Operating Instructions: Diesel Engine 8 V 2000 M60/M61 12V 2000 M60/M61 16V 2000 M60/M61

Operating Instructions

Diesel engine
8 V 2000 M60/M61
12V 2000 M60/M61
16V 2000 M60/M61

MW15406/17E

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© 2014 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.

Commissioning Note
Important
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.).

Table of Contents
1 Safety 3.13 12V 2000 M61 engine data 76
3.14 16V 2000 M60 engine data: Engine-
1.1 Important requirements for all products 8 mounted heat exchanger, reference
1.2 Personnel and organizational requirements 9 condition: 25 °C intake air temperature 79
1.3 Transport 10 3.15 16V 2000 M60 engine data: Engine-
1.4 Safety requirements for startup and mounted heat exchanger, reference
operation 11 condition: 45 °C intake air temperature 82
1.5 Safety requirements for maintenance and 3.16 16V 2000 M60 engine data: Separate heat
repair work 12 exchanger, reference condition: 25 °C
1.6 Fire prevention and environmental intake air temperature 85
protection, fluids and lubricants, auxiliary 3.17 16V 2000 M60 engine data: Separate heat
materials 15 exchanger, reference condition: 45 °C
1.7 Standards for safety notices in the text 17 intake air temperature 88
3.18 16V 2000 M61 engine data 91
2 General Information 3.19 16V 2000 M61 engine data 94
2.1 Product description 18 3.20 16V 2000 M61 engine data 97
2.2 Engine side and cylinder designations 27 3.21 16V 2000 M61 engine data 100
2.3 2000 M40-M91A/B engines – Overview 28 3.22 Firing order 103
2.4 Sensors and actuators – Overview 29 3.23 Engine – Main dimensions 104
3 Technical Data 4 Operation
3.1 8V 2000 M60 engine data: Engine-mounted 4.1 LOP controls (without Blue Line automation
heat exchanger, reference condition: 25 °C system) 105
intake air temperature 39 4.2 Putting the engine into operation after
3.2 8V 2000 M60 engine data: Engine-mounted extended out-of-service periods (>3 months) 107
heat exchanger, reference condition: 45 °C 4.3 Putting the engine into operation after
intake air temperature 42 scheduled out-of-service period 108
3.3 8V 2000 M60 engine data: Separate heat 4.4 Starting the engine from LOP (without Blue
exchanger, reference condition: 25 °C Line automation system) 109
intake air temperature 45 4.5 Starting the engine with the BlueLine
3.4 8V 2000 M60 engine data: Separate heat automation system (control stand) 110
exchanger, reference condition: 45 °C 4.6 Engine emergency stop at BlueLine
intake air temperature 48 automation system (control stand) 111
3.5 8V 2000M61 engina data 51 4.7 Operational checks 112
3.6 12V 2000 M60 engine data: Engine- 4.8 Coupling – Disengaging from LOP 113
mounted heat exchanger, reference 4.9 Waterjet – Flushing from LOP (optional) 114
condition: 25 °C intake air temperature 55 4.10 Stopping the engine from LOP (without Blue
3.7 12V 2000 M60 engine data: Engine- Line automation system) 115
mounted heat exchanger, reference 4.11 Stopping the engine at the BlueLine
condition: 45 °C intake air temperature 58 automation system (control stand) 116
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3.8 12V 2000 M60 engine data: Separate heat 4.12 Emergency stop from LOP (without Blue
exchanger, reference condition: 25 °C Line automation system) 117
intake air temperature 61 4.13 After stopping the engine 118
3.9 12V 2000 M60 engine data: Separate heat 4.14 Plant – Cleaning 119
exchanger, reference condition: 45 °C
intake air temperature 64 5 Maintenance
3.10 12V 2000 M61 engine data 67 5.1 Maintenance schedule reference table [QL1] 120
3.11 12V 2000 M61 engine data 70
3.12 12V 2000 M61 engine data 73
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6 Troubleshooting 7.11 Air Filter 182
7.11.1 Air filter – Replacement 182
6.1 LOP fault messages 121 7.11.2 Air filter – Removal and installation 183
6.2 Troubleshooting 130
7.12 Air Intake 184
7.12.1 Service indicator – Signal ring position check
7 Task Description (optional) 184
7.12.2 Air-flow control flap – Ease of movement
7.1 SOLAS 133
check 185
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 133 7.13 Starting Equipment 186
7.1.2 SOLAS shielding – Installation as per MTN 7.13.1 Starter – Condition check 186
5233 134
7.1.3 SOLAS shielding – Installation 135 7.14 Lube Oil System, Lube Oil Circuit 187
7.1.4 Installation locations for SOLAS shielding 136 7.14.1 Engine oil – Level check 187
7.1.5 Installation locations for SOLAS shielding 141 7.14.2 Engine oil – Change 188
7.2 Engine 146 7.15 Oil Filtration / Cooling 189

7.2.1 Engine ‒ Barring manually 146 7.15.1 Oil dipstick — Marking 189
7.2.2 Engine – Barring with starting system 147 7.15.2 Engine oil filter – Replacement 190
7.15.3 Centrifugal oil filter and filter sleeve –
7.3 Cylinder Liner 148 Cleaning and replacement 192
7.3.1 Cylinder liner – Endoscopic examination 148
7.3.2 Instructions and comments on endoscopic and 7.16 Coolant Circuit, General, High-Temperature
visual examination of cylinder liners 150 Circuit 195
7.16.1 Drain and venting points 195
7.4 Crankcase Breather 152 7.16.2 Engine coolant – Level check 200
7.4.1 Crankcase ventilation – Oil separator element 7.16.3 Engine coolant – Change 201
replacement, diaphragm check and 7.16.4 Engine coolant – Draining 202
replacement 152 7.16.5 Engine coolant ‒ Filling 203
7.4.2 Crankcase breather – Cleaning oil separator 7.16.6 HT coolant pump ‒ Relief bore check 204
element 154 7.16.7 Engine coolant – Sample extraction and
7.5 Valve Drive 155 analysis 205
7.5.1 Valve clearance – Check and adjustment 155 7.17 Raw Water Pump with Connections 206
7.5.2 Cylinder head cover – Removal and 7.17.1 Raw water pump – Priming 206
installation 158 7.17.2 Raw water pump – Relief bore check 207
7.6 Injection Pump / HP Pump 159 7.18 Belt Drive 208
7.6.1 Injection pump – Replacement 159 7.18.1 Drive belt – Condition check 208
7.6.2 Injection pump – Removal and installation 160
7.19 Battery-Charging Generator 209
7.7 Injection Valve / Injector 163 7.19.1 Battery-charging generator drive – Drive belt
7.7.1 Injector – Replacement 163 check and adjustment 209
7.7.2 HP fuel line – Pressure pipe neck replacement 164 7.19.2 Battery-charging generator drive – Drive belt
7.7.3 Injector – Removal and installation 166 replacement 211
7.8 Fuel System 170 7.20 Engine Mounting / Support 212
7.8.1 Fuel – Draining 170 7.20.1 Engine mounting – Checking condition of
7.8.2 Fuel system – Venting 171 resilient mounts 212
7.9 Fuel Filter 173 7.21 Universal Shaft 213
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7.9.1 Fuel filter – Replacement 173 7.21.1 Universal shaft – Greasing 213
7.9.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 175 7.22 Wiring (General) for Engine/Gearbox/Unit 214
7.9.3 Fuel prefilter – Draining 176 7.22.1 Engine wiring – Check 214
7.9.4 Fuel prefilter – Flushing 177
7.23 Accessories for (Electronic) Engine
7.9.5 Fuel prefilter – Filter element replacement 179
Governor / Control System 215
7.10 Charge-Air Cooling General, Left-Hand Side 181 7.23.1 Engine governor and connectors – Cleaning 215
7.10.1 Intercooler ‒ Checking condensate drain line 7.23.2 Engine monitoring unit and connectors –
for coolant discharge and obstruction 181 Cleaning 216
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7.23.3 Start interlock limit switch – Check 217
7.23.4 ECU – Plug connections check 218
7.23.5 Engine monitoring unit – Plug connections 8 Appendix A
check 219
7.23.6 Engine governor – Removal and installation 220
8.1 Abbreviations 227
8.2 MTU contact persons/service partners 230
7.24 Emergency Instrumentation (Local
Operating Panel) 222 9 Appendix B
7.24.1 LOP and connectors – Cleaning 222
7.24.2 LOP – Visual inspection 223 9.1 Special Tools 231
7.24.3 LOP – Test procedures 225 9.2 Index 239
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MW15406/17E 2014-05 | Table of Contents | 7

1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
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safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
8 | Safety | MW15406/17E 2014-05

1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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MW15406/17E 2014-05 | Safety | 9

1.3 Transport
Transport
Only use the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear-
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport

Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
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10 | Safety | MW15406/17E 2014-05

1.4 Safety requirements for startup and operation
Safety requirements for startup
The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.
All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.
Whenever the product is started, always ensure that:
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• Wearers of cardiac pacemakers or other active medical implants are well clear.
• The operating room is adequately ventilated.
• Exhaust pipework is leak-tight and routed to atmosphere.
• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.
• All personnel is clear of the danger zone represented by moving parts.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.
Safety requirements for operation

The operator must be familiar with the controls and displays.
The operator must be aware of the consequences of any operations he/she performs.
During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.
Malfunctions and emergency stop

Emergency procedures, in particular emergency stop, must be practiced on a regular basis.
Take the following steps if a system malfunction is detected or signaled by the system:
• Inform the duty supervisor(s).
• Evaluate the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.
Keep a safe distance away from the product whenever possible. Do not touch the product unless ex-
pressly instructed to do so.
Do not inhale exhaust gases emitted by the product.
Ensure that the following requirements have been fulfilled before starting the product:
• Ear protectors are worn.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
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agent.
Operation of electrical equipment

Some components are live (high voltage) when electrical equipment is in operation.
Observe the safety instructions for these appliances.
MW15406/17E 2014-05 | Safety | 11

1.5 Safety requirements for maintenance and repair work
Safety requirements before commencing maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.
Safety requirements during maintenance and repair work

Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
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Ensure that all retainers and dampers are installed correctly.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
12 | Safety | MW15406/17E 2014-05

Pay particular attention to cleanliness at all times.
Safety requirements after completing maintenance and repair work

Ensure that all personnel is clear of danger zones before cranking.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal

Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

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Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
MW15406/17E 2014-05 | Safety | 13

Working on electrical/electronic assemblies
Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cabling to lines bearing fluids.
Do not use cable ties to secure cabling.
Always use connector pliers to tighten union nuts on connectors.
Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Working with laser equipment

Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.
Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C. TIM-ID: 0000040535 - 005
14 | Safety | MW15406/17E 2014-05

1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Fluids and lubricants and auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
TIM-ID: 0000040536 - 005
coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MW15406/17E 2014-05 | Safety | 15

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Paints and varnishes

• Observe the relevant safety data sheet for all materials.
• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

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• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.
16 | Safety | MW15406/17E 2014-05

1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
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MW15406/17E 2014-05 | Safety | 17

2 General Information
2.1 Product description
Description of the engine
Engine
The engine is a liquid-cooled, four-stroke cycle diesel engine, rotating counter-clockwise (seen from
driving end), with direct injection, sequential turbocharging and charge-air cooling.
The engine is monitored by an engine control and monitoring system.
Monitoring in the engine room is carried out by the engine control and monitoring unit.
Fuel system
Electronically controlled unit injection pumps with jacketed HP lines.
The electronic control unit controls
• Beginning of injection
• Injection quantity
Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• Low surface temperature
• Reduced amount of heat to be dissipated by the coolant
• Absolute gas-tightness
Turbocharging
Sequential turbocharging with charge-air cooling (turbochargers can be cut in/out during operation).
Cooling system
Engine cooled by split-circuit cooling system with plate-core heat exchanger.
Service block
The service components are mounted at the auxiliary PTO end.
The arrangement facilitates easy access for maintenance operations.
Service components:
• Raw water pump, coolant pump
• Fuel duplex filter, switchable
• Lube-oil multiple filter, switchable
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• Centrifugal lube oil filter

• Coolant expansion tank
Electronic system
Electronic control and monitoring system with integrated safety and test system, providing interfaces to
Remote Control System (RCS) and Monitoring and Control System (MCS).
18 | General Information | MW15406/17E 2014-05

Electronic Engine Control Unit (ECU)
Functions:
• Engine speed control with fuel and speed limitation dependent on engine state and operating condi-
tions;
• Control of sequential turbocharging;
• Data processing logistics for analog and binary signals;
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring;
• RS 232 interface for connection of MTU dialog unit.
Electronic Engine Monitoring Unit (EMU), optional

Functions:
• Data processing logistics for analog and binary signals;
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring.
Electronic Gear Control Unit (GCU), ship-side wall-mounting

Functions:
• Date processing logistics for gear coupling control;
• Input/output signals as well as data transfer to CAN field bus for remote control and ship-side moni-
toring.
Monitoring in engine room

Engine control and monitoring unit (LOP)
Functions:
• Alphanumeric, monochrome LCD display for monitoring of measured values as well as alarms when
limits are violated;
• Pushbuttons for menu control and dimming unit;
• Combined control and display elements for local engine/gear control;
• Flashing light and horn for summary alarm in engine room;
• Interface to CAN field bus for connected, communicating monitoring system components.
SOLAS – Fire protection specifications

All fuel lines with fuel pressure >1.8 bar are fitted with SOLAS-compliant covers as per MTU standard
MTN5233.
All oil lines with oil pressure >1.8 bar are fitted with SOLAS-compliant covers as per MTU standard
MTN5233.
TIM-ID: 0000002178 - 006
MW15406/17E 2014-05 | General Information | 19

Fuel system covers
TIM-ID: 0000002178 - 006

TIM-ID: 0000002178 - 006

Lube oil system covers
TIM-ID: 0000002178 - 006

TIM-ID: 0000002178 - 006

Special unions
The following types of union are spray-proof in case of leakage even without covers and have been con-
firmed as being SOLAS-compliant by GL and DNV.
Plug-in pipe union

Design precludes lateral spray as the point of separation is shielded by the sleeve (4).
Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-
ring (3).
TIM-ID: 0000002178 - 006
The union is confirmed as being SOLAS-compliant by DNV and GL.
Plugs and sensors

Screw-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
The fluid must first pass the thread in case of a loose threaded union or faulty sealing ring (2).
The pressure is thus greatly reduced by this and the faulty sealing ring (2) that any leakage is not under
pressure.

High-pressure unions
1 Jacket pipe 8 Thrust ring 15 Union nut

2 HP line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 External pipe of HP line
4 Union nut 11 Connecting piece 18 Internal pipe of HP line
5 Recess for O-ring 12 Snap ring 19 Ball-type seal area
6 Thrust ring 13 Thrust ring 20 Leak fuel connection
7 Leakage overflow bore 14 Compensating disks
The HP fuel line is sealed by the thrust ring (8).
In case of leakage around the thrust ring (8) or the HP line (5) fuel escapes into the leakage chamber.
Leak fuel is allowed to escape without pressure via the leakage overflow bore (7). The leakage chamber
is sealed toward the outside by the O-rings (3).
This prevents leaking fuel from escaping.
The union is confirmed as being SOLAS-compliant by DNV and GL.
TIM-ID: 0000002178 - 006

Shielding of fuel filters and lube-oil filters
Shielding with plastic ring
The plastic ring (1) precludes lateral spray.

The fluid is diverted to the catch basin whereby the pressure is greatly reduced.
Shielding by overlapping design
TIM-ID: 0000002178 - 006
The overlap (1) precludes lateral spray.

The fluid is diverted to the catch basin whereby the pressure is greatly reduced.

2.2 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013

2.3 2000 M40-M91A/B engines – Overview
Engine – Overview of functional groups
010 Crankcase and externally 080 Fuel system (low pressure) 180 Lube oil system/lube oil
mounted components 100 Exhaust turbocharger circuit
020 Gear train 110 Charge-air cooling 200 Coolant circuit
030 Crank drive 120 Air intake/air supply 230 Mounting/support
040 Cylinder head 140 Exhaust system 250 PTO systems, driving end
050 Valve gear 170 Starting equipment and free end
070 Injection system (high 500 Monitoring, control and
pressure) regulation system
Engine model designation

Key to the engine model designations 8/12/16V 2000 M40-M91A/B
8,12,16 Number of cylinders
TIM-ID: 0000002082 - 007
V Cylinder arrangement: V engine

2000 Series
M Application: M = Marine
4, ...,9 Application segment
0, 1 Design index (0, ..., 9)
A/B Special feature: A = 50 Hz, B = 60 Hz
Table 1: Engine model designation

2.4 Sensors and actuators – Overview
Top view 12V 2000 M
1 B03 (intake air tempera- 4 B5.2 (lube oil pressure) 7 B07 (lube oil temperature)
ture) 5 F25 (lube-oil pressure dif- 8 B05 (lube oil pressure)
2 B10 (charge-air pressure) ference over filter)
3 B09 (charge-air tempera- 6 B34 (fuel pressure after fil-
ture) ter)
TIM-ID: 0000012937 - 004

Left engine side 12V 2000 M
1 F33 (coolant level) 2 Y27 (turbocharger control 3 B21 (raw water pressure)
valve)
TIM-ID: 0000012937 - 004

Engine free end 12V 2000 M
1 B06 (coolant temperature) 2 B6.2 (coolant tempera-

ture)
TIM-ID: 0000012937 - 004

Right engine side 12V 2000 M
1 B44 (turbocharger speed) 3 F46 (leak-off fuel level)

2 B16 (coolant pressure) 4 B33 (fuel temperature)
TIM-ID: 0000012937 - 004

Driving end 12V 2000 M
1 B01 (camshaft speed) 3 B13 (crankshaft speed) 5 B4.21 (exhaust bulk tem-
2 B4.22 (exhaust bulk tem- 4 B13.2 (crankshaft speed) perature, A side)
perature, B side)
TIM-ID: 0000012937 - 004

Top view 16V 2000 M
1 B03 (intake air tempera- 4 B5.2 (lube oil pressure) 7 B07 (lube oil temperature)
ture) 5 F25 (lube-oil pressure dif- 8 B05 (lube oil pressure)
2 B10 (charge-air pressure) ference over filter)
3 B09 (charge-air tempera- 6 B34 (fuel pressure after fil-
ture) ter)
TIM-ID: 0000012937 - 004

Left engine side 16V 2000 M
1 F33 (coolant level) 2 Y27 (turbocharger control 3 B21 (raw water pressure)
valve)
TIM-ID: 0000012937 - 004

Free end 16V 2000 M
1 B06 (coolant temperature) 2 B6.2 (coolant tempera-

ture)
TIM-ID: 0000012937 - 004

Right engine side 16V 2000 M
1 B44 (turbocharger speed) 3 F46 (leak-off fuel level)

2 B16 (coolant pressure) 4 B33 (fuel temperature)
TIM-ID: 0000012937 - 004

Driving end 16V 2000 M
1 B01 (camshaft speed) 3 B13 (crankshaft speed) 5 B4.21 (exhaust bulk tem-
2 B4.22 (exhaust bulk tem- 4 B13.2 (crankshaft speed) perature, A side)
perature, B side)
TIM-ID: 0000012937 - 004

3 Technical Data
3.1 8V 2000 M60 engine data: Engine-mounted heat exchanger,
reference condition: 25 °C intake air temperature
Explanation:
DL Ref. value: Continuous power (CP)
BL Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 8V
2000 M60
Application group 1A
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 1800
Fuel stop power ISO 3046 A kW 400
GENERAL CONDITIONS (for maximum power)

Intake air depression (new filter) A mbar 15
Intake air depression, max. L mbar 50
MODEL-RELATED DATA (basic design)

TIM-ID: 0000002883 - 001
Cylinder configuration: V angle degree 90
Bore mm 130
Stroke mm 150
Cylinder displacement liter 1.99
Total displacement liter 15.92
Number of inlet valves, per cylinder 2
Number of exhaust valves, per cylinder 2
MW15406/17E 2014-05 | Technical Data | 39

RAW WATER CIRCUIT (open circuit)
Raw water pump: inlet pressure, min. L bar -0.5
Raw water pump: inlet pressure, max. L bar +0.5
Pressure loss in the external raw water system, max. permissible L bar 0.7
LUBE OIL SYSTEM

Lube oil operating temperature before engine, from R °C 75
Lube oil operating temperature before engine, to R °C 80
Lube oil operating pressure before engine, from R bar 5.6
Lube oil operating pressure before engine, to R bar 6.1
Lube oil operating pressure, low idle (meas. point: before engine) R bar 2.0
FUEL SYSTEM
Fuel pressure at supply connection to engine (when engine is starting), min. L bar -0.3
Fuel pressure at supply connection to engine (when engine is running), min. L bar -0.3
Fuel pressure at supply connection to engine (when engine is starting), max. L bar +0.5
Fuel supply flow, max. R liter/min 1.4
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
STARTING (pneumatic starter)

Starting air pressure before starter motor, min. R bar 18
Starting air pressure before starter motor, max. R bar 30
TIM-ID: 0000002883 - 001
INCLINATIONS, STANDARD OIL SYSTEM (relative to: waterline)

Longitudinal inclination continuous max. drive side down (Design: max. operat- L degree 15
ing inclinations)
Longitudinal inclination temporary max. drive side down (Design: max. operat- L degree 22.5
ing inclinations)
Longitudinal inclination continuous max. drive side up (Design: max. operating L degree 0
inclinations)
40 | Technical Data | MW15406/17E 2014-05

Longitudinal inclination temporary max. drive side up (Design: max. operating L degree 10
inclinations)
Transverse inclination continuous max. (Design: max. operating inclinations) L degree 22.5
Transverse inclination temporary max. (Design: max. operating inclinations) L degree 40
CAPACITIES
Engine coolant capacity (with cooling equipment) R liter 70
Engine oil capacity, initial filling (standard oil system) (Option: max. operating R liter 65
inclinations)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R liter 60
nations)
Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. oper- L liter 45
ating inclinations)
Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. oper- L liter 55
ating inclinations)
WEIGHTS / MAIN DIMENSIONS

Engine dry weight (with attached standard accessories, without coupling) R kg 1790
ACOUSTICS
Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis- R db(A) 104
tance, ISO 6798)
Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- R db(A) 99
pressure level Lp, 1m distance, ISO 6798)
TIM-ID: 0000002883 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V
2000 M60


Bore mm 130
TIM-ID: 0000002931 - 001
Stroke mm 150

LUBE OIL SYSTEM

FUEL SYSTEM
Fuel pressure at supply connection to engine (when engine is running), min. L bar +0.3

STARTING (electric)

ing inclinations)
TIM-ID: 0000002931 - 001
ing inclinations)
inclinations)
inclinations)

CAPACITIES
inclinations)
nations)
ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000002931 - 001

3.3 8V 2000 M60 engine data: Separate heat exchanger,
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V
2000 M60


Bore mm 130
TIM-ID: 0000002966 - 001
Stroke mm 150

LUBE OIL SYSTEM
FUEL SYSTEM

STARTING (electric)


ing inclinations)
ing inclinations)
TIM-ID: 0000002966 - 001
inclinations)
inclinations)

CAPACITIES
inclinations)
nations)
ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000002966 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V
2000 M60


Bore mm 130
TIM-ID: 0000002991 - 001
Stroke mm 150

LUBE OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

ing inclinations)
ing inclinations)
inclinations)
inclinations)
TIM-ID: 0000002991 - 001
CAPACITIES
inclinations)
nations)

ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000002991 - 001

3.5 8V 2000M61 engina data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
- Not applicable
X Applicable
Reference conditions
Engine model 8V2000M 8V2000M 8V2000M 8V2000M
61 61 61 61
Application group 1A 1A 1A 1A
Intake air temperature °C 25 25 25 25
Charge air coolant temperature °C - - - -
Raw water inlet temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 8 8 8 8
Rated engine speed A rpm 1800 1800 1800 1800
Fuel stop power ISO 3046 A kW 400 400 400 400
General conditions (for maximum power)

Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 50 50 50 50
Model related data (basic design)

Cylinder arrangement: V-angle Degrees 90 90 90 90
(°)
Bore mm 130 130 130 130
TIM-ID: 0000051959 - 001
Stroke mm 150 150 150 150

Displacement, cylinder Liters 1.99 1.99 1.99 1.99
Displacement, total Liters 15.92 15.92 15.92 15.92
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2

Raw water circuit (open circuit)
Raw water pump: Inlet pressure, min. L bar - -0.4 -0.4 -0.4
Raw water pump: Inlet pressure, max. L bar - 0.5 0.5 0.5
Pressure loss in off-engine raw water sys- L bar - 0.7 0.7 0.7
tem, max.
Lube oil system

Lube oil operating temperature before en- R °C 75 75 75 75
gine, from
Lube oil operating temperature before en- R °C 80 80 80 80
gine, to
Lube oil operating pressure before engine, R bar 5.6 5.6 5.6 5.6
from
Lube oil operating pressure before engine, R bar 6.1 6.1 6.1 6.1
to
Lube oil operating pressure (low idle) R bar 2.0 2.0 2.0 2.0
(meas. point: before engine)
Fuel system
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is running)
Fuel pressure at engine inlet connection, L bar 0.5 0.5 0.5 0.5
max. (when engine is starting)
Fuel supply flow, max. A Liter/min 12 1.8 12 1.8
General operating data

Firing speed, from R rpm 100 100 100 100
Firing speed. to R rpm 120 120 120 120
Starting (electric)
TIM-ID: 0000051959 - 001
Rated starter voltage (standard design) R V= 24 24 24 24
Starting (with compressed air/hydraulic starter)

Starting air pressure before starter motor, R bar 18* 18* 18* 18*
min.
Starting air pressure before starter motor, R bar 30 30 30 30
max.

Inclinations - standard oil system (Reference: waterline)
Longitudinal inclination, continuous max. L Degrees 15* 15* 15* 15*
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, temporary max. L Degrees 22.5* 22.5* 22.5* 22.5*
driving end down (option: max. operating (°)
inclinations)
Longitudinal inclination, continuous max. L Degrees 0 0 0 0
driving end up (option: max. operating in- (°)
clinations)
Longitudinal inclination, temporary max. L Degrees 10* 10* 10* 10*
driving end up (option: max. operating in- (°)
clinations)
Transverse inclination continuous max. L Degrees 22.5* 22.5* 22.5* 22.5*
(Option: max. operating inclinations) (°)
Transverse inclination, temporary max. L Degrees 40* 40* 40* 40*
(option: max. operating inclinations) (°)
Capacities
Engine coolant capacity, engine side (with R Liters - 70* - 70*
cooling equipment)
Engine oil capacity, initial filling (standard R Liters 65 65 65 65
oil system) (option: max. operating inclina-
tions)
Oil change quantity, max. (standard oil R Liters 60 60 60 60
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 45 45 45 45
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 55 55 55 55
(standard oil system) (option: max. operat-
ing inclinations)
Weights / main dimensions

Engine dry weight (with standard accesso- R kg 1790 1790 1790 1790
ries installed, w/o coupling)
TIM-ID: 0000051959 - 001

Acoustics
Exhaust noise, unsilenced - BL (free-field R dB(A) 104 104 104 104
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 99 99 99 99
take noise (filter) - BL (free-field sound
power level Lp, 1 m distance, ISO 6798,
+2dB(A) tolerance)
TIM-ID: 0000051959 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V
2000 M60


Bore mm 130
TIM-ID: 0000003009 - 001
Stroke mm 150

LUBE OIL SYSTEM

FUEL SYSTEM

STARTING (electric)

TIM-ID: 0000003009 - 001

ing inclinations)
ing inclinations)
inclinations)

inclinations)
CAPACITIES
inclinations)
nations)
ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003009 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V
2000 M60


Bore mm 130
TIM-ID: 0000003024 - 001
Stroke mm 150

LUBE OIL SYSTEM

FUEL SYSTEM

STARTING (electric)

ing inclinations)
TIM-ID: 0000003024 - 001
ing inclinations)
inclinations)
inclinations)

CAPACITIES
inclinations)
nations)
ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003024 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V
2000 M60


Bore mm 130
TIM-ID: 0000003037 - 001
Stroke mm 150

LUBE OIL SYSTEM
FUEL SYSTEM
Fuel supply flow, max. R liter/min 25

STARTING (electric)


ing inclinations)
ing inclinations)
TIM-ID: 0000003037 - 001
inclinations)
inclinations)

CAPACITIES
inclinations)
nations)
ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003037 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 12V
2000 M60


Bore mm 130
TIM-ID: 0000003045 - 001
Stroke mm 150

LUBE OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

ing inclinations)
ing inclinations)
inclinations)
inclinations)
TIM-ID: 0000003045 - 001
CAPACITIES
inclinations)
nations)

ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003045 - 001

3.10 12V 2000 M61 engine data
Explanation:
A Design value
G Guaranteed value
R Guideline value
L Limit value up to which the engine can be operated without change (e.g. of power settings).
- Not applicable
X Applicable
Engine model 12V 2000
M61
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Rated engine speed A rpm 1800

Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 50
MODEL RELATED DATA (basic design)

Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000010991 - 002
Displacement per cylinder Liters 1.99

Total displacement Liters 23.88
Inlet valves per cylinder 2
Exhaust valves per cylinder 2

RAW-WATER CIRCUIT (open circuit)
Pressure loss in off-engine raw water system, max. L bar 0.7
LUBE-OIL SYSTEM
Lube-oil operating temperature before engine, to R °C 80
Lube-oil operating pressure before engine, from R bar 7.5
Lube-oil operating pressure before engine, to R bar 8.5
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.5
FUEL SYSTEM
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3
Fuel pressure at supply connection to engine, min. (when engine is running), L bar -0.3
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.5

STARTING (electric)
STARTING (with compressed air/hydraulic starter)

TIM-ID: 0000010991 - 002
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Longitudinal inclination, continuous max. driving end down (Option: max. oper- L Degrees 15
ating inclinations) (°)
Longitudinal inclination, temporary max. driving end down (Option: max. oper- L Degrees 22.5
Longitudinal inclination, continuous max. driving end up (Option: max. operat- L Degrees 5
ing inclinations) (°)

Longitudinal inclination, temporary max., driving end up (Option: max. operat- L Degrees 10
Transverse inclination continuous max. (Option: max. operating inclinations) L Degrees 22.5
(°)
Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees 40
(°)
CAPACITIES
Engine coolant, engine side (with cooling system) R Liters 110
Total engine oil capacity at initial filling (standard oil system) (Option: max. op- R Liters 105
erating inclinations)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R Liters 98
nations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 73
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 88

ACOUSTICS
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- R dB(A) 104
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter), BL, (free-field sound- R dB(A) 100
pressure level Lp, 1m distance, ISO 6798+2dB(A) tolerance)
TIM-ID: 0000010991 - 002

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
M61


(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000010995 - 002


LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)


TIM-ID: 0000010995 - 002
(°)
(°)

CAPACITIES
nations)

ACOUSTICS
TIM-ID: 0000010995 - 002

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
M61


(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000010998 - 002


LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

TIM-ID: 0000010998 - 002


(°)
(°)
CAPACITIES
nations)

ACOUSTICS
TIM-ID: 0000010998 - 002

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
M61


(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000011001 - 002


LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)


TIM-ID: 0000011001 - 002
(°)
(°)

CAPACITIES
nations)

ACOUSTICS
TIM-ID: 0000011001 - 002

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 16V
2000 M60


Bore mm 130
TIM-ID: 0000003053 - 001
Stroke mm 150

LUBE OIL SYSTEM

FUEL SYSTEM

STARTING (electric)

TIM-ID: 0000003053 - 001

ing inclinations)
ing inclinations)
inclinations)

inclinations)
CAPACITIES
inclinations)
nations)
ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003053 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 16V
2000 M60


Bore mm 130
TIM-ID: 0000003061 - 001
Stroke mm 150

LUBE OIL SYSTEM

FUEL SYSTEM

STARTING (electric)
INCLINATIONS, STANDARD OIL SYSTEM (relative to: Water level)

ing inclinations)
TIM-ID: 0000003061 - 001
ing inclinations)
inclinations)
inclinations)

CAPACITIES
inclinations)
nations)
ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003061 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 16V
2000 M60


Bore mm 130
TIM-ID: 0000003068 - 001
Stroke mm 150

LUBE OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

ing inclinations)
ing inclinations)
inclinations)
inclinations)
TIM-ID: 0000003068 - 001
CAPACITIES
inclinations)
nations)

ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003068 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 16V
2000 M60


Bore mm 130
TIM-ID: 0000003075 - 001
Stroke mm 150

LUBE OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

ing inclinations)
ing inclinations)
inclinations)
inclinations)
TIM-ID: 0000003075 - 001
CAPACITIES
inclinations)
nations)

ating inclinations)
ating inclinations)

ACOUSTICS
tance, ISO 6798)
TIM-ID: 0000003075 - 001

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
M61


(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000011004 - 002


LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

TIM-ID: 0000011004 - 002


(°)
(°)
CAPACITIES
nations)

ACOUSTICS
TIM-ID: 0000011004 - 002

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
M61


(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000011006 - 002


LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)


TIM-ID: 0000011006 - 002
(°)
(°)

CAPACITIES
nations)

ACOUSTICS
TIM-ID: 0000011006 - 002

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
M61


(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000011010 - 002


LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

TIM-ID: 0000011010 - 002


(°)
(°)
CAPACITIES
nations)

ACOUSTICS
TIM-ID: 0000011010 - 002

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
M61


(°)
Bore mm 130
Stroke mm 150
TIM-ID: 0000011015 - 002


LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)


TIM-ID: 0000011015 - 002
(°)
(°)

CAPACITIES
nations)

ACOUSTICS
TIM-ID: 0000011015 - 002

3.22 Firing order
Number of cylin- Firing order
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7
TIM-ID: 0000002802 - 004

3.23 Engine – Main dimensions
Engine model Length (A) Width (B) Height (C)

8 V 2000 M50-M61 approx. 2005 mm approx. 1280 mm approx. 1315 mm
TIM-ID: 0000002146 - 003

4 Operation
4.1 LOP controls (without Blue Line automation system)
LOP – Controls
Item Color Inscription Meaning / Function

1 White F1 Function keys to control the man-machine interface.
2 White F2 Functions vary and are displayed on the LCD screen.
3 White F3
4 White F4
5 White F5
TIM-ID: 0000008860 - 004
6 White ALARM ACKNOWL Pressing the button the first time stops alarm signaliza-
tion.
Pressing the button a second time acknowledges an ac-
tive alarm.
LED (spot) lights up when an alarm is active.
7 White DIM ↑ Holding down the button increases LCD background illu-
mination.
8 White DIM ↓ Holding down the button decreases LCD background illu-
mination.
MW15406/17E 2014-05 | Operation | 105

Item Color Inscription Meaning / Function
9 White LAMP TEST Pressing the button initiates lamp test.
10 Red TEST OVERSPEED Pressing the button initiates overspeed test.
LED (spot) lights up as long as the overspeed test is run-
ning.
11 Green (depending on type of FPP: Pressing the button engages gear ahead.
gearbox and propul- CPP, WJ, VS: Pressing the button engages clutch.
sion) LED (spot) lights up when GCU feedback is active.
12 Green FPP, CPP, WJ, VS: Pressing the button disengages clutch.
LED (spot) lights up when GCU feedback is active.
13 Green FPP: Pressing the button engages gear astern.
CPP, VS: No function assigned.
WJ: Holding down the button provides flushing of water jet
intake channel (water-jet reverse) .
LED (spot) lights up when GCU feedback is active.
14 White ENGINE SPEED IN- Engine speed is increased as long as the button is held
CREASE down.
15 White ENGINE SPEED DE- Engine speed is decreased as long as the button is held
CREASE down.
16 Green READY FOR OPERA- Pressing the button causes changeover between “Not
TION ready for operation” and “Ready for operation” status.
LED (spot) lights up at "Ready for operation" position.
17 Green LOCAL OPERATION Pressing the button activates changeover between local
and remote control mode.
LED (spot) lights up when local mode is active.
18 White START Pressing the button initiates the automatic engine start
sequence.
LED (spot) lights up as long as the starting procedure is
running.
19 White STOP Pressing the button initiates automatic engine stopping
procedure.
LED (spot) lights up as long as the STOP signal is available
(also if transmitted from RCS).
20 Red EMERGENCY STOP Pressing the button initiates an immediate emergency en-
gine stop.
LED (spot) flashes once the emergency stop has been
tripped and until the alarm has been acknowledged.
TIM-ID: 0000008860 - 004
106 | Operation | MW15406/17E 2014-05

4.2 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Preservation and Represervation Specifications (A001070/..) are available.
Putting the engine into operation (out-of-service period > 3 months)

Item Measure
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Universal shaft Lubricate (→ Page 213).
Lube oil system Check engine oil level (→ Page 187).
Fuel prefilter Fill with fuel (→ Page 179).
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 175).
gauge
Fuel system Vent (→ Page 171).
Raw-water pump (if located Prime with water (approx. 3 4 l) (→ Page 206).
above waterline)
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 201).
Coolant circuit Check coolant level (→ Page 200).
Coolant circuit Heat engine coolant with coolant preheating unit.
Engine governor ECU Check plug-in connections (→ Page 218).
Engine control system Switch master switch to ON;
Press illuminated pushbutton READY FOR OPERATION (→ Page 105).
LOP Press illuminated pushbutton LAMP TEST (→ Page 105).
TIM-ID: 0000002215 - 004
MW15406/17E 2014-05 | Operation | 107

4.3 Putting the engine into operation after scheduled out-of-
service period
Preconditions
Putting into operation

Item Task
Lube oil system Check oil level (→ Page 187).
Cooling system Check coolant level (→ Page 200).
Cooling system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 176).
Battery-charging generator Check condition of drive belt (→ Page 208).
drive
Engine control system Switch ON.
Press READY FOR OPERATION button (→ Page 105).
LOP Press LAMP TEST button (→ Page 105).
TIM-ID: 0000002684 - 003
108 | Operation | MW15406/17E 2014-05

4.4 Starting the engine from LOP (without Blue Line automation
system)
Preconditions
☑Gearbox is in neutral position.
☑External start interlock is not activated.
☑Emergency air shut-off flaps (if fitted) are open.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Cranking the engine (out-of-service period > 1 month)

Item Measure
Engine Crank on starter (→ Page 147).
Starting the engine from LOP

Item Measure
Engine Start in unloaded condition.
System Switch on.
LOP:
• Illuminated push button LOCAL OPERATION lights up brightly (local
control mode is active) (→ Page 105);
• Illuminated push button GEARBOX NEUTRAL lights up brightly (gear-
box is disengaged) (→ Page 105).
LOP Press illuminated pushbutton READY FOR OPERATION briefly (→ Page 105).
• Illuminated pushbutton READY FOR OPERATION lights up brightly.
LOP Press illuminated pushbutton START briefly (→ Page 105).
• Illuminated pushbutton START of the relevant engine lights up brightly;
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing speed;
• After completion of the starting sequence, the engine runs at idle
speed, and the illuminated pushbutton START changes to basic bright-
TIM-ID: 0000002241 - 003
ness.
MW15406/17E 2014-05 | Operation | 109

4.5 Starting the engine with the BlueLine automation system
(control stand)
DANGER
gine's danger zone.
WARNING
Barring the engine (out-of-service period > 1 month)

Item Measure
Engine Bar with starting system (→ Page 147).
Starting the engine at the BlueLine automation system (control stand)

Item Measure
Engine Start the engine at the BlueLine automation system (control stand) (→ Blue-
Line documentation).
TIM-ID: 0000002698 - 004
110 | Operation | MW15406/17E 2014-05

4.6 Engine emergency stop at BlueLine automation system
(control stand)
NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Engine emergency stop at BlueLine automation system

Item Measure
Engine Emergency stop at BlueLine automation system (→ Operating Instructions for
BlueLine).
TIM-ID: 0000002704 - 005
MW15406/17E 2014-05 | Operation | 111

4.7 Operational checks
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operational checks
Item Measure
Engine under load Visually inspect engine for leaks and general condition
Engine at nominal speed Check for abnormal running noises and vibration
Check exhaust color (→ Page 121).
Fuel prefilter Check that contamination indicator position at the fuel prefilter is within the
permissible limit (→ Page 175).
Drain water and contaminants (→ Page 176).
Intercooler Check drain line for water discharge and obstruction (→ Page 181).
Air filter Check signal ring position of service indicator (→ Page 184).
Replace air filter (→ Page 182) if the signal ring is completely visible in the
contamination indicator control window.
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 204).
Raw-water pump Check relief bore for escaping oil and water, check for contamination
(→ Page 207).
TIM-ID: 0000002268 - 003
112 | Operation | MW15406/17E 2014-05

4.8 Coupling – Disengaging from LOP
Preconditions
☑LOCAL OPERATION illuminated pushbutton lights up brightly (local operating mode is active).
☑Engine speed in disengagement window.
Disengaging coupling without reversing gearbox (CPP, WJ, VS)

Item Measure
LOP Press COUPLING OUT illuminated pushbutton (→ Page 105).
• COUPLING OUT button flashes.
• Coupling is disengaged.
• After receiving the feedback signal from coupling, the COUPLING OUT
button is illuminated brightly.
Disengaging coupling with reversing gearbox (FPP, WJ)

Item Measure
LOP Press COUPLING NEUTRAL illuminated pushbutton (→ Page 105).
• COUPLING NEUTRAL button flashes.
• Gearbox is disengaged (neutral position).
• After receiving the feedback signal from coupling, the COUPLING NEU-
TRAL button is illuminated brightly.
TIM-ID: 0000002810 - 004
MW15406/17E 2014-05 | Operation | 113

4.9 Waterjet – Flushing from LOP (optional)
Preconditions
☑LOCAL OPERATION illuminated pushbutton is lit brightly (local operating mode is active).
☑Vessel is at a standstill and waterjet bucket is below the waterline.
☑Engine speed is in engagement window.
☑No external engagement interlock is active.
NOTICE
Waterjet flushing puts excessive strain on the bearings.
Bearing damage!
• Do not flush waterjet for too long.
• Follow instructions of the waterjet manufacturer.
Flushing with reversing gearbox and flushing mode

Item Measure
LOP Press FLUSH illuminated pushbutton and keep pressed (→ Page 105).
• FLUSH pushbutton flashes.
• Gearbox is engaged astern.
• After receiving the feedback signal from coupling, the FLUSH pushbut-
ton is illuminated brightly.
LOP Release FLUSH illuminated pushbutton.
• FLUSH pushbutton flashes.
• Gearbox is disengaged (neutral position).
• Illumination of FLUSH pushbutton is switched off as soon as the feed-
back signal from coupling is received.
TIM-ID: 0000002330 - 006
114 | Operation | MW15406/17E 2014-05

4.10 Stopping the engine from LOP (without Blue Line automation
system)
Preconditions
☑Engine is running in Local mode.
NOTICE
Stopping the engine when it is running at full load causes extreme stress to the engine.
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes
until engine temperatures have dropped and constant values are displayed.
Stopping the engine from LOP

Item Measure
LOP Disengage gearbox (→ Page 105).
LOP Operate engine at idle speed (→ Page 105).
Temperature indications Wait until engine temperatures do not fall any further.
LOP Press illuminated pushbutton STOP (→ Page 105).
• STOP pushbutton is illuminated;
• Engine at a standstill.
TIM-ID: 0000002299 - 004
MW15406/17E 2014-05 | Operation | 115

4.11 Stopping the engine at the BlueLine automation system
(control stand)
NOTICE
Stopping the engine when it is running at full load causes extreme stress to the engine.
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes
until engine temperatures have dropped and constant values are displayed.
Stopping the engine at the BlueLine automation system (control stand)

Item Measure
Engine Stop the engine at the BlueLine automation system (control stand) (→ Blue-
Line Operating Instructions).
TIM-ID: 0000002702 - 005
116 | Operation | MW15406/17E 2014-05

4.12 Emergency stop from LOP (without Blue Line automation
system)
NOTICE
An emergency stop causes extreme stress to the engine plant.
• Initiate emergency stop only in emergency situations.
Emergency stop from LOP

Item Measure
LOP Open cap of illuminated pushbutton EMERGENCY STOP (→ Page 105).
LOP Press illuminated pushbutton EMERGENCY STOP.
• Engine is stopped by disconnecting the power supply to the ECU;
• On engines with emergency air-shutoff flaps: flaps close;
• Illuminated pushbutton EMERGENCY STOP flashes, Horn, flashing
lamp etc. are tripped.
After emergency stop from LOP

Item Measure
LOP Press illuminated pushbutton ALARM ACKNOWLEDGE (→ Page 105).
• Audible and visual alarm signaling stops.
LOP Press ALARM ACKNOWLEDGE button again.
• Power supply to ECU is provided;
• Alarm has been acknowledged.
Engine On engines with emergency air-shutoff flaps: open flaps.
• Engine is ready for starting.
TIM-ID: 0000002313 - 003
MW15406/17E 2014-05 | Operation | 117

4.13 After stopping the engine
Preconditions
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.
After stopping the engine

Item Measure
Coolant circuit Drain coolant (→ Page 202) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tem-
perature;
• antifreeze concentration is 50 % and engine-room temperature is be-
low -40°C.
Raw water Drain
• if freezing temperatures are to be expected and the engine is to re-
main out of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week
tem • Seal engine's air and exhaust sides.
Engine Out-of-service-period > 1 month
• Depreserve engine (→ MTU Preservation and Represervation Specifica-
tions A001070/..)
TIM-ID: 0000002324 - 008
118 | Operation | MW15406/17E 2014-05

4.14 Plant – Cleaning
Preconditions
☑Operating voltage is not applied.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 028
• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
MW15406/17E 2014-05 | Operation | 119

5 Maintenance
5.1 Maintenance schedule reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a separate publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance activity
W0500 Check engine oil level (→ Page 187)
W0501 Visually inspect engine for leaks and general condition (→ Page 112)
W0502 Check intercooler condensate drain (if applicable) (→ Page 112)
W0503 Check service indicator of air filter (→ Page 112)
W0505 Check relief bores on coolant pump(s) (→ Page 112)
W0506 Check for abnormal running noise, exhaust gas color and vibra- (→ Page 112)
tions
W0507 Drain water and impurities from fuel prefilter (if applicable) (→ Page 112)
W0508 Check vacuum gage reading on fuel prefilter (if applicable) (→ Page 112)
W1001 Replace fuel filter or fuel filter element (→ Page 173)
W1002 Check valve clearance (→ Page 155)
W1003 Check condition and tension of drive belt, replace belt if re- (→ Page 208)
quired
W1005 Replace air filter (→ Page 182)
W1006 Replace fuel injectors (→ Page 163)
W1007 Replace fuel injection pump(s) (→ Page 159)
W1008 Replace engine oil filter when changing engine oil, or when the (→ Page 190)
interval (years) is reached, at the latest
W1009 Check layer thickness of oil residue, clean and replace filter (→ Page 192)
sleeve (if applicable) when changing engine oil, at the latest
W1011 Perform endoscopic inspection of combustion chambers (→ Page 148)
W1140 Clean wire meshes of crankcase breather (→ Page 154)
W1178 Replace pressure pipe neck in cylinder head (→ Page 164)
Table 2: Maintenance schedule reference table [QL1]

TIM-ID: 0000033854 - 002
120 | Maintenance | MW15406/17E 2014-05

6 Troubleshooting
6.1 LOP fault messages
AL RCS Speed Demand Defect
Cause Corrective action
No speed demand signal. 1. Check remote control system.
2. Check LOP visually (→ Page 223).
3. Perform LOP test procedures (→ Page 225).
4. Check ECU plug-in connections (→ Page 218).
5. Check engine wiring (→ Page 214).
AL Battery Charger Failure

Battery not being charged. 1. Check power circuit breakers and fuses.
2. Check transistorized regulator.
3. Check drive belt (→ Page 209).
AL Press. Monitoring Fail (EMU)

EMU pressure monitoring u Contact Service.
failure. • Have EMU replaced.
AL ECU Defective
ECU 4 is defective. 1. Check LOP visually (→ Page 223).
2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
• have ECU checked and replaced, if required.
AL Output Stage Bank 1 Fault

Fault message of power output 1. Check LOP visually (→ Page 223).
stage, cylinder bank A 2. Perform LOP test procedures (→ Page 225).
TIM-ID: 0000042361 - 001

5. Contact Service.
MW15406/17E 2014-05 | Troubleshooting | 121

AL Output Stage Bank 2 Fault
Fault message of power output 1. Check LOP visually (→ Page 223).
stage, cylinder bank B 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
AL Gear Control Fail GCU

GCU fault. u Contact Service.
• Have GCU solenoid checked and replaced, if required.
• Have GCU wiring checked and replaced, if required .
AL Gear Oil Filter Clogged

Gear oil filter clogged. u Clean gear-oil filter and replace, if required (see gearbox
documentation).
AL Override Activated
Safety system override is active. u Status message:
• Override activated.
AL Power Failure Control

Power failure of control system. u Check power circuit breakers and fuses.
AL Power Failure Monitoring

Power failure. u Check power circuit breakers and fuses.
AL Transistor Output 1/2 Fail

One of the ECU 4 transistor u Contact Service.
TIM-ID: 0000042361 - 001
outputs (TAA1 or TAA2) • have ECU checked and replaced, if required.

defective.
AL Transistor Output 3/4 Fail

One of the ECU 4 transistor u Contact Service.
outputs (TAA3 or TAA4) • have ECU checked and replaced, if required.
defective.
122 | Troubleshooting | MW15406/17E 2014-05

AL Water in Fuel Prefilter
Water in fuel prefilter. u Drain fuel prefilter (→ Page 176).
DL 211+A001-A001
DIS not detected on default CAN 1. Check LOP visually (→ Page 223).
bus. 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
• Have DIS checked and replaced, if required.
DL 211+A001-A010
LCU of LOP 1 (PIM No. 21.X 1. Check LOP visually (→ Page 223).
+A001-A010) not detected on 2. Perform LOP test procedures (→ Page 225).
default CAN bus. 3. Check ECU plug-in connections (→ Page 218).
5. Contact Service.
• Have MPU 23 of PIM No. 21.X+A001-A010 checked and
replaced, if required.
DL 211+A001-A020
LMU of LOP 1 (PIM No. 21.X 1. Check LOP visually (→ Page 223).
default CAN bus. 3. Check ECU plug-in connections (→ Page 218).
5. Contact Service.
DL 211+A002-A030
GCU 1 (PIM No. 21.X+A002- 1. Check LOP visually (→ Page 223).
A030) not detected on default 2. Perform LOP test procedures (→ Page 225).
CAN bus. 3. Check ECU plug-in connections (→ Page 218).
TIM-ID: 0000042361 - 001
5. Contact Service.
• Have GCU/GMU checked and replaced if required.

DL 211+A002-A040
GMU 1 (PIM No. 21.X+A002- 1. Check LOP visually (→ Page 223).
A040) not detected on default 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
DL 211+A003-ECU
ECU 4 not detected on default 1. Check LOP visually (→ Page 223).
CAN bus. 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
DL 211+A004-EMU
EMU 1 not detected on default 1. Check LOP visually (→ Page 223).
CAN bus. 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
• have EMU checked and replaced, if required.
DL 211+A300-A500
RCS with PIM No. 21.X+A300- 1. Check LOP visually (→ Page 223).
A500 not detected on default 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
• Have RCS checked and replaced, if required.
DL 211+A300-A501
PCU (PIM No. 21.X+A300-A501) 1. Check LOP visually (→ Page 223).
TIM-ID: 0000042361 - 001
not detected on default CAN 2. Perform LOP test procedures (→ Page 225).
bus. 3. Check ECU plug-in connections (→ Page 218).
5. Contact Service.
• Have PCU checked and replaced, if required.

HI P-Oil Filter Fifference
Oil pressure difference between u Replace engine oil filter (→ Page 190).
oil pressures before and after
filter too high.
MG Disengagement Fault
RCS message. u Contact Service.
MG Eng Speed High/Low (Clutch)

RCS message. u Speed reduction
MG Engagement Fault
RCS message. u Contact Service.
MG Check Start Interlocks

Start conditions are not u Check start conditions and fulfill if necessary.
fulfiulled.
RL 211+A001-A001
DIS not detected on redundant 1. Check LOP visually (→ Page 223).
bus 2. Perform LOP test procedures (→ Page 225).
3. Contact Service.
• Have DIS checked and replaced, if required.
RL 211+A001-A010
TIM-ID: 0000042361 - 001
LCU of LOP 1 (PIM No. 21.X 1. Check LOP visually (→ Page 223).
redundant CAN bus. 3. Contact Service.

RL 211+A001-A020
LMU of LOP 1 (PIM No. 21.X 1. Check LOP visually (→ Page 223).
RL 211+A002-A030
GCU 1 (PIM No. 21.X+A002- 1. Check LOP visually (→ Page 223).
A030) not detected on 2. Perform LOP test procedures (→ Page 225).
RL 211+A002-A040
GMU 1 (PIM No. 21.X+A002- 1. Check LOP visually (→ Page 223).
A040) not detected on 2. Perform LOP test procedures (→ Page 225).
RL 211+A003-ECU
ECU 4 not detected on 1. Check LOP visually (→ Page 223).
redundant CAN bus. 2. Perform LOP test procedures (→ Page 225).
4. Contact Service.
RL 211+A004-EMU
EMU 1 not detected on 1. Check LOP visually (→ Page 223).
redundant bus 2. Perform LOP test procedures (→ Page 225).
3. Contact Service.
RL 211+A300-A500
TIM-ID: 0000042361 - 001

RCS with PIM No. 21.X+A300- 1. Check LOP visually (→ Page 223).
A500 not detected on redundant 2. Perform LOP test procedures (→ Page 225).
CAN bus. 3. Contact Service.
• Have RCS checked and replaced, if required.

RL 211+A300-A501
PCU (PIM No. 21.X+A30-A501) 1. Check LOP visually (→ Page 223).
not detected on redundant CAN 2. Perform LOP test procedures (→ Page 225).
bus. 3. Contact Service.
• Have PCU checked and replaced, if required.
SS Safety System Failure (EMU)

Safety system has detected fault u Contact Service.
on Engine Monitoring Unit.
SS Power Reduction Active

Safety system has requested 1. Determine cause of automatic power reduction.
power reduction. 2. Observe further display messages/alarms.
3. Contact Service.
SS Emergency Stop
Safety system has initiated an 1. Determine cause for shutoff and rectify.
emergency stop 2. Observe further display messages/alarms.
SS Emergency Stop External

Safety system has carried out an 1. Determine cause for shutoff and rectify.
externally triggered emergency 2. Observe further display messages/alarms.
stop.
SS P-Gear Lube Oil (GCU)

Safety system detects that gear u Check gearbox lube-oil level and top up, if required (see
control oil pressure is too low. gearbox documentation).
SS P- Gear Lube Oil (GMU)

TIM-ID: 0000042361 - 001
Safety system detects that gear u Check gearbox lube-oil level and top up, if required (see
lube oil pressure is too low. gearbox documentation).
SS P-Gear Control Oil (GCU)

Safety system detects that gear u Check gearbox control-oil level and top up, if required (see

SS P- Gear Control Oil (GMU)
Safety system detects that gear u Check gearbox control-oil level and top up, if required (see
SS P-Coolant
Safety system detects that u Check coolant level and top up if required (→ Page 200).
coolant pressure is too low.
SS P-Lube Oil (ECU)

Safety system detects that 1. Check lube-oil level and top up if required (→ Page 187).
engine-oil pressure is too low. 2. Contact Service.
SS P-Lube Oil (EMU)

Safety system detects that 1. Check lube-oil level and top up if required (→ Page 187).
engine-oil pressure is too low. 2. Contact Service.
SS Security Channel Def EMU

Safety system fault message. u Contact Service.
SS SDAF Closed
Safety system reports closed u Open emergency-air shutoff flaps (→ Page 185).
emergency-air shutoff flaps.
SS Security Shutdown
Safety system has triggered u Determine cause for shutoff and rectify.
engine stop.
SS T-Coolant (ECU)
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Safety system detects that u Reduce power.
coolant temperature is too high.

SS T-Coolant (EMU)
Safety system detects that the u Reduce power.
engine coolant temperature is
too high.
SS T-Lube Oil
Safety system detects that lube u Reduce power.
oil temperature is too high.
Stop Activated (EMU)

EMU has triggered automatic 1. Determine cause for shutoff and rectify.
stop command due to limit value 2. Observe further display messages/alarms.
violation.
TD P-Lube Oil
The two lube-oil pressure 1. Check LOP visually (→ Page 223).
sensors provide different values. 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
• Have sensors checked and replaced, if required.
TD T-Coolant
The two coolant temperature 1. Check LOP visually (→ Page 223).
sensors provide different values. 2. Perform LOP test procedures (→ Page 225).
5. Contact Service.
• Have sensors checked and replaced, if required.
Trolling Active
RCS measuring point. u Status report ("Trolling Active" lamp on).
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Cylinder cutout
Measuring point "Cylinder u Status report for "cylinder cutout/number of cylinders halved"
cutout active". during idling

6.2 Troubleshooting
Engine does not turn when starter is actuated
Battery flat or defective. u Charge or replace battery (see manufacturer's documentation).
Cable connections on battery u Check if cable connections are properly secured (see
are defective. manufacturer's documentation).
Engine wiring or starter u Check if cable connections are properly secured, contact
defective. Service.
Engine wiring faulty. u Check (→ Page 214).
Assemblies are not correctly u Perform visual inspection (→ Page 223).
connected in control panel LOP.
Plug-in connections at LOP
control panel are loose.
Plug connection are loose at u Check plug connections (→ Page 218).
engine control unit ECU.
Engine blocked (cannot be u Contact Service.
rotated by hand).
Start interlock limit switch is not u Check limit switch (→ Page 217).
installed.
Start interlock limit switch is u Check limit switch (→ Page 217).
defective.
Wiring of start interlock limit u Check wiring (→ Page 214).
switch is faulty.
Engine turns but does not fire

Poor rotation by starter: Battery u Charge or replace battery (see manufacturer's documentation).
flat or defective.
Air in fuel system. u Vent fuel system (→ Page 171).
Engine control unit ECU is u Contact Service.
defective.
Engine fires unevenly

Injector faulty. u Replace (→ Page 163).
Injection pump faulty. u Replace (→ Page 160).
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defective.

Engine does not reach full load speed
Fuel supply blocked. u Completely open shutoff valve upstream of fuel prefilter.
Fuel prefilter clogged. u Replace filter element (→ Page 179).
Easy-change fuel filter clogged. u Replace (→ Page 173).
Air filter clogged. u Check signal ring position of contamination indicator
(→ Page 184).
Overload. u Contact Service.
Vessel too heavy. u Check load.
Reduce load.
Trim position incorrect. u Trim vessel.
Marine growth on hull, propeller u Clean components.
shaft, propeller, rudder.
Rudder position incorrect. u Align rudder.
Propeller too big after u Install suitable propeller.
replacement.
Engine speed not steady

Speed sensor is faulty. u Contact Service.
defective.
Charge-air temperature too high

Incorrect engine coolant u Check (MTU test kit).
concentration.
Charge-air cooler is u Contact Service.
contaminated.
Air inlet temperature in engine u Check fan
room is too high. Check air inlet/outlet ducts.
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Charge-air pressure too low

(→ Page 184).
Charge-air cooler is u Contact Service.
contaminated.
Exhaust turbocharger faulty. u Contact Service.

Coolant leaks at intercooler
Major coolant discharge at u Contact Service.
charge-air cooler. Charge-air
cooler leaky.
Black exhaust gas

(→ Page 184).
Overload. u Contact Service.
Blue exhaust gas

Too much oil in engine. u Drain engine oil (→ Page 188).
Oil separator or oil preseparator u Replace (→ Page 152).
of crankcase breather clogged.
Exhaust turbocharger faulty. u Contact Service.
Cylinder head is faulty. u Contact Service.
Piston rings are defective. u Contact Service.
Cylinder liner defective. u Contact Service.
White exhaust gas

Engine is not at operating u Run engine to reach operating temperature.
temperature.
Water in fuel. u Check fuel system at fuel prefilter.
Drain fuel prefilter (→ Page 176).
Charge-air cooler leaky. u Contact Service.
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7 Task Description
7.1 SOLAS
7.1.1 SOLAS shielding as per MTN 5233 – Installation
Preconditions

Shield A4 735233000100 10
Shield A5 735233000101 14
Shield A7 735233000103 6
Shield A8 735233000104 2
SOLAS shielding – Installation

1. Pinpoint installation location (→ Page 136).
2. Install suitable shielding.
3. Press shielding until locked.
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MW15406/17E 2014-05 | Task Description | 133

7.1.2 SOLAS shielding – Installation as per MTN 5233
Preconditions

Shield A4 735233000100 5
Shield A5 735233000101 7
Shield A7 735233000103 6
Shield A8 735233000104 2
Installing SOLAS shielding

3. Press shielding until locked.
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134 | Task Description | MW15406/17E 2014-05

7.1.3 SOLAS shielding – Installation
Preconditions
☑Engine is cooled down to ambient temperature.

Oil filter shield X00009628
Fuel filter shield X00009654
Installing SOLAS shield on oil fil-

ter and fuel filter
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7.1.4 Installation locations for SOLAS shielding
General information
Primarily fit SOLAS shielding as per MTN 5233 (→ Page 133).
On crankcase
Item Type of shielding Remarks

1 Shield (A4) On brazed-on union
2 Shield (A5) On crankcase
Free end B-side
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1 Shield (A7) On fuel delivery pump
Free end
B-side

Free end B-side

1 Shield (A7) On HP fuel pump
Free end
B-side
Free end
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1 Shield (A7) Above fuel priming pump.
Free end

Free end

1 Shield (A7) Below fuel priming pump.
Free end
Free end
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1 Shield (A8) On fuel filter housing
Free end

Driving end A-side

1 Shield (A5) On valve plate
Driving end
Driving end A-side

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1 Shield (A5) On air flap control
Driving end
2 Shield (A4) On brazed-on union
Driving end
3 Shield (A5) On exhaust turbocharger flap control.
Driving end
4 Shield (A5) On exhaust turbocharger flap control.
Driving end

Driving end

1 Shield (A4) Exhaust turbocharger lubrication.
Driving end
2 Shield (A4) On brazed-on union.
Driving end
Driving end
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1 Shield (A4) Exhaust turbocharger lubrication.
Driving end

7.1.5 Installation locations for SOLAS shielding
General information
Primarily fit SOLAS shielding as per MTN 5233 (→ Page 133).
Free end B-side
Item Type of shielding Comments

1 (free end, B-side) Shield (A7) On fuel delivery pump
2 (free end, B-side) Shield (A7) On HP fuel pump
Free end
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1 (free end) Shield (A8) On fuel filter
2 (free end) Shield (A7) Above fuel priming pump
3 (free end) Shield (A7) Below fuel priming pump
Driving end A-side

1 (Driving end, A-side) Shield (A5) On air flap
2 (driving end, A-side) Shield (A4) On brazed-on union
3 (driving end, A-side) Shield (A5) On turbocharger flap
4 (driving end, A-side) Shield (A5) On turbocharger flap
Driving end A-side
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1 (Driving end, A-side) Shield (A5) To turbocharger lubrication
2 (driving end, A-side) Shield (A5) On valve plate
Driving end

1 (driving end) Shield (A4) Turbocharger lubrication, left side
2 (driving end) Shield (A4) Turbocharger lubrication, center
Driving end
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1 (driving end) Shield (A4) Turbocharger lubrication, right
side

Driving end B-side

1 (driving end, B-side) Shield (A5) Turbocharger flap
2 (driving end, B-side) Shield (A5) Turbocharger flap
3 (driving end, B-side) Shield (A4) On brazed-on union
4 (driving end, B-side) Shield (A5) On air flap
5 (driving end, B-side) Shield (A4) To turbocharger lubrication
Driving end B-side
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1 (driving end, B-side) Shield (A5) On valve plate

Driving end A-side

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

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

7.2 Engine
7.2.1 Engine ‒ Barring manually
Preconditions

Ratchet F30006212 1
Socket F30005655 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Engine ‒ Barring manually

1. Remove cover plate (2).
2. Attach ratchet with socket to barring de-
vice.
3. Rotate crankshaft in engine direction of ro-
tation. No resistance other than compres-
sion resistance may be encountered.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
4. For barring device removal, follow reverse
sequence of working steps.
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7.2.2 Engine – Barring with starting system
Connector pliers F30017884 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Engine – Barring with starting

system
1. Disengage the bayonet coupling (4) of con-
nector X4 with connector pliers (2) and
withdraw connector (3) from engine gover-
nor.
2. Bar engine in unloaded condition: Press
START button.
3. Let the crankshaft rotate until oil pressure
is indicated.
4. Engine start is automatically interrupted
when specified starting period is expired. If
necessary, re-start the engine after approx.
20 seconds.
5. Plug connector X4 (3) and use connector
pliers (2) to secure the bayonet cou-
pling (4) by turning it clockwise until it
latches into place.
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7.3 Cylinder Liner
7.3.1 Cylinder liner – Endoscopic examination
Preconditions
☑Engine is stopped and starting disabled

Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 158).
2. Remove injector (→ Page 166).
Positioning crankshaft at BDC

1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached
BDC.
2. Insert endoscope into cylinder liner through injector seat.
Cylinder liner – Endoscopic examination

Findings Task
• Thin carbon coating around circumference of carbon scraper ring No action required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark around circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Darker areas of even or varying color intensity Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and tion required as part of mainte-
do not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining cir-
cumference cannot be faulted
• Piston rings faultless
• On the entire circumference not only bright discoloration (not criti- Cylinder liner must be replaced,
cal for operation) clearly visible darker stripes that begin at the top contact Service.
piston ring
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• Heat discoloration in the direction of stroke and honing pattern

damage
• Heat discoloration of piston rings
1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 150).
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 steps
1. Install injector (→ Page 166).
2. Install cylinder head cover (→ Page 158).
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7.3.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex-
amination report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after
further operation of the engine.
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7.4 Crankcase Breather
7.4.1 Crankcase ventilation – Oil separator element replacement, diaphragm check
and replacement
Preconditions

Torque wrench, 6-50 Nm F30027336 1
Ratchet adapter F30027340 1
Filter element (→ Spare Parts Catalog)
Diaphragms (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing filter element of oil

separator
1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element into housing (4)
ensuring correct position, and fit end cov-
er (2) with new O-ring.
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4. Tighten screws of cover (2) to specified tightening torque.

Name Size Type Lubricant Value/Standard
Screw Tightening torque 6 Nm + 2 Nm
5. Replace further oil separator elements in the same way.

Checking diaphragms
1. Remove cover (4).
2. Take off spring (5), gasket (2) and dia-
phragm (3).
3. Check diaphragm (3) for damage.
4. Replace diaphragm if damaged.
5. Install diaphragm (3) on housing (1).
6. Install new gasket (2) and spring (5) togeth-
er with cover (4).
7. Tighten screws of cover (4) to specified tightening torque.

Screw Tightening torque 6 Nm + 2 Nm
8. Check diaphragms in further oil separators in the same way.
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7.4.2 Crankcase breather – Cleaning oil separator element
Preconditions

Fuel
Gasket (→ Spare Parts Catalog)
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Crankcase breather – Cleaning

oil separator element
1. Remove cover (1) from housing (4).
2. Remove oil separator (2) and gasket (3).
3. Clean oil separator (2) in fuel and blow dry
with compressed air.
4. Moisten oil separator (2) with engine oil.
5. Place oil separator (2) with new gasket (3)
onto housing (4) and install cover (1).
6. Clean other oil separator element in the
same way.
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7.5 Valve Drive
7.5.1 Valve clearance – Check and adjustment
Preconditions
☑Engine coolant temperature is max. 40 °C.
☑Valves are closed.

Box wrench bit, 17 mm F30030450 1
Feeler gauge Y4342013 1
Preparatory steps
1. Remove cover plate (2).
3. Bar engine manually in engine direction of
rotation until the markings (1) are aligned.
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Checking valve clearance at two
crankshaft positions
1. Check TDC position of piston in cylinder
A1:
• If the rocker arms are not under load on
cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cyl-
inder A1, the piston is in overlap TDC.
2. Check valve clearance with the engine
cold:
• Inlet = 0.4 mm;
• Exhaust = 0.6 mm;.
3. Check all valve clearances in two crank-
shaft positions (firing TDC and overlap TDC
of cylinder A1) as per diagram:
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use feeler gauge to determine the distance
between valve bridge and rocker arm.
5. If the deviation from the set value exceeds
0.1 mm, adjust valve clearance.
Adjusting valve clearance

1. Loosen locknut (1) and unscrew adjusting
screw (2) slightly.
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. TIM-ID: 0000004360 - 006
4. Tighten locknut (1) applying the specified tightening torque, holding adjusting screw (2) firmly with
screwdriver.
Locknut M12x1 Tightening torque 50 Nm

5. Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through
the gap.
Result: If not, adjust valve clearance.
Final steps
1. Remove barring device.
2. For installation of removed parts, follow reverse sequence of working steps.
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7.5.2 Cylinder head cover – Removal and installation
Preconditions

Centering jig F6783025 1
Sealing (→ Spare Parts Catalog)
Preparatory steps
1. Remove air filter (→ Page 183).
2. Remove air guide housing.
Removing and installing cylin-

der head cover
1. Remove screws (1).
2. Remove cylinder head cover (2) with gas-
ket from cylinder head.
3. Clean installation surface.
4. Check condition of gasket of cylinder head
cover.
Result: Replace damaged seals.
5. Align cylinder head cover (2) with centering
jig.
6. Tighten screws (1) to specified torque
20 Nm using a torque wrench.
Final steps
1. Install air filter (→ Page 183).
2. Install air guide housing.
3. Check cylinder head covers for leaks.
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7.6 Injection Pump / HP Pump
7.6.1 Injection pump – Replacement
Injection pump (→ Spare Parts Catalog)
Injection pump – Replacement

u Remove injection pump and install new one (→ Page 160).
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7.6.2 Injection pump – Removal and installation
Preconditions

Box wrench F30038493 1
Spider patch spanner, AF19 F30027424 1
Spider patch spanner, AF22 F30027425 1
Torque wrench, 0.5-5 Nm 0015384230 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933
Sealing ring (→ Spare Parts Catalog)
DANGER
gine's danger zone.
WARNING
• Do not smoke.
Preparatory steps
1. Close fuel supply line upstream of fuel filter.
2. Remove engine control system (→ Page 220).
3. Drain fuel (→ Page 170).
4. Remove charge-air pipes and all seals.
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Removing injection pump
1. Mark installation position of injection
pump.
2. Disconnect wiring (1) from injection pump.
3. Disconnect fuel line (2).
4. Unscrew injection pump securing screws
by approx. 6 mm.
Result: The preloaded compression spring presses
the injection pump out of the crankcase; if
not:
• Turn crankshaft with barring gear
(→ Page 146).
The pump cam on the camshaft presses
the injection pump out of the crankcase;
if not:
• Carefully press out injection pump at the
recess in the injection pump head.
5. Remove injection pump securing screws.
6. Remove injection pump.
7. Remove sealing rings from injection pump.
8. After removal, seal all openings with suita-
ble covers.
Installing injection pump

1. Remove all blanking plugs and covers.
2. Clean mating face of injection pump and
roller.
Note: Sealing ring (1) Ø47 mm
3. Coat sealing ring (1) with grease (Kluthe
Hakuform 30-10/Emulgier) and wind on to
injection pump.
Note: Sealing ring (2) Ø45 mm
4. Coat sealing ring (2) with grease (Kluthe
Hakuform 30-10/Emulgier) and wind on to
injection pump.
5. Coat roller (arrowed) with engine oil.
6. Clean sealing face and fuel bores in crank-
case.
7. Use barring gear (→ Page 146) to position
the pump cams on the camshaft at base
circle.
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8. Install injection pump, observing marked
installation position.
9. Install securing screws of injection pump and tighten to specified torque using a torque wrench.
Securing screw Tightening torque 60 Nm + 12 Nm
10. Install fuel line (2).
11. Tighten union nut on injection pump to specified torque using a torque wrench.
• Maximum permissible tightening torque: 35 Nm
Union nut Tightening torque 20 Nm + 5 Nm
12. Tighten union nut on pressure pipe neck to specified torque using a torque wrench.
• Maximum permissible tightening torque: 35 Nm
13. Install injection pump wiring (1).
14. Tighten screws to specified torque using a torque wrench.
Screw Tightening torque 1.0 Nm ± 0.2 Nm
Final steps
1. Remove engine barring gear (→ Page 146).
2. Clean mating faces on cylinder head and charge-air manifold.
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3. Check gaskets for damage and replace as necessary.

4. Coat gaskets with grease (Kluthe Hakuform 30-10/Emulgier) and place onto cylinder head.
5. Install charge-air pipes.
6. Install engine control system (→ Page 220).
7. Open fuel supply line before fuel filter.
8. Vent fuel system (→ Page 171).

7.7 Injection Valve / Injector
7.7.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 166).
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7.7.2 HP fuel line – Pressure pipe neck replacement
Preconditions

Open-end wrench bit F30025897 1
Spider patch spanner F30027425 1
Double-head box wrench F30011450 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933
Engine oil
Pressure pipe neck (→ Spare Parts Catalog)
WARNING
Fuels are flammable and explosive.
Danger to life! Risk of burns!
• Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and goggles / safety mask.
WARNING
Preparatory steps
Replacing pressure pipe neck

1. Remove fuel line (3).
2. Remove thrust screw (2).
3. Pull off pressure pipe neck (1).
4. Coat sealing ring with grease (Kluthe Haku-
form 30-10/Emulgier) and wind on to new
pressure pipe neck (1).
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5. Blow out fuel line (3) with compressed air.

6. Moisten taper of pressure pipe neck with
engine oil.
7. Insert pressure pipe neck into cylinder
head until it is in contact with the sealing
ring.
8. Fully press in pressure pipe neck (1) by
hand.

9. Tighten thrust screw (2) to specified torque using a torque wrench.
Thrust screw Tightening torque 40 Nm ± 5 Nm
Final steps
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7.7.3 Injector – Removal and installation
Preconditions

Puller 3555890163/00 1
Fuel suction device F30378207 1
Open-end wrench bit F30025897 1
Double-head box wrench F30011450 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
WARNING
• Do not smoke.
WARNING
Preparatory steps
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Removing injector
1. Remove leak-off-fuel lines.
2. Remove fuel line (3).
3. Remove thrust screw (2).
4. Pull off pressure pipe neck (1).
5. Extract fuel from the exposed bores using
the suction device.
6. Remove screw (5).

7. Take off clamp (4).
8. Screw puller into injector.
9. Remove injector with puller.
10. Remove injector sealing ring (1) using a
self-made hook.
11. After removal, seal all openings with suita-
ble covers.
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Installing injector
1. Remove all covers before installation.
2. Clean sealing surface on cylinder head and
protective sleeve.
3. Coat sealing ring (1) with grease and fit on-
to injector.
4. Coat sealing ring (2) with grease and fit on-
to injector.
5. Press injector (3) into cylinder head by
hand.
Result: • The pin is at 11-o'clock position to the
transversal axis of the engine.
• Pin is in recess of clamp (4).
6. Install clamp (4) with screw (5), positioning
it correctly.
Result: • Pin on injector is in the recess in the
clamp.
• Forked clamp end is engaged in the cov-
er recess.
7. Tighten screw (5) of the clamp by hand.
Result: Injector can still be turned.
8. Blow out fuel line (3) and pressure pipe
neck (1) with compressed air.
9. Coat sealing ring with grease and fit onto
pressure pipe neck (1).
10. Moisten taper of pressure pipe neck with
engine oil.
11. Insert pressure pipe neck into cylinder
head until it is in contact with the sealing
ring.
12. Fully press in pressure pipe neck (1) by
hand.
13. Tighten thrust screw (2) to specified torque using a torque wrench.
Thrust screw Tightening torque 40 Nm ±5 Nm
14. Tighten screw for clamp at injector to specified torque using a torque wrench.
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Screw Tightening torque 50 Nm
Union nut Tightening torque 20 Nm +5 Nm

Union nut Tightening torque 20 Nm +5 Nm
18. Install leak-off-fuel lines.
Final steps
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7.8 Fuel System
7.8.1 Fuel – Draining
Preconditions
WARNING
• Do not smoke.
Draining fuel
1. Release threaded vent plugs on filter head.
2. Open nipple on fuel line and drain fuel into

appropriate container.
3. When fuel stops emerging from system,
close nipple on fuel line.
4. Close threaded vent plugs on filter head.
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7.8.2 Fuel system – Venting
Preconditions
WARNING
• Do not smoke.
Venting fuel system

1. Unlock fuel priming pump, unscrew handle.
2. Open vent plugs on filter head.

3. Operate the pump with the handle until
bubble-free fuel emerges at the vent plugs.
4. Close vent plugs on filter head.
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5. Open nipple at fuel heat exchanger.
bubble-free fuel emerges at the nipple.
7. Close nipple at fuel heat exchanger.
8. Open nipple at fuel line.

bubble-free fuel emerges at the nipple.
10. Close nipple at fuel line.
11. Lock fuel priming pump, screw in handle.
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7.9 Fuel Filter
7.9.1 Fuel filter – Replacement
Preconditions

Oil filter wrench F30379104 1
Fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)
DANGER
WARNING
Fuels are flammable and explosive.
Danger to life! Risk of burns!
• Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and goggles / safety mask.
WARNING
Loud engine noises with the engine running:
Risk of hearing damage!
• Wear ear protection.
NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.
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Replacing easy-change fuel filter
with engine stopped
1. Cut out the filter to be replaced.
A Both filters cut in (operating posi-
tion)
B Left filter cut out
C Right filter cut out
2. Unscrew switched off easy-change filter
with oil filter wrench.
3. Clean sealing surface on filter head.
4. Check seal on new easy-change filter and
moisten with fuel.
5. Fit SOLAS shield (→ Page 18).
6. Screw on easy-change filter and tighten by
hand.
7. Set three-way cock to operating position
(both filters cut in).
8. Replace further fuel filters in the same way.
Replacing easy-change fuel filter

with engine running
2. Open the threaded vent plugs at the filter
head of the cut-out filter and make sure
that the fuel filter is not pressurized.
3. Close threaded vent plugs.
4. Unscrew switched off easy-change filter
with oil filter wrench.
5. Clean sealing surface on filter head.
6. Check seal on new easy-change filter and
moisten with fuel.
8. Screw on easy-change filter and tighten by
hand.
9. Set three-way cock to operating position
(both filters cut in).
10. Replace further fuel filters in the same way.
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7.9.2 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
WARNING
Differential pressure gauge ad-

justment
1. When installing the new filter element:
align adjustable pointer (2) with pressure-
indicating pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within
the limit.
Fuel prefilter – Checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of
pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 177).
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7.9.3 Fuel prefilter – Draining
Preconditions

Diesel fuel
Seal (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Fuel prefilter – Draining

1. Cut out the filter to be drained.
I Left filter cut in
II Right filter cut in
2. Open threaded vent plug (5) of the filter to

be drained.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from the fil-
ter until pure fuel emerges.
5. Close drain valve (6).
6. Remove screws securing the cover and
take off cover (2).
7. Fill filter housing with clean fuel.
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8. Place new seal in cover (2).

9. Fit cover with gasket and secure it with
screws.
10. Cut in the cut-out filter again.
11. Close threaded vent plug (5) when fuel
emerges from system.

7.9.4 Fuel prefilter – Flushing
Fuel
DANGER
WARNING
• Do not smoke.
WARNING
Fuel prefilter – Flushing

1. Cut out the contaminated filter.
1 Left filter cut in
2 Right filter cut in
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2. Open threaded 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 to the un-
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close threaded vent plug (5) and drain
cock (6).
Fuel prefilter – Filling with fuel

1. Stop engine (→ Page 115) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
4. Place new seal in cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 175).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel pre-
filter (→ Page 179).
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7.9.5 Fuel prefilter – Filter element replacement
Preconditions

Fuel
Filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing filter element

1. Cut out the contaminated filter.
I Left filter cut in
II Right filter cut in
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2. Open threaded vent plug (5) of contaminat-
ed filter.
3. Unlock drain valve (6) by pressing toggle
and open.
4. Drain water and contaminants from the fil-
ter.
5. Close drain valve (6).
6. Remove screws securing cover and take off
cover (2).
7. Remove spring housing (4) and filter ele-
ment (3).
8. Insert new filter element (3) and spring
housing (4).
10. Place new gasket in cover (2).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Set adjustable pointer of differential pres-
sure gage (→ Page 175).
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7.10 Charge-Air Cooling General, Left-Hand Side
7.10.1 Intercooler ‒ Checking condensate drain line for coolant discharge and
obstruction
DANGER
WARNING
WARNING
Intercooler ‒ Checking conden-

sate drain line for coolant dis-
charge and obstruction
1. With the engine running, check the conden-
sate drain line on engine driving end for air
discharge.
2. If no air emerges, remove condensate drain
line and blow out with compressed air.
3. Replace obstructed drain line by new one.
4. Install condensate drain line.
5. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con-
tact Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 163).
2. Bar engine manually (→ Page 146).
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3. Bar engine with starting system to blow out cylinder chambers (→ Page 147).
4. Install injectors (→ Page 166).

7.11 Air Filter
7.11.1 Air filter – Replacement
Air filter (→ Spare Parts Catalog)
Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 183).
2. Reset signal ring of contamination indicator (→ Page 184).
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7.11.2 Air filter – Removal and installation
Preconditions
Air filter – Removal and installa-

tion
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from
connecting flange of intake housing (3).
3. Verify that there are no objects in the
flange of the intake housing (3) and clean
it.
4. Place new air filter (1) with clamp (2) onto
intake housing (3).
5. Tighten clamp (2).
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7.12 Air Intake
7.12.1 Service indicator – Signal ring position check (optional)
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 182).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves
back to initial position.
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7.12.2 Air-flow control flap – Ease of movement check
Preconditions
Air-flow control flap – Check for

ease of movement
1. Actuate lever several times by hand, mov-
ing it between positions “A” and “B” to
check for ease of movement.
2. If the lever does not move freely, contact
Service.
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7.13 Starting Equipment
7.13.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 214).
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7.14 Lube Oil System, Lube Oil Circuit
7.14.1 Engine oil – Level check
Preconditions
Checking oil level prior to en-

gine start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds
and check oil level.
3. Oil level must be between “min.” and
“max.” marks.
Result: If there is no mark, mark the oil dipstick
(→ Page 189).
4. If necessary, top up to "max." mark
(→ Page 188).
5. Insert oil dipstick into guide tube up to the
stop.
Checking oil level after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between “min.” and “max.” marks.
Result: If there is no mark, mark the oil dipstick (→ Page 189).
4. If necessary, top up to "max." mark (→ Page 188).
5. Insert oil dipstick into guide tube up to the stop.
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7.14.2 Engine oil – Change
Preconditions
☑Engine is at operating temperature.

Engine oil
WARNING
Hot oil.
Oil change without semirotary hand pump: Draining oil at drain plug on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug and drain oil.
3. Install drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 190).
Oil change with semirotary hand pump: Oil extraction

1. Provide a suitable container to collect the oil.
2. Extract all oil from oil pan using the semirotary hand pump.
3. Replace engine oil filter (→ Page 190).
Filling with new oil

1. Open cover on filler neck.
2. Pour oil in at filler neck up to "max." mark
at oil dipstick.
3. Close cover on filler neck.
4. Check engine oil level (→ Page 187).
5. After oil change and filter replacement, bar
engine with starting system (→ Page 147).
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7.15 Oil Filtration / Cooling
7.15.1 Oil dipstick — Marking
Preconditions

Engine oil
Oil dipstick (→ Spare Parts Catalog)
WARNING
Hot oil.
Note: In the case of new engines and spare parts, oil dipsticks are delivered without marks.
Oil dipstick — Marking

1. Extract or drain off all oil from oil pan.
2. Pull out oil dipstick.
3. Fill in minimum oil quantity (→ engine data).
4. Insert oil dipstick and pull out again.
5. Mark a "Min." notch on the oil dipstick. Max. notch depth 1 mm.
6. Shorten oil dipstick as necessary.
7. Fill in maximum oil quantity (→ engine data).
8. Insert oil dipstick and pull out again.
9. Mark a "Max." notch on the oil dipstick. Max. notch depth 1 mm.
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7.15.2 Engine oil filter – Replacement
Engine oil
Oil filter (→ Spare Parts Catalog)
SOLAS shield (→ Spare Parts Catalog)
DANGER
WARNING
WARNING
Hot oil.
NOTICE
Damage to component!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.
Replacing oil filter with the en-

gine stopped
1. Stop engine (→ Page 115) and disable en-
gine start.
A Right filter cut out
B Both filters cut in (normal operating
position)
C Left filter cut out
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3. Unscrew cut-out oil filter with oil filter
wrench.
4. Clean sealing surface on connecting piece.
5. Check condition of new oil filter sealing
ring and coat it with oil.
7. Screw on and tighten new oil filter by hand.
8. Replace other oil filters in the same way.
9. Switch filter to normal position.
10. After each oil change and filter replace-
ment, crank engine with starting system
(→ Page 147).
11. Check oil level (→ Page 187).
Replacing oil filter with the engine running

1. Reduce engine speed to <1100 rpm.
2. Unscrew cut-out oil filter with oil filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing ring and coat it with oil.
6. Screw on and tighten new oil filter by hand.
7. Replace other oil filters in the same way.
8. Switch filter to normal position.
9. Check oil level (→ Page 187).
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7.15.3 Centrifugal oil filter and filter sleeve – Cleaning and replacement
Preconditions

Cold cleaner(Hakutex 50) X00056751 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Removing rotor of centrifugal oil

filter
1. Release nuts (3).
2. Remove housing cover (1).
3. Remove complete rotor (2) from housing.
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Cleaning centrifugal oil filter
and replacing filter sleeve
1. Remove nut, holding the rotor with an oil
filter wrench.
2. Remove nut (1), washer (2), rotor cap (3)

and O-ring (4).
3. Remove filter sleeve (1).

4. Measure the layer thickness of the oil resi-
due.
5. If maximum layer thickness (25 mm) is ex-
ceeded, shorten maintenance interval.
6. Clean rotor components and remove strain-
ers (2).
7. Wash standpipes (3) and nozzles (4) with
cleaner, blow out with compressed air.
8. Insert the new filter sleeve with the smooth
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surface facing the rotor cap.

9. Fit new O-ring (4).
10. Set on rotor cap (3), observe marks.
11. Fit washer (2).
12. Hold rotor (new design) with oil filter wrench and tighten nut (1) to specified torque using a torque
wrench.
Nut M18 x 1.5 Tightening torque 10 Nm
13. Hold rotor (old design) with oil filter wrench and tighten nut (1) to specified torque using a torque
wrench.
Nut M16 x 1.5 Tightening torque 40 Nm to 50 Nm
14. Insert complete rotor (2) into the housing
and check for ease-of-movement.
15. Set housing cover (1) with new O-ring onto
lower section, observe marks.
16. Tighten nuts (3) crosswise and evenly.
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7.16 Coolant Circuit, General, High-Temperature Circuit
7.16.1 Drain and venting points
Top side
1 Engine coolant vent 3 Overflow line 5 Fuel filter

2 Intercooler 4 Engine coolant expansion 6 Engine oil filter
tank
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Left side
1 Engine coolant drain plug 2 Engine coolant drain plug 3 Raw water pump drain
plug
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Free end (KGS)
1 Three-way cock 4 Raw water pump filling 7 Oil dipstick (connection

2 Fuel filter plug left or right engine side op-
3 Fuel vent valve 5 Raw water pump drain tional)
plug 8 Oil filler neck (connection
6 Connection for oil extrac- left or right engine side op-
tion tional)
9 Fuel priming pump
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Right side
1 Engine coolant drain plug 4 Fuel priming pump 7 Oil dipstick (connection
2 Engine coolant drain plug 5 Raw water pump filling left or right engine side op-
3 Engine oil filter plug tional)
6 Oil filler neck (connection 4 Leak-fuel tank
left or right engine side op-
tional)
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Driving end (KS)
1 Engine coolant drain plug 4 Oil dipstick (connection 7 Fuel vent

2 Oil filler neck (connection left or right engine side op-
left or right engine side optional)
tional) 5 Oil filler neck (connection
3 Oil dipstick (connection left or right engine side op-
left or right engine side optional)
tional) 6 Engine coolant drain plug
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7.16.2 Engine coolant – Level check
Preconditions
☑MTU Fluids and Lubricants Specification (A001061/..) is available.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Coolant-level check at filler

neck:
1. Turn breather valve on coolant expansion
tank (→ Page 28) counterclockwise until
first stop and allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
3. Check coolant level (coolant must be visi-
ble at the lower 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 en-
gine control system).
2. If required, top up with treated engine coolant (→ Page 203).
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7.16.3 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 202).
2. Fill with engine coolant (→ Page 203).
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7.16.4 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Engine coolant draining

1. Turn breather valve of coolant expansion
tank counterclockwise until the first stop
and allow pressure to escape.
3. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• Drain plug (4)
• Crankcase (1)
• Intercooler (6)
• Exhaust-pipe elbow (5)
• Heating connection (3)
• Engine oil heat exchanger (2)
5. Close all open drain points.
6. Place breather valve on filler neck and
close.
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7.16.5 Engine coolant ‒ Filling
Preconditions

Engine coolant
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Engine coolant ‒ Filling

1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
3. Remove plug (required only for first fill).
4. Pour coolant into engine until coolant level
reaches lower edge of cast-in eye of filler
neck.
5. Install plug screw.
6. Check proper condition of breather valve
and clean sealing faces.
7. Place breather valve on filler neck and
close.
8. Start the engine and operate it at idle
speed for some minutes.
9. Check coolant level (→ Page 200).
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7.16.6 HT coolant pump ‒ Relief bore check
DANGER
WARNING
HT coolant pump ‒ Relief bore

check
1. Check relief bore (arrow) for oil and coolant
discharge.
gine start.
3. Clean the relief bore (arrow) with a wire if it
is dirty.
• Permissible coolant discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.
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7.16.7 Engine coolant – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
WARNING
Engine coolant sample extrac-

tion and analysis
1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
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. Position breather valve on filler neck and
close.
7. Change engine coolant according to the
coolant operating times specified in
(→ MTU Fluids and Lubricants Specifica-
tions A001061/..)(→ Page 202).
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7.17 Raw Water Pump with Connections
7.17.1 Raw water pump – Priming
Preconditions

Raw water pump – Priming

Note: To prevent the raw water pump from run-
ning dry and being damaged and to ensure
proper intake performance, the pump must
be filled with 3 to 4 liters of water in the
following cases:
• Before initial operation.
• Following repair /maintenance work or
pump exchange
• After extended out-of-service period (to
compensate for evaporation loss or wa-
ter drained off from the system during
winter lay-up periods).
1. Remove plug screw (1) on raw water elbow
(3).
2. Fill 3 to 4 liters of water into the system
through the opening.
3. Install plug screw (1) with new sealing
ring (2) and tighten.
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7.17.2 Raw water pump – Relief bore check
DANGER
WARNING
Raw water pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
gine start.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible coolant discharge: up to
10 drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.
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7.18 Belt Drive
7.18.1 Drive belt – Condition check
Preconditions
☑Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 211)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
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7.19 Battery-Charging Generator
7.19.1 Battery-charging generator drive – Drive belt check and adjustment
Preconditions

Assembly device F6559691 1
Preparatory steps
1. Remove limit switch (4).
2. Remove indicator (1).
3. Remove screws (3) of protective cover (2).
4. Remove protective cover.
5. Check drive belt condition (→ Page 208).
Belt drive – Checking distance

1. Measure distance (A) with assembly de-
vice.
2. If measured value of distance (A) is not
within the tolerance of 98 mm ± 1.5 mm,
readjust belt tension.
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Adjusting belt tension
1. Hold adjustment lever (2) at square (5).
2. Rotate adjusting lever until drive belt (4) is released.
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.
Final steps
1. Install protective cover (2).
2. Install securing screws (3) of protective
cover (2).
3. Install indicator (1).
4. Install limit switch (4).
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7.19.2 Battery-charging generator drive – Drive belt replacement
Preconditions

Mandrel 8205892861/08 1
Preparatory steps
1. Remove safety equipment (if fitted).
2. Remove screws of protective cover (engine free end).
3. Remove protective cover.
Replacing drive belt

1. Hold adjusting lever at square.
2. Rotate adjusting lever until drive belt is released.
3. Use mandrel to lock adjusting lever in position.
4. Remove drive belt.
5. Check cleanness of belt pulleys.
6. Fit new drive belt.
7. Remove mandrel.
Final steps
1. Install protective cover.
2. Install screws of protective cover.
3. Install safety equipment (if fitted).
4. Check function of safety equipment (if fitted).
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7.20 Engine Mounting / Support
7.20.1 Engine mounting – Checking condition of resilient mounts
Preconditions
☑Engine is filled with engine coolant and engine oil.
☑Engine is under static load.

Vernier caliper, 300 mm Y20000275 1
Engine mounting – Checking

condition of resilient mounts
1. Measure height setting (b) with feeler
gauge.
2. Measure dimension (a) with calipers.
3. Calculate permissible value of dimen-
sion (a), considering the measured value of
height adjustment (b):
• Reference values: The permissible value
of dimension (a) is 144 mm when (b) =
5 mm.
• When measured height setting (b) =
6 mm, the permissible value of (a) is
145 mm.
• When measured height setting (b) =
4 mm, the permissible value of (a) is
143 mm.
4. Replace the resilient mount, if the meas-
ured value of dimension (a) is lower than
the permissible value.
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7.21 Universal Shaft
7.21.1 Universal shaft – Greasing
Preconditions

Lithium-soap greases according to DIN2–KP K–20
NOTICE
Damage to component.
• Do not press in grease at high pressure or with hard strokes.
• Permissible lubrication pressure max. 15 bar.
Universal shaft – Greasing

1. Remove guard from universal shaft.
2. Clean the two grease nipples on each joint
half.
3. Press grease into all nipples until it emerg-
es at the star seals and sealing rings.
4. Reinstall guard.
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7.22 Wiring (General) for Engine/Gearbox/Unit
7.22.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Verify that all cable clips are closed and in proper condition.
4. Replace cable clips if defective.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 020

7.23 Accessories for (Electronic) Engine Governor / Control System
7.23.1 Engine governor and connectors – Cleaning
Preconditions

Engine governor and connectors

– Cleaning
1. Remove coarse dirt from housing surface
with isopropyl alcohol.
2. Remove dirt from surface of connec-
tors (1), connector sockets and shrink
sleeves (2) using a cloth moistened with
isopropyl alcohol.
3. Check legibility of cable labels. Clean or re-
place illegible labels.
Cleaning severely contaminated

connectors on engine governor
1. Use connector pliers (2) to disengage bayo-
net union nut (4) and withdraw connec-
tor (3).
2. Clean connector housings, connector sock-
et housings (1) and all contacts with iso-
propyl alcohol.
3. When connectors, sockets and all contacts
are dry: Fit connectors and check governor
connections (→ Page 218).
TIM-ID: 0000000948 - 011

7.23.2 Engine monitoring unit and connectors – Cleaning
Preconditions

Engine monitoring unit and con-

nectors – Cleaning
1. Remove coarse dirt from housing surface
with isopropyl alcohol.
2. Remove dirt from surface of connec-
tors (1), connector sockets and shrink
sleeves (2) using a cloth moistened with
isopropyl alcohol.
3. Check legibility of cable labels. Clean or re-
place illegible labels.
Cleaning severely contaminated

EMU connectors
1. Use connector pliers (2) to disengage bayo-
net union nut (4) and withdraw connec-
tor (3).
2. Clean connector housings, connector sock-
et housings (1) and all contacts with iso-
propyl alcohol.
3. When connectors, sockets and all contacts
are dry: Fit connectors and check plug con-
nections on EMU (→ Page 219).
TIM-ID: 0000008391 - 007

7.23.3 Start interlock limit switch – Check
Preconditions
Note: Being in OFF-position, the limit switch initiates start interlock, i.e. the engine cannot be started.
Start interlock limit switch –
Check
1. Check if switch housing (1) and cover plate
(3) are mounted and the switch (2) is in
ON-position.
2. If switch housing (1) and/or cover plate (3)
is/are not mounted:
• Secure cover plate (3) with screws.
• Then install switch housing (1) with
screws, ensuring that the switch (2) is
actuated by the cover plate (3).
3. If switch housing (1) and cover plate (3) are
mounted, but switch (2) is in OFF-position:
• Make certain that the cover plate (3) at
the side of the switch (2) is not distort-
ed.
• Loosen switch housing (1) and fit it with
screws in a position providing that the
switch (2) is ON.
• If this is not feasible, contact Service.
TIM-ID: 0000008444 - 005

7.23.4 ECU – Plug connections check
Preconditions

Checking plug connection to

ECU
1. Use connector pliers (3) to make certain
that all plug-in connections of ECU are se-
curely seated.
2. Tighten loose bayonet couplings (2) with
connector pliers (3) by turning them clock-
wise until they latch into place.
3. Make sure that unassigned sockets are
closed off with cover caps.
4. If bayonet couplings are defective, contact
Service.
TIM-ID: 0000008479 - 006

7.23.5 Engine monitoring unit – Plug connections check
Preconditions

Checking engine monitoring unit

plug connections
1. Use connector pliers (3) to make certain
that all engine monitoring unit plug connec-
tions are securely seated.
2. Tighten loose bayonet couplings (2) with
connector pliers (3) by turning them clock-
wise until they latch into place.
3. Make sure that unassigned sockets are
closed off with cover caps.
4. If bayonet couplings are defective, contact
Service.
TIM-ID: 0000008394 - 004

7.23.6 Engine governor – Removal and installation
Preconditions

Covering caps for Cannon sockets
Removing engine governor from

engine
1. Note or mark assignment of cables to con-
nector sockets.
2. Use connector pliers (2) to disengage the
bayonet union nuts (4) of the connec-
tors (3) by turning them counterclockwise.
3. Remove all connectors.
4. Close connector sockets with appropriate
covering caps (1).
TIM-ID: 0000008487 - 005

5. Disconnect ground strap from engine gov-
ernor grounding stud (7).
6. If the screws (4) are easily accessible:
1. Screw off screws (4).
2. Remove engine governor housing (3)
from mounting brackets (2).
3. Unscrew mounting brackets (2), cable
shock absorbers (5) and further secur-
ing parts (6) as one unit from engine.
7. If the screws (4) are not easily accessible:
1. Remove screws (1).
2. Remove engine governor housing (3)
together with mounting brackets (2).
3. Unscrew cable shock absorbers (5) and
further securing parts (6) as one unit
from engine.
Installing engine governor on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Use connector pliers to turn the bayonet union nuts of the connectors clockwise until they latch into
place.
TIM-ID: 0000008487 - 005

7.24 Emergency Instrumentation (Local Operating Panel)
7.24.1 LOP and connectors – Cleaning
Preconditions

Cleaning LOP
1. Wipe LCD display with dry cloth, without applying excessive pressure.
2. Remove dirt from keys using isopropyl alcohol.
3. Remove heavy soiling from housing surface with isopropyl alcohol.
Cleaning connectors on LOP

1. Remove dirt from connector and socket surfaces using isopropyl alcohol.
2. Check legibility of cable labels. Clean or replace illegible labels.
TIM-ID: 0000008867 - 006

7.24.2 LOP – Visual inspection
Preconditions
Preparatory steps
1. If READY FOR OPERATION pushbutton is illuminated brightly, press switch briefly.
Result: READY FOR OPERATION pushbutton returns to basic brightness.
2. Switch master power switch to OFF.
3. Disconnect battery in accordance with battery manufacturer's instructions.
Checking housing and internal

assemblies for secure seating
1. Open LOP front door.
2. Check securing screws (1, 3, 4, 7) for firm
seating. Tighten loose threaded connec-
tions.
3. Check internal assemblies for firm seating,
this applies in particular to printed circuit
board (2) and PIMs (5, 6). Tighten loose
threaded connections.
4. Close LOP front door.
Checking plug connections

1. Check all connected cables to verify that
the two securing elements (1) are engaged
on the lugs (2) so that the respective male
connector (3) is held firmly in place in the
socket.
2. If this is not the case, press the securing el-
ements (1) concerned in the direction of
the arrow until they engage noticeably.
TIM-ID: 0000008868 - 006

Checking unassigned connector
sockets
1. Ensure that non-assigned connector sock-
ets are protected with covering caps.
2. Make certain that the two securing ele-
ments (1) are engaged in the lugs (2) so
that the covering cap (3) is held firmly in
place in the socket.
3. If this is not the case, press the securing el-
ements (1) concerned in the direction of
the arrow until they engage noticeably.
Checking pushbuttons and dis-

play
1. Pushbuttons: Ensure that
• Pushbutton caps are not damaged
(cracks or similar damage)
• Pushbuttons move easily
• Pushbutton housings are seated secure-
ly
• Seals (2) between PAN control panels
and LOP housing are not damaged.
2. Display: Ensure that
• Front glass is not damaged or pressed in
• Seal (1) between display housing and
LOP housing is not damaged.
3. Have damaged components replaced im-
mediately by Service.
Performing lamp test

1. Connect battery in accordance with battery
manufacturer's instructions.
2. Switch master power switch to ON.
3. Switch on engine control system.
4. Hold down LAMP TEST pushbutton:
Result: Indicators and controls light up.
5. Have damaged lamps immediately replaced
TIM-ID: 0000008868 - 006
by Service.

7.24.3 LOP – Test procedures
Preconditions
Preparatory steps
1. Connect battery in accordance with battery
manufacturer's instructions.
2. Switch master power switch to ON.
3. Switch on engine management system
ECS-5.
Result: • LOCAL OPERATION pushbutton (1) is il-
luminated brightly (local control mode is
active);.
Switching between Local and Remote mode (automatic on-board network)

1. Press LOCAL OPERATION pushbutton (1).
Result: • LOCAL OPERATION pushbutton (1) flashes: Setting does not correspond with feedback signal from
Engine Control Unit.
• LOCAL OPERATION pushbutton (1) is illuminated at basic brightness: Remote mode active.
2. Press LOCAL OPERATION pushbutton (1) again.
Result: LOCAL OPERATION pushbutton (1) is illuminated brightly (Local mode is active);.
TIM-ID: 0000008872 - 004

Overspeed test with the engine
at standstill
Note: Overspeed test with the engine at standstill
can only be carried out if the engine is
equipped with Engine Monitoring Unit.
1. Press OVERSPEED TEST illuminated push-
button (3). Observe speed limit and speed
simulated by Engine Monitoring Unit on dis-
play.
Result: • Engine Control Unit is de-energized by
the safety system.
• Engine governing is completely deacti-
vated.
• On engines with emergency air-shutoff
flaps: Flaps close.
• EMERGENCY STOP illuminated pushbut-
ton (2) flashes;. Alarm signalling by horn,
flashing light etc. is initiated. ALARM AC-
KNOWLEDGE pushbutton (1) is illuminat-
ed brightly.
2. Press ALARM ACKNOWLEDGE pushbutton
(1).
Result: Audible and visual alarm signaling stops.
(1) again.
Result: Power supply to Engine Control Unit is pro-
vided.
4. On engines with emergency air-shutoff
flaps: Open flaps.
Emergency stop simulation with

the engine at standstill
1. Open cap of EMERGENCY STOP pushbut-
ton (2).
2. Press EMERGENCY STOP pushbutton (2).
Result: • Engine Control Unit is deenergized by
the safety system.
• Engine governing is completely deacti-
vated.
• On engines with emergency air-shutoff
flaps: Flaps close.
• EMERGENCY STOP pushbutton (2) flash-
es;. Alarm signalling by horn, flashing
light etc. is initiated. ALARM ACKNOWL-
EDGE pushbutton (1) is illuminated
TIM-ID: 0000008872 - 004
brightly.
(1).
Result: Audible and visual alarm signaling stops.
(1) again.
Result: Power supply to Engine Control Unit is pro-
vided.
5. On engines with emergency air-shutoff
flaps: Open flaps.

8 Appendix A
8.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CCG Cross Connection Gear Transfer gearbox
CODAG Combined Diesel (engine) And Gas (tur-
bine propulsion)
CPP Controllable Pitch Propeller
DAG Diesel (engine) And Gas (turbine)
DE Diesel Engine
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN
= “Deutsche Industrie-Norm”)
DIS Display unit
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System
ECS-UNI Engine Control System UNIversal
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
GT Gas Turbine
HAT Harbor Acceptance Test
TIM-ID: 0000002049 - 005
HI High Alarm: Measured value exceeds 1st maximum limit

HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module
IMO International Maritime Organization
MW15406/17E 2014-05 | Appendix A | 227

tion
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
MRG Main Reduction Gear
OT Oberer Totpunkt Top Dead Center (TDC)
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
PT Power Turbine
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus missing
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Safety system alarm
TIM-ID: 0000002049 - 005
SSK Schnellschlussklappe(n) Emergency air shut-off flaps

SSS Synchronized Self-Shifting (clutch)
STBD Starboard
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom Dead Center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water jet Water jet drive
228 | Appendix A | MW15406/17E 2014-05

tion
WZK Werkzeugkatalog Tool Catalog (TC)
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for
signals from the ADEC engine governor
TIM-ID: 0000002049 - 005
MW15406/17E 2014-05 | Appendix A | 229

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
230 | Appendix A | MW15406/17E 2014-05

9 Appendix B
9.1 Special Tools
Assembly device
Part No.: F6559691
Qty.: 1
Used in: 7.19.1 Battery-charging generator drive – Drive belt
check and adjustment (→ Page 209)
Box wrench
Part No.: F30038493
Qty.: 1
Used in: 7.6.2 Injection pump – Removal and installation
(→ Page 160)
Box wrench bit, 17 mm

Part No.: F30030450
Qty.: 1
Used in: 7.5.1 Valve clearance – Check and adjustment
(→ Page 155)
DCL-ID: 0000013917 - 004
MW15406/17E 2014-05 | Appendix B | 231

Centering jig
Part No.: F6783025
Qty.: 1
Used in: 7.5.2 Cylinder head cover – Removal and installation
(→ Page 158)
Connector pliers
Part No.: F30017884
Qty.: 1
Used in: 7.2.2 Engine – Barring with starting system
(→ Page 147)
Qty.: 1
Used in: 7.23.1 Engine governor and connectors – Cleaning
(→ Page 215)
Qty.: 1
Used in: 7.23.2 Engine monitoring unit and connectors – Clean-
ing (→ Page 216)
Qty.: 1
Used in: 7.23.4 ECU – Plug connections check (→ Page 218)
Qty.: 1
Used in: 7.23.5 Engine monitoring unit – Plug connections
check (→ Page 219)
Qty.: 1
Used in: 7.23.6 Engine governor – Removal and installation
(→ Page 220)
Double-head box wrench

Part No.: F30011450
Qty.: 1
Used in: 7.7.2 HP fuel line – Pressure pipe neck replacement
(→ Page 164)
Qty.: 1
Used in: 7.7.3 Injector – Removal and installation (→ Page 166)
DCL-ID: 0000013917 - 004
232 | Appendix B | MW15406/17E 2014-05

Feeler gauge
Part No.: Y4342013
Qty.: 1
(→ Page 155)
Fuel suction device

Part No.: F30378207
Qty.: 1
Mandrel
Part No.: 8205892861/08
Qty.: 1
Used in: 7.19.2 Battery-charging generator drive – Drive belt re-
placement (→ Page 211)
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.16.7 Engine coolant – Sample extraction and analysis
(→ Page 205)
DCL-ID: 0000013917 - 004
MW15406/17E 2014-05 | Appendix B | 233

Oil filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.9.1 Fuel filter – Replacement (→ Page 173)
Qty.: 1
Used in: 7.15.2 Engine oil filter – Replacement (→ Page 190)
Qty.: 1
Used in: 7.15.3 Centrifugal oil filter and filter sleeve – Cleaning
and replacement (→ Page 192)
Open-end wrench bit

Part No.: F30025897
Qty.: 1
(→ Page 164)
Qty.: 1
Puller
Part No.: 3555890163/00
Qty.: 1
Ratchet
Part No.: F30006212
Qty.: 1
Used in: 7.2.1 Engine ‒ Barring manually (→ Page 146)
DCL-ID: 0000013917 - 004
234 | Appendix B | MW15406/17E 2014-05

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.4.1 Crankcase ventilation – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 152)
Qty.: 1
(→ Page 164)
Qty.: 1
Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.3.1 Cylinder liner – Endoscopic examination
(→ Page 148)
Socket
Part No.: F30005655
Qty.: 1
Used in: 7.2.1 Engine ‒ Barring manually (→ Page 146)
Spider patch spanner

Part No.: F30027425
Qty.: 1
(→ Page 164)
DCL-ID: 0000013917 - 004
Qty.: 1
MW15406/17E 2014-05 | Appendix B | 235

Spider patch spanner
Part No.: F30027424
Qty.: 1
(→ Page 164)
Qty.: 1
Spider patch spanner, AF19

Part No.: F30027424
Qty.: 1
(→ Page 160)
Spider patch spanner, AF22

Part No.: F30027425
Qty.: 1
(→ Page 160)
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.14 Plant – Cleaning (→ Page 119)
DCL-ID: 0000013917 - 004
236 | Appendix B | MW15406/17E 2014-05

Torque wrench, 0.5-5 Nm
Part No.: 0015384230
Qty.: 1
(→ Page 160)
Torque wrench, 20-100 Nm

Part No.: F30026582
Qty.: 1
(→ Page 160)
Qty.: 1

Part No.: F30026582
Qty.: 1
(→ Page 155)
Qty.: 1
(→ Page 164)

Part No.: F30027336
Qty.: 1
Used in: 7.4.1 Crankcase ventilation – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 152)
DCL-ID: 0000013917 - 004
MW15406/17E 2014-05 | Appendix B | 237

Vernier caliper, 300 mm
Part No.: Y20000275
Qty.: 1
Used in: 7.20.1 Engine mounting – Checking condition of resil-
ient mounts (→ Page 212)
DCL-ID: 0000013917 - 004
238 | Appendix B | MW15406/17E 2014-05

9.2 Index
Numerics C
12V 2000 M60 engine data: Engine-mounted heat ex- Centrifugal oil filter
changer, reference condition: 25 °C intake air temper- – Cleaning 192
ature 55 – Filter sleeve replacement 192
12V 2000 M60 engine data: Engine-mounted heat ex- Connectors
changer, reference condition: 45 °C intake air temper- – Cleaning 215, 216
ature 58 Contact persons 230
12V 2000 M60 engine data: Separate heat exchanger, ref- Controls (without Blue Line automation system)
erence condition: 25 °C intake air temperature 61 – LOP 105
12V 2000 M60 engine data: Separate heat exchanger, ref- Coolant
erence condition: 45 °C intake air temperature 64 – Change 201
12V 2000 M61 engine data 67, 70, 73, 76 Crankcase breather
16V 2000 M60 engine data: Engine-mounted heat ex- – Cleaning oil separator element 154
changer, reference condition: 25 °C intake air temper- Crankcase ventilation
ature 79 – Diaphragm check 152
16V 2000 M60 engine data: Engine-mounted heat ex- – Diaphragm replacement 152
changer, reference condition: 45 °C intake air temper- – Oil separator element replacement 152
ature 82 Cylinder
16V 2000 M60 engine data: Separate heat exchanger, ref- – Designation 27
erence condition: 25 °C intake air temperature 85 Cylinder head cover – Removal and installation 158
16V 2000 M60 engine data: Separate heat exchanger, ref- Cylinder liner
erence condition: 45 °C intake air temperature 88 – Endoscopic examination 148
16V 2000 M61 engine data 91, 94, 97, 100 – Instructions and comments on endoscopic and visual
2000 M40-M91A/B engines – Overview 28 examination 150
8V 2000 M60 engine data: Engine-mounted heat exchang-
er, reference condition: 25 °C intake air temperature D
39 Disengaging
8V 2000 M60 engine data: Engine-mounted heat exchang- – from LOP 113
er, reference condition: 45 °C intake air temperature Drain points 195
42 Drive belt
8V 2000 M60 engine data: Separate heat exchanger, refer- – Condition check 208
ence condition: 25 °C intake air temperature 45
8V 2000 M60 engine data: Separate heat exchanger, refer- E
ence condition: 45 °C intake air temperature 48 ECU – Plug connections
– Check 218
A Emergency stop from LOP (without Blue Line automation
Abbreviations 227 system) 117
Actuators Engine
– Overview 29 – Barring with starting system 147
After stopping the engine 118 – Main dimensions 104
Air filter – Stopping
– Installation 183 – At the BlueLine automation system (control stand)
– Removal 183 116
– Replacement 182 – Wiring check 214
DCL-ID: 0000013917 - 004
Air-flow control flap – Ease of movement check 185 Engine 8V 2000M61 — Data 51

Engine coolant
B – Change 201
Battery-charging generator drive – Draining 202
– Adjustment 209 – Filling 203
– Check 209 – Sample extraction and analysis 205
– Drive belt Engine coolant – Level check 200
– Replacement 211 Engine driving end
– Definition 27
Engine emergency stop
– At BlueLine automation system (control stand) 111
MW15406/17E 2014-05 | Appendix B | 239

Engine free end Injector
– Definition 27 – Removal
Engine governor – Installation 166
– Cleaning 215 – Replacement 163
– Removal and installation 220 Installation locations for SOLAS shielding 141
Engine monitoring unit Intercooler
– Cleaning 216 – Checking condensate drain line for coolant discharge
Engine monitoring unit plug connections and obstruction 181
– Check 219
Engine mounting L
– Checking condition of resilient mounts 212 LOP
Engine oil – Cleaning 222
– Change 188 – Connector cleaning 222
Engine oil filter – Controls (without Blue Line automation system) 105
– Replacement 190 – Fault messages 121
Engine oil level – Test procedures 225
– Check 187 – Visual inspection 223
Engine sides
– Designation 27 M
Engine wiring Main dimensions
– Check 214 – Engine 104
Engine - barring manually 146 MTU contact persons 230
F O
Fault messages Oil dipstick
– At LOP 121 – Marking 189
Firing order 103 Oil filter
Fuel – Replacement 190
– Draining 170 Oil separator element
– Prefilter – Replacement 152
– Differential pressure gauge - checking and adjust- Operational checks 112
ing 175
P
– Draining 176
– Filter element replacement 179 Plant
Fuel filter – Cleaning 119
– Replacement 173 Pressure pipe neck
Fuel prefilter – Replacement 164
– Differential pressure gauge Product description 18
– Checking and adjusting 175 Putting into operation
– Draining 176 – Preparations after extended out-of-service periods (>3
– Filter element months) 107
– Replacement 179 Putting the engine into operation after scheduled out-of-
– Flushing 177 service period 108
Fuel system
R
– Venting 171
Raw water pump
H – Priming 206
– Relief bore
DCL-ID: 0000013917 - 004
Hotline 230
HP fuel line – Check 207
– Pressure pipe neck replacement 164 Resilient mounts
HT coolant pump – Condition check 212
– Relief bore check 204
S
I Safety notices, standards 17
Injection pump
– Removal
– Installation 160
– Replacement 159
240 | Appendix B | MW15406/17E 2014-05

Safety regulations
– Auxiliary materials 15
– Environmental protection 15
– Fire prevention 15
– Fluids and lubricants 15
– Organizational requirements 9
– Personnel requirements 9
Safety requirements
– Important requirements 8
– Maintenance work 12
– Operation 11
– Repair work 12
– Safety notices, standards 17
– Startup 11
Sensors
– Overview 29
Service indicator
– Signal ring position check 184
Service partners 230
SOLAS shielding
– Installation 135
– Installation as per MTN 5233 134
– Installation locations 136
SOLAS shielding as per MTN 5233 – Installation 133
Spare parts service 230
Start interlock limit switch
– Check 217
Starter
– Condition check 186
Starting the engine from LOP (without Blue Line automa-
tion system) 109
Starting the engine with the BlueLine automation system
(control stand) 110
Stopping the engine from LOP (without Blue Line automa-
tion system) 115
T
Transport 10
Troubleshooting 130
U
Universal shaft
– Greasing 213
V
Valve clearance
– Adjustment 155
DCL-ID: 0000013917 - 004
– Check 155
Venting points 195
W
Waterjet
– Flushing
– From LOP (option) 114
MW15406/17E 2014-05 | Appendix B | 241


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Operating Instructions

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Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

3 Technical Data 4 Operation

MW15406/17E 2014-05 | Table of Contents | 5

7.2 Engine 146 7.15 Oil Filtration / Cooling 189

6 | Table of Contents | MW15406/17E 2014-05

MW15406/17E 2014-05 | Table of Contents | 7

8 | Safety | MW15406/17E 2014-05

Working clothes and personal protective equipment

MW15406/17E 2014-05 | Safety | 9

Setting the engine down after transport

TIM-ID: 0000002614 - 003

10 | Safety | MW15406/17E 2014-05

Safety requirements for operation

Malfunctions and emergency stop

Operation of electrical equipment

MW15406/17E 2014-05 | Safety | 11

Safety requirements during maintenance and repair work

Ensure that all retainers and dampers are installed correctly.

12 | Safety | MW15406/17E 2014-05

Safety requirements after completing maintenance and repair work

Hydraulic installation and removal

Working with batteries

MW15406/17E 2014-05 | Safety | 13

Working with laser equipment

Measuring component deviations

14 | Safety | MW15406/17E 2014-05

Environmental protection and disposal

Fluids and lubricants and auxiliary materials

coming into contact with ignition sources and do not smoke.

MW15406/17E 2014-05 | Safety | 15

Paints and varnishes

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

• Observe the relevant safety data sheet for all materials.

16 | Safety | MW15406/17E 2014-05

MW15406/17E 2014-05 | Safety | 17

• Centrifugal lube oil filter

18 | General Information | MW15406/17E 2014-05

Electronic Engine Monitoring Unit (EMU), optional

Electronic Gear Control Unit (GCU), ship-side wall-mounting

Monitoring in engine room

SOLAS – Fire protection specifications

MW15406/17E 2014-05 | General Information | 19

TIM-ID: 0000002178 - 006

20 | General Information | MW15406/17E 2014-05

MW15406/17E 2014-05 | General Information | 21

TIM-ID: 0000002178 - 006

22 | General Information | MW15406/17E 2014-05

MW15406/17E 2014-05 | General Information | 23

Plug-in pipe union

The union is confirmed as being SOLAS-compliant by DNV and GL.

Plugs and sensors

24 | General Information | MW15406/17E 2014-05

1 Jacket pipe 8 Thrust ring 15 Union nut

MW15406/17E 2014-05 | General Information | 25

Shielding with plastic ring

The plastic ring (1) precludes lateral spray.