MTU 16V2000S96 - Table of Contents

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
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