MTU 12V2000G series User manual
Operating Instructions
Diesel engine
12V2000Gx6x
16V2000Gx6x
MS15054/00E
Engine model kW/cyl. Application group
12V2000G16S 59.7 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G26S 67.5 kW/cyl. 3B, continuous operation, variable load, ICXN
3F, mains backup mode, unlimited, ICXN
3G, continuous operation, time-limited, ICXN
12V2000G36S 74.8 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G76S 74.2 kW/cyl. 3D, standby power, fuel stop power, IFN
3H, mains backup mode, special qualifications
12V2000G86S 82.3 kW/cyl. 3D, standby power, fuel stop power, IFN
16V2000G26S 62.4 kW/cyl. 3B, continuous operation, variable load, ICXN
3F, mains backup mode, unlimited, ICXN
3G, continuous operation, time-limited, ICXN
16V2000G76S 68.6 kW/cyl. 3D, standby power, fuel stop power, IFN
3H, mains backup mode, special qualifications
16V2000G86S 85.7 kW/cyl. 3D, standby power, fuel stop power, IFN
3H, mains backup mode, special qualifications
Table 1: Applicability
© 2015 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming 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 provisions for all products 5
1.2 Personnel and organizational requirements 7
1.3 Transport 8
1.4 Safety regulations for startup and operation 9
1.5 Safety precautions when working on the
engine 10
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13
1.7 Standards for safety notices in the text 15
2 General Information
2.1 Engine side and cylinder designations 16
2.2 Engine – Overview 17
2.3 Sensors and actuators – Overview 18
3 Technical Data
3.1 Engine data 12V/16V2000Gx6S, 3B,
continuous operation, variable load, ICXN,
optimized fuel consumption (provisional) 22
3.2 Engine data 12V/16V2000Gx6S, 3D,
standby current, fuel stop power (IFN),
optimized fuel consumption (provisional) 26
3.3 Engine data 12V/16V2000Gx6S, 3F,
standby operation mode, unlimited, ICXN,
optimized fuel consumption (provisional) 30
3.4 Engine data 12V/16V2000Gx6S, 3G,
continuous operation, time-limited, ICXN,
optimized fuel consumption (provisional) 33
3.5 Engine data 12V/16V2000Gx6S, 3H,
standby operation mode, special
qualifications, optimized fuel consumption
(provisional) 36
3.6 Engine data 12V/16V2000Gx6S, 3B,
continuous operation, variable load, ICXN,
EPA Nonroad T2 (40CFR89) (provisional) 40
3.7 Engine data 12V/16V2000Gx6S, 3D,
standby current, fuel stop power (IFN), EPA
Nonroad T2 (40CFR89) (provisional) 44
3.8 Engine data 12V/16V2000Gx6S, 3F,
standby operation mode, unlimited, ICXN,
EPA Nonroad T2 (40CFR89) and EPA
Stationary EMERG T2 (40CFR60)
(provisional) 48
3.9 Engine data 12V/16V2000Gx6S, 3G,
continuous operation, time-limited, ICXN,
EPA Nonroad T2 (40CFR89) (provisional) 52
3.10 Engine data 12V/16V2000Gx6S, 3H,
standby operation mode, special
qualifications, EPA Nonroad T2 (40CFR89)
and EPA Stationary EMERG T2 (40CFR60)
(provisional) 55
3.11 Firing order 59
3.12 Engine – Main dimensions 60
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 61
4.2 Putting the engine into operation after
scheduled out-of-service-period 62
4.3 Starting the engine 63
4.4 Operational checks 64
4.5 Emission label – Check 65
4.6 Engine shutdown 66
4.7 Emergency engine stop 67
4.8 After stopping the engine 68
4.9 Plant – Cleaning 69
5 Maintenance
5.1 Maintenance task reference table [QL1] 70
6 Troubleshooting
6.1 Troubleshooting 71
6.2 Engine Control Unit – ECU9 fault messages 74
7 Task Description
7.1 Engine 102
7.1.1 Engine – Cranking manually 102
7.1.2 Engine – Barring with starting system 103
7.2 Crankcase Breather 104
7.2.1 Crankcase breather – Oil mist fine separator
replacement 104
7.3 Valve Drive 105
7.3.1 Valve clearance – Check and adjustment 105
7.3.2 Cylinder head cover – Removal and
installation 108
7.4 Injector 109
7.4.1 Injector ‒ Replacement 109
7.4.2 Injector – Removal and installation 110
7.4.3 Injector functions 116
7.5 Fuel System 117
7.5.1 Fuel system – Venting 117
7.5.2 Fuel – Draining 118
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7.6 Fuel Filter 119
7.6.1 Fuel filter – Replacement 119
7.6.2 Fuel prefilter – Draining 120
7.6.3 Fuel prefilter – Filter element replacement 121
7.6.4 Fuel prefilter – Venting 123
7.7 Air Filter 124
7.7.1 Air filter – Replacement 124
7.7.2 Air filter – Removal and installation 125
7.8 Air Intake 126
7.8.1 Service indicator – Signal ring position check 126
7.9 Starting Equipment 127
7.9.1 Electric starter ‒ Overview 127
7.9.2 Starter – Removal 128
7.9.3 Starter ‒ Installation 129
7.10 Lube Oil System, Lube Oil Circuit 130
7.10.1 Engine oil – Level check 130
7.10.2 Engine oil – Change 131
7.11 Oil Filtration / Cooling 132
7.11.1 Engine oil filter – Replacement 132
7.11.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 133
7.12 Coolant Circuit, General, High-Temperature
Circuit 135
7.12.1 Engine coolant – Level check 135
7.12.2 Engine coolant – Change 136
7.12.3 Engine coolant – Draining 137
7.12.4 Engine coolant – Filling 138
7.12.5 Engine coolant pump – Relief bore check 140
7.12.6 Engine coolant – Sample extraction and
analysis 141
7.13 Low-Temperature Circuit 142
7.13.1 Charge-air coolant – Filling 142
7.13.2 Charge-air coolant – Draining 144
7.13.3 Charge-air coolant – Change 145
7.13.4 Charge-air coolant – Level check 146
7.13.5 Charge-air coolant pump – Relief bore check 147
7.13.6 Intercooler – Checking condensate drain for
coolant discharge and obstructions 148
7.14 Belt Drive 149
7.14.1 Drive belt – Condition check 149
7.14.2 Drive belt – Tension check 150
7.14.3 Drive belt ‒ Tension adjustment 152
7.14.4 Drive belt – Replacement 153
7.15 Battery-Charging Generator 154
7.15.1 Battery-charger drive – Drive belt replacement 154
7.16 Fuel Supply System 156
7.16.1 Differential pressure gage – Check 156
7.16.2 Coolant level sensor – Check 157
7.16.3 Pump capacity – Check 158
7.17 Engine Governor 159
7.17.1 Engine control system – Overview 159
7.17.2 Engine governor – Removal and installation 160
7.17.3 Engine governor plug connections – Check 161
7.18 Wiring (General) for Engine/Gearbox/Unit 162
7.18.1 Engine cabling – Check 162
7.19 Accessories for (Electronic) Engine
Governor / Control System 163
7.19.1 Engine governor and connector – Cleaning 163
8 Appendix A
8.1 List of abbreviations 164
8.2 MTU contact persons/service partners 166
9 Appendix B
9.1 Special Tools 167
9.2 Index 175
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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 infor-
mation 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 accompanying specifi-
cations.
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 rele-
vant 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 Lubricants
Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding 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 use-
ful 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 re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product may only be operated in explosive atmospheres if it was certified for such operating conditions.
Any other use, in particular malpractice, 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 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 author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized 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 compo-
nents 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, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
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 operational
life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted 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 transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These 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 engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, and
transport.
Personnel must not be under the influence of alcohol, drugs, or strong medication.
Working clothes and personal protective equipment
When working, always wear the necessary personal protective equipment (for example safety shoes, ear pro-
tectors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
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1.3 Transport
DANGER Suspended load
Danger to life
• Never stand under suspended loads!
• Wear appropriate personal protective equipment.
Transport
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta-
tion.
Only use the lifting eyes provided to transport the engine.
Use only suitable transport and lifting gear.
Take the engine's center of gravity into account.
Transport the engine only in installation position: max. permissible diagonal pull 10 degrees.
Remove any loose parts from the engine.
Lift/lower the engine slowly. Ensure that lifting cables/chains do not touch the engine or any of its compo-
nents. Readjust lifting tackle as necessary.
If the engine is supplied with special aluminum foil packing: Lift the engine at the lifting eyes of the bearing
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 transporta-
tion (if applicable).
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the en-
gine must be secured against moving and tilting.
Setting down the engine following transportation
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 down engines onto the oil pan unless expressly permitted by MTU on an engine-specific base.
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1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
When putting the product into operation, always ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• Hazardous gases may occur as a result of the combustion of paints or oils in the first operating hours of
the product. Enter the service room only with a suitable breathing protection.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems are working properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation
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 regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
Practice the procedures for emergencies, in particular, emergency stop, on a regular basis.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.
Operation of electrical equipment
During operation of electrical devices, certain elements of these devices are live/under high voltage.
Observe the warning information applicable to the devices.
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1.5 Safety precautions when working on the engine
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 suita-
ble 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 ventilated.
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 start-
ers are fitted.
Disconnect the control equipment from the product.
If special tools are specified, these special tools or other suitable tools must be used.
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 disassem-
bly.
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 en-
gines 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).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
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