MTU 12V2000M41B Operating Instructions Manual

Operating Instructions

Diesel engine

8V2000M40A, 8V2000M40B

8V2000M41A, 8V2000M41B

12V2000M40A, 12V2000M40B

12V2000M41A, 12V2000M41B

16V2000M40A, 16V2000M40B

16V2000M41A, 16V2000M41B

MS150031/06E

Engine model kW/cyl. Hz Application group *

8V2000M40A 48.1 kW/cyl. 50 Hz 3B, 3C

8V2000M40B 50.0 kW/cyl. 60 Hz 3B, 3C

8V2000M41A 48.1 kW/cyl. 50 Hz 3B

8V2000M41B 57.9 kW/cyl. 60 Hz 3B

12V2000M40A 47.9 kW/cyl. 50 Hz 3B, 3C

12V2000M40B 57.9 kW/cyl. 60 Hz 3B, 3C

12V2000M41A 47.9 kW/cyl. 50 Hz 3B

12V2000M41B 57.9 kW/cyl. 60 Hz 3B

16V2000M40A 48.1 kW/cyl. 50 Hz 3B, 3C

16V2000M40B 58.1 kW/cyl. 60 Hz 3B, 3C

16V2000M41A 48.1 kW/cyl. 50 Hz 3B

16V2000M41B 58.1 kW/cyl. 60 Hz 3B

*

3B

Continuous operation, variable load, ICXN

3C

Time-limited operation, ICXN

Table 1: Applicability

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-

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

filming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH

reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents

1 Safety

1.1 Important provisions for all products 6

1.2 Personnel and organizational requirements 7

1.3 Transportation 8

1.4 Safety regulations for maintenance and

repair work 11

1.5 Fire prevention and environmental

protection, fluids and lubricants, indirect

materials 15

1.6 Standards for safety notices in the text 17

2 General Information

2.1 Engine side and cylinder designations 18

2.2 Product description 19

2.3 Series 2000 M40A/B - M41A/B 27

2.4 Sensors and actuators – Overview 28

2.5 Sensors and actuators – Overview 32

3 Technical Data

3.1 8V 2000 M40A engine data: engine-

mounted heat exchanger, reference

conditions: 25 °C intake air temperature 42

3.2 8V 2000 M40A engine data: separate heat

exchanger, reference conditions: 25 °C

intake air temperature 45

3.3 8V 2000 M40B engine data, engine-mounted

heat exchanger, reference condition: 25 °C

intake air temperature 48

3.4 8V 2000 M40B engine data, separate heat

exchanger, reference condition: 25 °C

intake air temperature 51

3.5 8V 2000M41A engine data: Engine-mounted

heat exchanger 54

3.6 8V 2000M41A engine data: Remote heat

exchanger 57

3.7 8V 2000M41B engine data: Engine-mounted

heat exchanger 60

3.8 8V 2000M41B engine data: Remote heat

exchanger 63

3.9 12V 2000 M40A engine data: Engine-

mounted heat exchanger, reference

conditions: 45 °C intake air temperature 66

3.10 12V 2000 M40A engine data: Engine-

mounted heat exchanger, reference

conditions: 25 °C intake air temperature 69

3.11 12V 2000 M40A engine data: Separate heat

exchanger, reference conditions: 25 °C

intake air temperature 72

3.12 12V 2000 M40A engine data: Separate heat

exchanger, reference conditions: 45 °C

intake air temperature 75

3.13 16V 2000 M40A engine data: engine-

mounted heat exchanger, reference

conditions: 25 °C intake air temperature 78

3.14 16V 2000 M40A engine data: engine-

mounted heat exchanger, reference

conditions: 45 °C intake air temperature 81

3.15 16V 2000 M40A engine data: separate heat

exchanger, reference conditions: 25 °C

intake air temperature 84

3.16 16V 2000 M40A engine data: separate heat

exchanger, reference conditions: 45 °C

intake air temperature 87

3.17 16V 2000 M40B engine data, engine-

mounted heat exchanger, reference

condition: 45 °C intake air temperature 90

3.18 16V 2000 M40B engine data, engine-

mounted heat exchanger, reference

condition: 25 °C intake air temperature 93

3.19 16V 2000 M40B engine data, separate heat

exchanger, reference condition: 45 °C

intake air temperature 96

3.20 16V 2000 M40B engine data, separate heat

exchanger, reference condition: 25 °C

intake air temperature 99

3.21 ENGINE DATA 12V 2000M41A/B 102

3.22 ENGINE DATA 16V 2000M41A/B 105

3.23 Firing order 108

3.24 Engine – Main dimensions 109

4 Operation

4.1 LOP – Control elements 110

4.2 Putting the engine into operation (out-of-

service period > 3 months) 112

4.3 Putting the engine into operation after

scheduled out-of-service period 113

4.4 Starting the engine from LOP (without

BlueLine automation system) 114

4.5 Operational monitoring 115

4.6 Stopping the engine at the LOP 116

4.7 Emergency engine stop from LOP 117

4.8 After stopping the engine 118

4.9 Plant – Cleaning 119

5 Maintenance

5.1 Maintenance task reference table [QL1] 120

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6 Troubleshooting

6.1 ECU alarms 121

6.2 Troubleshooting 131

6.3 LOP fault messages 134

7 Task Description

7.1 SOLAS 139

7.1.1 SOLAS shielding as per MTN 5233 –

Installation 139

7.1.2 SOLAS shielding – Installation 140

7.1.3 Installation locations for SOLAS shielding 141

7.2 Engine 146

7.2.1 Engine – Barring manually 146

7.2.2 Engine – Cranking on starting system 147

7.3 Cylinder Liner 148

7.3.1 Cylinder liner – Endoscopic examination 148

7.3.2 Cylinder liner – Instructions and comments on

endoscopic and visual examination 150

7.4 Crankcase Breather 152

7.4.1 Crankcase breather – Oil separator

replacement, diaphragm check and

replacement 152

7.4.2 Crankcase breather – Cleaning oil pre-

separator element 154

7.5 Valve Drive 155

7.5.1 Valve clearance – Check and adjustment 155

7.5.2 Cylinder head cover – Removal and

installation 158

7.6 Injection Pump / HP Pump 159

7.6.1 Injection pump – Replacement 159

7.6.2 Injection pump – Removal and installation 160

7.7 Injection Valve / Injector 163

7.7.1 Injector – Replacement 163

7.7.2 Injector – Removal and installation 164

7.8 Fuel System 167

7.8.1 HP fuel line – Pressure pipe neck replacement 167

7.8.2 Fuel – Draining 169

7.8.3 Fuel system – Venting 170

7.9 Fuel Filter 172

7.9.1 Fuel filter – Replacement 172

7.9.2 Fuel prefilter – Differential pressure check

and adjustment of gauge 174

7.9.3 Fuel prefilter – Draining 176

7.9.4 Fuel prefilter – Flushing 179

7.9.5 Fuel prefilter – Filter element replacement 183

7.10 Charge-Air Cooling 187

7.10.1 Intercooler ‒ Checking condensate drain line

for coolant discharge and obstruction 187

7.11 Air Filter 188

7.11.1 Air filter – Replacement 188

7.11.2 Air filter – Removal and installation 189

7.12 Air Intake 190

7.12.1 Service indicator – Signal ring position check 190

7.13 Starting Equipment 191

7.13.1 Starter – Condition check 191

7.14 Lube Oil System, Lube Oil Circuit 192

7.14.1 Engine oil – Level check 192

7.14.2 Engine oil – Change 193

7.15 Oil Filtration / Cooling 194

7.15.1 Oil dipstick — Marking 194

7.15.2 Engine oil filter – Replacement 195

7.15.3 Centrifugal oil filter and filter sleeve –

Cleaning and replacement 197

7.16 Coolant Circuit, General, High-Temperature

Circuit 200

7.16.1 Drain and venting points 200

7.16.2 Engine coolant – Level check 205

7.16.3 Engine coolant – Change 206

7.16.4 Engine coolant – Draining 207

7.16.5 Engine coolant ‒ Filling 208

7.16.6 HT coolant pump ‒ Relief bore check 209

7.16.7 Engine coolant – Sample extraction and

analysis 210

7.17 Raw Water Pump with Connections 211

7.17.1 Raw water pump – Relief bore check 211

7.18 Belt Drive 212

7.18.1 Drive belt – Condition check 212

7.19 Battery-Charging Generator 213

7.19.1 Battery-charging generator drive – Drive belt

check and adjustment 213

7.19.2 Battery-charging generator drive – Drive belt

replacement 215

7.20 Engine Mounting / Support 217

7.20.1 Engine mounting – Checking condition of

resilient mounts 217

7.21 Wiring (General) for Engine/Gearbox/Unit 218

7.21.1 Engine cabling – Check 218

7.22 Accessories for (Electronic) Engine

Governor / Control System 219

7.22.1 Engine Control Unit and connectors – Cleaning 219

7.22.2 EMU and connectors – Cleaning 220

7.22.3 Start interlock limit switch – Check 221

7.22.4 ECU – Plug connections check 222

7.22.5 Engine monitoring unit, plug connections –

Check 223

7.22.6 Engine control system – Removal and

installation 224

7.23 Emergency Instrumentation (Local

Operating Panel) 225

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7.23.1 LOP and connectors – Cleaning 225

7.23.2 LOP – Visual inspection 226

7.23.3 LOP – Running test procedures 228

8 Appendix A

8.1 Abbreviations 230

8.2 MTU Contact/Service Partners 232

9 Appendix B

9.1 Special Tools 233

9.2 Index 240

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1 Safety

1.1 Important provisions for all products

General information

This product may pose a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Changes or modifications which are neither made nor authorized by the manufacturer

• Noncompliance with the safety instructions and warning notices

Nameplates

The product is identified by nameplate, model designation or serial number and must match with the infor-

mation on the title page of this manual.

Nameplates, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the

EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-

cations.

Emission regulations and emission labels

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional compo-

nents including the execution of calibration processes that might affect the emission characteristics of the

product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-

changed or repaired if the components used for this purpose are approved by the manufacturer.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-

lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.

The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-

tional life.

Exception: Engines used exclusively in land-based, military applications other than by US government agen-

cies.

Please note the following when replacing components with emission labels:

• The relevant emission labels must be affixed to the spare part.

• Emission labels shall not be transferred from the replaced part to the spare part.

• The emission labels must be removed from the replaced part and destroyed.

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1.2 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-

tion, or transportation.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,

repair, assembly, installation, and transport personnel at all times.

Personnel must receive instruction on product handling and repair based on this manual. In particular, per-

sonnel must have read and understood the safety requirements and warnings before starting work.

This is important in the case of personnel who only occasionally perform work on or around the product.

These personnel must be instructed repeatedly.

Personnel requirements

All work on the product must be carried out by trained, instructed and qualified personnel only:

• Training at the Training Center of the manufacturer

• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-

sembly, installation, and transport in writing.

Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,

goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-

tions of the individual activities.

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1.3 Transportation

Transport without flange-mounted gearbox

Illustration is essentially valid for 8V 2000 M engines

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

Transport with flange-mounted gearbox

Illustration is essentially valid for 8V 2000 M engines

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

Only use the lifting eyes provided to lift the engine.

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

flange-mounted gearboxes.

Only use transport and lifting devices approved by MTU.

Take the engine's center of gravity into account.

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The engine must only be transported in installation position, max. permissible diagonal pull 10°.

If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bearing

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 transporta-

tion.

Secure the engine against tilting during transport. In particular when going down inclines or ramps, the en-

gine must be secured against moving and tilting.

Setting the engine down after transport

Only set down engine on a firm, level surface.

Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.

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

basis.

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1.4 Safety regulations for maintenance and repair work

Safety regulations when preparing to perform maintenance and repair work

Have maintenance or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk

of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-

ble containers of adequate capacity to catch fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.

Never carry out maintenance and repair work with the product in operation, unless:

• It is expressly permitted to do so following a written procedure.

• The product is running in the low load range and only for as long as absolutely necessary.

Lock-out the product to preclude undesired starting, e.g.

• Start interlock

• Key switch

• With hydraulic starting system: shut off supply line.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.

Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-

ers are fitted.

Disconnect the control equipment from the product.

Use the recommended special tools or suitable equivalents when instructed to do so.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.

Only install them after painting the engine or mask them prior to painting.

The following applies to starters with copper-beryllium alloy pinions:

• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter

with compressed air. Clean the flywheel housing inside with a class H dust extraction device.

• Observe the safety data sheet.

Safety regulations when performing maintenance and repair work

Take special care when removing ventilation or plug screws from the product.

Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-

surized lines, shut off the lines first, then release the residual pressure.

Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-

bly.

Carry out work only on assemblies or plants which are properly secured.

Use appropriate lifting equipment for all components. Use all specified attachment points and observe the

center of gravity.

Never work on engines or components when they are held in place by lifting equipment.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that

components/tools fall down.

Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Special instructions

for outdoor areas: There must be no risk of slipping e.g. due to icing.

Keep fuel injection lines and connections clean.

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Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness

(e.g. components carrying oil, fuel, or air).

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Never bend lines and avoid damaging lines, particularly the fuel lines.

Ensure that all retainers and dampers are installed correctly.

Ensure that O-rings are not installed in a slanted/twisted condition.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact

with other components. Do not place fuel or oil lines near hot components.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or

resinous appearance.

Note cooling time for components which are heated for installation or removal (risk of burning).

Pay particular attention to cleanliness at all times.

Remove any accumulation of condensate after assembling chilled components. Coat the components with a

suitable corrosion inhibitor as necessary.

Safety regulations after performing maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safety equipment has been installed and that all tools and loose parts have been removed

(especially the barring tool).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Ensure that the grounding system is properly connected.

Welding work

Welding operations on the product or mounted units are not permitted. Cover the product when welding in

its vicinity.

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery cables or actuate the battery isolating switch.

• Separate the electrical ground of electronic equipment from the ground of the unit.

No other maintenance or repair work must be carried out in the vicinity of the product while welding is in

progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubricants.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The

welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-

tem.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-

ces for hydraulic removal/installation procedures.

Observe the max. permissible push-on pressure specified for the equipment.

Do not attempt to bend or apply force to lines which are under pressure.

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Before starting work, pay attention to the following:

• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.

• For hydraulic installation, screw on the tool with the piston retracted.

• For hydraulic removal, screw on the tool with the piston extended.

For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft

end until correct sealing is established.

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the

component to be installed/removed.

Working with batteries

Observe the safety instructions of the manufacturer when working on batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow battery acids to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.

Do not place objects on the battery.

Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray

acid if the battery terminals are connected incorrectly.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or

switching off any part of the electronic system required to do so.

De-energize the appropriate areas prior to working on assemblies.

ESD: Work on electrostatically endangered components which could be damaged by electrostatic discharge

(ESD) must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically con-

ductive work surfaces or antistatic wristbands.

Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-

ing operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable ties to secure lines.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to functional testing on completion of all repair work. The emergen-

cy stop function must be tested in particular.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package

faulty electronic components or assemblies properly before dispatching for repair:

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil (as necessary)

Working with laser equipment

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-

structions in the manufacturer's user manual when working with laser equipment.

Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).

Laser equipment must be fitted with the protective devices necessary for safe operation according to type

and application.

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Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-

perature of 20 °C.

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1.5 Fire prevention and environmental protection, fluids and

lubricants, indirect materials

Fire prevention

Flames, naked light and smoking are prohibited.

Ensure the area is well ventilated when working with combustible indirect materials (e.g. cleaning agents).

The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.

Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires so keep the product

clean at all times. Do not leave rags saturated with fluids and lubricants on the product. Do not store com-

bustible materials near the product.

Clean welding points with a non-flammable fluid before welding. Do not carry out welding work on pipes and

components carrying oil or fuel.

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.

Ensure that suitable extinguishing agents (fire extinguisher) are always available and that staff are familiar

with their correct handling.

Noise

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

Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating dan-

ger are drowned.

Environmental protection and disposal

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

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-

cled.

Indirect materials, fluids and lubricants

Indirect materials, fluids and lubricants may be hazardous or contain toxic substances. Observe the informa-

tion provided in the safety data sheet for the product when using indirect materials and other chemical sub-

stances. The safety data sheet may be obtained from the relevant manufacturer or from MTU.

Used oil

Used oil contains harmful combustion residue.

Wear protective gloves!

Wash relevant areas after contact with used oil.

Lead

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

• Switch on extraction system.

• Avoid direct contact with lead or pastes containing lead.

• Do not inhale lead vapors.

• Wash affected areas after contact with lead or substances containing lead.

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Compressed air

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-

tainers, risks causing an explosion.

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

• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)

for drying purposes or to check for leaks risks bursting them.

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

• Assemblies or products which are to be connected must be designed to withstand this pressure. Install

pressure-reducing or safety valves set to the admissible pressure if this is not the case.

• Hose couplings and connections must be securely attached.

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

• Relieve residual pressure before removing compressed-air equipment from the supply line. To depressu-

rize compressed-air lines, shut off the lines first, then release the residual pressure.

• Perform leak testing in accordance with instructions.

Paints and lacquers

• Observe the relevant safety data sheet for all materials.

• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure

that the area is well ventilated. Make sure that neighboring work areas are not impaired.

• Avoid open flames in the vicinity.

• No smoking.

• Observe fire prevention regulations.

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

Liquid nitrogen

• Observe the relevant safety data sheet for all materials.

• Work with liquid nitrogen may be carried out only by qualified personnel.

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

• Avoid body contact (eyes, hands).

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

• Make sure that the working area is well ventilated.

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

Acids/alkaline solutions/urea (AdBlue

®

, DEF)

• Observe the relevant safety data sheet for all materials.

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

tive clothing.

• Do not inhale vapors.

• If urea solution is swallowed, rinse out mouth and drink plenty of water.

• Remove any wet clothing immediately.

• Wash affected body areas with plenty of water after skin contact.

• Rinse eyes immediately with eyedrops or clean tap water after eye contact. Seek medical attention as

soon as possible.

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1.6 Standards for safety notices in the text

DANGER

In the event of immediate danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

WARNING

In the event of a situation involving potential danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!

• Remedial action.

NOTICE

In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!

• Remedial action.

• Additional product information.

Warning notices

1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-

tion, maintenance, repair, assembly, installation, or transportation.

2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-

al injury shall be considered to include a warning of potential damage.

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2 General Information

2.1 Engine side and cylinder designations

1 Left engine side (A-side)

2 Engine free end in accord-

ance with DIN ISO 1204

(KGS = Kupplungsgegen-

seite)

3 Right engine side (B-side)

4 Engine driving end in ac-

cordance with

DIN ISO 1204 (KS = Kup-

plungsseite)

Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-

hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of

each bank are numbered consecutively, starting with x=1 at driving end (4).

The numbering of other engine components also starts with 1 at driving end (4).

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2.2 Product description

Description of the engine

Engine

The engine is a liquid-cooled, four-stroke cycle diesel engine, rotating counter-clockwise (seen from driving

end), with direct injection, sequential turbocharging and charge-air cooling.

The engine is monitored by an engine control and monitoring system.

Monitoring in the engine room is carried out by the engine control and monitoring unit.

Fuel system

Electronically controlled unit injection pumps with jacketed HP lines.

The electronic control unit controls

• Beginning of injection

• Injection quantity

Exhaust system

The exhaust system is equipped with triple-walled, water-cooled exhaust lines.

The triple-walled design permits

• Low surface temperature

• Reduced amount of heat to be dissipated by the coolant

• Absolute gas-tightness

Turbocharging

Sequential turbocharging with charge-air cooling (turbochargers can be cut in/out during operation).

Cooling system

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

Service block

The service components are mounted at the auxiliary PTO end.

The arrangement facilitates easy access for maintenance operations.

Service components:

• Raw water pump, coolant pump

• Fuel duplex filter, switchable

• Lube-oil multiple filter, switchable

• Centrifugal lube oil filter

• Coolant expansion tank

Electronic system

Electronic control and monitoring system with integrated safety and test system, providing interfaces to Re-

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

Electronic Engine Control Unit (ECU)

Functions:

• Engine speed control with fuel and speed limitation dependent on engine state and operating conditions;

• 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.

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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 monitoring.

Monitoring in engine room

Engine control and monitoring unit (LOP)

Functions:

• Alphanumeric, monochrome LCD display for monitoring of measured values as well as alarms when limits

are violated;

• Pushbuttons for menu control and dimming unit;

• Combined control and display elements for local engine/gear control;

• Flashing light and horn for summary alarm in engine room;

• Interface to CAN field bus for connected, communicating monitoring system components.

SOLAS – Fire protection specifications

All fuel lines with fuel pressure >1.8 bar are fitted with SOLAS-compliant covers as per MTU standard

MTN5233.

All oil lines with oil pressure >1.8 bar are fitted with SOLAS-compliant covers as per MTU standard

MTN5233.

Fuel system covers

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MTU 12V2000M41B Operating Instructions Manual

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