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MTU 12V2000Gx6 series User Manual

MTU 12V2000Gx6 series
239 pages
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Operating Instructions
Diesel engine
12V2000Gx6x
16V2000Gx6x
MS15054/03E

Table of Contents

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MTU 12V2000Gx6 series Specifications

General IconGeneral
BrandMTU
Model12V2000Gx6 series
CategoryEngine
LanguageEnglish

Summary

Operating Instructions

Diesel Engine Models

Lists the diesel engine models covered by this manual.

Safety

Important Provisions for All Products

General safety information and warnings applicable to all products.

Correct Use of All Products

Defines the intended use and operational requirements for the product.

Personnel and Organizational Requirements

Outlines requirements for personnel qualifications and organizational measures.

Initial Start-up and Operation - Safety Regulations

Safety regulations for initial start-up and during engine operation.

Assembly, Maintenance, and Repair Work - Safety Regulations

Safety regulations to be followed during assembly, maintenance, and repair.

Fire and Environmental Protection, Fluids and Lubricants

Safety measures for fire prevention, environmental protection, and fluid handling.

Standards for Warning Notices and Highlighted Information

Explains the meaning of warning symbols and highlighted information.

Transport

Special Tools, Material, Spare Parts for Transport

Lists special tools, materials, and spare parts required for transport.

General Information

Engine Side and Cylinder Designations

Explains the engine side and cylinder nomenclature used in the manual.

Engine Overview

Provides a general overview of the engine and its main components.

Sensors and Actuators - Overview

Identifies key sensors and actuators on the engine.

Technical Data

Product Data: 12V/16V2000Gx6S, 3B Application

Technical specifications for 12V/16V2000Gx6S engines in 3B application.

Product Data: 12V/16V2000Gx6S, 3D Application

Technical specifications for 12V/16V2000Gx6S engines in 3D application.

Product Data: 12V/16V2000Gx6S, 3F Application

Technical specifications for 12V/16V2000Gx6S engines in 3F application.

Product Data: 12V/16V2000Gx6S, 3G Application

Technical specifications for 12V/16V2000Gx6S engines in 3G application.

Product Data: 12V/16V2000Gx6S, 3H Application

Technical specifications for 12V/16V2000Gx6S engines in 3H application.

Product Data: 12V/16V2000Gx6S, 3B EPA Nonroad T2

Technical specifications for 3B application with EPA Nonroad T2 certification.

Product Data: 12V/16V2000Gx6S, 3D EPA Nonroad T2

Technical specifications for 3D application with EPA Nonroad T2 certification.

Product Data: 12V/16V2000Gx6S, 3F EPA Certifications

Technical specifications for 3F application with EPA Nonroad T2 and Stationary EMERG T2.

Product Data: 12V/16V2000Gx6S, 3G EPA Nonroad T2

Technical specifications for 3G application with EPA Nonroad T2 certification.

Product Data: 12V/16V2000Gx6S, 3H EPA Certifications

Technical specifications for 3H application with EPA Nonroad T2 and Stationary EMERG T2.

Firing Order

Lists the firing order for different engine cylinder configurations.

Engine Main Dimensions

Provides physical dimensions of the engine for different configurations.

Operation

Putting Engine into Operation After Extended Out-of-Service Periods

Procedures for restarting an engine after long-term storage (>3 months).

Engine Starting Procedures

Step-by-step guide for starting the engine, including safety warnings.

Re-starting After Automatic Safety Shutdown

Steps for safely restarting the engine after an automatic shutdown event.

Operational Checks

Routine checks to ensure proper engine operation and identify potential issues.

Engine Shutdown Procedures

Safe procedures for shutting down the engine, including cooling down.

Emergency Engine Shutdown Procedures

Steps for executing an emergency engine shutdown and post-shutdown actions.

Actions After Stopping the Engine

Post-engine stop procedures, including coolant and system checks.

Plant Cleaning Procedures

Instructions for cleaning the plant using high-pressure cleaners and compressed air.

Maintenance

Maintenance Task Reference Table [QL1] for Non-EPA Regions

Table detailing maintenance tasks and intervals for Non-EPA regions.

Maintenance Task Reference Table [QL1] for EPA Regions

Table detailing maintenance tasks and intervals for EPA regions.

Troubleshooting

Troubleshooting Engine Start Issues

Diagnoses and actions for engine start problems.

ECU9 Fault Messages and Responses

Lists ECU9 fault codes, engine responses, and corrective actions.

ECU9 Fault Messages: Lube Oil and Coolant Issues

Diagnoses for lube oil pressure and coolant level faults.

ECU9 Fault Messages: Fuel Pressure and Rail Leakage

Diagnoses for fuel pressure and rail leakage issues.

ECU9 Fault Messages: Engine Speed and Starter Issues

Diagnoses for engine speed and starter problems.

ECU9 Fault Messages: Camshaft, Crankshaft, and Fuel Pressure Sensors

Diagnoses for camshaft, crankshaft, and fuel pressure sensor faults.

ECU9 Fault Messages: Cylinder Wiring Faults (A1-A8)

Troubleshooting specific cylinder wiring faults (A1-A8).

Task Description

Engine Test Run Procedures

Steps for performing an engine test run, including safety precautions.

Engine Barring Manually

Instructions for manually barring the engine using a barring tool.

Cylinder Liner

Cylinder Liner: Endoscopic and Visual Examination

Instructions and terms for examining cylinder liners.

Cylinder Liner Endoscopic Examination Procedure

Detailed steps for performing an endoscopic examination of cylinder liners.

Crankcase Breather

Crankcase Breather: Oil Mist Separator Replacement

Procedure for replacing the oil mist separator in the crankcase breather.

Fan Drive

Fan Drive: Drive Belt Condition Check

Steps to check the condition of the fan drive belt.

Fan Drive: Drive Belt Tension Check

Procedures for checking drive belt tension using frequency meters and preload gauges.

Fan Drive: Drive Belt Tension Adjustment

Steps to adjust the drive belt tension.

Fan Drive: Drive Belt Replacement

Procedure for replacing the fan drive belt.

Valve Drive

Valve Drive: Valve Clearance Check and Adjustment

Procedure for checking and adjusting valve clearance.

Cylinder Head Cover Removal and Installation

Procedures for removing and installing the cylinder head cover.

Injector

Injector Replacement

General guidance on replacing the injector.

Injector Removal and Installation

Detailed procedures and safety warnings for injector removal and installation.

Injector Functions: Drift Correction and Coding

Procedures for resetting drift correction parameters and entering injector coding.

Fuel System

Fuel System: HP Fuel Line and Pressure Pipe Neck Replacement

Procedure for replacing HP fuel lines and pressure pipe necks.

Fuel System Venting Procedures

Steps for venting the fuel system.

Fuel Draining Procedures

Instructions for draining fuel from the system.

Fuel Cooler: External Contamination and Leak-Tightness Check

Procedure for checking the fuel cooler for external contamination and leaks.

Fuel Cooler Cleaning Procedures

Instructions for cleaning the fuel cooler using compressed air or high-pressure cleaners.

Fuel Filter

Fuel Filter Replacement

Procedure for replacing the main fuel filter.

Fuel Prefilter Draining Procedures

Instructions for draining fuel prefilters (non-switchable and switchable).

Non-Switchable Fuel Prefilter: Filter Element Replacement

Procedure for replacing the filter element in non-switchable fuel prefilters.

Switchable Fuel Prefilter: Filter Element Replacement (Low Pressure Version A)

Procedure for replacing filter elements in switchable fuel prefilters (Low Pressure Version A).

Switchable Fuel Prefilter: Low Pressure Indicator Check

How to check the low pressure indicator on switchable fuel prefilters.

Fuel Prefilter Pressure Ratios Check

Procedure for checking fuel prefilter pressure ratios.

Fuel Prefilter Venting Procedures (Low Pressure Version A)

Steps for venting fuel prefilters (Low Pressure Version A).

Air Filter

Air Filter Replacement Procedures

Steps for replacing air filters and resetting the contamination indicator.

Air Filter Removal and Installation

Procedures for removing and installing air filters.

Starting Equipment

Electric Starter Overview

Diagram and parts list for the electric starter.

Electric Starter Removal Procedures

Steps for safely removing the electric starter.

Electric Starter Installation Procedures

Steps for installing and electrically connecting the electric starter.

Pneumatic Starter Overview

Diagram and parts list for the pneumatic starter.

Pneumatic Starter Removal Procedures

Steps for safely removing the pneumatic starter.

Pneumatic Starter Installation Procedures

Steps for installing and connecting the pneumatic starter.

Lube Oil System, Lube Oil Circuit

Engine Oil Level Check

Procedures for checking the engine oil level.

Engine Oil Change Procedures

Steps for changing engine oil, with and without a semirotary hand pump.

Engine Oil Filter Replacement Procedure

Steps for replacing the engine oil filter.

High-Temperature Coolant Circuit

Engine Coolant Level Check

Procedures for checking the engine coolant level.

Engine Coolant Change

Steps for changing the engine coolant.

Engine Coolant Draining

Procedures for draining engine coolant.

Engine Coolant Filling

Procedures for filling engine coolant.

Engine Coolant Pump Relief Bore Check

Procedure for checking the relief bore of the engine coolant pump.

Engine Coolant Sample Extraction and Analysis

Procedure for extracting and analyzing engine coolant samples.

Low-Temperature Circuit

Charge-Air Coolant Filling

Procedures for filling charge-air coolant.

Charge-Air Coolant Draining

Procedures for draining charge-air coolant.

Charge-Air Coolant Change

Steps for changing charge-air coolant.

Charge-Air Coolant Level Check

Procedures for checking charge-air coolant levels.

Charge-Air Coolant Pump Relief Bore Check

Procedure for checking the relief bore of the charge-air coolant pump.

Intercooler

Condensate Drain and Obstruction Check

Procedure for checking the intercooler condensate drain.

Battery-Charging Generator

Drive Belt Condition Check

Steps to check the condition of the drive belt for the battery-charging generator.

Drive Belt Tension Check

Procedures for checking drive belt tension on the battery-charging generator.

Drive Belt Tension Adjustment

Steps to adjust the drive belt tension on the battery-charging generator.

Drive Belt Replacement

Procedure for replacing the drive belt on the battery-charging generator.

Preheater

Preheater Overhaul Procedures

Overview of overhaul procedures for preheater components like switches, elements, and thermostats.

Preheater Function and Leak Check

Procedures for checking preheater function and for leaks.

Preheater: Heating Element and Housing Check

Procedure for checking the heating element and housing for contamination.

Preheater: Solenoid Switch Replacement (First Variant)

Procedure for replacing the solenoid switch.

Preheater: Safety Thermostat Replacement

Procedure for replacing the safety thermostat.

Preheater: Control Thermostat Replacement

Procedure for replacing the control thermostat.

Engine Mounting / Support

Engine Mounting: Checking Securing Screws

Procedure for checking and tightening engine mounting screws.

Engine Mounting: Checking Resilient Mounts Condition

Procedure for checking the condition of engine mounting resilient mounts.

Generator

Generator Mounting: Checking Resilient Mounts Condition

Procedure for checking generator mounting resilient mounts.

Generator Mounting: Checking Securing Screws Firm Seating

Procedure for checking the firm seating of generator mounting securing screws.

Engine Governor

Engine Governor: Engine Control Unit Overview

Diagram showing the location of the Engine Control Unit and its connectors.

Engine Control Unit Removal and Installation

Procedures for removing and installing the Engine Control Unit.

Engine Governor Plug Connections Check

Procedure for checking engine governor plug connections.

Wiring (General) for Engine/Gearbox/Unit

Wiring: Engine Cabling Check

Procedure for checking engine cabling and electrical components.

Appendix A

List of Abbreviations

Glossary of abbreviations used in the manual.

MTU Contact and Service Partners

Information on contacting MTU for support, hotlines, and spare parts.

Appendix B

Special Tools for Engine Maintenance

Lists special tools required for various engine maintenance tasks.

Special Tools for Barring and Valve Adjustment

Lists special tools for barring and valve adjustment.

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