MTU 8 V 2000 M51A 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
MW15550/06E
Printed in Germany
© 2012 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.
Table of Contents
1 Safety
1.1 General conditions 6
1.2 Personnel and organizational requirements 7
1.3 Transportation 8
1.4 Safety regulations for startup and operation 11
1.5 Safety regulations for maintenance and
repair work 12
1.6 Auxiliary materials, fire prevention and
environmental protection 15
1.7 Conventions for safety instructions in the
text 17
2 General Information
2.1 Engine side and cylinder designations 18
2.2 Product description 19
2.3 Engine overview 2000 M50-M61A/B 28
2.4 Sensors, actuators and injectors –
Overview 29
3 Technical Data
3.1 8V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 39
3.2 8V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 42
3.3 8V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 45
3.4 8V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 48
3.5 Engine data 8V 2000M51A, engine-
mounted heat exchanger 51
3.6 8V 2000 M51A engine data: Remote heat
exchanger 54
3.7 Engine data 8V 2000M51B, engine-
mounted heat exchanger 57
3.8 8V 2000 M51B engine data: Remote heat
exchanger 60
3.9 12V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 63
3.10 12V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 66
3.11 12V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 69
3.12 12V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake air
temperature 45 °C 72
3.13 12V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 75
3.14 12V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 78
3.15 12V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 81
3.16 12V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 45 °C 84
3.17 Engine data 12V 2000 M51A, engine-
mounted heat exchanger 87
3.18 12V 2000 M51A engine data: Remote heat
exchanger 90
3.19 Engine data 12V 2000M51B, engine-
mounted heat exchanger 93
3.20 12V 2000 M51B engine data: Remote heat
exchanger 96
3.21 16V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 99
3.22 16V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 102
3.23 16V 2000 M50A engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 105
3.24 16V 2000 M50A engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 45 °C 108
3.25 16V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 25 °C 111
3.26 16V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 25 °C 114
3.27 16V 2000 M50B engine data: Engine-
mounted heat exchanger, reference
condition: Intake-air temperature 45 °C 117
3.28 16V 2000 M50B engine data: Remote heat
exchanger, reference condition: Intake-air
temperature 45 °C 120
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3.29 Engine data 16V 2000M51A, engine-
mounted heat exchanger 123
3.30 16V 2000 M51A engine data: Remote heat
exchanger 126
3.31 Engine data 16V 2000M51B, engine-
mounted heat exchanger 129
3.32 16V 2000 M51B engine data: Remote heat
exchanger 132
3.33 Firing order 135
3.34 Engine – Main dimensions 136
4 Operation
4.1 Putting the engine into operation (out-of-
service period > 3 months) 137
4.2 Putting the engine into operation after
scheduled out-of-service period 138
4.3 Operational checks 139
4.4 LOP – Controls 140
4.5 Starting the engine from LOP 142
4.6 Stopping the engine from LOP (without
Blue Line automation system) 143
4.7 Emergency stop from LOP 144
4.8 After stopping the engine 145
4.9 Plant – Cleaning 146
5 Maintenance
5.1 Maintenance task reference table [QL1] 147
5.2 Maintenance task reference table [QL1] 148
6 Troubleshooting
6.1 Troubleshooting 149
6.2 LOP fault messages 152
7 Task Description
7.1 SOLAS 157
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 157
7.1.2 SOLAS shielding – Installation as per MTN
5233 158
7.1.3 SOLAS shielding – Installation 159
7.1.4 Installation locations for SOLAS shielding 160
7.2 Engine 166
7.2.1 Engine – Barring manually 166
7.2.2 Engine cranking on starter 167
7.3 Cylinder Liner 168
7.3.1 Cylinder liner – Endoscopic examination 168
7.3.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 170
7.4 Crankcase Breather 172
7.4.1 Crankcase ventilation – Oil separator element
replacement, diaphragm check and
replacement 172
7.4.2 Crankcase breather – Cleaning oil separator
element 174
7.5 Valve Drive 175
7.5.1 Valve clearance – Check and adjustment 175
7.5.2 Cylinder head cover – Removal and
installation 178
7.6 Injection Pump / HP Pump 179
7.6.1 Injection pump – Replacement 179
7.6.2 Injection pump – Removal and installation 180
7.7 Injection Valve / Injector 183
7.7.1 Injector – Replacement 183
7.7.2 HP fuel line – Pressure pipe neck
replacement 184
7.7.3 Injector – Removal and installation 186
7.8 Fuel System 190
7.8.1 HP fuel line – Pressure pipe neck
replacement 190
7.8.2 Fuel – Draining 192
7.8.3 Fuel system – Venting 193
7.9 Fuel Filter 195
7.9.1 Fuel filter – Replacement 195
7.9.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 197
7.9.3 Fuel prefilter – Draining 198
7.9.4 Fuel prefilter ‒ Flushing 199
7.9.5 Fuel prefilter – Filter element replacement 201
7.10 Charge-Air Cooling General, Left-Hand
Side 203
7.10.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 203
7.11 Air Filter 204
7.11.1 Air filter – Replacement 204
7.11.2 Air filter – Removal and installation 205
7.12 Air Intake 206
7.12.1 Contamination indicator – Signal ring position
check 206
7.13 Starting Equipment 207
7.13.1 Starter – Condition check 207
7.14 Lube Oil System, Lube Oil Circuit 208
7.14.1 Engine oil – Level check 208
7.14.2 Engine oil – Change 209
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7.15 Oil Filtration / Cooling 210
7.15.1 Oil dipstick – Marking 210
7.15.2 Engine oil filter – Replacement 211
7.15.3 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 213
7.16 Coolant Circuit, General, High-
Temperature Circuit 216
7.16.1 Drain and venting points 216
7.16.2 Engine coolant – Level check 221
7.16.3 Engine coolant – Change 222
7.16.4 Engine coolant – Draining 223
7.16.5 Engine coolant – Filling 224
7.16.6 HT coolant pump – Relief bore check 225
7.16.7 Engine coolant – Sample extraction and
analysis 226
7.17 Raw Water Pump with Connections 227
7.17.1 Raw water pump – Relief bore check 227
7.18 Belt Drive 228
7.18.1 Drive belt – Condition check 228
7.19 Battery-Charging Generator 229
7.19.1 Battery-charging generator drive – Drive belt
check and adjustment 229
7.19.2 Battery-charging generator drive – Drive belt
replacement 231
7.20 Engine Mounting / Support 233
7.20.1 Engine mounting – Checking condition of
resilient mounts 233
7.21 Wiring (General) for Engine/Gearbox/Unit 234
7.21.1 Engine wiring – Check 234
7.22 Accessories for (Electronic) Engine
Governor / Control System 235
7.22.1 Engine governor and connectors – Cleaning 235
7.22.2 Engine monitoring unit and connectors –
Cleaning 236
7.22.3 Start interlock limit switch – Check 237
7.22.4 ECU – Checking plug connections 238
7.22.5 Engine monitoring unit – Plug connection
check 239
7.22.6 Engine control unit – Removal and installation 240
7.23 Emergency Instrumentation (Local
Operating Panel) 242
7.23.1 LOP and connectors – Cleaning 242
7.23.2 LOP – Visual inspection 243
7.23.3 LOP – Test procedures 245
8 Appendix A
8.1 Abbreviations 247
8.2 MTU contacts/service partners 250
9 Appendix B
9.1 Special Tools 251
9.2 Index 255
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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 maintenance 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
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.
Depending on the kind of work, use the necessary personal protective equipment.
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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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This manual suits for next models
11
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