MTU 12 V 2000 M84 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. MTU Manuals
  4. Engine
  5. 12 V 2000 M84
  6. Operating instructions manual
MTU 12 V 2000 M84 Operating Instructions Manual

MTU 12 V 2000 M84 Operating Instructions Manual

Hide thumbs Also See for 12 V 2000 M84:
Table of Contents

Advertisement

Quick Links

See also: Operating Instructions Manual

Operating Instructions

Diesel engine
12 V 2000 M84
16 V 2000 M84
MS150063/01E

Advertisement

Table of Contents
loading

Related Manuals for MTU 12 V 2000 M84

Summary of Contents for MTU 12 V 2000 M84

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 2000 M84 16 V 2000 M84 MS150063/01E...
  • 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 4.13 Plant – Cleaning 1.1 General conditions 1.2 Personnel and organizational requirements 5 Maintenance 1.3 Transportation 1.4 Safety regulations for startup and operation 5.1 Maintenance task reference table [QL1] 1.5 Safety regulations for maintenance and repair work 1.6 Auxiliary materials, fire prevention and environmental protection...
  • Page 4 8 Appendix A 7.15.5 Engine coolant – Filling 8.1 Abbreviations 7.15.6 HT coolant pump — Relief bore check 8.2 MTU contacts/service partners 7.15.7 Engine coolant – Sample extraction and analysis 7.15.8 Coolant filter – Replacement 7.16 Raw Water Pump with Connections 9 Appendix B 7.16.1 Raw water pump –...

  • 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 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.

  • Page 7: Transportation

    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 MS150063/01E 2012-01 | Safety | 7...
  • Page 8 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. 8 | Safety | MS150063/01E 2012-01...
  • Page 9 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 10: 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: •...

  • Page 11: Safety Regulations For Maintenance And Repair Work

    1.5 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 12 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 13 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 14: Auxiliary Materials, 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 15 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 16: Conventions For Safety Instructions In The Text

    1.7 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 17: General Information

    2 General Information 2.1 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).

  • Page 18: Product Description

    2.2 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection, sequential turbocharging and charge-air cooling. An electronic management system provides engine control and monitoring. Fuel system with common rail injection Controlled by the engine electronics, the common rail injection system determines injection pressure, in‐...
  • Page 19 Open-loop control: • Injection (fuel pressure, injection timing, injection duration, operating status) • Sequential turbocharging (cutting-in and out) with secondary turbocharger • Engine protection with multi-stage safety systems: • Power reduction • Power limitation • Emergency stop Monitoring: • Exhaust gas temperature, A-side •...
  • Page 20 SOLAS – Fire protection specifications Special connections In case of leakage, the above-mentioned connection types are spray-protected even without a cover and have been confirmed compliant with SOLAS by GL and DNV. Plug-in pipe connection The sleeve (4) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐...
  • Page 21 The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under pressure. HP line between fuel injector and HP accumulator 1 Support ring 4 Union nut 7 Thrust ring 2 V-ring 5 HP line 8 V-ring 3 Thrust ring...
  • Page 22 HP line between distributor and HP accumulator 1 Union nut 4 Thrust screw 7 Thrust ring 2 O-ring 5 O-ring 8 Pressure pipe 3 Thrust ring 6 O-ring 9 Jacket pipe 22 | General Information | MS150063/01E 2012-01...
  • Page 23 HP line between distributor and HP accumulator 1 Jacket pipe 5 Thrust screw 9 Pressure pipe 2 O-ring 6 Thrust ring 10 O-ring 3 O-ring 7 O-ring 4 Thrust ring 8 HP line Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from where it is routed at atmospheric pressure into a level-monitored leak fuel tank.

  • Page 24: Engine - Overview

    2.3 Engine - Overview Overview of free end 1 Engine oil heat exchang‐ 10 Engine lifting eyes 20 Raw water pump 11 Exhaust turbocharger 21 Raw water connection 2 Engine oil filter 12 Actuating cylinder for ex‐ from sea 3 Coolant filter haust flap 22 Protective cover (belt pul‐...
  • Page 25 Overview driving end 1 Carrier housing upper 6 Electric starter 11 Bleeder valve section 7 Drive flange 12 Exhaust outlet 2 HP fuel pump 8 Flywheel housing KS = engine driving end 3 Oil filler neck 9 Carrier housing lower 4 Oil dipstick section 5 4/2-way directional con‐...

  • Page 26: Sensors, Actuators And Injectors - Overview

    2.4 Sensors, actuators and injectors – Overview Engine plan view Deviations from illustrations are insignificant. Also applies similarly to 12V. Item Description Monitoring of Lube oil temperature Charge-air pressure Turbocharger speed Intake air temperature Charge-air temperature 26 | General Information | MS150063/01E 2012-01...
  • Page 27 Engine free end Item Description Monitoring of Fuel pressure after filter B5.3 (option) Lube oil pressure before filter B5.1 Lube oil pressure after filter B5.2 (option) Lube oil pressure after filter Engine coolant level, expansion tank B21 (option) Raw water pressure B6.2 (option) Coolant temperature B6.1...
  • Page 28 Engine driving end Item Description Monitoring of B1 (ECU) Camshaft speed B13.2 (optional EMU) Crankshaft speed B13 (ECU) Crankshaft speed 28 | General Information | MS150063/01E 2012-01...
  • Page 29 Engine, right side Item Description Monitoring of YB33 Fuel temperature Fuel pressure (in rail) B16 (option) Coolant pressure Leak fuel level Y27.2 4-2-directional control valve, B-side B4.22 Exhaust temperature, B-side 2-2-directional control valve MS150063/01E 2012-01 | General Information | 29...
  • Page 30 Engine, left side Item Description Monitoring of B4.21 Exhaust gas temperature, A-side Y27.1 4-2-directional control valve, A-side B54 (option) Lube oil pressure, replenishment pump System sensors These sensors are fitted outside the engine. Description Monitoring of Starting-air pressure Fuel prefilter water level Exhaust back pressure Start interlock, switching status 30 | General Information | MS150063/01E 2012-01...

  • Page 31: Technical Data

    3 Technical Data 3.1 12V 2000 M84 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 up to which the engine can be operated without changes, e.g. load setting N Not yet defined value - Not applicable X Applicable...
  • Page 32 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.4 Raw water pump: inlet pressure, max. +0.5 Pressure loss in off-engine raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube-oil operating temperature before engine, to °C...
  • Page 33 CAPACITIES Number of cylinders Engine coolant capacity, engine side (with cooling equipment) liters Total engine oil capacity at initial filling (standard oil system) (Option: max. liters operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liters clinations) Oil pan capacity at dipstick mark "min."...

  • Page 34: 2000 M84 Engine Data

    3.2 16V 2000 M84 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 up to which the engine can be operated without changes, e.g. load setting N Not yet defined value - Not applicable X Applicable...
  • Page 35 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: inlet pressure, min. -0.4 Raw water pump: inlet pressure, max. +0.5 Pressure loss in off-engine raw water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube-oil operating temperature before engine, to °C...
  • Page 36 CAPACITIES Number of cylinders Engine coolant capacity, engine side (with cooling equipment) liters Total engine oil capacity at initial filling (standard oil system) (Option: max. liters operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liters clinations) Oil pan capacity at dipstick mark "min."...

  • Page 37: Firing Order

    3.3 Firing order Firing order A1-B4-A4-A2-B3-A3-B2-B1 10 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1 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 MS150063/01E 2012-01 | Technical Data | 37...

  • Page 38: Engine - Main Dimensions

    3.4 Engine – Main dimensions Main dimensions Engine model Length (A) Width (B) Height (C) 8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M92 approx. 1683 mm approx. 1147 mm approx. 1200 mm 8V 2000 M93 approx.

  • Page 39: Operation

    4.1 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 the engine into operation (out-of-service period > 3 months) Item Measure Engine Depreserve (→...

  • Page 40: Engine - Putting Into Operation After Scheduled Out-Of-Service-Period

    4.2 Engine – Putting into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Measure Lube oil system Check engine oil level (→ Page 95). Coolant circuit Check coolant level (→ Page 108). Coolant circuit Heat engine coolant with coolant preheating unit.

  • Page 41: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.3 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 43). Shut down fuel treatment system (→ Page 51). MS150063/01E 2012-01 | Operation | 41...

  • Page 42: 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 43: Fuel Treatment System - Putting Into Operation

    4.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 46). 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 44 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 46). Start engine (→ Page 47). 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 45: Operational Checks

    4.6 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 46: Fuel Treatment System - Switching On

    4.7 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 47: Starting The Engine

    4.8 Starting the engine Preconditions ☑ External start interlock is not activated. ☑ Emergency air shut-off flaps (if fitted) are open. 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 48: Stopping The Engine

    4.9 Stopping the engine Preconditions ☑ Engine is running in local mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed.

  • Page 49: Emergency Stop

    4.10 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. An emergency stop of the engine can be initiated from the following points : (→...

  • Page 50: After Stopping The Engine

    4.11 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Action Coolant circuit Drain coolant (→ Page 110) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze additive;...

  • Page 51: Fuel Treatment System - Shutdown

    4.12 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 52: Plant - Cleaning

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

  • Page 53: Maintenance

    5 Maintenance 5.1 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 54: Fuel Treatment System - Troubleshooting

    6 Troubleshooting 6.1 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 55: Troubleshooting

    6.2 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine wiring or starter defective Check if cable connections are proper‐...
  • Page 56 Engine speed not steady Component Probable Cause Task Fuel injection equip‐ Injector defective Replace (→ Page 78). ment Speed sensor Defective Replace. Fuel system Not vented Vent fuel system (→ Page 81). Defective Contact Service. Charge-air temperature too high Component Probable Cause Task Engine coolant...
  • Page 57 Exhaust gas white Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Drain fuel prefilter (→ Page 85). Intercooler Leaking Contact Service. MS150063/01E 2012-01 | Troubleshooting | 57...

  • Page 58: Task Description

    7 Task Description 7.1 SOLAS 7.1.1 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A4 735233000100 Shield A5 735233000101 Shield A7 735233000103 Shield A8 735233000104...

  • Page 59: Solas Shielding - Installation

    7.1.2 SOLAS shielding - Installation Preconditions ☑ Engine shut down and starting disabled. ☑ Engine cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil filter and fuel filter Pinpoint installation location (→...

  • Page 60: Installation Locations For Solas Shielding

    7.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 58). Free end B-side Item Type of shielding Comments 1 (free end, B-side) Shield (A7) On fuel delivery pump 2 (free end, B-side) Shield (A7) On HP fuel pump Free end...
  • Page 61 Item Type of shielding Comments 1 (free end) Shield (A8) On fuel filter 2 (free end) Shield (A7) Above fuel priming pump 3 (free end) Shield (A7) Below fuel priming pump Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) On air flap 2 (Driving end, A-side)
  • Page 62 Item Type of shielding Comments 1 (driving end, A-side) Shield (A5) To turbocharger lubrication 2 (driving end, A-side) Shield (A5) On valve plate Driving end Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, left side 2 (driving end) Shield (A4) Turbocharger lubrication, center Driving end...
  • Page 63 Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) Turbocharger flap 2 (driving end, B-side) Shield (A5) Turbocharger flap 3 (driving end, B-side) Shield (A4) On brazed-on union 4 (driving end, B-side) Shield (A5) On air flap 5 (driving end, B-side) Shield (A4) To turbocharger lubrication...
  • Page 64 Driving end A-side Item Type of shielding Comments 1 (driving end, A-side) Shield (A5) To flap control Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) To flap control 64 | Task Description | MS150063/01E 2012-01...

  • Page 65: Engine

    7.2 Engine 7.2.1 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 – danger to life! •...

  • Page 66: Engine - Barring With Starting Equipment

    7.2.2 Engine – Barring with starting equipment Preconditions ☑ Clutch is disengaged. ☑ Engine start is disabled. ☑ LOP is accessible and open. 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. •...

  • Page 67: Cylinder Liner

    7.3 Cylinder Liner 7.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 77). Remove injector (→...
  • Page 68 Final steps Install injector (→ Page 79). Install cylinder head cover (→ Page 77). 68 | Task Description | MS150063/01E 2012-01...

  • Page 69: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.3.2 Cylinder liner - Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 70 Findings Measure Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1.

  • Page 71: Crankcase Breather

    7.4 Crankcase Breather 7.4.1 Crankcase breather – Cleaning oil pre-separator element 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. WARNING Compressed air Risk of injury!

  • Page 72: Crankcase Ventilation- Oil Separator Replacement, Diaphragm Check And Replacement

    7.4.2 Crankcase ventilation– Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Filter element (→ Spare Parts Catalog) Diaphragms (→...
  • Page 73 Checking diaphragms Remove cover (4). Take off spring (5), gasket (2) and dia‐ phragm (3). Check diaphragm (3) for damage. Replace diaphragm if damaged. Install diaphragm (3) on housing (1). Install new gasket (2) and spring (5) togeth‐ er with cover (4). Tighten screws of cover (4) to specified tightening torque.

  • Page 74: Valve Drive

    7.5 Valve Drive 7.5.1 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 75 10V2000 Position Cylinder Firing TDC in cylinder A1 Bank A Bank B Overlap TDC in cylinder A1 Bank A Bank B “E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted 12V2000 Position Cylinder Firing TDC in cylinder A1 Bank A - A - - Bank B...

  • Page 76: Valve Clearance Adjustment

    Valve clearance adjustment Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. Tighten locknut (1) with torque wrench to the prescribed tightening torque of 50 Nm while holding the adjusting screw (2) with screwdriver.

  • Page 77: Cylinder-Head Cover - Removal And Installation

    7.5.2 Cylinder-head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Centering device F6783025 Gasket (→ Spare Parts Catalog) Preparatory steps Remove air filter (→ Page 92). Remove intake housing.

  • Page 78: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Remove injector and install new one. (→ Page 79) 78 | Task Description | MS150063/01E 2012-01...

  • Page 79: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Socket wrench 0005896803/00 Puller F6790629 Double box wrench F30011450 Open end wrench bit F30025897 Box wrench adapter F30451199 Alignment device F6790507...

  • Page 80: Installing Injector

    Installing injector Remove all plugs before installation. Fit new O-rings onto injector and coat with grease. Fit new sealing ring with grease on injector, ensuring correct installation position of sealing ring. Clean sealing surface on cylinder head and protective sleeve. Insert injector (1) in cylinder head, ensuring that it is correctly aligned with the HP line connection.

  • Page 81: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting 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. Venting fuel system Unlock fuel priming pump, unscrew handle.

  • Page 82: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...
  • Page 83 Easy-change fuel filter replacement with the engine stopped Stop engine and disable engine start. Cut out the filter to be replaced. B Left filter cut out C Right filter cut out Remove cut-out easy-change filter using the oil filter wrench. Clean sealing surface on filter head.

  • Page 84: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    7.8.2 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 85: Fuel Prefilter - Draining

    7.8.3 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 86: Fuel Prefilter ‒ Flushing

    7.8.4 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel 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 87 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing 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 88: Fuel Prefilter – Filter Element Replacement

    7.8.5 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 89 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 90: Charge-Air Cooling

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction 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).

  • Page 91: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter – Replacement Remove old air filter and install new air filter (→ Page 92). Reset signal ring of service indicator (→...

  • Page 92: Air Filter – Removal And Installation

    7.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it.

  • Page 93: Air Intake

    7.11 Air Intake 7.11.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 91). After installation of new filter, press reset button (1).

  • Page 94: Starting Equipment

    7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 124). 94 | Task Description | MS150063/01E 2012-01...

  • Page 95: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 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 96: Engine Oil – Change

    7.13.2 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 WARNING Hot oil.

  • Page 97: Oil Filtration / Cooling

    7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) Plastic ring (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components.
  • Page 98 Oil filter replacement with the engine stopped Stop engine (→ Page 48) and disable en‐ gine start. Cut out the filter to be replaced. A Right filter cut out B Both filters cut in (normal operating position) C Left filter cut out Remove cut-out oil filter using the oil filter wrench.

  • Page 99: Centrifugal Oil Filter – Cleaning And Filter Sleeve Replacement

    7.14.2 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. Strap wrench F30379104 Cold cleaner (Hakutex 50) 50622 Filter sleeve (→ Spare Parts Catalog) O-ring (→...
  • Page 100 Centrifugal oil filter – Cleaning and filter-sleeve replacement Remove nut, holding the rotor with a strap wrench. Remove nut (1), washer (2), rotor cap (3) and sealing ring (4). Remove sleeve (1). Measure the layer thickness of the oil resi‐ due.
  • Page 101 Fit new sealing ring (4). Set on rotor cap (3), observe marks. Fit washer (2). Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard M18 x 1.5 Tightening torque 10 Nm Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.

  • Page 102: Coolant Circuit, General, High Temperature Circuit

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Drain and venting points 8 V, 10 V 1 Overflow line, expansion 2 Filler neck tank 102 | Task Description | MS150063/01E 2012-01...
  • Page 103 12 V, 16 V 1 Overflow line, expansion 2 Filler neck tank MS150063/01E 2012-01 | Task Description | 103...
  • Page 104 Free end (KGS) 1 Fuel filter vent screws 4 Measuring point, pres‐ 5 Raw water pump drain 2 Engine coolant drain plug sure before raw water plug 3 Raw water pump filling pump 6 Connection for oil extrac‐ plug tion 104 | Task Description | MS150063/01E 2012-01...
  • Page 105 Left side 1 Engine coolant drain plug 2 Engine coolant drain plug (M14x1.5) MS150063/01E 2012-01 | Task Description | 105...
  • Page 106 Right side 1 Engine coolant drain plug 3 Oil dipstick (connection (M14x1.5) left or right engine side 2 Oil filler neck (connection optional) left or right engine side 4 Leak-off-fuel tank optional) 106 | Task Description | MS150063/01E 2012-01...
  • Page 107 Driving end (KS) 1 Engine coolant drain plug 2 Connection for oil extrac‐ tion MS150063/01E 2012-01 | Task Description | 107...

  • Page 108: Engine Coolant – Level Check

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

  • Page 109: Engine Coolant – Change

    7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 110). Fill with engine coolant (→ Page 111). MS150063/01E 2012-01 | Task Description | 109...

  • Page 110: Engine Coolant – Draining

    7.15.4 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide an appropriate container to collect the coolant or switch on the extraction device.

  • Page 111: Engine Coolant – Filling

    7.15.5 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. Engine coolant WARNING Coolant is hot and under pressure.

  • Page 112: Ht Coolant Pump — Relief Bore Check

    7.15.6 HT 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 113: Engine Coolant – Sample Extraction And Analysis

    • corrosion inhibitor concentration; • pH value. Fit breather valve and close it. Change engine coolant according to the coolant operating times specified in the (→ MTU Fluids and Lu‐ bricants Specifications A001061/..)(→ Page 110). MS150063/01E 2012-01 | Task Description | 113...

  • Page 114: Coolant Filter – Replacement

    7.15.8 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 115: Raw Water Pump With Connections

    7.16 Raw Water Pump with Connections 7.16.1 Raw water 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).

  • Page 116: Belt Drive

    7.17 Belt Drive 7.17.1 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 117: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 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 118: Fuel Supply System

    7.19 Fuel Supply System 7.19.1 Water drain valve – Check Checking water drain valve Open water drain valve. Check water outlet for obstructions. Close water drain valve. 118 | Task Description | MS150063/01E 2012-01...

  • Page 119: Differential Pressure Gauge – Check

    7.19.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking differential pressure gauge Switch on fuel treatment system (→ Page 46). Set the alarm points at the differential pressure gauge to zero.

  • Page 120: Water Level Probe (3-In-1 Rod Electrode Check

    7.19.3 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 121: Pump Capacity – Check

    7.19.4 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 122: Coalescer Filter Element – Replacement

    7.19.5 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 123 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 124: Wiring (General) For Engine/Gearbox/Unit

    7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 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 125: Accessories For (Electronic) Engine Governor / Control System

    7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 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 126: Engine Governor – Checking Plug-In Connections

    7.21.2 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 127: Emu – Checking Plug-In Connections

    7.21.3 EMU – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. EMU – checking plug-in connections Verify that all plug-in connections are securely seated. Secure loose connectors and latch. MS150063/01E 2012-01 | Task Description | 127...

  • Page 128: Engine Governor – Carry Out Self-Test

    7.21.4 Engine governor – Carry out self-test DANGER Electrical voltage. Risk of serious injury - danger to life! • Make certain that the power supply to the engine is switched off before starting to work. Ensure that the power supply cannot be switched on unintentionally! Carrying out self-test Switch off power supply to system.

  • Page 129: Emu And Connectors – Cleaning

    7.21.5 EMU and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol EMU and connectors – Cleaning Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol.

  • Page 130: Ecu 7 Engine Governor – Removal And Installation

    7.21.6 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 131: Engine Monitoring Unit – Removal And Installation

    7.21.7 Engine monitoring unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 132: Abbreviations

    Abgasturbolader Exhaust turbocharger (ETC) Backup Data Module Baureihe Series Betriebsstoffvorschrift MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting the drift correction with DiaSys in the engine control system Cyclic Redundancy Control Check sum procedure to detect data trans‐...
  • Page 133 Abbreviation Meaning Explanation Kraftseite Engine driving end in accordance with DIN ISO 1204 Light Emitting Diode Alarm: Measured value lower than 1st mini‐ mum limit LOLO Low Low Alarm: Measured value lower than 2nd mini‐ mum limit Motoren- und Turbinenunion Magnetventil Solenoid valve Original Equipment Manufacturer...

  • Page 134: Mtu Contacts/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 - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply.

  • Page 135: Special Tools

    9 Appendix B 9.1 Special Tools Alignment device Part No.: F6790507 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 79) Angular screw driver Part No.: F30002816 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 74) Barring tool Part No.: F6783914...
  • Page 136 Mandrel Part No.: 8205892861/08 Qty.: Used in: 7.18.1 Battery-charging generator drive – Drive belt replacement (→ Page 117) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.15.7 Engine coolant – Sample extraction and analysis (→ Page 113) Oil filter wrench Part No.:...
  • Page 137 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page 67) Socket wrench Part No.: F30030450 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 74) Socket wrench Part No.: 0005896803/00 Qty.: Used in: 7.6.2 Injector –...

  • Page 138: Index

    9.2 Index 12V 2000 M84 engine data 31 16V 2000 M84 engine data 34 ECU 7 engine governor – Removal and installation  130 Emergency stop 49 Abbreviations 132 EMU and connectors – Cleaning 129 After stopping the engine 50 EMU – Checking plug-in connections 127 Air filter Engine –...
  • Page 139 Water drain valve – Check  118 Water level probe (3-in-1 rod electrode) Maintenance work – Check  120 – Safety regulations  11 Wiring - engine MTU contact persons 134 – Check  124 Operation – Safety regulations  10 Operational checks 45 Personnel and organizational requirements 6...

This manual is also suitable for:

16 v 2000 m84

Table of Contents