Page 1
Operating Instructions
Diesel engine
12 V 2000 M92
16 V 2000 M92
M015700/06E
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Printed in Germany
© 2012 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 permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Page 3
Table of Contents
1 Safety
1.1 General conditions 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety regulations for startup and operation 8
1.5 Safety regulations for maintenance and
repair work 9
1.6 Auxiliary materials, fire prevention and
environmental protection 12
1.7 Conventions for safety instructions in the
text 15
2 General Information
2.1 Engine side and cylinder designations 16
2.2 Product description 17
2.3 Engine layout 23
2.4 Sensors, actuators and injectors –
Overview 25
3 Technical Data
3.1 12V 2000 M92 engine data 30
3.2 16V 2000 M92 engine data 33
3.3 Firing order 36
3.4 Engine – Main dimensions 37
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 38
4.2 Engine – Putting into operation after
scheduled out-of-service-period 39
4.3 Tasks after extended out-of-service periods
(>3 weeks) 40
4.4 Checks prior to start-up 41
4.5 Fuel treatment system – Putting into
operation 42
4.6 Operational checks 44
4.7 Fuel treatment system – Switching on 45
4.8 Starting the engine 46
4.9 Stopping the engine 47
4.10 Emergency stop 48
4.11 After stopping the engine 49
4.12 Fuel treatment system – Shutdown 50
4.13 Plant cleaning 51
5 Maintenance
5.1 Maintenance task reference table [QL1] 52
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting 53
6.2 Troubleshooting 54
7 Task Description
7.1 SOLAS 57
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 57
7.1.2 SOLAS shielding – Installation 58
7.1.3 Installation locations for SOLAS shielding 59
7.2 Engine 64
7.2.1 Engine – Barring manually 64
7.2.2 Engine – Barring with starting system 65
7.3 Cylinder Liner 66
7.3.1 Cylinder liner – Endoscopic examination 66
7.3.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 68
7.4 Crankcase Breather 70
7.4.1 Crankcase breather – Cleaning oil preseparator element 70
7.4.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 71
7.5 Valve Drive 73
7.5.1 Valve clearance – Check and adjustment 73
7.5.2 Cylinder-head cover – Removal and
installation 76
7.6 Injection Valve / Injector 77
7.6.1 Injector – Replacement 77
7.6.2 Injector – Removal and installation 78
7.7 Fuel System 80
7.7.1 Fuel system – Venting 80
7.8 Fuel Filter 81
7.8.1 Fuel filter – Replacement 81
7.8.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 83
7.8.3 Fuel prefilter – Draining 84
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7.8.4 Fuel prefilter – Flushing 85
7.8.5 Fuel prefilter – Filter element replacement 87
7.9 Charge-Air Cooling 89
7.9.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 89
7.10 Air Filter 90
7.10.1 Air filter – Replacement 90
7.10.2 Air filter – Removal and installation 91
7.11 Air Intake 92
7.11.1 Contamination indicator – Signal ring position
check (optional) 92
7.12 Starting Equipment 93
7.12.1 Starter – Condition check 93
7.13 Lube Oil System, Lube Oil Circuit 94
7.13.1 Engine oil – Level check 94
7.13.2 Engine oil – Change 95
7.14 Oil Filtration / Cooling 96
7.14.1 Engine oil filter – Replacement 96
7.14.2 Centrifugal oil filter – Cleaning and filtersleeve replacement 98
7.15 Coolant Circuit, General, HighTemperature Circuit 101
7.15.1 Drain and venting points 101
7.15.2 Engine coolant – Level check 106
7.15.3 Engine coolant – Change 107
7.15.4 Engine coolant – Draining 108
7.15.5 Engine coolant – Filling 109
7.15.6 HT coolant pump — Relief bore check 110
7.15.7 Engine coolant – Sample extraction and
analysis 111
7.15.8 Coolant filter – Replacement 112
7.16 Raw Water Pump with Connections 113
7.16.1 Raw water pump – Relief bore check 113
7.17 Belt Drive 114
7.17.1 Drive belt – Condition check 114
7.18 Battery-Charging Generator 115
7.18.1 Battery-charging generator drive – Drive belt
replacement 115
7.19 Fuel Supply System 116
7.19.1 Water drain valve – Check 116
7.19.2 Differential pressure gauge – Check 117
7.19.3 Water level probe (3-in-1 rod electrode) –
Check 118
7.19.4 Pump capacity – Check 119
7.19.5 Coalescer filter element – Replacement 120
7.20 Wiring (General) for Engine/Gearbox/Unit 122
7.20.1 Engine wiring – Check 122
7.21 Accessories for (Electronic) Engine
Governor / Control System 123
7.21.1 Engine governor and connectors – Cleaning 123
7.21.2 Engine governor – Checking plug-in
connections 124
7.21.3 EMU – Checking plug-in connections 125
7.21.4 Engine governor – Carry out self-test 126
7.21.5 EMU and connectors – Cleaning 127
7.21.6 ECU 7 engine governor – Removal and
installation 128
7.21.7 Engine monitoring unit – Removal and
installation 129
8 Appendix A
8.1 Abbreviations 130
8.2 MTU contacts/service partners 133
9 Appendix B
9.1 Special Tools 134
9.2 Index 140
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements
Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.
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1.3 Transport
Transport
Only use the lifting eyes provided to lift the engine.
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 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport
Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-tocase basis.
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1.4 Safety regulations for startup and operation
Safety precautions when putting the equipment into operation
Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐
tions and check the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems are working properly.
Safety regulations for equipment operation
Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of all operations to be performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
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1.5 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
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For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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1.6 Auxiliary materials, fire prevention and environmental
protection
Fire prevention
Rectify any fuel or oil leaks immediately; even quantities of oil or fuel on hot components can cause fires
– therefore always keep the engine in a clean condition. Do not leave cloths soaking with fluids and lubri‐
cants on the engine. Do not store combustible materials near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with
its handling.
SOLAS classification
On engines/plants with SOLAS classification, operational checks must include the following tasks:
• Check all covers (fitted in accordance with SOLAS requirements) on lube oil and fuel pipe connections
(>1.8 bar) for damage, replace as necessary. (→ Page 17)
Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating
danger are drowned.
In all work areas with a sound pressure level in excess of 85 dB (A), wear ear protection (cotton wool,
ear plug or capsules).
Environmental protection
Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and could involve the termination of the operating license by the emission authorities. MTU does not ac‐
cept any liability for violations of the emission regulations. MTU will provide assistance and advice if
emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure
the reliability and performance of MTU engines and must be complied with over the entire life cycle of the
engine.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applica‐
ble, which means work must only be carried out by authorized specialist companies (MTU is an author‐
ized specialist company).
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubri‐
cants and other chemical substances, follow the safety instructions that apply to the product. Take spe‐
cial care when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks
and do not smoke.
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Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Prevent the buildup of white powder of lead.
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash your hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective
clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately!
• Rinse injured parts of the body thoroughly with clean water!
• Rinse eyes immediately with eyedrops or clean mains water!
Paints, enamels and varnishes
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames!
• No smoking!
• Observe all fire-prevention regulations!
• Always wear a mask providing protection against paint and solvent vapors!
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands). Contact of this nature would cause frostbite and numbing.
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask!
• Make sure that working area is well ventilated. Suffocation will result at 88% contamination of breath‐
ing air with nitrogen.
• Take great care not to subject containers, fittings and tools to impact or shock.
Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extract‐
ed.
The pressure at which the air is kept can be read off at pressure gauges which must be connected to the
compressed air tanks and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Connecting devices and equipment must either be assembled for this pressure, or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing valve
and safety valve (set to permitted pressure) must form an intermediate connection. Hose couplings
and connections must be securely attached!
• Always wear protective goggles when blowing off tools or extracting chips!
• The snout of the air nozzle is provided with a protective disk (e.g. rubber disk), which prevents air‐
borne particles being reflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. sheet metal, plastic, glass) for drying purpos‐
es or to check for leaks will result in a risk of bursting!
• Blowing dirt from soiled clothes while still worn is prohibited!
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Used oil
Used oil may contain harmful combustion residues.
Rub your hands with skin protection cream!Wash your hands after contact with used oil.
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1.7 Conventions for safety instructions in the text
DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 Left engine side
2 KGS = Free end
3 Right engine side
4 KS = Driving end
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2.2 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection,
sequential turbocharging and charge-air cooling.
An electronic management system provides engine control and monitoring.
Fuel system with common rail injection
Controlled by the engine electronics, the common rail injection system determines injection pressure, in‐
jection timing and injection quantity independently of the engine speed.
Injection pressures up to 1800 bar ensure optimum fuel injection and combustion conditions.
Charging system
The charging system comprises charge-air system, exhaust system and sequential turbocharging.
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced thermal load,
• absolute gas-tightness.
Lube oil system
Wet-sump forced-feed lubrication system
Components supplied with oil:
• Bearings
• Piston cooling
• Control and actuating elements of the sequential turbocharging system
Cooling system
• Two separate cooling circuits:
• Engine coolant
• Raw water
• Coolant cooling by raw water-cooled plate-core heat exchanger
• Thermostat-controlled coolant system
• Coolant-cooled / preheated charge air
• Coolant-cooled fuel return
Electronic system
Electronic control and monitoring system with integrated security and test system with interfaces to re‐
mote control system (RCS) and to monitoring system (MCS).
Electronic engine control unit (ECU)
Closed-loop control:
• Engine speed
• Fuel HP
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Open-loop control:
• Injection (fuel pressure, injection timing, injection duration, operating status)
• Sequential turbocharging (cutting-in and out) with secondary turbocharger
• Engine protection with multi-stage safety systems:
• Power reduction
• Power limitation
• Emergency stop
Monitoring:
• Exhaust gas temperature, A-side
• Exhaust temperature, B-side
• Engine speed
• Oil pressure
• Differential oil pressure
• Coolant temperature
• Coolant level
• Exhaust turbocharger speed
• Leak fuel level
• Oil temperature
• Coolant pressure
• Fuel pressure after filter
Monitoring in engine room
Engine control and monitoring unit (LOP)
Functions:
• Engine speed, oil pressure and coolant temperature are monitored and displayed
• Integrated safety system
• Integrated test system
• Redundant CAN bus interface to governor and higher-level control and monitoring system
• 24 V DC power supply
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SOLAS – Fire protection specifications
Special connections
In case of leakage, the above-mentioned connection types are spray-protected even without a cover and
have been confirmed compliant with SOLAS by GL and DNV.
Plug-in pipe connection
The sleeve (4) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐
curs.
The connection is confirmed as compliant with SOLAS by DNV and GL.
Plugs and sensors
Screw-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
In case of a loose single-ended union or a defective sealing ring (2), the liquid first has to pass the
thread.
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The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under
pressure.
HP line between fuel injector and HP accumulator
1 Support ring
2 V-ring
3 Thrust ring
4 Union nut
5 HP line
6 Thrust screw
7 Thrust ring
8 V-ring
9 Support ring
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HP line between distributor and HP accumulator
1 Union nut
2 O-ring
3 Thrust ring
4 Thrust screw
5 O-ring
6 O-ring
7 Thrust ring
8 Pressure pipe
9 Jacket pipe
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HP line between distributor and HP accumulator
1 Jacket pipe
2 O-ring
3 O-ring
4 Thrust ring
5 Thrust screw
6 Thrust ring
7 O-ring
8 HP line
9 Pressure pipe
10 O-ring
Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from
where it is routed at atmospheric pressure into a level-monitored leak fuel tank.
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2.3 Engine layout
Engine layout
1 Engine oil heat ex‐
changer
2 Engine oil filter
3 Engine coolant filter
4 Change-over lever for
engine oil filter
5 Fuel cooler
6 Coolant distribution
housing with integral ex‐
pansion tank
7 Engine hoisting lug (free
end)
8 Electronic engine man‐
agement system
9 Air filter
10 Air intake
11 Air collector housing
(shroud)
12 Exhaust turbocharger,
right (secondary turbo‐
charger)
13 Carrier housing
14 Exhaust turbocharger
(primary turbocharger)
15 Exhaust turbocharger,
left (secondary turbo‐
charger)
16 Exhaust outlet (horizon‐
tal)
17 Actuating cylinder for ex‐
haust flap
18 Actuating cylinder for air
flap
19 Control valve for flap
control
20 Cylinder head cover
21 Exhaust manifold
22 Engine mounting
23 Electric starter
24 Oil pan
25 Battery-charging gener‐
ator
26 Raw-water connection
for gearbox cooling
27 Gearcase
28 Raw water pump
29 Raw-water connection
from sea
30 Raw water connection
to sea
31 Plate-core heat ex‐
changer
32 Thermostat housing
33 Fuel priming pump
34 Fuel duplex filter
(switchable)
KGS = free end
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1 Exhaust turbocharger,
left (secondary turbo‐
charger)
2 Exhaust turbocharger
(primary turbocharger)
3 Air intake
4 Engine hoisting lug
(driving end)
5 Exhaust turbocharger,
right (secondary turbo‐
charger)
6 Engine coolant filler
neck
7 Crankcase breather
8 Change-over lever for
engine oil filter
9 Engine coolant filter
10 Engine oil filter
11 Fuel filter
12 Engine oil heat exchang‐
er
13 Coolant distribution
housing with integral ex‐
pansion tank
14 Thermostat housing
15 Exhaust manifold
16 Coolant pump
17 HP fuel pump
18 Fuel delivery pump
19 Oil filler neck
20 Oil dipstick
21 Drive flange
22 Flywheel housing
23 Engine mounting
24 Carrier housing core
25 Carrier housing lower
part
26 Exhaust outlet
27 Carrier housing upper
part
KS = driving end
Engine model designation
Key to the model designation 12V/16V 2000 Mxy
• 12/16 = Number of cylinders
• V = Cylinder arrangement
• 2000 = Series
• Mx = application segment
• y = design index
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2.4 Sensors, actuators and injectors – Overview
Engine plan view
Deviations from illustrations are insignificant.
Also applies similarly to 12V.
Item Description Monitoring of
1 B7 Lube oil temperature
2 B10 Charge-air pressure
3 B44 Turbocharger speed
4 B3 Intake air temperature
5 B9 Charge-air temperature
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Engine free end
Item Description Monitoring of
1 B34 Fuel pressure after filter
2 B5.3 (option) Lube oil pressure before filter
3 B5.1 Lube oil pressure after filter
4 B5.2 (option) Lube oil pressure after filter
5 F33 Engine coolant level, expansion tank
6 B21 (option) Raw water pressure
7 B6.2 (option) Coolant temperature
8 B6.1 Coolant temperature
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Engine driving end
Item Description Monitoring of
1 B1 (ECU) Camshaft speed
2 B13.2 (optional EMU) Crankshaft speed
3 B13 (ECU) Crankshaft speed
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Engine, right side
Item Description Monitoring of
1 YB33 Fuel temperature
2 B48 Fuel pressure (in rail)
3 B16 (option) Coolant pressure
4 F46 Leak fuel level
5 Y27.2 4-2-directional control valve, B-side
6 B4.22 Exhaust temperature, B-side
7 F41 2-2-directional control valve
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Engine, left side
Item Description Monitoring of
1 B4.21 Exhaust gas temperature, A-side
2 Y27.1 4-2-directional control valve, A-side
3 B54 (option) Lube oil pressure, replenishment pump
System sensors
These sensors are fitted outside the engine.
Description Monitoring of
B19 Starting-air pressure
B70 Fuel prefilter water level
B41 Exhaust back pressure
S37 Start interlock, switching status
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3 Technical Data
3.1 12V 2000 M92 engine data
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 12V2000
M92
Application group 1DS
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100
Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 12
Rated engine speed A rpm 2450
Fuel stop power ISO 3046 A kW 1220
General conditions (for max. 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 off-engine 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. (when engine is running) L bar -0.3
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25
Fuel supply flow, max. A Liters/min 5.5
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
Starter rated 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. op‐
erating inclinations)
L Degrees
(°)
22.5
Longitudinal inclination, continuous max. driving end up (Option: max. oper‐
ating inclinations)
L Degrees
(°)
0
Longitudinal inclination, temporary max., driving end up (Option: max. oper‐
ating inclinations)
L Degrees
(°)
10
Transverse inclination, continuous max. (Option: max. operating inclina‐
tions)
L Degrees
(°)
22.5
Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees
(°)
32.5
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Capacities
Number of cylinders 12
Engine coolant, engine side (with cooling system) R Liters 125
Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐
ing inclinations)
R Liters 123
Oil change quantity, max. (standard oil system) (Option: max. operating in‐
clinations)
R Liters 113
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max.
operating inclinations)
L Liters 87
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max.
operating inclinations)
L Liters 105
Weights / main dimensions
Number of cylinders 12
Engine dry weight (with standard accessories installed, w/o coupling) R kg 2780
Sound
Number of cylinders 12
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1 m dis‐
tance, ISO 6798, +3dB(A) tolerance)
R dB(A) 108
Engine surface noise with attenuated intake noise (filter) - BL (free-field
sound pressure level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)
R dB(A) 102
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3.2 16V 2000 M92 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 changes (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 16V
2000
M92
Application group 1DS
Intake air temperature °C 25
Raw-water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 16
Engine rated speed A rpm 2450
Fuel stop power ISO 3046 A kW 1630
GENERAL CONDITIONS (for maximum power)
Number of cylinders 16
Intake air depression (new filter) A mbar 15
Intake air depression, max. L mbar 30
MODEL-RELATED DATA (basic design)
Number of cylinders 16
Cylinder configuration: V angle degree 90
Bore mm 135
Stroke mm 156
Cylinder displacement liter 2.23
Total displacement liter 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 the off-engine raw water system, max. L bar 0.7
LUBE OIL SYSTEM
Number of cylinders 16
Lube oil operating temperature before engine, from R °C 78
Lube oil operating temperature before engine, to R °C 86
Lube oil operating pressure before engine, from R bar 6.5
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 supply connection, min. (when engine is starting) L bar -0.3
Fuel pressure at engine supply connection, min. (when engine is running) L bar -0.3
Fuel pressure at engine supply connection, max. (when engine is starting) L bar +0.25
Fuel supply flow, max. R liter/min 7.3
GENERAL OPERATING DATA
Number of cylinders 16
Firing speed, from R rpm 100
Firing speed, to R rpm 120
STARTING (electric)
Number of cylinders 16
Starter, rated 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 degree 15
Longitudinal inclination, temporary max., driving end down (Option: max.
operating inclinations)
L degree 22.5
Longitudinal inclination, continuous max., driving end up (Option: max. op‐
erating inclinations)
L degree 0
Longitudinal inclination, temporary max., driving end up (Option: max. oper‐
ating inclinations)
L degree 10
Transverse inclination, continuous max. (Option: max. operating inclina‐
tions)
L degree 22.5
Transverse inclination, temporary max. (Option: max. operating inclinations) L degree 32.5
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CAPACITIES
Number of cylinders 16
Engine coolant capacity (with cooling equipment) R liter 135
Engine oil at initial filling (standard oil system) (Option: max. operating incli‐
nations)
R liter 168
Oil change quantity, max. (standard oil system) (Option: max. operating in‐
clinations)
R liter 155
Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐
erating inclinations)
L liter 115
Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐
erating inclinations)
L liter 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 dis‐
tance, ISO 6798)
R db(A) 109
Engine surface noise with attenuated intake noise (filter) - BL (free-field
sound pressure level Lp, 1m distance, ISO 6798)
R db(A) 103
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3.3 Firing order
Firing order
8V A1-B4-A4-A2-B3-A3-B2-B1
10 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1
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3.4 Engine – Main dimensions
Main dimensions
Engine model Length (A) Width (B) Height (C)
8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm
8V 2000 M92 approx. 1683 mm approx. 1147 mm approx. 1200 mm
8V 2000 M93 approx. 1683 mm approx. 1147 mm approx. 1200 mm
8V 2000 M84 approx. 1683 mm approx. 1147 mm approx. 1200 mm
8V 2000 M94 approx. 1683 mm approx. 1147 mm approx. 1200 mm
10V 2000 M72 approx. 1860 mm approx. 1147 mm approx. 1320 mm
10V 2000 M92 approx. 1860 mm approx. 1147 mm approx. 1320 mm
10V 2000 M93 approx. 1860 mm approx. 1147 mm approx. 1320 mm
10V 2000 M84 approx. 1860 mm approx. 1147 mm approx. 1320 mm
10V 2000 M94 approx. 1860 mm approx. 1147 mm approx. 1320 mm
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4 Operation
4.1 Putting the engine into operation after extended out-ofservice periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation (out-of-service period > 3 months)
Item Measure
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Lube oil system Check engine oil level (→ Page 94).
Fuel prefilter Fill with fuel (→ Page 87).
Fuel prefilter, pressure
gauge
Align adjustable pointer with position of pressure indicator (→ Page 83).
Fuel system Vent (→ Page 80).
Raw-water pump (if located
above waterline)
Prime (approx. 3 to 4 liters).
Filling point (→ Page 101).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 107).
Coolant circuit Check coolant level (→ Page 106).
Coolant circuit Heat engine coolant with coolant preheating unit.
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4.2 Engine – Putting into operation after scheduled out-ofservice-period
Preconditions
☑ Engine is stopped and starting disabled.
Putting into operation
Item Measure
Lube oil system Check engine oil level (→ Page 94).
Coolant circuit Check coolant level (→ Page 106).
Coolant circuit Heat engine coolant with coolant preheating unit.
Fuel prefilter Drain water and contaminants (→ Page 84).
Battery-charging generator
drive
Check condition of drive belt (→ Page 114).
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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 42).
2. Shut down fuel treatment system (→ Page 50).
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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 45).
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 45).
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 120).
2. Check sealing faces on coalescer filter element and in the pressure tank.
Initial operation: HAT
1. Replace fuel filter on engine (→ Page 81).
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 45).
Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is delivered
via the overflow tank back to the tank. Water which has settled in the tank is separated.
4. Start engine (→ Page 46).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replace‐
ment simulation with the engine running as part of the Harbor Acceptance Tests.
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Simulation of filter replacement with the engine running: HAT
1. Switch on fuel treatment system (→ Page 45).
2. Start engine (→ Page 46).
3. Run engine at idling speed.
4. Close ball cock (5) at the inlet to the fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball cock (19).
Result: Fuel emerges. If no fuel emerges:
• Open ball cock (5) at the inlet to the fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3).
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:
7. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If all engine operating values are within the specified limits, open ball cock (5) at the inlet to the fuel treat‐
ment4 system.
Simulation of power failure (emergency): HAT
1. Switch on fuel treatment system (→ Page 45).
2. Start engine (→ Page 46).
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 45).
2. Start engine (→ Page 46).
3. Run engine at idling speed.
4. Switch off pump (21) on switch cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
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4.6 Operational checks
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Operational checks
Item Measure
Engine under load
Engine at nominal speed
Visually inspect engine for leaks and general condition;
Check for abnormal running noises and vibration;
Check exhaust color (→ Page 54).
Fuel prefilter Check fuel prefilter contamination indicator for max. admissible value
(→ Page 83).
Drain water and contaminants (→ Page 84).
Air filter Check signal ring position of contamination indicator (→ Page 92).
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 110).
Raw water pump Check relief bore for oil and water discharge and contamination
(→ Page 113).
Intercooler Check condensate drain (if applicable) (→ Page 89).
Engine oil Check engine oil level (→ Page 94).
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4.7 Fuel treatment system – Switching on
Preconditions
☑ The on-board power supply is switched on.
CAUTION
Damage to engine/plant.
Major material damage!
• Before switching on, ensure that the engine/plant is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.
Switching on fuel treatment system
1. Carry out checks prior to start-up (→ Page 41).
2. Switch on master switch on switch cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.
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4.8 Starting the engine
Preconditions
☑ External start interlock is not active.
☑ Emergency air shut-off flaps (if fitted) are open.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
The engine can be started from the following points
Item Action
Control stand (→ Operating instructions for electronic system)
Local Operating Panel LOP (→ Operating instructions for electronic system)
Local Operation Station
LOS
(→ Operating instructions for electronic system)
CCU (→ Operating instructions for electronic system)
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4.9 Stopping the engine
Preconditions
☑ Engine is running in local mode.
CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until
engine temperatures have dropped and constant values are displayed.
The engine can be stopped from the following points :
1. (→ Operating instructions for electronic system)
2. Commanding control stand (→ Operating instructions for electronic system);
3. Local operating panel LOP (→ Operating instructions for electronic system);
4. Local Operation Station LOS (→ Operating instructions for electronic system);
5. CCU (→ Operating instructions for electronic system).
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4.10 Emergency stop
CAUTION
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
An emergency stop of the engine can be initiated from the following points :
1. (→ Operating instructions for electronic system)
2. Commanding control stand (→ Operating instructions for electronic system);
3. Local operating panel LOP (→ Operating instructions for electronic system);
4. Local Operation Station LOS (→ Operating instructions for electronic system);
5. CCU (→ Operating instructions for electronic system).
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4.11 After stopping the engine
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
After stopping the engine
Item Action
Coolant circuit Drain coolant (→ Page 108) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Raw water Drain
• If freezing temperatures are to be expected and the engine is to remain
out of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys‐
tem
Out-of-service-period > 1 week
• Seal engine's air and exhaust sides.
Engine Out-of-service-period > 1 month
• Preserve engine (→ MTU Fluids and Lubricants Specifications
A001061/.. )
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4.12 Fuel treatment system – Shutdown
Shutting down fuel treatment system
1. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet
stops.
2. Switch off fuel treatment system.
3. Close ball valve at the inlet to the fuel treatment system.
4. Close ball valve at the outlet of the fuel treatment system.
5. Open drain valve until pressure has escaped from fuel treatment system.
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4.13 Plant cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ Operating voltage is not present.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Steam jet cleaner
- 1
Cleaner (Hakupur 312)
30390 1
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
• Wear protective clothing, gloves, and goggles / safety mask.
NOTICE
Dry with compressed air.
Damage to component!
• Never aim compressed air directly at electronic components.
Plant cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.
4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.
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5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Measures
W0500 Check engine oil level (→ Page 94)
W0501 Visually inspect engine for leaks and general condition (→ Page 44)
W0502 Check intercooler drain (if applicable) (→ Page 44)
W0503 Check maintenance indicator of air filter (→ Page 44)
W0505 Check relief bores of coolant pump(s) (→ Page 44)
W0506 Check engine for abnormal running noises, exhaust color
and vibrations
(→ Page 44)
W0507 Drain water and dirt from fuel prefilter (if fitted) (→ Page 44)
W0508 Check contamination indicator of fuel prefilter (if fitted) (→ Page 44)
W1001 Replace fuel filter or fuel filter element (→ Page 81)
W1002 Check valve clearance (→ Page 73)
W1003 Check drive belt condition and tension, replace if necessary (→ Page 114)
W1005 Replace air filter (→ Page 90)
W1006 Replace fuel injectors (→ Page 77)
W1008 Replace engine oil filter at each oil change or when the time
limit (years) is reached, at the latest
(→ Page 96)
W1009 Check layer thickness of oil residue, clean and replace filter
sleeve (if fitted) during every oil change at the latest (if fitted)
(→ Page 98)
W1011 Perform endoscopic inspection of combustion chambers (→ Page 66)
W1036 Replace coolant filter (→ Page 112)
W1139 Replace paper or knitted fabric insert (if installed) of oil mist
separator
(→ Page 71)
W1140 Clean wire meshes of crankcase breather (→ Page 70)
W1244 Check operation of rod electrode (if fitted) (→ Page 118)
W1245 Differential-pressure gauge, check alarm function (if applica‐
ble)
(→ Page 117)
W1246 Check pump performance (if applicable) (→ Page 119)
Table 1: Maintenance task reference table [QL1]
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6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting
Illuminated pushbutton “Water alarm” is lit.
Cause Corrective action
When the maximum water level
is reached, the water level elec‐
trode opens the water drain
valve and water is discharged. If
the opening period of the valve
exceeds a preset limit (4 mi‐
nutes), the pump will switch off
and an alarm is initiated.
1. Press illuminated pushbutton “Water alarm” to acknowledge.
2. In addition to the automatic water drain function, water can also
be drained manually. To do so, press the illuminated pushbutton
“Water drain” to open the drain valve.
Signal lamp “Pump fault” is lit.
Cause Corrective action
The drive motor is equipped with
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-run‐
ning, the motor protection relay
triggers and the pump is switch‐
ed off.
u Reset motor protection relay.
Signal lamp “Warning filter” is lit.
Cause Corrective action
The differential pressure exceed‐
ed 1.3 bar.
u Replace coalescer filter element (→ Page 120).
Illuminated pushbutton “Replace filter element” is lit.
Cause Corrective action
The max. permissible differential
pressure of 1.5 bar was exceed‐
ed. If the coalescer filter element
is not replaced, pressure will in‐
crease further and the safety
valve will open. Fuel will be led
via the bypass directly into the
overflow tank.
1. Replace coalescer filter element (→ Page 120).
2. Press illuminated pushbutton “Replace filter element” to ac‐
knowledge.
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6.2 Troubleshooting
Engine does not turn when starter is actuated
Component Probable Cause Task
Battery Low or defective Charge or replace (see manufacturer's
documentation).
Cable connections defective Check if cable connections are proper‐
ly secured (see manufacturer's docu‐
mentation).
Starter Engine wiring or starter defective Check if cable connections are proper‐
ly secured, contact Service.
Engine wiring Defective Check (→ Page 122).
ECU Plug-in connections are loose Check plug-in connections for secure
seating.
Engine Running gear blocked (engine cannot
be barred manually)
Contact Service.
Engine turns but does not fire
Component Probable Cause Task
Starter Poor rotation by starter: Battery low or
defective
Charge or replace battery (see manu‐
facturer's documentation).
Engine wiring Defective Check (→ Page 122).
Fuel system Not vented Vent fuel system (→ Page 80).
ECU Defective Contact Service.
Engine fires unevenly
Component Probable Cause Task
Fuel injection equip‐
ment
Injector defective Replace (→ Page 77).
Engine wiring Defective Check (→ Page 122).
Fuel system Not vented Vent fuel system (→ Page 80).
ECU Defective Contact Service.
Engine does not reach nominal speed
Component Probable Cause Task
Fuel supply Fuel prefilter clogged Replace (→ Page 87).
Fuel filter clogged Replace (→ Page 81).
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 92).
Fuel injection equip‐
ment
Injector defective Replace (→ Page 77).
Engine wiring Defective Check (→ Page 122).
Engine Overloaded Contact Service.
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Engine speed not steady
Component Probable Cause Task
Fuel injection equip‐
ment
Injector defective Replace (→ Page 77).
Speed sensor Defective Replace.
Fuel system Not vented Vent fuel system (→ Page 80).
ECU Defective Contact Service.
Charge-air temperature too high
Component Probable Cause Task
Engine coolant Incorrect coolant concentration Check.
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fans and air supply / ventilation
ducts.
Charge air pressure too low
Component Probable Cause Task
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 92).
Intercooler Contaminated Contact Service.
Exhaust turbocharger Defective Contact Service.
Coolant leaks on intercooler
Component Probable Cause Task
Intercooler Leaking, major coolant discharge Contact Service.
Exhaust gas black
Component Probable Cause Task
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 92).
Fuel injection equip‐
ment
Injector defective Replace (→ Page 77).
Engine Overloaded Contact Service.
Exhaust gas blue
Component Probable Cause Task
Engine oil Too much oil in engine Drain engine oil (→ Page 95).
Oil separator or oil preseparator of
crankcase breather clogged
• Clean preseparator (→ Page 70).
• Replace filter element of oil separa‐
tor (→ Page 71).
Exhaust turbocharg‐
er, cylinder head, pis‐
ton rings, cylinder lin‐
er
Defective Contact Service.
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Exhaust gas white
Component Probable Cause Task
Engine Not at operating temperature Run engine to reach operating temper‐
ature.
Fuel system Water in fuel Drain fuel prefilter (→ Page 84).
Intercooler Leaking Contact Service.
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7 Task Description
7.1 SOLAS
7.1.1 SOLAS shielding as per MTN 5233 – Installation
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Shield A4
735233000100 10
Shield A5
735233000101 14
Shield A7
735233000103 6
Shield A8
735233000104 2
SOLAS shielding – Installation
1. Pinpoint installation location (→ Page 59).
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 59).
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 57).
Free end B-side
Item Type of shielding Comments
1 (free end, B-side) Shield (A7) On fuel delivery pump
2 (free end, B-side) Shield (A7) On HP fuel pump
Free end
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Item Type of shielding Comments
1 (free end) Shield (A8) On fuel filter
2 (free end) Shield (A7) Above fuel priming pump
3 (free end) Shield (A7) Below fuel priming pump
Driving end A-side
Item Type of shielding Comments
1 (Driving end, A-side) Shield (A5) On air flap
2 (Driving end, A-side) Shield (A4) On brazed-on union
3 (driving end, A-side) Shield (A5) On turbocharger flap
4 (driving end, A-side) Shield (A5) On turbocharger flap
Driving end A-side
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Item Type of shielding Comments
1 (driving end, A-side) Shield (A5) To turbocharger lubrication
2 (driving end, A-side) Shield (A5) On valve plate
Driving end
Item Type of shielding Comments
1 (driving end) Shield (A4) Turbocharger lubrication, left side
2 (driving end) Shield (A4) Turbocharger lubrication, center
Driving end
Item Type of shielding Comments
1 (driving end) Shield (A4) Turbocharger lubrication, right
side
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Driving end B-side
Item Type of shielding Comments
1 (driving end, B-side) Shield (A5) Turbocharger flap
2 (driving end, B-side) Shield (A5) Turbocharger flap
3 (driving end, B-side) Shield (A4) On brazed-on union
4 (driving end, B-side) Shield (A5) On air flap
5 (driving end, B-side) Shield (A4) To turbocharger lubrication
Driving end B-side
Item Type of shielding Comments
1 (driving end, B-side) Shield (A5) On valve plate
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Driving end A-side
Item Type of shielding Comments
1 (driving end, A-side) Shield (A5) To flap control
Driving end B-side
Item Type of shielding Comments
1 (driving end, B-side) Shield (A5) To flap control
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7.2 Engine
7.2.1 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Barring tool
F6783914 1
Ratchet
F30006212 1
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Engine – Barring manually
1. Fit ratchet with barring tool on barring tool connection at the vibration damper on engine free end.
2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.
Result: If the resistance exceeds the normal compression resistance, contact Service.
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7.2.2 Engine – Barring with starting system
Preconditions
☑ Clutch is disengaged.
☑ Engine start is disabled.
☑ LOP is accessible and open.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Barring
1. Press barring button on the LMB mother‐
board of the LOP and keep it depressed.
Result: Engine is barred by starter for max. 20 sec‐
onds.
2. Release barring 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 76).
2. Remove injector (→ Page 78).
Positioning crankshaft at BDC
1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached
BDC.
2. Insert endoscope into cylinder liner through injector seat.
Endoscopic examination of cylinder liner
Findings Action
• Thin carbon coating on circumference of carbon scraper ring
• Slight localized additive deposits at top edge
• Localized smooth areas on bottom edge
• Carbon deposits on circumference in clearance between top piston
ring and bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Consistent honing pattern without objections
• First signs of marks left by lower cooling bores
• Running pattern seems darker
No action required
• Dark areas with even or varying degrees of discoloration
• Beginning and end of the discoloration are not sharply defined and
do not cover the entire stroke area
• Dark areas in the upper section of the cooling bore, remaining cir‐
cumference without objections
• Piston rings without objections
Further endoscopic examina‐
tion required as part of main‐
tenance work
• On the entire circumference, apart from light areas of discoloration
(that do not impair operation) clearly darker stripes that start at the
top piston ring
• Heat discoloration in the direction of stroke and honing pattern dam‐
age
• Heat discoloration of piston rings
Cylinder liner must be re‐
placed; Service must be con‐
tacted
1. Compile endoscopy report using the table.
2. Use technical terms for description of the liner surface (→ Page 68).
3. Depending on findings:
• do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.
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Final steps
1. Install injector (→ Page 78).
2. Install cylinder head cover (→ Page 76).
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7.3.2 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐
nation report.
Findings Measure
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐
ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring
on the running surface under endoscope magnification. Cannot be felt with the
fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC
area and cross through the hone pattern in the direction of stroke.
Findings not critical.
Scored area These areas consist of scores of different length and depth next to one anoth‐
er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in‐
let/exhaust) along the transverse engine axis.
Findings not critical.
Smoothened area Smoothened areas are on the running surface but almost the whole honing
pattern is still visible. Smoothened areas appear brighter and more brilliant
than the surrounding running surface.
Findings not critical.
Bright area Bright areas are on the running surface and show local removal of the honing
pattern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐
perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern
is undisturbed. Discolorations extend in stroke direction and may be interrupt‐
ed.
Findings not critical.
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in
the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
Cylinder liners with a large number of black lines around the running surface
have limited service life and should be replaced.
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Findings Measure
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and
becoming more visible from the second TDC-ring 2 onwards and less pro‐
nounced from TDC-ring 1. The honing pattern is usually no longer visible and
displays a clearly defined (straight) edge to the undisturbed surface. The dam‐
aged surface is usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC ring 1 have to be
replaced.
Seizure marks, scuff‐
ing
Irregular circumference lengths and depths. Can be caused either by the pis‐
ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis‐
coloration. Severe, visible scoring.
Replace liner.
Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after fur‐
ther operation of the engine.
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7.4 Crankcase Breather
7.4.1 Crankcase breather – Cleaning oil pre-separator element
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Crankcase breather – Cleaning oil
pre-separator element
1. Remove cover (5) from housing (4).
2. Take off oil pre-separator element (1), gas‐
ket (3) and O-ring (2).
3. Wash oil pre-separator element (1) and
housing (4) in fuel and blow out with com‐
pressed air.
4. Moisten oil pre-separator element (1) with
engine oil.
5. Position oil pre-separator element (1) with
new gasket (3) and O-ring (2) on housing
(4) and install cover (5).
6. Clean further oil pre-separator elements in
the same way.
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7.4.2 Crankcase breather – Oil separator 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 adapter
F30027340 1
Filter element
(→ Spare Parts Catalog)
Diaphragm
(→ Spare Parts Catalog)
O-ring
(→ 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 filter element of oil
separator
1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element into housing (4)
ensuring correct installation position, and fit
cover (2) with new O-ring.
4. Tighten screws of cover (2) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 6 Nm + 2 Nm
5. Replace filter elements of further oil separators in the same way.
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Checking diaphragm
1. Remove cover (4).
2. Take off spring (5), seal (2) and diaphragm
(3).
3. Check diaphragm (3) for damage.
4. Fit new diaphragm if used one is damaged.
5. Mount diaphragm (3) on housing (1).
6. Install new seal (2) and spring (5) together
with cover (4).
7. Tighten screws of cover (4) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 6 Nm + 2 Nm
8. Check diaphragms in further oil separators in the same way.
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7.5 Valve Drive
7.5.1 Valve clearance – Check and adjustment
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Feeler gauge
Y4345893 1
Barring tool
F6783914 1
Ratchet
F30006212 1
Double box wrench
F30002800 1
Angular screw driver
F30002816 1
Socket wrench
F30030450 1
Torque wrench, 10-60 Nm
F30510423 1
Preparatory steps
1. Remove air filter (→ Page 91).
2. Remove cylinder head cover (→ Page 76).
Positioning A1 piston at TDC
1. Remove cable from sensor B13 (→ Page 25).
2. Remove sensor B13.
3. Using ratchet and barring tool, rotate crankshaft in engine direction of rotation until the marking on the
flywheel is aligned with the center of the sensor seat.
Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet (E) = 0.3 mm;
• Exhaust (A) = 0.4 mm.
3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the
table below.
8V2000
Position Cylinder 1 2 3 4 5 6 7 8 9
Firing TDC in cylinder A1 Bank A E A - A E - - A
Bank B E - E - - - - A
Overlap TDC in cylinder A1 Bank A - - E - - A E -
Bank B - A - A E A E -
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted
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10V2000
Position Cylinder 1 2 3 4 5 6 7 8 9
Firing TDC in cylinder A1 Bank A E A - - - - - A E -
Bank B E - - - - A E A E -
Overlap TDC in cylinder A1 Bank A - - E A E A E - - A
Bank B - A E A E - - - - A
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted
12V2000
Position Cylinder 1 2 3 4 5 6 7 8 9
Firing TDC in cylinder A1 Bank A E A E - - A E - - A - -
Bank B E - - - - A E - E A- A
Overlap TDC in cylinder A1 Bank A - - - A E - - A E - E A
Bank B - A E A E - - A - - E -
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted
16V2000
Position Cylinder 1 2 3 4 5 6 7 8 9
Firing TDC in cylinder A1 Bank A E A - A - A E - - A E - - - - -
Bank B E - - A - - E - E AE - E A- A
Overlap TDC in cylinder A1 Bank A - - E - E - - A E - - A E AE A
Bank B - A E - E A - A - - - A - - E -
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted
18V2000
Position Cylinder 1 2 3 4 5 6 7 8 9
Firing TDC in cylinder A1 Bank A E A E - - A E - - A - - - A - - - -
Bank B - A - A - - E A - - E AE - E A E -
Overlap TDC in cylinder A1 Bank A - - - A E - - A E - E A E - E A E A
Bank B E - E - E A - - E A- - - A - - - A
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.
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Valve clearance adjustment
1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gauge between valve bridge
and rocker arm.
3. Readjust adjusting screw (2) so that the
feeler gauge just passes through the gap.
4. Tighten locknut (1) with torque wrench to
the prescribed tightening torque of 50 Nm
while holding the adjusting screw (2) with
screwdriver.
5. Insert feeler gauge between valve bridge
and rocker arm to verify that the gauge just
passes through the gap.
Result: If not, adjust valve clearance.
Final steps
1. Install sensor B13.
2. Connect cable to sensor B13.
3. Remove barring tool.
4. Install cylinder head cover (→ Page 76).
5. Install air filter (→ Page 91).
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7.5.2 Cylinder-head cover – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Centering device
F6783025 1
Gasket
(→ Spare Parts Catalog)
Preparatory steps
1. Remove air filter (→ Page 91).
2. Remove intake housing.
Cylinder-head cover – Removal
and installation
1. Remove screws (1).
2. Remove cylinder-head cover (2) with gas‐
ket from cylinder head.
3. Clean mating faces.
4. Check condition of gasket of cylinder-head
cover.
Result: Replace damaged gasket(s).
5. Center cylinder-head cover (2) with center‐
ing device.
6. Use torque wrench to tighten screws (1) to
specified torque 20 Nm.
Final steps
1. Install air filter (→ Page 91).
2. Install intake housing.
3. Check cylinder-head covers for leaks.
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7.6 Injection Valve / Injector
7.6.1 Injector – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Injector
(→ Spare Parts Catalog)
Remove injector and install new one.
u (→ Page 78)
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7.6.2 Injector – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Socket wrench
0005896803/00 1
Puller
F6790629 1
Double box wrench
F30011450 1
Open end wrench bit
F30025897 1
Box wrench adapter
F30451199 1
Alignment device
F6790507 1
Grease (Kluthe Hakuform 30-10/Emulgier)
X00029933 1
Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Preparatory steps
1. Close fuel supply to engine.
2. Remove cylinder head cover (→ Page 76).
Removing injector
1. Remove HP line (5) using socket wrench.
2. Disconnect injector cable (4).
3. Remove screw (2).
4. Take off hold-down clamp (3).
5. Remove injector (1) with puller.
6. Remove O-rings from injector.
7. Mask all connections and bores or seal with
suitable plugs.
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Installing injector
1. Remove all plugs before installation.
2. Fit new O-rings onto injector and coat with grease.
3. Fit new sealing ring with grease on injector, ensuring correct installation position of sealing ring.
4. Clean sealing surface on cylinder head and protective sleeve.
5. Insert injector (1) in cylinder head, ensuring that it is correctly aligned with the HP line connection.
6. Fit hold-down clamp (3) in correct installation position, coat screw (2) with engine oil.
7. Screw in screw (2) and tighten by hand.
8. Coat thread and sealing cone of HP line (5) and injector (1) with engine oil.
9. Align injector (1) and HP line (5) with alignment device.
10. Connect HP line (5) to HP accumulator and tighten by hand.
11. Connect HP line (5) to injector (1) and tighten by hand.
12. Tighten screw of hold-down clamp (3) with a box wrench adapter and a torque wrench to specified tight‐
ening torque.
Name Size Type Lubricant Value/Standard
Screw M10 x 85 Tightening torque (Engine oil) 40 Nm + 4 Nm
13. Use socket wrench and torque wrench to tighten HP line (5) to the specified torque.
Name Size Type Lubricant Value/Standard
HP fuel line Tightening torque (Engine oil) 30 Nm + 5 Nm
14. Attach cable (4).
Final steps
1. Install cylinder head cover (→ Page 76).
2. Open fuel supply to engine.
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7.7 Fuel System
7.7.1 Fuel system – Venting
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Venting fuel system
1. Unlock fuel priming pump, unscrew handle.
2. Open vent plugs on filter head.
Note: New version has two threaded vent plugs,
old version has four threaded vent plugs.
3. Operate the pump with the handle until fuel
without bubbles comes out of the vent plugs
and the nipples.
4. Close vent plugs on filter head.
5. Operate the pump with the handle until fuel
without bubbles comes out of the nipple.
6. Lock fuel priming pump, screw in handle.
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7.8 Fuel Filter
7.8.1 Fuel filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oil filter wrench
F30379104 1
Diesel fuel
Easy-change filter
(→ Spare Parts Catalog)
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
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Replacing fuel filter with the engine
stopped
A Both filters cut in (operating position)
B Left filter cut out
C Right filter cut out
1. Stop engine and disable engine start.
2. Cut out the filter to be replaced.
3. Remove the cut-out easy-change filter with oil filter wrench.
4. Clean sealing surface on filter head.
5. Check seal on new easy-change filter and moisten it with fuel.
6. Screw on easy-change filter and tighten by hand.
7. Set three-way cock to operating position (both filters cut in).
8. Replace further fuel filters in the same way.
9. Vent fuel system (→ Page 80).
Replacing 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 the cut-out easy-change filter with
oil filter wrench.
5. Clean sealing surface on filter head.
6. Check seal on new easy-change filter and
moisten it with fuel.
7. Screw on easy-change filter and tighten by
hand.
8. Set three-way cock to operating position
(both filters cut in).
9. Replace further fuel filters in the same way.
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7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Differential pressure gauge
adjustment
1. When installing the new filter element: align
adjustable pointer (2) with pressure-indicat‐
ing pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within the
limit.
Fuel prefilter – Checking differential pressure
1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of
pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 85).
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7.8.3 Fuel prefilter – Draining
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Diesel fuel
Seal
(→ Spare Parts Catalog)
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Fuel prefilter – Draining
1. Cut out the filter to be drained.
I Left filter cut in
II Right filter cut in
2. Open threaded vent plug (5) of the filter to
be drained.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from the filter
until pure fuel emerges.
5. Close drain valve (6).
6. Remove screws securing the cover and
take off cover (2).
7. Fill filter housing with clean fuel.
8. Place new seal in cover (2).
9. Fit cover with gasket and secure it with
screws.
10. Cut in the cut-out filter again.
11. Close threaded vent plug (5) when fuel
emerges from system.
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7.8.4 Fuel prefilter – Flushing
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Diesel fuel
Seal
(→ Spare Parts Catalog)
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Fuel prefilter – Flushing
1. Switch off contaminated filter.
I Left filter cut in
II Right filter cut in
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2. Open threaded vent plug (5) of the filter to
be flushed.
3. Unlock drain valve (6) by pressing toggle,
open it and drain fuel.
Result: Fuel flows from filtered side back to the un‐
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close threaded vent plug (5) and drain
valve (6).
Fuel prefilter – Filling with fuel
1. Stop engine (→ Operating Instructions for electronic system ) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
3. Fill filter housing with clean fuel.
4. Place new seal in cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 83).
Result: If flushing did not improve differential pressure, fit new filter element in fuel prefilter (→ Page 87).
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7.8.5 Fuel prefilter – Filter element replacement
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Diesel fuel
Filter element
(→ Spare Parts Catalog)
Seal
(→ Spare Parts Catalog)
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Replacing filter element
1. Cut out the contaminated filter.
I Left filter cut in
II Right filter cut in
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2. Open threaded vent plug (5) of contaminat‐
ed filter.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from the fil‐
ter.
5. Close drain valve (6).
6. Remove screws securing the cover and
take off cover (2).
7. Remove spring housing (4) and filter ele‐
ment (3).
8. Insert new filter element (3) and spring
housing (4).
9. Fill filter housing with clean fuel.
10. Place new seal in cover (2).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Set adjustable pointer of differential pres‐
sure gauge (→ Page 83).
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7.9 Charge-Air Cooling
7.9.1 Intercooler – Checking condensate drain line for coolant discharge and
obstruction
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Intercooler – Checking condensate
drain line for coolant discharge and
obstruction
1. Check drain line for water discharge and
obstruction when the engine is running idle.
2. If no air emerges, remove condensate drain
line and blow out with compressed air.
3. Replace obstructed drain line by new one.
4. Install condensate drain line.
5. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con‐
tact Service.
Emergency measures prior to engine start with a leaking intercooler
1. Remove injectors (→ Page 77).
2. Bar engine manually (→ Page 64).
3. Bar engine with starting system to blow out combustion chambers (→ Page 65).
4. Install injectors (→ Page 78).
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7.10 Air Filter
7.10.1 Air filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Air filter
(→ Spare Parts Catalog)
Replacing the air filter
1. Remove old air filter and install new air filter (→ Page 91).
2. Reset signal ring of contamination indicator (→ Page 92).
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7.10.2 Air filter – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
Removing and installing air filter
1. Release clamp (2).
2. Remove air filter (3) and clamp (2) from
connecting flange of intake housing (1).
3. Verify that there are no objects in the con‐
necting flange of the intake housing (1) and
clean it.
4. Place new air filter (3) with clamp (2) onto
intake housing (1).
5. Tighten clamp (2).
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7.11 Air Intake
7.11.1 Contamination indicator – Signal ring position check (optional)
Preconditions
☑ Engine is stopped and starting disabled.
Checking signal ring position
1. If the signal ring is completely visible in the
observation window (2), replace air filter
(→ Page 90).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves back
to initial position.
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7.12 Starting Equipment
7.12.1 Starter – Condition check
Preconditions
☑ Engine is stopped and starting disabled.
Checking starter condition
1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 122).
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7.13 Lube Oil System, Lube Oil Circuit
7.13.1 Engine oil – Level check
Preconditions
☑ Engine is stopped and starting disabled.
Oil level check prior to engine start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds
and check oil level.
3. Oil level must be between "min." and "max."
marks.
4. Top up to "max." if required (→ Page 95).
5. Insert oil dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped
1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between “min.” and "max." marks.
4. Top up to "max." if required (→ Page 95).
5. Insert oil dipstick into guide tube up to the stop.
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7.13.2 Engine oil – Change
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Engine oil
WARNING
Hot oil.
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.
Version with extraction equipment: Extracting engine oil
1. Position a suitable container to drain the engine oil into.
2. Extract all engine oil from oil pan using the extraction equipment.
Filling with new engine oil
1. Determine amount of engine oil required for
oil change (→ Product Summary - Technical
Data).
2. Open cover on filler neck.
3. Fill engine oil through filler neck up to
“max.” mark on oil dipstick.
4. Close cover on filler neck.
5. Check engine oil level (→ Page 94).
6. After oil change, bar engine with starting
system.
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7.14 Oil Filtration / Cooling
7.14.1 Engine oil filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oil filter wrench
F30379104 1
Engine oil
Oil filter
(→ Spare Parts Catalog)
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
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.
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
Oil filter replacement with the
engine stopped
1. Stop engine and disable starting
2. Cut out the filter to be replaced.
A Right filter cut out
B Both filters cut in (operating position)
C Left filter cut out
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3. Remove cut-out oil filter using the oil filter
wrench.
4. Clean the sealing surface at the connecting
piece.
5. Check condition of the new sealing ring and
coat it with oil.
6. Fit the protective cover acc. to SOLAS re‐
quirements (→ Page 17).
7. Install and tighten new oil filter by hand.
8. Replace further oil filters in the same way.
9. After each oil change and filter replace‐
ment, bar engine with starting system
(→ Page 65).
10. Check oil level (→ Page 94).
Oil filter replacement with the engine running
1. Cut out the filter to be replaced.
2. Remove cut-out oil filter using the oil filter wrench.
3. Clean the sealing surface at the connecting piece.
4. Check condition of the new sealing ring and coat it with oil.
5. Fit the protective cover acc. to SOLAS requirements (→ Page 17).
6. Install and tighten new oil filter by hand.
7. Replace further oil filters in the same way.
8. Check oil level (→ Page 94).
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7.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Strap wrench
F30379104 1
Cold cleaner (Hakutex 50)
50622 1
Filter sleeve
(→ Spare Parts Catalog)
O-ring
(→ Spare Parts Catalog)
O-ring
(→ Spare Parts Catalog)
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Removing rotor of centrifugal oil
filter
1. Release nuts (3).
2. Remove housing cover (1).
3. Remove complete rotor (2) from housing.
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Cleaning centrifugal oil filter and
replacing filter sleeve
1. Remove nut, holding the rotor with a strap
wrench.
2. Remove nut (1), washer (2), rotor cap (3)
and sealing ring (4).
3. Remove sleeve (1).
4. Measure the layer thickness of the oil resi‐
due.
5. If maximum layer thickness (25 mm) is ex‐
ceeded, shorten maintenance interval.
6. Clean rotor components and remove strain‐
ers (2).
7. Wash standpipes (3) and nozzles (4) with
cleaner, blow out with compressed air.
8. Insert the new filter sleeve with the smooth
surface facing the rotor cap.
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9. Fit new sealing ring (4).
10. Set on rotor cap (3), observe marks.
11. Fit washer (2).
12. Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Nut M18 x 1.5 Tightening torque 10 Nm
13. Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Nut M16 x 1.5 Tightening torque 40 Nm to 50 Nm
14. Insert complete rotor (2) into the housing
and check for ease-of-movement.
15. Set housing cover (1) with new sealing ring
onto lower section, observe marks.
16. Tighten nuts (3) crosswise and evenly.
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