MTU 12 V 2000 S96 User manual
Operating Instructions
Diesel engine
12 V 2000 S96
16 V 2000 S96
MS150095/01E
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 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety regulations for maintenance and
repair work 8
1.5 Auxiliary materials, fluids and lubricants,
fire prevention and environmental
protection 11
1.6 Conventions for safety instructions in the
text 13
2 Product Summary
2.1 Engine – Overview 14
2.2 Engine side and cylinder designations 16
2.3 Engine – Main dimensions 17
2.4 Firing order 18
2.5 Technical Data 19
2.5.1 12/16V 2000 S96 engine data 19
3 Operation
3.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 22
3.2 Putting the engine into operation after
scheduled out-of-service-period 23
3.3 Tasks after extended out-of-service periods
(>3 weeks) 24
3.4 Checks prior to start-up 25
3.5 Fuel treatment system – Putting into
operation 26
3.6 Starting the engine 28
3.7 Fuel treatment system – Switching on 29
3.8 Operational checks 30
3.9 Stopping the engine 31
3.10 Emergency stop 32
3.11 After stopping the engine 33
3.12 Fuel treatment system – Shutdown 34
3.13 Plant cleaning 35
4 Maintenance
4.1 Maintenance task reference table [QL1] 36
5 Troubleshooting
5.1 Fuel treatment system – Troubleshooting 37
5.2 Troubleshooting 38
6 Task Description
6.1 Engine 41
6.1.1 Engine – Barring manually 41
6.1.2 Engine – Barring with starting system 42
6.2 Crankcase Breather 43
6.2.1 Crankcase breather – Oil mist fine separator
replacement 43
6.3 Valve Drive 44
6.3.1 Valve clearance – Check and adjustment 44
6.3.2 Cylinder head cover – Removal and
installation 47
6.4 Injection Valve / Injector 48
6.4.1 Injector – Replacement 48
6.4.2 Injector – Removal and installation 49
6.5 Fuel System 54
6.5.1 HP fuel line and pressure pipe neck –
Replacement 54
6.5.2 Fuel system – Venting 56
6.5.3 Fuel – Draining 57
6.6 Fuel Filter 58
6.6.1 Fuel filter – Replacement 58
6.6.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 59
6.6.3 Fuel prefilter – Draining 60
6.6.4 Fuel prefilter ‒ Flushing 61
6.6.5 Fuel prefilter – Filter element replacement 63
6.7 Air Filter 65
6.7.1 Air filter – Replacement 65
6.8 Air Intake 66
6.8.1 Service indicator – Check 66
6.9 Exhaust Gas Recirculation 67
6.9.1 Exhaust gas recirculation flaps – Overview 67
6.9.2 Exhaust gas circulation - Checking flap
operation 68
6.10 Lube Oil System, Lube Oil Circuit 69
6.10.1 Engine oil – Level check 69
6.10.2 Engine oil – Change 70
6.11 Oil Filtration / Cooling 71
6.11.1 Engine oil filter – Replacement 71
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6.11.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 72
6.12 Coolant Circuit, General, High-
Temperature Circuit 74
6.12.1 Drain and vent points 74
6.12.2 Engine coolant – Level check 79
6.12.3 Engine coolant – Change 80
6.12.4 Engine coolant – Draining 81
6.12.5 Engine coolant – Filling 82
6.12.6 Engine coolant pump – Relief bore check 84
6.12.7 Engine coolant – Sample extraction and
analysis 85
6.12.8 Coolant filter – Replacement 86
6.13 Low-Temperature Circuit 87
6.13.1 Intercooler – Vent and drain points 87
6.13.2 Charge-air coolant – Level check 88
6.13.3 Charge-air coolant – Change 89
6.13.4 Charge-air coolant – Filling 90
6.13.5 Charge-air coolant – Draining 92
6.13.6 Charge-air coolant pump – Relief bore check 93
6.14 Belt Drive 94
6.14.1 Drive belt – Condition check 94
6.14.2 Drive belt – Tension check 95
6.14.3 Drive belt – Tension adjustment 96
6.14.4 Drive belt – Replacement 97
6.15 Battery-Charging Generator 98
6.15.1 Battery-charging generator drive – Drive belt
replacement 98
6.16 Fuel Supply System 99
6.16.1 Water drain valve – Check 99
6.16.2 Differential pressure gauge – Check 100
6.16.3 Water level probe (3-in-1 rod electrode) –
Check 101
6.16.4 Pump capacity – Check 102
6.16.5 Coalescer filter element – Replacement 103
6.17 Engine Governor 105
6.17.1 Engine governor – Checking plug-in
connections 105
6.18 Wiring (General) for Engine/Gearbox/Unit 106
6.18.1 Engine wiring – Check 106
6.18.2 Lambda, NOx and humidity sensors –
Overview 107
6.18.3 Lambda sensor – Replacement 108
6.18.4 NOx sensor – Replacement 110
6.18.5 Humidity sensor – Replacement 112
6.19 Accessories for (Electronic) Engine
Governor / Control System 114
6.19.1 CDC parameters – Reset with DiaSys® 114
6.19.2 Engine governor and connectors – Cleaning 115
6.19.3 Engine governor – Checking plug-in
connections 116
7 Appendix A
7.1 List of abbreviations 117
7.2 MTU contact persons/service partners 120
8 Appendix B
8.1 Special Tools 121
8.2 Index 131
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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
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.
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1.3 Transport
Transport
Also valid for 12V engines
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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1.4 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
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For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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