MTU 12V2000B26F User manual
Operating Instructions
Diesel engine
12 V 2000 Gx6 F
16 V 2000 Gx6 F
18 V 2000 Gx6 F
12 V 2000 Bx6 F
16 V 2000 Bx6 F
18 V 2000 Bx6 F
12 V 2000 B76 switchable
16 V 2000 B76 switchable
18 V 2000 B76 switchable
MS150118/00E
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
© 2014 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 consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming 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 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, 16, 18 V 2000 B26 F 18
3.2 Engine data 12, 16, 18 V 2000 B76
switchable 1500 rpm 24
3.3 Engine data 12, 16, 18 V 2000 B76
switchable 1800 rpm 30
3.4 Engine data 12, 16 V 2000 G16 F 36
3.5 Engine data 12, 16, 18 V 2000 G26 F 40
3.6 Engine data 12, 16, 18 V 2000 G76 F 45
3.7 Engine data 16 V 2000 G36 F 50
3.8 Firing order 54
3.9 Engine – Main dimensions 55
4 Operation
4.1 Preparing startup after long out-of-service
periods (>3 months) 56
4.2 Preparations for startup after scheduled out-
of-service-period 57
4.3 Starting the engine 58
4.4 Operation monitoring 59
4.5 Engine ‒ Stopping 60
4.6 Emergency stop 61
4.7 After stopping the engine 62
4.8 Plant – Cleaning 63
5 Maintenance
5.1 Maintenance schedule ‒ Task reference
table [QL1] 64
6 Troubleshooting
6.1 Troubleshooting 65
7 Task Description
7.1 Engine 68
7.1.1 Engine – Cranking manually 68
7.1.2 Engine – Barring with starting system 69
7.2 Crankcase Breather 70
7.2.1 Crankcase breather – Oil mist fine separator
replacement 70
7.3 Valve Drive 71
7.3.1 Valve clearance – Check and adjustment 71
7.3.2 Cylinder head cover – Removal and
installation 74
7.4 Injection Valve / Injector 75
7.4.1 Injector ‒ Replacement 75
7.4.2 Injector – Removal and installation 76
7.4.3 Injector functions 81
7.5 Fuel System 82
7.5.1 HP fuel line and pressure pipe connection ‒
Replacement 82
7.5.2 Fuel system – Venting 85
7.5.3 Fuel – Draining 86
7.6 Fuel Filter 87
7.6.1 Fuel filter – Replacement 87
7.6.2 Fuel prefilter – Differential pressure gage
check and adjustment of gage 88
7.6.3 Fuel prefilter – Draining 89
7.6.4 Fuel prefilter – Flushing 90
7.6.5 Fuel prefilter – Filter element replacement 92
7.7 Air Filter 93
7.7.1 Air filter – Replacement 93
7.7.2 Air filter – Removal and installation 94
7.8 Air Intake 95
7.8.1 Service indicator – Signal ring position check 95
7.9 Starting Equipment 96
7.9.1 Electric starter – Overview 96
7.9.2 Starter – Removal 97
7.9.3 Starter ‒ Installation 98
7.10 Lube Oil System, Lube Oil Circuit 99
7.10.1 Engine oil – Level check 99
7.10.2 Engine oil – Change 100
7.11 Oil Filtration / Cooling 101
7.11.1 Engine oil filter – Replacement 101
7.11.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 102
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7.12 Coolant Circuit, General, High-Temperature
Circuit 104
7.12.1 Drain and vent points 104
7.12.2 Engine coolant – Level check 108
7.12.3 Engine coolant – Change 109
7.12.4 Engine coolant ‒ Draining 110
7.12.5 Engine coolant – Filling 111
7.12.6 Engine coolant pump – Relief bore check 113
7.12.7 Engine coolant – Sample extraction and
analysis 114
7.13 Belt Drive 115
7.13.1 Drive belt – Condition check 115
7.13.2 Drive belt – Tension check 116
7.13.3 Drive belt ‒ Tension adjustment 118
7.13.4 Drive belt – Replacement 119
7.14 Battery-Charging Generator 120
7.14.1 Battery-charger drive – Drive belt replacement 120
7.15 Fuel Supply System 122
7.15.1 Water drain valve – Check 122
7.15.2 Differential pressure gauge – Check 123
7.15.3 Water level probe (3-in-1 rod electrode) –
Check 124
7.15.4 Pump capacity – Check 125
7.15.5 Coalescer filter element – Replacement 126
7.16 Engine Governor 128
7.16.1 Engine control system – Overview 128
7.16.2 Engine control system – Removal and
installation 129
7.16.3 Engine governor plug connections – Check 130
7.17 Wiring (General) for Engine/Gearbox/Unit 131
7.17.1 Еngine wiring ‒ Check 131
7.18 Accessories for (Electronic) Engine
Governor / Control System 132
7.18.1 Engine governor and connectors – Cleaning 132
7.18.2 Engine governor plug connections – Check 133
8 Appendix A
8.1 List of abbreviations 134
8.2 MTU contact persons/service partners 136
9 Appendix B
9.1 Special Tools 137
9.2 Index 145
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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
Use only 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.
Transport the engine in the installation position only, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine by the lifting eyes of the trans-
port pallet or transport with equipment suitable for heavy loads (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 transportation. The engine must be additionally secured against
slipping or tilting when going up or down inclines and ramps.
Setting down the engine following transportation
Set the engine down on a firm, level surface only.
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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This manual suits for next models
11
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