Operating Instructions

Diesel Engine
12V2000M94
16V2000M94

MS150061/06E

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 Engine model kW/cyl. Application group
12V2000M94 119.3 kW/cyl. 1DS, continuous operation, variable, low load
factors
16V2000M94 121.2 kW/cyl. 1DS, continuous operation, variable, low load
factors

Table 1: Applicability

© 2016 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming 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.

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 Table of Contents
1 Safety 5.13 Plant – Cleaning 54
1.1 Important provisions for all products 5
6 Maintenance
1.2 Correct use for all products 6
1.3 Personnel and organizational requirements 7 6.1 Maintenance task reference table [QL1] 55
1.4 Safety regulations for startup and operation 8
1.5 Safety precautions when working on the 7 Troubleshooting
engine 10
1.6 Fire prevention and environmental 7.1 Control cabinet of fuel treatment system –
protection, fluids and lubricants, auxiliary Troubleshooting 56
materials 13 7.2 Troubleshooting 57
1.7 Standards for safety notices in the text 15
8 Task Description
2 Transport
8.1 SOLAS 60
2.1 Transportation 16 8.1.1 SOLAS shielding as per MTN 5233 –
Installation 60
2.2 Lifting requirements 17
8.1.2 SOLAS shielding – Installation 61
2.3 Resilient mount – Shipping lock 18
8.1.3 Installation locations for SOLAS shielding 62

3 General Information 8.2 Engine 67

8.2.1 Engine – Barring manually 67
3.1 Engine side and cylinder designations 19 8.2.2 Engine – Barring with starting system 68
3.2 Product description 20 8.3 Cylinder Liner 69
3.3 Engine overview 26 8.3.1 Cylinder liner – Endoscopic examination 69
3.4 Sensors and actuators – Overview 28 8.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 71
4 Technical Data
8.4 Crankcase Breather 73
4.1 Engine data 12V2000M94 33 8.4.1 Crankcase breather – Cleaning oil pre-
separator element 73
4.2 Engine data 16V2000M94 36
8.4.2 Crankcase breather – Oil separator
4.3 Firing order 39
replacement, diaphragm check and
4.4 Engine – Main dimensions 40 replacement 74

5 Operation 8.5 Valve Drive 76

8.5.1 Valve clearance – Check and adjustment 76
5.1 Putting the engine into operation after 8.5.2 Cylinder head cover – Removal and
extended out-of-service periods (>3 months) 41 installation 79
5.2 Engine – Putting into operation after 8.6 Injector 80
scheduled out-of-service-period 42 8.6.1 Injector – Replacement 80
5.3 Tasks after extended out-of-service periods 8.6.2 Injector – Removal and installation 81
(>3 weeks) 43
8.7 Fuel System 83
5.4 Checks prior to start-up 44 8.7.1 Fuel system – Venting 83
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5.5 Fuel treatment system – Putting into

operation 45 8.8 Fuel Filter 84
5.6 Operational checks 47 8.8.1 Fuel filter – Replacement 84
8.8.2 Fuel prefilter – Differential pressure check
5.7 Fuel treatment system – Switching on 48
and adjustment of gauge 87
5.8 Starting the engine 49
8.8.3 Fuel prefilter – Draining 88
5.9 Engine – Shutdown 50 8.8.4 Fuel prefilter – Flushing 90
5.10 Emergency engine shutdown 51 8.8.5 Fuel prefilter – Filter element replacement 92
5.11 After stopping the engine 52
5.12 Fuel treatment system – Shutdown 53 8.9 Charge-Air Cooling 94

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 8.9.1 Charge-air cooler – Checking condensate drain
line for coolant discharge and obstruction 94
8.19 Fuel Supply System 121
8.19.1 Water drain valve – Check 121
8.10 Air Filter 95 8.19.2 Differential pressure gauge – Check 122
8.10.1 Air filter – Replacement 95 8.19.3 Water level probe (3-in-1 rod electrode) –
8.10.2 Air filter – Removal and installation 96 Check 123
8.19.4 Pump capacity – Check 124
8.11 Air Intake 97 8.19.5 Coalescer filter element – Replacement 125
8.11.1 Service indicator – Signal ring position check 97
8.20 Wiring (General) for Engine/Gearbox/Unit 127
8.12 Starting Equipment 98 8.20.1 Engine cabling – Check 127
8.12.1 Starter – Condition check 98
8.21 Accessories for (Electronic) Engine
8.13 Lube Oil System, Lube Oil Circuit 99
Governor / Control System 128
8.13.1 Engine oil – Level check 99
8.21.1 Engine governor and connector – Cleaning 128
8.13.2 Engine oil – Change 100
8.21.2 EMU and connectors – Cleaning 129
8.14 Oil Filtration / Cooling 101 8.21.3 Engine governor plug connections – Check 130
8.14.1 Engine oil filter – Replacement 101 8.21.4 Engine Monitoring Unit EMU 7 – Plug
8.14.2 Centrifugal oil filter and filter sleeve – connection check 131
Cleaning and replacement 103 8.21.5 Interface module EIM plug connections –
Check 132
8.15 Coolant Circuit, General, High-Temperature 8.21.6 Engine Control Unit – Self-test 133
Circuit 106 8.21.7 Engine governor ECU 7 – Removal and
8.15.1 Draining and venting points 106 installation 134
8.15.2 Engine coolant level – Check 111 8.21.8 Engine Monitoring Unit – Removal and
8.15.3 Engine coolant – Change 112 installation 135
8.15.4 Engine coolant – Draining 113 8.21.9 Engine Interface Module EIM – Removal and
8.15.5 Engine coolant – Filling 114 installation 136
8.15.6 HT coolant pump – Relief bore check 115 8.21.10 Diagnostic features on EIM 137
8.15.7 Engine coolant sample extraction and analysis 116
8.15.8 Coolant filter – Replacement 117
9 Appendix A
8.16 Raw Water Pump with Connections 118
8.16.1 Raw water pump – Relief bore check 118 9.1 Abbreviations 140
8.17 Belt Drive 119 9.2 MTU Contact/Service Partners 143
8.17.1 Drive belt – Condition check 119
10 Appendix B
8.18 Battery-Charging Generator 120
8.18.1 Battery-charging generator drive – Drive belt 10.1 Special Tools 144
replacement 120
10.2 Index 151

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 1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.

General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices

Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents 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, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation 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.

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.
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 1.2 Correct use for all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in 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 re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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 1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These 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
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
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 1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.

Safety regulations during operation

The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.

Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
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to do so following a written procedure.

Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.

Operation of electrical equipment

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.

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 Follow the applicable warning instructions pertaining to such devices.
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 1.5 Safety precautions when working on the engine
Safety regulations prior to 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 suita-
ble collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
The following applies to starters with copper-beryllium alloy pinions:
• 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 flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.

Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.
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Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.

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 Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that O-rings are not installed in a slanted/twisted condition.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly. If necessary, coat the com-
ponents with a suitable corrosion inhibitor.

Safety regulations following maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv-
ably damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.
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Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.

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 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the
component being pressed.

Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in-
jury through the sudden discharge of acid or bursting of the battery body.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a functional testing on completion of all repair work. Check cor-
rect execution of the emergency stop function in particular.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.

Work with laser devices

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur-
ing safe operation.
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Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.

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 1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Flames, naked light and smoking are prohibited.
When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.
Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its
handling.

Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal

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 recy-
cled.

Auxiliary materials
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.

Used oil
Used oil contains combustion residues that are harmful to health.
Wear protective gloves!
Wash relevant areas after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.

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 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 con-
tainers, 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 which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing or replacing pneumatic equipment in the supply line. To de-
pressurize compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out leak test in accordance with the specifications.

Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

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

• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
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 1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.

Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
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 2 Transport
2.1 Transportation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80091731 1
Crossbeam T80092210 1

DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Transportation
1. Prior to transportation, install the transport locking device for the resilient mounts (→ Page 18).
2. Use lifting eyes provided for transporting the engine (→ Page 17).
3. Only use suitable transportation and lifting equipment.
4. The engine must only be transported in installation position (→ Page 17).
5. Remove any loose parts on engine.
6. Always raise/lower engine slowly. The lifting ropes or chains must not rub against the engine or its compo-
nents during the lifting procedure. Readjust lifting equipment as necessary.
7. For special packaging with aluminum foil: Attach engine to lifting eyes of bearing pedestal or transport with
means of transportation device suitable for the load (forklift truck).
8. Secure engine against tilting during transportation. Secure such as to preclude slipping and tipping when
driving up or down inclines and ramps.

Placement after transportation

1. Only set down engine on a firm, level surface.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Never set engine down on oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

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 2.2 Lifting requirements
Lifting requirements
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

1 Max. admissible diagonal 3 Max. admissible diagonal 5 Max. admissible diagonal

pull 40° pull 70° pull 10°
2 Max. admissible diagonal 4 Max. admissible diagonal 6 Center of gravity
pull 20° pull 35°

Take note of the engine center of gravity

See Installation/Arrangement drawings for details on engine center of gravity.
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 2.3 Resilient mount – Shipping lock

Shipping lock
Note: The shipping lock protects the resilient mount from shock and vibration damage during engine transport.
1. The shipping lock must be removed prior to initial engine start-up.
2. The shipping lock must be installed according to instructions before transporting the engine.

Removing shipping lock

1. Undo nuts (4) on all outer rings of resilient
mount (1) then unscrew and remove locking
screw (2) with washers (3) and nut (4) (4 x on
each mount).
2. Following removal, store parts (2, 3, 4) of the
shipping lock in a safe place for future use.

Installing shipping lock

1. Screw in locking screw (2) together with
washers (3) and nut (4) (4 x on each mount)
until screw head with washers makes contact
with mount.
2. Secure locking screw (2) with nut (4).
3. Label engine “Shipping lock installed”.

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 3 General Information
3.1 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).
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 3.2 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection, se-
quential turbocharging and charge-air cooling.
An electronic management system provides engine control and monitoring.

Fuel system with common-rail injection

Controlled by the electronic engine management system, the common rail injection system determines injec-
tion pressure, injection timing and injection quantity independently of the engine speed.
Injection pressures up to 1800 bar ensure optimum fuel injection and combustion conditions.

Turbocharging system
The charging system comprises charge-air system, exhaust system and sequential turbocharging.
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced thermal load,
• absolute gas-tightness

Lube oil system

Wet-sump forced-feed lubrication system
Components supplied with oil:
• Bearings
• Piston cooling
• Control and actuating elements of the sequential turbocharging system

Cooling system
• Two separate circuits:
– Engine coolant
– Raw water
• Coolant cooling by raw water-cooled plate-core heat exchanger
• Thermostat-controlled coolant system
• Coolant-cooled / preheated charge-air
• Coolant-cooled fuel return

Electronic system
Electronic control and monitoring system with integrated safety and test system with interfaces to the Re-
TIM-ID: 0000002177 - 005

mote Control System (RCS) and to the Monitoring and Control System (MCS).

Connection box EIM (Engine Interface Module)

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

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 Functions:
• Starter control (start repetition, tooth alignment, starter protection)
• Generator monitoring
• Open bus interface to the plant (SAE J1939)
• Emergency stop function with line break monitoring
• Redundant power supply
• Optional control of emergency-air shutoff flaps
• Key switch logic
• Interface to ECU and EMU
• MCS5 dialog interface
• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
• Connection facility for an MTU Local Operating Station (LOS)

Serial RS422 interface for diagnosis

The engine interface is divided into two parts. The first part is integrated in the engine wiring harness via the
62-pole Tyco connector X52. The second part is formed by those signals involving a higher current. Such
signals are routed out via M threaded pins and are also integrated in the engine wiring harness.
Functions
• ECU supply
• EMU supply
• Plant signals (ECU7 connector X1)
• Bus interface (2x MCS5 CAN)
• CAN dialog output (1x MCS5 CAN)
• ECU and EMU emergency stop
• Electric starter
• Terminal 45 starter A/B (engaged)
• Pneumatic starter
• Starting air pressure valve
• Starting air pressure sensor
• Barring device (Barring Gear 1 and 2)
• Generator (with exciter control)
• Optional emergency-air shutoff flaps
• Activation of SDAF 1+2
• Feedback from SDAF 1+2

Electronic engine control unit (ECU)

Closed-loop control:
• Engine speed
• High-pressure fuel
Valve gear:
• Injection (fuel pressure, injection timing, injection duration, operating status)
• Sequential turbocharging (cutting-in and out) with secondary turbocharger
• Engine protection with multi-stage safety systems:
– Power reduction
– Power limitation
– Emergency stop
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 Monitoring:
• Exhaust gas temperature, A-side
• Exhaust temperature, B-side
• Engine speed
• Oil pressure
• Differential oil pressure
• Coolant temperature
• Coolant level
• Exhaust turbocharger speed
• Leak fuel level
• Oil temperature
• Coolant pressure
• Fuel pressure after filter

Monitoring in engine room

Engine control and monitoring unit (LOP)
Functions:
• Engine speed, oil pressure and coolant temperature are monitored and displayed
• Integrated safety system
• Integrated Test System
• Redundant CAN bus interface to governor and higher-level control and monitoring system
• 24 V DC supply

SOLAS – Fire safety requirements

Special connections

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

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 Plug-in pipe union
The sleeve (3) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure decreases significantly if an O-ring (2) fault occurs.
The connection is confirmed as compliant with SOLAS by DNV and GL.

Plugs and sensors

Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN, or an
O-ring (ISO).
In case of a loose thread or a faulty sealing ring (1), the liquid first has to pass the thread.
The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under pres-
sure.

HP line between injector and HP accumulator

1 Support ring 4 HP line 7 Thrust ring

2 V-ring 5 Thrust screw 8 V-ring
3 Thrust ring 6 Support ring 9 Union nut
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 HP line between distributor and HP accumulator

1 Union nut 4 Thrust screw 7 Thrust ring

2 O-ring 5 O-ring 8 Pressure pipe
3 Thrust ring 6 O-ring 9 Jacket pipe

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 HP line between distributor and HP accumulator

1 Jacket pipe 5 O-ring 9 HP line

2 O-ring 6 Thrust screw 10 Pressure pipe
3 O-ring 7 Thrust ring
4 Thrust ring 8 O-ring

Leak-off fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from
where it is routed at atmospheric pressure into a level-monitored leak-fuel tank.
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 3.3 Engine overview
Figures also apply similarly to 16V.

Engine overview – Free end

1 Engine oil heat exchanger 11 Exhaust turbocharger 21 Raw water pump

2 Engine oil filter 12 Carrier housing 22 Raw water connection from
3 Coolant filter 13 Actuating cylinder for ex- overboard
4 Diverter lever for engine oil haust flap 23 Protective cover (belt pul-
filter 14 Cylinder head cover ley)
5 Coolant distribution housing 15 Engine mounting 24 Coolant pump
with integrated expansion 16 Oil pan 25 Plate-core heat exchanger
tank 17 Battery-charging generator 26 Centrifugal oil filter
6 Oil separator 18 Coolant filler neck 27 Fuel priming pump
7 Air filter (air intake) 19 Engine Interface Module 28 Fuel filter
8 Engine governor EIM KGS Free end
9 Air collector housing 20 Raw water connection to
10 Engine lifting equipment gearbox cooling system
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 Engine overview – Driving end

1 Carrier housing upper sec- 6 Electric starter 11 Bleeder valve

tion 7 Flywheel 12 Exhaust outlet
2 HP fuel pump 8 Flywheel housing KS Driving end
3 Oil filler neck 9 Carrier housing lower sec-
4 Oil dipstick tion
5 4-2 directional control valve 10 Carrier housing middle sec-
tion

Engine model designation

Key to the engine model designations 12V/16V2000Mxyz
12/16 Number of cylinders
V Cylinder arrangement: V engine
2000 Series
M Application
x Application segment (4, 5, 6, 7, 9)
y Design status (0, 1, 2,...)
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z Special features

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 3.4 Sensors and actuators – Overview
Engine plan view
Deviations from illustrations are insignificant.
Also applies similarly to 12V.

Item Designation Monitoring of

1 B3 Intake air temperature
2 B9 Charge-air temperature
3 B7 Lube oil temperature
4 B10 Charge-air pressure
5 B44 Turbocharger speed
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 Engine free end

Item Designation Monitoring of

1 B34 Fuel pressure after filter
2 B5.3 (optional) Lube oil pressure before filter
3 B5.1 Lube oil pressure after filter
4 B5.2 (optional) Lube oil pressure after filter
5 F33 Engine coolant level, expansion tank
6 B21 (optional) Raw water pressure
7 B6.2 (optional) Coolant temperature
8 B6.1 Coolant temperature
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 Engine driving end

Item Designation Monitoring of

1 B1 (ECU) Camshaft speed
2 B13.2 (optional EMU) Crankshaft speed
3 B13 (ECU) Crankshaft speed

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 Engine, right side

Item Designation Monitoring of

1 F41 2-2-directional control valve
2 YB33 Fuel temperature
3 B48 Fuel pressure (in rail)
4 B16 (optional) Coolant pressure
5 F46 Leak fuel level
6 Y27.2 4-2-directional control valve, B-side
7 B4.22 Exhaust temperature, B-side
TIM-ID: 0000008412 - 005

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 Engine, left side

Item Designation Monitoring of

1 B4.21 Exhaust gas temperature, A-side
2 Y27.1 4-2-directional control valve, A-side
3 B54 (optional) Lube oil pressure, replenishment pump

System sensors
These sensors are fitted outside the engine.
Designation Monitoring of
B19 Starting-air pressure
B70 Fuel prefilter water level
B41 Exhaust back pressure
S37 Start interlock, switching status
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 4 Technical Data
4.1 Engine data 12V2000M94
Explanation
Index (I) Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit up to which the engine can be operated without changes such as load setting
N Not yet defined value
- Not applicable
X Applicable

Reference conditions
Engine model 12V2000
M94
Application group 1DS
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 12
Rated engine speed A rpm 2450
Fuel stop power ISO 3046 A kW 1432

General conditions (for maximum power)

Number of cylinders 12
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30
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Model related data (basic design)

Number of cylinders 12
Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 135
Stroke mm 156
Cylinder displacement Liters 2.23

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 Number of cylinders 12
Total displacement Liters 26.76
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

Raw water circuit (open circuit)

Number of cylinders 12
Raw water pump: Inlet pressure, min. L bar -0.4
Raw water pump: Inlet pressure, max. L bar +0.5
Pressure loss in engine-external raw water system, max. L bar 0.7

Lube oil system

Number of cylinders 12
Lube oil operating temperature before engine, from R °C 82
Lube oil operating temperature before engine, to R °C 92
Lube oil operating pressure before engine, from R bar 7.5
Lube oil operating pressure before engine, to R bar 8.5
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3

Fuel system
Number of cylinders 12
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3
Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25
Fuel supply flow, max. R liters/min 7.1

General operating data

Number of cylinders 12
Firing speed, from R rpm 100
Firing speed, to R rpm 120

Starter (electric)
Number of cylinders 12
Rated starter voltage (standard design) R V= 24
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Inclinations – standard oil system (reference: waterline)

Number of cylinders 12
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
ating inclinations) (°)
Longitudinal inclination, continuous max. driving end up (Option: max. operat- L Degrees 0
ing inclinations) (°)

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 Number of cylinders 12
Longitudinal inclination, temporary max., driving end up (Option: max. operat- L Degrees 10
ing inclinations) (°)
Transverse inclination, continuous max. (Option: max. operating inclinations) L Degrees 22.5
(°)
Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees 32.5
(°)

Capacities
Number of cylinders 12
Engine coolant, engine side (with cooling system) R Liters 125
Engine oil capacity, initial filling (standard oil system) (Option: max. operating R Liters 123
inclinations)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R Liters 113
nations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 87
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 105
operating inclinations)

Weights / main dimensions

Number of cylinders 12
Engine dry weight (with standard accessories installed, without coupling) R kg 2780

Acoustics
Number of cylinders 12
Exhaust noise, unsilenced – BL (free-field sound-pressure level Lp, 1 m dis- R dB(A) 109
tance, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) – BL (free-field R dB(A) 104
sound-pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)
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 4.2 Engine data 16V2000M94
Explanation
Index (I) Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit up to which the engine can be operated without changes such as load setting
N Not yet defined value
- Not applicable
X Applicable

Reference conditions
Engine model 16V2000
M94
Application group 1DS
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 16
Rated engine speed A rpm 2450
Fuel stop power ISO 3046 A kW 1939

General conditions (for maximum power)

Number of cylinders 16
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 30

Model related data (basic design)

Number of cylinders 16
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Cylinder arrangement: V angle Degrees 90

(°)
Bore mm 135
Stroke mm 156
Cylinder displacement Liters 2.23
Total displacement Liters 35.68
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

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 Raw water circuit (open circuit)
Number of cylinders 16
Raw water pump: Inlet pressure, min. L bar -0.4
Raw water pump: Inlet pressure, max. L bar +0.5
Pressure loss in engine-external raw water system, max. L bar 0.7

Lube oil system

Number of cylinders 16
Lube oil operating temperature before engine, from R °C 75
Lube oil operating temperature before engine, to R °C 94
Lube oil operating pressure before engine, from R bar 6.0
Lube oil operating pressure before engine, to R bar 7.5
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.5

Fuel system
Number of cylinders 16
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3
Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25
Fuel supply flow, max. R liters/min 8.6

General operating data

Number of cylinders 16
Firing speed, from R rpm 100
Firing speed, to R rpm 120

Starter (electric)
Number of cylinders 16
Rated starter voltage (standard design) R V= 24

Inclinations – standard oil system (reference: waterline)

Number of cylinders 16
Longitudinal inclination, continuous max. driving end down (Option: max. oper- L Degrees 15
ating inclinations) (°)
Longitudinal inclination, temporary max. driving end down (Option: max. oper- L Degrees 22.5
TIM-ID: 0000010887 - 004

ating inclinations) (°)

Longitudinal inclination, continuous max. driving end up (Option: max. operat- L Degrees 0
ing inclinations) (°)
Longitudinal inclination, temporary max., driving end up (Option: max. operat- L Degrees 10
ing inclinations) (°)
Transverse inclination, continuous max. (Option: max. operating inclinations) L Degrees 22.5
(°)
Transverse inclination, temporary max. (Option: max. operating inclinations) L Degrees 32.5
(°)

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 Capacities
Number of cylinders 16
Engine coolant, engine side (with cooling system) R Liters 135
Engine oil capacity, initial filling (standard oil system) (Option: max. operating R Liters 168
inclinations)
Oil change quantity, max. (standard oil system) (Option: max. operating incli- R Liters 155
nations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 115
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 138
operating inclinations)

Weights / main dimensions

Number of cylinders 16
Engine dry weight (with standard accessories installed, without coupling) R kg 3337

Acoustics
Number of cylinders 16
Exhaust noise, unsilenced – BL (free-field sound-pressure level Lp, 1 m dis- R dB(A) 110
tance, ISO 6798, +3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) – BL (free-field R dB(A) 107
sound-pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)

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 4.3 Firing order
Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7
TIM-ID: 0000038135 - 002

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 4.4 Engine – Main dimensions
Main dimensions

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

12V2000M94 Approx. 2137 mm Approx. 1292.6 mm Approx. 1376 mm
16V2000M94 Approx. 2554 mm Approx. 1292.6 mm Approx. 1416 mm

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

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

Item Action
Engine Depreserve (→ MTU Preservation and Represervation Instructions
A001070/..).
Lube oil system Check engine oil level (→ Page 99).
Fuel prefilter Fill with fuel (→ Page 92).
Fuel prefilter, pressure gage Align adjustable pointer with position of pressure indicator (→ Page 87).
Fuel system Vent (→ Page 83).
Raw water pump (if located Prime (approx. 3 to 4 liters).
above waterline) Filling point (→ Page 106).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 112).
Coolant circuit Check coolant level (→ Page 111).
Coolant circuit Heat engine coolant with coolant preheating unit.
Engine Control Unit ECU Check plug connections (→ Page 130).
Engine Interface Module EIM Check plug connections (→ Page 132).
Engine Monitoring Unit EMU Check plug connections (→ Page 131).
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 5.2 Engine – Putting into operation after scheduled out-of-service-
period
Preconditions
☑ Engine is stopped and starting disabled.

Putting into operation

Item Action
Lube oil system Check engine oil level (→ Page 99).
Coolant circuit Check coolant level (→ Page 111).
Coolant circuit Heat engine coolant with coolant preheating unit.
Fuel prefilter Drain water and contaminants (→ Page 88).
Battery-charging generator Check condition of drive belt (→ Page 119).
drive
Engine Control Unit ECU Check plug connections (→ Page 130).
Engine Interface Module EIM Check plug connections (→ Page 132).
Engine Monitoring Unit EMU Check plug connections (→ Page 131).

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

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

Note: Operate fuel treatment system for at least 5 minutes.
1. Start up fuel treatment system (→ Page 45).
2. Shut down fuel treatment system (→ Page 53).
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 5.4 Checks prior to start-up

Checks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.
b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..).
2. Close drain valves on housing.
3. Open all supply and discharge valves.
4. Switch on fuel treatment system (→ Page 48).
5. Check direction of rotation of pump.
6. Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: The fuel treatment system is ready for operation.

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 5.5 Fuel treatment system – Putting into operation

Fuel treatment system – Overview

1. Switch on fuel treatment system (→ Page 48).

2. Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
1. Remove coalescer filter element (→ Page 125).
2. Check sealing faces on coalescer filter element and in the pressure tank.

Initial operation: HAT

1. Replace fuel filter on engine (→ Page 84).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install a pressure gauge in the fuel supply line from the shipyard-side fuel system to the engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 48).
Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is delivered via
the overflow tank back to the tank. Water which has settled in the tank is separated.
TIM-ID: 0000007738 - 006

4. Start engine (→ Page 49).

5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replace-
ment simulation with the engine running as part of the Harbor Acceptance Tests.

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 Simulation of filter replacement with the engine running: HAT
1. Switch on fuel treatment system (→ Page 48).
2. Start engine (→ Page 49).
3. Run engine at idling speed.
4. Close ball cock (5) at the inlet to the fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball cock (19).
Result: Fuel emerges. If no fuel emerges:
• Open ball cock (5) at the inlet to the fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If all engine operating values are within the specified limits, open ball cock (5) at the inlet to the fuel treat-
ment system.

Simulation of power failure (emergency): HAT

1. Switch on fuel treatment system (→ Page 48).
2. Start engine (→ Page 49).
3. Run engine at idling speed.
4. Switch off pump (21) on switch cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
6. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.

Simulation of power failure (emergency): SAT

1. Switch on fuel treatment system (→ Page 48).
2. Start engine (→ Page 49).
3. Run engine at idling speed.
4. Switch off pump (21) on switch cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful. TIM-ID: 0000007738 - 006

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 5.6 Operational checks
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Operational checks
Item 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 57).
Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter is within the limit
(→ Page 87).
Drain water and contaminants (→ Page 88).
Air filter Check signal ring position of contamination indicator (→ Page 97).
Replace air filter (→ Page 95), if the signal ring is completely visible in the
service indicator observation window.
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 115).
Raw water pump Check relief bore for oil and water discharge and contamination
(→ Page 118).
Intercooler Check condensate drain (if applicable) (→ Page 94).
Engine oil Check engine oil level (→ Page 99).
TIM-ID: 0000002274 - 007

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 5.7 Fuel treatment system – Switching on
Preconditions
☑ The on-board power supply is switched on.

NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
• Before switching on, ensure that the engine/system is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.

Fuel treatment system – Switching on

1. Carry out checks prior to start-up (→ Page 44).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.

TIM-ID: 0000007731 - 006

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 5.8 Starting the engine
Preconditions
☑ External start interlock is not active.
☑ Emergency air shut-off flaps (if fitted) are open.

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

The engine can be started from the following points

Item Action
Control stand (→ Operating instructions for electronic system)
Local Operating Panel LOP (→ Operating instructions for electronic system)
Local Operation Station LOS (→ Operating instructions for electronic system)
CCU (→ Operating instructions for electronic system)
TIM-ID: 0000002240 - 004

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 5.9 Engine – Shutdown
Preconditions
☑ Engine is running in Local mode

CAUTION
Shutting down from full-load operation may cause hot water to escape from the expansion tank.
Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety goggles / safety mask.

NOTICE
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until
engine temperatures have dropped and constant values are displayed.

The engine can be stopped from the following points

Item Action
Control stand (→ Operating instructions for electronic system)
Local Operating Panel LOP (→ Operating instructions for electronic system)
Local Operation Station LOS (→ Operating instructions for electronic system)
CCU (→ Operating instructions for electronic system)

TIM-ID: 0000002298 - 004

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 5.10 Emergency engine shutdown
CAUTION
Shutting down from full-load operation may cause hot water to escape from the expansion tank.
Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety goggles / safety mask.

NOTICE
An emergency stop subjects the engine system to an extremely high load.
Risk of overheating, damage to components!
• Trigger an emergency stop only in emergency situations.

The engine can be stopped from the following points in an emergency

Item Action
Control stand (→ Operating instructions for electronic system)
Local Operating Panel LOP (→ Operating instructions for electronic system)
Local Operation Station LOS (→ Operating instructions for electronic system)
CCU (→ Operating instructions for electronic system)
TIM-ID: 0000002312 - 005

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

NOTICE
Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at
temperatures below 0 °C.
Risk of sensor damage!
• Remove pressure sensors and shake off residual water.

After stopping the engine

Item Measure
Coolant circuit Drain coolant (→ Page 113) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze addi-
tive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Raw water Drain
• if freezing temperatures are to be expected and the engine is to remain
out of service for an extended period.
Engine Control System Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week
tem • Seal engine's air and exhaust sides.
Engine Out-of-service-period > 1 month
• Carry out engine preservation (→ MTU Preservation and Represervation
Specifications A001070/..)

TIM-ID: 0000002324 - 009

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 5.12 Fuel treatment system – Shutdown

Shutting down fuel treatment system

1. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet
stops.
2. Switch off fuel treatment system.
3. Close ball valve at the inlet to the fuel treatment system.
4. Close ball valve at the outlet of the fuel treatment system.
5. Open drain valve until pressure has escaped from fuel treatment system.
TIM-ID: 0000007732 - 005

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 5.13 Plant – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ No operating voltage is applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
High-pressure cleaning unit - 1
Cleaner (Hakupur 50/136) X00056700 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
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety 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 protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• 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 - 032

• 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 direct compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.

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 6 Maintenance
6.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option

Task Maintenance tasks

W0500 Check engine oil level. (→ Page 99)

W0501 Visually inspect engine for leaks and general condition. (→ Page 47)
W0502 Check charge-air cooler drain(s). (→ Page 47)
W0503 Check service indicator of air filter. (→ Page 47)
W0505 Check relief bores of water pump(s). (→ Page 47)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 47)
and vibrations.
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 47)
W0508 X Check reading on contamination indicator of fuel prefilter. (→ Page 47)
W1001 Replace fuel filter or fuel filter element. (→ Page 84)
W1005 Replace air filter. (→ Page 95)
W1006 Replace fuel injectors. (→ Page 80)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 101)
the interval (years) is reached, at the latest.
W1009 X Check layer thickness of oil residue, clean and replace filter (→ Page 103)
sleeve, at every oil change, at the latest.
W1011 Perform endoscopic examination. (→ Page 69)
W1036 Replace coolant filter. (→ Page 117)
W1046 Replace filter or filter element. (→ Page 74)
W1140 Clean wire meshes of crankcase breather. (→ Page 73)
W1207 Check valve clearance and adjust if necessary. IMPORTANT! (→ Page 76)
Initial setting after 1,000 operating hours and after every
overhaul of the cylinder heads after 1,000 operating hours.
W1244 X Check function of rod electrode. (→ Page 123)
W1245 X Check alarm function of differential pressure gauge. (→ Page 122)
TIM-ID: 0000043954 - 002

W1246 X Check pump capacity. (→ Page 124)

Table 2: Maintenance task reference table [QL1]

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 7 Troubleshooting
7.1 Control cabinet of fuel treatment system – Troubleshooting
Water alarm
Cause Corrective action
When the maximum water level is 1. Press illuminated pushbutton 'Water alarm' for acknowledgment.
reached, the water level electrode 2. In addition to the automatic water drain function, water can also be
opens the water drain valve and drained manually: Press illuminated pushbutton 'Water drain'.
water is discharged. If the opening The water drain valve opens.
period of the valve exceeds a
preset limit (4 minutes), the pump
will switch off and an alarm is
initiated.

Pump fault
Cause Corrective action
The drive motor is equipped with u Reset motor protection relay.
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-running,
the motor protection relay
triggers and the pump is switched
off.

Pre-alarm
Cause Corrective action
The differential pressure u Replace coalescer filter element (→ Page 125).
exceeded 1.3 bar.

Replace filter element

Cause Corrective action
The max. permissible differential 1. Replace coalescer filter element (→ Page 125).
pressure exceeded 1.5 bar. If the 2. Press illuminated pushbutton 'Water alarm' for acknowledgment.
coalescer filter element is not
replaced, pressure will increase
further and the safety valve will
TIM-ID: 0000007734 - 009

open. Fuel will be led via the

bypass directly into the overflow
tank.

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 7.2 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery low or faulty u Charge or replace (see manufacturer's documentation).
Battery: Cable connections faulty u Check if cable connections are properly secured (see
manufacturer's documentation).
Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
Engine cabling defective u Check (→ Page 127).
Loose plug connections on Engine u Check plug connections (→ Page 130).
Control Unit
Loose plug connections on Engine u Check plug connections (→ Page 132).
Interface Module (EIM)
Fuse F1 in engine wiring harness u Check fuse (replace if required) and re-start the system by
defective (fuse lamp on EIM actuating the key switch.
flashes with relevant flashing
code)
Running gear blocked (engine u Contact Service.
cannot be barred manually)

Engine turns on starting but does not fire

Cause Corrective action
Poor rotation by starter: Battery u Charge or replace battery (see manufacturer's documentation).
low or faulty
Engine cabling defective u Check (→ Page 127).
Air in fuel system u Vent fuel system (→ Page 83).
Engine Control Unit defective u Contact Service.

Engine fires unevenly

Cause Corrective action
Injector defective u Replace (→ Page 80).
Engine cabling defective u Check (→ Page 127).
Air in fuel system u Vent fuel system (→ Page 83).
Engine Control Unit defective u Contact Service.

Engine does not reach nominal speed

TIM-ID: 0000044001 - 002

Cause Corrective action

Fuel prefilter clogged u Replace (→ Page 92).
Easy-change fuel filter clogged u Replace (→ Page 84).
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 97).
Fuel injection: Injector defective u Replace (→ Page 80).
Engine cabling defective u Check (→ Page 127).
Engine: Overload u Contact Service.

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 Engine speed not steady
Cause Corrective action
Fuel injection: Injector defective u Replace (→ Page 80).
Speed transmitter defective u Contact Service.
Air in fuel system u Vent fuel system (→ Page 83).
Engine Control Unit defective u Contact Service.

Charge-air temperature too high

Cause Corrective action
Incorrect coolant concentration u Check (MTU test kit).
Charge-air cooler clogged u Contact Service.
Engine room: Air-intake u Check fans and air supply/ventilation ducts.
temperature too high

Charge-air pressure too low

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 97).
Charge-air cooler contaminated u Contact Service.
Exhaust turbocharger defective u Contact Service.

Coolant leaks at charge-air cooler

Cause Corrective action
Charge-air cooler leaking, major u Contact Service.
coolant discharge

Black exhaust gas

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 97).
Fuel injection: Injector defective u Replace (→ Page 80).
Engine: Overload u Contact Service.

Blue exhaust gas

Cause Corrective action
Too much engine oil in the engine u Drain engine oil (→ Page 100).
TIM-ID: 0000044001 - 002

Oil separator or oil pre-separator 1. Clean preseparator (→ Page 73).

of crankcase breather clogged 2. Replace oil separator element (→ Page 74).
Exhaust turbocharger, cylinder u Contact Service.
head, piston rings, cylinder liner
defective

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 White exhaust gas
Cause Corrective action
Engine is not at operating u Run engine to reach operating temperature.
temperature
Water in fuel u Drain fuel prefilter (→ Page 88).
Charge-air cooler leaking u Contact Service.
TIM-ID: 0000044001 - 002

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 8 Task Description
8.1 SOLAS
8.1.1 SOLAS shielding as per MTN 5233 – Installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Shield A4 735233000100 10
Shield A5 735233000101 14
Shield A7 735233000103 6
Shield A8 735233000104 2

SOLAS shielding – Installation

1. Pinpoint installation location (→ Page 62).
2. Install suitable shielding.
3. Press shielding until locked.

TIM-ID: 0000010550 - 003

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 8.1.2 SOLAS shielding – Installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is cooled down to ambient temperature.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Oil filter shield X00009628
Fuel filter shield X00009654

Installing SOLAS shield on oil fil-

ter and fuel filter
1. Pinpoint installation location (→ Page 62).
2. Install suitable shielding.
TIM-ID: 0000010702 - 005

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 8.1.3 Installation locations for SOLAS shielding
General information
Install SOLAS shielding as per MTN 5233 as a matter of priority (→ Page 60).

Free end, B side

Item Type of shielding Comments

1 Shield (A7) On fuel delivery pump
2 Shield (A7) On HP fuel pump

Free end

TIM-ID: 0000010064 - 007

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 Item Type of shielding Comments
1 Shield (A8) On fuel filter
2 Shield (A7) Above fuel priming pump
3 Shield (A7) Below fuel priming pump

Driving end, A-side

Item Type of shielding Comments

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

Driving end, A-side

TIM-ID: 0000010064 - 007

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 Item Type of shielding Comments
1 Shield (A5) To exhaust turbocharger lubrication
2 Shield (A5) On valve plate

Driving end

Item Type of shielding Comments

1 Shield (A4) Turbocharger lubrication, left side
2 Shield (A4) Exhaust turbocharger lubrication, center

Driving end

TIM-ID: 0000010064 - 007

Item Type of shielding Comments

1 Shield (A4) Turbocharger lubrication, right side

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 Driving end, B-side

Item Type of shielding Comments

1 Shield (A5) Turbocharger flap
2 Shield (A5) Turbocharger flap
3 Shield (A4) On brazed-on union
4 Shield (A5) On air flap
5 Shield (A4) To exhaust turbocharger lubrication

Driving end, B-side

TIM-ID: 0000010064 - 007

Item Type of shielding Comments

1 Shield (A5) On valve plate

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 Driving end, A-side

Item Type of shielding Comments

1 Shield (A5) To flap control

Driving end, B-side

Item Type of shielding Comments

TIM-ID: 0000010064 - 007

1 Shield (A5) To flap control

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 8.2 Engine
8.2.1 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine barring device F6783914 1
Ratchet with extension F30006212 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring engine manually

1. Fit ratchet with barring device on barring device connection at the vibration damper on engine free end.
2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.
Result: If the resistance exceeds the normal compression resistance, contact Service.
TIM-ID: 0000002527 - 005

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 8.2.2 Engine – Barring with starting system
Preconditions
☑ Engine is disengaged.
☑ Engine is stopped and starting disabled.
☑ LOP is accessible and open.

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring
1. Press and hold the "Turn" button on the LMB
motherboard of the LOP.
Result: Engine is barred by starter for max. 20 sec-
onds.
2. Release "Turn" button.

TIM-ID: 0000027968 - 004

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 8.3 Cylinder Liner
8.3.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring device F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1

Preparatory steps
1. Remove cylinder head cover (→ Page 79).
2. Remove injector (→ Page 81).

Positioning crankshaft at BDC

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

Endoscopic examination of cylinder liner

Findings Measure
• Thin carbon coating around carbon scraper ring No actions required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and do tion required as part of mainte-
not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference are faultless
• Piston rings are faultless
• On the entire circumference, apart from light areas of discoloration (do Cylinder liner must be replaced,
TIM-ID: 0000003304 - 006

not impair operation) clearly darker stripes that start at the top piston contact Service.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
age
• Heat discoloration of piston rings

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 1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 71).
3. Depending on findings:
• Do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.

Final steps
1. Install injector (→ Page 81).
2. Install cylinder head cover (→ Page 79).

TIM-ID: 0000003304 - 006

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 8.3.2 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 examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Findings not critical.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Findings not critical.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Findings not critical.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed 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.
Findings not critical.
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
TIM-ID: 0000000014 - 015

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.

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

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 8.4 Crankcase Breather
8.4.1 Crankcase breather – Cleaning oil pre-separator element
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

Crankcase breather, cleaning oil

pre-separator element
1. Undo clamp (2).
2. Remove hose (1) and clamp (2) from cov-
er (3).
3. Slacken screws (4).
4. Remove screws (4) and washers (5).
5. Remove cover (3), gasket (6), oil pre-separa-
tor (7) and gasket (8).
6. Wash oil pre-separator element (7) and cov-
er (3) in fuel and blow out with compressed
air.
7. Moisten oil pre-separator element (7) with
engine oil.
8. Insert gasket (8) and oil pre-separator ele-
ment (7) with new gasket (6).
9. Place cover (3) in position and tighten screws
(4) and washers (4).
10. Place clamp (2) and hose (1) on cover (3).
11. Tighten clamp (2).
12. Clean other oil pre-separator elements in the
same way.
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 8.4.2 Crankcase breather – Oil separator replacement, diaphragm check and
replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8-40 Nm F30043446 1
Ratchet adapter F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
Diaphragms (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Replacing oil separator filter el-

ement
1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Install cover (2) with new O-ring.

5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
TIM-ID: 0000000017 - 010

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm

6. Replace further oil separator elements in the same way.

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 Checking diaphragm
1. Remove cover (4).
2. Remove spring (5), gasket (2) and dia-
phragm (3).
3. Check diaphragm (3) for damage, fit new dia-
phragm if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new gasket (2) and spring (5) together
with cover (4).

6. Use torque wrench to tighten the screws of cover (4) to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 10 Nm −2 Nm

7. Check diaphragm in other oil separators in the same manner.

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 8.5 Valve Drive
8.5.1 Valve clearance – Check and adjustment
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Valve clearance gage Y4345893 1
Engine barring device F6783914 1
Ratchet with extension F30006212 1
Double-head box wrench F30002800 1
Angular screw driver F30453001 1
Socket wrench F30030450 1
Torque wrench, 20–100 Nm F30026582 1
Measuring instrument Y4345888 1
Engine oil

Preparatory steps
1. Remove air filter (→ Page 96).
2. Remove cylinder head cover (→ Page 79).

Positioning piston of cylinder A1

at TDC
Note: With cylinder head and valve gear installed.
1. Insert preloaded dial gage (2) into measuring
device (4) and secure using screw (1).
2. Install measuring device (4) in cylinder head
and secure using knurled screw (3).
3. Set dial gage (2) to zero.
4. Turn engine using barring tool until piston A1
reaches firing TDC.
Result: The piston is at firing TDC when both rocker
arms are unloaded, i.e. have clearance.
TIM-ID: 0000050016 - 003

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 Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder 1 bank A:
• If rocker arms on cylinder 1 bank A are unloaded, the piston is in firing TDC.
• If rocker arms on cylinder 1 bank A are loaded, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet (I) = 0.3 mm;
• Exhaust (X) = 0.4 mm.
3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table
below.
Position Cylinder 1 2 3 4 5 6 7 8 9 10
12V
Firing TDC in cylinder A1 Bank A IX I– –X I– –X ––
Bank B I– –– –X I– IX –X
Overlap TDC in cylinder A1 Bank A –– –X I– –X I– IX
Bank B –X IX I– –X –– I–
16V
Firing TDC in cylinder A1 Bank A IX –X –X I– –X I– –– ––
Bank B I– –X –– I– IX I– IX –X
Overlap TDC in cylinder A1 Bank A –– I– I– –X I– –X IX IX
Bank B –X I– IX –X –– –X –– I–
I Inlet: Inlet valve adjustment admissible
X Exhaust: Exhaust valve adjustment admissible
– Valve adjustment inadmissible
4. Check gap between valve bridge and rocker arm with valve clearance gage.
5. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance

1. Undo locknut (1) and unscrew adjusting
screw (2) by a few turns.
2. Insert valve clearance gage (3) between valve
bridge and rocker arm.
3. Turn adjusting screw (2) so that valve clear-
ance gage (3) just passes through the gap.
TIM-ID: 0000050016 - 003

4. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)
with Allen key to prevent it from turning.
Name Size Type Lubricant Value/Standard
Locknut M12x1 Tightening torque (Engine oil) 50 Nm

5. Check that valve clearance gage (3) just passes through between valve bridge and rocker arm.
Result: If not, adjust valve clearance.

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 Final steps
1. Remove barring device.
2. Install cylinder head cover (→ Page 79).
3. Install air filter (→ Page 96).

TIM-ID: 0000050016 - 003

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 8.5.2 Cylinder head cover – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8-40 Nm F30043446 1
Centering device F6783025 1
Gasket (→ Spare Parts Catalog)

Preparatory steps
1. Remove air filter (→ Page 96).
2. Remove air guide housing.

Removing and installing cylin-

der head cover
1. Remove screws (1).
2. Remove cylinder head cover (2) with gasket
from cylinder head.
3. Clean installation surface.
4. Check condition of gasket of cylinder head
cover.
Result: Replace damaged seals.
5. Align cylinder head cover (2) with centering
device.
6. Insert and tighten screws (1).

Final steps
1. Install air filter (→ Page 96).
2. Install air guide housing.
3. Check cylinder head covers for leaks.
TIM-ID: 0000004470 - 003

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 8.6 Injector
8.6.1 Injector – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Injector (→ Spare Parts Catalog)

Injector – Replacement
u Remove injector and install new one (→ Page 81).

TIM-ID: 0000042329 - 002

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 8.6.2 Injector – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Socket wrench F30451502 1
Puller F6790629 1
Double-head box wrench F30011450 1
Open-end wrench bit F30025897 1
Box wrench F30451199 1
Alignment device F6790507 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
Pressure pipe tube (→ Spare Parts Catalog)
Hold-down clamp screw (→ Spare Parts Catalog)
Injector (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Preparatory steps
1. Close off fuel supply to engine.
2. Remove cylinder head cover (→ Page 79).

Remove injector
1. Remove HP line (5) using socket wrench.
2. Disconnect cable (4) at injector.
3. Remove screw (2).
4. Take off hold-down clamp (3).
5. Remove injector (1) with puller.
6. Remove O-rings from injector.
7. Mask all connections and bores or seal with
suitable plugs.
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 Installing injector
1. Prior to installation, remove all blanking
plugs.
2. Fit new O-rings on injector and coat with as-
sembly compound.
3. Secure new sealing ring with assembly com-
pound on injector, observing installation posi-
tion of sealing ring.
4. Clean sealing surface on cylinder head and
protective sleeve.
5. Insert injector (1) in cylinder head, ensuring
that it is correctly aligned with the HP line
connection.
6. Fit hold-down clamp (3) in correct installation
position, coat screw (2) with engine oil.
7. Screw in screw (2) and tighten by hand.
8. Coat thread and sealing cone of HP line (5)
and injector (1) with engine oil.
9. Align injector (1) and HP line (5) with align-
ment device.
10. Connect HP line (5) to HP accumulator and
tighten by hand.
11. Connect HP line (5) to injector (1) and tighten
by hand.
12. Tighten screw of hold-down clamp (3) with a box wrench adapter and a torque wrench to specified tightening
torque.
Name Size Type Lubricant Value/Standard
Screw M10 x 85 Tightening torque (Engine oil) 40 Nm + 4 Nm

13. Use socket wrench and torque wrench to tighten HP line (5) to the specified torque.
Name Size Type Lubricant Value/Standard
HP line Tightening torque (Engine oil) 30 Nm + 5 Nm

14. Attach cable (4).

Final steps
1. Install cylinder head cover (→ Page 79).
2. Open fuel supply to engine. TIM-ID: 0000004650 - 005

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 8.7 Fuel System
8.7.1 Fuel system – Venting
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Venting fuel system

1. Unscrew handle (3) at fuel priming pump (2).
2. Open vent plug (1).
3. Operate the pump with the handle (3) until
bubble-free fuel emerges from the vent plug
(1).
4. Close vent plug (1).
5. Unscrew handle (3) at fuel priming pump (2).
TIM-ID: 0000004716 - 004

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 8.8 Fuel Filter
8.8.1 Fuel filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oil filter wrench F30379104 1
Easy-change filter (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial 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.

Preparatory step
u Provide a suitable container to collect the fuel.

Replacing fuel filter with the en-

gine running
1. Note the three-way cock settings listed be-
low:
(A) Both filters are cut in (standard posi-
tion).
TIM-ID: 0000043257 - 003

(B) Right filter is cut out.

(C) Left filter is cut out.

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 Note: Filter replacement on a running engine is per-
missible only with a short-time cutout of the
filter to be replaced.
2. Turn three-way cock to setting (B) to cut out
the filter (2) which is to be replaced:
Result: Fuel filter (2) is cut out of the fuel circuit, but
is still under pressure.
3. Connect venting hose to threaded vent plug
(1) of filter which has been cut out. Lead the
end of the hose to the prepared collecting
container.
4. Carefully turn the threaded vent plug (1) of
the cut out filter to the left. Check that the
fuel filter is depressurized.
5. Close vent plug (1).
6. Unscrew switched off easy-change filter (2)
with oil filter wrench.
7. Clean sealing surface on filter head.
8. Lightly oil sealing ring of new easy-change fil-
ter.
9. Screw on easy-change filter (2) by hand until
seal makes contact, then tighten by hand.
Note: Cut the fuel filter back in slowly following re-
placement to return both filters to operation.
The engine may shut down if the filter is cut
back in too quickly.
10. Turn three-way cock slowly to position (A) to
allow fuel to flow through both filters (stand-
ard position).
11. Replace other fuel filters in the same way.

Replacing fuel filter with the en-

gine at standstill
1. Note the three-way cock settings listed be-
low:
(A) Both filters are cut in (standard posi-
tion).
(B) Right filter is cut out.
(C) Left filter is cut out.
TIM-ID: 0000043257 - 003

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 2. Stop engine and disable engine start.
3. Turn three-way cock to setting (B) to cut out
the filter (1) which is to be replaced.
4. Unscrew switched off easy-change filter (1)
with oil filter wrench.
5. Clean sealing surface on filter head.
6. Lightly oil sealing ring of new easy-change fil-
ter.
7. Screw on easy-change filter (1) by hand until
gasket makes contact, then tighten by hand.
8. Turn three-way cock to position (A) so both
filters are in use (standard position).
9. Replace other fuel filters in the same way.
10. Vent fuel system (→ Page 83).

TIM-ID: 0000043257 - 003

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 8.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Setting adjustable pointer of dif-

ferential pressure gauge
1. After installation of a new filter element, align
adjustable pointer (2) with pressure-indicat-
ing pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within the
limit.

Fuel prefilter – checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating point-
er (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 90).
TIM-ID: 0000045555 - 001

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 8.8.3 Fuel prefilter – Draining
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Draining fuel prefilter

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

TIM-ID: 0000045553 - 004

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 2. Open threaded vent plug (1) of the filter to be
drained.
3. Open drain valve (2).
4. Drain water and contaminants from the filter
until pure fuel emerges.
5. Close drain valve (2).

6. Connect filling pump to filling connection (1)

on the intake side of the filter.
7. Open vent valve (2) and fill with fuel until fuel
emerges from the vent pipe (3).
8. Close vent valve (2).
9. Open rotary slide valve (4) a little (by approx.
30°) and open vent valve(s) (2), until fuel
emerges from the vent pipe (3).
10. Close vent valve(s) (2).
11. Turn rotary slide valve (4) back to locked po-
sition.
TIM-ID: 0000045553 - 004

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 8.8.4 Fuel prefilter – Flushing
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Diesel fuel

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Fuel prefilter – Flushing

1. Cut out contaminated filter (A or B):
1 Filter A cut out
2 Filter B cut out TIM-ID: 0000042959 - 005

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 2. Open threaded vent plug (1) of filter to be
flushed.
3. Open drain valve (2) and drain fuel.
Result: Fuel flows from filtered side back to the unfil-
tered side, flushing the filter deposits down-
wards out of the filter.
4. Close threaded vent plug (1) and drain
valve (2).

Fuel prefilter, filling with fuel

1. Stop engine (→ Page 50) and disable engine start.
2. Connect filling pump to filling connection (1)
on the intake side of the filter.
3. Open vent valve (2) and fill with fuel until fuel
emerges from the vent pipe (3).
4. Close vent valve (2).
5. Open rotary slide valve (4) a little (by approx.
30°) and open vent valve(s) (2), until fuel
emerges from the vent pipe (3).
6. Close vent valve(s) (2).
7. Turn rotary slide valve (4) back to locked po-
sition.
8. Check differential pressure (→ Page 87).
Result: If flushing did not improve differential pres-
sure, replace filter element in fuel prefilter
(→ Page 92).
TIM-ID: 0000042959 - 005

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 8.8.5 Fuel prefilter – Filter element replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel
Filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Replacing filter element

1. Cut out the filter to be replaced (A or B).
1 Filter A cut out
2 Filter B cut out

TIM-ID: 0000045554 - 004

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 2. Open threaded vent plug (1) of contaminated
filter.
3. Unlock drain valve (5) by pressing toggle and
open it.
4. Drain water and dirt from filter.
5. Close drain valve (5).
6. Remove screws securing cover (2) and take
off cover.
7. Remove spring cartridge (3) and filter ele-
ment (4).
8. Insert new filter element (4) and spring car-
tridge (3).
9. Fill filter housing with clean fuel.
10. Place new seal in cover.
11. Fit cover with gasket and secure it with
screws (2).
12. Cut in the cut-out filter again.
13. Close threaded vent plug (1) when fuel
emerges.
14. Set differential pressure display instrument
(→ Page 87).
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 8.9 Charge-Air Cooling
8.9.1 Charge-air cooler – Checking condensate drain line for coolant discharge and
obstruction
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

Charge-air cooler, checking con-

densate drain line for coolant
discharge and obstruction
1. Check drain line for water discharge and ob-
struction when the engine is running idle.
2. If no air emerges, remove condensate drain
line and blow out with compressed air.
3. Replace obstructed drain line by new one.
4. Install condensate drain line.
5. If a large amount of coolant is continuously
discharged, the charge-air cooler is leaking.
Contact Service.

Emergency measures prior to engine start with a leaking charge-air cooler

1. Remove injectors (→ Page 80).
2. Bar engine manually (→ Page 67).
TIM-ID: 0000027574 - 005

3. Bar engine on starting system to blow out combustion chambers (→ Page 68).
4. Install injectors (→ Page 81).

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 8.10 Air Filter
8.10.1 Air filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Air filter (→ Spare Parts Catalog)

Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 96).
2. Reset signal ring of contamination indicator (→ Page 97).
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 8.10.2 Air filter – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque screwdriver, 1–5 Nm F30452774 1

Removing and installing air fil-

ter
1. Release clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of intake housing (3).
3. Verify that there are no objects in the con-
necting flange of the intake housing (3) and
clean it.
4. Place new air filter (1) with clamp (2) onto in-
take housing (3).

5. Tighten screw on clamp (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw - Tightening torque 5 Nm

TIM-ID: 0000005457 - 011

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 8.11 Air Intake
8.11.1 Service indicator – Signal ring position check
Preconditions
☑ Engine is stopped and starting disabled.

Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 95).
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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MS150061/06E 2016-02 | Air Intake | 97

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 8.12 Starting Equipment
8.12.1 Starter – Condition check
Preconditions
☑ Engine is stopped and starting disabled.

Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 127).

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98 | Starting Equipment | MS150061/06E 2016-02

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 8.13 Lube Oil System, Lube Oil Circuit
8.13.1 Engine oil – Level check
Preconditions
☑ Engine is stopped and starting disabled.

Oil level check prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds and
check oil level.
3. Oil level must be between "min." (2) and
"max." (1) marks.
4. Top up with oil up to the "max" (1) mark
(→ Page 100) if required.
5. Insert oil dipstick into guide tube up to the
stop.

Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between "min." and "max." marks.
4. Top up to "max." if required (→ Page 100).
5. Insert oil dipstick into guide tube up to the stop.
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MS150061/06E 2016-02 | Lube Oil System, Lube Oil Circuit | 99

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 8.13.2 Engine oil – Change
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Version with extraction equipment: Engine oil extraction

1. Position a suitable container to drain the engine oil into.
2. Extract all engine oil from oil pan using the extraction equipment.

Filling with new engine oil

1. Determine amount of engine oil required for
oil change (→ Product Summary - Technical
Data).
2. Open cover on filler neck.
3. Pour engine oil in at filler neck up to “max.”
mark on oil dipstick.
4. Close cap on filler neck.
5. Check engine oil level (→ Page 99).
6. After oil change, crank engine on starting
system.

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100 | Lube Oil System, Lube Oil Circuit | MS150061/06E 2016-02

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 8.14 Oil Filtration / Cooling
8.14.1 Engine oil filter – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oil filter wrench F30379104 1
Engine oil
Oil filter (→ Spare Parts Catalog)
SOLAS shield (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Replacing oil filter with the en-

gine stopped
1. Stop engine (→ Page 50) and disable engine
start.
2. Cut out the filter to be replaced.
A Right filter cut out
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B Both filters cut in (normal operating

position)
C Left filter cut out

MS150061/06E 2016-02 | Oil Filtration / Cooling | 101

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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.
6. Fit SOLAS shield (→ Page 60).
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 replacement,
crank engine with starting system
(→ Page 68).
11. Check oil level (→ Page 99).

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.
5. Fit SOLAS shield (→ Page 60).
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 99).

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102 | Oil Filtration / Cooling | MS150061/06E 2016-02

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 8.14.2 Centrifugal oil filter and filter sleeve – Cleaning and replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Oil filter wrench F30379104 1
Cold cleaner(Hakutex 50) X00056751 1
Filter sleeve (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

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.

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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MS150061/06E 2016-02 | Oil Filtration / Cooling | 103

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 Cleaning centrifugal oil filter
and replacing filter sleeve
1. Remove nut, holding the rotor with an oil fil-
ter 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.

104 | Oil Filtration / Cooling | MS150061/06E 2016-02

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 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.
Name Size Type Lubricant Value/Standard
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.
Name Size Type Lubricant Value/Standard
Nut M16 x 1.5 Tightening torque 40 Nm to 50 Nm

14. Insert complete rotor (2) into the housing and

check for ease-of-movement.
15. Set housing cover (1) with new O-ring onto
lower section, observe marks.
16. Tighten nuts (3) crosswise and evenly.
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MS150061/06E 2016-02 | Oil Filtration / Cooling | 105

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 8.15 Coolant Circuit, General, High-Temperature Circuit
8.15.1 Draining and venting points
Figures also apply similarly to 12V and 16V.

Plan view

1 Overflow line, expansion 2 Filler neck

tank

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106 | Coolant Circuit, General, High-Temperature Circuit | MS150061/06E 2016-02

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 Free end (KGS)

1 Fuel filter vent screws 3 Raw water pump filling plug 5 Raw water pump drain plug
2 Engine coolant drain plug 4 Measuring point, pressure 6 Oil extraction connection
before raw water pump
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MS150061/06E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 107

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 Left side

1 Engine coolant drain plug 2 Engine coolant drain plug

(M14x1.5)

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108 | Coolant Circuit, General, High-Temperature Circuit | MS150061/06E 2016-02

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 Right side

1 Engine coolant drain plug 3 Oil dipstick (connection on

(M14x1.5) left or right engine selecta-
2 Oil filler neck (connection ble)
on left or right engine se- 4 Leak-fuel tank
lectable)
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MS150061/06E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 109

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 Driving end (KS)

1 Engine coolant drain plug 2 Oil extraction connection

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110 | Coolant Circuit, General, High-Temperature Circuit | MS150061/06E 2016-02

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 8.15.2 Engine coolant level – Check
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Checking coolant level at filler

neck:
1. Turn breather valve of coolant expansion tank
(→ Page 26) counterclockwise until the first
stop and allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
3. Check coolant level (coolant must be visible
at the lower edge of the cast-in eye of the fill-
er neck).

Coolant-level check by means of level sensor:

1. Switch engine control system on and check display (coolant level is automatically monitored by the engine
control system).
2. Top up with treated coolant as necessary (→ Page 114).
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MS150061/06E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 111

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 8.15.3 Engine coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Engine coolant change

1. Drain engine coolant (→ Page 113).
2. Fill with engine coolant (→ Page 114).

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112 | Coolant Circuit, General, High-Temperature Circuit | MS150061/06E 2016-02

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 8.15.4 Engine coolant – Draining
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Preparatory steps
1. Provide an appropriate container to collect the coolant or
2. Switch on the extraction device.
3. Switch off preheating unit.

Draining engine coolant

1. Turn breather valve of filler neck on coolant expansion tank (→ Page 106) counterclockwise to first stop and
allow pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck.
4. Open drain valves/plugs (→ Page 106) and drain or pump out engine coolant.
5. Close all open drain points.
6. Place breather valve on filler neck and close.
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MS150061/06E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 113

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 8.15.5 Engine coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine coolant

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

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.

Filling with engine coolant

1. Turn breather valve of coolant expansion tank (→ Page 26) counterclockwise until the first stop and allow
pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Pour coolant into engine until coolant level reaches bottom edge of cast-in eye of filler neck.
4. Check satisfactory condition of breather valve and clean sealing faces.
5. Place breather valve on filler neck and close.
6. Start the engine and operate it at idle speed for some minutes.
7. Check coolant level (→ Page 111).

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114 | Coolant Circuit, General, High-Temperature Circuit | MS150061/06E 2016-02

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 8.15.6 HT coolant pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

HT coolant pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Operating Instructions for
Electronic System) and disable engine start.
3. Clean relief bore with a wire if dirty.
• Admissible engine coolant discharge: up to
10 drops per hour;
• Admissible oil discharge: up to 5 drops per
hour.
4. Contact Service if discharge exceeds the
specified limits.
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MS150061/06E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 115

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 8.15.7 Engine coolant sample extraction and analysis
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

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

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Engine coolant sample extraction and analysis

1. Turn breather valve of coolant expansion tank (→ Page 106) counterclockwise until the first stop and allow
pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
4. Draw off approx. 1 liter coolant and drain into a clean container.
5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Fit breather valve and close it.
7. Replace engine coolant corresponding to coolant operation times as per (→ MTU Fluids and Lubricants Speci-
fications A001061/..) (→ Page 113).

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116 | Coolant Circuit, General, High-Temperature Circuit | MS150061/06E 2016-02

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 8.15.8 Coolant filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Oil filter wrench F30379104 1
Coolant filter (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Replacing coolant filter

1. Turn breather valve of coolant expansion tank
counterclockwise (→ Page 26) to the first
stop and allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
3. Remove coolant filter using the oil filter
wrench.
4. Clean the sealing face on the adapter.
5. Coat sealing ring of the new coolant filter
with engine oil.
6. Install and tighten coolant filter by hand.
7. Close breather valve.
8. Check coolant level (→ Page 111).
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MS150061/06E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 117

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 8.16 Raw Water Pump with Connections
8.16.1 Raw water pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Raw water pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Page 50) and disable engine
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, con-
tact Service.

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118 | Raw Water Pump with Connections | MS150061/06E 2016-02

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 8.17 Belt Drive
8.17.1 Drive belt – Condition check
Preconditions
☑ Engine is stopped and starting disabled.
☑ 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 120)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
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MS150061/06E 2016-02 | Belt Drive | 119

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 8.18 Battery-Charging Generator
8.18.1 Battery-charging generator drive – Drive belt replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Drive belt (→ Spare Parts Catalog)

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. Counterhold adjusting lever at square (2).
2. Rotate adjusting lever until drive belt is re-
leased.
3. Secure adjusting lever with screwdriver (1).
4. Remove drive belt.
5. Check cleanness of belt pulleys.
6. Fit new drive belt.
7. Release securing element at adjusting lever.
8. Mount adjusting lever with square (2) slowly
on drive belt.

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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120 | Battery-Charging Generator | MS150061/06E 2016-02

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 8.19 Fuel Supply System
8.19.1 Water drain valve – Check

Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
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MS150061/06E 2016-02 | Fuel Supply System | 121

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 8.19.2 Differential pressure gauge – Check
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking differential pressure gauge

1. Switch on fuel treatment system (→ Page 48).
2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is issued after preset time.
3. Reset alarm points at pressure gauge for differential pressure.

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122 | Fuel Supply System | MS150061/06E 2016-02

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 8.19.3 Water level probe (3-in-1 rod electrode) – Check
Preconditions
☑ System is put out of service and emptied.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking water level probe (3-in-1 rod electrode)

1. Disconnect connector from water level probe.
2. Unscrew water level probe.
3. Disconnect connector from water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
5. Switch on the system.
Result: Water drain valve opens.
6. Leave water level probe in tank.
Result: Alarm must be issued after the preset time.
7. Switch off the system.
8. Disconnect connector from water level probe.
9. Remove water level electrode from tank.
10. Screw in water level electrode.
11. Disconnect connector from water level probe.
12. Fill system, vent and put into operation.
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MS150061/06E 2016-02 | Fuel Supply System | 123

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 8.19.4 Pump capacity – Check
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking pump capacity

1. Install suitable pressure gauge in the intake connection of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 48).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel
and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Checking pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
The wear limit has been reached when the measured value (reduced suction) is 10% lower than the meas-
ured pressure (normal). Repair pump (Contact Service).

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124 | Fuel Supply System | MS150061/06E 2016-02

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 8.19.5 Coalescer filter element – Replacement
Preconditions
☑ System is switched off and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8-40 Nm F30043446 1
Ratchet adapter F30027340 1
Diesel fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Replacing coalescer filter ele-

ment
1. Close ball valve at the inlet and outlet of the
fuel treatment system.
2. Open drain ball valve.
3. Drain fuel.
4. Close drain ball valve.
5. Remove nuts (9) and washers (2).
6. Remove screws (1).
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7. Remove cover with gasket (10).

8. Remove nut (3), washer (8) and end plate (4).
9. Remove coalescer filter element (5).
10. Collect emerging fuel.
11. Clean housing with a non-linting cloth, rinse
with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element (5).
15. Install end plate (4), washer (8) and nut (3).

MS150061/06E 2016-02 | Fuel Supply System | 125

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 16. Use torque wrench to tighten nut (3) to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm

17. Fit gasket (10).

18. Install cover.
19. Install screws (1), washers (2) and nuts (9).
20. Tighten nuts (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.

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126 | Fuel Supply System | MS150061/06E 2016-02

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 8.20 Wiring (General) for Engine/Gearbox/Unit
8.20.1 Engine cabling – Check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037 1

Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
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 8.21 Accessories for (Electronic) Engine Governor / Control System
8.21.1 Engine governor and connector – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037 1

NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.

Engine governor and connector – Cleaning

1. Use isopropyl alcohol to remove coarse dirt from housing surface.
2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.
3. Check legibility of cable labels. Clean or replace illegible labels.

Heavily contaminated connectors on engine governor – Cleaning

Note: Close connectors that are not plugged in with the protective cap supplied.
1. Release latches of connectors and withdraw connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.

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128 | Accessories for (Electronic) Engine Governor / Control System | MS150061/06E 2016-02
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 8.21.2 EMU and connectors – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037 1

NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.

Cleaning EMU and connectors

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

Cleaning severely contaminated connectors on EMU

1. Release the latch and pull off connector.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit and latch connectors.
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 8.21.3 Engine governor plug connections – Check
Preconditions
☑ Engine stopped and starting disabled.
☑ Electronic engine management system is de-energized.

NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.

Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Lock loose connectors.
3. Check dust cap on ECU and EXU connectors for damage and correct seating.

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 8.21.4 Engine Monitoring Unit EMU 7 – Plug connection check
Preconditions
☑ Engine is stopped and starting disabled.

Checking EMU plug connections

1. Check both connectors on EMU (2) for firm
seating. Ensure that the clips (1) are engag-
ed.
2. Check screws (3) of cable clamps on EMU (2)
for firm seating. Ensure that cable clamps are
not faulty.
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 8.21.5 Interface module EIM plug connections – Check
Preconditions
☑ Engine is stopped and starting disabled.

Checking EIM plug connections

1. Check both Tyco plugs (62-pole) (2) on EIM
for firm seating. Ensure that clips (3) are en-
gaged.
2. Check screws (1) of cable clamps on EIM for
firm seating. Ensure that cable clamps are
not faulty.

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 8.21.6 Engine Control Unit – Self-test
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!

ECU7 self-test
1. Switch off power supply to system.
2. Remove connectors X1, X2 and X4 from the
Engine Control Unit.
a) Release lock (3) of connectors (2).
b) Unplug connector (2).
3. Switch on power supply
Result: • The Engine Control Unit is operable if the
diagnostic lamp (1) changes to continuous
illumination within 30 seconds after power
has been switched on.
• If the diagnostic lamp (1) flashes after 30
seconds, replace Engine Control Unit and
(→ contact Service).
• Check the power supply if the diagnostic
lamp remains dark.
4. Switch off power supply.
5. Refit connectors X1, X2 and X4 on Engine
Control Unit.
a) Plug in connector (2).
b) Lock connectors.
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 8.21.7 Engine governor ECU 7 – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine electronics is powered off.

NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.

Removing engine governor from

engine
1. Note or mark assignment of cables and
plugs.
2. Remove all screws (3).
3. Undo clips (2) on connectors.
4. Remove all male connectors.
5. Remove screws (1).
6. Take off engine governor.

Installing engine governor on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.

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 8.21.8 Engine Monitoring Unit – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.

Removing Engine Control Unit

with Engine Monitoring Unit
from engine
1. Note or mark assignment of cables and con-
nectors.
2. Remove all screws (2).
3. Release lock (3) on connectors.
4. Remove all connectors.
5. Remove screws (1).
6. Remove Engine Control Unit (1) with Engine
Monitoring Unit (4).

Removing Engine Monitoring Unit

1. Unscrew screws on base of Engine Monitoring Unit (4).
2. Remove Engine Monitoring Unit (4) with Engine Control Unit (1).

Installing Engine Monitoring Unit

1. Place Engine Monitoring Unit (4) in position on Engine Control Unit (1).
2. Screw in and tighten screws on base of Engine Monitoring Unit (4).

Installing Engine Control Unit with Engine Monitoring Unit on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
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 8.21.9 Engine Interface Module EIM – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Removing EIM from the engine

1. Note or mark assignment of cables and con-
nectors.
2. Unscrew all screws (1).
3. Undo clips (2) on connectors.
4. Disconnect all connectors.
5. Unscrew power and starter cable.
6. Remove screws (3).
7. Take off EIM.

Installing EIM on the engine

1. Install in reverse order. When doing so, observe correct assignment between cables and plugs.
2. Check seal before installing.
Result: Replace seal if porous or defective.

Downloading software
1. The new EIM still does not have appropriate FSW and parameter/descriptor module (the diagnostic lamp (DI-
LA) indicates flashing code 4 when the power supply is connected, (→ Page 137)).
2. The FSW and the parameter/descriptor module must first be downloaded from the central database (CDB)
based on the relevant engine number using the DiaSys software tool, and then loaded in the EIM.

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 8.21.10 Diagnostic features on EIM
Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM).
It indicates the operating status of the EIM.
Functions of diagnostic lamp DILA
DILA lights Engine Interface Module (EIM) is OK.
DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes Hardware or software fault in the Engine Interface Module.

The diagnostic lamp (DILA) signals the following states:

1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM faulty 8 Application crashed
3 Ready for operation 6 External FLASH faulty

Fuse lamp (SILA)

A second indicator is the fuse lamp.
TIM-ID: 0000038009 - 004

This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a "tripped fuse" fault directly at the unit as it is often difficult
to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark Normal operating state
SILA flashes orange One or more fuses have tripped.

The fuse lamp (SILA) signals the following states:

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 1 Preamble 6VSP current path failed (S5) 11 ES pushbutton current path
2 ECU current path failed (S1) 7SLD current path failed (S6) failed – 24 V external (S10)
3 MCS current path failed 8DDV current path failed (S7) 12 Key switch current path
(S2) 9Gear monitoring current failed (S11)
4 EMU current path failed path failed (S8) 13 SDAF 1 and 2 current path
(S3) 10 Emergency stop current failed (S12)
5 Starter voltage: Terminal path failed – 24 V internal 14 PIM current path failed
30, 31 not connected and (S9) (S13)
PR 10.0600.001 has value 15 Spare current path failed
1 or 2 (S4) (S14) (only for EIM with
ECU 7)
The failed current paths are signaled consecutively following the preamble (1) (LED on for 4 seconds). There
is a pause lasting 4 seconds in between.

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 Sample flashing sequences

A Fuse S5 failure (1/2 second B Fuse S1 and fuse S4 failure

steps) (1/2 second steps)
Note:
These bit patterns are continuously transmitted.
The CAN message "Status of internal power supply" also contains information on the current path states of
the EIM.
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 9 Appendix A
9.1 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
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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

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 Abbrevia- Meaning Explanation
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

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 Abbrevia- Meaning Explanation
tion
WZK Werkzeugkatalog Tool Catalog (TC)
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for
signals from the ADEC engine governor

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 9.2 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure 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 high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
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: spare.parts@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
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 10 Appendix B
10.1 Special Tools
Alignment device
Part No.: F6790507
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 81)

Angular screw driver

Part No.: F30453001
Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

Barring device
Part No.: F6555766
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 69)

DCL-ID: 0000010704 - 006

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 Box wrench
Part No.: F30451199
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 81)

Centering device
Part No.: F6783025
Qty.: 1
Used in: 8.5.2 Cylinder head cover – Removal and installation
(→ Page 79)

Crossbeam
Part No.: T80091731
Qty.: 1
Used in: 2.1 Transportation (→ Page 16)

Crossbeam
Part No.: T80092210
Qty.: 1
Used in: 2.1 Transportation (→ Page 16)
DCL-ID: 0000010704 - 006

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 Double-head box wrench
Part No.: F30002800
Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

Double-head box wrench

Part No.: F30011450
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 81)

Endoscope
Part No.: Y20097353
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 69)

Engine barring device

Part No.: F6783914
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 67)
Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
DCL-ID: 0000010704 - 006

(→ Page 76)

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 High-pressure cleaning unit
Part No.: -
Qty.: 1
Used in: 5.13 Plant – Cleaning (→ Page 54)

Measuring instrument
Part No.: Y4345888
Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 8.15.7 Engine coolant sample extraction and analysis
(→ Page 116)

Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 8.8.1 Fuel filter – Replacement (→ Page 84)
Qty.: 1
Used in: 8.14.1 Engine oil filter – Replacement (→ Page 101)
Qty.: 1
Used in: 8.14.2 Centrifugal oil filter and filter sleeve – Cleaning and
replacement (→ Page 103)
Qty.: 1
Used in: 8.15.8 Coolant filter – Replacement (→ Page 117)
DCL-ID: 0000010704 - 006

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 Open-end wrench bit
Part No.: F30025897
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 81)

Puller
Part No.: F6790629
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 81)

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.4.2 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 74)
Qty.: 1
Used in: 8.19.5 Coalescer filter element – Replacement
(→ Page 125)

Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 8.2.1 Engine – Barring manually (→ Page 67)
Qty.: 1
Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 69)
DCL-ID: 0000010704 - 006

Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

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 Socket wrench
Part No.: F30030450
Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

Socket wrench
Part No.: F30451502
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 81)

Torque screwdriver, 1–5 Nm

Part No.: F30452774
Qty.: 1
Used in: 8.10.2 Air filter – Removal and installation (→ Page 96)

Torque wrench, 20–100 Nm

Part No.: F30026582
Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
(→ Page 76)
DCL-ID: 0000010704 - 006

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 Torque wrench, 8-40 Nm
Part No.: F30043446
Qty.: 1
Used in: 8.4.2 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 74)
Qty.: 1
Used in: 8.5.2 Cylinder head cover – Removal and installation
(→ Page 79)
Qty.: 1
Used in: 8.19.5 Coalescer filter element – Replacement
(→ Page 125)

Valve clearance gage

Part No.: Y4345893
Qty.: 1
Used in: 8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

DCL-ID: 0000010704 - 006

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 10.2 Index
A Cylinder liner 
Abbreviations 140 – Endoscopic examination  69
Actuators  – Instructions and comments on endoscopic and visual
– Overview  28 examination  71
After stopping the engine 52
D
Air filter 
– Installation  96 Diagnostic features 
– Removal  96 – On EIM  137
– Replacement  95 Diagnostic lamp (DILA) 
– On EIM  137
B Differential pressure gauge 
Battery-charging generator drive  – Check  122
– Drive belt   Dimensions 
– Replacement  120 – Engine  40
Draining points 106
C Drive belt 
Cabling  – Condition check  119
– Check   – Replacement  
– On engine  127 – Battery-charging generator drive  120
Centrifugal oil filter 
E
– Cleaning  103
– Filter sleeve replacement  103 ECU 7 
Charge-air cooler  – Installation  134
– Check   – Removal  134
– Condensate drain line  94 EMU 
– Coolant discharge  94 – Cleaning  129
– Obstruction  94 EMU 7 
Checks  – Plug connection check  131
– Prior to start-up  44 Engine 
Coalescer filter element  – Barring  
– Replacement  125 – Manually  67
Connector  – Barring with starting system  68
– Cleaning  128 – Emergency shutdown  51
Connectors  – Main dimensions  40
– Cleaning  129 – Overview  26
Contact persons 143 – Shutdown  50
Coolant  – Start  49
– Change  112 Engine cabling 
– Sample   – Check  127
– Analysis  116 Engine Control Unit 
– Extraction  116 – Self-test  133
Coolant filter  Engine coolaant 
– Replacement  117 – Sample  
– Extraction  116
DCL-ID: 0000010704 - 006

Crankcase breather 
– Cleaning oil pre-separator element  73 Engine coolant 
– Diaphragm check  74 – Change  112
– Oil separator element replacement  74 – Draining  113
Cylinder  – Filling  114
– Designation  19 – Sample  
Cylinder head cover  – Analysis  116
– Installation  79 Engine coolant level 
– Removal  79 – Check  111
Engine data 
– 12V2000M94  33
– 16V2000M94  36

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 Engine driving end  I
– Definition  19 Injector 
Engine free end  – Installation  81
– Definition  19 – Removal  81
Engine governor  – Replacement  80
– Cleaning  128 Installation locations 
– Plug connections   – SOLAS shielding  62
– Check  130 Interface module EIM 
Engine governor ECU 7  – Check  132
– Installation  134
– Removal  134 L
Engine Interface Module EIM   Lifting requirements 17
– Removal and installation  136
Engine Monitoring Unit  M
– Removal and installation  135 Main dimensions 
Engine Monitoring Unit EMU 7  – Engine  40
– Plug connection check  131 Maintenance schedule 
Engine oil  – Maintenance task reference table [QL1]  55
– Change  100 MTU contact persons 143
Engine oil filter 
– Replacement  101 O
Engine oil level  Oil filter 
– Check  99 – Replacement  101
Engine sides  Oil pre-seperator element 
– Designation  19 – Cleaning  73
Operational checks  47
F
Firing order 39 P
Fuel  Plant 
– Treatment system   – Cleaning  54
– Switching on  48 Plug connections 
– Troubleshooting  56 – Check  132
– treatment system   Product description 20
– Shutdown  53 Pump capacity 
Fuel filter  – Check  124
– Replacement  84 Putting into operation 
Fuel prefilter  – Fuel treatment system  45
– Differential pressure gauge  
– Adjustment  87 R
– Check  87 Raw water pump 
– Draining  88 – Relief bore  
– Filter element   – Check  118
– Replacement  92 Resilient mount 
– Flushing  90 – Shipping lock  
Fuel system  – Installation  18
– Venting  83 – Removal  18
Fuel treatment system 
S
DCL-ID: 0000010704 - 006

– Putting into operation  45

– Shutdown  53 Safety notices, standards 15
– Switching on  48
Fuse lamp (SILA) 
– On EIM  137

H
Hotline 143
HT coolant pump 
– Check  
– Relief bore  115

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 Safety regulations 
– Auxiliary materials  13
– Environmental protection  13
– Fire prevention  13
– Fluids and lubricants  13
– Important provisions  5, 6
– Maintenance work  10
– Operation  8
– Organizational requirements  7
– Personnel requirements  7
– Repair work  10
– Startup  8
Safety requirements 
– Safety notices, standards  15
Sensors 
– Overview  28
Service indicator 
– Signal ring position check  97
Service partners 143
Shipping lock 
– Installation  
– Resilient mount  18
– Removal  
– Resilient mount  18
SOLAS shielding 
– Installation  61
– Installation locations  62
SOLAS shielding as per MTN 5233 – Installation 60
Spare parts service 143
Starter 
– Condition check  98
Startup 
– After extended out-of-service periods (>3 months)  41
– Putting into operation after scheduled out-of-service-pe-
riod  42

T
Tasks 
– After extended out-of-service periods  43
Tasks after extended out-of-service periods (>3 weeks) 43
Transportation 
– Description  16
– Lifting requirements  17
Troubleshooting 57
– Fuel treatment system  56

V
DCL-ID: 0000010704 - 006

Valve clearance 
– Adjustment  76
– Check  76
Venting points 106

W
Water drain valve 
– Check  121
Water level probe (3-in-1 rod electrode) 
– Check  123

MS150061/06E 2016-02 | Index | 153

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