MTU 12 V 2000 Gx6F User manual
Operating Instructions
Diesel Engine
12 V 2000 Gx6F
MS150111/01E
Engine model kW/cyl. Application group
12V2000G56F 55.4 kW/cyl. 3B, continuous operation, variable
12V2000G66F 59.1 kW/cyl. 3B, continuous operation, variable
Table 1: Validity overview
© 2014 Copyright MTU Friedrichshafen GmbH
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written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
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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 requirements for all products 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety requirements for maintenance and
repair work 8
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 11
1.6 Standards for safety notices in the text 13
2 General Information
2.1 Engine side and cylinder designations 14
2.2 Engine overview 15
3 Technical Data
3.1 Engine data 12 V 2000 G56/66F 16
3.2 Firing order 19
3.3 Engine – Main dimensions 20
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 21
4.2 Putting the engine into operation after
scheduled out-of-service-period 22
4.3 Tasks after extended out-of-service periods
(>3 weeks) 23
4.4 Checks prior to start-up 24
4.5 Fuel treatment system – Putting into
operation 25
4.6 Starting the engine 28
4.7 Fuel treatment system – Switching on 29
4.8 Operational checks 30
4.9 Stopping the engine 31
4.10 Emergency stop 32
4.11 After stopping the engine 33
4.12 Fuel treatment system – Shutdown 34
4.13 Plant – Cleaning 35
5 Maintenance
5.1 Maintenance task reference table [QL1] 36
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting 38
6.2 Troubleshooting 39
7 Task Description
7.1 Engine 42
7.1.1 Engine – Barring manually 42
7.1.2 Engine – Barring with starting system 43
7.2 Crankcase Breather 44
7.2.1 Crankcase breather – Oil mist fine separator
replacement 44
7.3 Valve Drive 45
7.3.1 Valve clearance – Check and adjustment 45
7.3.2 Cylinder head cover – Removal and
installation 47
7.4 Injection Valve / Injector 48
7.4.1 Injector – Replacement 48
7.4.2 Injector – Removal and installation 49
7.4.3 Injector functions 54
7.5 Fuel System 55
7.5.1 HP fuel line and pressure pipe neck ‒
Replacement 55
7.5.2 Fuel system – Venting 58
7.5.3 Fuel – Draining 59
7.6 Fuel Filter 60
7.6.1 Fuel filter – Replacement 60
7.6.2 Fuel prefilter – Differential pressure gage
check and adjustment of gage 61
7.6.3 Fuel prefilter – Draining 62
7.6.4 Fuel prefilter – Flushing 63
7.6.5 Fuel prefilter – Filter element replacement 65
7.7 Air Filter 66
7.7.1 Air filter – Replacement 66
7.7.2 Air filter – Removal and installation 67
7.8 Air Intake 68
7.8.1 Service indicator – Signal ring position check
(optional) 68
7.9 Exhaust Gas Recirculation 69
7.9.1 Exhaust gas recirculation flaps – Overview 69
7.9.2 Exhaust gas circulation ‒ Checking flap
operation 70
7.10 Lube Oil System, Lube Oil Circuit 71
7.10.1 Engine oil – Level check 71
7.10.2 Engine oil – Change 72
7.11 Oil Filtration / Cooling 73
7.11.1 Engine oil filter – Replacement 73
7.11.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 74
7.12 Coolant Circuit, General, High-Temperature
Circuit 76
7.12.1 Drain and vent points 76
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7.12.2 Engine coolant – Level check 81
7.12.3 Engine coolant – Change 82
7.12.4 Engine coolant ‒ Draining 83
7.12.5 Engine coolant – Filling 84
7.12.6 Engine coolant pump – Relief bore check 86
7.12.7 Engine coolant – Sample extraction and
analysis 87
7.13 Low-Temperature Circuit 88
7.13.1 Intercooler – Venting and draining 88
7.13.2 Charge-air coolant – Level check 89
7.13.3 Charge-air coolant – Change 90
7.13.4 Charge-air coolant – Filling 91
7.13.5 Charge-air coolant ‒ Draining 93
7.13.6 Charge-air coolant pump – Relief bore check 94
7.14 Belt Drive 95
7.14.1 Drive belt – Condition check 95
7.14.2 Drive belt – Tension check 96
7.14.3 Drive belt – Tension adjustment 97
7.14.4 Drive belt – Replacement 98
7.15 Battery-Charging Generator 99
7.15.1 Battery-charging generator drive – Drive belt
replacement 99
7.16 Fuel Supply System 100
7.16.1 Water drain valve – Check 100
7.16.2 Differential pressure gauge – Check 101
7.16.3 Water level probe (3-in-1 rod electrode) –
Check 102
7.16.4 Pump capacity – Check 103
7.16.5 Coalescer filter element – Replacement 104
7.17 Engine Governor 106
7.17.1 Engine governor – Overview 106
7.17.2 Engine governor – Removal and installation 107
7.17.3 Engine governor plug connections – Check 108
7.18 Wiring (General) for Engine/Gearbox/Unit 109
7.18.1 Engine wiring – Check 109
7.18.2 Lambda, NOx and humidity sensors –
Overview 110
7.18.3 Lambda sensor – Replacement 111
7.18.4 NOx sensor – Replacement 113
7.18.5 Humidity sensor – Replacement 115
7.19 Accessories for (Electronic) Engine
Governor / Control System 117
7.19.1 Engine governor and connectors – Cleaning 117
7.19.2 Engine governor plug connections – Check 118
8 Appendix A
8.1 List of abbreviations 119
8.2 MTU contact persons/service partners 121
9 Appendix B
9.1 Special Tools 122
9.2 Index 131
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1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended 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 management/parameters)
• In compliance with all safety regulations and in accordance 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 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 re-
sulting from improper, non-intended use.
Changes or modifications
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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1.2 Personnel and organizational requirements
Organizational measures of the operator
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.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
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
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment
Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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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 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 requirements for maintenance and repair work
Safety requirements before commencing 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 collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• 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 interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.
Safety requirements during maintenance and repair work
Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
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Pay particular attention to cleanliness at all times.
Safety requirements after completing maintenance and repair work
Ensure that all personnel is clear of danger zones before cranking.
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
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the 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 function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries
Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
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Working on electrical/electronic assemblies
Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cabling to lines bearing fluids.
Do not use cable ties to secure cabling.
Always use connector pliers to tighten union nuts on connectors.
Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Working with laser equipment
Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.
Measuring component deviations
Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C.
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Table of contents
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