MTU 8 V 2000 M50A User manual
Operating Instructions
Diesel Engine
8 V 2000 M50A, M50B
8 V 2000 M51A, M51B
12 V 2000 M50A, M50B
12 V 2000 M51A, M51B
16 V 2000 M50A, M50B
16 V 2000 M51A, M51B
MW15550/07E
Printed in Germany
© 2013 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, mi-
crofilming 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.
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, auxiliary
materials 14
1.6 Standards for warning notices in the text 16
2 General Information
2.1 Engine side and cylinder designations 17
2.2 Product description 18
2.3 2000 M40-M91A/B engines – Overview 27
2.4 Sensors, actuators and injectors – Overview 28
2.5 Sensors, actuators and injectors – Overview 32
3 Technical Data
3.1 8V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 42
3.2 8V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 45
3.3 8V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 48
3.4 8V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 51
3.5 Engine data 8V 2000M51A, engine-mounted
heat exchanger 54
3.6 8V 2000 M51A engine data: Remote heat
exchanger 57
3.7 Engine data 8V 2000M51B, engine-mounted
heat exchanger 60
3.8 8V 2000 M51B engine data: Remote heat
exchanger 63
3.9 12V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 66
3.10 12V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 69
3.11 12V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 72
3.12 12V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake air
temperature 45 °C 75
3.13 12V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 78
3.14 12V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 81
3.15 12V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 84
3.16 12V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 45 °C 87
3.17 Engine data 12V 2000 M51A, engine-
mounted heat exchanger 90
3.18 12V 2000 M51A engine data: Remote heat
exchanger 93
3.19 Engine data 12V 2000M51B, engine-
mounted heat exchanger 96
3.20 12V 2000 M51B engine data: Remote heat
exchanger 99
3.21 16V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 102
3.22 16V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 105
3.23 16V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 108
3.24 16V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 45 °C 111
3.25 16V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 114
3.26 16V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 117
3.27 16V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 120
3.28 16V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 45 °C 123
3.29 Engine data 16V 2000M51A, engine-
mounted heat exchanger 126
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3.30 16V 2000 M51A engine data: Remote heat
exchanger 129
3.31 Engine data 16V 2000M51B, engine-
mounted heat exchanger 132
3.32 16V 2000 M51B engine data: Remote heat
exchanger 135
3.33 Firing order 138
3.34 Engine – Main dimensions 139
4 Operation
4.1 LOP – Controls 140
4.2 Putting the engine into operation (out-of-
service period > 3 months) 142
4.3 Putting the engine into operation after
scheduled out-of-service period 143
4.4 Starting the engine from LOP 144
4.5 Operational checks 145
4.6 Stopping the engine at the LOP 146
4.7 Emergency stop from LOP 147
4.8 After stopping the engine 148
4.9 Plant cleaning 149
5 Maintenance
5.1 Maintenance task reference table [QL1] 150
5.2 Maintenance task reference table [QL1] 151
6 Troubleshooting
6.1 ECU alarms 152
6.2 Troubleshooting 162
6.3 LOP fault messages 165
7 Task Description
7.1 SOLAS 170
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 170
7.1.2 SOLAS shielding – Installation as per MTN
5233 171
7.1.3 SOLAS shielding – Installation 172
7.1.4 Installation locations for SOLAS shielding 173
7.2 Engine 178
7.2.1 Engine – Barring manually 178
7.2.2 Engine cranking on starter 179
7.3 Cylinder Liner 180
7.3.1 Cylinder liner – Endoscopic examination 180
7.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 182
7.4 Crankcase Breather 184
7.4.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 184
7.4.2 Crankcase breather – Cleaning oil separator
element 186
7.4.3 Crankcase ventilation – Oil separator element
replacement, diaphragm check and
replacement 187
7.5 Valve Drive 189
7.5.1 Valve clearance – Check and adjustment 189
7.5.2 Cylinder head cover – Removal and
installation 192
7.6 Injection Pump / HP Pump 193
7.6.1 Injection pump – Replacement 193
7.6.2 Injection pump – Removal and installation 194
7.7 Injection Valve / Injector 197
7.7.1 Injector – Replacement 197
7.7.2 Injector – Removal and installation 198
7.8 Fuel System 202
7.8.1 HP fuel line – Pressure pipe neck replacement 202
7.8.2 Fuel – Draining 204
7.8.3 Fuel system – Venting 205
7.9 Fuel Filter 207
7.9.1 Fuel filter – Replacement 207
7.9.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 209
7.9.3 Fuel prefilter – Draining 210
7.9.4 Fuel prefilter – Flushing 211
7.9.5 Fuel prefilter – Filter element replacement 213
7.10 Charge-Air Cooling General, Left-Hand Side 215
7.10.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 215
7.11 Air Filter 216
7.11.1 Air filter – Replacement 216
7.11.2 Air filter – Removal and installation 217
7.12 Air Intake 218
7.12.1 Service indicator – Signal ring position check
(optional) 218
7.13 Starting Equipment 219
7.13.1 Starter – Condition check 219
7.14 Lube Oil System, Lube Oil Circuit 220
7.14.1 Engine oil – Level check 220
7.14.2 Engine oil – Change 221
7.15 Oil Filtration / Cooling 222
7.15.1 Oil dipstick — Marking 222
7.15.2 Engine oil filter – Replacement 223
7.15.3 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 225
7.16 Coolant Circuit, General, High-Temperature
Circuit 228
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7.16.1 Drain and venting points 228
7.16.2 Engine coolant – Level check 233
7.16.3 Engine coolant – Change 234
7.16.4 Engine coolant – Draining 235
7.16.5 Engine coolant – Filling 236
7.16.6 HT coolant pump – Relief bore check 237
7.16.7 Engine coolant – Sample extraction and
analysis 238
7.17 Raw Water Pump with Connections 239
7.17.1 Raw water pump – Relief bore check 239
7.18 Belt Drive 240
7.18.1 Drive belt – Condition check 240
7.19 Battery-Charging Generator 241
7.19.1 Battery-charging generator drive – Drive belt
check and adjustment 241
7.19.2 Battery-charging generator drive – Drive belt
replacement 243
7.20 Engine Mounting / Support 245
7.20.1 Engine mounting – Checking condition of
resilient mounts 245
7.21 Wiring (General) for Engine/Gearbox/Unit 246
7.21.1 Engine wiring – Check 246
7.22 Accessories for (Electronic) Engine
Governor / Control System 247
7.22.1 Engine governor and connectors – Cleaning 247
7.22.2 Engine monitoring unit and connectors –
Cleaning 248
7.22.3 Start interlock limit switch – Check 249
7.22.4 ECU – Plug connections check 250
7.22.5 Engine monitoring unit – Plug connection
check 251
7.22.6 Engine control unit – Removal and installation 252
7.23 Emergency Instrumentation (Local
Operating Panel) 254
7.23.1 LOP and connectors – Cleaning 254
7.23.2 LOP – Visual inspection 255
7.23.3 LOP – Test procedures 257
8 Appendix A
8.1 Abbreviations 259
8.2 MTU contact persons/service partners 262
9 Appendix B
9.1 Special Tools 263
9.2 Index 270
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ product data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ applicable Spare Parts
Catalog)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
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1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and protective equipment
Wear proper protective clothing for all work.
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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 bear-
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport
Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
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