MTU 12V2000Gx5 User manual
Operating Instructions
Diesel engine
12V2000Gx5, Gx5 TB
16V2000Gx5, Gx5 TB
18V2000Gx5, Gx5 TB
Application group 3B
MS15019/04E
Engine model kW/cyl. Application group
12V2000G25 48.3 kW/cyl. 3B, continuous operation, variable load, ICXN
12V 2000 G25-TB 48.3 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G45 59.2 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G45-TB 59.2 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G65 57.9 kW/cyl. 3B, continuous operation, variable load, ICXN
12V 2000 G65-TB 57.9 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G85 67.5 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G85-TB 67.5 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G25 50.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G25-TB 50.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G45 57.2 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G45-TB 57.2 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G65 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V 2000 G65-TB 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G85 63.1 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G85-TB 63.1 kW/cyl. 3B, continuous operation, variable load, ICXN
18V2000G65 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
18V 2000 G65-TB 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
18V2000G85 66.2 kW/cyl. 3B, continuous operation, variable load, ICXN
18V2000G85-TB 66.2 kW/cyl. 3B, continuous operation, variable load, ICXN
Table 1: Applicability
© 2016 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 Correct use for all products 6
1.3 Personnel and organizational requirements 7
1.4 Safety regulations for startup and operation 8
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 Transport
2.1 Transportation 16
2.2 Lifting requirements 17
3 General Information
3.1 Engine side and cylinder designations 18
3.2 Engine overview 19
3.3 Sensors and actuators – Overview 21
4 Technical Data
4.1 12/16/18V2000Gx5 engine data, fuel
optimized 23
4.2 12/16/18V2000Gx5-TB engine data, fuel
optimized 28
4.3 12V2000Gx5, engine data, emissions
optimized 33
4.4 16/18V2000Gx5 engine data, emissions
optimized 37
4.5 12/16/18V2000Gx5-TB engine data,
emissions optimized 43
4.6 Firing order 48
4.7 Engine – Main dimensions 49
5 Operation
5.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 50
5.2 Putting the engine into operation after
scheduled out-of-service-period 51
5.3 Engine – Starting in manual mode (test run) 52
5.4 Safety system – Override 53
5.5 Operational monitoring 54
5.6 Engine – Stopping in manual mode (test
run) 55
5.7 Engine – Emergency stop 56
5.8 After stopping the engine – Engine remains
ready for operation 57
5.9 After stopping the engine – Putting the
engine out of operation 58
6 Maintenance
6.1 Maintenance task reference table [QL1] 59
7 Troubleshooting
7.1 Fault indication on SAM display – Genset
applications 60
7.2 Troubleshooting 84
8 Task Description
8.1 Engine 87
8.1.1 Engine – Barring manually 87
8.1.2 Engine – Barring with starting system 88
8.1.3 Engine – Test run 89
8.2 Cylinder Liner 90
8.2.1 Cylinder liner – Endoscopic examination 90
8.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 92
8.3 Crankcase Breather 94
8.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 94
8.3.2 Crankcase breather – Wire mesh cleaning 96
8.4 Valve Drive 97
8.4.1 Valve clearance – Check and adjustment 97
8.4.2 Cylinder head cover – Removal and
installation 100
8.5 Injection Pump / HP Pump 101
8.5.1 Injection pump – Replacement 101
8.5.2 Injection pump – Removal and installation 102
8.6 Injection Valve / Injector 105
8.6.1 Injector – Replacement 105
8.6.2 Injector – Removal and installation 106
8.7 Fuel System 111
8.7.1 Fuel injection line – Pressure pipe neck
replacement 111
8.7.2 Fuel – Draining 114
8.7.3 Fuel pressure relief valve – Removal and
installation 116
8.7.4 Fuel system – Venting 117
8.8 Fuel Filter 119
8.8.1 Fuel filter – Replacement 119
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8.8.2 Fuel prefilter – Differential pressure gage
check and adjustment of gage 120
8.8.3 Fuel prefilter – Draining 121
8.8.4 Fuel prefilter – Flushing 123
8.8.5 Fuel prefilter – Cleaning 125
8.8.6 Fuel prefilter – Filter element replacement 126
8.9 Charge-Air Cooling General, Left-Hand Side 128
8.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 128
8.10 Air Filter 129
8.10.1 Air filter – Replacement 129
8.10.2 Air filter – Removal and installation 130
8.11 Air Intake 131
8.11.1 Service indicator – Signal ring position check 131
8.12 Starting Equipment 132
8.12.1 Air starter – Manual operation 132
8.13 Lube Oil System, Lube Oil Circuit 133
8.13.1 Engine oil – Level check 133
8.13.2 Engine oil – Change 134
8.14 Oil Filtration / Cooling 135
8.14.1 Engine oil filter – Replacement 135
8.15 Coolant Circuit, General, High-Temperature
Circuit 136
8.15.1 Engine coolant – Level check 136
8.15.2 Engine coolant – Change 137
8.15.3 Engine coolant – Draining 138
8.15.4 Engine coolant – Filling 139
8.15.5 Coolant pump – Relief bore check 141
8.16 Low-Temperature Circuit 142
8.16.1 Charge-air coolant – Filling 142
8.16.2 Charge-air coolant – Draining 144
8.16.3 Charge-air coolant – Change 145
8.16.4 Charge-air coolant – Level check 146
8.17 Battery-Charging Generator 147
8.17.1 Battery-charging generator drive – Drive-belt
check and adjustment 147
8.17.2 Battery-charging generator drive – Drive belt
replacement 149
8.18 Fan Drive 150
8.18.1 Fan drive – Drive-belt check and adjustment 150
8.18.2 Fan drive – Drive belt replacement 153
8.19 Wiring (General) for Engine/Gearbox/Unit 154
8.19.1 Engine cabling – Check 154
8.20 Accessories for (Electronic) Engine
Governor / Control System 155
8.20.1 Engine governor and connector – Cleaning 155
8.20.2 Engine governor plug connections – Check 156
8.20.3 Engine governor ECU 7 – Removal and
installation 157
9 Appendix A
9.1 Abbreviations 158
9.2 MTU Contact/Service Partners 161
10 Appendix B
10.1 Special Tools 162
10.2 Index 169
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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
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
On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional 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:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.
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1.2 Correct use for all products
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 preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion 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
• In compliance with the maintenance work and intervals specified in 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 re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. 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.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
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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1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, 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, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment
Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
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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.
Whenever the product is subsequently taken into operation 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.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• 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 signaling and alarm systems work 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 emergency procedures, especially emergency stopping, at regular intervals.
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 by taking any necessary emergency action, e.g. 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
Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.
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Follow the applicable warning instructions pertaining to such 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 cables or actuate the battery isolating switch, if fitted. 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.
Use the recommended special tools or suitable equivalents when instructed to do so.
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.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
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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