MTU 16V2000S56 User manual

Operating Instructions
Diesel engine
12V2000S56
16V2000S56
12V2000C66
16V2000C66
12V2000C66R
12V2000S96
16V2000S96
MS150094/02E

© 2015 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
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 provisions for all products 5
1.2 Personnel and organizational requirements 7
1.3 Transport 8
1.4 Safety precautions when working on the
engine 9
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 12
1.6 Standards for safety notices in the text 14
2 Product Summary
2.1 Engine – Overview 15
2.2 Engine side and cylinder designations 17
2.3 Engine – Main dimensions 18
2.4 Firing order 19
2.5 Technical Data 20
2.5.1 12/16V 2000 C66 engine data 20
2.5.2 Engine data 12V2000C66R 24
2.5.3 Engine data 12/16V2000S56 28
2.5.4 12/16V 2000 S96 engine data 31
3 Operation
3.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 34
3.2 Putting the engine into operation after
scheduled out-of-service-period 35
3.3 Starting the engine 36
3.4 Operational checks 37
3.5 Engine shutdown 38
3.6 Emergency engine stop 39
3.7 After stopping the engine – Putting the
engine out of operation 40
3.8 Plant – Cleaning 41
4 Maintenance
4.1 Maintenance task reference table [QL1] 42
5 Troubleshooting
5.1 Troubleshooting 43
5.2 Engine Control Unit – ECU9 fault messages 46
6 Task Description
6.1 Engine 74
6.1.1 Engine – Barring manually 74
6.1.2 Engine – Barring with starting system 75
6.2 Crankcase Breather 76
6.2.1 Crankcase breather – Oil mist fine separator
replacement 76
6.3 Valve Drive 77
6.3.1 Valve clearance – Check and adjustment 77
6.3.2 Cylinder head cover – Removal and
installation 80
6.4 Injector 81
6.4.1 Injector – Replacement 81
6.4.2 Injector – Removal and installation 82
6.5 Fuel System 87
6.5.1 HP fuel line and pressure pipe neck –
Replacement 87
6.5.2 Fuel system – Venting 89
6.5.3 Fuel – Draining 90
6.6 Fuel Filter 91
6.6.1 Fuel filter – Replacement 91
6.6.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 92
6.6.3 Fuel prefilter – Draining 93
6.6.4 Fuel prefilter – Flushing 94
6.6.5 Fuel prefilter – Filter element replacement 96
6.7 Air Filter 98
6.7.1 Air filter – Replacement 98
6.8 Air Intake 99
6.8.1 Service indicator – Check 99
6.9 Exhaust Gas Recirculation 100
6.9.1 Exhaust gas recirculation flaps – Overview 100
6.9.2 Exhaust gas circulation ‒ Checking flap
operation 101
6.10 Lube Oil System, Lube Oil Circuit 102
6.10.1 Engine oil – Level check 102
6.10.2 Engine oil – Change 103
6.11 Oil Filtration / Cooling 104
6.11.1 Engine oil filter – Replacement 104
6.11.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 105
6.12 Coolant Circuit, General, High-Temperature
Circuit 107
6.12.1 Drain and vent points 107
6.12.2 Engine coolant – Level check 112
6.12.3 Engine coolant – Change 113
6.12.4 Engine coolant – Draining 114
6.12.5 Engine coolant – Filling 115
6.12.6 Engine coolant pump – Relief bore check 117
6.12.7 Engine coolant – Sample extraction and
analysis 118
MS150094/02E 2015-05 | Table of Contents | 3
DCL-ID: 0000007590 - 008

6.12.8 Coolant filter – Replacement 119
6.13 Low-Temperature Circuit 120
6.13.1 Intercooler – Vent and drain points 120
6.13.2 Charge-air coolant – Level check 121
6.13.3 Charge-air coolant – Change 122
6.13.4 Charge-air coolant – Filling 123
6.13.5 Charge-air coolant – Draining 125
6.13.6 Charge-air coolant pump – Relief bore check 126
6.14 Belt Drive 127
6.14.1 Drive belt – Condition check 127
6.14.2 Drive belt – Tension check 128
6.14.3 Drive belt – Tension adjustment 130
6.14.4 Drive belt – Replacement 132
6.15 Battery-Charging Generator 133
6.15.1 Battery-charging generator drive – Drive belt
replacement 133
6.16 Engine Governor 134
6.16.1 Engine governor – Overview 134
6.16.2 Engine governor – Removal 135
6.16.3 Engine governor – Installation 136
6.16.4 Engine governor plug connections – Check 137
6.17 Wiring (General) for Engine/Gearbox/Unit 138
6.17.1 Engine cabling – Check 138
6.17.2 Lambda, NOx and humidity sensors –
Overview 139
6.17.3 Lambda sensor – Replacement 140
6.17.4 NOx sensor – Replacement 142
6.17.5 Humidity sensor – Replacement 144
6.18 Accessories for (Electronic) Engine
Governor / Control System 146
6.18.1 Resetting CDC parameter and entering IIG
with DiaSys® 146
6.18.2 Engine governor and connector – Cleaning 147
6.18.3 Engine governor plug connections – Check 148
7 Appendix A
7.1 Abbreviations 149
7.2 MTU contact persons/service partners 151
8 Appendix B
8.1 Special Tools 152
8.2 Index 161
4 | Table of Contents | MS150094/02E 2015-05
DCL-ID: 0000007590 - 008

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 infor-
mation 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 accompanying specifi-
cations.
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 rele-
vant 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 Lubricants
Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding 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 use-
ful 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 re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product may only be operated in explosive atmospheres if it was certified for such operating conditions.
Any other use, in particular malpractice, 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 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 author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
MS150094/02E 2015-05 | Safety | 5
TIM-ID: 0000040530 - 007

Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents 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, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
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 operational
life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted 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.
6 | Safety | MS150094/02E 2015-05
TIM-ID: 0000040530 - 007

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 transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These 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 engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, and
transport.
Personnel must not be under the influence of alcohol, drugs, or strong medication.
Working clothes and personal protective equipment
When working, always wear the necessary personal protective equipment (for example safety shoes, ear pro-
tectors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
MS150094/02E 2015-05 | Safety | 7
TIM-ID: 0000040531 - 007

1.3 Transport
Transport
Also valid for 12V engines
Only use 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.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bearing
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 transporta-
tion.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the en-
gine must be secured against moving and tilting.
Setting the engine down after transport
Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-case
basis .
8 | Safety | MS150094/02E 2015-05
TIM-ID: 0000024082 - 001

1.4 Safety precautions when working on the engine
Safety regulations prior to 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 suita-
ble collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
If special tools are specified, these special tools or other suitable tools must be used.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
The following applies to starters with copper-beryllium alloy pinions:
• 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 flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work
Take special care when removing ventilation or plug screws from the product. Cover the screw or plug with a
rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down . Use the specified lifting equipment for all components.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
MS150094/02E 2015-05 | Safety | 9
TIM-ID: 0000040535 - 011

Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that O-rings are not installed in a slanted/twisted condition.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly. If necessary, coat the com-
ponents with a suitable corrosion inhibitor.
Safety regulations following maintenance and repair work
Before barring, make sure that nobody is standing in the danger zone of the product.
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 removed
(especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Make sure the grounding device is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current may otherwise induce an interference voltage in the wiring harnesses which could conceiva-
bly damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal
Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
10 | Safety | MS150094/02E 2015-05
TIM-ID: 0000040535 - 011