Operating Instructions Diesel engine - MTU

Operating Instructions Diesel engine 8 V 2000 M40A, 8 V 2000 M40B 12 V 2000 M40A, 12 V 2000 M40B 12 V 2000 M41A, 12 V 2000 M41B 16 V 2000 M40A, 16 V 2000 M40B 16 V 2000 M41A, 16 V 2000 M41B

MS150031/03E

Printed in Germany © 2011 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.

Commissioning Note Important Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ ranty, spare parts, etc.).

Table of Contents 1 Safety 1.1 1.2 1.3 1.4

General conditions Personnel and organizational requirements Transportation Safety precautions when working on the engine 1.5 Fluids and lubricants, fire prevention and environmental protection 1.6 Conventions for safety instructions in the text

8 9 10 13 15 17

2 Product Summary

DCL-ID: 0000005762 - 004

2.1 2.2 2.3 2.4 2.5 2.6

Product description Series 2000 M40A/B - M41A/B Engine side and cylinder designations Engine – Main dimensions Firing order Technical Data

2.6.1 8V 2000 M40A engine data: engine-mounted heat exchanger, reference conditions: 25 °C intake air temperature 2.6.2 8V 2000 M40A engine data: separate heat exchanger, reference conditions: 25 °C intake air temperature 2.6.3 8V 2000 M40B engine data, engine-mounted heat exchanger, reference condition: 25 °C intake air temperature 2.6.4 8V 2000 M40B engine data, separate heat exchanger, reference condition: 25 °C intake air temperature 2.6.5 12V 2000 M40A engine data: Enginemounted heat exchanger, reference conditions: 45 °C intake air temperature 2.6.6 12V 2000 M40A engine data: Enginemounted heat exchanger, reference conditions: 25 °C intake air temperature 2.6.7 12V 2000 M40A engine data: Separate heat exchanger, reference conditions: 25 °C intake air temperature 2.6.8 12V 2000 M40A engine data: Separate heat exchanger, reference conditions: 45 °C intake air temperature 2.6.9 16V 2000 M40A engine data: engine-mounted heat exchanger, reference conditions: 25 °C intake air temperature 2.6.10 16V 2000 M40A engine data: engine-mounted heat exchanger, reference conditions: 45 °C intake air temperature 2.6.11 16V 2000 M40A engine data: separate heat exchanger, reference conditions: 25 °C intake air temperature

18 27 28 29 30 31 31

34

37

40

43

46

2.6.12 16V 2000 M40A engine data: separate heat exchanger, reference conditions: 45 °C intake air temperature 2.6.13 16V 2000 M40B engine data, engine-mounted heat exchanger, reference condition: 45 °C intake air temperature 2.6.14 16V 2000 M40B engine data, engine-mounted heat exchanger, reference condition: 25 °C intake air temperature 2.6.15 16V 2000 M40B engine data, separate heat exchanger, reference condition: 45 °C intake air temperature 2.6.16 16V 2000 M40B engine data, separate heat exchanger, reference condition: 25 °C intake air temperature 2.6.17 ENGINE DATA 12V 2000M41A/B 2.6.18 ENGINE DATA 16V 2000M41A/B

3.1 LOP – Controls 3.2 Putting the engine into operation (out-ofservice period > 3 months) 3.3 Putting the engine into operation after scheduled out-of-service period 3.4 Starting the engine from LOP 3.5 Operational checks 3.6 Stopping the engine at the LOP 3.7 Emergency stop from LOP 3.8 After stopping the engine 3.9 Plant – Cleaning

70

73

76 79 82

85 87 88 89 90 91 92 93 94

4 Maintenance 4.1 Maintenance task reference table [QL1]

5 Troubleshooting

52

5.1 Troubleshooting 5.2 LOP alarms

58

67

3 Operation

49

55

64

95

96 99

6 Task Description 6.1 Engine

6.1.1 Engine – Barring manually 6.1.2 Engine – Barring with starting system

104

104 105

61

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6.2.1 Cylinder liner – Endoscopic examination 6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners

6.3 Crankcase Breather

6.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement 6.3.2 Crankcase breather – Cleaning oil separator element 6.3.3 Crankcase breather – Oil separator replacement, diaphragm check and replacement

6.4 Valve Drive

6.4.1 Valve clearance – Checking and adjusting 6.4.2 Cylinder head cover – Removal and installation

6.5 Injection Pump / HP Pump

6.5.1 Injection pump – Replacement 6.5.2 Injection pump – Removal and installation

6.6 Injection Valve / Injector

6.6.1 Injector – Replacement 6.6.2 Injector – Removal and installation

6.7 Fuel System

6.7.1 HP fuel line – Pressure pipe union replacement 6.7.2 Fuel – Draining 6.7.3 Fuel system venting

6.8 Fuel Filter

6.8.1 Fuel filter – Replacement 6.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge 6.8.3 Fuel prefilter – Draining 6.8.4 Fuel prefilter – Flushing 6.8.5 Fuel prefilter – Filter element replacement

6.9 Charge-Air Cooling

6.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction

6.10 Air Filter

6.10.1 Air filter – Replacement 6.10.2 Air filter – Removal and installation

106

106 108

110 110 112

113

115

115 118

119

119 120

123

123 124

128 128 130 131

133

133 135 136 137 139

141 141

142

142 143

6.11 Air Intake

144

6.12 Starting Equipment

145

6.13 Lube Oil System, Lube Oil Circuit

146

6.14 Oil Filtration / Cooling

148

6.11.1 Service indicator - Signal ring position check 6.12.1 Starter – Condition check 6.13.1 Engine oil level – Check 6.13.2 Engine oil – Change

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144

6.14.1 Oil dipstick – Marking 6.14.2 Engine oil filter – Replacement 6.14.3 Centrifugal oil filter – Cleaning and filtersleeve replacement

6.15 Coolant Circuit, General, HighTemperature Circuit 6.15.1 6.15.2 6.15.3 6.15.4 6.15.5 6.15.6 6.15.7

Drain and venting points Engine coolant – Level check Engine coolant – Change Engine coolant – Draining Engine coolant filling HT coolant pump – Relief bore check Engine coolant – Sample extraction and analysis

148 149 151

154

154 159 160 161 162 163 164

6.16 Raw Water Pump with Connections

165

6.17 Belt Drive

166

6.18 Battery-Charging Generator

167

6.16.1 Raw water pump – Relief bore check 6.17.1 Drive belt – Condition check 6.18.1 Battery-charging generator drive – Drive belt check and adjustment 6.18.2 Battery-charging generator drive – Drive belt replacement

6.19 Engine Mounting / Support

6.19.1 Engine mounting – Checking condition of resilient mounts

165 166

167 169

171 171

6.20 Wiring (General) for Engine/Gearbox/Unit

172

6.21 Accessories for (Electronic) Engine Governor / Control System

173

6.20.1 Engine wiring – Check

6.21.1 Engine control unit and connectors – Cleaning 6.21.2 Engine monitoring unit and connectors – Cleaning 6.21.3 Start interlock limit switch – Check 6.21.4 ECU – Checking plug connections 6.21.5 Engine monitoring unit, plug connections – Check 6.21.6 Engine control unit – Removal and installation

6.22 Emergency Instrumentation (Local Operating Panel) 6.22.1 LOP and connectors – Cleaning 6.22.2 LOP – Visual inspection 6.22.3 LOP – Test procedures

172

173 174 175 176 177 178

180

180 181 183

145 146 147

7 Appendix A 7.1 Abbreviations 7.2 MTU contacts/service partners

185 187

DCL-ID: 0000005762 - 004

6.2 Cylinder Liner

8 Appendix B 188

192 194

DCL-ID: 0000005762 - 004

8.1 Special Tools

8.2 Consumables 8.3 Index

MS150031/03E 2011-10 | Table of Contents | 7

1 Safety 1.1 General conditions General In addition to the instructions in this publication, the applicable country-specific legislation and other com‐ pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may nevertheless present a risk of injury or damage in the following cases: • Incorrect use • Operation, maintenance and repair by unqualified personnel • Modifications or conversions • Noncompliance with the Safety Instructions

Correct use The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐ aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user alone. Correct use also includes observation of and compliance with the operating instructions and mainte‐ nance and repair specifications.

Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.

Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

Reworking components

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Repair or engine overhaul must be carried out in workshops authorized by MTU.

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1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company.

Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐ tion. Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and transport personnel at all times. Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐ nel must have read and understood the safety-relevant instructions. This is especially important for personnel who work on the engine only on an occasional basis. These persons shall receive repeated instruction. Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.

Working clothes and protective equipment Wear proper protective clothing for all work.

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

MS150031/03E 2011-10 | Safety | 9

1.3 Transportation Transport without flange-mounted gearbox Illustration is essentially valid for 8V 2000 M engines

Transport with flange-mounted gearbox Illustration is essentially valid for 8V 2000 M engines

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

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

Only use the lifting eyes provided to lift the engine. The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plants with flange-mounted gearboxes. Only use transport and lifting devices approved by MTU. Take the engine's center of gravity into account. MS150031/03E 2011-10 | Safety | 11

The engine must only be transported in installation position, max. permissible diagonal pull 10°. If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐ ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck). Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐ portation. Secure the engine against tilting during transport. In particular when going down inclines or ramps, the engine must be secured against moving and tilting.

Setting the engine down after transport Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.

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Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-tocase basis.

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1.4 Safety precautions when working on the engine

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Safety requirements for maintenance and repair work • Maintenance and repair work may only be carried out by authorized, qualified personnel. • Allow the engine to cool down before commencing maintenance work (oil vapors present a risk of ex‐ plosion). • Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. • Take special care when removing ventilation or plug screws from engine. Cover the screw or plug with a rag to prevent fluids escaping under pressure. • Take special care when draining hot fluids ⇒ risk of burning. • When changing the engine oil or working on the fuel system, ensure that the engine room is ade‐ quately ventilated. • Prior to all work, allow the engine / genset to cool down. • Observe maintenance and repair instructions. • Never perform care or maintenance work with the engine running unless expressly instructed to do so. • Lock-out/tag-out the engine to preclude undesired starting. • With electric starter, disconnect the battery. • Close the main valve on the compressed-air system and vent the compressed-air line when air start‐ ers are fitted. • Disconnect the control device from the assembly or plant. • Only use adequate, calibrated tools.During assembly and disassembly, observe the specified tighten‐ ing torques. • Carry out work only on assemblies or plants that are secured as specified. • Do not use lines as climbing aids. • Keep fuel injection lines and connections clean. • Always fit caps/covers to close off any openings exposed by removing or opening lines. • Take care to avoid damaging fuel lines in the course of care and maintenance work. • Ensure that all mounts and dampers are correctly installed. • Ensure that all fuel injection and pressurized oil lines are installed with enough space to prevent con‐ tact with other components. Do not place fuel or oil lines near hot components. • Do not touch elastomeric seals (e.g. Viton sealing rings) if they have carbonized or resinous appear‐ ance. • Note cooling period for components which are heated for installation or removal ⇒ Risk of burning! • When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐ nents are placed on stable surfaces. • Observe special cleanness during maintenance and repair work on the assembly or plant. After com‐ pletion of maintenance and repair work, make sure that no loose objects are in/on the assembly or plant. • Ensure that all personnel is clear of danger zones before turning the engine. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the en‐ gine. • If starters with beryllium copper pinions are installed, the following also applies: To avoid health risks with the pinion containing beryllium, breathing protection of filter class P2 must be worn during maintenance work. Do not blow out the interior of the flywheel housing and the starter with compressed air. The interior of the flywheel housing must be additionally cleaned with a dustremoval machine of class H.

Welding work Never carry out welding work on the assembly or engine plant or mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or plant as a ground terminal. Never place the welding cable across or near wiring harnesses of MTU plants. The welding current may otherwise induce an interference voltage in the wiring harnesses which could damage the electrical sys‐ tem. MS150031/03E 2011-10 | Safety | 13

If welding has to be carried out on components (e.g. exhaust manifold), these components must first be removed from the engine.

Hydraulic installation and removal Check the tools and devices to be used for perfect operation and safe condition. Only use the specified devices for force-fitting/removing parts. Observe the maximum press-on pressure for the device for force-fitting/removing parts. Do not attempt to bend or exert force on H.P. lines. Observe the following before starting the pressing procedure: • Bleed air from jigs and fixtures for force-fitting/removing parts, pumps and piping at the points provid‐ ed for the system concerned (e.g. open threaded vent plugs, pump until no bubbles can be discerned in the oil, close threaded vent plugs). • 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 tool with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed.

Working on electrical/electronic assemblies Before starting any maintenance or repair work, or before switching off any electronic components nec‐ essary to carry out the work, permission must first be obtained from the relevant manager or supervisor. Before work is carried out on the assemblies, the power supply to the relevant areas must be switched off. Do not damage wiring during the removal work. When reinstalling, ensure that the wiring cannot be dam‐ aged during engine operation through contact with sharp edges, rubbing against a component or through contact with a hot surface. Do not secure cables on lines carrying fluids. Do not use cable clamps to secure the lines. Only tighten union nuts of connectors with connector pliers. On completion of all repair work, the device or system must undergo a function check. Before replacement, ensure that spare parts are correctly stored, i.e. in particular, protected against moisture. Defective electronic components and assemblies must be suitably packed when dispatched for repair, i.e. in particular, protected against moisture and impact and wrapped in antistatic foil if necessary.

Work with laser devices

Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensuring safe operation. For conducting light-beam procedures and measurement work, only the following laser devices may be used: • Laser devices in classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface have been designed in such a way as to prevent any risk to the eyes.

14 | Safety | MS150031/03E 2011-10

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When working with laser equipment, always wear special laser-protection goggles ⇒ eye injury through strongly concentrated beam.

1.5 Fluids and lubricants, fire prevention and environmental protection Fire prevention Correct fuel or oil leaks immediately. Quantities of oil or fuel on hot components can cause fires – there‐ fore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying on or near the assembly or plant. Do not store inflammable material near the assembly or plant. Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid. When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter. Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its handling.

Noise Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating danger are drowned. At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors.

Environmental protection and disposal Modification or removal of mechanical or electronic components or the installation of additional compo‐ nents as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations. Emission control units/systems may only be main‐ tained, exchanged or repaired if the components used for this purpose are approved by MTU. Noncom‐ pliance with these guidelines might represent a violation of the Clean Air Act and could involve the termi‐ nation of the operating license by the emission authorities. MTU does not accept any liability for viola‐ tions of the emission regulations. MTU will provide assistance and advice if emission-relevant compo‐ nents are intended to be modified. The MTU Maintenance Schedules ensure the reliability and perform‐ ance of MTU engines and must be complied with over the entire life cycle of the engine. Only fuels of the specified quality required to achieve emission limits must be used. Dispose of used fluids, lubricants and filters in accordance with local regulations. Batteries can be returned within the EU to MTU FN / MTU Onsite Energy free of charge for correct recy‐ cling/disposal.

Fluids and lubricants

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Use only fluids and lubricants that have been tested and approved by MTU. Fluids and lubricants must be kept in suitable, correctly labeled containers. When using fluids, lubricants and other chemical substances, follow the safety instructions that apply to the product. Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do not smoke.

Used oil Used oil contains combustion residue harmful to health. Rub your hands with skin protection cream. Wash your hands after contact with used oil.

MS150031/03E 2011-10 | Safety | 15

Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Prevent the buildup of white powder of lead. • Switch on fume extraction system. • After coming into contact with lead or lead-containing materials, wash your hands!

Compressed air When working with compressed air, safety precautions must be constantly observed: • Pay special attention to the pressure level in the compressed air network and pressure vessel! • Assemblies or plants to be connected must either be designed for this pressure, or, if the permitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. • Hose couplings and connections must be securely attached. • Always wear protective goggles when blowing off tools or extracting chips. • Provide the mouthpiece of the air nozzle with a protective disk (e.g. made of rubber). • First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or before equipment or tool is to be replaced. • Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a risk of explosion! • Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of bursting! • Carry out the leak check as specified.

Painting • When carrying out painting work outside the spray stands provided with fume extraction systems, en‐ sure that the area is well ventilated. Make sure that neighboring work areas are not impaired. • No naked flames! • No smoking! • Observe all fire-prevention regulations! • Always wear a mask providing protection against paint and solvent vapors!

Liquid nitrogen • • • • •

Store liquid nitrogen only in small quantities and always in specified containers without fixed covers. Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask! Make sure that working area is well ventilated. Take great care not to subject containers, fittings and tools to impact or shock.

• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing. • If acids or alkalis are spilled onto clothing, remove the affected clothing immediately! • Rinse injured parts of the body thoroughly with clean water! • Rinse eyes immediately with eyedrops or clean mains water!

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Acids/alkaline solutions

1.6 Conventions for safety instructions in the text DANGER

WARNING

CAUTION

Note:

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

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

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

This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions Read and familiarize yourself with all safety notices before starting up or repairing the product. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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1. 2.

MS150031/03E 2011-10 | Safety | 17

2 Product Summary 2.1 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving end), with direct injection, exhaust turbocharging and intercooling. The engine is monitored by an engine control and monitoring system. Monitoring in the engine room is carried out by the engine control and monitoring unit.

Fuel system Electronically controlled unit injection pumps with jacketed HP lines. The electronic control unit controls • Injection start • Injection quantity

Exhaust system The exhaust system is equipped with triple-walled, water-cooled exhaust lines. The triple-walled design permits • Low surface temperature, • Reduced amount of heat to be dissipated by the coolant • Absolute gas-tightness.

Turbocharging Sequential turbocharging with intercooling (turbochargers can be cut in/out during operation).

Cooling system Engine cooled by split-circuit cooling system with plate-core heat exchanger.

Service block The service components are mounted at the auxiliary PTO end. Service-components: • Raw water pump, coolant pump • Fuel duplex filter, switchable • Lube-oil multiple filter, switchable • Centrifugal lube oil filter • Coolant expansion tank

Electronic system Electronic control and monitoring system with integrated safety and test system, providing interfaces to Remote Control System (RCS) and Monitoring and Control System (MCS).

18 | Product Summary | MS150031/03E 2011-10

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The arrangement facilitates easy access for maintenance operations.

Electronic Engine Control Unit (ECU) Functions: • Engine speed control with fuel and speed limitation dependent on engine state and operating condi‐ tions; • Control of sequential turbocharging; • Data processing logistics for analog and binary signals; • Interface for data transfer to CAN field bus for remote control and ship-side monitoring; • RS 232 interface for connection of MTU dialog unit. Electronic Engine Monitoring Unit (EMU), optional Functions: • Data processing logistics for analog and binary signals; • Interface for data transfer to CAN field bus for remote control and ship-side monitoring. Electronic Gear Control Unit (GCU), ship-side wall-mounting Functions: • Date processing logistics for gear coupling control; • Input/output signals as well as data transfer to CAN field bus for remote control and ship-side monitor‐ ing. Monitoring in engine room Engine control and monitoring unit (LOP) Functions: • Alphanumeric, monochrome LCD display for monitoring of measured values as well as alarms when limits are violated; • Pushbuttons for menu control and dimming unit; • Combined control and display elements for local engine/gear control; • Flashing light and horn for summary alarm in engine room; • Interface to CAN field bus for connected, communicating monitoring system components.

SOLAS – Fire protection specifications All fuel lines with fuel pressure >1.8 bar are fitted with SOLAS-compliant covers acc. to MTU standard MTN5233.

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All oil lines with oil pressure >1.8 bar are fitted with SOLAS-compliant covers acc. to MTU standard MTN5233.

MS150031/03E 2011-10 | Product Summary | 19

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Fuel system covers


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Lube oil system covers


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Special unions

The following types of union are spray-proof in case of leakage even without covers and have been con‐ firmed as being SOLAS-compliant by GL and DNV. Plug-in pipe union Design precludes lateral spray as the parting line is shielded by the sleeve (4).

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


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Only seepage along the pipeline is possible whereby the pressure is greatly reduced by a faulty O-ring (3).

High-pressure unions

1 2 3 4 5 6 7

Jacketed pipe HP line O-ring Union nut Recess for O-ring Thrust ring Leakage overflow bore

8 9 10 11 12 13 14

Thrust ring Union nut Union nut Connecting piece Snap ring Thrust ring Shims

15 16 17 18 19 20

Union nut Thrust ring External pipe of HP line Internal pipe of HP line Spherical sealing area Leak fuel connection

The HP fuel line is sealed by the thrust ring (8). If leakage in the area of the thrust ring (8) or the HP line (5) occurs, the emerging fuel is routed to the leakage chamber. Leak fuel is allowed to escape without pressure via the leakage overflow bore (7). The leakage chamber is sealed toward the outside by the O-rings (3). This prevents leaking fuel from escaping.

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


Shielding of fuel filters and lube-oil filters Shielding with plastic ring

The plastic ring (1) precludes lateral spray. The fluid is diverted to the catch basin whereby the pressure is greatly reduced.

The overhang (1) prevents lateral spray. The fluid is diverted to the catch basin whereby the pressure is greatly reduced.


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Shielding by structural overhang

2.2 Series 2000 M40A/B - M41A/B Engine – Overview of functional groups

010 Crankcase and externally mounted components 020 Gear train 030 Crank drive 040 Cylinder head 050 Valve gear 070 Fuel system (high pres‐ sure)

080 Fuel system (low pres‐ sure) 100 Exhaust turbocharger 110 Intercooler 120 Air intake/air supply 140 Exhaust system 170 Starting equipment

180 Lube oil system/lube oil circuit 200 Coolant circuit 230 Mounting/support 250 PTO systems, driving end and free end 500 Monitoring, control and regulation system

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Engine model designation Key to the engine model designations 8/12/16V 2000 M40A/B - M41A/B • 8/12/16 = Number of cylinders • V = Cylinder arrangement • 2000 = Series • M4 = Application segment • 0/1 = Design index • A/B = Special features


2.3 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end of the engine. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

3 KS = Driving end 4 Left engine side

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1 KGS = Free end 2 Right engine side


2.4 Engine – Main dimensions Engine – Main dimensions

Length (A)

Width (B)

Height (C)

8V 2000 M40A / M40B

approx. 2005 mm

approx. 1280 mm

approx. 1315 mm

12V 2000 M40A / M40B / approx. 2106 mm M41A /M41B

approx. 1398 mm

approx. 1291 mm

16V 2000 M40A / M40B / approx. 2815 mm M41A /M41B

approx. 1425 mm

approx. 1291 mm

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Engine model


2.5 Firing order Firing order A1-B4-A4-A2-B3-A3-B2-B1

12 V

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

16 V

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

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8V


2.6 Technical Data 2.6.1

8V 2000 M40A engine data: engine-mounted heat exchanger, reference conditions: 25 °C intake air temperature Explanation: DL BL A G R L N X

Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g. of power setting) Not yet defined value Not applicable Applicable

REFERENCE CONDITIONS Engine model

8V 2000 M40A

Application group

3B

Intake air temperature

°C

25

Raw water inlet temperature

°C

25

Barometric pressure

mbar

Site altitude above sea level

m

1000 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046) Number of cylinders

8

Engine rated speed

A

rpm

1500

Continuous power ISO 3046 (10% overload capability) (design power DIN 6280, ISO 8528)

A

kW

385

GENERAL CONDITIONS (for maximum power) Number of cylinders

8

Intake air depression (new filter)

A

mbar

15

Intake air depression, max.

L

mbar

50

TIM-ID: 0000010982 - 001

MODEL-RELATED DATA (basic design) Number of cylinders

8

Cylinder configuration: V angle

Degrees

90

Bore

mm

130

Stroke

mm

150

Cylinder displacement

liter

1.99

Total displacement

liter

15.92

Number of inlet valves per cylinder

2

Number of exhaust valves per cylinder

2 MS150031/03E 2011-10 | Product Summary | 31

RAW WATER CIRCUIT (open circuit) Number of cylinders

8

Raw water pump: Inlet pressure, min.

L

bar

-0.2

Raw water pump: Inlet pressure, max.

L

bar

+0.5

Pressure loss in external raw water system, max.

L

bar

1.0

LUBE OIL SYSTEM Number of cylinders

8

Lube-oil operating temperature before engine, from

R

°C

70

Lube oil operating temperature before engine, to

R

°C

75

Lube oil operating pressure before engine, from

R

bar

4.8

Lube oil operating pressure before engine, to

R

bar

5.3

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

R

bar

2.0

FUEL SYSTEM Number of cylinders

8

Fuel pressure at engine supply connection, min. (when engine is starting)

L

bar

-0.3

Fuel pressure at supply connection to engine, min. (when engine is run‐ ning)

L

bar

-0.3

Fuel pressure at engine supply connection, max. (when engine is starting)

L

bar

+0.5

Fuel supply flow, max.

R

liter/min

1.3

GENERAL OPERATING DATA Number of cylinders

8

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120

STARTING (electric) Number of cylinders Starter, rated voltage (standard design)

8 R

V=

24

STARTING SYSTEM (with air/hydraulic starter motor) 8

Starting air pressure before starter motor, min.

R

bar

18*

Starting air pressure before starter motor, max.

R

bar

30


TIM-ID: 0000010982 - 001

Number of cylinders

CAPACITIES Number of cylinders

8

Engine coolant, engine-side (with cooler)

R

liter

70

Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ R nations)

liter

65

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

R

liter

60

Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L erating inclinations)

liter

45

Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐ L erating inclinations)

liter

55

WEIGHTS / MAIN DIMENSIONS Number of cylinders

8

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

R

kg

1790

ACOUSTICS Number of cylinders

8

Exhaust noise, unsilenced, DL , (free-field sound pressure level Lp, 1m dis‐ R tance, ISO 6798)

db(A)

105

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

db(A)

102

TIM-ID: 0000010982 - 001

R


2.6.2

8V 2000 M40A engine data: separate heat exchanger, reference conditions: 25 °C intake air temperature Explanation: DL BL A G R L N X



8V 2000 M40A

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


8

Engine rated speed

A

rpm

1500


A

kW

385


8


A

mbar

15


L

mbar

50

MODEL-RELATED DATA (basic design) 8


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

15.92


2


2


TIM-ID: 0000010986 - 001

Number of cylinders


8


R

°C

70


R

°C

75


R

bar

4.8


R

bar

5.3


R

bar

2.0


8


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

10


8

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120

STARTING (electric) Number of cylinders

8

Starter, rated voltage (standard design)

R

V=

24

STARTING SYSTEM (with air/hydraulic starter motor) Number of cylinders

8


R

bar

18*


R

bar

30

CAPACITIES

TIM-ID: 0000010986 - 001

Number of cylinders

8


liter

65


R

liter

60


liter

45


liter

55


8


R

kg

1750



8 R

db(A)

105


R

db(A)

102

TIM-ID: 0000010986 - 001

Exhaust noise, unsilenced, DL, (free-field sound pressure level Lp, 1m dis‐ tance, ISO 6798)


2.6.3

8V 2000 M40B engine data, engine-mounted heat exchanger, reference condition: 25 °C intake air temperature Explanation: DL BL A G R L N X



8V 2000 M40B

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


8

Engine rated speed

A

rpm

1800


A

kW

400


8


A

mbar

15


L

mbar

50

MODEL-RELATED DATA (basic design)

TIM-ID: 0000011003 - 001

Number of cylinders

8


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

15.92


2


2



8


L

bar

-0.2


L

bar

+0.5


L

bar

1.0


8


R

°C

75


R

°C

80


R

bar

5.6


R

bar

6.1


R

bar

2.0


8


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

1.6


8

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


8 R

V=

24

STARTING SYSTEM (with air/hydraulic starter motor) 8


R

bar

18*


R

bar

30


TIM-ID: 0000011003 - 001

Number of cylinders


8


R

liter

70*


liter

65


R

liter

60


liter

45


liter

55


8


R

kg

1790


8


db(A)

105


db(A)

103

TIM-ID: 0000011003 - 001

R


2.6.4

8V 2000 M40B engine data, separate heat exchanger, reference condition: 25 °C intake air temperature Explanation: DL BL A G R L N X



8V 2000 M40B

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


8

Engine rated speed

A

rpm

1800


A

kW

400


8


A

mbar

15


L

mbar

50



Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

15.92


2


2


TIM-ID: 0000011005 - 001

Number of cylinders


8


R

°C

75


R

°C

80


R

bar

5.6


R

bar

6.1


R

bar

2.0


8


L

bar

-0.3


L

bar

+0.3


L

bar

+0.5


R

liter/min

11.9


8

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


8


R

V=

24


8


R

bar

18*


R

bar

30

CAPACITIES

TIM-ID: 0000011005 - 001

Number of cylinders

8


liter

65


R

liter

60


liter

45


liter

55


8


R

kg

1750



8


db(A)

105


db(A)

103

TIM-ID: 0000011005 - 001

R


2.6.5

12V 2000 M40A engine data: Engine-mounted heat exchanger, reference conditions: 45 °C intake air temperature Explanation: CP FSP A G R L N X

Ref. value: Continuous power (CP) Ref. value: Fuel stop power (FSP) Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable


12V 2000 M40A

Application group

3B


°C

45

Raw-water inlet temperature

°C

32

Barometric pressure

mbar


m

1000 100


12

Engine rated speed

A

rpm

1500


A

kW

575


12


A

mbar

15


L

mbar

50

MODEL-RELATED DATA (basic design) TIM-ID: 0000002959 - 001

Number of cylinders

12


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

23.88

Number of inlet valves, per cylinder

2

Number of exhaust valves, per cylinder

2



12

Raw water pump: inlet pressure, min.

L

bar

-0.2

Raw water pump: inlet pressure, max.

L

bar

+0.5


L

bar

1.0


12

Lube oil temperature before engine, from

R

°C

73

Lube oil temperature before engine, to

R

°C

78


R

bar

7.5


R

bar

8.5

Lube oil operating pressure, low idle (meas. point: before engine)

R

bar

3.5


12

Fuel pressure at supply connection on engine, min. (when engine is start‐ ing)

L

bar

-0.3

Fuel pressure at supply connection on engine, min. (when engine is run‐ ning)

L

bar

-0.3

Fuel pressure at supply connection on engine, max. (when engine is start‐ ing)

L

bar

+0.5


R

liter/min

2.7


12

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120

STARTING (electric) Number of cylinders Rated starter voltage (standard design)

12 R

V=

24

STARTING (pneumatic starter) 12

Starting-air pressure before starter motor, min.

R

bar

21

Starting-air pressure before starter motor, max.

R

bar

30


TIM-ID: 0000002959 - 001

Number of cylinders


12

Engine coolant capacity (with cooling equipment)

R

liter

110

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

R

liter

105


R

liter

98


liter

73


liter

88


12


R

kg

2600


12 R

db(A)

111

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

R

db(A)

99

TIM-ID: 0000002959 - 001

Exhaust noise, unsilenced, CP, (free-field sound pressure level Lp, 1m dis‐ tance, ISO 6798)


2.6.6

12V 2000 M40A engine data: Engine-mounted heat exchanger, reference conditions: 25 °C intake air temperature Explanation: CP FSP A G R L N X



12V 2000 M40A

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


12

Engine rated speed

A

rpm

1500


A

kW

575


12


A

mbar

15


L

mbar

50



Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

23.88


2


2


TIM-ID: 0000002984 - 001

Number of cylinders


12

Raw water pump: inlet pressure, min.

L

bar

-0.2

Raw water pump: inlet pressure, max.

L

bar

+0.5


L

bar

1.0


12


R

°C

70


R

°C

75


R

bar

7.5


R

bar

8.5


R

bar

3.5


12


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

2.6


12

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


12 R

V=

24

STARTING (pneumatic starter) TIM-ID: 0000002984 - 001

Number of cylinders

12


R

bar

21


R

bar

30



12

Engine coolant capacity (with cooling equipment)

R

liter

110


R

liter

105


R

liter

98


liter

73


liter

88

WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine dry weight (with attached standard accessories, without coupling)

12 R

kg

2600


12 R

db(A)

111


R

db(A)

99

TIM-ID: 0000002984 - 001



2.6.7

12V 2000 M40A engine data: Separate heat exchanger, reference conditions: 25 °C intake air temperature Explanation: CP FSP A G R L N X



12V 2000 M40A

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


12

Engine rated speed

A

rpm

1500


A

kW

575


12


A

mbar

15


L

mbar

50

MODEL-RELATED DATA (basic design) TIM-ID: 0000003004 - 001

Number of cylinders

12


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

23.88


2


2



12


R

°C

75


R

°C

85


R

bar

7.5


R

bar

8.5


R

bar

3.5


12


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

21


12

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


12 R

V=

24

STARTING (pneumatic starter) Number of cylinders

12


R

bar

21


R

bar

30

CAPACITIES 12


R

liter

105


R

liter

98


liter

73


liter

88


TIM-ID: 0000003004 - 001

Number of cylinders


12


R

kg

2600


12 R

db(A)

111


R

db(A)

99

TIM-ID: 0000003004 - 001



2.6.8

12V 2000 M40A engine data: Separate heat exchanger, reference conditions: 45 °C intake air temperature Explanation: CP FSP A G R L N X



12V 2000 M40A

Application group

3B


°C

45


°C

32

Barometric pressure

mbar


m

1000 100


12

Engine rated speed

A

rpm

1500


A

kW

575


12


A

mbar

15


L

mbar

50



Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

23.88


2


2


TIM-ID: 0000003019 - 001

Number of cylinders


12


R

°C

75


R

°C

85


R

bar

7.5


R

bar

8.5


R

bar

3.5


12


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

21


12

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


12

Rated starter voltage (standard design)

R

V=

24

STARTING (pneumatic starter) Number of cylinders

12


R

bar

21


R

bar

30

CAPACITIES

TIM-ID: 0000003019 - 001

Number of cylinders

12


R

liter

105


R

liter

98


liter

73


liter

88



12 R

kg

2600


12 R

db(A)

111


R

db(A)

99

TIM-ID: 0000003019 - 001



2.6.9




16V 2000 M40A

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1500


A

kW

770


16


A

mbar

15


L

mbar

50


TIM-ID: 0000010994 - 001

Number of cylinders

16


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2



16


L

bar

-0.2


L

bar

+0.5


L

bar

1.0


16


R

°C

75


R

°C

80


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

3.4


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16 R

V=

24


16 R

bar

24*


R

bar

30 TIM-ID: 0000010994 - 001




16


R

liter

160


liter

134


R

liter

127


liter

97


liter

117


16


R

kg

3200


16


db(A)

109


db(A)

107

TIM-ID: 0000010994 - 001

R


2.6.10




16V 2000 M40A

Application group

3B


°C

45


°C

32

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1500


A

kW

770


16


A

mbar

15


L

mbar

50



Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2


TIM-ID: 0000010989 - 001

Number of cylinders


16


L

bar

-0.2


L

bar

+0.5


L

bar

1.0


16


R

°C

75


R

°C

80


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

3.5


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16


R

V=

24


16 R

bar

24*


R

bar

30

TIM-ID: 0000010989 - 001



CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler)

16 R

liter

160


liter

134


R

liter

127


liter

97


liter

117


16 R

kg

3200


16


db(A)

109


db(A)

107

TIM-ID: 0000010989 - 001

R


2.6.11




16V 2000 M40A

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1500


A

kW

770


16


A

mbar

15


L

mbar

50


TIM-ID: 0000011000 - 001

Number of cylinders

16


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2



16


R

°C

75


R

°C

80


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

20


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16 R

V=

24


16


R

bar

24*


R

bar

30

CAPACITIES 16


liter

134


R

liter

127


liter

97


liter

117



16 R

kg

3200

TIM-ID: 0000011000 - 001

Number of cylinders


16


db(A)

109


db(A)

107

TIM-ID: 0000011000 - 001

R


2.6.12




16V 2000 M40A

Application group

3B


°C

45


°C

32

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1500


A

kW

770


16


A

mbar

15


L

mbar

50



Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2


TIM-ID: 0000010997 - 001

Number of cylinders


16


R

°C

75


R

°C

80


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

20


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16


R

V=

24


16


R

bar

24*


R

bar

30

CAPACITIES

TIM-ID: 0000010997 - 001

Number of cylinders

16


liter

134


R

liter

127


liter

97


liter

117


16


R

kg

3200



16


db(A)

109


db(A)

107

TIM-ID: 0000010997 - 001

R


2.6.13




16V 2000 M40B

Application group

3B


°C

45


°C

32

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1800


A

kW

930


16


A

mbar

15


L

mbar

50


TIM-ID: 0000011008 - 001

Number of cylinders

16


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2



16


L

bar

-0.2


L

bar

+0.5


L

bar

1.0


16


R

°C

80


R

°C

85


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

4.2


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16 R

V=

24


16 R

bar

24*


R

bar

30 TIM-ID: 0000011008 - 001




16


R

liter

160


liter

134


R

liter

127


liter

97


liter

117


16


R

kg

3200


16


db(A)

111


db(A)

107

TIM-ID: 0000011008 - 001

R


2.6.14




16V 2000 M40B

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1800


A

kW

930


16


A

mbar

15


L

mbar

50



Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2


TIM-ID: 0000011013 - 001

Number of cylinders


16


L

bar

-0.2


L

bar

+0.5


L

bar

1.0


16


R

°C

80


R

°C

85


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

4.2


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16


R

V=

24


16 R

bar

24*


R

bar

30

TIM-ID: 0000011013 - 001



CAPACITIES Number of cylinders Engine coolant, engine-side (with cooler)

16 R

liter

160


liter

134


R

liter

127


liter

97


liter

117


16 R

kg

3200


16


db(A)

111


db(A)

107

TIM-ID: 0000011013 - 001

R


2.6.15




16V 2000 M40B

Application group

3B


°C

45


°C

32

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1800


A

kW

930


16


A

mbar

15


L

mbar

50


TIM-ID: 0000011018 - 001

Number of cylinders

16


Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2



16


R

°C

80


R

°C

85


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

24


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16 R

V=

24


16


R

bar

24*


R

bar

30

CAPACITIES 16


liter

134


R

liter

127


liter

97


liter

117



16 R

kg

3200

TIM-ID: 0000011018 - 001

Number of cylinders


16


db(A)

111


db(A)

107

TIM-ID: 0000011018 - 001

R


2.6.16




16V 2000 M40B

Application group

3B


°C

25


°C

25

Barometric pressure

mbar


m

1000 100


16

Engine rated speed

A

rpm

1800


A

kW

930


16


A

mbar

15


L

mbar

50



Degrees

90

Bore

mm

130

Stroke

mm

150


liter

1.99

Total displacement

liter

31.84


2


2


TIM-ID: 0000011022 - 001

Number of cylinders


16


R

°C

80


R

°C

85


R

bar

6.0


R

bar

7.0


16


L

bar

-0.3


L

bar

-0.3


L

bar

+0.5


R

liter/min

24


16

Firing speed, from

R

rpm

100

Firing speed, to

R

rpm

120


16


R

V=

24


16


R

bar

24*


R

bar

30

CAPACITIES

TIM-ID: 0000011022 - 001

Number of cylinders

16


liter

134


R

liter

127


liter

97


liter

117


16


R

kg

3200



16


db(A)

111


db(A)

107

TIM-ID: 0000011022 - 001

R


2.6.17

ENGINE DATA 12V 2000M41A/B Explanation: DL BL A G R L N X

Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without change (e.g. of power settings). Not yet defined value Not applicable Applicable

Engine model

Application group

12V2000 M41A heat ex‐ changer installed

12V2000 M41A heat ex‐ changer separate

12V2000 M41B heat ex‐ changer installed

12V2000 M41B heat ex‐ changer separate

3B

3B

3B

3B


°C

25

25

25

25

Charge-air coolant temperature

°C

-

-

-

-


°C

25

25

25

25

Barometric pressure

mbar

1000

1000

1000

1000


m

100

100

100

100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Number of cylinders Rated engine speed

12

12

12

12

A

rpm

1500

1500

1800

1800

Continuous power ISO 3046 (10% over‐ A load capability) (design power DIN 6280, ISO 8528)

kW

575

575

695

695

12

12

12

12

GENERAL CONDITIONS (for maximum power) Number of cylinders Intake depression (new filter)

A

mbar

15

15

15

15

Intake depression, max.

L

mbar

50

50

50

50

12

12

12

12

90

90

90

90

TIM-ID: 0000019122 - 001

MODEL-RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V-angle

Degrees (°)

Bore

mm

130

130

130

130

Stroke

mm

150

150

150

150


Liters

1.99

1.99

1.99

1.99

Total displacement

Liters

23.88

23.88

23.88

23.88


Number of cylinders

12

12

12

12


2

2

2

2


2

2

2

2

12

12

12

12

RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min.

L

bar

-0.2

-

-0.2

-


L

bar

+0.5

-

+0.5

-

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

L

bar

1.0

-

1.0

-

12

12

12

12

LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from

R

°C

70

75

75

75


R

°C

75

85

80

85

Lube oil operating pressure before en‐ gine, from

R

bar

7.5

7.5

7.5

7.5

Lube oil operating pressure before en‐ gine, to

R

bar

8.5

8.5

8.5

8.5


R

bar

3.5

3.5

3.5

3.5

12

12

12

12

FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connec‐ tion, min. (when engine is starting)

L

bar

-0.3

-0.3

-0.3

-0.3

Fuel pressure at engine supply connec‐ tion, min. (during engine operation)

L

bar

-0.3

-0.3

-0.3

-0.3

Fuel pressure at engine supply connec‐ tion (when engine is starting), max.

L

bar

+0.5

+0.5

+0.5

+0.5

Fuel supply flow rate, max.

A

liters/min

2.6

21

3.2

26

12

12

12

12

Number of cylinders Firing speed, from

R

rpm

100

100

100

100

Firing speed, to

R

rpm

120

120

120

120

12

12

12

12

24

24

24

24

STARTING SYSTEM (electric) Number of cylinders Rated starter voltage (standard design)


R

V=

TIM-ID: 0000019122 - 001

GENERAL OPERATING DATA

STARTING SYSTEM (with compressed air/hydraulic starter motor) Number of cylinders Starting-air pressure before starter mo‐ tor, min.

12

12

12

12

R

bar

21*

21*

21*

21*

Starting-air pressure before starter, max. R

bar

30

30

30

30

12

12

12

12

FILLING CAPACITIES Number of cylinders Engine coolant, engine side (with cool‐ ing system)

R

liters

110

-

110

-

Engine oil, total, for initial filling (stand‐ ard oil system) (option: max. operating inclinations)

R

liters

105

105

105

105

Oil change quantity, max. (standard oil system) (Option: max. operating inclina‐ tions)

R

liters

98

98

98

98

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

L

liters

73

73

73

73

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

L

liters

88

88

88

88

12

12

12

12

2600

2600

2600

2600

12

12

12

12

WEIGHTS / MAIN DIMENSIONS Number of cylinders Dry engine weight (with standard acces‐ R sories, without coupling)

kg

NOISE Number of cylinders R

dB(A)

104

104

103

103

Engine surface noise with attenuated in‐ R take noise (filter) - BL (free-field soundpressure level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)

dB(A)

99

99

100

100

TIM-ID: 0000019122 - 001

Exhaust noise, unsilenced, DL, (freefield sound-pressure level Lp, 1m dis‐ tance, ISO 6798)


2.6.18

ENGINE DATA 16V 2000M41A/B Explanation: DL BL A G R L N X

Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without change (e.g. of power settings). Not yet defined value Not applicable Applicable

Engine model

Application group

16V2000 M41A heat ex‐ changer installed

16V2000 M41A heat ex‐ changer separate

16V2000 M41B heat ex‐ changer installed

16V2000 M41B heat ex‐ changer separate

3B

3B

3B

3B


°C

25

25

25

25

Charge-air coolant temperature

°C

-

-

-

-


°C

25

25

25

25

Barometric pressure

mbar

1000

1000

1000

1000


m

100

100

100

100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Number of cylinders Rated engine speed

16

16

16

16

A

rpm

1500

1500

1800

1800

Continuous power ISO 3046 (10% over‐ A load capability) (design power DIN 6280, ISO 8528)

kW

770

770

930

930

16

16

16

16

GENERAL CONDITIONS (for maximum power) Number of cylinders Intake depression (new filter)

A

mbar

15

15

15

15

Intake depression, max.

L

mbar

50

50

50

50

16

16

16

16

90

90

90

90

Number of cylinders Cylinder arrangement: V-angle

Degrees (°)

Bore

mm

130

130

130

130

Stroke

mm

150

150

150

150


liters

1.99

1.99

1.99

1.99

Total displacement

liters

31.84

31.84

31.84

31.84


TIM-ID: 0000019124 - 001


Number of cylinders

16

16

16

16


2

2

2

2


2

2

2

2

16

16

16

16

RAW WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min.

L

bar

-0.2

-

-0.2

-


L

bar

+0.5

-

+0.5

-

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

L

bar

1.0

-

1.0

-

16

16

16

16

LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from

R

°C

75

75

80

80


R

°C

80

80

85

85

Lube oil operating pressure before en‐ gine, from

R

bar

6.0

6.0

6.0

6.0

Lube oil operating pressure before en‐ gine, to

R

bar

7.0

7.0

7.0

7.0


R

bar

N

N

N

N

16

16

16

16

FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connec‐ tion, min. (when engine is starting)

L

bar

-0.3

-0.3

-0.3

-0.3

Fuel pressure at engine supply connec‐ tion, min. (during engine operation)

L

bar

-0.3

-0.3

-0.3

-0.3

Fuel pressure at engine supply connec‐ tion (when engine is starting), max.

L

bar

+0.5

+0.5

+0.5

+0.5

Fuel supply flow rate, max.

A

liters/min

3.4

20

4.2

24

16

16

16

16

GENERAL OPERATING DATA

TIM-ID: 0000019124 - 001

Number of cylinders Firing speed, from

R

rpm

100

100

100

100

Firing speed, to

R

rpm

120

120

120

120

16

16

16

16

24

24

24

24

STARTING SYSTEM (electric) Number of cylinders Rated starter voltage (standard design)

R

V=


STARTING SYSTEM (with compressed air/hydraulic starter motor) Number of cylinders Starting-air pressure before starter mo‐ tor, min.

16

16

16

16

R

bar

24*

24*

24*

24*

Starting-air pressure before starter, max. R

bar

30

30

30

30

16

16

16

16

FILLING CAPACITIES Number of cylinders Engine coolant, engine side (with cool‐ ing system)

R

liters

160

-

160

-

Engine oil, total, for initial filling (stand‐ ard oil system) (option: max. operating inclinations)

R

liters

134

134

134

134

Oil change quantity, max. (standard oil system) (Option: max. operating inclina‐ tions)

R

liters

127

127

127

127

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

L

liters

97

97

97

97

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

L

liters

117

117

117

117

16

16

16

16

3200

3200

3200

3200

16

16

16

16

WEIGHTS / MAIN DIMENSIONS Number of cylinders Dry engine weight (with standard acces‐ R sories, without coupling)

kg

NOISE Number of cylinders R

dB(A)

109

109

111

111

Engine surface noise with attenuated in‐ R take noise (filter) - BL (free-field soundpressure level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)

dB(A)

107

107

107

107

TIM-ID: 0000019124 - 001

Exhaust noise, unsilenced, DL, (freefield sound-pressure level Lp, 1m dis‐ tance, ISO 6798)


3 Operation 3.1 LOP – Controls

TIM-ID: 0000008856 - 003

LOP – Controls

Item

Color

Lettering

Meaning / Function

1

White

F1

2

White

F2

Function keys to control the human-machine interface. Functions vary and are displayed on the LCD screen.

3

White

F3

4

White

F4

5

White

F5

6

White

ALARM AC‐ KNOWLEDGE

Pressing the key the first time stops alarm signalization. Pressing the button a second time acknowledges an active alarm. LED (spot) lights up when an alarm is active.

7

White

DIMMER ↑

Holding down the key increases LCD background illumina‐ tion.

MS150031/03E 2011-10 | Operation | 85

Item

Color

Lettering

Meaning / Function

8

White

DIMMER ↓

Holding down the key decreases LCD background illumina‐ tion.

9

White

LAMP TEST

Pressing the button initiates lamp test.

10

Red

TEST OVER‐ SPEED

Pressing the button initiates overspeed test. LED (spot) lights up as long as the overspeed test is run‐ ning.

11

Green

(none)

(none)

12

Green

(none)

(none)

13

Green

(none)

(none)

14

White

ENGINE SPEED INCREASE

Engine speed is increased as long as the button is held down.

15

White

ENGINE SPEED DECREASE

Engine speed is decreased as long as the button is held down.

16

Green

READY FOR OP‐ ERATION

Pressing the switch causes changeover between “Not ready for operation” and “Ready for operation” status. LED (spot) lights up at "Ready for operation" switch posi‐ tion.

17

Green

LOCAL OPERA‐ TION

Pressing the switch activates changeover between local and remote control mode. LED (spot) lights up when local mode is active.

18

White

START

Pressing the pushbutton initiates the automatic engine start sequence. LED (spot) lights up as long as the starting procedure is running.

19

White

STOP

Pressing the button initiates automatic engine stopping pro‐ cedure. Spot LED lit when stop signal is applied (also from remote control system).

20

Red

EMERGENCY STOP

Pressing the pushbutton initiates an immediate emergency engine stop.

TIM-ID: 0000008856 - 003

LED (spot) flashes once the emergency stop has been trip‐ ped and until the alarm has been acknowledged.

86 | Operation | MS150031/03E 2011-10

3.2 Putting the engine into operation (out-of-service period > 3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available.

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

Task

Engine

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

Lube oil system

Check oil level (→ Page 146).

Fuel prefilter

Prime (→ Page 139).

Fuel prefilter, pressure gauge

Align adjustable pointer with position of pressure indicator (→ Page 135).

Fuel system

Vent (→ Page 131).

Raw-water pump (if located Prime (approx. 3 to 4 liters). above waterline) Cooling system

If engine is out of service for more than one year, change coolant (→ Page 160).

Cooling system

Check coolant level (→ Page 159).

Cooling system

Preheat coolant with preheating unit.

ECU

Check plug-in connections (→ Page 176).

Engine control system

Switch ON. Press READY FOR OPERATION button (→ Page 85). Press LAMP TEST button (→ Page 85).

TIM-ID: 0000002205 - 001

LOP

MS150031/03E 2011-10 | Operation | 87

3.3 Putting the engine into operation after scheduled out-ofservice period Preconditions ☑ Engine is stopped and starting disabled.

Putting into operation Item

Task

Lube oil system

Check oil level (→ Page 146).

Cooling system

Check coolant level (→ Page 159).

Cooling system

Preheat coolant with preheating unit.

Fuel prefilter

Drain (→ Page 136).

Battery-charging generator Check condition of drive belt (→ Page 166). drive Engine control system

Switch ON. Press READY FOR OPERATION button (→ Page 85). Press LAMP TEST button (→ Page 85).

TIM-ID: 0000002684 - 001

LOP

88 | Operation | MS150031/03E 2011-10

3.4 Starting the engine from LOP Preconditions ☑ Gearbox is disengaged. ☑ External start interlock is not activated. ☑ Emergency air-shut-off flaps (if provided) are open. DANGER

WARNING

Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone.

Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.

Barring the engine (out-of-service period > 1 month) Item

Task

Engine

Bar with starting system (→ Page 105).

Starting the engine from LOP Item

Task

Engine

Make sure that engine is in unloaded condition.


Switch ON. LOP: • LOCAL OPERATION button is illuminated brightly (local operating mode is active) (→ Page 85); • CLUTCH NEUTRAL button is illuminated brightly (gearbox is disengag‐ ed) (→ Page 85).

LOP

Press READY FOR OPERATION button briefly (→ Page 85). • READY FOR OPERATION button is illuminated brightly.

TIM-ID: 0000002234 - 001

LOP

Press START button briefly (→ Page 85). • • • •

START button of the engine concerned is illuminated brightly; Automatic starting procedure is performed; Tachometer indicates increasing crankshaft speed; After the starting procedure is completed, engine is running at idle speed and START button is reset to basic illumination.

MS150031/03E 2011-10 | Operation | 89

3.5 Operational checks DANGER

WARNING

Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine.


Operational checks Item

Task

Engine under load

Visually inspect the engine for leaks and general condition;

Engine at nominal speed

Check for abnormal noises and vibrations; Check exhaust color (→ Page 96).

Fuel prefilter

Check if suction-side pressure indicated at the fuel prefilter pressure gauge is within the limit. (→ Page 135). Drain off water and dirt (→ Page 136)

Intercooler

Check drain line for water discharge and obstruction (→ Page 141).

Air filter

Check signal ring position of service indicator (→ Page 144); Replace air filter (→ Page 142), if the signal ring is completely visible in the service indicator control window. Check relief bore for oil and coolant discharge and dirt (→ Page 163).

Raw-water pump

Check relief bore for oil and water discharge and dirt (→ Page 165)

TIM-ID: 0000002268 - 001

HT coolant pump

90 | Operation | MS150031/03E 2011-10

3.6 Stopping the engine at the LOP Preconditions ☑ Engine is running in local mode. CAUTION

Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated.

Stopping the engine at the LOP Item

Action

LOP

Operate engine at idle speed (→ Page 85).

Temperature readings

Wait until engine is at operating temperature.

LOP

Press STOP pushbutton (→ Page 85).

TIM-ID: 0000002293 - 004

• STOP pushbutton is illuminated; • engine is stopped.

MS150031/03E 2011-10 | Operation | 91

3.7 Emergency stop from LOP CAUTION

An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations.

Emergency stop from LOP Item

Task

LOP

Open cap of EMERGENCY STOP button (→ Page 85).

LOP

Press EMERGENCY STOP button. • • • •

Engine is stopped by switching off power supply to ECU; Engine control is deactivated; Engines with emergency air-shut-off flaps: Flaps close; EMERGENCY STOP button flashes.signalization by horn, flash lamp etc. is released.

After emergency stop from LOP Item

Task

LOP

Press ALARM ACKNOWLEDGE button (→ Page 85). • Audible and visual signalization stops.

LOP

Press ALARM ACKNOWLEDGE button again. • Power supply to ECU is provided; • Alarm is acknowledged.

Engine

Engines with emergency air-shut-off flaps: Flaps open.

TIM-ID: 0000002309 - 002

• Engine is ready for operation.

92 | Operation | MS150031/03E 2011-10

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

After stopping the engine Item

Action

Coolant circuit

Drain coolant (→ Page 161) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze additive; • the engine room is not heated; • the coolant is not kept at a suitable temperature; • the antifreeze concentration is insufficient for the engine-room tempera‐ ture; • antifreeze concentration is 50 % and engine-room temperature is below -40 °C.

Raw water

Drain • If freezing temperatures are to be expected and the engine is to remain out of service for an extended period.


Switch off.

Air intake and exhaust sys‐ Out-of-service-period > 1 week tem • Seal engine's air and exhaust sides. Out-of-service-period > 1 month • Preserve engine (→ MTU Fluids and Lubricants Specifications A001061/.. )

TIM-ID: 0000002324 - 003

Engine

MS150031/03E 2011-10 | Operation | 93

3.9 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied.

Special tools, Material, Spare parts Designation / Use

Part No.

Qty.

Steam jet cleaner

-

1

30390

1

Cleaner (Hakupur 312) WARNING

WARNING

CAUTION

Note:

Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Water jet. Risk of injury and scalding! • Do not direct water jet at persons. • Wear protective clothing, gloves, and goggles / safety mask. Excessive reaction time of cleaning agents on components. Damage to component! • Observe manufacturer's instructions. • Wear protective clothing, gloves, and goggles / safety mask. There is a risk of damaging sensors with compressed air.

1. 2. 3. 4.

Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐ tection). Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit carefully and observe the safety precautions. For external cleaning with high-pressure jet, use a flat-mouth nozzle only. Carry out external cleaning as follows: a) Remove coarse dirt. b) Spray on cleaner sparingly and leave it for 1 to 5 minutes. c) Use the high-pressure jet to remove the loosened dirt. d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must be observed. The temperature of the cleaning medium must not exceed 80°C.

94 | Operation | MS150031/03E 2011-10

TIM-ID: 0000010171 - 017

Plant – Cleaning

4 Maintenance 4.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the maintenance schedule. Task W0500

(→ Page 146)

W0501

(→ Page 90)

W0502

(→ Page 141)

W0503

(→ Page 90)

W0505

(→ Page 90)

W0506

(→ Page 96)

W0507

(→ Page 90)

W0508

(→ Page 90)

W1001

(→ Page 133)

W1002

(→ Page 115)

W1005

(→ Page 90)

W1006

(→ Page 123)

W1007

(→ Page 120)

W1008

(→ Page 149)

W1009

(→ Page 151)

W1011

(→ Page 106)

W1140

(→ Page 112)

W1178

(→ Page 128)

TIM-ID: 0000019125 - 002

Table 1: Maintenance task reference table [QL1]

MS150031/03E 2011-10 | Maintenance | 95

5 Troubleshooting 5.1 Troubleshooting Engine does not turn when starter is actuated Component

Probable Cause

Task

Battery

Low or defective

Charge or replace (see manufacturer's documentation).

Cable connections defective

Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation).

Starter (electric)

Engine wiring or starter defective

Check if cable connections are proper‐ ly secured, contact Service.

Starter (compressed air)

Starting-air pressure not available

Check firm seating of connections, check starting-air pressure and main valve of compressed-air system. Con‐ tact Service.

Engine wiring

Defective

Check (→ Page 172).

LOP

Secure seating of assemblies or con‐ nectors not provided

Perform visual inspection (→ Page 181).

ECU

Plug-in connections are loose

Check plug-in connections (→ Page 176).

Engine

Running gear blocked (engine cannot be barred manually)

Contact Service.

Start-interlock limit switch

Limit switch not installed

Check limit switch (→ Page 175).

Limit switch defective Wiring defective

Check wiring (→ Page 172).

Component

Probable Cause

Task

Starter

Poor rotation by starter: Battery low or defective

Charge or replace battery (see manu‐ facturer's documentation).

Engine wiring

Defective


Fuel system

Not vented

Vent fuel system (→ Page 131).

ECU

Defective

Contact Service.

Engine fires unevenly Component

Probable Cause

Task

Fuel injection equip‐ ment

Injector defective

Replace (→ Page 123).

Injection pump defective


Engine wiring

Defective


Fuel system

Not vented


ECU

Defective

Contact Service.

96 | Troubleshooting | MS150031/03E 2011-10

TIM-ID: 0000002547 - 001

Engine turns but does not fire

Engine does not reach nominal speed Component

Probable Cause

Task

Fuel supply

Fuel supply shut off

Open shut-off valve before fuel prefilter completely.

Fuel prefilter clogged


Fuel filter clogged


Air supply

Air filter clogged

Check signal ring position of service in‐ dicator (→ Page 144).


Injector defective




Engine wiring

Defective


Engine

Overloaded

Contact Service.

Engine speed not steady Component

Probable Cause

Task


Injector defective




Speed sensor

Defective

Contact Service.

Fuel system

Not vented


ECU

Defective

Contact Service.

Charge-air temperature too high Component

Probable Cause

Task

Engine coolant

Incorrect coolant concentration

Check (MTU test kit).

Intercooler

Contaminated

Contact Service.

Engine room

Air-intake temperature too high

Check fans Check air supply / ventilation ducts.

Charge-air pressure too low Component

Probable Cause

Task

Air supply

Air filter clogged


Intercooler

Contaminated

Contact Service.

TIM-ID: 0000002547 - 001

Exhaust turbocharger Defective

Contact Service.

Coolant leaks on intercooler Component

Probable Cause

Task

Intercooler

Leaking, major coolant discharge.

Contact Service.

MS150031/03E 2011-10 | Troubleshooting | 97

Exhaust gas black Component

Probable Cause

Task

Air supply

Air filter clogged



Injector defective




Engine

Overloaded

Contact Service.

Component

Probable Cause

Task

Engine oil

Too much oil in engine

Drain engine oil (→ Page 147).

Oil separator or oil preseparator of crankcase breather clogged


Exhaust gas blue

Exhaust turbocharger Defective

Contact Service.

Cylinder head Piston rings Cylinder liner

Exhaust gas white Component

Probable Cause

Task

Engine

Not at operating temperature

Run engine to reach operating temper‐ ature.

Fuel system

Water in fuel

Check fuel system on fuel prefilter; Drain fuel prefilter (→ Page 136).

Leaking

Contact Service.

TIM-ID: 0000002547 - 001

Intercooler


5.2 LOP alarms LOP At the LOP, alarm texts and measuring-point messages are indicated on the DIS. Explanation of the dis‐ played texts can be gathered by pressing the help key on the touch screen. Alarms can also be caused by defective sensors / actuators. If troubleshooting in accordance with the following table is not success‐ ful, contact Service to have the sensors / actuators checked and, if required, replaced. Display text

Meaning

AL RCS Speed De‐ mand Defect

No speed demand signal

Task 1. Check speed demand source sys‐ tem (e. g. from automatic on-board network). 2. Check LOP visually (→ Page 181); 3. Perform LOP test procedures (→ Page 183). 4. Check ECU plug-in connections (→ Page 176). 5. Check engine wiring (→ Page 172).

AL Shutdown Expect‐ Yellow alarm occurred; Red alarm with ed engine shutdown will probably follow

1. Start the other genset

AL Battery Charger Fail

No battery charging

1. Check power circuit breakers and fuses. 2. Check transistor controllers.

AL Press Monitoring Fail (EMU)

EMU pressure monitoring failure

AL ECU Defect

ECU 4 is defective

Contact Service • Have EMU replaced. 1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have ECU checked and re‐ placed, if required.

AL Power Amplifier 1 Power amplifier cylinder side A failure Fail

TIM-ID: 0000008898 - 001

as a preventive measure. 2. Determine cause of yellow alarm and rectify.

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have ECU checked and re‐ placed, if required.


Meaning

AL Power Amplifier 2 Power amplifier cylinder side B failure Fail

Task 1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have ECU checked and re‐ placed, if required.

AL Override Activat‐ ed

Engine safety system not active

Status message: • Override activated.

AL Power Fail Con‐ trol

Power failure of control system

Check power circuit breakers and fuses.

AL Power Fail Moni‐ toring

Power failure

Check power circuit breakers and fuses.

AL Transistor Output 1/2 Fail

One of the ECU transistor outputs (TAA1 or TAA2) is defective

Contact Service • Have ECU checked and replaced, if required.

AL Transistor Output 3/4 Fail

One of the ECU transistor outputs (TAA3 or TAA4) is defective

Contact Service • Have ECU checked and replaced, if required.

AL Water in Fuel Pre‐ Water in fuel prefilter filter

Drain fuel prefilter (→ Page 136).

DL 211+A001-A001

Display panel DIS not detected on de‐ fault bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have DIS checked and re‐ placed, if required.

DL 211+A001-A010

LCU of LOP 1 (PIM No. 21.X+A001A010) not detected on default bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have MPU 23 of PIM No. 21.X +A001-A010 checked and re‐ placed, if required.

DL 211+A001-A020

LMU of LOP 1 (PIM No. 21.X+A001A020) not detected on default bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have MPU 23 of PIM No. 21.X +A001-A020 checked and re‐ placed, if required.


TIM-ID: 0000008898 - 001

Display text

TIM-ID: 0000008898 - 001

Display text

Meaning

Task

DL 211+A003-ECU

ECU 4 not detected on default bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have ECU checked and re‐ placed, if required.

DL 211+A004-EMU

EMU 1 not detected on default bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have EMU checked and re‐ placed, if required.

HI P-Oil Filter Differ‐ ence

Excessive oil-pressure difference be‐ tween oil-filter inlet and outlet

Replace engine oil filter (→ Page 149).

MG Check Start In‐ terlocks

Start conditions not fulfilled

Check start conditions and fulfill if nec‐ essary.

RL 211+A001-A001

DIS not detected on redundant bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Contact Service • Have DIS checked and re‐ placed, if required.

RL 211+A001-A010

LCU of LOP 1 (PIM No. 21.X+A001A010) not detected on redundant bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Contact Service • Have MPU 23 of PIM No. 21.X +A001-A010 checked and re‐ placed, if required.

RL 211+A001-A020

LMU of LOP 1 (PIM No. 21.X+A001A020) not detected on redundant bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Contact Service • Have MPU 23 of PIM No. 21.X +A001-A020 checked and re‐ placed, if required.

RL 211+A003-ECU

ECU 4 not detected on redundant bus

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Contact Service • Have ECU checked and re‐ placed, if required.


Display text

Meaning

Task

RL 211+A004-EMU

EMU 1 not detected on redundant bus

SS Safety System Fail (EMU)

Safety system has detected EMU fail‐ ure

SS Power Reduction Active

Safety system has requested power reduction

1. Determine cause of automatic power reduction. 2. Note further alarms / indications on display. 3. Contact Service.

SS Emergency Stop

Safety system has tripped an emer‐ gency stop

1. Determine cause of shutdown and rectify. 2. Note further alarms / indications on display.

SS Emergency Stop Ext.

Safety system has executed an exter‐ nally tripped emergency stop


SS P-Coolant

Safety system detects that coolant pressure is too low

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Contact Service • Have EMU checked and re‐ placed, if required. Contact Service.

SS P-Lube Oil (ECU) Safety system detects that engine-oil pressure is too low

1. Check lube oil level and top up if required (→ Page 146). 2. Contact Service.

SS P-Lube Oil (EMU) Safety system detects that engine-oil pressure is too low

1. Check lube oil level and top up if required (→ Page 146). 2. Contact Service.

SS Security Channel Def EMU

Fault message of safety system

Contact Service • Have EMU checked and replaced, if required.

SS SDAF Closed

Safety system reports closed emer‐ gency air-shut-off flaps

Open air-shutoff flaps

SS Security Shut‐ down

Safety system has tripped a shutdown

Determine cause of shutdown and rec‐ tify.

SS T-Coolant (ECU)

Safety system detects excessive cool‐ ant temperature

Reduce power.

SS T-Coolant (EMU)

Safety system detects excessive cool‐ ant temperature

Reduce power.

SS T-Lube Oil

Safety system detects excessive lubeoil temperature

Reduce power.

Stop Activated (EMU) EMU has tripped automatic stop com‐ mand due to limit value violation



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Check coolant level and top up if re‐ quired (→ Page 159).

Display text

Meaning

Task

TD P-Lube Oil

Different measurement values trans‐ mitted by the two sensors for lube-oil pressure measurement

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have sensors checked and re‐ placed, if required.

TD T-Coolant

Different measurement values trans‐ mitted by the two sensors for coolant temperature measurement

1. Check LOP visually (→ Page 181). 2. Perform LOP test procedures (→ Page 183). 3. Check ECU plug-in connections (→ Page 176). 4. Check engine wiring (→ Page 172). 5. Contact Service • Have sensors checked and re‐ placed, if required.

Cylinder Cutout

Measuring point "Cylinder Cutout"

TIM-ID: 0000008898 - 001

Status message of 'Cylinder cutout / half of cylinders running' mode in idle operation.


6 Task Description 6.1 Engine 6.1.1

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


DANGER

Part No.

Qty.

Ratchet

F30006212

1

Socket

F30005655

1

Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

Engine – Barring manually 1. 2. 3.

Result:

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4.

Remove cover plate (2). Attach ratchet with socket to barring tool. Rotate crankshaft in engine direction of ro‐ tation. Apart from the normal compression resistance, there should be no abnormal re‐ sistance. If the resistance exceeds compression re‐ sistance, contact Service. For barring-tool removal follow reverse se‐ quence of working steps.

104 | Task Description | MS150031/03E 2011-10

6.1.2

Engine – Barring with starting system Special tools, Material, Spare parts

DANGER

Designation / Use

Part No.

Qty.

Connector pliers

0135315483

1

Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

Engine – Barring with starting system 1.

2. 3. 4.

TIM-ID: 0000000950 - 002

5.

Disengage the bayonet coupling (4) of con‐ nector X4 with connector pliers (2) and withdraw connector (3) from engine gover‐ nor. Bar engine in unloaded condition: Press START button. Let the crankshaft rotate until oil pressure is indicated. Engine start is automatically interrupted when specified starting period is expired. If necessary, re-start the engine after approx. 20 seconds. Plug connector X4 (3) and use connector pliers (2) to secure the bayonet coupling (4) by turning it clockwise until it latches into place.

MS150031/03E 2011-10 | Task Description | 105

6.2 Cylinder Liner 6.2.1

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


Part No.

Qty.

Rigid endoscope

Y20097353

1

Preparatory steps 1. 2.

Remove cylinder head cover (→ Page 118). Remove injector (→ Page 124).

Positioning crankshaft at BDC 1. 2.

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

Endoscopic examination of cylinder liner Findings

Measure

• • • •

No action required

• Dark areas with even or varying degrees of discoloration • Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area • Dark areas in the upper section of the cooling bore, remaining cir‐ cumference without objections • Piston rings without objections

Further endoscopic examina‐ tion required as part of main‐ tenance work

• On the entire circumference, apart from light areas of discoloration Cylinder liner must be re‐ (that do not impair operation) clearly darker stripes that start at the placed; Service must be con‐ top piston ring tacted • Heat discoloration in the direction of stroke and honing pattern dam‐ age • Heat discoloration of piston rings 1. 2. 3.

Compile endoscopic report using the table. Use technical terms for description of the liner surface (→ Page 108). 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.


TIM-ID: 0000000015 - 008

• • • • •

Thin carbon coating on circumference of carbon scraper ring Slight localized additive deposits at top edge Localized smooth areas at bottom edge Carbon deposits on circumference in clearance between top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Consistent honing pattern without objections First signs of marks left by lower cooling bores Running pattern seems darker

Final steps Install injector (→ Page 124). Install cylinder head cover (→ Page 118).

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1. 2.


6.2.2

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 exami‐ nation report. Finding

Action

Minor dirt scores

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

Single scores

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

Scored area

These areas consist of scores of different length and depth next to one anoth‐ er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in‐ let/exhaust) along the transverse engine axis. Findings not critical.

Smoothened area

Smoothened areas are on the running surface but almost the whole honing pattern is still visible. Smoothened areas appear brighter and more brilliant than the surrounding running surface. Findings not critical.

Polished area

Polished areas are on the running surface and show local removal of the hon‐ ing pattern. Grooves from honing process are not visible any more.

Discoloration

This is caused by oxidation (surface discoloration through oil or fuel) and tem‐ perature differences around the liner. It appears rather darker within the honed structure in contrast to the bright metallic running surface. The honing pattern is undisturbed. Discolorations extend in stroke direction and may be interrupt‐ ed. Findings not critical.

Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in the overlap (open) position. They are clearly visible due to the dark color of the honing groove bottom. This corrosion is not critical unless there are corrosion pittings. Black lines are a step towards heat discoloration. They are visible as a clear discoloration from TDC to BDC in the running surface and the start of localized damage to the honing pattern. Cylinders with a number of black lines around the running surface have limited service life and should be replaced.


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Black lines

Finding

Action

Discolorations (Heat)

These are caused by a disturbance in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring onwards and less pro‐ nounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam‐ aged surface is usually discolored. The circumferential length varies. Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.

Seizures, Seizure marks

Irregular circumference lengths and depths. Can be caused either by the pis‐ ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis‐ coloration. Severe, visible scoring. Replace liner.

Evaluation of findings and further measures

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The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in‐ vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un‐ necessary disassembly work, it is recommended that another inspection be carried out after further oper‐ ation of the engine.


6.3 Crankcase Breather 6.3.1

Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled.


WARNING

Part No.

Qty.

Torque wrench, 6-50 Nm

F30027336

1

Ratchet adapter

F30027340

1

Engine oil Filter element

(→ Spare Parts Catalog)

Diaphragm


Gasket


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.

1. 2. 3. 4.

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

5.

Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Screw

6.

Size

TIM-ID: 0000000017 - 006

Replacing oil separator element

Type

Lubricant

Value/Standard

Tightening torque

(Engine oil)

10 Nm − 2 Nm

Replace further oil separator elements in the same way.


Checking diaphragm 1. 2. 3. 4. 5.

6.

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

Use torque wrench to tighten the screws of cover (4) to the specified torque. Name Screw

Type

Lubricant

Value/Standard

Tightening torque

(Engine oil)

10 Nm − 2 Nm

Check diaphragms in further oil separators in the same way.

TIM-ID: 0000000017 - 006

7.

Size


6.3.2

Crankcase breather – Cleaning oil separator element Preconditions ☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts Designation / Use Fuel Gasket WARNING

WARNING

Part No.

Qty.


Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors.

Crankcase breather – Cleaning oil separator element 1. 2. 3. 4. 5.

TIM-ID: 0000003470 - 004

6.

Remove cover (1) from housing (4). Remove oil separator (2) and gasket (3). Clean oil separator (2) in fuel and blow dry with compressed air. Moisten oil separator (2) with engine oil. Place oil separator (2) with new gasket (3) onto housing (4) and install cover (1). Clean further oil separator element in the same way.


6.3.3

Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled.


WARNING

Part No.

Qty.


F30027336

1

Ratchet adapter

F30027340

1

Filter element


Diaphragm


O-ring



TIM-ID: 0000003491 - 003

Replacing filter element of oil separator 1. 2. 3.

Remove cover (2) with O-ring (3). Remove filter element (1) from housing (4). Insert new filter element into housing (4) ensuring correct installation position, and fit cover (2) with new O-ring.

4.

Tighten screws of cover (2) to specified tightening torque. Name Screw

5.

Size

Type

Lubricant

Tightening torque

Value/Standard 6 Nm + 2 Nm

Replace filter elements of further oil separators in the same way.


Checking diaphragm 1. 2. 3. 4. 5. 6.

7.

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

Tighten screws of cover (4) to specified tightening torque. Name Screw

Type Tightening torque

Lubricant


Check diaphragms in further oil separators in the same way.

TIM-ID: 0000003491 - 003

8.

Size


6.4 Valve Drive 6.4.1

Valve clearance – Checking and adjusting Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed.


Part No.

Qty.


F30026582

1

Ratchet adapter

F30062582

1

Feeler gage

Y4342013

1

Preparatory steps Remove cover plate (2). Remove cylinder head cover (→ Page 118). Bar engine manually in engine direction of rotation until the markings (1) are aligned.

TIM-ID: 0000004360 - 003

1. 2. 3.


Checking valve clearance at two crankshaft positions 1 2 I X

1. 2. 3.

Check TDC position of piston in cylinder A1: • If the rocker arms are not under load on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. Check valve clearance with the engine cold: • Inlet = 0.4 mm; • Exhaust = 0.6 mm;. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram. Use feeler gage to determine the distance between valve bridge and rocker arm. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.

TIM-ID: 0000004360 - 003

4. 5.

Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve


Adjusting valve clearance 1. 2. 3.

4.

Loosen locknut (1) and unscrew adjusting screw (2) slightly. Insert feeler gage between valve bridge and rocker arm. Readjust adjusting screw (2) so that the feeler gage just passes through the gap.

Tighten locknut (1) applying the specified tightening torque, holding adjusting screw (2) firmly with screw‐ driver. Name Locknut

5. Result:

Size

Type

Lubricant

Tightening torque

Value/Standard 50 Nm

Insert feeler gage between valve bridge and rocker arm to verify that the gage just passes through the gap. If not, adjust valve clearance.

Final steps Remove barring device. For barring device removal, follow reverse sequence of working steps.

TIM-ID: 0000004360 - 003

1. 2.


6.4.2

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


Part No.

Qty.


F30027336

1

Ratchet adapter

F30027340

1

Gasket


Preparatory steps 1. 2.

Remove air filter (→ Page 142). Remove mounting bracket with control valves for exhaust turbocharger and air flap switching.

Removing and installing cylinder head cover 1. 2.

5.

Remove screws. Remove cylinder head cover with gasket from cylinder head. Clean installation surface. Check condition of profile gasket in cylinder head cover. Replace damaged gaskets.

6.

Place cylinder head covers onto crankcase and tighten screws applying the specified tightening torque.

3. 4.

Name Screw

Size


Lubricant


1. 2.

Install mounting bracket with control valves for exhaust turbocharger and air flap switching. Install air filter (→ Page 142).


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Final steps

6.5 Injection Pump / HP Pump 6.5.1

Injection pump – Replacement Special tools, Material, Spare parts Designation / Use

Part No.

Injection pump

Qty.


Remove injection pump and install new one . (→ Page 120)

TIM-ID: 0000000020 - 001

u


6.5.2

Injection pump – Removal and installation Preconditions ☑ Engine is stopped and starting disabled.


DANGER

WARNING

Part No.

Qty.


F30026582

1

Ratchet adapter

F30027340

1

Crow-foot box wrench

F30027424

1


F30027425

1

Torque wrench, 0.5-5 Nm

0015384230

1

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933

Sealing ring


Sealing ring


Unguarded rotating and moving engine components. Risk of serious injury – Danger to life! • Before barring the engine, ensure that nobody is in the danger zone.

Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke.

Preparatory steps Shut off fuel supply line before fuel filter. Remove Engine Control System (→ Page 178). Drain fuel (→ Page 130). Remove charge-air pipes and all seals.

TIM-ID: 0000004579 - 002

1. 2. 3. 4.


Removing injection pump 1. 2. 3. 4.

5. 6. 7. 8.

Mark installation position of injection pump. Disconnect cabling (1) from injection pump. Remove fuel line (2). Unscrew securing screws of injection pump by approx. 6 mm. • The pretensioned compression spring presses the injection pump out of the crankcase, if not: a) turn crankshaft with engine barring de‐ vice, (→ Page 104) • The pump cam presses the injection pump out of the crankcase, if not: . b) Carefully force out injection pump at the recess in the injection pump head. Remove injection pump securing screws. Remove injection pump. Remove sealing rings from injection pump. After removal, seal all openings with suita‐ ble covers.

Installing injection pump 1. 2.

Remove all blanking plugs and covers. Clean mating face of injection pump and roller.

Note: 3.

Sealing ring (1) Ø47 mm Coat sealing ring (1) with grease (Kluthe Hakuform 30-10/Emulgier) and fit on to in‐ jection pump.

Note: 4.

Sealing ring (2) Ø45 mm Coat sealing ring (2) with grease (Kluthe Hakuform 30-10/Emulgier) and fit on to in‐ jection pump. Coat roller (arrowed) with engine oil. Clean sealing surface and fuel bores in crankcase. Use barring tool (→ Page 104) to position the pump cams on the camshaft at base cir‐ cle.

5. 6.

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7.


8.

Install injection pump, observing marked in‐ stallation position.

9.

Install securing screws of injection pump and tighten with torque wrench to the specified torque. Name

Size

Securing screw

Type

Lubricant

Tightening torque


10.

Install fuel line (2).

11.

Tighten union nut on the injection pump to the specified tightening torque using a torque wrench. • Maximum permissible tightening torque: 35 Nm Name

Size

Union nut 12.

Type

Lubricant

Tightening torque


Tighten union nut on the pressure-tube connection piece to the specified tightening torque using a torque wrench. • Maximum permissible tightening torque: 35 Nm Name

Size

Union nut

Type

Lubricant

Tightening torque

20 Nm + 5 Nm

13.

Install injection pump cabling (1).

14.

Use torque wrench to tighten screws to the specified tightening torque. Name Screw

Size


Value/Standard

Lubricant

Value/Standard 1.0 Nm ± 0.2 Nm

1. 2. 3. 4. 5. 6. 7. 8.

Remove barring device (→ Page 104). Clean mating faces on cylinder head and charge-air manifold. Check seals for damage and replace them, if required. Coat seals with grease (Kluthe Hakuform 30-10/Emulgier) and place onto cylinder head. Install charge-air pipes. Install Engine Control System (→ Page 178). Open fuel supply line before fuel filter. Vent fuel system (→ Page 131).


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Final steps

6.6 Injection Valve / Injector 6.6.1

Injector – Replacement Special tools, Material, Spare parts Designation / Use Injector

Part No.

Qty.


Remove injector and install new injector. (→ Page 124)

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u


6.6.2

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

Special tools, Material, Spare parts Designation / Use Puller

WARNING

WARNING

Part No.

Qty.

3555890163/00

Fuel suction device

F30378207

1


F30026582

1

Open end socket wrench

F30025897

1


F30027425

1


F30027424

1

Double-head box wrench

F30011450

1

Ratchet adapter

F30027340

1


X00029933

1

Sealing ring


Sealing ring



Preparatory steps Remove cylinder head cover (→ Page 118). Drain fuel (→ Page 130).

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1. 2.


Removing injector 1. 2. 3. 4. 5.

Remove leak-off-fuel lines. Remove fuel line (3). Remove thrust screw (2). Pull off pressure pipe union (1). Extract fuel from the exposed bores using the suction device.

6. 7. 8. 9. 10.

Remove screw (2). Take off clamp (1). Screw puller into injector. Remove injector with puller. Remove injector sealing ring using a selfmade hook. After removal, seal all openings with suita‐ ble covers.

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11.


Installing injector

3. 4. 5. Result:

6. Result:

7. Result: 8. 9. 10. 11. 12.

13.

Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring (1) with grease and fit on‐ to injector. Coat sealing ring (2) with grease and fit on‐ to injector. Press injector into cylinder head by hand. • The pin is at 11-o'clock position to the transversal axis of the engine. • The pin is engaged in the recess of the clamp (4). Install clamp (4) with screw (5), positioning it correctly. • Pin on injector is in the recess in the clamp. • Forked clamp end is engaged in the cov‐ er recess. Tighten screw (5) of the clamp by hand. Injector can still be turned. Blow out fuel line (3) and pressure pipe un‐ ion (1) with compressed air. Coat sealing ring with grease and fit onto pressure pipe union (1). Coat taper on pressure pipe union with en‐ gine oil. Insert pressure pipe union into cylinder head until it is in contact with the sealing ring. Fully press in pressure pipe union (1) by hand.

Tighten thrust screw (2) with torque wrench to the specified tightening torque. Name

Size

Thrust screw 14.

Type

Lubricant

Tightening torque

Value/Standard 40 Nm ±5 Nm

Use torque wrench to tighten screw for clamp at injector to the specified tightening torque. Name

Size

Screw

Type

Lubricant

Tightening torque


15.


16.

Tighten union nut on the injection pump to the specified tightening torque using a torque wrench. Name Union nut

Size



Lubricant

Value/Standard 20 Nm +5 Nm

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1. 2.

17.

Tighten union nut on the pressure-tube connection piece to the specified tightening torque using a torque wrench. Name

Size

Union nut 18.


Lubricant

Value/Standard 20 Nm +5 Nm

Install leak-off-fuel lines.

Final steps Install cylinder head cover (→ Page 118). Vent fuel system (→ Page 131).

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1. 2.


6.7 Fuel System 6.7.1

HP fuel line – Pressure pipe union replacement Preconditions ☑ Engine is stopped and starting disabled.


Part No.

Qty.


F30026582

1

Open end socket wrench

F30025897

1


F30027425

1


F30027424

1

Double-head box wrench

F30011450

1

Ratchet adapter

F30027340

1


X00029933

Engine oil Pressure pipe union WARNING

WARNING



Preparatory steps Remove cylinder head cover (→ Page 118). Drain fuel (→ Page 130).

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1. 2.


Replacing pressure pipe union 1. 2. 3. 4. 5. 6. 7. 8.

9.

Remove fuel line (3). Remove thrust screw (2). Pull off pressure pipe union (1). Coat sealing ring with grease (Kluthe Haku‐ form 30-10/Emulgier) and fit on to new pressure pipe union (1). Blow out fuel line (3) with compressed air. Coat sealing cone of pressure pipe union with engine oil. Insert pressure pipe union into cylinder head until it is in contact with the sealing ring. Fully press in pressure pipe union (1) by hand.

Tighten thrust screw (2) with torque wrench to the specified tightening torque. Name

Size

Thrust screw

Type

Lubricant

Tightening torque

Value/Standard 40 Nm ± 5 Nm

10.


11.

Tighten union nut on the injection pump to the specified tightening torque using a torque wrench. Name

Size

Union nut 12.

Type

Lubricant

Tightening torque


Tighten union nut on the pressure-tube connection piece to the specified tightening torque using a torque wrench. Name Union nut

Size


Lubricant


Final steps Install cylinder head cover (→ Page 118). Vent fuel system (→ Page 131).

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1. 2.


6.7.2

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

WARNING


Fuel – Draining 1.

Release threaded vent plugs on filter head.

2.

Open nipple on fuel line and drain fuel into appropriate container. When fuel stops emerging from system, close nipple on fuel line. Close vent plugs on filter head.

3.

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4.


6.7.3

Fuel system venting Preconditions ☑ Engine is stopped and starting disabled.

WARNING


Fuel system venting 1.

Unlock fuel priming pump, unscrew handle.

2. 3.

Open vent plugs on filter head. Operate the pump with the handle until fuel without bubbles comes out of the vent plugs and the nipples. Close vent plugs on filter head.

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4.


5. 6. 7.

8. 9.

Open nipple at fuel line. Operate the pump with the handle until fuel without bubbles comes out of the nipple. Close nipple at fuel line. Lock fuel priming pump, screw in handle.

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10. 11.

Open nipple at fuel heat exchanger. Operate the pump with the handle until fuel without bubbles comes out of the nipple. Close nipple at fuel heat exchanger.


6.8 Fuel Filter 6.8.1

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

Special tools, Material, Spare parts Designation / Use Oil filter wrench

DANGER

WARNING

WARNING

Qty.

F30379104

1

Diesel fuel Easy-change filter


Synthetic ring



Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.

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

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CAUTION

Part No.


Fuel filter replacement with the engine stopped 1.

2. 3. 4. 5. 6. 7. 8. 9.

Cut out the filter to be replaced. A Both filters cut in (operating position) B Left filter cut out C Right filter cut out Unscrew switched off easy-change filter with oil filter wrench. Clean sealing surface on filter head. Check sealing ring of the new easy-change filter and moisten it with fuel. Fit SOLAS shield (→ Page 18). Screw on easy-change filter and tighten by hand. Set three-way cock to operating position for both filters (normal position). Replace further fuel filters in the same way. Vent fuel system (→ Page 131).

Replacing fuel filter with the engine running 1. 2. 3. 4. 5. 6. 7. 8. 9.

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10.

Shut down the filter to be replaced. Open the threaded vent plugs at the filter head of the cut-out filter and make sure that the fuel filter is not pressurized. Close threaded vent plugs. Unscrew switched off easy-change filter with oil filter wrench. Clean sealing surface on filter head. Check sealing ring of the new easy-change filter and moisten it with fuel. Fit SOLAS shield (→ Page 18). Screw on easy-change filter and tighten by hand. Set three-way cock to operating position for both filters (normal position). Replace further fuel filters in the same way.


6.8.2 DANGER

WARNING

Fuel prefilter – Differential pressure check and adjustment of gauge Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine.


Differential pressure gauge adjustment 1. 2.

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

Fuel prefilter – Checking differential pressure With the engine running at full load or rated power, read off pressure at gauge (1). If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 137).

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1. 2.


6.8.3

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

Special tools, Material, Spare parts Designation / Use Diesel fuel Seal WARNING

Part No.

Qty.



1.

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

2.

Open threaded vent plug (5) of the filter to be drained. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the filter until pure fuel emerges. Close drain valve (6). Remove screws securing the cover and take off cover (2). Fill filter housing with clean fuel. Place new seal in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges from system.

3. 4. 5. 6. 7. 8. 9. 10. 11.


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Fuel prefilter – Draining

6.8.4

Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use

Part No.

Diesel fuel Gasket DANGER

WARNING

WARNING

Qty.



Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.

Flushing fuel prefilter Switch off contaminated filter. I Left filter cut in II Right filter cut in

TIM-ID: 0000004937 - 010

1.


2. 3. Result: 4.

Open threaded vent plug (5) of the filter to be flushed. Unlock drain valve (6) by pressing toggle, open it and drain fuel. Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

Filling fuel prefilter with fuel Stop engine (→ Page 91) and disable engine start. Remove screws securing the cover and take off cover (2). Fill filter housing with clean fuel. Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Check differential pressure (→ Page 135). If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐ ter (→ Page 139).

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1. 2. 3. 4. 5. 6. Result:


6.8.5

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


WARNING

Part No.

Diesel fuel Filter element


Seal


Qty.


Replacing filter element Cut out the contaminated filter. I Left filter cut in II Right filter cut in

TIM-ID: 0000004946 - 003

1.


2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

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14.

Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the fil‐ ter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3). Insert new filter element (3) and spring housing (4). Fill filter housing with clean fuel. Place new seal in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges. Set adjustable pointer of differential pres‐ sure gauge (→ Page 135).


6.9 Charge-Air Cooling 6.9.1

DANGER

WARNING

WARNING

Intercooler – Checking condensate drain line for coolant discharge and obstruction Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine.


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

Intercooler – Checking condensate drain line for coolant discharge and obstruction 1. 2. 3. 4. 5.

With the engine running, check the conden‐ sate drain line on engine driving end for air discharge. If no air emerges, remove condensate drain line and blow out with compressed air. Replace obstructed drain line by new one. Install condensate drain line. If a large amount of coolant is continuously discharged, the intercooler is leaking. Con‐ tact Service.

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Emergency measures prior to engine start with a leaking intercooler 1. 2. 3. 4.

Remove injectors (→ Page 123). Bar engine manually (→ Page 104). Bar engine with starting system to blow out cylinder chambers (→ Page 105). Install injectors (→ Page 124).


6.10 Air Filter 6.10.1

Air filter – Replacement Special tools, Material, Spare parts Designation / Use Air filter

Part No.

Qty.


Remove old air filter and install new air filter . u

(→ Page 143)

Reset signal ring of service indicator . (→ Page 144)

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u


6.10.2

Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled.

Air filter – Removal and installation 1. 2. 3. 4.

TIM-ID: 0000000904 - 005

5.

Loosen clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it. Place new air filter (3) with clamp (2) onto intake housing (1). Tighten clamp (2).


6.11 Air Intake 6.11.1

Service indicator - Signal ring position check Preconditions ☑ Engine is stopped and starting disabled.

Checking signal ring position 1. 2.

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Result:

If the signal ring is completely visible in the control window (2), replace air filter (→ Page 142). After installation of new filter, press reset button (1). Engaged piston with signal ring moves back to initial position.


6.12 Starting Equipment 6.12.1

Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled.

Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 172).

TIM-ID: 0000000905 - 009

1. 2.


6.13 Lube Oil System, Lube Oil Circuit 6.13.1

Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled.

Checking oil level prior to engine start 1. 2. 3. Result: 4. 5.

Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between “min.” and “max.” marks. If there is no mark, mark the oil dipstick (→ Page 148). If necessary, top up to "max." mark (→ Page 147). Insert oil dipstick into guide tube up to the stop.

Checking oil level after the engine is stopped 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between “min.” and “max.” marks. If there is no mark, mark the oil dipstick (→ Page 148). If necessary, top up to "max." mark (→ Page 147). Insert oil dipstick into guide tube up to the stop.

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1. 2. 3. Result: 4. 5.


6.13.2

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


Part No.

Engine oil Sealing ring WARNING

Qty.



Oil change without semirotary hand pump: Draining oil at drain plug on oil pan 1. 2. 3. 4.

Provide a suitable container to collect the oil. Remove drain plug and drain oil. Install drain plug with new sealing ring. Replace engine oil filter (→ Page 149).

Oil change with semirotary hand pump: Oil extraction 1. 2. 3.

Provide a suitable container to collect the oil. Extract all oil from oil pan using the semirotary hand pump. Replace engine oil filter (→ Page 149).

Filling with new oil 1. 2.

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3. 4. 5.

Open cover on filler neck. Pour oil in at filler neck up to "max." mark at oil dipstick. Close cover on filler neck. Check engine oil level (→ Page 146). After oil change and filter replacement, bar engine with starting system (→ Page 105).


6.14 Oil Filtration / Cooling 6.14.1

Oil dipstick – Marking Preconditions ☑ Engine is stopped and starting disabled.

WARNING

Note:

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. In the case of new engines and spare parts, oil dipsticks are delivered without marks.

Oil dipstick – Marking Draw-off or bleed out engine oil completely of oil pan. Withdraw oil dipstick. Fill in minimum oil quantity. Insert oil dipstick and withdraw it again. Mark a "Min." notch on the oil dipstick. Max. notch depth 1mm. Shorten oil dipstick. Fill in maximum oil quantity. Insert oil dipstick and withdraw it again. Mark a "Max." notch on the oil dipstick. Max. notch depth 1mm.

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1. 2. 3. 4. 5. 6. 7. 8. 9.


6.14.2

Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Oil filter wrench

DANGER

WARNING

WARNING

CAUTION

Part No.

Qty.

F30379104

1

Engine oil Oil filter


Plastic ring




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

Replacing oil filters on a shut-down engine

TIM-ID: 0000006365 - 002

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


1. 2.

Stop engine (→ Page 91) and disable engine start. Cut out the filter to be replaced.

3.

Remove cut-out oil filter using the oil filter wrench. Clean sealing surface on connecting piece. Check condition of new oil filter sealing ring and coat it with oil. Fit SOLAS shield (→ Page 18). Screw on and tighten new engine oil filter by hand. Replace other oil filters in the same way. Switch filter to normal position. After each oil change and filter replace‐ ment, crank engine with starting system (→ Page 105). Check oil level (→ Page 146).

4. 5. 6. 7. 8. 9. 10. 11.

Replacing oil filters on a running engine Reduce engine speed to