MTU 16V2000M72 User manual

Operating Instructions
Diesel engine
12 V 2000 M72
16V 2000 M72
M015650/03E

Printed in Germany
© 2011 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 permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Commissioning Note
Important
Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐
ranty, spare parts, etc.).

Table of Contents
1 Safety
1.1 General conditions 7
1.2 Personnel and organizational requirements 8
1.3 Transport 9
1.4 Safety regulations for startup and operation 10
1.5 Safety precautions when working on the
engine 11
1.6 Auxiliary materials, fire prevention and
environmental protection 13
1.7 Conventions for safety instructions in the
text 16
2 General Information
2.1 Engine side and cylinder designations 17
2.2 Product description 18
2.3 Engine layout 24
2.4 Sensors, actuators and injectors –
Overview 26
3 Technical Data
3.1 12V 2000 M72 engine data: Engine-
mounted heat exchanger, EPA stage 2 31
3.2 12 V 2000 M72 engine data: remote heat
exchanger, EPA stage 2 34
3.3 16V 2000 M72 engine data: Engine-
mounted heat exchanger, EPA stage 2 37
3.4 16V 2000 M72 engine data: Separate heat
exchanger, EPA stage 2 40
3.5 Firing order 43
3.6 Engine – Main dimensions 44
4 Operation
4.1 Engine – Putting the engine into operation
(out of service > 3 months) 45
4.2 Putting the engine into operation after
scheduled out-of-service period 46
4.3 Tasks after extended out-of-service periods
(>3 weeks) 47
4.4 Checks prior to start-up 48
4.5 Fuel treatment system – Start-up 49
4.6 Operational checks 51
4.7 Fuel treatment system – Switching on 52
4.8 Starting the engine 53
4.9 Stopping the engine 54
4.10 Emergency stop 55
4.11 After stopping the engine 56
4.12 Fuel treatment system – Shutdown 57
4.13 Plant – Cleaning 58
5 Maintenance
5.1 Maintenance task reference table [QL1] 59
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting 60
6.2 Troubleshooting 61
7 Task Description
7.1 SOLAS 64
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 64
7.1.2 SOLAS shielding - Installation 65
7.1.3 Installation locations for SOLAS shielding 66
7.2 Engine 72
7.2.1 Engine – Barring manually 72
7.2.2 Engine – Barring with starting system 73
7.3 Cylinder Liner 74
7.3.1 Cylinder liner – Endoscopic examination 74
7.3.2 Instructions and comments on endoscopic
and visual examination of cylinder liners 76
7.4 Crankcase Breather 78
7.4.1 Crankcase breather – Cleaning oil pre-
separator element 78
7.4.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 79
7.5 Valve Drive 81
7.5.1 Valve clearance – Check and adjustment 81
7.5.2 Cylinder-head cover – Removal and
installation 84
7.6 Injection Valve / Injector 85
7.6.1 Injector – Replacement 85
7.6.2 Injector – Removal and installation 86
7.7 Fuel System 88
7.7.1 Fuel system – Venting 88
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7.8 Fuel Filter 89
7.8.1 Fuel filter – Replacement 89
7.8.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 91
7.8.3 Fuel prefilter – Draining 92
7.8.4 Fuel prefilter – Flushing 93
7.8.5 Fuel prefilter – Filter element replacement 95
7.9 Charge-Air Cooling 97
7.9.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 97
7.10 Air Filter 98
7.10.1 Air filter – Replacement 98
7.10.2 Air filter – Removal and installation 99
7.11 Air Intake 100
7.11.1 Service indicator - Signal ring position check 100
7.12 Starting Equipment 101
7.12.1 Starter – Condition check 101
7.13 Lube Oil System, Lube Oil Circuit 102
7.13.1 Engine oil – Level check 102
7.13.2 Engine oil – Change 103
7.14 Oil Filtration / Cooling 104
7.14.1 Engine oil filter – Replacement 104
7.14.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 106
7.15 Coolant Circuit, General, High-
Temperature Circuit 109
7.15.1 Drain and venting points 109
7.15.2 Engine coolant – Level check 115
7.15.3 Engine coolant – Change 116
7.15.4 Engine coolant – Draining 117
7.15.5 Engine coolant – Filling 118
7.15.6 HT coolant pump — Relief bore check 119
7.15.7 Engine coolant – Sample extraction and
analysis 120
7.15.8 Coolant filter – Replacement 121
7.16 Raw Water Pump with Connections 122
7.16.1 Raw water pump – Relief bore check 122
7.17 Belt Drive 123
7.17.1 Drive belt – Condition check 123
7.18 Battery-Charging Generator 124
7.18.1 Battery-charging generator drive – Drive belt
replacement 124
7.19 Fuel Treatment System 125
7.19.1 Water drain valve – Check 125
7.19.2 Differential pressure gauge – Check 126
7.19.3 Water level probe (3-in-1 rod electrode) –
Check 127
7.19.4 Pump capacity – Check 128
7.19.5 Coalescer filter element – Replacement 129
7.20 Wiring (General) for Engine/Gearbox/Unit 131
7.20.1 Engine wiring – Check 131
7.21 Accessories for (Electronic) Engine
Governor / Control System 132
7.21.1 Engine governor and connectors – Cleaning 132
7.21.2 Engine governor – Checking plug-in
connections 133
7.21.3 EMU – Checking plug-in connections 134
7.21.4 Engine governor – Carry out self-test 135
7.21.5 EMU and connectors – Cleaning 136
7.21.6 ECU 7 engine governor – Removal and
installation 137
7.21.7 Engine monitoring unit – Removal and
installation 138
8 Appendix A
8.1 Abbreviations 139
8.2 MTU contacts/service partners 142
9 Appendix B
9.1 Special Tools 143
9.2 Index 146
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present 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
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the operating instructions and mainte‐
nance and repair specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.
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1.3 Transport
Transport
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 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 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.
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1.4 Safety regulations for startup and operation
Safety requirements for initial operation
Prior to initial operation of the unit, install the assembly or unit according to the specifications and check
the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that nobody is in the danger area of moving machine parts.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the signaling and alarm systems work properly.
Safety requirements for operators
The procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the control and display elements.
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.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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