MTU 12 V 2000 M86 User manual

Operating Instructions
Diesel engine
12 V 2000 M86
12 V 2000 M96
12 V 2000 M96L
16 V 2000 M86
16 V 2000 M96
16 V 2000 M96L
MS150119/00E

Engine model kW/cyl. Application group
12V2000M86 102 kW/cyl. 1D, Continuous operation, variable, medium load
12V2000M96 112 kW/cyl. 1DS, Continuous operation, variable, low load
12V2000M96L 119 kW/cyl. 1DS, Continuous operation, variable, low load
16V2000M86 102 kW/cyl. 1D, Continuous operation, variable, medium load
16V2000M96 112 kW/cyl. 1DS, Continuous operation, variable, low load
16V2000M96L 121 kW/cyl. 1DS, Continuous operation, variable, low load
Table 1: Applicability
© 2014 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
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All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety
1.1 Important requirements for all products 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety requirements for startup and
operation 8
1.5 Safety requirements for maintenance and
repair work 9
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 12
1.7 Standards for safety notices in the text 14
2 General Information
2.1 Torque specifications for screws and nuts 15
2.2 Engine side and cylinder designations 26
2.3 Product description 27
2.4 Engine layout 33
2.5 Sensors and actuators – Overview 35
3 Technical Data
3.1 12V 2000 M86/M96/M96L engine data 40
3.2 16V 2000 M86/M86/M96L engine data 43
3.3 Firing order 46
3.4 Engine – Main dimensions 47
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 48
4.2 Engine – Putting into operation after
scheduled out-of-service-period 49
4.3 Operational checks 50
4.4 Starting the engine 51
4.5 Engine – Shutdown 52
4.6 Emergency engine stop 53
4.7 After stopping the engine 54
4.8 Plant – Cleaning 55
5 Maintenance
5.1 Maintenance task reference table [QL1] 56
6 Troubleshooting
6.1 Troubleshooting 57
7 Task Description
7.1 SOLAS 60
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 60
7.1.2 SOLAS shielding – Installation 61
7.1.3 Installation locations for SOLAS shielding 62
7.2 Engine 67
7.2.1 Engine – Barring manually 67
7.2.2 Engine – Cranking on starting system 68
7.3 Cylinder Liner 69
7.3.1 Instructions and comments on endoscopic and
visual examination of cylinder liners 69
7.3.2 Cylinder liner – Endoscopic examination 71
7.4 Crankcase Breather 73
7.4.1 Crankcase breather – Cleaning oil pre-
separator element 73
7.4.2 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 74
7.5 Valve Drive 76
7.5.1 Cylinder head cover – Removal and
installation 76
7.5.2 Valve clearance – Check and adjustment 77
7.6 Injection Pump / HP Pump 79
7.6.1 HP fuel pump – Filling with engine oil 79
7.7 Injector 80
7.7.1 Injector – Replacement 80
7.7.2 Injector – Removal and installation 81
7.8 Fuel System 83
7.8.1 Fuel system – Venting 83
7.9 Fuel Filter 84
7.9.1 Fuel filter – Replacement 84
7.9.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 85
7.9.3 Fuel prefilter – Draining 86
7.9.4 Fuel prefilter – Flushing 88
7.9.5 Fuel prefilter – Filter element replacement 90
7.10 Charge-Air Cooling 92
7.10.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 92
7.11 Air Filter 93
7.11.1 Air filter – Replacement 93
7.11.2 Air filter – Removal and installation 94
7.12 Air Intake 95
7.12.1 Service indicator – Signal ring position check 95
7.13 Starting Equipment 96
7.13.1 Starter – Condition check 96
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7.14 Lube Oil System, Lube Oil Circuit 97
7.14.1 Engine oil – Level check 97
7.14.2 Engine oil – Change 98
7.15 Oil Filtration / Cooling 99
7.15.1 Engine oil filter – Replacement 99
7.16 Coolant Circuit, General, High-Temperature
Circuit 100
7.16.1 Engine coolant drain and venting points 100
7.16.2 Engine coolant – Level check 103
7.16.3 Engine coolant – Change 104
7.16.4 Engine coolant – Draining 105
7.16.5 Engine coolant – Filling 106
7.16.6 HT coolant pump – Relief bore check 107
7.16.7 Engine coolant – Sample extraction and
analysis 108
7.17 Low-Temperature Circuit 109
7.17.1 Charge-air coolant – Draining 109
7.18 Raw Water Pump with Connections 110
7.18.1 Raw water pump – Relief bore check 110
7.19 Engine Mounting / Support 111
7.19.1 Engine mounting – Checking securing screws
for firm seating 111
7.19.2 Engine mounting – Checking condition of
resilient mounts 112
7.20 Belt Drive 113
7.20.1 Drive belt – Condition check 113
7.21 Battery-Charging Generator 114
7.21.1 Battery-charging generator drive – Drive belt
replacement 114
7.22 Wiring (General) for Engine/Gearbox/Unit 115
7.22.1 Еngine wiring ‒ Check 115
7.23 Accessories for (Electronic) Engine
Governor / Control System 116
7.23.1 Engine governor and connectors – Cleaning 116
7.23.2 EMU and connectors – Cleaning 117
7.23.3 Engine governor plug connections – Check 118
7.23.4 Engine Monitoring Unit EMU 8 – Plug
connections check 119
7.23.5 Interface module EIM plug connections –
Check 120
7.23.6 Engine Control Unit – Self-test 121
7.23.7 Engine governor ECU 9 – Removal and
installation 122
7.23.8 Engine Monitoring Unit – Removal and
installation 123
7.23.9 Engine Interface Module EIM – Removal and
installation 124
7.23.10 Diagnostic features of EIM 125
8 Appendix A
8.1 List of abbreviations 128
8.2 MTU contact persons/service partners 130
9 Appendix B
9.1 Special Tools 131
9.2 Index 138
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1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
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1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment
Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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1.3 Transport
Transport
Use only the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
Transport the engine in the installation position only, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine by the lifting eyes of the trans-
port pallet or transport with equipment suitable for heavy loads (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transportation. The engine must be additionally secured against
slipping or tilting when going up or down inclines and ramps.
Setting down the engine following transportation
Set the engine down on a firm, level surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis .
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1.4 Safety requirements for startup and operation
Safety requirements for startup
The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.
All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.
Whenever the product is started, always ensure that:
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• Wearers of cardiac pacemakers or other active medical implants are well clear.
• The operating room is adequately ventilated.
• Exhaust pipework is leak-tight and routed to atmosphere.
• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.
• All personnel is clear of the danger zone represented by moving parts.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.
Safety requirements for operation
The operator must be familiar with the controls and displays.
The operator must be aware of the consequences of any operations he/she performs.
During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.
Malfunctions and emergency stop
Emergency procedures, in particular emergency stop, must be practiced on a regular basis.
Take the following steps if a system malfunction is detected or signaled by the system:
• Inform the duty supervisor(s).
• Evaluate the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.
Keep a safe distance away from the product whenever possible. Do not touch the product unless ex-
pressly instructed to do so.
Do not inhale exhaust gases emitted by the product.
Ensure that the following requirements have been fulfilled before starting the product:
• Ear protectors are worn.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
Operation of electrical equipment
Some components are live (high voltage) when electrical equipment is in operation.
Observe the safety instructions for these appliances.
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1.5 Safety requirements for maintenance and repair work
Safety requirements before commencing maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.
Safety requirements during maintenance and repair work
Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
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Pay particular attention to cleanliness at all times.
Safety requirements after completing maintenance and repair work
Ensure that all personnel is clear of danger zones before cranking.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal
Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries
Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
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