MTU 12V2000Gx6x User manual

Operating Instructions
Diesel engine
12V2000Gx6x
16V2000Gx6x
18V2000Gx6x
12V2000Bx6x
16V2000Bx6x
18V2000Bx6x
MS150118/01E

Engine model kW/cyl. rpm Application group
12V2000B26F 55 kW/cyl. 1500 3A, continuous operation, without restric-
tions
12V2000B76 switchable 59/60 kW/cyl. 1500/1800 3B, continuous operation, variable load,
ICXN
16V2000B26F 44 kW/cyl. 1500 3A, continuous operation, without restric-
tions
16V2000B76 switchable 56/62 kW/cyl. 1500/1800 3B, continuous operation, variable load,
ICXN
18V2000B26F 49 kW/cyl. 1500 3A, continuous operation, without restric-
tions
18V2000B76 switchable 61/61 kW/cyl. 1500/1800 3B, continuous operation, variable load,
ICXN
12V2000G16F 55 kW/cyl. 1500 3B, continuous operation, variable load,
ICXN
12V2000G26F 59 kW/cyl. 1500 3B, continuous operation, variable load,
ICXN
16V2000G16F 50 kW/cyl. 1500 3B, continuous operation, variable load,
ICXN
16V2000G26F 56 kW/cyl. 1500 3B, continuous operation, variable load,
ICXN
16V2000G36F 63 kW/cyl. 1500 3B, continuous operation, variable load,
ICXN
18V2000G26F 61 kW/cyl. 1500 3B, continuous operation, variable load,
ICXN
Table 1: Overview of validity
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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 provisions for all products 5
1.2 Personnel and organizational requirements 7
1.3 Transport 8
1.4 Safety regulations for maintenance and
repair work 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 General Information
2.1 Engine side and cylinder designations 15
2.2 Engine – Overview 16
3 Technical Data
3.1 12V/16V/18V2000B26F – Engine data 19
3.2 Engine data 12V/16V/
18V2000B76switchable 1500 rpm 25
3.3 Engine data 12V/16V/
18V2000B76switchable 1800 rpm 31
3.4 12V/16V2000G16F – Engine data 37
3.5 12V/16V/18V2000G26F – Engine data 41
3.6 16V2000G36F – Engine data 46
3.7 Firing order 50
3.8 Engine – Main dimensions 51
4 Operation
4.1 Preparing startup after long out-of-service
periods (>3 months) 52
4.2 Preparations for startup after scheduled out-
of-service-period 53
4.3 Starting the engine 54
4.4 Operation monitoring 55
4.5 Engine shutdown 56
4.6 Emergency engine stop 57
4.7 After stopping the engine 58
4.8 Plant – Cleaning 59
5 Maintenance
5.1 Maintenance schedule task reference table
[QL1] 60
6 Troubleshooting
6.1 Troubleshooting 61
6.2 Engine Control Unit – ECU9 fault messages 64
7 Task Description
7.1 Engine 92
7.1.1 Engine – Cranking manually 92
7.1.2 Engine – Barring with starting system 93
7.2 Crankcase Breather 94
7.2.1 Crankcase breather – Oil mist fine separator
replacement 94
7.3 Valve Drive 95
7.3.1 Valve clearance – Check and adjustment 95
7.3.2 Cylinder head cover – Removal and
installation 98
7.4 Injection Valve / Injector 99
7.4.1 Injector ‒ Replacement 99
7.4.2 Injector – Removal and installation 100
7.4.3 Injector functions 106
7.5 Fuel System 107
7.5.1 Fuel system – Venting 107
7.5.2 Fuel – Draining 108
7.6 Fuel Filter 109
7.6.1 Fuel filter – Replacement 109
7.6.2 Fuel prefilter – Differential pressure gage
check and adjustment of gage 110
7.6.3 Fuel prefilter – Draining 111
7.6.4 Fuel prefilter – Flushing 112
7.6.5 Fuel prefilter – Filter element replacement 114
7.7 Air Filter 115
7.7.1 Air filter – Replacement 115
7.7.2 Air filter – Removal and installation 116
7.8 Air Intake 117
7.8.1 Service indicator – Signal ring position check 117
7.9 Starting Equipment 118
7.9.1 Electric starter ‒ Overview 118
7.9.2 Starter – Removal 119
7.9.3 Starter ‒ Installation 120
7.10 Lube Oil System, Lube Oil Circuit 121
7.10.1 Engine oil – Level check 121
7.10.2 Engine oil – Change 122
7.11 Oil Filtration / Cooling 123
7.11.1 Engine oil filter – Replacement 123
7.11.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 124
7.12 Coolant Circuit, General, High-Temperature
Circuit 126
7.12.1 Engine coolant – Level check 126
7.12.2 Engine coolant – Change 127
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7.12.3 Engine coolant ‒ Draining 128
7.12.4 Engine coolant – Filling 129
7.12.5 Engine coolant pump – Relief bore check 131
7.12.6 Engine coolant – Sample extraction and
analysis 132
7.13 Belt Drive 133
7.13.1 Drive belt – Condition check 133
7.13.2 Drive belt – Tension check 134
7.13.3 Drive belt ‒ Tension adjustment 136
7.13.4 Drive belt – Replacement 137
7.14 Battery-Charging Generator 138
7.14.1 Battery-charger drive – Drive belt replacement 138
7.15 Fuel Supply System 140
7.15.1 Differential pressure gage – Check 140
7.15.2 Coolant level sensor – Check 141
7.15.3 Pump capacity – Check 142
7.15.4 Coalescer filter element – Replacement 143
7.16 Engine Governor 145
7.16.1 Engine control system – Overview 145
7.16.2 Engine governor – Removal and installation 146
7.16.3 Engine governor plug connections – Check 147
7.17 Wiring (General) for Engine/Gearbox/Unit 148
7.17.1 Engine cabling – Check 148
7.18 Accessories for (Electronic) Engine
Governor / Control System 149
7.18.1 Engine governor and connector – Cleaning 149
8 Appendix A
8.1 List of 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
Taking the engine's center of gravity into account
For information regarding the center of gravity of the engine, refer to the installation/arrangement
drawing of the engine/genset/system.
Transport
• Lift the engine/genset/system only with the lifting eyes provided.
• Only use transport and lifting devices approved by MTU.
• The engine/genset/system must only be transported in installation position.
• Max. permissible diagonal pull 10°.
• If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes
of the trestle or use a means of transportation which is appropriate for the given weight (forklift
truck).
• Prior to transporting the engine/genset/system, it is imperative to install the transport locking de-
vice for the crankshaft.
• Prior to transporting the engine/genset/system, it is imperative to install the transport locks for the
engine mounts.
• Secure the engine/genset/system such as to preclude tipping during transport.
• Secure the engine/system/genset as to preclude slipping and tipping when driving up or down in-
clines and ramps.
Setting the engine down after transport
• Make sure that the consistency and load-bearing capacity of the ground or support surface is ade-
quate.
• Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by
MTU on a case-to-case basis.
• Place the engine/genset/system on a firm, flat surface only.
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1.4 Safety regulations for maintenance and repair work
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
suitable 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 venti-
lated.
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
starters are fitted.
Disconnect the control equipment from the product.
Use special tools if they are specified for the relevant work.
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 dis-
assembly.
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
engines 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).
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Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
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 ina 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
components 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 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
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
conceivably 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 HP 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 plunger extended.
• During the removal procedure, screw on device with plunger retracted.
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