.2 Engine coolant – Level check 117

7.15.3 Engine coolant – Change 118

7.15.4 Engine coolant – Draining 119

7.15.5 Engine coolant – Filling 120

7.15.6 HT coolant pump — Relief bore check 121

7.15.7 Engine coolant – Sample extraction and analysis 122

7.15.8 Coolant filter – Replacement 123

7.16 Raw Water Pump with Connections 124

7.16.1 Raw water pump – Relief bore check 124

7.17 Belt Drive 125

7.17.1 Drive belt – Condition check 125

7.18 Battery-Charging Generator 126

7.18.1 Battery-charging generator drive – Drive belt replacement 126

7.19 Fuel Supply System 127

7.19.1 Water drain valve – Check 127

7.19.2 Differential pressure gauge – Check 128

7.19.3 Water level probe (3-in-1 rod electrode) – Check 129

7.19.4 Pump capacity – Check 130

7.19.5 Coalescer filter element – Replacement 131

7.20 Wiring (General) for Engine/Gearbox/Unit 133

7.20.1 Engine wiring – Check 133

7.21 Accessories for (Electronic) Engine Governor / Control System 134

7.21.1 Engine governor and connectors – Cleaning 134

7.21.2 Engine governor – Checking plug-in connections 135

7.21.3 EMU – Checking plug-in connections 136

7.21.4 Engine governor – Carry out self-test 137

7.21.5 EMU and connectors – Cleaning 138

7.21.6 ECU 7 engine governor – Removal and installation 139

7.21.7 Engine monitoring unit – Removal and installation 140

8 Appendix A

8.1 Abbreviations 141

8.2 MTU contact persons/service partners 144

9 Appendix B

9.1 Special Tools 145

9.2 Consumables 152

9.3 Spare Parts 154

9.4 Index 156

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1 Safety

1.1 General conditions

General

In addition to the instructions in this publication, the applicable country-specific legislation and other com‐ pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may nevertheless present 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

Correct use

The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐ aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user alone.

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

Modifications or conversions

Unauthorized modifications to the engine represent a safety risk.

MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.

Spare parts

Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

Reworking components

Repair or engine overhaul must be carried out in workshops authorized by MTU.

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1.2 Personnel and organizational requirements

Personnel requirements

All work on the engine shall be carried out by trained and qualified personnel only.

The specified legal minimum age must be observed.

The operator must specify the responsibilities of the operating, maintenance and repair personnel.

Organizational measures

This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐ tion.

Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair and transport personnel at all times.

Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety-relevant instructions.

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

For the identification and layout of the spare parts during maintenance or repair work, take photos or use the spare parts catalog.

Working clothes and protective equipment

Wear proper protective clothing for all work.

Use the necessary protective equipment for the given work to be done.

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1.3 Transport

Transport without flange-mounted gearbox

A max. permissible diago‐

nal pull 70°

B max. permissible diago‐

nal pull 35°

Illustration is valid for 12/16V 2000 M engines

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Transport with flange-mounted gearbox

Illustration is valid for 12/16V 2000 M engines

Lift the engine only with the lifting eyes provided.

The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plants with flange-mounted gearboxes.

Only use transport and lifting devices approved by MTU.

Take the engine's center of gravity into account.

The engine must only be transported in installation position, max. permissible diagonal pull with flangemounted gearbox is 10°.

If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐ ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).

Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐ portation.

Secure the engine against tilting during transport. In particular when going down inclines or ramps, the engine must be secured against moving and tilting.

Setting the engine down after transport

Only set down engine on a firm, level surface.

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

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

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1.4 Safety regulations for startup and operation

Safety precautions when putting the equipment into operation

Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐ tions and check the installation according to the MTU specifications.

Before putting the device or plant into operation, always ensure:

• that all maintenance and repair work is completed,

• that all loose parts have been removed from rotating machine components,

• that all persons are clear of the danger zone of moving machine components.

Immediately after putting the device or plant into operation, make sure that all control and display instru‐ ments as well as the monitoring, signaling and alarm systems are working properly.

Safety regulations for equipment operation

Emergency procedures must be practiced regularly.

The operator must be familiar with the controls and displays.

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

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

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

• inform supervisor(s) in charge,

• analyze the message,

• if required, carry out emergency operations e.g. emergency engine stop.

Engine operation

The following conditions must be fulfilled before starting the engine:

• Wear ear protectors.

• Ensure that the engine room is well ventilated.

• Do not inhale engine exhaust gases.

• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.

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

• Protect battery terminals, battery-charger terminals and cables against accidental contact.

• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipment

When operating electrical equipment, certain components of this equipment are live.

Observe the safety instructions for these devices.

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1.5 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair work

Have maintenance and repair work carried out by qualified and authorized personnel only.

Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).

Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.

Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug with a rag to prevent fluids escaping under pressure.

Take special care when draining hot fluids ⇒ Risk of injury.

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

Allow the engine / system to cool down before starting to work.

Observe the maintenance and repair instructions.

Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.

Secure the engine against accidental starting.

Disconnect the battery when electrical starters are fitted.

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 assembly or system.

Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.

Carry out work only on assembles and/or units which are properly secured.

Never use lines for climbing.

Keep fuel injection lines and connections clean.

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

Take care not to damage lines, in particular fuel lines, during maintenance and repair work.

Ensure that all retainers and dampers are installed correctly.

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

Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐ ly protected.

Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.

When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐ nents are placed on stable surfaces.

Observe special cleanness when conducting maintenance and repair work on the assembly or system. After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐ bly or system.

Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the engine.

The following additional instructions apply to starters with beryllium copper pinion:

• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐ ards caused by the beryllium-containing pinion. 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 de‐ vice as an additional measure.

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Welding work

Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity.

Do not use the assembly or system as ground terminal.

Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.

Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removal

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

Observe the max. permissible push-on pressure specified for the equipment.

Do not attempt to bend or apply force to lines.

Before starting work, pay attention to the following:

• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).

• For hydraulic installation, screw on the tool with the piston retracted.

• For hydraulic removal, screw on the tool with the piston extended.

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

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the component to be installed/removed.

Working on electrical/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 reinstalling ensure that wiring is not damaged during operation by contact with sharp objects, by rubbing against other components or by a hot surface.

Do not secure cables on lines carrying fluids.

Do not use cable binders to secure cables.

Always use connector pliers to tighten connectors.

Subject the device or system to a function check on completion of all repair work.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐ fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐ ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐ diation.

Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application.

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For conducting light-beam procedures and measurement work, only the following laser devices must be used:

• Laser devices of classes 1, 2 or 3A.

• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

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1.6 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection

Fire prevention

Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires – therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐ cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.

Do not weld 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 keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their use.

Noise

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

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

Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo‐ nents as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations. Emission control units/systems may only be main‐ tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐ lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act and involves the termination of the operating license by the emission authorities. MTU does not accept any liability for violations of the emission regulations. MTU will provide assistance and advice if emissionrelevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐ ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.

Use only fuel of prescribed quality to comply with emission limit values.

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

Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.

Auxiliary materials, fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU.

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐ line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.

Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions that apply to the product. Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do not smoke.

Used oil

Used oil contains harmful combustion residues.

Rub barrier cream into hands.

Wash hands after contact with used oil.

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Lead

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

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

• Switch on extraction system.

• Wash hands after contact with lead or lead-containing substances.

Compressed air

Observe special safety precautions when working with compressed air:

• Pay special attention to the pressure level in the compressed air network and pressure vessel.

• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐ mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection.

• Hose couplings and connections must be securely attached.

• Wear goggles when blowing off components or blowing away chips.

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

• First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or before equipment or tool is to be replaced.

• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a risk of explosion.

• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of bursting.

• Carry out leak test in accordance with the specifications.

Paints and lacquers

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

• No open flames.

• No smoking.

• Observe fire prevention regulations.

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

Liquid nitrogen

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

• Avoid body contact (eyes, hands).

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

• Make sure that working area is well ventilated.

• Avoid all knocks and jars to the containers, fixtures or workpieces.

Acids and alkaline solutions

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

• If such solutions are spilled onto clothing, remove the affected clothing immediately.

• Rinse injured parts of the body thoroughly with clean water.

• Rinse eyes immediately with eyedrops or clean tap water.

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1.7 Conventions for safety instructions in the text

DANGER

In the event of immediate danger. Consequences: Death or serious injury

• Remedial action

WARNING

In the event of potentially dangerous situations. Consequences: Death or serious injury

• Remedial action

CAUTION

In the event of dangerous situations. Consequences: Minor injury or material damage

• Remedial action

NOTICE

In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage.

• Remedial action

• Additional product information

Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which

begin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions

1. Read and familiarize yourself with all safety notices before starting up or repairing the product.

2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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2 General Information

2.1 Tightening specifications for screws, nuts and bolts

Tightening torques for setscrew and stud joints as per MTN 5008 standard

This works standard applies to setscrews subjected to little dynamic load as per MMN 384, DIN 912, EN 24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.

It does not apply to heat-resistant screws in the hot component area.

Tightening torques MA are specified for screws of strength class 8.8 (surface condition bare, phosphat‐ ized or galvanized) and 10.9 (surface condition bare or phosphatized).

The values given in the table are based on a friction coefficient µtot.= 0.125. Prerequisite: Threads and mating faces of screws and nuts must be lubricated with engine oil prior to assembly.

When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening during assembly.

When machine-tightening, the permissible assembly tolerance is +15 %.

Thread

Hand-tightening Machine-tightening

8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)

M6 9 12 8 11

M8 21 31 20 28

M8 x 1 23 32 21 30

M10 42 60 40 57

M10 x 1.25 45 63 42 60

M12 74 100 70 92

M12 x 1.25 80 110 75 105

M12 x 1.5 76 105 72 100

M14 115 160 110 150

M14 x 1.5 125 180 120 170

M16 180 250 170 235

M16 x 1.5 190 270 180 255

M18 250 350 240 330

M18 x 1.5 280 400 270 380

M20 350 500 330 475

M2 x 1.5 390 550 350 520

M22 480 680 450 650

M22 x 1.5 520 730 490 700

M24 600 850 570 810

M24 x 1.5 680 950 640 900

M24 x 2 660 900 620 850

M27 900 1250 850 1175

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Thread

Hand-tightening Machine-tightening

8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)

M27 x 2 960 1350 900 1275

M30 1200 1700 1100 1600

M30 x 2 1350 1900 1250 1800

MA= tightening torques

Tightening torques for stress bolt connections as per MTN 5007 standard

This standard applies to statically and dynamically loaded stress bolt connections of strength class 10.9 and for corresponding nuts.

Shaft and transition dimensions as per MMN 209 standard and material and machining as per MMN 389 standard (bright surface or phosphatized).

The values given in the table are based on a friction coefficient µtot.= 0.125. Prerequisite: Threads and mating faces of screws and nuts must be lubricated with engine oil prior to assembly.

When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening during assembly.

The values in the tables are for manual tightening using a torque wrench.

Thread

Not torsion-protected MA(Nm) Torsion-protected MA(Nm)

M6 9 12

M8 21 28

M8 x 1 24 30

M10 42 55

M10 x 1.25 46 60

M12 75 93

M12 x 1.5 78 99

M14 120 150

M14 x 1.5 135 160

M16 180 225

M16 x 1.5 200 245

M18 250 315

M18 x 1.5 300 360

M20 350 450

M20 x 1.5 430 495

M22 500 620

M22 x 1.5 560 675

M24 640 790

M24 x 2 700 850

M27 900 1170

M27 x 2 1000 1230

M30 1250 1575

*Protect screw shank against torsion when tightening.

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MA= tightening torques

Tightening torques for plug screws as per MTN 5183-1 standard

This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852 shape A (sealed by sealing ring DIN 7603-Cu).

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Tightening torques MA are given for plug screws made of steel (St) with phosphatized surface-protection and oiled or galvanized. Thread and mating faces beneath heads must be coated in engine oil prior to

assembly. When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening during assembly.

Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug).

Thread

Screwed into

Steel/gray cast iron M

(Nm)

AI alloy M

(Nm)

M10 x 1 15 15

M12 x 1.5 30 25

M14 x 1.5 35 30

M16 x 1.5 40 35

M18 x 1.5 50 40

M20 x 1.5 60 50

M22 x 1.5 70 70

M24 x 1.5 85 80

M26 x 1.5 100 100

M27 x 2 100 100

M30 x 1.5 110 110

M30 x 2 120 120

M33 x 2 160 160

M36 x 1.5 190 180

M38 x 1.5 220 200

M42 x 1.5 260 240

M45 x 1.5 290 270

M48 x 1.5 310 *300

M52 x 1.5 325 320

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Thread

Screwed into

Steel/gray cast iron M

(Nm)

AI alloy M

(Nm)

M56 x 2 380 360

M64 x 2 400 400

MA= tightening torques

Tightening torques for plug screws DIN 7604C (with long screwed plug)

Thread

Screwed into

Steel/gray cast iron M

(Nm)

Al alloy M

(Nm)

M8 x 1 10 10

M22 x 1.5 80 65

M26 x 1.5 105 90

M30 x 1.5 130 130

M38 x 1.5 140 120

M45 x 1.5 160 140

MA= tightening torques

Tightening torques for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603Cu.

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The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled or galvanized and for copper-aluminum alloy.

Thread and mating faces beneath heads must be coated with engine oil prior to assembly.

Tightening torques for steel banjo screws

Thread

Screwed into steel/gray cast iron/Al alloy M

(Nm)

M8 x 1 10

M10 x 1 15

M12 x 1.5 20

M14 x 1.5 25

M16 x 1.5 25

M18 x 1.5 30

M22 x 1.5 60

M26 x 1.5 90

M30 x 1.5 130

M38 x 1.5 140

M45 x 1.5 160

MA= tightening torques

Tightening torques for copper-aluminum alloy banjo screws

Thread

Screwed into steel/gray cast iron/Al alloy M

(Nm)

M10 x 1 15

M16 x 1.5 30

MA= tightening torques

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Tightening torques for male connectors as per MTN standard 5183-3

This standard applies to male connectors DIN 2353, L series, with screwed plug DIN 3852, model A (sealed by sealing ring DIN 7603-Cu).

Tightening torques MA are given for male connectors made of steel (St) with surface protected by a phos‐ phate coating and oiled or galvanized.

Thread and mating faces beneath heads must be coated with engine oil prior to assembly.

Thread

Screwed into steel/gray cast iron M

(Nm)

M10 x 1 15

M12 x 1.5 20

M14 x 1.5 35

M16 x 1.5 50

M18 x 1.5 60

M22 x 1.5 70

M26 x 1.5 100

M32 x 2 160

M42 x 2 260

M48 x 2 320

MA= tightening torques

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Tightening torques for union nuts as per DIN 3859-2

1 Union nut 2 Screw fixture 3 O-ring 4 Linear ball bearing

Union nut: When installing the linear ball bearing, after firm hand-tightening (noticeable increase in force) the union nut is further tightened by a quarter of a rotation (90°) beyond this point.

Tightening torques for screwed plugs with O-ring as per ISO 6149-2

Thread Torque (Nm) + 10%

M8 x 1 10

M10 x 1 20

M12 x 1.5 35

M14 x 1.5 45

M16 x 1.5 55

M18 x 1.5 70

M20 x 1.5

M22 x 1.5 100

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Thread Torque (Nm) + 10%

M27 x 2 170

M33 x 2 310

M42 x 2 330

M48 x 2 420

M60 x 2 500

Only for closing off installation spaces for screw-in valves (see ISO 7789)

Tightening torques for screwed plugs with O-ring as per ISO 6149-3

Thread Torque (Nm) + 10%

M8 x 1 8

M10 x 1 15

M12 x 1.5 25

M14 x 1.5 35

M16 x 1.5 40

M18 x 1.5 45

M22 x 1.5 60

M27 x 2 100

M33 x 2 160

M42 x 2 210

M48 x 2 260

M60 x 2 315

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Tightening torques for plug screws as per MTN 5183-6

Thread

Screwed into

Steel/gray cast iron M

(Nm)

AI alloy M

(Nm)

M10 x 1 20 10+ 2

M12 x 1.5 35 14+ 2

M14 x 1.5 45 15+ 3

M16 x 1.5 55 18+ 3

M18 x 1.5 70 23+ 3

M22 x 1.5 100 33+ 4

M27 x 2 170 57+ 5

M33 x 2 310 103+ 10

M42 x 2 330 110+ 11

M48 x 2 420 140+ 14

M60 x 2

200+ 20

Value still to be determined

Assembly instructions and tightening torques for hose fittings with union nuts

In contrast to the instructions for pipe unions, hose fittings with sealing heads and the associated adapt‐ ers must be installed and connected as follows (these instructions do not apply to ORFS fittings).

Hose fitting, metallic sealing with union nut: Tighten union nut by hand then tighten a further max. 1/4 of a revolution with a wrench.

Hose fitting with O-ring and union nut: Tighten union nut by hand then tighten a further max. 1/2 of a revolution with a wrench.

Hoses must be suitably aligned before tightening the union nuts.

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Sealing head/sealing cone with metric union nut

Metric thread Pipe outer dia. Torque (Nm)

M12 x 1.5 6 20

M14 x 1.5 8 38

M16 x 1.5 8

M18 x 1.5 10

M20 x 1.5 12 58

M22 x 1.5 14

M24 x 1.5 16 74

M26 x 1.5 18 105

M30 x 2 20

135

M36 x 2 25

166

M42 x 2 30 240

M45 x 2 35 290

M52 x 2 38

330

Sealing head with BSP union nut

BSPP thread Torque (Nm)

G1/4 20

G3/8 34

G1/2 60

G5/8 69

G3/4 115

G1 140

G1.1/4 210

G1.1/2 290

G2 400

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2.2 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).

The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO

1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.

Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 Left engine side 2 KGS = Free end

3 Right engine side 4 KS = Driving end

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2.3 Product description

Description of the engine

Engine

The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection, sequential turbocharging and charge-air cooling.

An electronic management system provides engine control and monitoring.

Fuel system with common rail injection

Controlled by the engine electronics, the common rail injection system determines injection pressure, in‐ jection timing and injection quantity independently of the engine speed.

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

Charging 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 cooling 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 security and test system with interfaces to re‐ mote control system (RCS) and to monitoring system (MCS).

Electronic engine control unit (ECU)

Closed-loop control:

• Engine speed

• Fuel HP

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Open-loop control:

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

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

• Engine protection with multi-stage safety systems:

• Power reduction

• Power limitation

• Emergency stop

Monitoring:

• Exhaust gas temperature, A-side

• 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 power supply

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SOLAS – Fire protection specifications

Special connections

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

Plug-in pipe connection

The sleeve (4) covers the joint to prevent lateral spray.

Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐ curs.

The connection is confirmed as compliant with SOLAS by DNV and GL.

Plugs and sensors

Screw-in plugs (2) 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 single-ended union or a defective sealing ring (2), the liquid first has to pass the thread.

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The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under pressure.

HP line between fuel injector and HP accumulator

1 Support ring 2 V-ring 3 Thrust ring

4 Union nut 5 HP line 6 Thrust screw

7 Thrust ring 8 V-ring 9 Support ring

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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 Thrust screw 6 Thrust ring 7 O-ring 8 HP line

9 Pressure pipe

10 O-ring

Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from where it is routed at atmospheric pressure into a level-monitored leak fuel tank.

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2.4 Engine - Overview

Overview of free end

1 Engine oil heat ex‐

changer 2 Engine oil filter 3 Coolant filter 4 Diverter lever for engine

oil filter 5 Coolant distribution

housing with integrated

expansion tank 6 Oil separator 7 Air filter (air intake) 8 Engine governor 9 Air collecting housing

10 Engine lifting eyes

11 Exhaust turbocharger 12 Actuating cylinder for ex‐

haust flap 13 Carrier housing 14 Cylinder head cover 15 Engine mounting 16 Oil pan 17 Battery-charging genera‐

tor 18 Coolant filler neck 19 Raw water connection to

gearbox cooling system 20 Raw water pump

21 Raw water connection

from sea

22 Protective cover (belt

pulley) 23 Coolant pump 24 Plate-core heat ex‐

changer 25 Centrifugal oil filter 26 Fuel priming pump 27 Fuel filter

KGS = engine free end

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Overview driving end

1 Carrier housing upper

section 2 HP fuel pump 3 Oil filler neck 4 Oil dipstick 5 4/2-way directional con‐

trol valve

6 Electric starter 7 Drive flange 8 Flywheel housing 9 Carrier housing lower

section

10 Carrier housing middle

section

11 Bleeder valve 12 Exhaust outlet

KS = engine driving end

Engine model designation

Key to the engine model designation 12V/16V 2000 Mxy

12/16 Number of cylinders

v Cylinder arrangement

2000 Series

Mx Application segment

y Design index

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2.5 Sensors, actuators and injectors – Overview

Engine plan view

Deviations from illustrations are insignificant.

Also applies similarly to 12V.

Item Description Monitoring of

1 B7 Lube oil temperature

2 B10 Charge-air pressure

3 B44 Turbocharger speed

4 B3 Intake air temperature

5 B9 Charge-air temperature

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Engine free end

Item Description Monitoring of

1 B34 Fuel pressure after filter

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

3 B5.1 Lube oil pressure after filter

4 B5.2 (option) Lube oil pressure after filter

5 F33 Engine coolant level, expansion tank

6 B21 (option) Raw water pressure

7 B6.2 (option) Coolant temperature

8 B6.1 Coolant temperature

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Engine driving end

Item Description Monitoring of

1 B1 (ECU) Camshaft speed

2 B13.2 (optional EMU) Crankshaft speed

3 B13 (ECU) Crankshaft speed

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Engine, right side

Item Description Monitoring of

1 YB33 Fuel temperature

2 B48 Fuel pressure (in rail)

3 B16 (option) Coolant pressure

4 F46 Leak fuel level

5 Y27.2 4-2-directional control valve, B-side

6 B4.22 Exhaust temperature, B-side

7 F41 2-2-directional control valve

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Engine, left side

Item Description Monitoring of

1 B4.21 Exhaust gas temperature, A-side

2 Y27.1 4-2-directional control valve, A-side

3 B54 (option) Lube oil pressure, replenishment pump

System sensors

These sensors are fitted outside the engine.

Description Monitoring of

B19 Starting-air pressure

B70 Fuel prefilter water level

B41 Exhaust back pressure

S37 Start interlock, switching status

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3 Technical Data

3.1 12V 2000 M94 engine data

Explanation:

CP Reference value: Continuous power

FP Reference value: Fuel stop power

A Design value G Guaranteed value R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power setting)

N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 12V2000

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 12

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 1432

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 12

Cylinder arrangement: V angle Degrees

(°)

Bore mm 135

Stroke mm 156

Cylinder displacement Liters 2.23

Displacement, total Liters 26.76

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 12

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 0.7

LUBE OIL SYSTEM

Number of cylinders 12

Lube oil operating temperature upstream of engine, from R °C 82

Lube-oil operating temperature upstream of engine, to R °C 92

Lube oil operating pressure upstream of engine, from R bar 7.5

Lube oil operating pressure upstream of engine, to R bar 8.5

Lube oil operating pressure (low idle) (meas. point: upstream of engine) R bar 3

FUEL SYSTEM

Number of cylinders 12

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

Fuel pressure at engine inlet connection, min. (when engine is running), 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 7.1

GENERAL OPERATING DATA

Number of cylinders 12

Firing speed, from R rpm 100

Firing speed, to R rpm 120

STARTER (electric)

Number of cylinders 12

Rated starter voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 12

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

L Degrees

(°)

Longitudinal inclination, temporary max. driving end down (Option: max. op‐ erating inclinations)

L Degrees

(°)

22.5

Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ ating inclinations)

L Degrees

(°)

Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ ating inclinations)

L Degrees

(°)

Transverse inclination, continuous max. (Option: max. operating inclina‐ tions)

L Degrees

(°)

22.5

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

(°)

32.5

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CAPACITIES

Number of cylinders 12

Engine coolant, engine side (with cooling system) R Liters 125

Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ ing inclinations)

R Liters 123

Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations)

R Liters 113

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

L Liters 87

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

L Liters 105

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 12

Engine dry weight (with attached standard accessories, without coupling) R kg 2780

NOISE

Number of cylinders 12

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

R dB(A) 109

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

R dB(A) 104

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3.2 16V 2000 M94 engine data

Explanation:

CP Reference value: Continuous power

FP Reference value: Fuel stop power

A Design value G Guaranteed value R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 16V2000

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 16

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 1939

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 16

Cylinder arrangement: V angle Degrees

(°)

Bore mm 135

Stroke mm 156

Cylinder displacement Liters 2.23

Displacement, total Liters 35.68

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 16

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 0.7

LUBE-OIL SYSTEM

Number of cylinders 16

Lube oil operating temperature upstream of engine, from R °C 75

Lube-oil operating temperature upstream of engine, to R °C 94

Lube oil operating pressure upstream of engine, from R bar 6.0

Lube oil operating pressure upstream of engine, to R bar 7.5

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

FUEL SYSTEM

Number of cylinders 16

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

Fuel pressure at engine inlet connection, min. (when engine is running), 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 8.6

GENERAL OPERATING DATA

Number of cylinders 16

Firing speed, from R rpm 100

Firing speed, to R rpm 120

STARTER (electric)

Number of cylinders 16

Rated starter voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 16

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

L Degrees

(°)

Longitudinal inclination, temporary max. driving end down (Option: max. op‐ erating inclinations)

L Degrees

(°)

22.5

Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ ating inclinations)

L Degrees

(°)

Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ ating inclinations)

L Degrees

(°)

Transverse inclination, continuous max. (Option: max. operating inclina‐ tions)

L Degrees

(°)

22.5

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

(°)

32.5

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CAPACITIES

Number of cylinders 16

Engine coolant, engine side (with cooling system) R Liters 135

Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ ing inclinations)

R Liters 168

Oil change quantity, max. (standard oil system) (Option: max. operating in‐ clinations)

R Liters 155

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

L Liters 115

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

L Liters 138

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 16

Engine dry weight (with installed standard accessories, without coupling) R kg 3337

NOISE

Number of cylinders 16

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

R dB(A) 110

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

R dB(A) 107

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3.3 Firing order

Firing order

12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1

16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7

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3.4 Engine – Main dimensions

Main dimensions

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

12V 2000 M92 approx. 2069 mm approx. 1295 mm approx. 1350 mm

12V 2000 M93 approx. 2069 mm approx. 1295 mm approx. 1350 mm

12V 2000 M84 approx. 2094 mm approx. 1295 mm approx. 1350 mm

12V 2000 M94 approx. 2094 mm approx. 1295 mm approx. 1350 mm

16V 2000 M92 approx. 2486 mm approx. 1295 mm approx. 1390 mm

16V 2000 M93 approx. 2486 mm approx. 1295 mm approx. 1390 mm

16V 2000 M84 approx. 2511 mm approx. 1295 mm approx. 1390 mm

16V 2000 M94 approx. 2511 mm approx. 1295 mm approx. 1390 mm

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4 Operation

4.1 Putting the engine into operation after extended out-ofservice periods (>3 months)

Preconditions

☑ Engine is stopped and starting disabled.

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

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

Item Measure

Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).

Lube oil system Check engine oil level (→ Page 105).

Fuel prefilter Fill with fuel (→ Page 98).

Fuel prefilter, pressure gauge

Align adjustable pointer with position of pressure indicator (→ Page 94).

Fuel system Vent (→ Page 91).

Raw-water pump (if located above waterline)

Prime (approx. 3 to 4 liters).

Filling point (→ Page 112).

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

(→ Page 118).

Coolant circuit Check coolant level (→ Page 117).

Coolant circuit Heat engine coolant with coolant preheating unit.

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4.2 Engine – Putting into operation after scheduled out-ofservice-period

Preconditions

☑ Engine is stopped and starting disabled.

Putting into operation

Item Measure

Lube oil system Check engine oil level (→ Page 105).

Coolant circuit Check coolant level (→ Page 117).

Coolant circuit Heat engine coolant with coolant preheating unit.

Fuel prefilter Drain water and contaminants (→ Page 95).

Battery-charging generator drive

Check condition of drive belt (→ Page 125).

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

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

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

1. Start up fuel treatment system (→ Page 53).

2. Shut down fuel treatment system (→ Page 61).

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4.4 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 56).

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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4.5 Fuel treatment system – Putting into operation

Fuel treatment system – Overview

1. Switch on fuel treatment system (→ Page 56).

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 131).

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

Initial operation: HAT

1. Replace fuel filter on engine (→ Page 92).

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 56).

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 57).

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 56).

2. Start engine (→ Page 57).

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‐

ment4 system.

Simulation of power failure (emergency): HAT

1. Switch on fuel treatment system (→ Page 56).

2. Start engine (→ Page 57).

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 56).

2. Start engine (→ Page 57).

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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4.6 Operational checks

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Take special care when working on a running engine.

WARNING

Engine noise above 85 dB (A). Risk of damage to hearing!

• 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 65).

Fuel prefilter Check fuel prefilter contamination indicator for max. admissible value

(→ Page 94).

Drain water and contaminants (→ Page 95).

Air filter Check signal ring position of contamination indicator (→ Page 103).

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

(→ Page 121).

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

(→ Page 124).

Intercooler Check condensate drain (if applicable) (→ Page 100).

Engine oil Check engine oil level (→ Page 105).

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4.7 Fuel treatment system – Switching on

Preconditions

☑ The on-board power supply is switched on.

CAUTION

Damage to engine/plant. Major material damage!

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

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

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

Switching on fuel treatment system

1. Carry out checks prior to start-up (→ Page 52).

2. Switch on master switch on switch 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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4.8 Starting the engine

Preconditions

☑ External start interlock is not active.

☑ Emergency air shut-off flaps (if fitted) are open.

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Before barring or starting the engine, make sure that nobody is in the danger zone.

WARNING

Engine noise above 85 dB (A). 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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4.9 Stopping the engine

Preconditions

☑ Engine is running in local mode.

CAUTION

Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components!

• Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed.

The engine can be stopped from the following points :

1. (→ Operating instructions for electronic system)

2. Commanding control stand (→ Operating instructions for electronic system);

3. Local operating panel LOP (→ Operating instructions for electronic system);

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

5. CCU (→ Operating instructions for electronic system).

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4.10 Emergency stop

CAUTION

An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components!

• Initiate emergency stop only in emergency situations.

An emergency stop of the engine can be initiated from the following points :

1. (→ Operating instructions for electronic system)

2. Commanding control stand (→ Operating instructions for electronic system);

3. Local operating panel LOP (→ Operating instructions for electronic system);

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

5. CCU (→ Operating instructions for electronic system).

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4.11 After stopping the engine

Preconditions

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

After stopping the engine

Item Action

Coolant circuit Drain coolant (→ Page 119) 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 tempera‐ ture;

• 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 sys‐ tem

Out-of-service-period > 1 week

• Seal engine's air and exhaust sides.

Engine Out-of-service-period > 1 month

• Preserve engine (→ MTU Fluids and Lubricants Specifications A001061/.. )

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4.12 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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4.13 Plant cleaning

Preconditions

☑ Engine is stopped and starting disabled.

☑ Operating voltage is not present.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Steam jet cleaner

- 1

Cleaner (Hakupur 312)

30390 1

WARNING

Compressed air Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

WARNING

Water jet. Risk of injury and scalding!

• Do not direct water jet at persons.

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

CAUTION

Excessive reaction time of cleaning agents on components. Damage to component!

• Observe manufacturer's instructions.

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

NOTICE

Dry with compressed air. Damage to component!

• Never aim compressed air directly at electronic components.

Plant cleaning

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

2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit carefully and observe the safety precautions.

3. During external cleaning of the plant with water/steam-jet units, 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.

5. Carry out external cleaning as follows:

a) Seal all openings in a suitable fashion. 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.

Note: Never aim compressed air directly at electronic components.

e) Dry engine.

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5 Maintenance

5.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication.

The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

Task Maintenance tasks

W0500 Check engine oil level (→ Page 105)

W0501 Visually inspect engine for leaks and general condition (→ Page 55)

W0502 Check intercooler drain (if fitted) (→ Page 100)

W0503 Check signal ring position of service indicator on air filter (→ Page 103)

W0505 Check relief bores of coolant pump(s) (→ Page 121)

W0506 Check engine for abnormal running noises, exhaust color

and vibrations

(→ Page 55)

W0507 Drain water and contaminants from fuel prefilter (if fitted) (→ Page 95)

W0508 Check reading on differential pressure gauge of fuel prefilter

(if fitted)

(→ Page 94)

W1001 Replace fuel filter or fuel filter element (→ Page 92)

W1002 Check valve clearance (→ Page 84)

W1005 Replace air filter (→ Page 101)

W1006 Replace fuel injectors (→ Page 88)

W1008 Replace engine oil filter at each oil change or when the time

limit (years) is reached, at the latest

(→ Page 107)

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

sleeve (if fitted) at each oil change or when the time limit (years) is reached, at the latest

(→ Page 109)

W1011 Perform endoscopic inspection of combustion chambers (→ Page 77)

W1036 Replace coolant filter (→ Page 123)

W1140 Clean wire meshes of crankcase breather (→ Page 81)

W1244 Check operation of rod electrode (if fitted) (→ Page 129)

W1245 Check alarm function of differential pressure gauge (if fitted) (→ Page 128)

W1246 Check pump capacity (if fitted) (→ Page 130)

Table 1: Maintenance task reference table [QL1]

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6 Troubleshooting

6.1 Fuel treatment system – Troubleshooting

Illuminated pushbutton “water alarm” is lit.

Cause Corrective action

When the maximum water level is reached, the water level elec‐ trode opens the water drain valve and water is discharged. If the opening period of the valve exceeds a pre-set limit (4 mi‐ nutes), the pump will switch off and an alarm is initiated.

1. Press illuminated pushbutton “Water alarm” to acknowledge.

2. In addition to the automatic water drain function, water can also be drained manually. To do so, press the illuminated pushbutton “Water drain” to open the drain valve.

Signal lamp “Pump fault” is lit.

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-run‐ ning, the motor protection relay triggers and the pump is switch‐ ed off.

u Reset motor protection relay.

Signal lamp “Warning filter” is lit.

Cause Corrective action

The differential pressure exceed‐ ed 1.3 bar.

u Replace coalescer filter element (→ Page 131).

Illuminated pushbutton “Replace filter element” is lit.

Cause Corrective action

The max. permissible differential pressure of 1.5 bar was exceed‐ ed. If the coalescer filter element is not replaced, pressure will in‐ crease 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 131).

2. Press illuminated pushbutton “Replace filter element” to ac‐ knowledge.

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6.2 Troubleshooting

Engine does not turn when starter is actuated

Component Cause Action

Battery Low or faulty Charge or replace (see manufacturer's

documentation).

Cable connections faulty Check if cable connections are proper‐

ly secured (see manufacturer's docu‐ mentation).

Starter Engine wiring or starter faulty Check if cable connections are proper‐

ly secured, contact Service.

Engine cabling Faulty Check (→ Page 133).

ECU Plug-in connections possibly loose Check plug connections for secure

seating.

Engine Running gear blocked (engine cannot

be barred manually)

Contact Service.

Engine turns but does not fire

Component Cause Action

Starter Poor rotation by starter:Battery low or

faulty

Charge or replace battery (see manu‐ facturer's documentation).

Engine cabling Faulty Check (→ Page 133).

Fuel system Air in fuel system Vent fuel system (→ Page 91)

ECU Faulty Contact Service.

Engine fires unevenly

Component Cause Action

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 88).

Engine cabling Faulty Check (→ Page 133).

Fuel system Air in fuel system Vent fuel system (→ Page 91)

ECU Faulty Contact Service.

Engine does not reach rated speed

Component Cause Action

Fuel supply Fuel prefilter clogged Replace (→ Page 98).

Fuel filter clogged Replace (→ Page 92).

Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 103).

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 88).

Engine cabling Faulty Check (→ Page 133).

Engine Overloaded Contact Service.

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Engine speed not steady

Component Cause Action

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 88).

Speed sensor Faulty Replace.

Fuel system Air in fuel system Vent fuel system (→ Page 91)

ECU Faulty Contact Service.

Charge air temperature too high

Component Cause Action

Engine coolant Engine coolant treatment incorrect Check.

Intercooler Contaminated Contact Service.

Engine room Air-intake temperature too high Check fans and air supply / ventilation

ducts.

Charge-air pressure too low

Component Cause Action

Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 103).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Faulty Contact Service.

Coolant leaks at intercooler

Component Cause Action

Intercooler Leaking, major coolant discharge Contact Service.

Black exhaust gas

Component Cause Action

Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 103).

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 88).

Engine Overloaded Contact Service.

Blue exhaust gas

Component Cause Action

Engine oil Too much oil in engine Drain engine oil (→ Page 106).

Oil separator or oil-preseparator of crankcase breather clogged

• Clean preseparator (→ Page 81);

• Replace oil separator element (→ Page 82).

Exhaust turbocharg‐ er, cylinder head, pis‐ ton rings, cylinder lin‐ er

Faulty Contact Service.

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White exhaust gas

Component Cause Action

Engine Not at operating temperature Run engine to reach operating temper‐

ature.

Fuel system Water in fuel Drain fuel prefilter (→ Page 95).

Intercooler Leaking Contact Service.

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7 Task Description

7.1 SOLAS

7.1.1 SOLAS shielding as per MTN 5233 – Installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Shield A4

735233000100 10

Shield A5

735233000101 14

Shield A7

735233000103 6

Shield A8

735233000104 2

SOLAS shielding – Installation

1. Pinpoint installation location (→ Page 70).

2. Install suitable shielding.

3. Press shielding until locked.

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7.1.2 SOLAS shielding – Installation

Preconditions

☑ Engine is stopped and starting disabled.

☑ Engine is cooled down to ambient temperature.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter shield

X00009628

Fuel filter shield

X00009654

Installing SOLAS shield on oil filter and fuel filter

1. Pinpoint installation location (→ Page 70).

2. Install suitable shielding.

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7.1.3 Installation locations for SOLAS shielding

General information

Primarily fit SOLAS shielding as per MTN 5233 (→ Page 68).

Free end B-side

Item Type of shielding Comments

1 (free end, B-side) Shield (A7) On fuel delivery pump

2 (free end, B-side) Shield (A7) On HP fuel pump

Free end

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Item Type of shielding Comments

1 (free end) Shield (A8) On fuel filter

2 (free end) Shield (A7) Above fuel priming pump

3 (free end) Shield (A7) Below fuel priming pump

Driving end A-side

Item Type of shielding Comments

1 (Driving end, A-side) Shield (A5) On air flap

2 (Driving end, A-side) Shield (A4) On brazed-on union

3 (driving end, A-side) Shield (A5) On turbocharger flap

4 (driving end, A-side) Shield (A5) On turbocharger flap

Driving end A-side

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Item Type of shielding Comments

1 (driving end, A-side) Shield (A5) To turbocharger lubrication

2 (driving end, A-side) Shield (A5) On valve plate

Driving end

Item Type of shielding Comments

1 (driving end) Shield (A4) Turbocharger lubrication, left side

2 (driving end) Shield (A4) Turbocharger lubrication, center

Driving end

Item Type of shielding Comments

1 (driving end) Shield (A4) Turbocharger lubrication, right

side

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Driving end B-side

Item Type of shielding Comments

1 (driving end, B-side) Shield (A5) Turbocharger flap

2 (driving end, B-side) Shield (A5) Turbocharger flap

3 (driving end, B-side) Shield (A4) On brazed-on union

4 (driving end, B-side) Shield (A5) On air flap

5 (driving end, B-side) Shield (A4) To turbocharger lubrication

Driving end B-side

Item Type of shielding Comments

1 (driving end, B-side) Shield (A5) On valve plate

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Driving end A-side

Item Type of shielding Comments

1 (driving end, A-side) Shield (A5) To flap control

Driving end B-side

Item Type of shielding Comments

1 (driving end, B-side) Shield (A5) To flap control

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7.2 Engine

7.2.1 Engine – Barring manually

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring tool

F6783914 1

Ratchet

F30006212 1

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Before barring or starting the engine, ensure that nobody is in the danger zone.

• After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

Engine – Barring manually

1. Fit ratchet with barring tool on barring tool 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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7.2.2 Engine – Barring with starting equipment

Preconditions

☑ Clutch is disengaged.

☑ Engine start is disabled.

☑ LOP is accessible and open.

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Before barring or starting the engine, ensure that nobody is in the danger zone.

• After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

Barring

1. Press barring button on the LMB mother‐ board of the LOP and keep it depressed.

Result: Engine is barred by starter for max. 20 sec‐

onds.

2. Release barring pushbutton.

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7.3 Cylinder Liner

7.3.1 Cylinder liner – Endoscopic examination

Preconditions

☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Rigid endoscope

Y20097353 1

Preparatory steps

1. Remove cylinder head cover (→ Page 87).

2. Remove injector (→ Page 89).

Positioning crankshaft at BDC

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

2. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder liner

Findings Action

• Thin carbon coating on circumference of carbon scraper ring

• Slight localized additive deposits at top edge

• Localized smooth areas on bottom edge

• Carbon deposits on circumference in clearance 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

• Consistent honing pattern without objections

• First signs of marks left by lower cooling bores

• Running pattern seems darker

No action 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 cir‐ cumference without objections

• Piston rings without objections

Further endoscopic examina‐ tion required as part of main‐ tenance work

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

• Heat discoloration in the direction of stroke and honing pattern dam‐ age

• Heat discoloration of piston rings

Cylinder liner must be re‐ placed; Service must be con‐ tacted

1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 79).

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.

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Final steps

1. Install injector (→ Page 89).

2. Install cylinder head cover (→ Page 87).

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7.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination

Terms used for endoscopic examination

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

Findings Measure

Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐

ucts, 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 anoth‐

er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in‐ let/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

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

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐

perature 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 interrupt‐ ed.

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

discoloration 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.

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Findings Measure

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

over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam‐ aged 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, scuff‐ ing

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

Replace liner.

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 fur‐ ther operation of the engine.

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7.4 Crankcase Breather

7.4.1 Crankcase breather – Cleaning oil pre-separator element

Preconditions

☑ Engine is stopped and starting disabled.

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Compressed air Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

Crankcase breather – Cleaning oil pre-separator element

1. Remove cover (5) from housing (4).

2. Take off oil pre-separator element (1), gas‐ ket (3) and O-ring (2).

3. Wash oil pre-separator element (1) and housing (4) in fuel and blow out with com‐ pressed air.

4. Moisten oil pre-separator element (1) with engine oil.

5. Position oil pre-separator element (1) with new gasket (3) and O-ring (2) on housing (4) and install cover (5).

6. Clean further oil pre-separator elements in the same way.

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7.4.2 Crankcase breather – Oil separator element replacement, diaphragm check and replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 6-50 Nm

F30027336 1

Ratchet

F30027340 1 Engine oil Filter element

(→ Spare Parts Catalog)

Diaphragm

(→ 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 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 dia‐ phragm (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 seal (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 diaphragms in further oil separators in the same way.

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7.5 Valve Drive

7.5.1 Valve clearance – Check and adjustment

Preconditions

☑ Engine is stopped and starting disabled.

☑ Engine coolant temperature is max. 40 °C.

☑ Valves are closed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Feeler gauge

Y4345893 1

Barring tool

F6783914 1

Ratchet

F30006212 1

Double box wrench

F30002800 1

Angular screw driver

F30002816 1

Socket wrench

F30030450 1

Torque wrench, 10-60 Nm

F30510423 1

Measuring device

Y4345888 1

Preparatory steps

1. Remove air filter (→ Page 102).

2. Remove cylinder head cover (→ Page 87).

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 screw (3).

3. Zero dial gauge (2).

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

Result: The piston is at firing TDC when both rock‐

er 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 A1, the piston is in firing TDC.

• If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.

2. Check valve clearance with cold engine:

• Inlet (E) = 0.3 mm;

• Exhaust (A) = 0.4 mm.

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

8V2000

Position Cylinder 1 2 3 4 5 6 7 8 9

Firing TDC in cylinder A1 Bank A E A - A E - - A

Bank B E - E - - - - A

Overlap TDC in cylinder A1 Bank A - - E - - A E -

Bank B - A - A E A E -

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

10V2000

Position Cylinder 1 2 3 4 5 6 7 8 9

Firing TDC in cylinder A1 Bank A E A - - - - - A E -

Bank B E - - - - A E A E -

Overlap TDC in cylinder A1 Bank A - - E A E A E - - A

Bank B - A E A E - - - - A

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

12V2000

Position Cylinder 1 2 3 4 5 6 7 8 9

Firing TDC in cylinder A1 Bank A E A E - - A E - - A - -

Bank B E - - - - A E - E A- A

Overlap TDC in cylinder A1 Bank A - - - A E - - A E - E A

Bank B - A E A E - - A - - E -

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

16V2000

Position Cylinder 1 2 3 4 5 6 7 8 9

Firing TDC in cylinder A1 Bank A E A - A - A E - - A E - - - - -

Bank B E - - A - - E - E AE - E A- A

Overlap TDC in cylinder A1 Bank A - - E - E - - A E - - A E AE A

Bank B - A E - E A - A - - - A - - E -

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

18V2000

Position Cylinder 1 2 3 4 5 6 7 8 9

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Firing TDC in cylinder A1 Bank A E A E - - A E - - A - - - A - - - -

Bank B - A - A - - E A - - E AE - E A E -

Overlap TDC in cylinder A1 Bank A - - - A E - - A E - E A E - E A E A

Bank B E - E - E A - - E A- - - A - - - A

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

4. Use feeler 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.

Valve clearance adjustment

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

2. Insert feeler gauge between valve bridge and rocker arm.

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

4. Tighten locknut (1) with torque wrench to the prescribed tightening torque of 50 Nm while holding the adjusting screw (2) with Allen key.

5. Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap.

Result: If not, adjust valve clearance.

Final steps

1. Remove barring tool.

2. Install cylinder head cover (→ Page 87).

3. Install air filter (→ Page 102).

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7.5.2 Cylinder-head cover – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Centering device

F6783025 1

Gasket

(→ Spare Parts Catalog)

Preparatory steps

1. Remove air filter (→ Page 102).

2. Remove intake housing.

Cylinder-head cover – Removal and installation

1. Remove screws (1).

2. Remove cylinder-head cover (2) with gas‐ ket from cylinder head.

3. Clean mating faces.

4. Check condition of gasket of cylinder-head cover.

Result: Replace damaged gasket(s).

5. Center cylinder-head cover (2) with center‐ ing device.

6. Use torque wrench to tighten screws (1) to specified torque 20 Nm.

Final steps

1. Install air filter (→ Page 102).

2. Install intake housing.

3. Check cylinder-head covers for leaks.

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7.6 Injection Valve / Injector

7.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Injector

(→ Spare Parts Catalog)

Remove injector and install new one.

u (→ Page 89)

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7.6.2 Injector – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Socket wrench

0005896803/00 1

Puller

F6790629 1

Double box wrench

F30011450 1

Open end wrench bit

F30025897 1

Box wrench adapter

F30451199 1

Alignment device

F6790507 1

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933 1

Engine oil

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Preparatory steps

1. Close fuel supply to engine.

2. Remove cylinder head cover (→ Page 87).

Removing injector

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

2. Disconnect injector cable (4).

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. Remove all plugs before installation.

2. Fit new O-rings onto injector and coat with grease.

3. Fit new sealing ring with grease on injector, ensuring correct 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 tight‐ ening 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 fuel line Tightening torque (Engine oil) 30 Nm + 5 Nm

14. Attach cable (4).

Final steps

1. Install cylinder head cover (→ Page 87).

2. Open fuel supply to engine.

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7.7 Fuel System

7.7.1 Fuel system – Venting

Preconditions

☑ Engine is stopped and starting disabled.

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Venting fuel system

1. Unlock fuel priming pump, unscrew handle.

2. Open vent plugs on filter head.

Note: New version has two threaded vent plugs,

old version has four threaded vent plugs.

3. Operate the pump with the handle until fuel without bubbles comes out of the vent plugs and the nipples.

4. Close vent plugs on filter head.

5. Operate the pump with the handle until fuel without bubbles comes out of the nipple.

6. Lock fuel priming pump, screw in handle.

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7.8 Fuel Filter

7.8.1 Fuel filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter wrench

F30379104 1 Diesel fuel Easy-change filter

(→ Spare Parts Catalog)

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Take special care when working on a running engine.

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Take special care when working on a running engine.

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Engine noise above 85 dB (A). Risk of damage to hearing!

• Wear ear protectors.

CAUTION

Damage to component. Serious damage to plant!

• For filter replacement with the engine running, operate the engine at low engine load.

• The filter which is to be exchanged must be cut out for a brief period only.

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Easy-change fuel filter replacement with the engine stopped

1. Stop engine and disable engine start.

2. Cut out the filter to be replaced. B Left filter cut out

C Right filter cut out

3. Remove cut-out easy-change filter using

the oil filter wrench.

4. Clean sealing surface on filter head.

5. Check sealing ring of the new easy-change

filter and coat it with fuel.

6. Fit SOLAS shield (→ Page 68).

7. Screw on easy-change filter and tighten by

hand.

8. Set three-way cock to operating position (A)

so that both filters are cut in (operating po‐ sition).

9. Replace further fuel filters in the same way.

10. Vent fuel system (→ Page 91).

Easy-change fuel filter replacement with the engine running

1. Cut out the filter to be replaced.

2. Open the threaded vent plugs at the filter

head of the cut-out filter and make sure that the fuel filter is not pressurized.

Note: New version has two threaded vent plugs,

old version has four threaded vent plugs.

3. Close threaded vent plugs.

4. Remove cut-out easy-change filter using

the oil filter wrench.

5. Clean sealing surface on filter head.

6. Check sealing ring of the new easy-change

filter and coat it with fuel.

7. Fit SOLAS shield (→ Page 68).

8. Screw on easy-change filter and tighten by

hand.

9. Set three-way cock to operating position

(both filters cut in).

10. Replace further fuel filters in the same way.

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7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Take special care when working on a running engine.

WARNING

Engine noise above 85 dB (A). Risk of damage to hearing!

• Wear ear protectors.

Differential pressure gauge adjustment

1. When installing the new filter element: align adjustable pointer (2) with pressure-indicat‐ ing 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 indicator of pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 96).

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7.8.3 Fuel prefilter – Draining

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel Seal

(→ Spare Parts Catalog)

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Fuel prefilter – Draining

1. Cut out the filter to be drained. I Left filter cut in

II Right filter cut in

2. Open threaded vent plug (5) of the filter to

be drained.

3. Unlock drain valve (6) by pressing toggle

and open it.

4. Drain water and contaminants from the filter

until pure fuel emerges.

5. Close drain valve (6).

6. Remove screws securing the cover and

take off cover (2).

7. Fill filter housing with clean fuel.

8. Place new seal in cover (2).

9. Fit cover with gasket and secure it with

screws.

10. Cut in the cut-out filter again.

11. Close threaded vent plug (5) when fuel emerges from system.

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7.8.4 Fuel prefilter ‒ Flushing

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Fuel Gasket

(→ Spare Parts Catalog)

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Take special care when working on a running engine.

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Engine noise above 85 dB (A). Risk of damage to hearing!

• Wear ear protectors.

Fuel prefilter ‒ Flushing

1. Cut out clogged filter. I Left filter cut in

II Right filter cut in

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2. Open threaded vent plug (5) of filter to be flushed.

3. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel.

Result: Fuel flows from filtered side back to the un‐

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

4. Close threaded vent plug (5) and drain valve (6).

Fuel prefilter – Topping up with fuel

1. Stop engine (→ Page 58) and disable engine start.

2. Remove screws for cover and take off cover (2).

3. Fill filter housing with clean fuel.

4. Place new gasket in cover (2).

5. Fit cover with gasket and secure it with screws.

6. Check differential pressure (→ Page 94).

Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐

ter (→ Page 98).

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7.8.5 Fuel prefilter – Filter element replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel Filter element

(→ Spare Parts Catalog)

Seal

(→ Spare Parts Catalog)

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Replacing filter element

1. Cut out the contaminated filter. I Left filter cut in

II Right filter cut in

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2. Open threaded vent plug (5) of contaminat‐ ed filter.

3. Unlock drain valve (6) by pressing toggle and open it.

4. Drain water and contaminants from the fil‐ ter.

5. Close drain valve (6).

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

7. Remove spring housing (4) and filter ele‐ ment (3).

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

9. Fill filter housing with clean fuel.

10. Place new seal in cover (2).

11. Fit cover with gasket and secure it with screws.

12. Cut in the cut-out filter again.

13. Close threaded vent plug (5) when fuel emerges.

14. Set adjustable pointer of differential pres‐ sure gauge (→ Page 94).

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7.9 Charge-Air Cooling

7.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction

DANGER

Unguarded rotating and moving engine components. Risk of serious injury – danger to life!

• Take special care when working on a running engine.

WARNING

Engine noise above 85 dB (A). Risk of damage to hearing!

• Wear ear protectors.

WARNING

Compressed air Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

Intercooler – 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 intercooler is leaking. Con‐ tact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 88).

2. Bar engine manually (→ Page 75).

3. Bar engine with starting system to blow out combustion chambers (→ Page 76).

4. Install injectors (→ Page 89).

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