MTU MW15406/17E User manual
Operating Instructions
Diesel engine
8 V 2000 M60/M61
12V 2000 M60/M61
16V 2000 M60/M61
MW15406/17E
© 2014 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 consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming 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.
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
(warranty, spare parts, etc.).
Table of Contents
1 Safety
1.1 Important requirements for all products 8
1.2 Personnel and organizational requirements 9
1.3 Transport 10
1.4 Safety requirements for startup and
operation 11
1.5 Safety requirements for maintenance and
repair work 12
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 15
1.7 Standards for safety notices in the text 17
2 General Information
2.1 Product description 18
2.2 Engine side and cylinder designations 27
2.3 2000 M40-M91A/B engines – Overview 28
2.4 Sensors and actuators – Overview 29
3 Technical Data
3.1 8V 2000 M60 engine data: Engine-mounted
heat exchanger, reference condition: 25 °C
intake air temperature 39
3.2 8V 2000 M60 engine data: Engine-mounted
heat exchanger, reference condition: 45 °C
intake air temperature 42
3.3 8V 2000 M60 engine data: Separate heat
exchanger, reference condition: 25 °C
intake air temperature 45
3.4 8V 2000 M60 engine data: Separate heat
exchanger, reference condition: 45 °C
intake air temperature 48
3.5 8V 2000M61 engina data 51
3.6 12V 2000 M60 engine data: Engine-
mounted heat exchanger, reference
condition: 25 °C intake air temperature 55
3.7 12V 2000 M60 engine data: Engine-
mounted heat exchanger, reference
condition: 45 °C intake air temperature 58
3.8 12V 2000 M60 engine data: Separate heat
exchanger, reference condition: 25 °C
intake air temperature 61
3.9 12V 2000 M60 engine data: Separate heat
exchanger, reference condition: 45 °C
intake air temperature 64
3.10 12V 2000 M61 engine data 67
3.11 12V 2000 M61 engine data 70
3.12 12V 2000 M61 engine data 73
3.13 12V 2000 M61 engine data 76
3.14 16V 2000 M60 engine data: Engine-
mounted heat exchanger, reference
condition: 25 °C intake air temperature 79
3.15 16V 2000 M60 engine data: Engine-
mounted heat exchanger, reference
condition: 45 °C intake air temperature 82
3.16 16V 2000 M60 engine data: Separate heat
exchanger, reference condition: 25 °C
intake air temperature 85
3.17 16V 2000 M60 engine data: Separate heat
exchanger, reference condition: 45 °C
intake air temperature 88
3.18 16V 2000 M61 engine data 91
3.19 16V 2000 M61 engine data 94
3.20 16V 2000 M61 engine data 97
3.21 16V 2000 M61 engine data 100
3.22 Firing order 103
3.23 Engine – Main dimensions 104
4 Operation
4.1 LOP controls (without Blue Line automation
system) 105
4.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 107
4.3 Putting the engine into operation after
scheduled out-of-service period 108
4.4 Starting the engine from LOP (without Blue
Line automation system) 109
4.5 Starting the engine with the BlueLine
automation system (control stand) 110
4.6 Engine emergency stop at BlueLine
automation system (control stand) 111
4.7 Operational checks 112
4.8 Coupling – Disengaging from LOP 113
4.9 Waterjet – Flushing from LOP (optional) 114
4.10 Stopping the engine from LOP (without Blue
Line automation system) 115
4.11 Stopping the engine at the BlueLine
automation system (control stand) 116
4.12 Emergency stop from LOP (without Blue
Line automation system) 117
4.13 After stopping the engine 118
4.14 Plant – Cleaning 119
5 Maintenance
5.1 Maintenance schedule reference table [QL1] 120
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6 Troubleshooting
6.1 LOP fault messages 121
6.2 Troubleshooting 130
7 Task Description
7.1 SOLAS 133
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 133
7.1.2 SOLAS shielding – Installation as per MTN
5233 134
7.1.3 SOLAS shielding – Installation 135
7.1.4 Installation locations for SOLAS shielding 136
7.1.5 Installation locations for SOLAS shielding 141
7.2 Engine 146
7.2.1 Engine ‒ Barring manually 146
7.2.2 Engine – Barring with starting system 147
7.3 Cylinder Liner 148
7.3.1 Cylinder liner – Endoscopic examination 148
7.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 150
7.4 Crankcase Breather 152
7.4.1 Crankcase ventilation – Oil separator element
replacement, diaphragm check and
replacement 152
7.4.2 Crankcase breather – Cleaning oil 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 HP fuel line – Pressure pipe neck replacement 164
7.7.3 Injector – Removal and installation 166
7.8 Fuel System 170
7.8.1 Fuel – Draining 170
7.8.2 Fuel system – Venting 171
7.9 Fuel Filter 173
7.9.1 Fuel filter – Replacement 173
7.9.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 175
7.9.3 Fuel prefilter – Draining 176
7.9.4 Fuel prefilter – Flushing 177
7.9.5 Fuel prefilter – Filter element replacement 179
7.10 Charge-Air Cooling General, Left-Hand Side 181
7.10.1 Intercooler ‒ Checking condensate drain line
for coolant discharge and obstruction 181
7.11 Air Filter 182
7.11.1 Air filter – Replacement 182
7.11.2 Air filter – Removal and installation 183
7.12 Air Intake 184
7.12.1 Service indicator – Signal ring position check
(optional) 184
7.12.2 Air-flow control flap – Ease of movement
check 185
7.13 Starting Equipment 186
7.13.1 Starter – Condition check 186
7.14 Lube Oil System, Lube Oil Circuit 187
7.14.1 Engine oil – Level check 187
7.14.2 Engine oil – Change 188
7.15 Oil Filtration / Cooling 189
7.15.1 Oil dipstick — Marking 189
7.15.2 Engine oil filter – Replacement 190
7.15.3 Centrifugal oil filter and filter sleeve –
Cleaning and replacement 192
7.16 Coolant Circuit, General, High-Temperature
Circuit 195
7.16.1 Drain and venting points 195
7.16.2 Engine coolant – Level check 200
7.16.3 Engine coolant – Change 201
7.16.4 Engine coolant – Draining 202
7.16.5 Engine coolant ‒ Filling 203
7.16.6 HT coolant pump ‒ Relief bore check 204
7.16.7 Engine coolant – Sample extraction and
analysis 205
7.17 Raw Water Pump with Connections 206
7.17.1 Raw water pump – Priming 206
7.17.2 Raw water pump – Relief bore check 207
7.18 Belt Drive 208
7.18.1 Drive belt – Condition check 208
7.19 Battery-Charging Generator 209
7.19.1 Battery-charging generator drive – Drive belt
check and adjustment 209
7.19.2 Battery-charging generator drive – Drive belt
replacement 211
7.20 Engine Mounting / Support 212
7.20.1 Engine mounting – Checking condition of
resilient mounts 212
7.21 Universal Shaft 213
7.21.1 Universal shaft – Greasing 213
7.22 Wiring (General) for Engine/Gearbox/Unit 214
7.22.1 Engine wiring – Check 214
7.23 Accessories for (Electronic) Engine
Governor / Control System 215
7.23.1 Engine governor and connectors – Cleaning 215
7.23.2 Engine monitoring unit and connectors –
Cleaning 216
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7.23.3 Start interlock limit switch – Check 217
7.23.4 ECU – Plug connections check 218
7.23.5 Engine monitoring unit – Plug connections
check 219
7.23.6 Engine governor – Removal and installation 220
7.24 Emergency Instrumentation (Local
Operating Panel) 222
7.24.1 LOP and connectors – Cleaning 222
7.24.2 LOP – Visual inspection 223
7.24.3 LOP – Test procedures 225
8 Appendix A
8.1 Abbreviations 227
8.2 MTU contact persons/service partners 230
9 Appendix B
9.1 Special Tools 231
9.2 Index 239
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1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match 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:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
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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 personal protective equipment
Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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1.3 Transport
Transport
Only use the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
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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