Technical Publication · 2020. 9. 16. · Technical Publication Diesel Engine 8 V 2000 M72 10 V...

Technical Publication

Diesel Engine 8 V 2000 M72 10 V 2000 M72 Operating Instructions M015630/01E

Printed in Germany © 2006 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten. Printed in Germany © 2006 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, microfilming 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. Imprimé en Allemagne © 2006 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne. Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. Modifications réservées. Impreso en Alemania © 2006 Copyright MTU Friedrichshafen GmbH Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones. Stampato in Germania © 2006 Copyright MTU Friedrichshafen GmbH Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH. II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche. Impresso na Alemanha © 2006 Copyright MTU Friedrichshafen GmbH A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line. Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores. Salvo alterações.

Wichtig – Important – Importante

Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH zurücksenden.

Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik- Support (Gewährleistung, Ersatzteile etc.).

Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.

The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.).

Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen GmbH.

Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en exploitation contractuelle (garantie, rechanges, etc.).

Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU Friedrichshafen GmbH.

Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico contractual (garantía, piezas de repuesto, etc.).

Ritagliare “Avviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen GmbH.

Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).

É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU Friedrichshafen.

Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças sobressalentes, etc.) estabelecido contratualmente.

Postcard

MTU Friedrichshafen GmbH

Department SCSD

88040 Friedrichshafen

GERMANY

Bitte in Blockschrift ausfüllen! Please use block capitals! Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma!

Motornr.: Engine No.: No du moteur: No de motor: Motore N.: No. do motor:

Auftragsnr.:MTU works order No.: N° de commande: N° de pedido: N. commessa: No. do pedido:

Motortyp:

Engine model: Type du moteur: Tipo de motor: Motore tipo: Tipo do motor:

Inbetriebnahmedatum:Date put into operation: Mise en service le: Fecha de puesta en servicio: Messa in servizio il: Data da colocação em serviço:

Eingebaut in:

Installation site: Lieu de montage: Lugar de montaje: Installato: Incorporado em:

Schiffstyp / Schiffshersteller:Vessel/type/class / Shipyard: Type du bateau / Constructeur: Tipo de buque / Constructor: Tipo di barca / Costruttore Tipo de embarcação/estaleiro naval:

Endabnehmer/Anschrift:

End user`s address: Adresse du client final: Dirección del cliente final: Indirizzo del cliente finale: Usuário final/endereço:

Bemerkung:

Remarks: Remarques: Observaciones: Commento: Observações:

Inbetriebnahme-meldung Commissioning Note Notice de mise en service Aviso de puesta en servicio Avviso di messa in servizio Participação da colocação em serviço

Table of Contents 01

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05

1.1 General conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05

1.2 Personnel and organizational requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06

1.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07

1.4 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08

1.5 Auxiliary materials, fire prevention and environmental protection . . . . . . . . . . . . . . . . 11

1.6 Standards for warning notices in the publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 Product Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1 Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.1.1 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.1.2 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.2 Engine Side and Cylinder Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.2.1 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.3 Main Engine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252.3.1 Engine – Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262.4.1 Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272.5.1 8V 2000 M72 engine data : Separate heat exchanger . . . . . . . . . . . . . . . . . . . . . 272.5.2 8V 2000 M72 engine data: Engine-mounted heat exchanger . . . . . . . . . . . . . . . . 302.5.3 10V 2000 M72 engine data: Separate heat exchanger . . . . . . . . . . . . . . . . . . . . 342.5.4 10V 2000 M72 engine data: Engine-mounted heat exchanger . . . . . . . . . . . . . . . 37

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.1 Switchgear cabinet – Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.2 Putting the engine into operation (out-of-service period > 3 months) . . . . . . . . . . . . . . 43

3.3 Putting the engine into operation after scheduled out-of-service period . . . . . . . . . . . 44

3.4 Tasks after extended out-of-service periods (>3 weeks) . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.5 Checks prior to startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.6 Fuel treatment system – Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.7 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.8 Fuel treatment system – Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.9 Operational checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.10 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.11 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.12 After stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.13 Fuel treatment system – Putting out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

M015630/01E 06-11 © MTU

02 Table of Contents

4.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.2 Maintenance schedule matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.1 Fuel treatment system – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6 Task Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.1.1 Engine – Barring manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.1.2 Engine – Barring with starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.2 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716.2.1 Cylinder liner – Endoscopic examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

6.3 Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.3.1 Crankcase breather – Cleaning oil pre-separator element . . . . . . . . . . . . . . . . . . 746.3.2 Crankcase breather – Oil separator replacement, diaphragm check and

replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

6.4 Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776.4.1 Valve clearance – Check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776.4.2 Cylinder-head cover – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6.5 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816.5.1 Injector – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816.5.2 Injector – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.6.1 Fuel system – Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

6.7 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 856.7.1 Fuel filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 856.7.2 Fuel prefilter, differential pressure gauge – Inspection and adjustment . . . . . . . . 876.7.3 Fuel prefilter - Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 886.7.4 Fuel prefilter – Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906.7.5 Fuel prefilter – Filter element replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

6.8 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946.8.1 Air filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946.8.2 Air filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6.9 Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 966.9.1 Service indicator – Signal ring position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

6.10 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 976.10.1 Starter – Condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

6.11 Lube-oil System, Lube-oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 986.11.1 Engine oil – Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 986.11.2 Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

6.12 Oil Filtration / Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

M015630/01E 06-11 © MTU

Table of Contents 03

6.12.1 Engine oil filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006.12.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement . . . . . . . . . . . . . . . . 102

6.13 General Cooling Circuit, HT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056.13.1 Drain and venting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056.13.2 Engine coolant – Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116.13.3 Engine coolant – Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1126.13.4 Engine coolant – Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1136.13.5 Engine coolant system – Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1146.13.6 HT coolant pump – Relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1156.13.7 Engine coolant – Sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . 1166.13.8 Coolant filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6.14 Raw Water Pump with Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1186.14.1 Raw water pump – Relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

6.15 Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1196.15.1 Drive belt – Condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6.16 Battery-charging Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1206.16.1 Battery-charging generator drive – Drive belt check and adjustment . . . . . . . . . . 1206.16.2 Battery-charging generator drive – Drive belt replacement . . . . . . . . . . . . . . . . . . 121

6.17 Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1226.17.1 Water drain valve – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1226.17.2 Differential pressure gauge – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1236.17.3 3-in-1 bar electrode – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1246.17.4 Pump capacity – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1256.17.5 Coalescer filter element – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.18 General Cabling for Engine / Gearbox / Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1286.18.1 Engine wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1286.18.2 Sensors, actuators and injectors – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

6.19 Accessories for Engine Governor (Electronic) / Control System . . . . . . . . . . . . . . . . . 1346.19.1 ECU and connectors – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1346.19.2 EMU and connectors – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1356.19.3 ECU – Checking plug-in connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1366.19.4 EMU – Checking plug-in connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1376.19.5 ECU – Self-test implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1386.19.6 ECU – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1396.19.7 EMU – Installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

7.1 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

7.2 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

8 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.1 Manufacturer’s documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.2 MTU contact person/service partner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

8.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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04 Table of Contents

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Safety 05

1 Safety

1.1 General conditions

GeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other compulsoryregulations regarding accident prevention must be observed. This engine is a state-of-the art product and conformswith all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:

• Incorrect use• Operation, maintenance and repair by unqualified personnel• Modifications or conversions• Non-compliance with the Safety Instructions

Correct useThe engine is intended exclusively for the application specified in the contract or defined at the timeof delivery. Any other use is considered improper use. The manufacturer will accept no liability forany resultant damage. The responsibility is borne by the user alone.Correct use also includes observation of and compliance with the maintenance specifications.

Modifications or ConversionsModifications made by the customer to the engine may affect safety.MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.

Spare partsOnly genuine MTU spare parts must be used to replace components or assemblies. In theevent of any damage caused by the use of other spare parts, no liability nor warranty claimsvis-à-vis the engine manufacturer will be accepted.

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06 Safety

1.2 Personnel and organizational requirements

PersonnelWork on the engine must only be carried out by properly qualified and instructed personnel.The specified legal minimum age must be observed.Responsibilities of the operating, maintenance and repair personnel must be specified.

OrganizationThis publication must be issued to all personnel involved in operation, maintenance, repair or transportation.It must be kept at hand near the engine and accessible at any time to all personnel involvedin operation, maintenance, repair or transportation.The personnel must be instructed on engine operation and repair by means of this publication,and in particular the safety instructions must be explained.This is especially important for personnel who work on the engine only on an occasional basis.Such personnel must be given instructions repeatedly.

Working clothes and protective equipmentWear proper work clothing for all work.Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.Work clothing must be tight fitting so that it does not catch on rotating or projecting components.Do not wear jewelry (e.g. rings, chains etc.).

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Safety 07

1.3 Transport

TransportLift the engine only with the lifting eyes provided.Use only the transport and lifting equipment approved by MTU.Take note of the engine center of gravity.The engine must only be transported in installation position, max. permissible diagonal pull 10°.In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of thetransport pallet or transport with equipment for heavy loads (forklift truck).Prior to transporting the engine, it is imperative to install transportation lockingdevices for crankshaft and engine mounts.Secure the engine against tilting during transportation. The engine must be especially securedagainst slipping or tilting when going up or down inclines and ramps.

Setting the engine down after transportPlace the engine only on an even, firm surface.Ensure appropriate consistency and load-bearing capacity of the ground or support surface.Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

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08 Safety

1.4 Safety precautions when working on the engine

Safety precautions when putting the equipment into operationPrior to initial operation, the product must have been installed correctly and approved according to MTU specifications.Before putting the device or the system into operation, always ensure

• that all maintenance and repair work is completed• that all loose components have been removed from rotating parts• that nobody is standing in the danger zone of moving engine components.

Immediately after putting the device or system into operation, make sure that all control and displayinstruments as well as the signaling and alarm systems work properly.

Safety requirements for operatorsProcedures for cases of emergency must be practised regularly.The operator must be familiar with the controls and displays.The operator must know the consequences of each operation to be carried out.The operator must carry out the individual operations according to the documentation.During operation, the displays and monitoring units must be permanently observed with regard to presentoperating 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:

• notify the supervisory personnel in charge• analyze the message• if required, carry out emergency operations e.g. emergency engine stop.

Engine operationWhen the engine is running, always wear ear protectors.Ensure that the engine room is well ventilated.Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a healthhazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.During engine operation, do not touch battery terminals, generator terminals or cables.Inadequate protection of electrical components can lead to electric shocks and serious injuries.When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Maintenance and repairStrict adherence to the maintenance and repair schedule is an essential safety factor.Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.Lock-out/tag-out the engine to preclude undesired 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 air starters are fitted. Postthe "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special toolsrequired. Have maintenance and repair work carried out by qualified and authorized personnel only.Use only proper, calibrated tools.Do not work on engines or components which are only held by lifting equipment or crane. Always support bysuitable means which conform with the applicable regulations before commencing maintenance or repair work.Before barring the engine, make sure that nobody is standing in the danger zone. After completingwork on the engine, check that all protective devices/safety guards have been installed and thatall tools and loose parts have been removed from the engine.Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Beforestarting work, relieve pressure in systems and H.P. lines which are to be opened.Never bend a fuel line and do not install bent lines. 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 fuel lines during maintenance and repair work. To tighten the connections when installingthe lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.

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Safety 09

Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to othercomponents to avoid contact with them. Do not place fuel or oil lines near hot components,except when necessary for design reasons during installation.Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposeswhen exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in thiscase. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric sealsif they have carbonized or resinous appearance. Wear protective gloves!Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!Take special care when removing ventilation or plugs from engine. In order to avoid discharge ofhighly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if theengine has recently been shut down, as the liquids can still be hot.Take special care when draining hot fluids. ⇒ Risk of injury!When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe orsoak them with a suitable bonding agent.When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.When working high on the engine, always use suitable ladders and work platforms. Makesure components are placed on stable surfaces.In order to prevent back injuries when lifting heavy components adults, depending on age and sex,should only lift weights between max. 10 kg and 30 kg, therefore:

• Use lifting gear or seek assistance.• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that

hooks are correctly positioned. Lifting eyes must not be unevenly loaded.

Welding workNever carry out welding work on the engine or engine-mounted units.Never use the engine as a ground connection. This prevents the welding current passing throughthe engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which maylead to bearing seizure and/or other material damage.Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwiseinduce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.The welding unit ground connection must not be more than 60 cm from the weld point.If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.It is not necessary to remove the connector and the connections when carrying out welding operationon MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wireis disconnected from the negative and positive poles on the battery.

Hydraulic installation and removalOnly the hydraulic installation and removal equipment specified in the work schedule andin the assembly instructions must be used.The max. permissible push-on pressure specified for the equipment must not be exceeded.The H.P. lines for hydraulic installation and removal are tested with 3800 bar.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 system tobe 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 spindleinto shaft end until correct sealing is achieved.During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of thecomponent to be installed/removed. As long as the system is under pressure, there is the risk that thecomponent to be installed/removed may be suddenly released from the pressure connection.Before use, the tools must be checked at regular intervals (crack test).

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10 Safety

Working on electrical/electronic assembliesAlways obtain the permission of the person in charge before commencing maintenance and repairwork or switching off any part of the electronic system required to do so.De-energize the appropriate areas prior to working on assemblies. Any measures requiring a powersupply are expressly defined as such at the appropriate place in the manual.Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow batteryacids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on thebattery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may leadto injury through the sudden discharge of acid or bursting of the battery body.Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it isnot damaged by contact with sharp objects, by rubbing against other component or by a hot surface.Do not secure wiring to fluid-carrying lines.On completion of the maintenance and repair work, any cables which have become loosemust be correctly connected and secured.On completion of all repair work, the component and system must be subjected to a function check.Separate testing of the repaired component without system integration is insufficient.If wires are installed beside mechanical components and there is a risk of chafing, usecable clamps to properly support the wires.For this purpose, no cable binders must be used as, during maintenance and / or repair work,the binders can be removed but not installed a second time.Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defectiveelectronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularlyprotected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipmentWhen working with laser equipment, always wear special laser-protection goggles.Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emissionin the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal andoptomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.Laser equipment must be fitted with the protective devices necessary for safeoperation according to type and application.For conducting light-beam procedures and measurement work, only the following laser devices must be used:

• Laser devices of classes 1, 2 or 3A,• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 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.

Operation of electrical equipmentWhen operating electrical equipment, certain components of this equipment are live.Noncompliance with the warning instructions given for this equipment may result inserious injury or damage to property.

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Safety 11

1.5 Auxiliary materials, fire prevention and environmentalprotection

Fire preventionRectify 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 lubricantslying around on the engine. Do not store combustible fluids near the engine.Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.When starting the engine with a foreign 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 foreign power sourceto the ground lead of the engine or to the ground terminal of the starter.Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.

SOLAS classificationOn engines/plants with SOLAS classification, operational checks must include the following tasks:

• Check all protective covers (according to SOLAS) of lube-oil and fuel connections (>1.8bar) for damage, replace if necessary (→ )

NoiseNoise can lead to an increased risk of accident if acoustic signals, warning shouts ornoises indicating danger are drowned.At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors(protective wadding, plugs or capsules).

Environmental protectionDispose of used fluids, lubricants and filters in accordance with local regulations.Manipulation of the injection control system can influence the engine performance and exhaust emissions.As a result, compliance with environmental regulations may no longer be guaranteed.Only fuels of the specified quality required to achieve emission limits must be used.In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, whichmeans work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).

Auxiliary materialsUse only fluids and lubricants that have been tested and approved by MTU.Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants andother chemical substances, follow the safety instructions applicable to the product. Take care when handlinghot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.

Lead• When working with lead or lead-containing pastes, avoid direct contact with the

skin and do not inhale lead vapors.• Adopt suitable measures to avoid the formation of lead dust!• Switch on fume extraction system.• After coming into contact with lead or lead-containing materials, wash hands!

Acids and alkaline solutions• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.• Immediately remove clothing wetted by acids and alkalis!• Rinse injuries with plenty of water!• Rinse eyes immediately with eyedrops or clean tap water.

Painting• When painting in other than spray booths equipped with extractors, ensure good ventilation.

Make sure that adjacent work areas are not affected.• No naked flames!• No smoking.• Observe fire prevention regulations!• It is absolutely necessary to wear masks providing protection against paint and solvent fumes.

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12 Safety

Liquid nitrogen• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.• Wear protective clothing, gloves, closed shoes and protective goggles!• Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffocation.• Avoid all knocks and jars to the containers, fixtures or workpieces.

Compressed airCompressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.The pressure at which the air is kept can be read off at pressure gauges which must be connectedto the compressed air tanks and the compressed air lines.When working with compressed air, safety precautions must be constantly observed:

• Pay special attention to the pressure level in the compressed air network and pressure vessel!• Connecting devices and equipment must either be designed for this pressure or, if the permitted

pressure for the connecting elements is lower than the pressure required, a pressure reducingvalve and safety valve (set to permitted pressure) must form an intermediate connection. Hosecoupling and connections must be securely attached!

• Always wear protective goggles when blowing off tools or extracting chips!• The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents

air-borne particles being reflected and thereby prevents injury to eyes.• First shut off compressed air lines before compressed air equipment is disconnected from the

supply line or before equipment or tool is to be replaced!• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII

and B) out of containers, results in a risk of explosion!• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)

for drying purposes or to check for leaks, results in a risk of explosion!• Do not blow dirty clothing with compressed air when being worn on the body.

Used oilUsed oil may contain health-threatening combustion residues.Rub barrier cream into hands!Wash hands after contact with used oil.

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Safety 13

1.6 Standards for warning notices in the publication

DANGER

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

• Preventive measures

WARNING

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


CAUTION

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


Note: This Publication contains especially emphasized safety instructions in accordance with the Americanstandard ANSI Z535, which begin with one of the above signal words according to the degree of danger:

Warning notices1. Read and become acquainted with all cautions and symbols before operating or repairing this product.2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

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14 Safety

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Product Summary 15

2 Product Summary

2.1 Engine Layout

2.1.1 Product description

Description of the engineEngineThe engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, directinjection, sequential turbocharging and charge-air cooling.An electronic management system provides engine control and monitoring.

Fuel system with Common Rail injectionControlled by the electronic engine management system, the Common Rail injection system determinesinjection pressure, commencement and amount of injection independently of engine speed.Injection pressures up to 1800 bar provide optimum injection and combustion conditions.

Charging systemThe 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 systemWet-sump forced-feed lubrication systemThe following components are supplied with lube oil:

• Bearings• Piston cooling• Control and actuating elements of the sequential turbocharging system

Cooling system• Two separate circuits:

• Engine coolant• Raw water

• Coolant cooled by raw-water cooled plate-core heat exchangers• Thermostat-controlled coolant circuit• Charge air cooled or heated by coolant• Return fuel cooled by coolant

Electronic systemElectronic control and monitoring system with integrated security and test system with interfaces toremote control system (RCS) and to monitoring system (MCS).Electronic engine governor (ECU)Closed-loop control:

• Speed• High-pressure fuel

Open-loop control:• Fuel injection (fuel pressure, commencement of injection, injection duration, operating status)• Sequential turbocharging (cut-in/cut-out) of the secondary turbocharger• Engine protection by multistage safety systems:

• Power reduction

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16 Product Summary

• Power limitation• Emergency stop

Monitoring:• Exhaust temperature, A side• Exhaust temperature, B side• Engine speed• Oil pressure• Differential oil pressure• Coolant temperature• Coolant level• Turbocharger speed• Leak-off fuel level• Oil temperature• Coolant pressure• Fuel pressure after filter

Monitoring in engine roomEngine 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 VDC power supply

SOLAS – Fire protection specificationsProtective covers on pressure lines >1.8 barAll lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown.Actuating cylinders (on left and right sides), oil supply

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Product Summary 17

Fuel filter, oil filter

HP fuel pump

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18 Product Summary

Special connectionsIn case of leakage, the following connection types are spray-protected even without a cover andhave been confirmed compliant with SOLAS by GL and DNV.

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Product Summary 19

Plug-in pipe connectionThe sleeve (4) covers the joint to prevent lateral spray.Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (3) defect occurs.The connection is confirmed as compliant with SOLAS by DNV and GL.Plug and sensorsScrew-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 loose thread or a defective sealing ring (2), the liquid first has to pass the thread.Because of the defective sealing ring (2), the pressure is so reduced, that the leak runs off without pressure.

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20 Product Summary

HP connections

1 Jacketed barrel2 HP fuel line3 O-ring4 Union nut5 Groove for O-ring6 Thrust ring

7 Leakage-overflow bore8 Thrust ring9 Union nut

10 Union nut11 Connecting piece12 Circlip

13 Thrust ring14 Shims15 Union nut16 Thrust ring17 O-ring

The HP fuel line is sealed by the thrust ring (8).If leakage in the area of the thrust ring (8) or the HP line (5) occurs, the emerging fuel is routed to the leakage chamber.The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakagechamber is sealed toward the outside by the O-rings (3).This prevents the leak from escaping.The connection is confirmed as compliant with SOLAS by DNV and GL.

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Product Summary 21

Protective cover of fuel filters and lube oil filtersProtective cover with a plastic ring

The plastic ring (1) prevents lateral spray.The liquid is routed into the collector bowl and the pressure is greatly reduced.Protective cover with lip

The lip (1) prevents lateral spray.The liquid is routed into the collector bowl and the pressure is greatly reduced.

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22 Product Summary

2.1.2 Engine layout

Engine layout

1 Engine oil heat exchanger2 Engine oil filter3 Engine coolant filter4 Changeover lever for engine oil filter5 Coolant distribution housing with

integral expansion tank6 Fuel cooler7 Engine hoisting lug (free end)8 Air filter with service indicator9 Air intake

10 Electronic engine managementsystem

11 Intake-air manifold (scoop)12 Exhaust turbocharger, right

(primary turbocharger)

13 Carrier housing14 Exhaust turbocharger, left

(secondary turbocharger)15 Exhaust outlet16 Crankcase ventilation filter /

oil separator17 Actuating cylinder for exhaust flap18 Actuating cylinder for air flap19 Control valve for flap control20 Cylinder head cover21 Exhaust manifold22 Engine mounts23 Electric starter24 Oil pan25 Battery-charging generator

26 Raw water connection forgearbox cooling

27 Gearcase28 Raw water pump29 Raw water connection from sea30 Vibration damper31 Coolant pump32 Plate-core heat exchanger33 Raw water connection to sea34 Thermostat housing35 Fuel priming pump36 Fuel duplex filter (switchable)

KGS = free end

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Product Summary 23

1 Crankcase breather2 Engine hoisting lug (driving end)3 Engine coolant filler neck4 HP fuel pump5 Fuel delivery pump

6 Oil filler neck7 Oil dipstick8 Drive flange9 Flywheel housing

10 Carrier console

11 Carrier housing core12 Carrier housing lower part13 Wastegate14 Carrier housing upper partKS = driving end

Engine model designationKey to the 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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24 Product Summary

2.2 Engine Side and Cylinder Designations

2.2.1 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.The numbering of engine components is also from the driving end, starting with No. 1.

1 KGS = Free end2 Right side

3 KS = Driving end4 Left side

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Product Summary 25

2.3 Main Engine Dimensions

2.3.1 Engine – Main dimensions

Engine – Main dimensions

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

8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm










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26 Product Summary

2.4 Firing Order

2.4.1 Firing order

Firing order

8 V 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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Product Summary 27

2.5 Technical Data

2.5.1 8V 2000 M72 engine data : Separate heat exchangerExplanation:

DL Ref. value: Continuous powerBL Ref. value: Fuel stop power (FSP)

A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated, without change (e.g. of power setting)N Not yet defined value- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 8V2000 M72

Application group 1B

Intake air temperature °C 25

Raw water inlet temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

POWER RELATED DATA (power ratings are net brake power to ISO 3046)

Number of cylinders 8

Engine rated speed A rpm 2250

Fuel stop power ISO 3046 A kW 720

GENERAL CONDITIONS (for maximum power)


Intake air depression (new filter) A mbar 15

Intake air depression, max. L mbar 30

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28 Product Summary

MODEL RELATED DATA (basic design)


Cylinder configuration: V angle degree 90

Bore mm 135

Stroke mm 156

Cylinder displacement liter 2.23

Total displacement liter 17.84

Number of inlet valves, per cylinder 2

Number of exhaust valves, per cylinder 2

LUBE-OIL SYSTEM


Lube-oil operating temperature before engine, from R °C 82

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

Lube-oil operating pressure before engine, from R bar 8.5

Lube-oil operating pressure before engine, to R bar 9.5

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

FUEL SYSTEM


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

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

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

Fuel supply flow, max. R liter/min 3.2

GENERAL OPERATING DATA


Firing speed, from R rpm 100

Firing speed, to R rpm 120

STARTING (electric)


Rated starter voltage (standard design) R V= 24

M015630/01E 06-11 © MTU

Product Summary 29

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)


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

L degree 15

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

L degree 20

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

L degree 0

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

L degree 10

Transverse inclination, continuous max. (Option: max. operating inclinations) L degree 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degree 40

CAPACITIES


Engine oil capacity, initial filling (standard oil system) (Option: max. operatinginclinations)

R liter 73

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

R liter 67

Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operatinginclinations)

L liter 54

Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. operatinginclinations)

L liter 62

WEIGHTS / MAIN DIMENSIONS


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

ACOUSTICS


Exhaust noise, unsilenced - FSP (free-field sound-pressure level Lp, 1m distance,ISO 6798)

R db(A) 108

Engine surface noise with attenuated intake noise (filter) - FSP (free-field soundpressure level Lp, 1m distance, ISO 6798)

R db(A) 104

M015630/01E 06-11 © MTU

30 Product Summary

2.5.2 8V 2000 M72 engine data: Engine-mounted heat exchangerExplanation:



X Applicable
















M015630/01E 06-11 © MTU

Product Summary 31




Bore mm 135

Stroke mm 156





RAW WATER CIRCUIT (open circuit)


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







FUEL SYSTEM






M015630/01E 06-11 © MTU

32 Product Summary





STARTING (electric)






L degree 15


L degree 20


L degree 0


L degree 10



CAPACITIES


Engine coolant capacity (with cooling equipment) R liter 100


R liter 73


R liter 67


L liter 54


L liter 62




M015630/01E 06-11 © MTU

Product Summary 33

ACOUSTICS



R db(A) 108


R db(A) 104

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34 Product Summary

2.5.3 10V 2000 M72 engine data: Separate heat exchangerExplanation:



X Applicable
















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Product Summary 35




Bore mm 135

Stroke mm 156





LUBE-OIL SYSTEM







FUEL SYSTEM










STARTING (electric)



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36 Product Summary




L degree 15


L degree 20


L degree 5


L degree 10



CAPACITIES



R liter 81


R liter 75


L liter 64


L liter 70




ACOUSTICS



R db(A) 106


R db(A) 107

M015630/01E 06-11 © MTU

Product Summary 37

2.5.4 10V 2000 M72 engine data: Engine-mounted heat exchangerExplanation:



X Applicable
















M015630/01E 06-11 © MTU

38 Product Summary




Bore mm 135

Stroke mm 156





RAW WATER CIRCUIT (open circuit)


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







FUEL SYSTEM






M015630/01E 06-11 © MTU

Product Summary 39





STARTING (electric)






L degree 15


L degree 20


L degree 5


L degree 10



CAPACITIES


Engine coolant capacity (with cooling equipment) R liter 114


R liter 81


R liter 75


L liter 64


L liter 70




M015630/01E 06-11 © MTU

40 Product Summary

ACOUSTICS



R db(A) 106


R db(A) 107

M015630/01E 06-11 © MTU

Operation 41

3 Operation

3.1 Switchgear cabinet – Control elements

Pos. Color Inscription Meaning/Function

1 Green Signal lamp Indicates „Pump running“.

2 Red Signal lamp Indicates „Pump fault“.

3 Yellow Illuminatedpushbutton

Indicates „Water drain“ / Press to carry out water drain manually.

4 Red Illuminatedpushbutton

Indicates „Water alarm“ / Press to acknowledge.

5 Yellow Signal lamp Indicates „Filter warning“ due to increased differential pressure.

6 Red Illuminatedpushbutton

Indicates alarm „Replace filter element“ / Press to acknowledge.

7 Switch Press to switch pump ON/OFF.

8 White Signal lamp Indicates „Control voltage present”.

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42 Operation

Pos. Color Inscription Meaning/Function

9 Hour meter Displays runtime of pump.

10 Master switch

M015630/01E 06-11 © MTU

Operation 43

3.2 Putting the engine into operation (out-of-serviceperiod > 3 months)

Preconditions• Engine is stopped and starting disabled.• MTU Fluids and Lubricants Specification (A001061/..) is available.

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

Item Task

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

Lube oil system Check oil level (→ Page 98).

Fuel prefilter Prime (→ Page 92).

Fuel prefilter, pressure gauge Align adjustable pointer with position of pressure indicator (→ Page 87).

Fuel system Vent (→ Page 84).

Raw-water pump (if locatedabove waterline)

Prime (approx. 3 to 4 liters).Filling point (→ Page 105)

Coolant system If engine is out of service for more than one year, change coolant (→ Page 112).

Coolant system Check coolant level (→ Page 111).

Coolant system Preheat coolant with preheating unit.

Engine control system Switch on (→Operating instructions BlueVision )

Engine Start (→Operating instructions BlueVision ).

M015630/01E 06-11 © MTU

44 Operation

3.3 Putting the engine into operation after scheduledout-of-service period

Preconditions• Engine is stopped and starting disabled.

Startup

Item Task

Lube oil system Check oil level (→ Page 98).

Coolant system Check coolant level (→ Page 111).

Coolant system Preheat coolant with preheating unit.

Fuel prefilter Drain (→ Page 88).

Battery-charging generatordrive

Check condition of drive belt (→ Page 119).

Engine control system Switch on (→Operating instructions BlueVision ).

Engine Start (→Operating instructions BlueVision ).

M015630/01E 06-11 © MTU

Operation 45

3.4 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. Put fuel treatment system into operation (→ Page 47).2. Put fuel treatment system out of service (→ Page 55).

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46 Operation

3.5 Checks prior to startupChecks prior to startup

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:1.1. Clean affected components.1.2. 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 (→ ).5. Check direction of rotation of pump.6. Vent bypass and fuel lines of the system.

6.1. Open ball valve for pressure tank.6.2. Open ball valve for overflow tank.6.3. Close ball valve at the inlet to the fuel treatment system.

Result: Bypass line is vented via the overflow tank.6.4. Open ball valve at the inlet to the fuel treatment system.

7. Check the fuel treatment system for leaks.Result: If no leaks are detected, the fuel treatment system is ready for operation.

M015630/01E 06-11 © MTU

Operation 47

3.6 Fuel treatment system – Putting into operationFuel treatment system – Overview

1. Switch on fuel treatment system (→ Page 50).2. Check the differential pressure at the 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 126).2. Check sealing faces on coalescer filter element and in the pressure tank.

Initial operation: Harbor Acceptance Tests1. Replace fuel filter on engine (→ Page 85).

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 shipside fuel system to the engine.3. Switch on fuel treatment system and operate it for some minutes (→ Page 50).

Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel isdelivered via the overflow tank back to the tank. Water which has settled in the tank is separated.

4. Start engine (→ Page 49).5. Run engine at idling speed.6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.

M015630/01E 06-11 © MTU

48 Operation

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

Simulation of filter replacement with the engine running: Harbor Acceptance Tests1. Switch on fuel treatment system (→ Page 50).2. Start engine (→ Page 49).3. Run engine at idling speed.4. Close ball valve (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 unitopens and fuel flows through bypass (3) and bypass (2).

5. Open ball valve (19) .Result: Fuel emerges. If no fuel emerges:• Open ball valve (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.


7. Increase engine speed to 1000 rpm and monitor suction pressure.Result: If all engine operating values are within the specified limits, open ball valve (5) at the inlet to thefuel treatment system.

Simulation of power failure (emergency): Harbor Acceptance Tests1. Switch on fuel treatment system (→ Page 50).2. Start engine (→ Page 49).3. Run engine at idling speed.4. Switch off pump (21) on switchgear 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.


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): Sea Acceptance Tests1. Switch on fuel treatment system (→ Page 50).2. Start engine (→ Page 49).3. Run engine at idling speed.4. Switch off pump (21) on switchgear 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.


6. Operate engine at full load and monitor suction pressure.Result: If the suction pressure is within the specified limits, simulation was successful.

M015630/01E 06-11 © MTU

Operation 49

3.7 Starting the engine

Preconditions• External start interlock is not activated.• 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, ensure 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 (→Operating instructions for electronic system):1. Commanding control stand (→Operating instructions for electronic system);2. Local operating panel LOP (→Operating instructions for electronic system);3. Local Operation Station LOS (→Operating instructions for electronic system);4. CCU (→Operating instructions for electronic system).

M015630/01E 06-11 © MTU

50 Operation

3.8 Fuel treatment system – Switching on

Preconditions• The onboard 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.

Fuel treatment system – Switching on1. Carry out checks prior to start-up (→ Page 46).2. Switch on master switch on switchgear cabinet.

Result: Signal lamp “Control voltage present” lights up.3. Switch on switch for pump.

Result: Signal lamp “Pump running” lights up.

M015630/01E 06-11 © MTU

Operation 51

3.9 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



Operational checks

Item Task

Engine under loadEngine at nominal speed

Visually inspect the engine for leaks and general condition;Check for abnormal noises and vibrations;Check exhaust color (→ Page 66);Check drain line on expansion tank for coolant discharge (→ Page 105),contact Service in case of severe coolant discharge.

Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter pressure gauge iswithin the limit (→ Page 87).Drain water and contaminants (→ Page 88).

Air filter Check signal ring position of service indicator (→ Page 96);Replace air filter (→ Page 94), if the signal ring is completely visible in theservice indicator control window.

HT coolant pump Check relief bore for oil and coolant discharge and contaminations(→ Page 115).

Raw water pump Check relief bore for oil and water discharge and contaminations (→ Page 118).

M015630/01E 06-11 © MTU

52 Operation

3.10 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 10mins. until engine temperatures have dropped and constant values are displayed.

The engine can be stopped from the following points (→Operating instructions for electronic system):1. Commanding control stand (→Operating instructions for electronic system);2. Local operating panel LOP (→Operating instructions for electronic system);3. Local Operation Station LOS (→Operating instructions for electronic system);4. CCU (→Operating instructions for electronic system).

M015630/01E 06-11 © MTU

Operation 53

3.11 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 (→Operating instructionsfor electronic system):

1. Commanding control stand (→Operating instructions for electronic system);2. Local operating panel LOP (→Operating instructions for electronic system);3. Local Operation Station LOS (→Operating instructions for electronic system);4. CCU (→Operating instructions for electronic system).

M015630/01E 06-11 © MTU

54 Operation

3.12 After stopping the engine

Preconditions• MTU Fluids and Lubricants Specification (A001061/..) is available.

After stopping the engine

Item Task

Cooling system Drain coolant (→ Page 113) if:• freezing temperatures are expected and the engine is to remain out of

service for an extended period and engine coolant has no antifreezeadditive;

• the engine room is not heated;• the coolant is not maintained at a suitable temperature;• the antifreeze concentration is insufficient for the engine-room

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

below -40 °C.

Raw water Drain• if freezing temperatures are expected and the engine is to remain out

of service for an extended period.

Engine control system Switch OFF.

Air intake and exhaust system Out-of-service-period > 1 week• Seal engine’s air and exhaust sides.

Out-of-service-period > 1 month• Preserve engine (→MTU Fluids and Lubricants Specification

A001061/.. ).

M015630/01E 06-11 © MTU

Operation 55

3.13 Fuel treatment system – Putting out of serviceFuel treatment system – Putting out of service

1. Press the illuminated pushbutton “Water drain” on the switchgear cabinet until water discharge from theoutlet 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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56 Operation

M015630/01E 06-11 © MTU

Maintenance 57

4 Maintenance

4.1 Preface

MTU maintenance conceptThe maintenance system for MTU products is based on a preventive maintenance concept. Preventivemaintenance facilitates advance planning and ensures a high level of equipment availability.The maintenance schedule is based on the load profile / load factor specified below. The time intervals at whichthe maintenance work is to be carried out and the relevant checks and tasks involved are average values basedon operational experience and are therefore to be regarded as guidelines only. Special operating conditionsand technical requirements may require additional maintenance work and/or modification of the maintenanceintervals. Special operating conditions and technical requirements may require additional maintenance workand/or modification of the maintenance intervals. The various Qualification Levels QL1 to QL4 reflect thelevels of training offered in MTU courses and the contents of the tool kits required:

QL1: Operational monitoring and maintenance which can be carried out during a breakin operation without disassembling the engine.

QL3: Operational monitoring and maintenance which can be carried out during a breakin operation without disassembling the engine.

QL4: Maintenance work which requires complete disassembly of the engine.The maintenance schedule matrix normally finishes with extended component maintenance. Followingthis, maintenance work is to be continued at the intervals indicated.The "Task" numbers stated in the list of jobs to be done/action to be taken indicate the relevant maintenance item.They provide a reference to the scope of parts required and appear on the labels of the appropriate replacement parts.

Preventive maintenance instructionsSpecifications for fluids and lubricants, guideline values for their maintenance and change intervals and lists ofrecommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001061 and inthe fluids and lubricants specifications produced by the component manufacturers. They are therefore not includedin the maintenance schedule (exception: deviations from the Fluids and Lubricants Specifications). All fluids andlubricants used must meet MTU specifications and be approved by the relevant component manufacturer.Amongst other items, the operator/customer must carry out the following additional maintenance work:

• Protect components made of rubber or synthetic material from oil. Never treat themwith organic detergents. Wipe with a dry cloth only.

• Fuel prefilter:Maintenance depends on how dirty fuel is. The paper inserts in fuel prefilters must bechanged every two years at the latest (Task 9998).

• Battery:Battery maintenance depends on the level of use and the ambient conditions. The batterymanufacturer’s instructions must be obeyed.

The relevant manufacturer’s instructions apply with respect to the maintenance of any componentswhich do not appear in this maintenance schedule.

Out-of-Service PeriodsIf the engine is to remain out of service for more than one month, carry out engine preservation in accordancewith the MTU Fluids and Lubricants Specifications, Publication No. A001061/..

Application group

1B Propulsion for fast vessels with high load factors

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58 Maintenance

Load profileLoad-profile table

Load factor 100% <15%

Corresponding operating time 75% 25%

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Maintenance 59

4.2 Maintenance schedule matrix

0-5,250 operating hours

Hours of operation [h]Item

Lim

itye

ars

Dai

ly25

050

075

01,

000

1,25

01,

500

1,75

02,

000

2,25

02,

500

2,75

03,

000

3,25

03,

500

3,75

04,

000

4,25

04,

500

4,75

05,

000

5,25

0

Engine oil filter 2

Engine operation - X

Crankcase breather - X X X X X X X X X X X X X X X X X X X X X

Crankcase breather - X X X X X X X X X X

Centrifugal oil filter - X X X X X X X X X X

Fuel filter 2 X X X X X X X X X X

Valve gear - X X X X X

Belt drive 2 X

Air filter 3 X

Fuel injectors -

Combustion chambers -

Component maintenance -

Cylinder head -

Extended component maintenance 18

M015630/01E 06-11 © MTU

60 Maintenance

5,500-10,750 operating hours


Lim

itye

ars

5,50

05,

750

6,00

06,

250

6,50

06,

750

7,00

07,

250

7,50

07,

750

8,00

08,

250

8,50

08,

750

9,00

09,

250

9,50

09,

750

10,0

0010

,250

10,5

0010

,750

Engine oil filter 2

Engine operation -

Crankcase breather - X X X X X X X X X X X X X X X X X X X X X X

Crankcase breather - X X X X X X X X X X X

Centrifugal oil filter - X X X X X X X X X X X

Fuel filter 2 X X X X X X X X X X X

Valve gear - X X X X X

Belt drive 2 X X

Air filter 3 X X

Fuel injectors - X

Combustion chambers - X

Component maintenance - X

Cylinder head -

Extended component maintenance 18

M015630/01E 06-11 © MTU

Maintenance 61

11,000-12,000 operating hours


Lim

itye

ars

11,0

0011

,250

11,5

0011

,750

12,0

00

Engine oil filter 2

Engine operation -

Crankcase breather - X X X X X

Crankcase breather - X X X

Centrifugal oil filter - X X X

Fuel filter 2 X X X

Valve gear - X X

Belt drive 2 X

Air filter 3 X

Fuel injectors - X

Combustion chambers - X

Component maintenance - X

Cylinder head - X

Extended component maintenance 18 X

M015630/01E 06-11 © MTU

62 Maintenance

4.3 Maintenance tasks

IntervalQual-ifica-tion [h] [a]

Item Maintenance tasks Task

QL1 - 2 Engine oil filter Replace oil filter when changing engine oil, or when the interval(years) is reached, at the latest (→ Page 100).

W1008

QL1 Daily - Engine operation Check engine oil level (→ Page 51). W0500

Perform a visual check of the leak-tightness and general condition ofthe engine (→ Page 51).

W0501

Check intercooler drain (if fitted) (→ Page 51). W0502

Check signal ring position of service indicator on air filter (→ Page 51). W0503

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

Check for abnormal running noise, exhaust color and vibration(→ Page 51).

W0506

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

Check reading on differential pressure gauge of fuel prefilter (if fitted)(→ Page 51).

W0508

QL1 250 - Crankcase breather Replace paper or textile insert (if fitted) of oil mist separator(→ Page 75).

W1139

QL1 500 - Crankcase breather Clean wire meshes of crankcase breather (→ Page 74). W1140

QL1 500 - Centrifugal oil filter Centrifugal oil filter (if fitted): Measure thickness of oil residue layer,clean and replace filter sleeve (→ Page 102).

W1009

QL1 500 2 Fuel filter Replace fuel filter or fuel filter element (→ Page 85). W1001

QL1 1.000 - Valve gear Check valve clearance (→ Page 77). W1002

QL1 3.000 2 Belt drive Check drive belt condition and tension, replace if necessary(→ Page 119).

W1003

QL1 3.000 3 Air filter Replace air filter (→ Page 94). W1005

QL1 6.000 - Fuel injectors Replace injectors (→ Page 81). W1006

QL1 6.000 - Combustion chambers Perform endoscopic examination (→ Page 71). W1011

QL3 6.000 - Component maintenance Before starting maintenance work, drain coolant and flush coolantcircuits.

W2000

Clean air ducting (→Workshop Manual). W2002

Clean intercooler and check for leaks (→Workshop Manual). W2003

Check coolant thermostat and replace thermal actuator. W2006

Check centrifugal oil filter for wear (if fitted) (→Workshop Manual). W2009

Check vibration damper (→Workshop Manual). W2011

Replace diaphragm of crankcase breather (→Workshop Manual). W2014

Clean coolant cooler and check for leaks, if feasible (→WorkshopManual).

W2017

Clean engine oil heat exchanger and check for leaks (→WorkshopManual).

W2018

Check engine alignment. W2036

M015630/01E 06-11 © MTU

Maintenance 63

IntervalQual-ifica-tion [h] [a]

Item Maintenance tasks Task

Clean fuel cooler (→Workshop Manual). W2059

Overhaul charge-air coolant pump (→Workshop Manual). W2070

Check rocker arms, valve bridge, pushrods and ball joints for wear(→Workshop Manual).

W2074

Overhaul exhaust turbocharger. W2075

Replace sealing material of all disassembled components(→Workshop Manual).

W2062

Overhaul engine coolant pump. W2110

Overhaul raw water pump. W2111

QL3 12.000 - Cylinder head Overhaul cylinder heads, visually inspect piston crowns and runningpattern of cylinder liners (→Workshop Manual).

W1063

QL4 12.000 18 Extended componentmaintenance

Perform complete engine disassembly. Inspect engine componentsacc. to assembly instructions; repair or replace as necessary(→Workshop Manual).

W3000

Replace all elastomer parts, seals and gaskets (→Workshop Manual). W3001

Replace piston rings (→Workshop Manual). W3002

Replace conrod bearings (→Workshop Manual). W3003

Replace crankshaft bearings (→Workshop Manual). W3004

Replace cylinder liners (→Workshop Manual). W3005

Replace PTO antifriction bearings (→Workshop Manual). W3006

Replace HP fuel pump (→Workshop Manual). W3007

Replace actuating cylinders of air flaps (→Workshop Manual). W3011

Replace actuating cylinder of exhaust flaps (→Workshop Manual). W3012

Replace bearings of exhaust flaps (→Workshop Manual). W3013

Overhaul starter (→Workshop Manual). W3041

Overhaul battery-charging generator (→Workshop Manual). W3042

Replace fuel pressure relief valve. W3043

Replace HP fuel sensor (→Workshop Manual). W3057

Replace water filter. W3058

Replace wire meshes of crankcase breather. W3056

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64 Maintenance

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Troubleshooting 65

5 Troubleshooting

5.1 Fuel treatment system – Troubleshooting

Symptom Meaning Task

Illuminated pushbutton“water alarm” is lit.

When the maximum water level is reached,the water level electrode opens the waterdrain valve and water is discharged. If theopening period of the valve exceeds a presetlimit (4 minutes), the pump will switch off andan alarm is initiated.

A Press illuminated pushbutton“Water alarm” foracknowledgement.

B In addition to the automaticwater drain function,water can also be drainedmanually. To do so, pressthe illuminated pushbutton“Water drain” to open thedrain valve.

Signal lamp“Pump fault” is lit.

The drive motor is equipped with an overloadprotection. If the maximum permissiblecurrent consumption is exceeded, e.g. incase of a blockage or dry-running, the motorprotection relay triggers and the pump isswitched off.

Reset motor protection relay.

Signal lamp “Warning filter”is lit.

The differential pressure exceeded 1.3 bar. Replace coalescer filter element(→ Page 126).

Illuminated pushbutton“Replace filter element” islit.

The max. permissible differential pressureof 1.5 bar was exceeded. If the coalescerfilter element is not replaced, pressure willincrease further and the safety valve willopen. Fuel will be led via the bypass directlyinto the overflow tank.

1. Replace coalescer filterelement (→ Page 126).

2. Press illuminated pushbutton“Replace filter element” foracknowledgement.

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66 Troubleshooting

5.2 TroubleshootingEngine does not turn when starter is actuated

Component Probable Cause Task

Low or defective Charge or replace (see manufacturer’sdocumentation).

Battery

Cable connections defective Check if cable connections areproperly secured (see manufacturer’sdocumentation).

Starter Engine wiring or starter defective Check if cable connections are properlysecured, contact Service.

Engine wiring Defective Check (→ Page 128).

ECU Plug-in connections are loose Check plug-in connections for secureseating

Engine Running gear blocked (enginecannot be barred manually)

Contact Service.

Engine turns but does not fire


Starter Poor rotation by starter: Batterylow or defective

Charge or replace battery (seemanufacturer’s documentation).


Fuel system Not vented Vent fuel system (→ Page 84).

ECU Defective Contact Service.

Engine fires unevenly


Fuel injection equipment Injector defective Replace (→ Page 81).




M015630/01E 06-11 © MTU

Troubleshooting 67

Engine does not reach nominal speed


Fuel prefilter clogged Replace (→ Page 92).Fuel supply

Fuel filter clogged Replace (→ Page 85).

Air supply Air filter clogged Check signal ring position of service indicator(→ Page 96).



Engine Overloaded Contact Service.

Engine speed not steady



Speed sensor Defective Replace.



Charge-air temperature too high


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


Air supply Air filter clogged Check signal ring position of serviceindicator (→ Page 96).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercooler


Intercooler Leaking, major coolant discharge Contact Service.

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68 Troubleshooting

Exhaust gas black


Air supply Air filter clogged Check signal ring position of serviceindicator (→ Page 96).


Engine Overloaded Contact Service.

Exhaust gas blue


Too much oil in engine Drain engine oil (→ Page 99).Engine oil

Oil separator or oil-preseparatorof crankcase breather clogged

• Clean oil separator (→ Page 74);• Replace filter element of oil separator

(→ Page 75).

Exhaust turbocharger, cylinderhead, piston rings, cylinderliner

Defective Contact Service.

Exhaust gas white


Engine Not at operating temperature Run engine to reach operating temperature.

Fuel system Water in fuel Drain fuel prefilter (→ Page 88).

Intercooler Leaking Contact Service.

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Task Description 69

6 Task Description

6.1 Engine

6.1.1 Engine – Barring manually


Special toolsDesignation / Use Part No. Qty.Barring tool F6783914 1Ratchet 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 manually1. 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 abnormal resistance.Result: If the resistance exceeds compression resistance, contact Service.

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70 Task Description

6.1.2 Engine – Barring with starting system

Preconditions• Clutch is disengaged.• Engine start is disabled.• LOP is accessible and open.

DANGER

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

• Before barring or starting the engine, ensure that nobody is in the danger zone.• After working on the engine, check that all protective devices have been reinstalled

and all tools removed from the engine.

Barring1. Press barring button on the LMB motherboard of

the LOP and keep it depressed.Result: Engine is barred by starter for max. 20seconds.

2. Release barring button.

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Task Description 71

6.2 Cylinder Liner

6.2.1 Cylinder liner – Endoscopic examination


Special toolsDesignation / Use Part No. Qty.Rigid endoscope Y20097353 1

Preparatory steps1. Remove cylinder-head cover (→ Page 80).2. Remove injector (→ Page 82).

Positioning crankshaft at BDC1. Using barring device, turn crankshaft until crankpin of the cylinder to be tested has reached BDC.2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner - Endoscopic examination

Findings Task

• Thin carbon coating on carbon scraper ring• Slight localized additive deposits at top edge• Localized smooth areas at lower edge• Carbon deposits on entire circumference between top piston ring and

lower edge of carbon scraper ring• First signs of marks left by top piston ring• Bright mark on entire circumference• Faultless, even honing pattern• First signs of marks left by lower cooling bores• Running pattern seems darker

No actions required

• Darker areas of even or varying color intensity• Beginning and end of the discoloration are not sharply defined and do

not cover the entire stroke area• Dark areas in the upper section of the cooling bore, remaining

circumference cannot be faulted• Piston rings cannot be faulted

Further endoscopic examinationrequired as part of maintenancework

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

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

Cylinder liner must be replaced;Service must be contacted

1. Compile endoscopy report using the table.2. Use technical terms for description of the liner surface (→ Page 72).3. Depending on findings:

• Do not take any action or• carry out further endoscopic examination as part of maintenance work or• contact Service: cylinder liner must be replaced.

Final steps1. Install injector (→ Page 82).2. Install cylinder-head cover (→ Page 80).

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72 Task Description

6.2.2 Instructions and comments on endoscopic and visualexamination of cylinder liners

Terms used for endoscopic examinationUse the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report.

Minor dirt scores Light scoring can take place during the assembly of a new engine (honing products,particles, broken-off burrs). Removed cylinders clearly show such scoring on therunning surface under endoscope magnification. Cannot be felt with the fingernail.Findings not critical.

Single scores Clearly visible scores from hard particles. They usually start in the TDC area and crossthrough the hone pattern in the direction of stroke.Findings not critical.

Scored area These areas consist of scores of different length and depth next to one another. Inmost cases, they are found at the 6-o’clock and 12-o’clock positions (inlet/exhaust)along the transverse engine axis.Findings not critical.

Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern isstill visible. Smoothened areas appear brighter and more brilliant than the surroundingrunning surface.Findings not critical.

Polished area Polished areas are on the running surface and show local removal of the honingpattern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and temperaturedifferences around the liner. It appears rather darker within the honed structure incontrast to the bright metallic running surface. The honing pattern is undisturbed.Discolorations extend in stroke direction and may be interrupted.Findings not critical.

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

Black lines Black lines are a step towards heat discoloration. They are visible as a cleardiscoloration from TDC to BDC in the running surface and the start of localizeddamage to the honing pattern.Cylinders with a number of black lines around the running surface have limited servicelife and should be replaced.

Discolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they runover the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becomingmore visible from the second TDC-ring onwards and less pronounced from TDC-ring1. The honing pattern is usually no longer visible and displays a clearly defined(straight) edge to the undisturbed surface. The damaged surface is usually discolored.The circumferential length varies.Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.

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

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Task Description 73

Evaluation of findings and further measuresThe findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough investigationand compliance with the above evaluation criteria allows a definite evaluation. To avoid unnecessary disassemblywork, it is recommended that another inspection be carried out after further operation of the engine.

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74 Task Description

6.3 Crankcase Ventilation

6.3.1 Crankcase breather – Cleaning oil pre-separator element


WARNING

Fuels are combustible.Risk of fire and explosion!

• Avoid naked flames, electrical sparks and ignition sources.• Do not smoke.

WARNING

Compressed air.Risk of injury!

• Do not direct compressed-air jet at persons.• Wear protective goggles / safety mask and ear protectors.

Crankcase breather – Cleaning oil pre-separatorelement

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 pre-separator element in the

same way.

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Task Description 75

6.3.2 Crankcase breather – Oil separator replacement, diaphragmcheck and replacement


Special toolsDesignation / Use Part No. Qty.Torque wrench 6-50 Nm F30027336 1Ratchet adapter F30027340 1

Spare partsDesignation / Use Part No. Qty.Filter elementDiaphragmO-ring

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 separator1. Remove cover (2) with O-ring (3).2. Remove filter element (1) from housing (4).3. Insert new filter element into housing (4) ensuring

correct installation position, and fit cover (2)with new O-ring.

4. Tighten screws of cover (2) to specified tighteningtorque of 6 Nm + 2 Nm.

5. Replace filter elements of further oil separators inthe same way.

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76 Task Description

Checking diaphragm1. Remove cover (4).2. Take off spring (5), seal (2) and diaphragm (3).3. Check diaphragm (3) for damage.4. Fit new diaphragm if used one is damaged.5. Mount diaphragm (3) on housing (1).6. Install new seal (2) and spring (5) together with

cover (4).7. Tighten screws of cover (4) to specified tightening

torque of 6 Nm + 2 Nm.8. Check diaphragms in further oil separators in

the same way.

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Task Description 77

6.4 Valve Drive

6.4.1 Valve clearance – Check and adjustment

Preconditions• Engine is stopped and starting disabled.• Engine coolant temperature is max. 40 °C.• Valves are closed.

Special toolsDesignation / Use Part No. Qty.Feeler gauge Y4345893 1Barring tool F6783914 1Ratchet F30006212 1Double box wrench F30002800 1Allen key F30002816 1Socket wrench F30030450 1

Preparatory steps1. Remove air filter (→ Page 95).2. Remove cylinder head cover (→ Page 80).

Positioning A1 piston at TDC1. Remove cable from sensor B13.2 (→ Page 129).2. Remove sensor B13.2.3. 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 positions1. 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.

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78 Task Description

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

8V 2000

Position Cylinder 1 2 3 4 5 6 7 8

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

Bank B E - E - - - - A

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

Bank B - A - A E A E -

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

10 V2000


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

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

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

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


12 V2000


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

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

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

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


16 V2000


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

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

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

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


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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Task Description 79

Adjusting valve clearance1. 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 whileholding the adjusting screw (2) with screwdriver.

5. Check whether the feeler gauge just passesthrough between valve bridge and rocker arm.Result: If not, adjust valve clearance.

Final steps1. Install sensor B13.2.2. Connect the cable to sensor B13.2.3. Remove barring tool.4. Install cylinder head cover (→ Page 80).5. Install air filter (→ Page 95).

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80 Task Description

6.4.2 Cylinder-head cover – Removal and installation


Special toolsDesignation / Use Part No. Qty.Centering device F6783025 1

Spare partsDesignation / Use Part No. Qty.Gasket

Preparatory steps1. Remove air filter (→ Page 95).2. Remove intake housing.

Cylinder-head cover – Removal and installation1. Remove screws (1).2. Remove cylinder-head cover (2) with gasket

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 centering

device.6. Use torque wrench to tighten screws (1) to

specified torque 20 Nm.

Final steps1. Install air filter (→ Page 95).2. Install intake housing.3. Check cylinder-head covers for leaks.

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Task Description 81

6.5 Injector

6.5.1 Injector – Replacement

Spare partsDesignation / Use Part No. Qty.Injector

Remove injector and install new one (→ Page 82).

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82 Task Description

6.5.2 Injector – Removal and installation


Special toolsDesignation / Use Part No. Qty.Socket wrench 0005896803/00 1Assembly device F6784160 1Double box wrench F30011450 1Open end wrench bit F30025897 1Box wrench adapter F30451199 1

MaterialDesignation / Use Part No. Qty.Petroleum jelly, white 40317 1Engine oil

WARNING



Preparatory steps1. Close fuel supply to engine.2. Remove cylinder head cover (→ Page 80).

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 assembly device.6. Remove O-rings from injector.7. Mask all connections and bores or seal with

suitable plugs.

Installing injector1. Remove all plugs before installation.2. Fit new O-rings (supplied with the injector) on the injector and coat with petroleum jelly.3. Fit new sealing ring with petroleum jelly on injector, ensuring correct installation position of sealing ring.

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Task Description 83

4. Clean sealing surface on cylinder head and protective sleeve.5. Use assembly device to 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. Connect HP line (5) to HP fuel accumulator and tighten by hand.

10. Connect HP line (5) to injector (1) and tighten by hand.11. Tighten screw of hold-down clamp (3) to specified tightening torque of 40 Nm + 4 Nm using a box wrench

adapter and a torque wrench.12. Use socket wrench and torque wrench to tighten HP line (5) to the specified torque:

• Thrust screw on injector to 20 Nm + 5 Nm• Thrust screw on rail to 30 Nm + 5 Nm

13. Attach cable (4).

Final steps1. Install cylinder head cover (→ Page 80).2. Open fuel supply to engine.

M015630/01E 06-11 © MTU

84 Task Description

6.6 Fuel System

6.6.1 Fuel system – Venting


WARNING



Fuel system – Venting1. Unlock fuel priming pump, unscrew handle.

2. Open vent plugs on filter head.3. Operate the pump with the handle until fuel

without bubbles comes out of the vent plugsand 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.

M015630/01E 06-11 © MTU

Task Description 85

6.7 Fuel Filter

6.7.1 Fuel filter – Replacement

Special toolsDesignation / Use Part No. Qty.Oil filter wrench F30379104 1

MaterialDesignation / Use Part No. Qty.Diesel fuel

Spare partsDesignation / Use Part No. Qty.Easy-change filter

DANGER



WARNING



WARNING



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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86 Task Description

A Both filters cut in (operating position)B Left filter cut outC Right filter cut out

Fuel filter replacement with the engine stopped1. Stop engine and disable starting2. Cut out the filter to be replaced.3. Remove cut-out filter using the oil filter wrench.4. Clean the sealing surface of the filter head.5. Check sealing ring of the new easy-change filter

and coat it with fuel.6. Fit the protective cover acc. to SOLAS

requirements (→ Page 15).7. Install and tighten new filter by hand.8. Set three-way cock to operating position (both

filters cut in).9. Replace further fuel filters in the same way.

10. Vent fuel system (→ Page 84).

Fuel filter replacement with the engine running1. Cut out the filter to be replaced.2. Open vent plug of the cut-out filter and make

sure that the pressure is completely releasedfrom the filter.

3. Close vent plugs.4. Remove cut-out filter using the oil filter wrench.5. Clean the sealing surface of the filter head.6. Check sealing ring of the new easy-change filter

and coat it with fuel.7. Fit the protective cover acc. to SOLAS

requirements (→ Page 15).8. Install and tighten new filter by hand.9. Set three-way cock to operating position (both

filters cut in).10. Replace further fuel filters in the same way.

M015630/01E 06-11 © MTU

Task Description 87

6.7.2 Fuel prefilter, differential pressure gauge – Inspection and adjustment

DANGER



WARNING



Differential pressure – Adjustment of indicator1. When commissioning the new filter element: Align

adjustable pointer (2) with pressure indicator (3) onpressure gauge (1).

2. Check the differential pressure.

Fuel prefilter – Differential pressure check1. 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 90).

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88 Task Description

6.7.3 Fuel prefilter - Draining



Spare partsDesignation / Use Part No. Qty.Seal

WARNING



M015630/01E 06-11 © MTU

Task Description 89

I Left filter cut inII Right filter cut in

Fuel prefilter, water draining1. Shut off the filter to be drained.

2. Open vent plug (5) of the filter to be drained.3. Unlock drain cock (6) by pressing toggle and

open it.4. Drain water and contaminants from the filter until

pure fuel emerges.5. Close drain cock (6).6. Remove screws securing the cover and take

off cover (2).7. Fill filter housing with clean fuel.8. Place new gasket in cover (2).9. Fit cover with gasket and secure it with screws.

10. Turn the cut-off filter on again.11. When fuel emerges from system, close vent

plug (5).

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90 Task Description

6.7.4 Fuel prefilter – Flushing


Spare partsDesignation / Use Part No. Qty.Gasket

DANGER



WARNING



WARNING



M015630/01E 06-11 © MTU

Task Description 91


Fuel prefilter – Flushing1. Cut out the contaminated filter.

2. Open vent plug (5) of the filter to be flushed.3. Unlock drain cock (6) by pressing toggle, open it

and drain fuel.Result: Fuel flows from filtered side back tothe unfiltered side, flushing the filter depositsdownwards out of the filter.

4. Close vent plug (5) and drain cock (6).

Fuel prefilter – Filling with fuel1. Stop the engine (→Operating instructions for electronic system) and disable engine start.2. Remove screws securing the cover and take off cover (2).3. Fill filter housing with clean fuel.4. Place new gasket in cover (2).5. Fit cover with gasket and secure it with screws.6. Check differential pressure (→ Page 87).

Result: If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 92).

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92 Task Description

6.7.5 Fuel prefilter – Filter element replacement



Spare partsDesignation / Use Part No. Qty.Filter elementSeal

WARNING



M015630/01E 06-11 © MTU

Task Description 93


Replace filter element1. Shut off the contaminated filter.

2. Open vent plug (5) of the contaminated filter.3. Unlock drain cock (6) by pressing toggle and

open it.4. Drain water and contaminants from the filter.5. Close drain cock (6).6. Remove screws securing the cover and take

off cover (2).7. Remove spring (4) and filter element (3).8. Insert new filter element (3) and spring (4).9. Fill filter housing with clean fuel.

10. Place new gasket in cover (2).11. Fit cover with gasket and secure it with screws.12. Turn the cut-off filter on again.13. Close vent plug (5) when fuel emerges.14. Adjust the differential pressure gauge.

(→ Page 87).

M015630/01E 06-11 © MTU

94 Task Description

6.8 Air Filter

6.8.1 Air filter replacement

Spare partsDesignation / Use Part No. Qty.Air filter

Remove air filter and install new one (→ Page 95).

Reset signal ring of service indicator (→ Page 96).

M015630/01E 06-11 © MTU

Task Description 95

6.8.2 Air filter removal and installation


Air filter removal and installation1. Loosen 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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96 Task Description

6.9 Air Intake

6.9.1 Service indicator – Signal ring position check


Signal ring position check1. If the signal ring is completely visible in the control

window (2), replace air filter (→ Page 94).2. After installation of new filter, press reset button (1).

Result: Engaged piston with signal ring movesback to initial position.

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Task Description 97

6.10 Starting Equipment

6.10.1 Starter – Condition check


Starter – Condition check1. Check starter securing screws for secure seating.2. Tighten loose screw connections.3. Check wiring (→ Page 128).

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98 Task Description

6.11 Lube-oil System, Lube-oil Circuit

6.11.1 Engine oil – Level check


Oil level check prior to engine start1. Withdraw dipstick from guide tube and wipe it.2. Insert dipstick into guide tube up to the stop,

withdraw after approx. 10 seconds and checkoil level.

3. Oil level must be between "min." and "max." marks.4. Top up to "max." if required (→ Page 99).5. Insert dipstick into guide tube up to the stop.

Oil level check after the engine is stopped1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.2. Insert 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 99).5. Insert dipstick into guide tube up to the stop.

M015630/01E 06-11 © MTU

Task Description 99

6.11.2 Engine oil change

Preconditions• Engine is stopped and starting disabled.• Engine is at operating temperature.• MTU Fluids and Lubricants Specification (A001061/..) is available.

MaterialDesignation / Use Part No. Qty.Engine oil

Spare partsDesignation / Use Part No. Qty.Sealing ring

WARNING



Oil change with extraction device: Oil extraction1. Provide a suitable container in which to collect the oil.2. Extract all oil from oil pan using the extraction device.

Engine oil system filling1. Determine amount of engine oil required for oil

change (→ Product Summary - Technical Data).2. Open cover of filler neck.3. Pour oil in at filler neck up to "max." mark at oil

dipstick.4. Close cover of filler neck.5. Check oil level (→ Page 98).6. After oil change and oil filter replacement, bar

engine with starting system (LOP).

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100 Task Description

6.12 Oil Filtration / Cooling

6.12.1 Engine oil filter – Replacement


MaterialDesignation / Use Part No. Qty.Engine oil

Spare partsDesignation / Use Part No. Qty.Oil filter

DANGER



WARNING



WARNING



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.

M015630/01E 06-11 © MTU

Task Description 101

A Right filter cut outB Both filters cut in (operating position)C Left filter cut out

Oil filter replacement with the engine stopped1. Stop engine and disable starting2. Cut out the filter to be replaced.

3. Remove cut-out oil filter using the oil filter wrench.4. Clean the sealing surface at the connecting piece.5. Check condition of the new sealing ring and

coat it with oil.6. Fit the protective cover acc. to SOLAS

requirements (→ Page 15).7. Install and tighten new oil filter by hand.8. Replace further oil filters in the same way.9. After each oil change and filter replacement, bar

engine with starting system (→ Page 70).10. Check oil level (→ Page 98).

Oil filter replacement with the engine running1. Cut out the filter to be replaced.2. Remove cut-out oil filter using the oil filter wrench.3. Clean the sealing surface at the connecting piece.4. Check condition of the new sealing ring and coat it with oil.5. Fit the protective cover acc. to SOLAS requirements (→ Page 15).6. Install and tighten new oil filter by hand.7. Replace further oil filters in the same way.8. Check oil level (→ Page 98).

M015630/01E 06-11 © MTU


6.12.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement


Special toolsDesignation / Use Part No. Qty.Strap wrench F30379104 1

MaterialDesignation / Use Part No. Qty.Cleaner Hakutex 60

Spare partsDesignation / Use Part No. Qty.Filter sleeveO-ringO-ring

WARNING

Compressed air.Risk of injury!

• Do not direct compressed-air jet at persons.• Wear protective goggles / safety mask and ear protectors.

Centrifugal oil filter – Rotor removal1. Release nuts (3).2. Remove housing cover (1).3. Remove complete rotor (2) from housing.

M015630/01E 06-11 © MTU


Centrifugal oil filter – Cleaning and filter-sleevereplacement

1. Remove nut, holding the rotor with a strap wrench.

2. Remove nut (1), washer (2), rotor cap (3) andsealing ring (4).

3. Remove sleeve (1).4. Measure the layer thickness of the oil residue.5. If maximum layer thickness (25 mm) is exceeded,

shorten maintenance interval.6. Clean rotor components and remove strainers (2).7. Wash standpipes (3) and nozzles (4) with cleaner,

blow out with compressed air.8. Insert the new filter sleeve with the smooth surface

facing the rotor cap.

M015630/01E 06-11 © MTU


9. Fit new sealing ring (4).10. Set on rotor cap (3), observe marks.11. Fit washer (2).12. Hold rotor with strap wrench and tighten nut

(1) with torque wrench to the specified torque:40 to 50 Nm.

13. Insert complete rotor (2) into the housing andcheck for ease-of-movement.

14. Set housing cover (1) with new sealing ring ontolower section, observe marks.

15. Tighten nuts (3) crosswise and evenly.

M015630/01E 06-11 © MTU


6.13 General Cooling Circuit, HT Circuit

6.13.1 Drain and venting points

8 V, 10 V

1 Overflow line, expansion tank 2 Filler neck

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12 V, 16 V

1 Overflow line, expansion tank 2 Filler neck

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Free end (KGS)

1 Fuel filter vent screws2 Engine coolant drain plug3 Raw water pump filling plug

4 Measuring point, pressure beforeraw water pump

5 Raw water pump drain plug

6 Connection for oil extraction

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Left side

1 Engine coolant drain plug2 Engine coolant drain plug

(M14x1.5)

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Right side

1 Engine coolant drain plug(M14x1.5)

2 Oil filler neck (connection left orright engine side optional)

3 Oil dipstick (connection left orright engine side optional)

4 Leak-off-fuel tank

M015630/01E 06-11 © MTU


6.13.2 Engine coolant – Level check


WARNING

Coolant is hot and under pressure.Risk of injury and scalding!

• Let the engine cool down.• Wear protective clothing, gloves, and goggles / safety mask.

Coolant-level check at filler neck:1. Turn breather valve on coolant expansion tank

(→ Page 22) counterclockwise until first stop andallow pressure to escape.

2. Continue to turn breather valve counterclockwiseand remove.

3. Check coolant level (coolant must be visible at thelower edge of the cast-in eye).

Coolant-level check by means of level sensor:1. Switch engine control system on and check display (coolant level is automatically monitored by the engine

control system).2. If required, top up with treated engine coolant (→ Page 114).

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6.13.3 Engine coolant – Change

MaterialDesignation / Use Part No. Qty.Engine coolant

Drain engine coolant (→ Page 113).

Fill engine coolant system (→ Page 114).

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6.13.4 Engine coolant – Draining


WARNING



Preparatory steps1. Provide an appropriate container to collect the coolant or2. switch on the extraction device.3. Switch off preheating unit.

Engine coolant – Draining1. Turn breather valve on coolant expansion tank (→ Page 105)counterclockwise to the first stop and release

pressure.2. Continue to turn breather valve counterclockwise and remove.3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.4. Open drain valves or drain plugs (→ Page 105) and drain or pump off coolant.5. Close all open drain points.6. Set breather valve onto filler neck and close it.

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6.13.5 Engine coolant system – Filling


MaterialDesignation / Use Part No. Qty.Engine coolant

WARNING



CAUTION

Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!

• Fill / top up coolant only into cold engine.

Engine coolant system – Filling1. Turn breather valve on coolant expansion tank (→ Page 22)counterclockwise to first stop and allow pressure

to escape.2. Continue to turn breather valve counterclockwise and remove.3. Pour coolant into engine until coolant level reaches lower edge of cast-in eye of filler neck.4. Check proper condition of breather valve and clean sealing faces.5. Set breather valve onto filler neck and close it.6. Start the engine and operate it at idle speed for some minutes.7. Check coolant level (→ Page 111) .

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6.13.6 HT coolant pump – Relief bore check

DANGER



WARNING



HT coolant pump – Relief bore check1. Check relief bore for oil and coolant discharge.2. Stop the engine (→Operating instructions for

electronic system)and disable engine start.3. Clean the relief bore with a wire if it is dirty.

• Permissible coolant discharge: up to 10 dropsper hour;

• Permissible oil discharge: up to 5 drops perhour.

4. If discharge exceeds the specified limits, contactService.

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6.13.7 Engine coolant – Sample extraction and analysis


Special toolsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1

WARNING



Engine coolant – Sample extraction and analysis1. Turn breather valve on coolant expansion tank (→ Page 105)counterclockwise until first stop and allow

pressure to escape.2. Continue to turn breather valve counterclockwise and remove.3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.4. Draw off approx. 1 liter coolant and drain into a clean container.5. Using the equipment and chemicals from the MTU test kit, examine coolant for:

• antifreeze concentration;• corrosion inhibitor concentration;• pH value.

6. Fit breather valve and close it.7. Change engine coolant according to the coolant operating times specified in the (→MTU Fluids and Lubricants

Specifications A001061/..) (→ Page 113).

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6.13.8 Coolant filter – Replacement



Spare partsDesignation / Use Part No. Qty.Engine coolant filter

WARNING



Coolant filter – Replacement1. Turn breather valve on coolant expansion tank

(→ Page 22)counterclockwise until first stop andallow pressure to escape.

2. Continue to turn breather valve counterclockwiseand remove.

3. Remove coolant filter using the oil filter wrench.4. Clean the sealing surface at the connecting piece.5. Moisten sealing ring of the new coolant filter

with engine oil.6. Install and tighten coolant filter by hand.7. Close breather valve.8. Check coolant level (→ Page 111).

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6.14 Raw Water Pump with Connections

6.14.1 Raw water pump – Relief bore check

DANGER



WARNING



Raw water pump – Relief bore check1. Check relief bore for oil and coolant discharge.2. Stop the engine (→Operating instructions for

electronic system) and disable engine start.3. Clean the relief bore with a wire if it is dirty.

• Permissible coolant discharge: up to 10 dropsper hour;

• Permissible oil discharge: up to 5 drops perhour.

4. If discharge exceeds the specified limits, contactService.

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6.15 Belt Drive

6.15.1 Drive belt – Condition check

Preconditions• Engine is stopped and starting disabled.• Guard is removed.

Item Findings Task

Drive belt A Breaks in a few individual places None

Drive belt Belt is oily, shows signs ofoverheating

Drive belt B Breaks around the entirecircumference

Drive belt C Areas of belt material missing

Replace (→ Page 121)

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6.16 Battery-charging Generator

6.16.1 Battery-charging generator drive – Drive belt check and adjustment


Special toolsDesignation / Use Part No. Qty.Assembly device F6559691 1

Check drive belt condition (→ Page 119).

Drive belt – Checking distance1. Measure distance (A) with assembly device.2. If measured value of distance (A) is not within the

tolerance of 98 mm ± 1.5 mm, readjust belt tension.

Adjusting belt tension1. Counterhold adjustment lever (2) at square (5).2. Rotate adjusting lever until drive belt (4) is detensioned.3. Loosen screws (1) and (3).4. Use assembly device to adjust distance (A) by turning adjustment lever (2).5. Tighten screws (1) and (3).6. Measure distance (A) with assembly device.

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6.16.2 Battery-charging generator drive – Drive belt replacement


Special toolsDesignation / Use Part No. Qty.Mandrel 8205892861/08 1

Preparatory steps1. Remove safety equipment (if fitted).2. Remove screws of protective cover (engine free end).3. Take off protective cover.

Replacing drive belt1. Counterhold adjusting lever at square.2. Rotate adjusting lever until drive belt is detensioned.3. Use mandrel to lock adjusting lever in position.4. Remove drive belt.5. Check cleanness of belt pulleys.6. Insert new drive belt.7. Remove mandrel.

Final steps1. Check distance dimension of belt drive (→ Page 120).2. Install guard.3. Install screws of protective cover.4. Install safety equipment (if fitted).5. Check function of safety equipment (if fitted).

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6.17 Fuel Supply System

6.17.1 Water drain valve – CheckWater drain valve – Check

1. Open water drain valve.2. Check water outlet for obstructions.3. Close water drain valve.

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6.17.2 Differential pressure gauge – Check

WARNING



Differential pressure gauge – Check1. Switch on fuel treatment system (→ Page 50).2. Set the alarm points at the differential pressure gauge to zero.

Result: Alarm is initiated with preset delay.3. Reset the alarm points at the differential pressure gauge to the specified values.

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6.17.3 3-in-1 bar electrode – Check

Preconditions• System is put out of service and emptied.

WARNING



3-in-1 bar electrode – Check1. Remove connector from 3-in-1 bar electrode.2. Unscrew 3-in-1 bar electrode.3. Plug connector into 3-in-1 bar electrode.4. Immerse 3-in-1 bar electrode into a tank filled with water up to the thread.

Result: Water drain valve opens.5. Keep 3-in-1 bar electrode in the tank.

Result: Alarm must be initiated with the preset delay.6. Remove connector from 3-in-1 bar electrode.7. Remove 3-in-1 bar electrode from tank.8. Screw in 3-in-1 bar electrode.9. Plug connector into 3-in-1 bar electrode.

10. Put the fuel treatment system into operation.

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6.17.4 Pump capacity – Check

Special toolsDesignation / Use Part No. Qty.Pressure gauge

WARNING



Pump capacity – Check1. Install pressure gauge in the intake connection of the pump.2. Check pump pressure.

2.1. Switch on fuel treatment system (→ Page 50).

Note: The pressure limiting valve at the pump might respond and open. Audible noise is causedby overflowing fuel and can be disregarded.

2.2. Close ball valve at the outlet of the fuel treatment system.2.3. Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.

3. Checking pump pressure with reduced suction3.1. Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.3.2. Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.3.3. Open ball valve at inlet and outlet of fuel treatment system.

4. Calculate wear limit.

Example:

Measured value (normal condition). 3 bar

Measured value (reduced suction condition). 2.6 bar

If the measured value (reduced suction condition) is 10% lower than the measured value (normal condition), thewear limit is reached. Repair pump (contact Service).

M015630/01E 06-11 © MTU


6.17.5 Coalescer filter element – Replacement

Preconditions• System is switched off and starting disabled.

Special toolsDesignation / Use Part No. Qty.Torque wrench, 6-50 Nm F30027336 1Ratchet adapter F30027339 1


Spare partsDesignation / Use Part No. Qty.Coalescer filter elementSeal

WARNING



CAUTION

Contamination of components.Damage to component!

• Observe manufacturer’s instructions.• Check components for special cleanness.

CAUTION

Incorrect installation of components and lines.Damage to component!

• Ensure that components/lines are installed so that they are never under tension or strain.• Ensure correct installation position of components.

M015630/01E 06-11 © MTU


Coalescer filter element – Replacement1. Close ball valve at inlet and outlet of fuel treatment

system.2. Open drain valve.3. Drain fuel.4. Close drain valve.5. Remove nut (9) with washer (2).6. Remove screws (1).7. Remove cover with seal (10).8. Remove nut (3), washer (8) and end plate (7).9. Remove coalescer filter element (4).

10. Collect emerging fuel.11. Clean housing with a non-linting cloth, rinse

with fuel if required.12. Check housing for corrosion.13. Clean housing sealing surfaces.14. Install coalescer filter element.15. Install end plate (7), washer (8) and nut (3).16. Use torque wrench to tighten nut (3) to the

specified tightening torque. Tightening torque:30 Nm

17. Fit seal (10).18. Install cover.19. Install screw (1), washer (2) and nut (9).20. Tighten nut (9).21. Open ball valve at inlet and outlet of fuel treatment

system.Result: The fuel treatment system is ready foroperation.

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6.18 General Cabling for Engine / Gearbox / Unit

6.18.1 Engine wiring check


MaterialDesignation / Use Part No. Qty.Isopropyl alcohol

Engine wiring check1. Check securing screws of cable clamps on the engine and tighten loose screw connections.2. Make certain that cables are securely seated in clamps and cannot move freely.3. Check cable binders for secure seating, tighten loose cable binders.4. Replace defective cable binders.5. Inspect electrical components visually for damage:

• connector housings;• contacts;• connector sockets;• cables and terminals;• plug-in contacts.

6. If conductors are damaged, contact Service.7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.

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6.18.2 Sensors, actuators and injectors – Overview

Pos. Designation Monitors

1 B9 Charge-air temperature

2 B10 Charge-air pressure

3 B7 Lube-oil temperature

4 B3 Ambient air temperature

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1 B34 Fuel line: pressure downstream of filter

2 B5.3 Lube oil pressure upstream of filter

3 B5.2 Lube oil pressure

4 B5 Lube oil pressure

5 F33 Coolant pressure

6 B21 Raw water pressure

7 B16 Coolant pressure

8 B6.2 Coolant temperature

9 B6 Coolant temperature

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1 B44 Turbocharger speed

2–6 Y39.x Injector

7 B33 Fuel temperature

8 B48 Fuel pressure in Common Rail

9 M8 H.P. pump

10 B13.2 Crankshaft speed

11 B13 Crankshaft speed

12 F46 Leak-off fuel level

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1–5 Y39.x Injector

6 B4.21 Exhaust temperature, A bank

7 Y27 Exhaust temperature, B bank

System sensorsThese sensors are fitted outside the engine.

Designation Monitors

B19 Intake air depression

B70 Water level in fuel prefilter

B41 Exhaust backpressure

S37 Start interlock, switching status

M015630/01E 06-11 © MTU


6.19 Accessories for Engine Governor (Electronic) / ControlSystem

6.19.1 ECU and connectors – Cleaning



ECU and connectors – Cleaning1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.2. Remove dirt from connector and cable surfaces with isopropyl alcohol.3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated connectors on ECU1. Release latches of connectors and withdraw connectors.2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches.

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6.19.2 EMU and connectors – Cleaning



EMU and connectors – Cleaning1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.2. Remove dirt from connector and cable surfaces with isopropyl alcohol.3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated EMU connectors1. Release latches of connectors and withdraw connectors.2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches.

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6.19.3 ECU – Checking plug-in connections


ECU – Checking plug-in connections1. Verify that all plug-in connections are securely seated.2. Secure loose connectors and latch.

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6.19.4 EMU – Checking plug-in connections


EMU – checking plug-in connections1. Verify that all plug-in connections are securely seated.2. Secure loose connectors and latch.

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6.19.5 ECU – Self-test implementation

DANGER

Electrical voltage.Risk of serious injury - danger to life!

• Make certain that the power supply to the engine is switched off before starting to work.Ensure that the power supply cannot be switched on unintentionally!

Self-test implementation1. Switch off power supply to system.2. Remove connectors X1, X2 and X4 from the

engine governor.2.1. Release lock (3) of connectors (2).2.2. Withdraw connectors (2).

3. Switch on power supply.Result:• The engine governor is operable if the

diagnostic lamp (1) changes to continuousillumination within 30 seconds after power hasbeen switched on.

• If the diagnostic lamp (1) flashes after 30seconds, replace engine governor (→ContactService).

• If the diagnostic lamp stays dark, check powersupply.

4. Switch off power supply.5. Refit connectors X1, X2 and X4 on engine

governor.5.1. Plug in connector (2).5.2. Lock connectors.

M015630/01E 06-11 © MTU


6.19.6 ECU – Removal and installation


ECU – Removal1. Note or mark assignment of cables and

connectors.2. Remove all screws (2).3. Release lock (3) of connectors.4. Withdraw all connectors.5. Remove screws (1).6. Remove ECU.

ECU – Installation1. For installation follow reverse sequence of working steps. Ensure that connectors are plugged in the correct

socket.2. Check rubber bearing before installation.

Result: If the rubber bearing is porous or defective, fit a new one.

M015630/01E 06-11 © MTU


6.19.7 EMU – Installation and removal


Removing ECU with EMU from the engine1. Mark or note down cable to connection

assignment.2. Remove all screws (2).3. Undo latches (3) of the connectors.4. Withdraw all connectors.5. Remove screws (1).6. Take off ECU (1) with EMU (4).

Removing EMU1. Remove screws from the lower side of EMU (4).2. Take off EMU (4) from ECU (1).

Installing EMU1. Place EMU (4) on ECU (1).2. Install screws on the lower side of EMU (4) and tighten.

Installing ECU with EMU on engine1. For installation, follow the reverse sequence of work steps as described for removal. Ensure that the cables

are correctly assigned to the connections.2. Check rubber mount before installation.

Result: If the rubber mount is porous or defective, fit a new one.

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Special Tools 141

7 Special Tools

7.1 Special tools

Part No. Designation / Use Qty.

F6783914 Barring tool 1

F30006212 Ratchet 1

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146 Special Tools


F6783025 Centering device 1

0005896803/00 Socket wrench 1

F6784160 Assembly device 1

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Special Tools 151


F30027336 Torque wrench, 6-50 Nm 1

F30027339 Ratchet adapter 1

Pressure gauge

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152 Special Tools

7.2 Standard tools – Overview

Part No. DesignationUse

Qty.

8205891159/00 General tools kit 1

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154 Annex

8.2 MTU contact person/service partnerYou will find the MTU contact person/service partner for your region at www.mtu-online.com,worldwide, in the left-hand navigation margin.

M015630/01E 06-11 © MTU

Annex 155

8.3 Index10V 2000 M72 engine data: Engine-mountedheat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 3710V 2000 M72 engine data: Separate heatexchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343-in-1 bar electrode – Check . . . . . . . . . . . . . . 1248V 2000 M72 engine data : Separate heatexchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278V 2000 M72 engine data: Engine-mountedheat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 30

AAccessories for Engine Governor (Electronic) /Control System . . . . . . . . . . . . . . . . . . . . . . . . 134

ECU – Checking plug-inconnections . . . . . . . . . . . . . . . . . . . . . 136ECU – Removal and installation . . . . . . 139ECU – Self-test implementation . . . . . . 138ECU and connectors – Cleaning . . . . . . 134EMU – Checking plug-inconnections . . . . . . . . . . . . . . . . . . . . . 137EMU – Installation and removal . . . . . . 140EMU and connectors – Cleaning . . . . . 135

After stopping the engine . . . . . . . . . . . . . . . . 54Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Air filter removal and installation . . . . . . 95Air filter replacement . . . . . . . . . . . . . . . 94

Air filter removal and installation . . . . . . . . . . . 95Air filter replacement . . . . . . . . . . . . . . . . . . . . 94Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Service indicator – Signal ring positioncheck . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Auxiliary materials, fire prevention andenvironmental protection . . . . . . . . . . . . . . . . . 11

BBattery-charging Generator . . . . . . . . . . . . . . 120

Battery-charging generator drive – Drivebelt check and adjustment . . . . . . . . . . 120Battery-charging generator drive – Drivebelt replacement . . . . . . . . . . . . . . . . . . 121

Battery-charging generator drive – Drive beltcheck and adjustment . . . . . . . . . . . . . . . . . . . 120Battery-charging generator drive – Drive beltreplacement . . . . . . . . . . . . . . . . . . . . . . . . . . 121Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Drive belt – Condition check . . . . . . . . . 119

CCentrifugal oil filter – Cleaning and filter-sleevereplacement . . . . . . . . . . . . . . . . . . . . . . . . . . 102Checks prior to startup . . . . . . . . . . . . . . . . . . 46

Coalescer filter element – Replacement . . . . . 126Coolant filter – Replacement . . . . . . . . . . . . . . 117Crankcase breather – Cleaning oil pre-separatorelement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Crankcase breather – Oil separator replacement,diaphragm check and replacement . . . . . . . . . 75Crankcase Ventilation . . . . . . . . . . . . . . . . . . . 74

Crankcase breather – Cleaning oilpre-separator element . . . . . . . . . . . . . 74Crankcase breather – Oil separatorreplacement, diaphragm check andreplacement . . . . . . . . . . . . . . . . . . . . . 75

Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . 71Cylinder liner – Endoscopicexamination . . . . . . . . . . . . . . . . . . . . . 71Instructions and comments on endoscopicand visual examination of cylinderliners . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Cylinder liner – Endoscopic examination . . . . 71Cylinder-head cover – Removal andinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

DDifferential pressure gauge – Check . . . . . . . . 123Drain and venting points . . . . . . . . . . . . . . . . . 105Drive belt – Condition check . . . . . . . . . . . . . . 119

EECU – Checking plug-in connections . . . . . . . 136ECU – Removal and installation . . . . . . . . . . . 139ECU – Self-test implementation . . . . . . . . . . . 138ECU and connectors – Cleaning . . . . . . . . . . . 134Emergency stop . . . . . . . . . . . . . . . . . . . . . . . 53EMU – Checking plug-in connections . . . . . . . 137EMU – Installation and removal . . . . . . . . . . . 140EMU and connectors – Cleaning . . . . . . . . . . 135Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Engine – Barring manually . . . . . . . . . . 69Engine – Barring with startingsystem . . . . . . . . . . . . . . . . . . . . . . . . . 70

Engine – Barring manually . . . . . . . . . . . . . . . 69Engine – Barring with starting system . . . . . . . 70Engine – Main dimensions . . . . . . . . . . . . . . . 25Engine coolant – Change . . . . . . . . . . . . . . . . 112Engine coolant – Draining . . . . . . . . . . . . . . . . 113Engine coolant – Level check . . . . . . . . . . . . . 111Engine coolant – Sample extraction andanalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Engine coolant system – Filling . . . . . . . . . . . . 114

M015630/01E 06-11 © MTU

156 Annex

Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . 22Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine layout . . . . . . . . . . . . . . . . . . . . 22Product description . . . . . . . . . . . . . . . . 15

Engine oil – Level check . . . . . . . . . . . . . . . . . 98Engine oil change . . . . . . . . . . . . . . . . . . . . . . 99Engine oil filter – Replacement . . . . . . . . . . . . 100Engine side and cylinder designations . . . . . . 24Engine Side and Cylinder Designations . . . . . 24

Engine side and cylinderdesignations . . . . . . . . . . . . . . . . . . . . . 24

Engine wiring check . . . . . . . . . . . . . . . . . . . . 128

FFiring order . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Firing order . . . . . . . . . . . . . . . . . . . . . . 26Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Fuel filter – Replacement . . . . . . . . . . . 85Fuel prefilter – Filter elementreplacement . . . . . . . . . . . . . . . . . . . . . 92Fuel prefilter – Flushing . . . . . . . . . . . . 90Fuel prefilter - Draining . . . . . . . . . . . . . 88Fuel prefilter, differential pressure gauge– Inspection and adjustment . . . . . . . . . 87

Fuel filter – Replacement . . . . . . . . . . . . . . . . 85Fuel prefilter – Filter element replacement . . . 92Fuel prefilter – Flushing . . . . . . . . . . . . . . . . . 90Fuel prefilter - Draining . . . . . . . . . . . . . . . . . . 88Fuel prefilter, differential pressure gauge –Inspection and adjustment . . . . . . . . . . . . . . . 87Fuel Supply System . . . . . . . . . . . . . . . . . . . . 122

3-in-1 bar electrode – Check . . . . . . . . . 124Coalescer filter element –Replacement . . . . . . . . . . . . . . . . . . . . 126Differential pressure gauge – Check . . . 123Pump capacity – Check . . . . . . . . . . . . 125Water drain valve – Check . . . . . . . . . . 122

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 84Fuel system – Venting . . . . . . . . . . . . . 84

Fuel system – Venting . . . . . . . . . . . . . . . . . . . 84Fuel treatment system – Putting intooperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Fuel treatment system – Putting out ofservice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Fuel treatment system – Switching on . . . . . . 50Fuel treatment system – Troubleshooting . . . . 65

GGeneral Cabling for Engine / Gearbox /Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Engine wiring check . . . . . . . . . . . . . . . 128

Sensors, actuators and injectors –Overview . . . . . . . . . . . . . . . . . . . . . . . . 129

General conditions . . . . . . . . . . . . . . . . . . . . . 05General Cooling Circuit, HT Circuit . . . . . . . . . 105

Coolant filter – Replacement . . . . . . . . . 117Drain and venting points . . . . . . . . . . . . 105Engine coolant – Change . . . . . . . . . . . 112Engine coolant – Draining . . . . . . . . . . . 113Engine coolant – Level check . . . . . . . . 111Engine coolant – Sample extraction andanalysis . . . . . . . . . . . . . . . . . . . . . . . . . 116Engine coolant system – Filling . . . . . . 114HT coolant pump – Relief borecheck . . . . . . . . . . . . . . . . . . . . . . . . . . 115

HHT coolant pump – Relief bore check . . . . . . . 115

IIndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Injector – Removal and installation . . . . 82Injector – Replacement . . . . . . . . . . . . . 81

Injector – Removal and installation . . . . . . . . . 82Injector – Replacement . . . . . . . . . . . . . . . . . . 81Instructions and comments on endoscopic andvisual examination of cylinder liners . . . . . . . . 72

LLube-oil System, Lube-oil Circuit . . . . . . . . . . 98

Engine oil – Level check . . . . . . . . . . . . 98Engine oil change . . . . . . . . . . . . . . . . . 99

MMain Engine Dimensions . . . . . . . . . . . . . . . . 25

Engine – Main dimensions . . . . . . . . . . 25Maintenance schedule matrix . . . . . . . . . . . . . 59Maintenance tasks . . . . . . . . . . . . . . . . . . . . . 62Manufacturer’s documentation . . . . . . . . . . . . 153MTU contact person/service partner . . . . . . . . 154

OOil Filtration / Cooling . . . . . . . . . . . . . . . . . . . 100

Centrifugal oil filter – Cleaning andfilter-sleeve replacement . . . . . . . . . . . . 102Engine oil filter – Replacement . . . . . . . 100

Operational checks . . . . . . . . . . . . . . . . . . . . . 51

PPersonnel and organizational require-ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Annex 157

Product description . . . . . . . . . . . . . . . . . . . . . 15Pump capacity – Check . . . . . . . . . . . . . . . . . 125Putting the engine into operation (out-of-serviceperiod > 3 months) . . . . . . . . . . . . . . . . . . . . . 43Putting the engine into operation after scheduledout-of-service period . . . . . . . . . . . . . . . . . . . . 44

RRaw water pump – Relief bore check . . . . . . . 118Raw Water Pump with Connections . . . . . . . . 118

Raw water pump – Relief borecheck . . . . . . . . . . . . . . . . . . . . . . . . . . 118

SSafety precautions when working on theengine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08Sensors, actuators and injectors –Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Service indicator – Signal ring positioncheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 141Standard tools – Overview . . . . . . . . . . . . . . . 152Standards for warning notices in thepublication . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Starter – Condition check . . . . . . . . . . . . . . . . 97Starting Equipment . . . . . . . . . . . . . . . . . . . . . 97

Starter – Condition check . . . . . . . . . . . 97Starting the engine . . . . . . . . . . . . . . . . . . . . . 49

Stopping the engine . . . . . . . . . . . . . . . . . . . . 52Switchgear cabinet – Control elements . . . . . . 41

TTasks after extended out-of-service periods (>3weeks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 27

10V 2000 M72 engine data:Engine-mounted heat exchanger . . . . . 3710V 2000 M72 engine data: Separateheat exchanger . . . . . . . . . . . . . . . . . . . 348V 2000 M72 engine data : Separate heatexchanger . . . . . . . . . . . . . . . . . . . . . . . 278V 2000 M72 engine data:Engine-mounted heat exchanger . . . . . 30

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 66

VValve clearance – Check and adjustment . . . . 77Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Cylinder-head cover – Removal andinstallation . . . . . . . . . . . . . . . . . . . . . . . 80Valve clearance – Check andadjustment . . . . . . . . . . . . . . . . . . . . . . 77

WWater drain valve – Check . . . . . . . . . . . . . . . 122

M015630/01E 06-11 © MTU

Technical Publication · 2020. 9. 16. · Technical Publication Diesel Engine 8 V 2000 M72 10 V...

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Transcript of Technical Publication · 2020. 9. 16. · Technical Publication Diesel Engine 8 V 2000 M72 10 V...