MTU 12 V 2000 M84 User manual

Operating Instructions

Diesel engine

12 V 2000 M84

16 V 2000 M84

MS150063/01E

Printed in Germany

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 5

1.2 Personnel and organizational requirements 6

1.3 Transportation 7

1.4 Safety regulations for startup and operation 10

1.5 Safety regulations for maintenance and

repair work 11

1.6 Auxiliary materials, fire prevention and

environmental protection 14

1.7 Conventions for safety instructions in the

text 16

2 General Information

2.1 Engine side and cylinder designations 17

2.2 Product description 18

2.3 Engine - Overview 24

2.4 Sensors, actuators and injectors –

Overview 26

3 Technical Data

3.1 12V 2000 M84 engine data 31

3.2 16V 2000 M84 engine data 34

3.3 Firing order 37

3.4 Engine – Main dimensions 38

4 Operation

4.1 Putting the engine into operation after

extended out-of-service periods (>3

months) 39

4.2 Engine – Putting into operation after

scheduled out-of-service-period 40

4.3 Tasks after extended out-of-service periods

(>3 weeks) 41

4.4 Checks prior to start-up 42

4.5 Fuel treatment system – Putting into

operation 43

4.6 Operational checks 45

4.7 Fuel treatment system – Switching on 46

4.8 Starting the engine 47

4.9 Stopping the engine 48

4.10 Emergency stop 49

4.11 After stopping the engine 50

4.12 Fuel treatment system – Shutdown 51

4.13 Plant – Cleaning 52

5 Maintenance

5.1 Maintenance task reference table [QL1] 53

6 Troubleshooting

6.1 Fuel treatment system – Troubleshooting 54

6.2 Troubleshooting 55

7 Task Description

7.1 SOLAS 58

7.1.1 SOLAS shielding as per MTN 5233 –

Installation 58

7.1.2 SOLAS shielding - Installation 59

7.1.3 Installation locations for SOLAS shielding 60

7.2 Engine 65

7.2.1 Engine – Barring manually 65

7.2.2 Engine – Barring with starting equipment 66

7.3 Cylinder Liner 67

7.3.1 Cylinder liner – Endoscopic examination 67

7.3.2 Cylinder liner - Instructions and comments on

endoscopic and visual examination 69

7.4 Crankcase Breather 71

7.4.1 Crankcase breather – Cleaning oil pre-

separator element 71

7.4.2 Crankcase ventilation– Oil separator

replacement, diaphragm check and

replacement 72

7.5 Valve Drive 74

7.5.1 Valve clearance – Check and adjustment 74

7.5.2 Cylinder-head cover – Removal and

installation 77

7.6 Injection Valve / Injector 78

7.6.1 Injector – Replacement 78

7.6.2 Injector – Removal and installation 79

7.7 Fuel System 81

7.7.1 Fuel system – Venting 81

7.8 Fuel Filter 82

7.8.1 Fuel filter – Replacement 82

7.8.2 Fuel prefilter – Differential pressure check and

adjustment of gauge 84

7.8.3 Fuel prefilter – Draining 85

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7.8.4 Fuel prefilter ‒ Flushing 86

7.8.5 Fuel prefilter – Filter element replacement 88

7.9 Charge-Air Cooling 90

7.9.1 Intercooler – Checking condensate drain line

for coolant discharge and obstruction 90

7.10 Air Filter 91

7.10.1 Air filter – Replacement 91

7.10.2 Air filter – Removal and installation 92

7.11 Air Intake 93

7.11.1 Contamination indicator – Signal ring position

check 93

7.12 Starting Equipment 94

7.12.1 Starter – Condition check 94

7.13 Lube Oil System, Lube Oil Circuit 95

7.13.1 Engine oil – Level check 95

7.13.2 Engine oil – Change 96

7.14 Oil Filtration / Cooling 97

7.14.1 Engine oil filter – Replacement 97

7.14.2 Centrifugal oil filter – Cleaning and filter-

sleeve replacement 99

7.15 Coolant Circuit, General, High-

Temperature Circuit 102

7.15.1 Drain and venting points 102

7.15.2 Engine coolant – Level check 108

7.15.3 Engine coolant – Change 109

7.15.4 Engine coolant – Draining 110

7.15.5 Engine coolant – Filling 111

7.15.6 HT coolant pump — Relief bore check 112

7.15.7 Engine coolant – Sample extraction and

analysis 113

7.15.8 Coolant filter – Replacement 114

7.16 Raw Water Pump with Connections 115

7.16.1 Raw water pump – Relief bore check 115

7.17 Belt Drive 116

7.17.1 Drive belt – Condition check 116

7.18 Battery-Charging Generator 117

7.18.1 Battery-charging generator drive – Drive belt

replacement 117

7.19 Fuel Supply System 118

7.19.1 Water drain valve – Check 118

7.19.2 Differential pressure gauge – Check 119

7.19.3 Water level probe (3-in-1 rod electrode) –

Check 120

7.19.4 Pump capacity – Check 121

7.19.5 Coalescer filter element – Replacement 122

7.20 Wiring (General) for Engine/Gearbox/Unit 124

7.20.1 Engine wiring – Check 124

7.21 Accessories for (Electronic) Engine

Governor / Control System 125

7.21.1 Engine governor and connectors – Cleaning 125

7.21.2 Engine governor – Checking plug-in

connections 126

7.21.3 EMU – Checking plug-in connections 127

7.21.4 Engine governor – Carry out self-test 128

7.21.5 EMU and connectors – Cleaning 129

7.21.6 ECU 7 engine governor – Removal and

installation 130

7.21.7 Engine monitoring unit – Removal and

installation 131

8 Appendix A

8.1 Abbreviations 132

8.2 MTU contacts/service partners 134

9 Appendix B

9.1 Special Tools 135

9.2 Index 138

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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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1.4 Safety regulations for startup and operation

Safety requirements for initial operation

Prior to initial operation of the unit, install the assembly or unit according to the specifications and check

the installation according to the MTU specifications.

Before putting the device or plant into operation, always ensure:

• that all maintenance and repair work is completed,

• that all loose parts have been removed from rotating machine components,

• that nobody is in the danger area of moving machine parts.

Immediately after putting the device or plant into operation, make sure that all control and display instru‐

ments as well as the signaling and alarm systems work properly.

Safety requirements for operators

The procedures for cases of emergency must be practiced regularly.

The operator must be familiar with the control and display elements.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with re‐

gard to present operating status, violation of limit values and warning or alarm messages.

The following steps must be taken if a malfunction of the system is recognized or reported by the system:

• inform supervisor(s) in charge,

• analyze the message,

• if required, carry out emergency operations e.g. emergency engine stop.

Engine operation

The following conditions must be fulfilled before starting the engine:

• Wear ear protection.

• Ensure that the engine room is well ventilated.

• Do not inhale engine exhaust gases.

• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.

• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.

• Protect battery terminals, battery-charger terminals and cables against accidental contact.

• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.

Observe the safety instructions for these devices.

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