MTU 12 V 2000 M84, 16 V 2000 M84 Operating Instructions Manual

Operating Instructions

Diesel engine

12 V 2000 M84
16 V 2000 M84

MS150063/02E

Engine model kW/cyl. Application group

12V2000M84 101.7 kW/cyl. 1D, Continuous operation, variable, medium load

factors

16V2000M84 101.9 kW/cyl. 1D, Continuous operation, variable, medium load

factors

Table 1: Applicability

Printed in Germany

© 2014 Copyright MTU Friedrichshafen GmbH

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

All information in this manual was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents

1 Safety

1.1 Important requirements for all products 5

1.2 Personnel and organizational requirements 6

1.3 Transport 7

1.4 Safety requirements for startup and
operation 9

1.5 Safety requirements for maintenance and
repair work 10

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

1.7 Standards for safety notices in the text 15

2 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 layout 34

2.5 Sensors and actuators – Overview 36

3 Technical Data

3.1 12V 2000 M84 engine data 41

3.2 16V 2000 M84 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 Engine – Shutdown 58

4.10 Emergency engine 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 – Cranking on starting system 76

7.3 Cylinder Liner 77

7.3.1 Cylinder liner – Endoscopic examination 77

7.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 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 86

7.6 Injection Valve / Injector 87

7.6.1 Injector – Replacement 87

7.6.2 Injector – Removal and installation 88

7.7 Fuel System 90

7.7.1 Fuel system – Venting 90

7.8 Fuel Filter 91

7.8.1 Fuel filter – Replacement 91

7.8.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 93

7.8.3 Fuel prefilter – Draining 94

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

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7.10.1 Air filter – Replacement 101

7.10.2 Air filter – Removal and installation 102

7.11 Air Intake 103

7.11.1 Service 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 and filter sleeve –
Cleaning and replacement 109

7.15 Coolant Circuit, General, High-Temperature
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 EMU and connectors – Cleaning 135

7.21.3 Engine governor plug connections – Check 136

7.21.4 Engine Monitoring Unit EMU 7 – Plug
connection check 137

7.21.5 Interface module EIM plug connections –
Check 138

7.21.6 Engine Control Unit – Self-test 139

7.21.7 Engine Control Unit ECU 7 – Removal and
installation 140

7.21.8 Engine Monitoring Unit – Removal and
installation 141

7.21.9 Engine Interface Module EIM – Removal and
installation 142

7.21.10 Diagnostic features of EIM 143

8 Appendix A

8.1 Abbreviations 146

8.2 MTU contact persons/service partners 148

9 Appendix B

9.1 Special Tools 149

9.2 Index 156

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1 Safety

1.1 Important requirements for all products

Nameplate

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

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

General information

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

• Improper use

• Operation, maintenance and repair by unqualified personnel

• Changes or modifications

• Noncompliance with the safety instructions and warning notices

Intended use

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

Intended use entails operation:

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

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

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

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

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

• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product

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

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

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

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

Changes or modifications

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

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

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1.2 Personnel and organizational requirements

Organizational measures of the operator

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

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

Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe­ty-relevant instructions, in particular, must be read and understood.

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

Personnel requirements

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

• Training at the Training Center of the manufacturer

• Qualified personnel specialized in mechanical and plant engineering

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

Working clothes and personal protective equipment

Wear proper protective clothing for all work.

When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec­tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.

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1.3 Transport

Transport without flange-mounted gearbox

A max. permissible diagonal

pull 70°

B max. permissible diagonal

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 bear­ing 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 trans­portation.

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 requirements for startup and operation

Safety requirements for startup

The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.

All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.

Whenever the product is started, always ensure that:

• All maintenance and repair work has been completed.

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

• Wearers of cardiac pacemakers or other active medical implants are well clear.

• The operating room is adequately ventilated.

• Exhaust pipework is leak-tight and routed to atmosphere.

• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.

• All personnel is clear of the danger zone represented by moving parts.

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

Safety requirements for operation

The operator must be familiar with the controls and displays.

The operator must be aware of the consequences of any operations he/she performs.

During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.

Malfunctions and emergency stop

Emergency procedures, in particular emergency stop, must be practiced on a regular basis.

Take the following steps if a system malfunction is detected or signaled by the system:

• Inform the duty supervisor(s).

• Evaluate the message.

• Respond to the emergency appropriately, e.g. execute an emergency stop.

Operation

Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.

Keep a safe distance away from the product whenever possible. Do not touch the product unless ex­pressly instructed to do so.

Do not inhale exhaust gases emitted by the product.

Ensure that the following requirements have been fulfilled before starting the product:

• Ear protectors are worn.

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

Operation of electrical equipment

Some components are live (high voltage) when electrical equipment is in operation.

Observe the safety instructions for these appliances.

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1.5 Safety requirements for maintenance and repair work

Safety requirements before commencing maintenance and repair work

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

Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.

Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.

Do not perform maintenance or repair work when the product is running unless:

• expressly instructed to do so.

• the product is running in the low load range and only for as long as necessary to complete the task.

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

Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.

Disconnect the battery. Lock the contactor.

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

Disconnect the control facility from the product.

For starters with pinions made of copper-beryllium alloy:

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

• Observe the safety data sheet.

Safety requirements during maintenance and repair work

Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.

Take care when draining hot fluids and lubricants (risk of burning).

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

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

Never climb up on the lines.

Keep fuel injection lines and connections clean.

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

Fit new seals when re-installing lines.

Avoid damaging lines, particularly the fuel lines.

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
contact with other components. Never route fuel or oil lines in the vicinity of hot components.

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

Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).

Always use suitable ladders and work platforms when working above head-height. Ensure that compo­nents or assemblies are placed on stable surfaces.

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Pay particular attention to cleanliness at all times.

Safety requirements after completing maintenance and repair work

Ensure that all personnel is clear of danger zones before cranking.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safety equipment has been installed and that all tools and loose parts have been re­moved (especially the barring gear).

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

Welding work

Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.

Before commencing welding work:

• Switch off the master power supply switch.

• Disconnect the battery.

• Disconnect electronic and genset grounds.

Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.

Do not use the product as a grounding terminal.

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

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

Hydraulic installation and removal

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

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

Do not attempt to bend or exert force on HP lines.

Before starting work, pay attention to the following:

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

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

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

For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.

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

Working with batteries

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

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

Do not allow electrolyte (battery acid) to come into contact with skin or clothing.

Wear goggles and protective gloves.

Do not place tools on the battery.

Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.

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Working on electrical/electronic assemblies

Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.

De-energize the appropriate areas prior to working on assemblies.

Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cabling to lines bearing fluids.

Do not use cable ties to secure cabling.

Always use connector pliers to tighten union nuts on connectors.

Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.

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

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil if necessary.

Working with laser equipment

Always wear special laser-protection goggles when working with laser equipment (danger due to in­tensely focused radiation).

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

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 nm 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.

Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C.

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

Fire prevention

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

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

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

Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.

Noise

Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.

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

Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com­ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu­facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.

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

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

Fluids and lubricants and auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera­tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.

Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum­ables and other chemical substances, follow the safety regulations that apply to the product. Take spe­cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
coming into contact with ignition sources and do not smoke.

Used oil

Used oil contains combustion residues that are harmful to health.

Rub barrier cream into hands.

Wash hands after contact with used oil.

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Lead

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

• Switch on extraction system.

• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.

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

Compressed air

Observe special safety precautions when working with compressed air:

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

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

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

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

• Assemblies or products to be connected must either be designed for that pressure, or, if the permis­sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.

• Hose couplings and connections must be securely attached.

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

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

• Carry out leak test in accordance with the specifications.

Paints and varnishes

• Observe the relevant safety data sheet for all materials.

• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.

• There must be no naked flames in the vicinity.

• No smoking.

• Observe fire prevention regulations.

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

Liquid nitrogen

• Observe the relevant safety data sheet for all materials.

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

• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).

• Avoid body contact (eyes, hands).

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

• Make sure that working area is well ventilated.

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

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

• Observe the relevant safety data sheet for all materials.

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

• Do not inhale vapors.

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

• If spilled onto clothing, remove the affected clothing immediately.

• After contact with skin, rinse affected parts of the body with plenty of water.

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

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1.7 Standards for safety notices in the text

DANGER

In the event of immediate danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

WARNING

In the event of a situation involving potential danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!

• Remedial action.

NOTICE

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

Consequences: Material damage!

• Remedial action.

• Additional product information.

Safety notices

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

2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.

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2 General Information

2.1 Tightening specifications for screws, nuts and bolts

Tightening torques for setscrew and stud joints to MTN 5008 standard

This standard applies to setscrews not subject to dynamic loads and the associated nuts according to:

• MMN 384

• DIN 912

• ISO 4014 (DIN 931-1)

• ISO 4017 (DIN 933)

• EN 28765 (DIN 960)

• EN 28676 (DIN 961)

• DIN 6912

This standard applies to studs not subject to dynamic loads and the associated nuts according to:

• DIN 833

• DIN 835

• DIN 836

• DIN 938

• DIN 939

The standard does not apply to heat-resistant screws in the hot component zone.

Tightening torques MA are specified for screws of strength class 8.8 (surface finish bare metal, phosph­atized or galvanized) and 10.9 (surface finish bare metal or phosphatized).

The values in the table are based on a friction coefficient µtot = 0.125.

Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.

When hand-tightening (defined torque), an assembly tolerance of +10% of the figures in the table is per­mitted.

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

M20 x 1.5 390 550 350 520

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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)

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

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 to MTN 5007 standard

This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic
load of strength class 10.9 as well as to the associated nuts.

Shank and junction dimensions to MMN 209 standard and material and manufacture to MMN 389
standard (bare metal or phosphatized).

The values in the table are based on a friction coefficient µtot = 0.125.

Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.

An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations
during the tightening process.

The figures in the table are for hand-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

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Thread

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

M27 900 1170

M27 x 2 1000 1230

M30 1250 1575

*Protect screw shaft from torsion when tightening.

MA= tightening torques

Tightening torques for plug screws to MTN 5183-1 standard

This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852
Form A (sealed with sealing ring to DIN 7603-Cu).

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Tightening torques MA are given for screw plugs made of steel (St) with surface protected by a phos­phate coating and oiled or galvanized.

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

An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations
during the tightening process.

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

Thread

Screwed into

Steel/gray cast iron M

A

(Nm)

AI alloy M

A

(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

M56 x 2 380 360

M64 x 2 400 400

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MA= tightening torques

Tightening torques for plug screws to DIN 7604C (with long threaded end)

Thread

Screwed into

Steel/gray cast iron M

A

(Nm)

Al alloy M

A

(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 to MTN 5183-2 standard

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

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The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface coating
and oiled, or galvanized, and to banjo screws made of copper/aluminum alloys.

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

An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations
during the tightening process.

Tightening torques for steel banjo screws

Thread

Screwed into steel/gray cast iron/Al alloy M

A

(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 banjo screws made of copper-aluminum alloy

Thread

Screwed into steel/gray cast iron/Al alloy M

A

(Nm)

M10 x 1 15

M16 x 1.5 30

MA= tightening torques

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Tightening torques for male unions to MTN 5183-3 standard

This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A
(sealed by sealing ring to DIN 7603-Cu).

Tightening torques MA are given for male unions made of steel (St) with phosphatized surface coating
and oiled, or galvanized.

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

An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations
during the tightening process.

Thread

Screwed into steel/gray cast iron M

A

(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 to DIN 3859-2

1 Union nut
2 Union body
3 O-ring
4 Ferrule

Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable
increase in force), it should be tightened another 1/4 turn (90°) past this point.

Tightening torques for spigot unions with O-ring to 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

1)

80

M22 x 1.5 100

M27 x 2 170

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Thread Torque (Nm) +10%

M33 x 2 310

M42 x 2 330

M48 x 2 420

M60 x 2 500

1)

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

Tightening torques for spigot unions with O-ring to 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 to MTN 5183-6

Thread

Screwed into

Steel/gray cast iron M

A

(Nm)

AI alloy M

A

(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

1)

200+ 20

1)

Figure not yet determined

Assembly instructions and tightening torques for hose fittings with union nuts

These instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose
fittings with sealing heads and the matching adapters must be fitted and connected as follows.

Hose fitting forming metallic seal with union nut: tighten union nut by hand then tighten a further
max. 1/4 of a turn 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
turn with a wrench.

Hoses must be properly aligned before tightening the union nuts.

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

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Sealing head/sealing cone with metric union nut

Metric thread Pipe outer dia. Torque (Nm)

M16 x 1.5 8

10

45

M18 x 1.5 10

12

51

M20 x 1.5 12 58

M22 x 1.5 14

15

74

M24 x 1.5 16 74

M26 x 1.5 18 105

M30 x 2 20

22

135

M36 x 2 25

28

166

M42 x 2 30 240

M45 x 2 35 290

M52 x 2 38

42

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) (4).

For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on
the left-hand side of the engine and the letter "B" (3) to refer to the cylinders on the right-hand side. The
cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.

The numbering of other engine components also starts with no. 1 at the driving end.

1 Left-hand side of engine
2 Free end

3 Right-hand side of engine
4 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 electronic engine management system, the common rail injection system determines
injection pressure, injection timing and injection quantity independently of the engine speed.

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

Turbocharging system

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

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

The triple-walled design permits

• low surface temperature,

• reduced thermal load,

• absolute gas-tightness.

Lube oil system

Wet-sump forced-feed lubrication system

Components supplied with oil:

• Bearings

• Piston cooling

• Control and actuating elements of the sequential turbocharging system

Cooling system

• Two separate 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 safety and test system with interfaces to the
Remote Control System (RCS) and to the Monitoring and Control System (MCS).

Connection box EIM (Engine Interface Module)

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

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Functions:

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

• Generator monitoring

• Open bus interface to the plant (SAE J1939)

• Emergency stop function with line break monitoring

• Redundant power supply

• Optional control of emergency air-shutoff flaps

• Key switch logic

• Interface to ECU and EMU

• MCS5 dialog interface

• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)

• Connection facility for an MTU Local Operating Station (LOS)

Serial RS422 interface for diagnosis

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

Functions

• ECU supply

• EMU supply

• Plant signals (ECU7 connector X1)

• Bus interface (2x MCS5 CAN)

• CAN dialog output (1x MCS5 CAN)

• ECU and EMU emergency stop

• Electric starter

• Terminal 45 starter A/B (engaged)

• Pneumatic starter

• Starting air pressure valve

• Starting air pressure sensor

• Barring gear (Barring Gear 1 and 2)

• Generator (with exciter control)

• Optional emergency air-shutoff flaps

• Activation of SDAF 1+2

• Feedback from SDAF 1+2

Electronic engine control unit (ECU)

Closed-loop control:

• Engine speed

• Fuel HP

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

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Monitoring:

• Exhaust gas temperature, A side

• Exhaust temperature, B-side

• Engine speed

• Oil pressure

• Differential oil pressure

• Coolant temperature

• Coolant level

• Exhaust turbocharger speed

• Leak fuel level

• Oil temperature

• Coolant pressure

• Fuel pressure after filter

Monitoring in engine room

Engine control and monitoring unit (LOP)

Functions:

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

• Integrated safety system

• Integrated Test System

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

• 24 V DC supply

SOLAS – Fire protection specifications

Special connections

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

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Plug-in pipe union

The sleeve (3) covers the joint to prevent lateral spray.

Only leak-off along the line is possible, the pressure decreases significantly if an O-ring (2) fault occurs.

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

Plugs and sensors

Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).

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

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

HP line between fuel injector and HP accumulator

1 Support ring
2 V-ring
3 Thrust ring

4 HP line
5 Thrust screw
6 Support ring

7 Thrust ring
8 V-ring
9 Union nut

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HP line between distributor and HP accumulator

1 Union nut
2 O-ring
3 Thrust ring

4 Thrust screw
5 O-ring
6 O-ring

7 Thrust ring
8 Pressure pipe
9 Jacket pipe

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HP line between distributor and HP accumulator

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

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

9 HP line

10 Pressure pipe

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

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2.4 Engine layout

View on free end

Also valid for 16V engines

1 Engine oil heat exchanger
2 Engine oil filter
3 Coolant filter
4 Diverter lever for engine

oil filter

5 Coolant distribution hous-

ing 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 generator
18 Coolant filler neck
19 Engine Interface Module

EIM
20 Raw water connection to

gearbox cooling system

21 Raw water pump
22 Raw water connection

from sea

23 Protective cover (belt pul-

ley)
24 Coolant pump
25 Plate-core heat exchanger
26 Centrifugal oil filter
27 Fuel priming pump
28 Fuel filter

KGS = engine free end

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View on driving end

1 Carrier housing upper sec-

tion
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 sec-

tion

10 Carrier housing middle

section

11 Relief valve
12 Exhaust outlet
KS = engine driving end

Engine model designation

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

12/16 Number of cylinders

V Cylinder arrangement: V engine

2000 Series

M Application

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

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

z Special features

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2.5 Sensors and actuators – Overview

Engine plan view

Deviations from illustrations are insignificant.

Also applies similarly to 12V.

Item Designation Monitoring of

1 B3 Intake air temperature

2 B9 Charge-air temperature

3 B7 Lube oil temperature

4 B10 Charge-air pressure

5 B44 Turbocharger speed

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Engine free end

Item Designation Monitoring of

1 B34 Fuel pressure after filter

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

3 B5.1 Lube oil pressure after filter

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

5 F33 Engine coolant level, expansion tank

6 B21 (optional) Raw water pressure

7 B6.2 (optional) Coolant temperature

8 B6.1 Coolant temperature

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Engine driving end

Item Designation 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 Designation Monitoring of

1 F41 2-2-directional control valve

2 YB33 Fuel temperature

3 B48 Fuel pressure (in rail)

4 B16 (optional) Coolant pressure

5 F46 Leak fuel level

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

7 B4.22 Exhaust temperature, B-side

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Engine, left side

Item Designation Monitoring of

1 B4.21 Exhaust gas temperature, A-side

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

3 B54 (optional) Lube oil pressure, replenishment pump

System sensors

These sensors are fitted outside the engine.

Designation 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 M84 engine data

Explanation:

DL Ref. value: Continuous power
BL Ref. value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

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

N Not yet defined value

- Not applicable

X Applicable

Reference conditions

Engine model 12V2000

M84

Application group 1D

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

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

Number of cylinders 12

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 1220

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

(°)

90

Bore mm 135

Stroke mm 156

Cylinder displacement Liters 2.23

Total displacement 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 before engine, from R °C 82

Lube-oil operating temperature before engine, to R °C 90

Lube oil operating pressure before engine, from R bar 7.5

Lube oil operating pressure before engine, to R bar 8.5

Lube oil operating pressure (low idle) (meas. point: before 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. (during engine operation) L bar -0.3

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

Fuel supply flow, max. R liters/min 6.3

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

(°)

15

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

L Degrees

(°)

22.5

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

L Degrees

(°)

0

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

L Degrees

(°)

10

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

(°)

22.5

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

(°)

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. operating
inclinations)

R Liters 123

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

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

Acoustics

Number of cylinders 12

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

R dB(A) 108

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) 103

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3.2 16V 2000 M84 engine data

Explanation:

DL Ref. value: Continuous power
BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

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

- Not applicable

X Applicable

Reference conditions

Engine model 16V2000

M84

Application group 1D

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

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

Number of cylinders 16

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 1630

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

(°)

90

Bore mm 135

Stroke mm 156

Cylinder displacement Liters 2.23

Total displacement 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 before engine, from R °C 75

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

Lube oil operating pressure before engine, from R bar 6.0

Lube oil operating pressure before engine, to R bar 7.5

Lube oil operating pressure (low idle) (meas. point: before 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. (during engine operation) L bar -0.3

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

Fuel supply flow, max. R liters/min 7.3

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

(°)

15

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

L Degrees

(°)

22.5

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

L Degrees

(°)

0

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

L Degrees

(°)

10

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

(°)

22.5

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

(°)

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. operating
inclinations)

R Liters 168

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

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 attached standard accessories, without coupling) R kg 3337

Acoustics

Number of cylinders 16

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis­tance, 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) 106

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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 M84 approx. 2094 mm approx. 1295 mm approx. 1350 mm

16V 2000 M84 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-of-service
periods (>3 months)

Preconditions

☑Engine is stopped and starting disabled.

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

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

Item Action

Engine Depreserve (→ MTU Preservation and Represervation Instructions

A001070/..).

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

Fuel prefilter Fill with fuel (→ Page 98).

Fuel prefilter, pressure gage Align adjustable pointer with position of pressure indicator (→ Page 93).

Fuel system Vent (→ Page 90).

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.

Engine Control Unit ECU Check plug connections (→ Page 136).

Engine Interface Module EIM Check plug connections (→ Page 138).

Engine Monitoring Unit EMU Check plug connections (→ Page 137).

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

Preconditions

☑Engine is stopped and starting disabled.

Putting into operation

Item Action

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

Coolant circuit Check coolant level (→ Page 117).

Coolant circuit Heat engine coolant with coolant preheating unit.

Fuel prefilter Drain water and contaminants (→ Page 94).

Battery-charging generator
drive

Check condition of drive belt (→ Page 125).

Engine Control Unit ECU Check plug connections (→ Page 136).

Engine Interface Module EIM Check plug connections (→ Page 138).

Engine Monitoring Unit EMU Check plug connections (→ Page 137).

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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 91).

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 deliv-

ered 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 re-

placement 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

treatment 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

Rotating and moving engine parts.

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

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Operational checks

Item Action

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

(→ Page 93).
Drain water and contaminants (→ Page 94).

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

Replace air filter (→ Page 101), if the signal ring is completely visible in the
service indicator observation window.

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

(→ Page 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.

NOTICE

Risk of damage to engine/system.

Risk of severe damage to property!

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

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

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

Fuel treatment system – Switching on

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

2. Switch on master switch on switchgear cabinet.

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

3. Switch on switch for pump.

Result: Signal lamp “Pump running” lights up.

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4.8 Starting the engine

Preconditions

☑External start interlock is not active.

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

DANGER

Rotating and moving engine parts.

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

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

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

The engine can be started from the following points

Item Action

Control stand (→ Operating instructions for electronic system)

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

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

CCU (→ Operating instructions for electronic system)

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4.9 Engine – Shutdown

Preconditions

☑Engine is running in Local mode

NOTICE

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

Risk of overheating, damage to components!

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

The engine can be stopped from the following points

Item Action

Control stand (→ Operating instructions for electronic system)

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

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

CCU (→ Operating instructions for electronic system)

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4.10 Emergency engine stop

NOTICE

An emergency stop causes extreme stress to the engine plant.

Risk of overheating, damage to components!

• Initiate emergency stop only in emergency situations.

An emergency engine stop can be initiated from the following points

Item Action

Control stand (→ 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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4.11 After stopping the engine

Preconditions

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

After stopping the engine

Item Measure

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 tem­perature;

•

antifreeze concentration is 50 % and engine-room temperature is be­low -40°C.

Raw water Drain

•

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

Engine control system Switch off.

Air intake and exhaust sys­tem

Out-of-service-period > 1 week

•

Seal engine's air and exhaust sides.

Engine Out-of-service-period > 1 month

•

Depreserve engine (→ MTU Preservation and Represervation Specifica­tions A001070/..)

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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 applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Steam jet cleaner

- 1

Cleaner (Hakupur 312)

30390 1

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

WARNING

Steam jet cleaner ejects jet of pressurized water.

Risk of injury to eyes and scalding!

• Never direct water jet at people.

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

NOTICE

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

Damage to components is possible!

• Observe manufacturer's instructions.

NOTICE

Blowing down product with compressed air.

Entry of dirt and damage to components is possible!

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

Plant – Cleaning

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

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

3. For external cleaning of the plant with water or steam-jet cleaners:

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

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

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

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

Note: Never aim compressed air directly at electronic components.

5. Carry out external cleaning as follows:

a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.

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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(s). (→ Page 55)

W0503 Check service indicator of air filter. (→ Page 55)

W0505 Check relief bores of coolant pump(s). (→ Page 55)

W0506 Check engine for abnormal running noises, exhaust color and

vibrations.

(→ Page 55)

W0507 Drain water and contaminants from fuel prefilter. (→ Page 55)

W0508 Check reading on differential pressure gage of fuel prefilter. (→ Page 55)

W1001 Replace fuel filter or fuel filter element. (→ Page 91)

W1002 Check valve clearance. (→ Page 84)

W1005 Replace air filter. (→ Page 101)

W1006 Replace fuel injectors. (→ Page 87)

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

interval (years) is reached, at the latest.

(→ Page 107)

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

sleeve, at every oil change, at the latest.

(→ Page 109)

W1011 Perform endoscopic examination. (→ Page 77)

W1036 Replace coolant filter. (→ Page 123)

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

W1244 Check function of rod electrode. (→ Page 129)

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

W1246 Check pump capacity. (→ Page 130)

Table 2: 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
electrode opens the water drain
valve and water is discharged. If
the opening period of the valve
exceeds a pre-set limit
(4 minutes), 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 dry­running, the motor protection
relay triggers and the pump is
switched off.

u Reset motor protection relay.

Signal lamp “Warning filter” is lit.

Cause Corrective action

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

1. Replace coalescer filter element (→ Page 131).

2. Press illuminated pushbutton “Replace filter element” to
acknowledge.

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6.2 Troubleshooting

Engine does not turn when starter is actuated

Cause Corrective action

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

Battery: Cable connections
faulty

u Check if cable connections are properly secured (see

manufacturer's documentation).

Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
Engine cabling defective u Check (→ Page 133).

Loose plug connections on
Engine Control Unit

u Check plug connections (→ Page 136).

Loose plug connections on
Engine Interface Module (EIM)

u Check plug connections (→ Page 138).

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

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

actuating the key switch.

Running gear blocked (engine
cannot be barred manually)

u Contact Service.

Engine turns on starting but does not fire

Cause Corrective action

Poor rotation by starter: Battery
low or faulty

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

Engine cabling defective u Check (→ Page 133).
Air in fuel system u Vent fuel system (→ Page 90).
Engine Control Unit defective u Contact Service.

Engine fires unevenly

Cause Corrective action

Injector faulty u Replace (→ Page 87).
Engine cabling defective u Check (→ Page 133).
Air in fuel system u Vent fuel system (→ Page 90).
Engine Control Unit defective u Contact Service.

Engine does not reach nominal speed

Cause Corrective action

Fuel prefilter clogged u Replace (→ Page 98).
Easy-change fuel filter clogged u Replace (→ Page 91).
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 103).
Fuel injection: Injector faulty u Replace (→ Page 87).
Engine cabling defective u Check (→ Page 133).
Engine: Overload u Contact Service.

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Engine speed not steady

Cause Corrective action

Fuel injection: Injector faulty u Replace (→ Page 87).
Speed transmitter defective u Contact Service.
Air in fuel system u Vent fuel system (→ Page 90).
Engine Control Unit defective u Contact Service.

Charge-air temperature too high

Cause Corrective action

Incorrect coolant concentration u Check (MTU test kit).
Intercooler dirty u Contact Service.

Engine room: Air-intake
temperature too high

u Check fans and air supply/ventilation ducts.

Charge-air pressure too low

Cause Corrective action

Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 103).
Intercooler dirty u Contact Service.
Exhaust turbocharger defective u Contact Service.

Coolant leaks at intercooler

Cause Corrective action

Intercooler leakíng, major
coolant discharge

u Contact Service.

Black exhaust gas

Cause Corrective action

Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 103).
Fuel injection: Injector faulty u Replace (→ Page 87).
Engine: Overload u Contact Service.

Blue exhaust gas

Cause Corrective action

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

Oil separator or oil-preseparator
of crankcase breather clogged

1. Clean preseparator (→ Page 81).

2. Replace oil separator element (→ Page 82).

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

u Contact Service.

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White exhaust gas

Cause Corrective action

Engine is not at operating
temperature

u Run engine to reach operating temperature.

Water in fuel u Drain fuel prefilter (→ Page 94).
Intercooler leaking u 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.

Engine barring gear

F6783914 1

Ratchet

F30006212 1

DANGER

Rotating and moving engine parts.

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

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

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

Barring engine manually

1. Fit ratchet with barring gear on barring gear 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 – Cranking on starting system

Preconditions

☑Clutch is disengaged.

☑Engine start is disabled.

☑LOP is accessible and open.

DANGER

Rotating and moving engine parts.

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

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

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

Turning

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

Result: Engine is cranked on starter for max.

20 seconds.

2. Release TURN button.

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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 86).

2. Remove injector (→ Page 88).

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.

Cylinder liner – Endoscopic examination

Findings Task

•

Thin carbon coating around circumference of carbon scraper ring

•

Slight localized additive deposits at top edge

•

Localized smooth areas at bottom edge

•

Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring

•

First signs of marks left by top piston ring

•

Bright mark around circumference

•

Faultless, even honing pattern

•

First signs of marks left by lower cooling bores

•

Running pattern seems darker

No action required.

•

Darker areas of even or varying color intensity

•

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

•

Dark areas in the upper section of the cooling bore, remaining cir­cumference cannot be faulted

•

Piston rings faultless

Further endoscopic examina­tion required as part of mainte­nance work.

•

On the entire circumference not only bright discoloration (not criti­cal for operation) clearly visible darker stripes that begin at the top
piston ring

•

Heat discoloration in the direction of stroke and honing pattern
damage

•

Heat discoloration of piston rings

Cylinder liner must be replaced,
contact Service.

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 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 88).

2. Install cylinder head cover (→ Page 86).

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

Terms used for endoscopic examination

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

Findings Explanations/Action

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

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

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

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

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

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

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

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

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

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

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

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

Corrosion fields /
spots

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

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

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

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

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

Seizure marks, scuff­ing

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

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Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after
further operation of the engine.

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7.4 Crankcase Breather

7.4.1 Crankcase breather – Cleaning oil pre-separator element

Preconditions

☑Engine is stopped and starting disabled.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

Crankcase breather – Cleaning
oil pre-separator element

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

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

3. Wash oil pre-separator element (1) and
housing (4) in fuel and blow out with com­pressed 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 other 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 dia­phragm (3).

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

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

5. Install new 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 gage

Y4345893 1

Engine barring gear

F6783914 1

Ratchet

F30006212 1

Double-head box wrench

F30002800 1

Offset screwdriver

F30002816 1

Socket wrench

F30030450 1

Torque wrench, 10-60 Nm

F30510423 1

Measuring instrument

Y4345888 1

Preparatory steps

1. Remove air filter (→ Page 102).

2. Remove cylinder head cover (→ Page 86).

Positioning piston of cylinder A1
at TDC

Note: With cylinder head and valve gear installed.

1. Insert preloaded dial gage (2) into measur­ing device (4) and secure using screw (1).

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

3. Zero dial gage (2).

4. Turn engine using barring gear 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 (I) = 0.3 mm;

• Exhaust (X) = 0.4 mm.

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

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

12V

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

Bank B I – – – – X I – I X – X

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

Bank B – X I X I – – X – – I –

16V

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

Bank B I – – X – – I – I X I – I X – X

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

Bank B – X I – I X I X – – – X – – I –

I

Inlet: Inlet valve adjustment admissible

X

eXhaust: Exhaust valve adjustment admissible

–

Valve adjustment inadmissible

4. Use feeler gage to determine the distance between valve bridge and rocker arm.

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

Adjusting valve clearance

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

2. Insert feeler gage (3) between valve bridge
and rocker arm.

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

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

5. Check that the feeler gage (3) just passes
through between valve bridge and rocker
arm.

Result: If not, adjust valve clearance.

Final steps

1. Remove barring gear.

2. Install cylinder head cover (→ Page 86).

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 jig

F6783025 1

Sealing

(→ Spare Parts Catalog)

Preparatory steps

1. Remove air filter (→ Page 102).

2. Remove air guide housing.

Removing and installing cylin­der head cover

1. Remove screws (1).

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

3. Clean installation surface.

4. Check condition of gasket of cylinder head
cover.

Result: Replace damaged seals.

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

6. Tighten screws (1) to specified torque
20 Nm using a torque wrench.

Final steps

1. Install air filter (→ Page 102).

2. Install air guide 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 88)

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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-head box wrench

F30011450 1

Open-end wrench bit

F30025897 1

Box wrench

F30451199 1

Alignment device

F6790507 1

Grease(Kluthe Hakuform 30-11C)

X00059351 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 off fuel supply to engine.

2. Remove cylinder head cover (→ Page 86).

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. Prior to installation, remove all blanking plugs.

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

3. Fit new sealing ring with grease on injector, observe 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 jig.

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

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

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

Name Size Type Lubricant Value/Standard

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

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

Name Size Type Lubricant Value/Standard

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

14. Attach cable (4).

Final steps

1. Install cylinder head cover (→ Page 86).

2. Open up 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

Rotating and moving engine parts.

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

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

NOTICE

Damage to component!

Severe material damage!

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

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

Replacing 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 is cut out
C Right filter is 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
position).

9. Replace further fuel filters in the same way.

10. Vent fuel system (→ Page 90).

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Replacing easy-change fuel filter
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

Rotating and moving engine parts.

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

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Setting adjustable pointer of dif­ferential pressure gauge

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

2. Verify that differential pressure is within
the limit.

Fuel prefilter – checking differential pressure

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

2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 96).

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7.8.3 Fuel prefilter – Draining

Preconditions

☑Engine is stopped and starting disabled.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Draining fuel prefilter

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

1 Filter A switched off
2 Filter B switched off

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

3. Open drain valve (2).

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

5. Close drain valve (2).

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

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

8. Close vent valve (2).

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

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

11. Turn slide (4) back to the locked position.

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7.8.4 Fuel prefilter – Flushing

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel

DANGER

Rotating and moving engine parts.

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

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Flushing fuel prefilter

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

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

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

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

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

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

Filling fuel prefilter with fuel

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

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

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

4. Close vent valve (2).

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

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

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

8. Check differential pressure (→ Page 93).

Result: If flushing did not improve differential pres-

sure, replace filter element in fuel prefilter
(→ 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)

Sealing

(→ 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. Switch off filter which is to be changed (A
or B):

1 Filter A switched off
2 Filter B switched off

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

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

4. Drain water and dirt from filter.

5. Close drain valve (5).

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

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

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

9. Fill filter housing with clean fuel.

10. Place new seal in cover.

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

12. Cut in the cut-out filter again.

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

14. Set adjustable pointer of differential pres­sure gage (→ Page 93).

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7.9 Charge-Air Cooling

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

DANGER

Rotating and moving engine parts.

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

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

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. Con­tact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 87).

2. Bar engine manually (→ Page 75).

3. Crank engine on starting system to blow out combustion chambers (→ Page 76).

4. Install injectors (→ Page 88).

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