MTU 8 V 2000 M84, 10 V 2000 M84 Operating Instructions Manual

Operating Instructions

Diesel engine
8 V 2000 M84
10 V 2000 M84

MS150062/01E

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.

Table of Contents

1 Safety

1.1 General conditions 5

1.2 Personnel and organizational requirements 6

1.3 Transportation 7

1.4 Safety regulations for startup and operation 10

1.5 Safety regulations for maintenance and
repair work 11

1.6 Auxiliary materials, fire prevention and
environmental protection 14

1.7 Conventions for safety instructions in the
text 16

2 General Information

2.1 Engine side and cylinder designations 17

2.2 Product description 18

2.3 Engine layout 24

2.4 Sensors, actuators and injectors –
Overview 26

3 Technical Data

3.1 8V 2000M84 engine data 31

3.2 10V 2000 M84 engine data 34

3.3 Firing order 37

3.4 Engine – Main dimensions 38

4 Operation

4.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 39

4.2 Engine – Putting into operation after
scheduled out-of-service-period 40

4.3 Tasks after extended out-of-service periods
(>3 weeks) 41

4.4 Checks prior to start-up 42

4.5 Fuel treatment system – Putting into
operation 43

4.6 Operational checks 45

4.7 Fuel treatment system – Switching on 46

4.8 Starting the engine 47

4.9 Stopping the engine 48

4.10 Emergency stop 49

4.11 After stopping the engine 50

4.12 Fuel treatment system – Shutdown 51

4.13 Plant – Cleaning 52

5 Maintenance

5.1 Maintenance task reference table [QL1] 53

6 Troubleshooting

6.1 Fuel treatment system – Troubleshooting 54

6.2 Troubleshooting 55

7 Task Description

7.1 SOLAS 58

7.1.1 SOLAS shielding – Installation as per MTN
5233 58

7.1.2 SOLAS shielding – Installation 59

7.1.3 Installation locations for SOLAS shielding 60

7.2 Engine 66

7.2.1 Engine – Barring manually 66

7.2.2 Engine – Barring with starting equipment 67

7.3 Cylinder Liner 68

7.3.1 Cylinder liner – Endoscopic examination 68

7.3.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 70

7.4 Crankcase Breather 72

7.4.1 Crankcase breather – Cleaning oil separator
element 72

7.4.2 Crankcase ventilation – Oil separator element
replacement, diaphragm check and
replacement 73

7.5 Valve Drive 75

7.5.1 Valve clearance – Check and adjustment 75

7.5.2 Cylinder-head cover – Removal and
installation 78

7.6 Injection Valve / Injector 79

7.6.1 Injector – Replacement 79

7.6.2 Injector – Removal and installation 80

7.7 Fuel System 82

7.7.1 Fuel system – Venting 82

7.8 Fuel Filter 83

7.8.1 Fuel filter – Replacement 83

7.8.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 85

7.8.3 Fuel prefilter – Draining 86

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7.8.4 Fuel prefilter ‒ Flushing 87

7.8.5 Fuel prefilter – Filter element replacement 89

7.9 Charge-Air Cooling 91

7.9.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 91

7.10 Air Filter 92

7.10.1 Air filter – Replacement 92

7.10.2 Air filter – Removal and installation 93

7.11 Air Intake 94

7.11.1 Contamination indicator – Signal ring position
check 94

7.12 Starting Equipment 95

7.12.1 Starter – Condition check 95

7.13 Lube Oil System, Lube Oil Circuit 96

7.13.1 Engine oil – Level check 96

7.13.2 Engine oil – Change 97

7.14 Oil Filtration / Cooling 98

7.14.1 Engine oil filter – Replacement 98

7.14.2 Centrifugal oil filter – Cleaning and filter­sleeve replacement 100

7.15 Coolant Circuit, General, High­Temperature Circuit 103

7.15.1 Drain and venting points 103

7.15.2 Engine coolant – Level check 109

7.15.3 Engine coolant – Change 110

7.15.4 Engine coolant – Draining 111

7.15.5 Engine coolant – Filling 112

7.15.6 HT coolant pump — Relief bore check 113

7.15.7 Engine coolant – Sample extraction and
analysis 114

7.15.8 Coolant filter – Replacement 115

7.16 Raw Water Pump with Connections 116

7.16.1 Raw water pump – Relief bore check 116

7.17 Belt Drive 117

7.17.1 Drive belt – Condition check 117

7.18 Battery-Charging Generator 118

7.18.1 Battery-charging generator drive – Drive belt
replacement 118

7.19 Fuel Supply System 119

7.19.1 Water drain valve – Check 119

7.19.2 Differential pressure gauge – Check 120

7.19.3 Water level probe (3-in-1 rod electrode) –
Check 121

7.19.4 Pump capacity – Check 122

7.19.5 Coalescer filter element – Replacement 123

7.20 Wiring (General) for Engine/Gearbox/Unit 125

7.20.1 Engine wiring – Check 125

7.21 Accessories for (Electronic) Engine
Governor / Control System 126

7.21.1 Engine governor and connectors – Cleaning 126

7.21.2 Engine governor – Checking plug-in
connections 127

7.21.3 EMU – Checking plug-in connections 128

7.21.4 Engine governor – Carry out self-test 129

7.21.5 EMU and connectors – Cleaning 130

7.21.6 ECU 7 engine governor – Removal and
installation 131

7.21.7 Engine monitoring unit – Removal and
installation 132

8 Appendix A

8.1 Abbreviations 133

8.2 MTU contacts/service partners 136

9 Appendix B

9.1 Special Tools 137

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

Work on the engine must only be carried out by appropriately qualified and instructed personnel.

Observe the minimum legal age.

Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.

Organizational measures

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

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

Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.

This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.

Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.

Working clothes and protective equipment

Wear proper protective clothing for all work.

Depending on the kind of work, use the necessary personal protective equipment.

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1.3 Transportation

Transport without flange-mounted gearbox

Illustration is essentially valid for 8V 2000 M engines

Illustration is essentially valid for 12/16V 2000 M engines

Transport with flange-mounted gearbox

Illustration is essentially valid for 8V 2000 M engines

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Illustration is essentially valid for 12/16V 2000 M engines

Only use the lifting eyes provided to lift the engine.

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

Only use transport and lifting devices approved by MTU.

Take the engine's center of gravity into account.

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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 requirements for initial operation

Prior to initial operation of the unit, install the assembly or unit according to the specifications 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 nobody is in the danger area of moving machine parts.

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

Safety requirements for operators

The procedures for cases of emergency must be practiced regularly.

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

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

During operation, the display instruments and monitoring units must be permanently observed with 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 protection.

• 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 spilt 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 electrical equipment is in operation, certain components of these appliances are electrically 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 splashes of oil or fuel on hot components can cause fires ­therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.

Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.

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

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

Noise

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

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

Environmental protection and disposal

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

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

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

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

Auxiliary materials, fluids and lubricants

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

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

Used oil

Used oil contains harmful combustion residues.

Rub barrier cream into hands.

Wash hands after contact with used oil.

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Lead

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

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

• Switch on extraction system.

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

Compressed air

Observe special safety precautions when working with compressed air:

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

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

• Hose couplings and connections must be securely attached.

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

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

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

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

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

• Carry out leak test in accordance with the specifications.

Painting

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

• No open flames.

• No smoking.

• Observe fire prevention regulations.

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

Liquid nitrogen

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

• Avoid body contact (eyes, hands).

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

• Make sure that working area is well ventilated.

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

Acids and alkaline solutions

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

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

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

• Rinse eyes immediately with eyedrops or clean tap water.

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1.7 Conventions for safety instructions in the text

DANGER

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

• Remedial action

WARNING

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

• Remedial action

CAUTION

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

• Remedial action

NOTICE

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

• Remedial action

• Additional product information

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

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

Safety instructions

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

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

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2 General Information

2.1 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 with "A" and those of the right side with "B" (as per
DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the en‐
gine's driving end.

Other components are numbered in the same way, i.e. starting with No. 1 at the engine's driving end.

1 KGS = free end
2 Right engine side

3 KS = driving end
4 Left engine side

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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

View on free end

1 Engine oil heat exchang‐

er

2 Engine oil filter
3 Coolant filter
4 Coolant distribution hous‐

ing with integrated expan‐
sion tank

5 Air filter (air intake)
6 Engine governor
7 Exhaust turbocharger

8 Oil separator

9 Actuating cylinder
10 2/2-way solenoid
11 4/2-way solenoid valve
12 Starter
13 Battery-charging genera‐

tor

14 Raw water connection to

gearbox cooling system

15 Raw water pump

16 Raw water connection

from sea

17 Protective cover (belt pul‐

ley)

18 Plate-core heat exchang‐

er
19 Centrifugal oil filter
20 Fuel priming pump
21 Fuel filter

KGS = engine free end

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View on driving end

1 Vent housing
2 Diverter lever for oil filters
3 Cylinder head
4 Exhaust housing
5 Coolant pump
6 Engine mount
7 HP fuel pump

8 Oil filler neck

9 Oil dipstick
10 Preheating pump
11 Oil pan
12 Flywheel
13 Flywheel housing
14 Auxiliary PTO

15 Carrier housing lower

section

16 Carrier housing middle

section
17 Relief valve
18 Exhaust outlet

KS = engine driving end

Engine model designation

Key to the engine model designation 8V/10V 2000 Mxy

• 8/10 = Number of cylinders

• V = Cylinder configuration

• 2000 = Series

• Mx = Application segment

• y = Design index

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2.4 Sensors, actuators and injectors – Overview

Top view

No. Description Monitoring of

1 B10 Charge-air pressure

2 B9 Charge-air temperature

3 B7 Lube oil temperature

4 B3 Intake air temperature

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Free end

No. Description Monitoring of

1 B34 Fuel line pressure after filter

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

3 B5.1 Lube oil pressure

4 B5.2 (optional) Lube oil pressure

5 F33 Coolant level

6 B21 (optional) Raw water pressure

7 B6.2 (optional) Coolant pressure

8 B6.1 Coolant temperature

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Driving end

No. Description Monitoring of

1 B4.22 Exhaust temperature, B-side

2 B1 Camshaft speed

3 B13 Crankshaft speed

4 B13.2 (option) Crankshaft speed

5 B4.21 Exhaust gas temperature, A side

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Right engine side

No. Description Monitoring of

1 B44 Turbocharger speed

2 B33 Fuel temperature

3 B48 Fuel pressure in Common Rail

4 B16 (optional) Coolant pressure

5 F46 Leak fuel level

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Left engine side

No. Description Monitoring of

1 Y41 Wastegate solenoid valves

6 Y27 Solenoid valves for turbocharger control

7 B54 (optional) Oil replenishment pump pressure

System sensors

The sensors are fitted on the off-engine system.

Description Monitoring of

B19 Starting-air pressure

B70 Water level in fuel prefilter

B41 Exhaust backpressure

S37 Start interlock, switching status

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3 Technical Data

3.1 8V 2000M84 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

Engine model 8V2000M

84

Application group 1D

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

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

Number of cylinders 8

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 A kW 810

General conditions (for maximum power)

Number of cylinders 8

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

Model related data (basic design)

Number of cylinders 8

Cylinder arrangement: V angle Degrees

(°)

90

Bore mm 135

Stroke mm 156

Cylinder displacement Liters 2.23

Total displacement Liters 17.84

Number of inlet valves per cylinder 2

Number of exhaust valves per cylinder 2

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Raw-water circuit (open circuit)

Number of cylinders 8

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

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

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

Lube oil system

Number of cylinders 8

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

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

Lube oil operating pressure before engine, from R bar 9.0

Lube oil operating pressure before engine, to R bar 10.0

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

Fuel system

Number of cylinders 8

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

Fuel pressure at engine inlet connection, min. (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 5.2

General operating data

Number of cylinders 8

Firing speed, from R rpm 100

Firing speed, to R rpm 120

Starter (electric)

Number of cylinders 8

Rated starter voltage (standard design) R V= 24

Inclinations, standard oil system (reference: waterline)

Number of cylinders 8

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

L Degrees

(°)

15

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

L Degrees

(°)

20

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

(°)

40

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Capacities

Number of cylinders 8

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

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

R Liters 73

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

R Liters 67

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

L Liters 54

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

L Liters 62

Weights / main dimensions

Number of cylinders 8

Engine dry weight (with standard accessories installed, w/o coupling) R kg 1970

Sound

Number of cylinders 8

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

R dB(A) 105

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

R dB(A) 104

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3.2 10V 2000 M84 engine data

Explanation:

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

A Design value
G Guaranteed value
R Guideline value

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

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 10V 2000

M84

Application group 1D

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

POWER-RELATED DATA (performance refers to net brake power as per ISO 3046)

Number of cylinders 10

Engine rated speed A rpm 2450

Fuel stop power ISO 3046 A kW 1015

GENERAL CONDITIONS (for maximum power)

Number of cylinders 10

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)

Number of cylinders 10

Cylinder arrangement: V angle Degrees

(°)

90

Bore mm 135

Stroke mm 156

Displacement per cylinder liters 2.23

Total displacement liters 22.30

Number of inlet valves, per cylinder 2

Number of exhaust valves, per cylinder 2

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RAW WATER CIRCUIT (open circuit)

Number of cylinders 10

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

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

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

LUBE OIL SYSTEM

Number of cylinders 10

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

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

Lube oil operating pressure before engine, from R bar 8.0

Lube oil operating pressure before engine, to R bar 9.0

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

FUEL SYSTEM

Number of cylinders 10

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

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

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

Fuel supply flow, max. R Liter/min 5.9

GENERAL OPERATING DATA

Number of cylinders 10

Firing speed, from R rpm 100

Firing speed, to R rpm 120

STARTER (electric)

Number of cylinders 10

Starter rated voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Number of cylinders 10

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

L Degrees

(°)

15

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

L Degrees

(°)

20

Longitudinal inclination, continuous max., driving end up (Option: max. op‐
erating inclinations)

L Degrees

(°)

5

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

(°)

35

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CAPACITIES

Number of cylinders 10

Engine coolant capacity (with cooling equipment) R liters 114

Total engine oil capacity at initial filling (standard oil system) (Option: max.
operating inclinations)

R liters 81

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

L liters 64

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

L liters 70

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 10

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

ACOUSTICS

Number of cylinders 10

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

R db(A) 107

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

R db(A) 107

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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

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

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

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3.4 Engine – Main dimensions

Main dimensions

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

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

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

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

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

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

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

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

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

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

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4 Operation

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

Preconditions

☑ Engine is stopped and starting disabled.

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

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

Item Measure

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

Lube oil system Check engine oil level (→ Page 96).

Fuel prefilter Fill with fuel (→ Page 89).

Fuel prefilter, pressure
gauge

Align adjustable pointer with position of pressure indicator (→ Page 85).

Fuel system Vent (→ Page 82).

Raw-water pump (if located
above waterline)

Prime (approx. 3 to 4 liters).

Filling point (→ Page 103).

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

(→ Page 110).

Coolant circuit Check coolant level (→ Page 109).

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 96).

Coolant circuit Check coolant level (→ Page 109).

Coolant circuit Heat engine coolant with coolant preheating unit.

Fuel prefilter Drain water and contaminants (→ Page 86).

Battery-charging generator
drive

Check condition of drive belt (→ Page 117).

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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 43).

2. Shut down fuel treatment system (→ Page 51).

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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 46).

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 46).

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 123).

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

Initial operation: HAT

1. Replace fuel filter on engine (→ Page 83).

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 46).

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 47).

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 46).

2. Start engine (→ Page 47).

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 46).

2. Start engine (→ Page 47).

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 46).

2. Start engine (→ Page 47).

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 55).

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

(→ Page 85).

Drain water and contaminants (→ Page 86).

Air filter Check signal ring position of contamination indicator (→ Page 94).

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

(→ Page 113).

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

(→ Page 116).

Intercooler Check condensate drain (if applicable) (→ Page 91).

Engine oil Check engine oil level (→ Page 96).

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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 42).

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 111) 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 applied.

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.

Note: There is a risk of damaging sensors with compressed air.

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

4. Carry out external cleaning as follows:

a) Remove coarse dirt.
b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
c) Use the high-pressure jet to remove the loosened dirt.
d) 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.

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5 Maintenance

5.1 Maintenance task reference table [QL1]

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

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

Task Maintenance tasks

W0500 Check engine oil level (→ Page 96)

W0501 Visually inspect engine for leaks and general condition (→ Page 45)

W0502 Check intercooler drain (if fitted) (→ Page 91)

W0503 Check signal ring position of service indicator on air filter (→ Page 94)

W0505 Check relief bores of coolant pump(s) (→ Page 113)

W0506 Check engine for abnormal running noises, exhaust color

and vibrations

(→ Page 45)

W0507 Drain water and contaminants from fuel prefilter (if fitted) (→ Page 86)

W0508 Check reading on differential pressure gauge of fuel prefilter

(if fitted)

(→ Page 85)

W1001 Replace fuel filter or fuel filter element (→ Page 83)

W1002 Check valve clearance (→ Page 75)

W1005 Replace air filter (→ Page 92)

W1006 Replace fuel injectors (→ Page 79)

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

limit (years) is reached, at the latest

(→ Page 98)

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

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

(→ Page 100)

W1011 Perform endoscopic inspection of combustion chambers (→ Page 68)

W1036 Replace coolant filter (→ Page 115)

W1140 Clean wire meshes of crankcase breather (→ Page 72)

W1244 Check operation of rod electrode (if fitted) (→ Page 121)

W1245 Check alarm function of differential pressure gauge (if fitted) (→ Page 120)

W1246 Check pump capacity (if fitted) (→ Page 122)

Table 1: Maintenance task reference table [QL1]

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6 Troubleshooting

6.1 Fuel treatment system – Troubleshooting

Illuminated pushbutton “water alarm” is lit.

Cause Corrective action

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

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

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

Signal lamp “Pump fault” is lit.

Cause Corrective action

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

u Reset motor protection relay.

Signal lamp “Warning filter” is lit.

Cause Corrective action

The differential pressure exceed‐
ed 1.3 bar.

u Replace coalescer filter element (→ Page 123).

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 123).

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 125).

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 125).

Fuel system Not vented Vent fuel system (→ Page 82).

ECU Defective Contact Service.

Engine fires unevenly

Component Probable Cause Task

Fuel injection equip‐
ment

Injector defective Replace (→ Page 79).

Engine wiring Defective Check (→ Page 125).

Fuel system Not vented Vent fuel system (→ Page 82).

ECU Defective Contact Service.

Engine does not reach nominal speed

Component Probable Cause Task

Fuel supply Fuel prefilter clogged Replace (→ Page 89).

Fuel filter clogged Replace (→ Page 83).

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

dicator (→ Page 94).

Fuel injection equip‐
ment

Injector defective Replace (→ Page 79).

Engine wiring Defective Check (→ Page 125).

Engine Overloaded Contact Service.

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Engine speed not steady

Component Probable Cause Task

Fuel injection equip‐
ment

Injector defective Replace (→ Page 79).

Speed sensor Defective Replace.

Fuel system Not vented Vent fuel system (→ Page 82).

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 94).

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 94).

Fuel injection equip‐
ment

Injector defective Replace (→ Page 79).

Engine Overloaded Contact Service.

Exhaust gas blue

Component Probable Cause Task

Engine oil Too much oil in engine Drain engine oil (→ Page 97).

Oil separator or oil preseparator of
crankcase breather clogged

• Clean preseparator (→ Page 72).

• Replace filter element of oil separa‐
tor (→ Page 73).

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 86).

Intercooler Leaking Contact Service.

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7 Task Description

7.1 SOLAS

7.1.1 SOLAS shielding – Installation as per MTN 5233

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Shield A4

735233000100 5

Shield A5

735233000101 7

Shield A7

735233000103 6

Shield A8

735233000104 2

Installing SOLAS shielding

1. Pinpoint installation location (→ Page 60).

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 60).

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 58).

On crankcase

Item Type of shielding Remarks

1 Shield (A4) On brazed-on union

2 Shield (A5) On crankcase

Free end B-side

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Item Type of shielding Remarks

1

Free end
B-side

Shield (A7) On fuel delivery pump

Free end B-side

Item Type of shielding Remarks

1

Free end
B-side

Shield (A7) On HP fuel pump

Free end

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Item Type of shielding Remarks

1

Free end

Shield (A7) Above fuel priming pump

Free end

Item Type of shielding Remarks

1

Free end

Shield (A7) Below fuel priming pump

Free end

Item Type of shielding Remarks

1

Free end

Shield (A8) On fuel filter housing

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Driving end A-side

Item Type of shielding Remarks

1

Driving end

Shield (A5) On valve plate

Driving end A-side

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Item Type of shielding Remarks

1

Driving
end

Shield (A5) On air flap control

2

Driving
end

Shield (A4) On brazed-on union

3

Driving
end

Shield (A5) On exhaust turbocharger flap control

4

Driving
end

Shield (A5) On exhaust turbocharger flap control

Driving end

Item Type of shielding Remarks

1

Driving
end

Shield (A4) Exhaust turbocharger lubrication

2

Driving
end

Shield (A4) On brazed-on union

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Driving end

Item Type of shielding Remarks

1

Driving
end

Shield (A4) Exhaust turbocharger lubrication

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7.2 Engine

7.2.1 Engine – Barring manually

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring tool

F6783914 1

Ratchet

F30006212 1

DANGER

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

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

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

Engine – Barring manually

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

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

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

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7.2.2 Engine – Barring with starting equipment

Preconditions

☑ Clutch is disengaged.

☑ Engine start is disabled.

☑ LOP is accessible and open.

DANGER

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

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

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

Barring

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

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

onds.

2. Release barring pushbutton.

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7.3 Cylinder Liner

7.3.1 Cylinder liner – Endoscopic examination

Preconditions

☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Rigid endoscope

Y20097353 1

Preparatory steps

1. Remove cylinder head cover (→ Page 78).

2. Remove injector (→ Page 80).

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 70).

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 80).

2. Install cylinder head cover (→ Page 78).

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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 separator element

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Fuel
Gasket

(→ Spare Parts Catalog)

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
separator element

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

2. Remove oil separator (2) and gasket (3).

3. Clean oil separator (2) in fuel and blow dry
with compressed air.

4. Moisten oil separator (2) with engine oil.

5. Place oil separator (2) with new gasket (3)
onto housing (4) and install cover (1).

6. Clean further oil separator element in the
same way.

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

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 6-50 Nm

F30027336 1

Ratchet 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 position, and fit end 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 further oil separator elements in the same way.

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Checking diaphragms

1. Remove cover (4).

2. Take off spring (5), gasket (2) and dia‐
phragm (3).

3. Check diaphragm (3) for damage.

4. Replace diaphragm if damaged.

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

6. Install new gasket (2) and spring (5) togeth‐
er 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 93).

2. Remove cylinder head cover (→ Page 78).

Positioning A1 piston at TDC

1. Remove cable from sensor B13 (→ Page 26).

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 78).

5. Install air filter (→ Page 93).

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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 93).

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 93).

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 80)

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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 78).

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 78).

2. Open fuel supply to engine.

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7.7 Fuel System

7.7.1 Fuel system – Venting

Preconditions

☑ Engine is stopped and starting disabled.

WARNING

Fuels are combustible.
Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Venting fuel system

1. Unlock fuel priming pump, unscrew handle.

2. Open vent plugs on filter head.

Note: New version has two threaded vent plugs,

old version has four threaded vent plugs.

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

4. Close vent plugs on filter head.

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

6. Lock fuel priming pump, screw in handle.

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7.8 Fuel Filter

7.8.1 Fuel filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter wrench

F30379104 1
Diesel fuel
Easy-change filter

(→ Spare Parts Catalog)

DANGER

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

• Take special care when working on a running engine.

DANGER

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

• Take special care when working on a running engine.

WARNING

Fuels are combustible.
Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

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

• Wear ear protectors.

CAUTION

Damage to component.
Serious damage to plant!

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

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

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Easy-change fuel filter replacement
with the engine stopped

1. Stop engine and disable engine start.

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

C Right filter cut out

3. Remove cut-out easy-change filter using

the oil filter wrench.

4. Clean sealing surface on filter head.

5. Check sealing ring of the new easy-change

filter and coat it with fuel.

6. Fit SOLAS shield (→ Page 58).

7. Screw on easy-change filter and tighten by

hand.

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

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

9. Replace further fuel filters in the same way.

10. Vent fuel system (→ Page 82).

Easy-change fuel filter replacement
with the engine running

1. Cut out the filter to be replaced.

2. Open the threaded vent plugs at the filter

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

Note: New version has two threaded vent plugs,

old version has four threaded vent plugs.

3. Close threaded vent plugs.

4. Remove cut-out easy-change filter using

the oil filter wrench.

5. Clean sealing surface on filter head.

6. Check sealing ring of the new easy-change

filter and coat it with fuel.

7. Fit SOLAS shield (→ Page 58).

8. Screw on easy-change filter and tighten by

hand.

9. Set three-way cock to operating position

(both filters cut in).

10. Replace further fuel filters in the same way.

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7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge

DANGER

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

• Take special care when working on a running engine.

WARNING

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

• Wear ear protectors.

Differential pressure gauge
adjustment

1. When installing the new filter element: align
adjustable pointer (2) with pressure-indicat‐
ing pointer (3) of pressure gauge (1).

2. Verify that differential pressure is within the
limit.

Fuel prefilter – Checking differential pressure

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

2. If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of
pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 87).

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7.8.3 Fuel prefilter – Draining

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel
Seal

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.
Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Fuel prefilter – Draining

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

II Right filter cut in

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

be drained.

3. Unlock drain valve (6) by pressing toggle

and open it.

4. Drain water and contaminants from the filter

until pure fuel emerges.

5. Close drain valve (6).

6. Remove screws securing the cover and

take off cover (2).

7. Fill filter housing with clean fuel.

8. Place new seal in cover (2).

9. Fit cover with gasket and secure it with

screws.

10. Cut in the cut-out filter again.

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

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7.8.4 Fuel prefilter ‒ Flushing

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Fuel
Gasket

(→ Spare Parts Catalog)

DANGER

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

• Take special care when working on a running engine.

WARNING

Fuels are combustible.
Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

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

• Wear ear protectors.

Fuel prefilter ‒ Flushing

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

II Right filter cut in

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

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

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

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

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

Fuel prefilter – Topping up with fuel

1. Stop engine (→ Page 48) and disable engine start.

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

3. Fill filter housing with clean fuel.

4. Place new gasket in cover (2).

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

6. Check differential pressure (→ Page 85).

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

ter (→ Page 89).

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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 85).

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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 79).

2. Bar engine manually (→ Page 66).

3. Bar engine with starting system to blow out combustion chambers (→ Page 67).

4. Install injectors (→ Page 80).

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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 93).

2. Reset signal ring of contamination indicator (→ Page 94).

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7.10.2 Air filter – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Air filter – Removal and installation

1. Release clamp (2).

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

3. Verify that there are no objects in the 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

Preconditions

☑ Engine is stopped and starting disabled.

Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 92).

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.

Starter – Condition check

1. Check securing screws of starter for secure seating and tighten if required.

2. Check wiring (→ Page 125).

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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 97).

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 97).

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 96).

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)

Plastic ring

(→ 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.

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Oil filter replacement with the
engine stopped

1. Stop engine (→ Page 48) and disable en‐
gine start.

2. Cut out the filter to be replaced.

A Right filter cut out
B Both filters cut in (normal operating

position)

C Left filter cut out

3. Remove cut-out oil filter using the oil filter
wrench.

4. Clean sealing surface on connecting piece.

5. Check condition of new oil filter sealing ring
and coat it with oil.

6. Fit SOLAS shield (→ Page 58).

7. Screw on and tighten new engine oil filter
by hand.

8. Replace other oil filters in the same way.

9. Switch filter to normal position.

10. After each oil change and filter replace‐
ment, crank engine with starting system
(→ Page 67).

11. Check oil level (→ Page 96).

Oil filter replacement with the engine running

1. Reduce engine speed to <1100 rpm.

2. Remove cut-out oil filter using the oil filter wrench.

3. Clean sealing surface on connecting piece.

4. Check condition of new oil filter sealing ring and coat it with oil.

5. Fit SOLAS shield (→ Page 58).

6. Screw on and tighten new engine oil filter by hand.

7. Replace other oil filters in the same way.

8. Switch filter to normal position.

9. Check oil level (→ Page 96).

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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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