MTU 12V2000M93 User manual

Operating Instructions
Diesel engine
12V2000M93
16V2000M93
M015655/05E

Engine model kW/cyl. Application group
12V2000M93 111.7 kW/cyl. 1DS, continuous operation, variable, low load
factors
16V2000M93 111.9 kW/cyl. 1DS, continuous operation, variable, low load
factors
Table 1: Applicability
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GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Personnel and organizational requirements 7
1.3 Transport 8
1.4 Safety regulations for startup and operation 10
1.5 Safety regulations for maintenance and
repair work 12
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 15
1.7 Standards for safety notices in the text 17
2 General Information
2.1 Tightening specifications for screws, nuts
and bolts 18
2.2 Engine side and cylinder designations 31
2.3 Product description 32
2.4 Engine – Overview 38
2.5 Sensors and actuators – Overview 40
3 Technical Data
3.1 Engine data 12V2000M93 45
3.2 Engine data 16V2000M93 48
3.3 Firing order 51
3.4 Engine – Main dimensions 52
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 53
4.2 Engine – Putting into operation after
scheduled out-of-service-period 54
4.3 Tasks after extended out-of-service periods
(>3 weeks) 55
4.4 Checks prior to start-up 56
4.5 Fuel treatment system – Putting into
operation 57
4.6 Operational checks 59
4.7 Fuel treatment system – Switching on 60
4.8 Starting the engine 61
4.9 Engine – Shutdown 62
4.10 Emergency engine stop 63
4.11 After stopping the engine 64
4.12 Fuel treatment system – Shutdown 65
4.13 Plant – Cleaning 66
5 Maintenance
5.1 Maintenance task reference table [QL1] 67
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting 68
6.2 Troubleshooting 69
7 Task Description
7.1 SOLAS 72
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 72
7.1.2 SOLAS shielding – Installation 73
7.1.3 Installation locations for SOLAS shielding 74
7.2 Engine 79
7.2.1 Engine – Barring manually 79
7.2.2 Engine – Cranking on starting system 80
7.3 Cylinder Liner 81
7.3.1 Cylinder liner – Endoscopic examination 81
7.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 83
7.4 Crankcase Breather 85
7.4.1 Crankcase breather – Cleaning oil pre-
separator element 85
7.4.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 86
7.5 Valve Drive 88
7.5.1 Valve clearance – Check and adjustment 88
7.5.2 Cylinder head cover – Removal and
installation 91
7.6 Injection Valve / Injector 92
7.6.1 Injector – Replacement 92
7.6.2 Injector – Removal and installation 93
7.7 Fuel System 95
7.7.1 Fuel system – Venting 95
7.8 Fuel Filter 96
7.8.1 Fuel filter – Replacement 96
7.8.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 98
7.8.3 Fuel prefilter – Draining 99
7.8.4 Fuel prefilter – Flushing 101
7.8.5 Fuel prefilter – Filter element replacement 103
7.9 Charge-Air Cooling 105
7.9.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 105
7.10 Air Filter 106
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7.10.1 Air filter – Replacement 106
7.10.2 Air filter – Removal and installation 107
7.11 Air Intake 108
7.11.1 Service indicator – Signal ring position check 108
7.12 Starting Equipment 109
7.12.1 Starter – Condition check 109
7.13 Lube Oil System, Lube Oil Circuit 110
7.13.1 Engine oil – Level check 110
7.13.2 Engine oil – Change 111
7.14 Oil Filtration / Cooling 112
7.14.1 Engine oil filter – Replacement 112
7.14.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 114
7.15 Coolant Circuit, General, High-Temperature
Circuit 116
7.15.1 Drain and venting points 116
7.15.2 Engine coolant – Level check 121
7.15.3 Engine coolant – Change 122
7.15.4 Engine coolant – Draining 123
7.15.5 Engine coolant – Filling 124
7.15.6 HT coolant pump – Relief bore check 125
7.15.7 Engine coolant – Sample extraction and
analysis 126
7.15.8 Coolant filter – Replacement 127
7.16 Raw Water Pump with Connections 128
7.16.1 Raw water pump – Relief bore check 128
7.17 Belt Drive 129
7.17.1 Drive belt – Condition check 129
7.18 Battery-Charging Generator 130
7.18.1 Battery-charging generator drive – Drive belt
replacement 130
7.19 Fuel Supply System 131
7.19.1 Water drain valve – Check 131
7.19.2 Differential pressure gauge – Check 132
7.19.3 Water level probe (3-in-1 rod electrode) –
Check 133
7.19.4 Pump capacity – Check 134
7.19.5 Coalescer filter element – Replacement 135
7.20 Wiring (General) for Engine/Gearbox/Unit 137
7.20.1 Engine cabling – Check 137
7.21 Accessories for (Electronic) Engine
Governor / Control System 138
7.21.1 Engine governor and connector – Cleaning 138
7.21.2 EMU and connectors – Cleaning 139
7.21.3 Engine governor plug connections – Check 140
7.21.4 Engine Monitoring Unit EMU 7 – Plug
connection check 141
7.21.5 Interface module EIM plug connections –
Check 142
7.21.6 Engine Control Unit – Self-test 143
7.21.7 Engine Control Unit ECU 7 – Removal and
installation 144
7.21.8 Engine Monitoring Unit – Removal and
installation 145
7.21.9 Engine Interface Module EIM – Removal and
installation 146
7.21.10 Diagnostic features on EIM 147
8 Appendix A
8.1 Abbreviations 150
8.2 MTU contact persons/service partners 152
9 Appendix B
9.1 Special Tools 153
9.2 Index 161
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine
in the EU: The second nameplate must be affixed in a prominent position as described in the accompa-
nying specifications.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct 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 control/parameters)
• In compliance with all safety regulations and in adherence 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 is considered improper use. 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 resulting from
improper, non-intended use.
Modifications or conversions
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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Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions
regulation authorities. The manufacturer does not accept any liability for violations of the emission reg-
ulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of
the product.
Replacing components with emission labels
Emission labels are attached to all MTU engines. These must remain on the engine throughout its op-
erational life.
Engines used exclusively in land-based, military applications other than by US government agencies are
excepted from this proviso.
Please note the following when replacing components with emission labels:
• Appropriate emission labels must be affixed on spare parts.
• Emission labels may not be transferred from old components to new ones.
• Emission labels on old components must be removed and destroyed.
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1.2 Personnel and organizational requirements
Organizational measures of the user/manufacturer
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.
Personnel must receive instruction on product handling and maintenance on the basis of this manual
with a special emphasis on safety requirements and warnings.
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
• Technical personnel from the areas mechanical engineering, plant construction and electrical engi-
neering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Personnel must not be under the influence of alcohol, drugs or strong medication.
Work clothing and personal protective equipment
When working, always wear the necessary personal protective equipment (e.g. safety shoes, ear protec-
tors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
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1.3 Transport
Transport without flange-mounted gearbox
A max. permissible diagonal
pull 70°
B max. permissible diagonal
pull 35°
Illustration is also valid for 12V/16V2000Mxx engines
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Transport with flange-mounted gearbox
Illustration is also valid for 12V/16V2000Mxx engines
Only use the lifting eyes provided to lift the engine.
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.
The engine must only be transported in installation position, max. permissible diagonal pull with flange-
mounted gearbox is 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear-
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting down the engine following transportation
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 down engines onto the oil pan unless expressly permitted by MTU on an engine-specific base.
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1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica-
tions before putting the product into service. All necessary approvals must be granted by the relevant
authorities and all requirements for initial startup must be fulfilled.
When putting the product into operation, always ensure that
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is
switched on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• Keep clear of the service room during the first operating hours. Hazardous gases may occur as a re-
sult of the combustion of paints or oils.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
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.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re-
gard to present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
The procedures for emergencies, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely neces-
sary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly in-
structed to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder
agent.
Operation of electrical equipment
During operation of electrical devices, certain elements of these devices are live/under high voltage.
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