MTU 16 V 2000 S96 Betriebsanleitung

Operating InstructionsDiesel engine12 V 2000 S9616 V 2000 S96MS150095/01E

For conducting light-beam procedures and measurement work, only the following laser devices must beused:• Laser devices of classes 1, 2 or 3A.• Laser

6.16.2 Differential pressure gauge – CheckWARNINGFuels are combustible.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition

6.16.3 Water level probe (3-in-1 rod electrode) – CheckPreconditions☑ System is put out of service and emptied.WARNINGFuels are combustible.Risk of fi

6.16.4 Pump capacity – CheckWARNINGFuels are combustible.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition sources.• Do n

6.16.5 Coalescer filter element – ReplacementPreconditions☑ System is switched off and starting disabled.Special tools, Material, Spare partsDesignati

16. Tighten nut (3) to specified tightening torque using a torque wrench.Name Size Type Lubricant Value/StandardNut M16 Tightening torque (Engine oil)

6.17 Engine Governor6.17.1 Engine governor – Checking plug-in connectionsPreconditions☑ Engine is stopped and starting disabled.Note: Always use test

6.18 Wiring (General) for Engine/Gearbox/Unit6.18.1 Engine wiring – CheckPreconditions☑ Engine is stopped and starting disabled.Special tools, Materia

6.18.2 Lambda, NOx and humidity sensors – Overview1 Humidity sensor 2 NOx sensor 3 Lambda sensorMS150095/01E 2012-08 | Task Description | 107TIM-ID: 0

6.18.3 Lambda sensor – ReplacementPreconditions☑ Engine is stopped and starting disabled.☑ Preparatory steps have been completed.Special tools, Materi

Installing lambda sensorNote: The sensor is considered defective after be‐ing exposed to shock load or impact andmust not be used.1. Remove the protec

1.5 Auxiliary materials, fluids and lubricants, fire prevention andenvironmental protectionFire preventionRectify any fuel or oil leaks immediately; e

6.18.4 NOx sensor – ReplacementPreconditions☑ Engine is stopped and starting disabled.☑ Preparatory steps have been completed.Special tools, Material,

Installing NOx sensorNote: The sensor is considered defective after be‐ing exposed to shock load or impact andmust not be used.1. Remove the protectiv

6.18.5 Humidity sensor – ReplacementPreconditions☑ Engine is stopped and starting disabled.☑ Preliminary steps are completed.Special tools, Material,

Humidity sensor – InstallationNote: Apply lubricant for O-ring sparingly.1. Insert sensor (2) in bore, ensuring correctinstallation position.Note: Tak

6.19 Accessories for (Electronic) Engine Governor / ControlSystem6.19.1 CDC parameters – Reset with DiaSys®Preconditions☑ Engine is stopped and starti

6.19.2 Engine governor and connectors – CleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation

6.19.3 Engine governor – Checking plug-in connectionsPreconditions☑ Engine is stopped and starting disabled.Note: Always use test connectors to enter

7 Appendix A7.1 List of abbreviationsAbbrevia‐tionMeaning ExplanationADEC Advanced Diesel Engine Controller Engine management systemAL Alarm General a

Abbrevia‐tionMeaning ExplanationIMO International Maritime OrganizationISO International Organization for Stand‐ardizationInternational umbrella organ

Abbrevia‐tionMeaning ExplanationWJ Water Jet Water jet driveWZK Werkzeugkatalog Tool Catalog (TC)MS150095/01E 2012-08 | Appendix A | 119TIM-ID: 000000

Lead• When working with lead or lead-containing compounds, avoid direct contact to the skin and do notinhale lead vapors.• Adopt suitable measures to

7.2 MTU contact persons/service partnersOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters

8 Appendix B8.1 Special ToolsAdapterPart No.: F30006234Qty.:Used in:1 6.4.2 Injector – Removal and installation (→ Page 49)Qty.:Used in:1 6.5.1 HP fue

Belt tension tester, 150-600 NPart No.: Y20097429Qty.:Used in:1 6.14.2 Drive belt – Tension check (→ Page 95)Crowfoot wrench, 19 mmPart No.: F30027424

Double-head box wrenchPart No.: F30002800Qty.:Used in:1 6.3.1 Valve clearance – Check and adjustment (→ Page44)Double-head box wrenchPart No.: F300114

Fuel suction devicePart No.: F30378207Qty.:Used in:1 6.4.2 Injector – Removal and installation (→ Page 49)Installation devicePart No.: F6790085Qty.:Us

Oil filter wrenchPart No.: F30379104Qty.:Used in:1 6.12.8 Coolant filter – Replacement (→ Page 86)Open-end socket wrench, 19 mmPart No.: F30453236Qty.

RatchetPart No.: F30006212Qty.:Used in:1 6.1.1 Engine – Barring manually (→ Page 41)Qty.:Used in:1 6.3.1 Valve clearance – Check and adjustment (→ Pag

Ratchet adapter ½"Part No.: F30027340Qty.:Used in:1 6.14.3 Drive belt – Tension adjustment (→ Page 96)Ratchet adapter ½"Part No.: F30027340Q

Steam jet cleanerPart No.: -Qty.:Used in:1 3.13 Plant cleaning (→ Page 35)TesterPart No.: Y4345711Qty.:Used in:1 6.14.2 Drive belt – Tension check (→

Torque wrench, 10-60 NmPart No.: F30510423Qty.:Used in:1 6.18.3 Lambda sensor – Replacement (→ Page 108)Qty.:Used in:1 6.18.4 NOx sensor – Replacement

1.6 Conventions for safety instructions in the textDANGERIn the event of immediate danger.Consequences: Death or serious injury• Remedial actionWARNIN

Torque wrench, 6-50 NmPart No.: F30027336Qty.:Used in:1 6.16.5 Coalescer filter element – Replacement (→ Page103)Torque wrench, 6-50 NmPart No.: F3002

8.2 Index12/16V 2000 S96 engine data 19AAfter stopping the engine 33Air filter– Replacement  65Auxiliary materials 11BBattery-charging generator drive

Engine side– Designation  16Engine wiring– Check  106Environmental protection 11Exhaust gas recirculation– Flaps  – Operation check  68FFilter– Air  –

Pump capacity– Check  102Putting into operation– After scheduled out-of-service period  – Preparation  23– Fuel treatment system  26Putting the engine

2 Product Summary2.1 Engine – Overview12/16 V 2000 C66/S96This overview also applies to 16 V 2000 C66 and 16 V 2000 S96 engines.1 Exhaust turbocharger

Key to the engine model designationC/S Application: C, charge-air cooling in internal circuit, withpiston coolingApplication S: Exhaust turbocharging

2.2 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side

2.3 Engine – Main dimensionsItem Engine model / Dimension Engine model / Dimension12 V 2000 C66/S96 16 V 2000 C66/S96Length (A) approx. 2028 mm approx

2.4 Firing orderFiring order for 12 / 16 V 2000 C66/S96 enginesNumber of cylin‐dersFiring order12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B116 V A1-B5-A3-A

2.5 Technical Data2.5.1 12/16V 2000 S96 engine dataExplanation:DL Ref. value: Continuous powerBL Ref. value: Fuel stop powerA Design valueG Guaranteed

Printed in Germany© 2012 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole

Number of cylinders 12 16Cylinder displacement Liters 2.233 2.233Total displacement Liters 26.80 35.73Compression ratio 16.5 16.5Inlet valves per cyli

GENERAL OPERATING DATANumber of cylinders 12 16Cold start capability: air temperature (w/o start aid, w/o preheat‐ing) - (case A)R °C 0 0Firing speed,

3 Operation3.1 Putting the engine into operation after extended out-of-service periods (>3 months)Preconditions☑ Engine is stopped and starting dis

3.2 Putting the engine into operation after scheduled out-of-service-periodPreconditions☑ Engine is stopped and starting disabled.Putting into operati

3.3 Tasks after extended out-of-service periods (>3 weeks)Tasks after extended out-of-service periods (>3 weeks)Note: Operate fuel treatment sys

3.4 Checks prior to start-upChecks prior to start-up1. Check tank and the entire pipework for cleanness. If microorganisms are detected:a) Clean affec

3.5 Fuel treatment system – Putting into operationFuel treatment system – Overview1. Switch on fuel treatment system (→ Page 29).2. Check the differen

Simulation of filter replacement with the engine running: HAT1. Switch on fuel treatment system (→ Page 29).2. Start engine (→ Page 28).3. Run engine

3.6 Starting the enginePreconditions☑ Engine is not connected to load.DANGERUnguarded rotating and moving engine components.Risk of serious injury – d

3.7 Fuel treatment system – Switching onPreconditions☑ The on-board power supply is switched on.CAUTIONDamage to engine/plant.Major material damage!•

Table of Contents1 Safety1.1 General conditions 51.2 Personnel and organizational requirements 61.3 Transport 71.4 Safety regulations for maintenance

3.8 Operational checksDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special care when working o

3.9 Stopping the enginePreconditions☑ Engine is not connected to load.CAUTIONStopping the engine when it is running at full load causes extreme stress

3.10 Emergency stopCAUTIONAn emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!• Initiate emergency stop on

3.11 After stopping the enginePreconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.Note: If freezing temperatures are to

3.12 Fuel treatment system – ShutdownShutting down fuel treatment system1. Press the illuminated pushbutton "Water drain" on the switch cabi

3.13 Plant cleaningPreconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not present.Special tools, Material, Spare partsDesig

4 Maintenance4.1 Maintenance task reference table [QL1]The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. T

5 Troubleshooting5.1 Fuel treatment system – TroubleshootingIlluminated pushbutton “Water alarm” is lit.Cause Corrective actionWhen the maximum water

5.2 TroubleshootingEngine does not turn when starter is actuatedComponent Cause ActionBattery Low or faulty Charge or replace (see manufacturer's

Engine speed not steadyComponent Cause ActionFuel injection equip‐mentInjector faulty Replace (→ Page 48).Speed sensor Faulty Contact Service.Fuel sys

6.11.2 Centrifugal oil filter – Cleaning and filtersleeve replacement 726.12 Coolant Circuit, General, High-Temperature Circuit 746.12.1 Drain and ven

White exhaust gasComponent Cause ActionEngine Not at operating temperature Run engine to reach operating temper‐ature.Fuel system Water in fuel Check

6 Task Description6.1 Engine6.1.1 Engine – Barring manuallyPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare parts

6.1.2 Engine – Barring with starting systemDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Before barr

6.2 Crankcase Breather6.2.1 Crankcase breather – Oil mist fine separator replacementPreconditions☑ Engine is stopped and starting disabled.Special too

6.3 Valve Drive6.3.1 Valve clearance – Check and adjustmentPreconditions☑ Engine is stopped and starting disabled.☑ Engine coolant temperature is max.

Checking valve clearance at two crankshaft positions1. Check TDC position of piston in cylinder A1:• If the rocker arms are unloaded on cylinder A1, t

4. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)with Allen key to prevent it from turning

6.3.2 Cylinder head cover – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesigna

6.4 Injection Valve / Injector6.4.1 Injector – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Injector(→ Spare Parts Ca

6.4.2 Injector – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

1 Safety1.1 General conditionsGeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other com‐pu

Removing injector1. Remove fuel line (1).2. Unscrew union nut (2).3. Pull out pressure pipe neck (3).4. Extract fuel from the exposed bores usingthe s

Installing injector1. Remove all covers before installation.2. Clean sealing surface on cylinder head andprotective sleeve.3. Coat sealing ring on inj

8. Use torque wrench to tighten screw (3) for hold-down clamp (2) to the specified tightening torque.Name Size Type Lubricant Value/StandardScrew M8 T

4. 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 Val

6.5 Fuel System6.5.1 HP fuel line and pressure pipe neck – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material,

HP fuel line and pressure pipeneck – Replacement1. Remove leak-off fuel line from cylinderhead.2. Remove HP fuel line (2).3. Remove thrust screw (4).4

6.5.2 Fuel system – VentingPreconditions☑ Engine is not connected to load.Fuel system – VentingNote: The fuel system can only be vented with the engin

6.5.3 Fuel – DrainingPreconditions☑ Engine is stopped and starting disabled.WARNINGFuels are combustible.Risk of fire and explosion!• Avoid open flame

6.6 Fuel Filter6.6.1 Fuel filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation /

6.6.2 Fuel prefilter – Differential pressure check and adjustment of gaugeDANGERUnguarded rotating and moving engine components.Risk of serious injury

1.2 Personnel and organizational requirementsPersonnel requirementsAll work on the engine shall be carried out by trained and qualified personnel only

6.6.3 Fuel prefilter – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Q

6.6.4 Fuel prefilter ‒ FlushingSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.FuelGasket(→ Spare Parts Catalog)DANGERUnguarded rot

2. Open threaded vent plug (5) of filter to beflushed.3. Unlock drain valve (6) by pressing valvetoggle, open it and drain fuel.Result: Fuel flows fro

6.6.5 Fuel prefilter – Filter element replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignatio

2. Open threaded vent plug (5) of contaminat‐ed filter.3. Unlock drain valve (6) by pressing toggleand open it.4. Drain water and contaminants from th

6.7 Air Filter6.7.1 Air filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.For air filter replacement, carry out operations as

6.8 Air Intake6.8.1 Service indicator – CheckSee manufacturer's documentation.66 | Task Description | MS150095/01E 2012-08TIM-ID: 0000005482 - 00

6.9 Exhaust Gas Recirculation6.9.1 Exhaust gas recirculation flaps – OverviewMS150095/01E 2012-08 | Task Description | 67TIM-ID: 0000024288 - 001

6.9.2 Exhaust gas circulation - Checking flap operationPreconditions☑ Engine is stopped and starting disabled.WARNINGComponent is hot.Risk of burning!

6.10 Lube Oil System, Lube Oil Circuit6.10.1 Engine oil – Level checkPreconditions☑ Engine is stopped and starting disabled.Oil level check prior to e

1.3 TransportTransportAlso valid for 12V enginesOnly use the lifting eyes provided to lift the engine.Only use transport and lifting devices approved

6.10.2 Engine oil – ChangePreconditions☑ Engine is stopped and starting disabled.☑ Engine is at operating temperature.☑ MTU Fluids and Lubricants Spec

6.11 Oil Filtration / Cooling6.11.1 Engine oil filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spa

6.11.2 Centrifugal oil filter – Cleaning and filter sleeve replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material,

Centrifugal oil filter cleaning andfilter sleeve replacement1. Remove clamp (14).2. Release cover screw (2) and take off cov‐er (1).3. Carefully lift

6.12 Coolant Circuit, General, High-Temperature Circuit6.12.1 Drain and vent points12 V, 16 V1 Engine coolant vent74 | Task Description | MS150095/01E

Left side1 Engine coolant drainplug2 Oil drain plug 3 Engine coolant drainplugMS150095/01E 2012-08 | Task Description | 75TIM-ID: 0000025286 - 001

Right side1 Engine coolant drainplug2 Engine coolant drainplug3 Oil drain plug4 Engine coolant drainplug76 | Task Description | MS150095/01E 2012-08TI

Driving end (KS)1 Oil drain plugMS150095/01E 2012-08 | Task Description | 77TIM-ID: 0000025286 - 001

Free end (KGS)1 Oil drain plug2 Engine coolant fillingplug3 Oil drain plug4 Engine coolant drainplug78 | Task Description | MS150095/01E 2012-08TIM-ID

6.12.2 Engine coolant – Level checkPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are

1.4 Safety regulations for maintenance and repair workSafety regulations for maintenance and repair workHave maintenance and repair work carried out b

6.12.3 Engine coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantEngine coolant – Change1. Drain engine coolant

6.12.4 Engine coolant – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No.

6.12.5 Engine coolant – FillingPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are avai

Final steps1. Start the engine and operate it at idle speed for some minutes.2. Check coolant level (→ Page 79), top up with coolant if required.MS150

6.12.6 Engine coolant pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take spe

6.12.7 Engine coolant – Sample extraction and analysisPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specification

6.12.8 Coolant filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part N

6.13 Low-Temperature Circuit6.13.1 Intercooler – Vent and drain points12 V, 16 V1 Intercooler vent plugsMS150095/01E 2012-08 | Task Description | 87TI

6.13.2 Charge-air coolant – Level checkPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..)

6.13.3 Charge-air coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantCharge-air coolant – Change1. Drain charge

Welding workNever carry out welding work on the assembly, system, or engine-mounted units. Cover the engine whenwelding in its vicinity.Do not use the

6.13.4 Charge-air coolant – FillingPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are

Charge-air coolant – Filling1. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant levelreaches m

6.13.5 Charge-air coolant – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part

6.13.6 Charge-air coolant pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take

6.14 Belt Drive6.14.1 Drive belt – Condition checkPreconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.Drive belt – Condition che

6.14.2 Drive belt – Tension checkPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No.

6.14.3 Drive belt – Tension adjustmentPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Par

6.14.4 Drive belt – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Q

6.15 Battery-Charging Generator6.15.1 Battery-charging generator drive – Drive belt replacementPreconditions☑ Engine is stopped and starting disabled.

6.16 Fuel Supply System6.16.1 Water drain valve – CheckWater drain valve – Check1. Open water drain valve.2. Check water outlet for obstructions.3. Cl