MTU 12 V 2000 S96 Operating Instructions Manual
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MTU 12 V 2000 S96 Operating Instructions Manual

MTU 12 V 2000 S96 Operating Instructions Manual

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Operating Instructions

Diesel engine
12 V 2000 S96
16 V 2000 S96
MS150095/01E

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Summary of Contents for MTU 12 V 2000 S96

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 2000 S96 16 V 2000 S96 MS150095/01E...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 5 Troubleshooting 1.1 General conditions 5.1 Fuel treatment system – Troubleshooting 1.2 Personnel and organizational requirements 5.2 Troubleshooting 1.3 Transport 1.4 Safety regulations for maintenance and repair work 6 Task Description 1.5 Auxiliary materials, fluids and lubricants, fire prevention and environmental 6.1 Engine protection...
  • Page 4 6.14.2 Drive belt – Tension check 6.14.3 Drive belt – Tension adjustment 7.1 List of abbreviations 6.14.4 Drive belt – Replacement 7.2 MTU contact persons/service partners 6.15 Battery-Charging Generator 6.15.1 Battery-charging generator drive – Drive belt replacement 8 Appendix B 6.16 Fuel Supply System...

  • Page 5: Safety

    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.

  • Page 6: Personnel And Organizational Requirements

    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‐...

  • Page 7: 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 .

  • Page 8: Safety Regulations For Maintenance And Repair Work

    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.
  • Page 9 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.
  • Page 10 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.

  • Page 11: Auxiliary Materials, Fluids And Lubricants, Fire Prevention And Environmental Protection

    Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.
  • Page 12 Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 13: Conventions For Safety Instructions In The Text

    1.6 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 14: Product Summary

    2 Product Summary 2.1 Engine – Overview 12/16 V 2000 C66/S96 This overview also applies to 16 V 2000 C66 and 16 V 2000 S96 engines. 1 Exhaust turbocharger 7 Power supply 13 Valve gear 2 Air intake/air supply 8 Cooling air system 14 Cylinder head 3 EGR cooler 9 Coolant system...
  • Page 15 Key to the engine model designation Application: C, charge-air cooling in internal circuit, with piston cooling Application S: Exhaust turbocharging with supercharger Application segment (0, 1, 2,...,9) Design index (0, 1, 2,...,9) MS150095/01E 2012-08 | Product Summary | 15...

  • Page 16: Engine Side And Cylinder Designations

    2.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. Other components are numbered in the same way, i.e.

  • Page 17: Engine - Main Dimensions

    2.3 Engine – Main dimensions Item Engine model / Dimension Engine model / Dimension 12 V 2000 C66/S96 16 V 2000 C66/S96 Length (A) approx. 2028 mm approx. 2378 mm Width (B) approx. 1276.5 mm approx. 1287 mm Height (C) approx.

  • Page 18: Firing Order

    2.4 Firing order Firing order for 12 / 16 V 2000 C66/S96 engines Number of cylin‐ Firing order ders 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 18 | Product Summary | MS150095/01E 2012-08...

  • Page 19: Technical Data

    2.5 Technical Data 2.5.1 12/16V 2000 S96 engine data Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 20 Number of cylinders Cylinder displacement Liters 2.233 2.233 Total displacement Liters 26.80 35.73 Compression ratio 16.5 16.5 Inlet valves per cylinder Exhaust valves per cylinder Standard housing connecting flange (engine main PTO) COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling °C equipment) Coolant temperature after engine, warning...
  • Page 21 GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/o preheat‐ °C ing) - (case A) Firing speed, from Firing speed, to INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Op‐ Degrees tion: max.

  • Page 22: Operation

    3.1 Putting the engine into operation after extended out-of- service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→...

  • Page 23: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    3.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 69). Coolant circuit Check engine coolant level (→ Page 79), check charge-air coolant level (→...

  • Page 24: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    3.3 Tasks after extended out-of-service periods (>3 weeks) Tasks after extended out-of-service periods (>3 weeks) Note: Operate fuel treatment system for at least 5 minutes. Start up fuel treatment system (→ Page 26). Shut down fuel treatment system (→ Page 34). 24 | Operation | MS150095/01E 2012-08...

  • Page 25: Checks Prior To Start-Up

    Checks prior to start-up Check tank and the entire pipework for cleanness. If microorganisms are detected: a) Clean affected components. b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..). Close drain valves on housing. Open all supply and discharge valves.

  • Page 26: Fuel Treatment System - Putting Into Operation

    3.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 29). Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system: 0.1 bar to 0.3 bar. Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
  • Page 27 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 29). Start engine (→ Page 28). Run engine at idling speed. Close ball cock (5) at the inlet to the fuel treatment system. Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass (3) and bypass (2).

  • Page 28: Starting The Engine

    3.6 Starting the engine Preconditions ☑ Engine is not connected to load. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 29: Fuel Treatment System - Switching On

    3.7 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant is ready for operation. • Before switching on, ensure that all housings are closed. •...

  • Page 30: Operational Checks

    3.8 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 31: Stopping The Engine

    3.9 Stopping the engine Preconditions ☑ Engine is not connected to load. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated.

  • Page 32: Emergency Stop

    3.10 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Item Action Emergency stop pushbut‐ Press EMERGENCY STOP button. • Engine is stopped by disconnecting the power supply to the ECU; •...

  • Page 33: After Stopping The Engine

    If the engine is to remain out of service for more than 1 week, seal the engine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Fluids and Lubricants Specifications A001061/..).

  • Page 34: Fuel Treatment System - Shutdown

    3.12 Fuel treatment system – Shutdown Shutting down fuel treatment system Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.

  • Page 35: Plant Cleaning

    3.13 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 36: Maintenance

    4 Maintenance 4.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 37: Fuel Treatment System - Troubleshooting

    5 Troubleshooting 5.1 Fuel treatment system – Troubleshooting Illuminated pushbutton “Water alarm” is lit. Cause Corrective action When the maximum water level 1. Press illuminated pushbutton “Water alarm” to acknowledge. is reached, the water level elec‐ 2. In addition to the automatic water drain function, water can also trode opens the water drain be drained manually.

  • Page 38: Troubleshooting

    5.2 Troubleshooting Engine does not turn when starter is actuated Component Cause Action Battery Low or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine cabling or starter faulty Check cable connections for secure seating ;...
  • Page 39 Faulty Contact Service. Charge-air temperature too high Component Cause Action Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fan; check air inlet/outlet ducts. Charge-air pressure too low...
  • Page 40 White exhaust gas Component Cause Action Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter (→ Page 60). Intercooler Leaking Contact Service. 40 | Troubleshooting | MS150095/01E 2012-08...

  • Page 41: Task Description

    6 Task Description 6.1 Engine 6.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6783914 Ratchet F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 42: Engine - Barring With Starting System

    6.1.2 Engine – Barring with starting system DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

  • Page 43: Crankcase Breather

    6.2 Crankcase Breather 6.2.1 Crankcase breather – Oil mist fine separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist fine separator (→ Spare Parts Catalog) O-ring (→...

  • Page 44: Valve Drive

    6.3 Valve Drive 6.3.1 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty.

  • Page 45: Valve Clearance Adjustment

    Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: •...
  • Page 46 Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) with Allen key to prevent it from turning. Name Size Type Lubricant Value/Standard Locknut Tightening torque 50 Nm +5 Nm Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap.

  • Page 47: Cylinder Head Cover - Removal And Installation

    6.3.2 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F30043446 Ratchet F30027340 Gasket (→ Spare Parts Catalog) Preparatory steps On cylinder head covers with crankcase breather: Loosen clamps.

  • Page 48: Injection Valve / Injector

    6.4 Injection Valve / Injector 6.4.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 49). 48 | Task Description | MS150095/01E 2012-08...

  • Page 49: Injector - Removal And Installation

    6.4.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation device F6790085 Puller F6790636 Fuel suction device F30378207 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 20-100 Nm F30026582 Ratchet F30027340...
  • Page 50 Removing injector Remove fuel line (1). Unscrew union nut (2). Pull out pressure pipe neck (3). Extract fuel from the exposed bores using the suction device. Disconnect terminals (arrow) on injector and pull out cable lugs. Remove gasket. Remove screw (3). Note: Screw (3) may be installed only once.
  • Page 51 Installing injector Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring on injector (1) with grease. Note: Use either the installation tool or the hold- down clamp to press injector (1) into the cylinder head.
  • Page 52 Use torque wrench to tighten screw (3) for hold-down clamp (2) to the specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 40 Nm +4 Nm Tighten union nut (2) on pressure pipe neck with torque wrench to the specified tightening torque. Name Size Type...
  • Page 53 Tighten union nut of fuel line (1) on pressure pipe neck (2) to the specified tightening torque using a tor‐ que wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque (Engine oil) 37 Nm +3 Nm Fitting gasket and connecting injector cable Place gasket on cylinder head, ensuring correct installation position.

  • Page 54: Fuel System

    6.5 Fuel System 6.5.1 HP fuel line and pressure pipe neck – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet adapter F30027340 Adapter F30006234 Socket wrench, 19 mm...
  • Page 55 HP fuel line and pressure pipe neck – Replacement Remove leak-off fuel line from cylinder head. Remove HP fuel line (2). Remove thrust screw (4). Withdraw pressure pipe neck (5). Coat sealing ring of new pressure pipe neck with grease. Coat sealing cone of pressure pipe neck with engine oil.

  • Page 56: Fuel System - Venting

    6.5.2 Fuel system – Venting Preconditions ☑ Engine is not connected to load. Fuel system – Venting Note: The fuel system can only be vented with the engine running. Start engine (→ Page 28). Operate the engine until it runs smoothly. 56 | Task Description | MS150095/01E 2012-08...

  • Page 57: Fuel - Draining

    6.5.3 Fuel – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel – Draining Provide a suitable container in which to collect the fuel. Remove fuel filter (→...

  • Page 58: Fuel Filter

    6.6 Fuel Filter 6.6.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 59: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    6.6.2 Fuel prefilter – Differential pressure check and adjustment of gauge DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 60: Fuel Prefilter - Draining

    6.6.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Seal (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 61: Fuel Prefilter - Flushing

    6.6.4 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 62 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

  • Page 63: Fuel Prefilter - Filter Element Replacement

    6.6.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Seal (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 64 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the fil‐ ter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐...

  • Page 65: Air Filter

    6.7 Air Filter 6.7.1 Air filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. For air filter replacement, carry out operations as specified by the manufacturer – filter is plant/vehicle manufacturer's supply. MS150095/01E 2012-08 | Task Description | 65...

  • Page 66: Air Intake

    6.8 Air Intake 6.8.1 Service indicator – Check See manufacturer's documentation. 66 | Task Description | MS150095/01E 2012-08...

  • Page 67: Exhaust Gas Recirculation

    6.9 Exhaust Gas Recirculation 6.9.1 Exhaust gas recirculation flaps – Overview MS150095/01E 2012-08 | Task Description | 67...

  • Page 68: Exhaust Gas Circulation - Checking Flap Operation

    6.9.2 Exhaust gas circulation - Checking flap operation Preconditions ☑ Engine is stopped and starting disabled. WARNING Component is hot. Risk of burning! • Wear protective gloves. Checking exhaust flap operation For installation position of exhaust flaps, refer to overview (→ Page 67). Check operability and ease of movement of exhaust flaps and control linkage by moving the assembly at the points (arrowed) shown...

  • Page 69: Lube Oil System, Lube Oil Circuit

    6.10 Lube Oil System, Lube Oil Circuit 6.10.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Oil level check prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx.

  • Page 70: Engine Oil - Change

    6.10.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring (→...

  • Page 71: Oil Filtration / Cooling

    6.11 Oil Filtration / Cooling 6.11.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 72: Sleeve Replacement

    6.11.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 73 Centrifugal oil filter cleaning and filter sleeve replacement Remove clamp (14). Release cover screw (2) and take off cov‐ er (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3).

  • Page 74: Coolant Circuit, General, High Temperature Circuit

    6.12 Coolant Circuit, General, High-Temperature Circuit 6.12.1 Drain and vent points 12 V, 16 V 1 Engine coolant vent 74 | Task Description | MS150095/01E 2012-08...
  • Page 75 Left side 1 Engine coolant drain 2 Oil drain plug 3 Engine coolant drain plug plug MS150095/01E 2012-08 | Task Description | 75...
  • Page 76 Right side 1 Engine coolant drain 3 Oil drain plug plug 4 Engine coolant drain 2 Engine coolant drain plug plug 76 | Task Description | MS150095/01E 2012-08...
  • Page 77 Driving end (KS) 1 Oil drain plug MS150095/01E 2012-08 | Task Description | 77...
  • Page 78 Free end (KGS) 1 Oil drain plug 3 Oil drain plug 2 Engine coolant filling 4 Engine coolant drain plug plug 78 | Task Description | MS150095/01E 2012-08...

  • Page 79: Engine Coolant – Level Check

    6.12.2 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 80: Engine Coolant – Change

    6.12.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 81). Fill with engine coolant (→ Page 82). 80 | Task Description | MS150095/01E 2012-08...

  • Page 81: Engine Coolant – Draining

    6.12.4 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing rings (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 82: Engine Coolant – Filling

    6.12.5 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 83 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 79), top up with coolant if required. MS150095/01E 2012-08 | Task Description | 83...

  • Page 84: Engine Coolant Pump – Relief Bore Check

    6.12.6 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 85: Engine Coolant – Sample Extraction And Analysis

    Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil. Draw off approx. 1 liter coolant and drain into a clean container. Using the equipment and chemicals from the MTU test kit, examine coolant for: • antifreeze concentration;...

  • Page 86: Coolant Filter – Replacement

    6.12.8 Coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 87: Intercooler – Vent And Drain Points

    6.13 Low-Temperature Circuit 6.13.1 Intercooler – Vent and drain points 12 V, 16 V 1 Intercooler vent plugs MS150095/01E 2012-08 | Task Description | 87...

  • Page 88: Charge-Air Coolant – Level Check

    6.13.2 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 89: Charge-Air Coolant – Change

    6.13.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 92). Fill with charge-air coolant (→ Page 90). MS150095/01E 2012-08 | Task Description | 89...

  • Page 90: Charge-Air Coolant – Filling

    6.13.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure.
  • Page 91 Charge-air coolant – Filling Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marking plate. Install plug screws of filling points with new sealing rings. Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it.

  • Page 92: Charge-Air Coolant – Draining

    6.13.5 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 93: Charge-Air Coolant Pump – Relief Bore Check

    6.13.6 Charge-air coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 94: Drive Belt – Condition Check

    6.14 Belt Drive 6.14.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily, shows signs of over‐ Replace (→...

  • Page 95: Drive Belt – Tension Check

    6.14.2 Drive belt – Tension check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y4345711 Belt tension tester, 150-600 N Y20097429 Fan drive – Checking belt tension Remove protective cover. Set belt tension tester onto the drive belt in the middle between the belt pulleys (arrow).

  • Page 96: Drive Belt – Tension Adjustment

    6.14.3 Drive belt – Tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet adapter ½" F30027340 Torque wrench, 40-200 Nm F30027337 Engine oil Drive belt –...

  • Page 97: Drive Belt – Replacement

    6.14.4 Drive belt – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Fan drive – Drive belt replacement Remove protective cover from radiator. Remove fan.

  • Page 98: Battery-Charging Generator Drive – Drive Belt Replacement

    6.15 Battery-Charging Generator 6.15.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Mandrel 8205892861/08 Preparatory steps Remove safety equipment (if fitted). Remove screws of protective cover (engine free end). Remove protective cover.

  • Page 99: Water Drain Valve – Check

    6.16 Fuel Supply System 6.16.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. MS150095/01E 2012-08 | Task Description | 99...

  • Page 100: Differential Pressure Gauge – Check

    6.16.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Differential pressure gauge – Check Switch on fuel treatment system (→ Page 26). Set the alarm points at the differential pressure gauge to zero.

  • Page 101: Water Level Probe (3-In-1 Rod Electrode Check

    6.16.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) –...

  • Page 102: Pump Capacity – Check

    6.16.4 Pump capacity – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Pump capacity – Check Install suitable pressure gauge in the intake connection of the pump. Check pump pressure.

  • Page 103: Coalescer Filter Element – Replacement

    6.16.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 104 Tighten nut (3) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system.

  • Page 105: Engine Governor

    6.17 Engine Governor 6.17.1 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating.

  • Page 106: Wiring (General) For Engine/Gearbox/Unit

    6.18 Wiring (General) for Engine/Gearbox/Unit 6.18.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 107: Lambda, Nox And Humidity Sensors Overview

    6.18.2 Lambda, NOx and humidity sensors – Overview 1 Humidity sensor 2 NOx sensor 3 Lambda sensor MS150095/01E 2012-08 | Task Description | 107...

  • Page 108: Lambda Sensor – Replacement

    6.18.3 Lambda sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Preparatory steps have been completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet adapter ½" F30027340 Lambda sensor WARNING Component is hot.
  • Page 109 Installing lambda sensor Note: The sensor is considered defective after be‐ ing exposed to shock load or impact and must not be used. Remove the protective cap from the thread immediately before installation. Note: Do not wipe off the grease the manufactur‐ er applied on the thread.

  • Page 110: Nox Sensor – Replacement

    6.18.4 NOx sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Preparatory steps have been completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet adapter ½" F30027340 NOx sensor WARNING Component is hot.
  • Page 111 Installing NOx sensor Note: The sensor is considered defective after be‐ ing exposed to shock load or impact and must not be used. Remove the protective cap from the thread immediately before installation. Note: Do not wipe off the grease the manufactur‐ er applied on the thread.

  • Page 112: Humidity Sensor – Replacement

    6.18.5 Humidity sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Preliminary steps are completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet adapter ½" F30027340 Engine NOx sensor CAUTION Contamination of components.
  • Page 113 Humidity sensor – Installation Note: Apply lubricant for O-ring sparingly. Insert sensor (2) in bore, ensuring correct installation position. Note: Take direction of air flow into account. Screw in screws (1). Use torque wrench to tighten screws (1) to the specified tightening torque. Name Size Type...

  • Page 114: Accessories For (Electronic) Engine Governor / Control System

    6.19 Accessories for (Electronic) Engine Governor / Control System 6.19.1 CDC parameters – Reset with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Resetting CDC parameters (DiaSys® is available) Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐ cable.

  • Page 115: Engine Governor And Connectors – Cleaning

    6.19.2 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.

  • Page 116: Engine Governor – Checking Plug-In Connections

    6.19.3 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating.

  • Page 117: List Of Abbreviations

    U.S. standards Abgasturbolader Exhaust turbocharger (ETC) Backup Data Module Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica‐ tion No. A01061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller Common Rail Deutsches Institut für Normung e. V.
  • Page 118 Abbrevia‐ Meaning Explanation tion International Maritime Organization International Organization for Stand‐ International umbrella organization of all standards ardization institutes Kraftgegenseite Engine free end in accordance with DIN ISO 1204 Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly...
  • Page 119 Abbrevia‐ Meaning Explanation tion Water Jet Water jet drive Werkzeugkatalog Tool Catalog (TC) MS150095/01E 2012-08 | Appendix A | 119...

  • Page 120: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 121: Special Tools

    8 Appendix B 8.1 Special Tools Adapter Part No.: F30006234 Qty.: Used in: 6.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Barring device Part No.: F6783914 Qty.:...
  • Page 122 Belt tension tester, 150-600 N Part No.: Y20097429 Qty.: Used in: 6.14.2 Drive belt – Tension check (→ Page 95) Crowfoot wrench, 19 mm Part No.: F30027424 Qty.: Used in: 6.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 6.5.1 HP fuel line and pressure pipe neck –...
  • Page 123 Double-head box wrench Part No.: F30002800 Qty.: Used in: 6.3.1 Valve clearance – Check and adjustment (→ Page Double-head box wrench Part No.: F30011450 Qty.: Used in: 6.4.2 Injector – Removal and installation (→ Page 49) Feeler gauge Part No.: Y4345893 Qty.: Used in:...
  • Page 124 Mandrel Part No.: 8205892861/08 Qty.: Used in: 6.15.1 Battery-charging generator drive – Drive belt re‐ placement (→ Page 98) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 6.12.7 Engine coolant – Sample extraction and analysis (→ Page 85) 124 | Appendix B | MS150095/01E 2012-08...
  • Page 125 Oil filter wrench Part No.: F30379104 Qty.: Used in: 6.12.8 Coolant filter – Replacement (→ Page 86) Open-end socket wrench, 19 mm Part No.: F30453236 Qty.: Used in: 6.4.2 Injector – Removal and installation (→ Page 49) Open-end socket wrench, 24 mm Part No.: F30453238 Qty.:...
  • Page 126 Ratchet Part No.: F30006212 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 41) Qty.: Used in: 6.3.1 Valve clearance – Check and adjustment (→ Page Ratchet Part No.: F30027340 Qty.: Used in: 6.3.2 Cylinder head cover – Removal and installation (→ Page 47) Qty.: Used in:...
  • Page 127 Ratchet adapter ½" Part No.: F30027340 Qty.: Used in: 6.14.3 Drive belt – Tension adjustment (→ Page 96) Ratchet adapter ½" Part No.: F30027340 Qty.: Used in: 6.18.3 Lambda sensor – Replacement (→ Page 108) Qty.: Used in: 6.18.4 NOx sensor – Replacement (→ Page 110) Qty.: Used in: 6.18.5 Humidity sensor –...
  • Page 128 Steam jet cleaner Part No.: Qty.: Used in: 3.13 Plant cleaning (→ Page 35) Tester Part No.: Y4345711 Qty.: Used in: 6.14.2 Drive belt – Tension check (→ Page 95) Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in: 6.4.2 Injector –...
  • Page 129 Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 6.18.3 Lambda sensor – Replacement (→ Page 108) Qty.: Used in: 6.18.4 NOx sensor – Replacement (→ Page 110) Qty.: Used in: 6.18.5 Humidity sensor – Replacement (→ Page 112) Torque wrench, 20-100 Nm Part No.: F30026582...
  • Page 130 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 6.16.5 Coalescer filter element – Replacement (→ Page 103) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 6.11.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 72) Torque wrench, 8-40 Nm Part No.: F30043446...

  • Page 131: Index

    8.2 Index 12/16V 2000 S96 engine data 19 Crankcase breather – Oil mist fine separator replacement  43 Cylinder After stopping the engine 33 – Designation  16 Air filter Cylinder head cover – Replacement  65 – Removal and installation  47 Auxiliary materials 11 Differential pressure Battery-charging generator drive –...
  • Page 132 – Maintenance task reference table [QL1]  36 Fuel Maintenance work – Draining  57 – Safety regulations  8 – Filter   MTU contact persons 120 – Replacement  58 – Injector   – Removal and Installation  49 NOx sensor – Prefilter   – Replacement  110...
  • Page 133 Pump capacity – Check  102 Putting into operation – After scheduled out-of-service period   – Preparation  23 – Fuel treatment system  26 Putting the engine into operation after extended out-of- service periods (>3 months) 22 Putting the engine into operation after scheduled out-of- service-period 23 Repair work –...

This manual is also suitable for:

16 v 2000 s96

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