MTU Engines - Quality engineering only expected from the Germans

Hurricane

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Friedrichshafen is the home of MTU Engines - the second largest employer in the region. The first being ZF Gearboxes so you can see that beautiful part of Germany is a special place for marine engineering.

So, why was I there?
Most on this forum will already know that last year we bought a new Princess 67.
She's fitted with twin MTU CR 2000 8V engines and at 1200 hp, I wanted to know as much as I could about these fabulous machines. Apart from a couple of minor electronic warnings, these engines have performed perfectly since we took delivery last April.
Anyway, when I was asked if I would like to go on a service course at the factory, you can imagine that "wild horses couldn’t keep me away".

So, while the UK was under a layer of snow, I was away in the MTU factory at Friedrichshafen.

MTU offer these courses to owners and skippers who want to have a good understanding of the basic operation of their engines. The courses last four days and every aspect of a specific engine range is covered. As leisure boaters, our interest is in the new common rail 2000 range which like most of their models is a V format engine. This range of common rail engines goes up to about 2000 hp but the 2000 doesn’t stand for the horsepower – it’s the approximate size of each cylinder (actually about 2.2 litres each). The difference between the models in the range is the number of cylinders. For example, my engines are 1200 hp and are V8s which means that they are about 18 litres each!!

It seems that the larger end of the marine leisure boating matket would use this CR 2000 model.

So, here are some pics.
First the CR 2000 – this one is the 16V version.
My 8V engines only have 2 stage turbos whereas the 16V has 3.

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They didnt have any 8Vs in the training workshop so here's a pic of mine actually fitten in the boat.

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The courses cover interesting introductions to other ranges of MTU engines whilst focusing on the running and maintenance of your own specific machines. We also had a tour of the actual factory – sorry, I wasn’t allowed to take any photos inside, due mainly to their involvement in military designs, but I was allowed to photograph the engines in the Training Centre. I took loads of pics of the CR 2000 from various angles – might be useful later. At the end of the course, you get an MTU qualification that enables you to service your own engines.

Here's some other models - it seems to me that mine were the smallest ones that they make!!

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And this big bugger - about 20 of these each year.

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And Gas engines for power stations

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And this one is specially designed for local railway systems - I believe that there are over 800 of these running around the UK rail network.

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And this special cut away one is great for training - actually, the product/model was designed just after the war and is still in production.

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The thing that really impressed me was the robustness of the equipment which is very apparent when you look at the service intervals. Typically, if you use the lubricants, MTU recommend oil changes only every 2 years or 500 hours. In reality, the requirement for the first service is usually after the engines initial warranty has expired. I’m quite a “hands on” person so engine servicing without invalidating the warranty was very appealing. In fact, my new qualification even covers me for resetting the valve clearances when they are due at 500 hours!!!

Anyway enough for the moment - I have some more specific technical stuff/photos - if you are interested I'll keep the thread going.
 
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Nice kit, Hurricane. Does the team that built each unit sign it off, as with Aston Martin ?

How much of the control system can be fixed by an owner/engineer ? Sensors, computer control stuff, I mean.

Is there an RS232 or similar connector that will transmit all the key data up to your multi-screens ?
 
Years Ago I went to MTU in Friedrichshafen as when I worked for Condor we had a fleet initially of Hydrofoils which all had MTU engines and ZF gearboxes and we had the 16 Cylinder 396 series ( 65 litre) in a 160F hydrofoil and a waterjet catamaran, unfortunately we had crankshaft failures with this engine but probably due to the application and the long whippy drive shafts, in the first passenger only catamaran we put KHD Deutz engines which were a problem and then when we looked first at Wavepiercing car ferries we looked at the MTU 20 V 1163 series ( 232 litre each ) at about 6,500 kw (from memory) each , the boat needed four engines, in the ned we went for the Ruston Diesels which were the standard units in those boats.

They ran an 1163 up on a test bed to show us.

MTU is no longer partly owned by Mercedes Benz, I think it was bought out by Norwegian venture capitalists.

An amazing company and product with fantastic engineering, with a large part of their range being military.

Good luck with the boat and engines.
 
Would agree. Sadly they were always streets ahead of the UK Paxmans which is now why most of the rail HST have been re-engined with the 4000 model. ( something like 20% less better fuel and 20% less oil) I use 2MW MTU V16s as well as Cats for my standby power needs.
Incidentally, MTU have just opened up a rebuild factory in East Grinstead, idea being you wip the maintenance due engine out of the HST stick another one in overnight returning the train to service for the next morning rush hour and East Grinstead does the specialist work. All the rail operator has to do is keep the oil and water levels correct. I think MTU have a power by the hour type contract , I know they look at the engines by remote monitoring thus pick up faults before they cause failures in service.

Brian
 
Another useless piece of information is that the Factory is there because i belive it was then called Maybach engines, produced engines for the Zeppelins as did ZF produce the gearboxes.

Under the terms of surrender of the first world war they were banned from producing petrol engines so switched to Diesel which gave them a great lead in the second world war for the diesel engines in the submarines and the E boats and i blieve tanks but i am not sure about the last ones.

So while the Brits and americans had MTB's with petrol engines ( Merlins) and 5000 gallons of four star ( not great when someone is shooting at you) they had steel e boats with diesel engines.

The Germans with maybach which became MTU after a merger with other companies has been a world leader in powerfull lightweight diesel engines since the second world war.
 
I went to MTU. My small company supplied some parts for their military engines. Nuff said.

Not all British MTBs had Merlins. The one I was brought up on, MTB452, built by the British Power Boat Co. at Hythe, was fitted with three 1200hp Packard petrol engines.
 
The very first Merlins were pretty straight copies but Packard quickly started doing their own modifications and improved on the British manufacture mainly by virtue of better production techniques (sound familiar?). In fairness to Roll-Royce they were being bombed pretty much constantly and had a dearth of quality materials. According to Wiki the Packard Merlins had Indium plating - I can just imagine how a request for Indium would have gone in the UK in the early 1940's but it is generally accepted that the US were able to improve on the build of the engine but not the basic design.

The Merlins in Mustang P51's were slightly different but close enough to be changed into equivalent "Rolls-Royce" Merlins by replacing parts and a bit light engineering.
 
I think most were. My Father always reckoned that the Merlins that were fitted came from crashed aircraft where the RAF were "reluctant" to re-use them (well he said "too scared" actually but then he was Matelot). No idea if that's accurate though.
 
I dont know about "sign offs" etc but there did seem to be two methods on build in the factory. The old engine that I said was still built was beilg built by a very experienced team on a one off basis - i.e. single team building the whole unit. Whereas most of the modern and smaller engines were on a JIT production line.

Part of the course was on sensors. We were told how each type worked and how to test them etc. This was done with a view to the curcuit diagrams and the electronic control panels which can also identify sensor failures.

As for engine integration with other onboard systems, this industry still has a long way to go. The hardware already has an RJ45/LAN connector but the software isnt yet written. I believe that they do have other ways of integration but it was suggested that a web style interface would be produced in future software releases. However, they do have an engineers PC/Laptop conection on the same unit. Unlike Volvo, they allow 4 levels of access to the system's electronics. Level 1 is one that I could be given access. It is basically a "read only" access to the parameters. Each level builds the access until you get to a level that can change all the parameters - and possibly do damage if not understood.

For me though, the basic displays provide enough information, now that I understand how to use them properly.
 
Yes, we were given the history lesson.
It seems that Mercedes Benz did own part of the business and then sold their interest. The company then grew and recently, Mercedes Benz have a new interest so its come full circle.

Interestingly, the main factory has a large Mercedes Benz free standing logo/spire on the top of the main office building beside the lake. It illuminates at night and as a result has become a documented navigation beacon. When Mercedes Benz pulled out, there was a plan to remove the logo/spire and there was some concern over safety but now that they are back in the team it can stay.
 
I dont know if anyone's interested but I thought I'd post the techy bit as well.

As I said, the MTU CR 2000 is bieng used in quite a few of the larger boats - the big Sunseekers and the Princess use them on their larger models. The difference in the models in the number of cylinders and the larger ones have an extra turbo charger.

So here is the basic block

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With the liners in place

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Here's a view of one of the turbos - my engines have two and this one has three.

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Lift the valve covers and you can see the injectors.

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And this is an injector

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Each cylinder has a removable head - here's one with valves fitted.

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On our trip to the Med, we had an electronic warning that caused the port engine to run in its safety mode. If djefabs is reading this he will remember - both of us went down into the engine room to see if anything was evidently wrong. We both noted that one engine had a piston in and the other's equivalent piston was the other way (out). I've since (as a result of this course) established that these pistons control the turbo flaps. The feeling at MTU is that we were running the engines at the edge of the second stage "coming in". As a result the engines wouldnt settle down comfortably. The solution at the time was simple - reboot - (I mean restart the port engine). The problem dissapeard and never reappeared.

On the course, we also discussed the power curves. On my engines, there are two places on the curve where my engines operate most effeciently. One within each turob's stage so it seems that if I were to run just a little faster, I will, not only operate more effeciently but will avoid the hunting in and out of the sacond stage turbo. Maybe a planing range 300 miles is possible after all - we'll see.

Here is a pic of the turbo housing - the piston that operates the turbo is on the outside of the housing. Again, this engine is the 12V and has an extra stage turbo so there is a piston each side on this shot.

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And a pic inside the housing of the actual flap that it operates.

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Generally speaking the course was brilliant - its a shame more manufacturers dont have "hands on" courses for owners and skippers. The atmosphere was relaxed - you can see from this pic. A discussion over a VERY large machine.

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We stripped dow the CR 2000 to expose the bits that we are now qualified to service.

Refitting a turbo charger.

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I hope this isnt too boreing - It was, obviously a really useful course for me though.

Anyway - I'll end with a little quiz

Firstly what do you think this is?

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And secondly what is this?

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[ QUOTE ]
I dont know if anyone's interested

[/ QUOTE ]

I am

Are these courses based at people who already have a lot of knowledge of engines, or just any owner who is interested. I could probably pick over the engine management system, though would not know a liner from a bin liner, unless someone told me the difference. I'd learn fast, though from a very basic point of view, as I've never worked on an engine of that size, only car engines.
 
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