MTU 12 V 2000 M72 Instructions d'exploitation

Operating InstructionsDiesel engine12 V 2000 M7216V 2000 M72M015650/04E

1.4 Safety regulations for startup and operationSafety requirements for initial operationPrior to initial operation of the unit, install the assembly

7.11 Air Intake7.11.1 Contamination indicator – Signal ring position checkPreconditions☑ Engine is stopped and starting disabled.Checking signal ring

7.12 Starting Equipment7.12.1 Starter – Condition checkPreconditions☑ Engine is stopped and starting disabled.Starter – Condition check1. Check securi

7.13 Lube Oil System, Lube Oil Circuit7.13.1 Engine oil – Level checkPreconditions☑ Engine is stopped and starting disabled.Oil level check prior to e

7.13.2 Engine oil – ChangePreconditions☑ Engine is stopped and starting disabled.☑ Engine is at operating temperature.☑ MTU Fluids and Lubricants Spec

7.14 Oil Filtration / Cooling7.14.1 Engine oil filter – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Oil filter wrenc

3. Remove cut-out oil filter using the oil filterwrench.4. Clean the sealing surface at the connectingpiece.5. Check condition of the new sealing ring

7.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material,

Centrifugal oil filter – Cleaning andfilter sleeve replacement1. Remove nut, holding the rotor with a strapwrench.2. Remove nut (1), washer (2), rotor

9. Fit new sealing ring (4).10. Set on rotor cap (3), observe marks.11. Fit washer (2).12. Hold rotor (new design) with strap wrench and tighten nut (

7.15 Coolant Circuit, General, High-Temperature Circuit7.15.1 Drain and venting points8 V, 10 V1 Overflow line, expansiontank2 Filler neckM015650/04E

1.5 Safety regulations for maintenance and repair workSafety regulations for maintenance and repair workHave maintenance and repair work carried out b

12 V, 16 V1 Overflow line, expansiontank2 Filler neck110 | Task Description | M015650/04E 2012-02TIM-ID: 0000006696 - 001

Free end (KGS)1 Fuel filter vent screws2 Engine coolant drain plug3 Raw water pump fillingplug4 Measuring point, pres‐sure before raw waterpump5 Raw w

Left side1 Engine coolant drain plug 2 Engine coolant drain plug(M14x1.5)112 | Task Description | M015650/04E 2012-02TIM-ID: 0000006696 - 001

Right side1 Engine coolant drain plug(M14x1.5)2 Oil filler neck (connectionleft or right engine sideoptional)3 Oil dipstick (connectionleft or right e

Driving end (KS)1 Engine coolant drain plug 2 Connection for oil extrac‐tion114 | Task Description | M015650/04E 2012-02TIM-ID: 0000006696 - 001

7.15.2 Engine coolant – Level checkPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specification (A001061/..) is av

7.15.3 Engine coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Engine coolantEngine coolant – Change1. Drain engine

7.15.4 Engine coolant – DrainingPreconditions☑ Engine is stopped and starting disabled.WARNINGCoolant is hot and under pressure.Risk of injury and sca

7.15.5 Engine coolant – FillingPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are avai

7.15.6 HT coolant pump — Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special

Welding workNever carry out welding work on the assembly, system, or engine-mounted units. Cover the engine whenwelding in its vicinity.Do not use the

7.15.7 Engine coolant – Sample extraction and analysisPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specification

7.15.8 Coolant filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part N

7.16 Raw Water Pump with Connections7.16.1 Raw water pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious inj

7.17 Belt Drive7.17.1 Drive belt – Condition checkPreconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.Drive belt – Condition che

7.18 Battery-Charging Generator7.18.1 Battery-charging generator drive – Drive belt replacementPreconditions☑ Engine is stopped and starting disabled.

7.19 Fuel Treatment System7.19.1 Water drain valve – CheckChecking water drain valve1. Open water drain valve.2. Check water outlet for obstructions.3

7.19.2 Differential pressure gauge – CheckWARNINGFuels are combustible.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition

7.19.3 Water level probe (3-in-1 rod electrode) – CheckPreconditions☑ System is put out of service and emptied.WARNINGFuels are combustible.Risk of fi

7.19.4 Pump capacity – CheckWARNINGFuels are combustible.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition sources.• Do n

7.19.5 Coalescer filter element – ReplacementPreconditions☑ System is switched off and starting disabled.Special tools, Material, Spare partsDesignati

For conducting light-beam procedures and measurement work, only the following laser devices must beused:• Laser devices of classes 1, 2 or 3A.• Laser

16. Tighten nut (3) to specified tightening torque using a torque wrench.Name Size Type Lubricant Value/StandardNut M16 Tightening torque (Engine oil)

7.20 Wiring (General) for Engine/Gearbox/Unit7.20.1 Engine wiring – CheckPreconditions☑ Engine is stopped and starting disabled.Special tools, Materia

7.21 Accessories for (Electronic) Engine Governor / ControlSystem7.21.1 Engine governor and connectors – CleaningPreconditions☑ Engine is stopped and

7.21.2 Engine governor – Checking plug-in connectionsPreconditions☑ Engine is stopped and starting disabled.Note: Always use test connectors to enter

7.21.3 EMU – Checking plug-in connectionsPreconditions☑ Engine is stopped and starting disabled.EMU – checking plug-in connections1. Verify that all p

7.21.4 Engine governor – Carry out self-testDANGERElectrical voltage.Risk of serious injury - danger to life!• Make certain that the power supply to t

7.21.5 EMU and connectors – CleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part

7.21.6 ECU 7 engine governor – Removal and installationPreconditions☑ Engine is stopped and starting disabled.CAUTIONWrong engine governor installed.E

7.21.7 Engine monitoring unit – Removal and installationPreconditions☑ Engine is stopped and starting disabled.CAUTIONWrong engine governor installed.

8 Appendix A8.1 AbbreviationsAbbrevia‐tionMeaning ExplanationADEC Advanced Diesel Engine Control Engine governorAL Alarm Alarm (general)ANSI American

1.6 Auxiliary materials, fire prevention and environmentalprotectionFire preventionRectify any fuel or oil leaks immediately; even splashes of oil or

Abbrevia‐tionMeaning ExplanationIDM Interface Data ModuleIMO International Maritime OrganizationISO International Organization for Stand‐ardizationInt

Abbrevia‐tionMeaning ExplanationTD Transmitter Deviation Alarm: Deviation in transmitter valuesUT Unterer Totpunkt Bottom Dead Center (BDC)VS Voith Sc

8.2 MTU contacts/service partnersServiceOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters

9 Appendix B9.1 Special ToolsAlignment devicePart No.: F6790507Qty.:Used in:1 7.6.2 Injector – Removal and installation (→ Page 86)Angular screw drive

MandrelPart No.: 8205892861/08Qty.:Used in:1 7.18.1 Battery-charging generator drive – Drive belt replacement (→ Page 124)MTU test kitPart No.: 560589

Rigid endoscopePart No.: Y20097353Qty.:Used in:1 7.3.1 Cylinder liner – Endoscopic examination (→ Page 74)Socket wrenchPart No.: F30030450Qty.:Used in

9.2 Index12 V 2000 M72 engine data: remote heat exchanger,EPA stage 2 3512V 2000 M72 engine data: Engine-mounted heat ex‐changer, EPA stage 2  3216V 2

Fuel– Prefilter  – Differential pressure gauge - Check and adjust‐ment  91– Draining  92– Filter element replacement  95– Treatment system  – Troubles

Lead• When working with lead or lead-containing pastes, avoid direct contact with the skin and do not inhalelead vapors.• Adopt suitable measures to a

Used oilUsed oil may contain health-threatening combustion residues.Rub barrier cream into hands! Wash hands after contact with used oil.16 | Safety

1.7 Conventions for safety instructions in the textDANGERIn the event of immediate danger.Consequences: Death or serious injury• Remedial actionWARNIN

2 General Information2.1 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS).The cylinders of

2.2 Product descriptionDescription of the engineEngineThe engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direc

Printed in Germany© 2012 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole

Open-loop control:• Injection (fuel pressure, injection timing, injection duration, operating status)• Sequential turbocharging (cutting-in and out) w

SOLAS – Fire protection specificationsSpecial connectionsIn case of leakage, the above-mentioned connection types are spray-protected even without a c

The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not underpressure.HP line between fuel injector and HP

HP line between distributor and HP accumulator1 Union nut2 O-ring3 Thrust ring4 Thrust screw5 O-ring6 O-ring7 Thrust ring8 Pressure pipe9 Jacket pipeM

HP line between distributor and HP accumulator1 Jacket pipe2 O-ring3 O-ring4 Thrust ring5 Thrust screw6 Thrust ring7 O-ring8 HP line9 Pressure pipe10

2.3 Engine layoutEngine layout1 Engine oil heat exchang‐er2 Engine oil filter3 Engine coolant filter4 Change-over lever for en‐gine oil filter5 Fuel c

1 Exhaust turbocharger, left(secondary turbocharger)2 Exhaust turbocharger(primary turbocharger)3 Air intake4 Engine hoisting lug (driv‐ing end)5 Exha

2.4 Sensors, actuators and injectors – OverviewEngine plan viewDeviations from illustrations are insignificant.Also applies similarly to 12V.Item Desc

Engine free endItem Description Monitoring of1 B34 Fuel pressure after filter2 B5.3 (option) Lube oil pressure before filter3 B5.1 Lube oil pressure a

Engine driving endItem Description Monitoring of1 B1 (ECU) Camshaft speed2 B13.2 (optional EMU) Crankshaft speed3 B13 (ECU) Crankshaft speedM015650/04

Commissioning NoteImportantPlease complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.The Commissioning Note informati

Engine, right sideItem Description Monitoring of1 YB33 Fuel temperature2 B48 Fuel pressure (in rail)3 B16 (option) Coolant pressure4 F46 Leak fuel lev

Engine, left sideItem Description Monitoring of1 B4.21 Exhaust gas temperature, A-side2 Y27.1 4-2-directional control valve, A-side3 B54 (option) Lube

3 Technical Data3.1 12V 2000 M72 engine data: Engine-mounted heatexchanger, EPA stage 2Explanation:DL Ref. value: Continuous powerBL Ref. value: Fuel

Number of cylinders 12Inlet valves per cylinder 2Exhaust valves per cylinder 2RAW-WATER CIRCUIT (open circuit)Number of cylinders 12Raw water pump: In

INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)Number of cylinders 12Longitudinal inclination, continuous max., driving end down (Option: max

3.2 12 V 2000 M72 engine data: remote heat exchanger, EPAstage 2Explanation:DL Ref. value: Continuous powerBL Ref. value: Fuel stop powerA Design valu

LUBE OIL SYSTEMNumber of cylinders 12Lube oil operating temperature before engine, from R °C 79Lube oil operating temperature before engine, to R °C 8

CAPACITIESNumber of cylinders 12Engine oil capacity, initial filling (standard oil system) (option: max. operat‐ing inclinations)R Liters 123Oil chang

3.3 16V 2000 M72 engine data: Engine-mounted heatexchanger, EPA stage 2Explanation:DL Ref. value: Continuous powerBL Ref. value: Fuel stop powerA Desi

RAW-WATER CIRCUIT (open circuit)Number of cylinders 16Raw water pump: Inlet pressure, min. L bar -0.4Raw water pump: Inlet pressure, max. L bar +0.5Pr

CAPACITIESNumber of cylinders 16Engine coolant, engine-side (with cooler) R liters 135Total engine oil capacity at initial filling (standard oil syste

3.4 16V 2000 M72 engine data: Separate heat exchanger, EPAstage 2Explanation:DL Ref. value: Continuous powerBL Ref. value: Fuel stop powerA Design val

LUBE OIL SYSTEMNumber of cylinders 16Lube oil operating temperature before engine, from R °C 78Lube oil operating temperature before engine, to R °C 8

CAPACITIESNumber of cylinders 16Total engine oil capacity at initial filling (standard oil system) (Option: max.operating inclinations)R liters 168Oil

3.5 Firing orderFiring order8V A1-B4-A4-A2-B3-A3-B2-B110 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B112 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B116 V A1-B5-A3-A5-B2-B8

3.6 Engine – Main dimensionsMain dimensionsEngine model Length (A) Width (B) Height (C)8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm8V 2

4 Operation4.1 Engine – Putting the engine into operation (out of service > 3months)Preconditions☑ Engine is stopped and starting disabled.☑ MTU Fl

4.2 Putting the engine into operation after scheduled out-of-service periodPreconditions☑ Engine is stopped and starting disabled.StartupItem TaskLube

4.3 Tasks after extended out-of-service periods (>3 weeks)Tasks after extended out-of-service periods (>3 weeks)Note: Operate fuel treatment sys

4.4 Checks prior to start-upChecks prior to start-up1. Check tank and the entire pipework for cleanness. If microorganisms are detected:a) Clean affec

Table of Contents1 Safety1.1 General conditions 71.2 Personnel and organizational requirements 81.3 Transport 91.4 Safety regulations for startup and

4.5 Fuel treatment system – Putting into operationFuel treatment system – Overview1. Switch on fuel treatment system (→ Page 53).2. Check the differen

Simulation of filter replacement with the engine running: HAT1. Switch on fuel treatment system (→ Page 53).2. Start engine (→ Page 54).3. Run engine

4.6 Operational checksDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special care when working o

4.7 Fuel treatment system – Switching onPreconditions☑ The on-board power supply is switched on.CAUTIONDamage to engine/plant.Major material damage!•

4.8 Starting the enginePreconditions☑ External start interlock is not activated.☑ Emergency air shut-off flaps (if fitted) are open.DANGERUnguarded ro

4.9 Stopping the enginePreconditions☑ Engine is running in local mode.CAUTIONStopping the engine when it is running at full load causes extreme stress

4.10 Emergency stopCAUTIONAn emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!• Initiate emergency stop on

4.11 After stopping the enginePreconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.After stopping the engineItem ActionC

4.12 Fuel treatment system – ShutdownShutting down fuel treatment system1. Press the illuminated pushbutton "Water drain" on the switch cabi

4.13 Plant – CleaningPreconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not applied.Special tools, Material, Spare partsDes

7.8 Fuel Filter 897.8.1 Fuel filter – Replacement 897.8.2 Fuel prefilter – Differential pressure check andadjustment of gauge 917.8.3 Fuel prefilter –

5 Maintenance5.1 Maintenance task reference table [QL1]The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. T

6 Troubleshooting6.1 Fuel treatment system – TroubleshootingIlluminated pushbutton “Water alarm” is lit.Cause Corrective actionWhen the maximum water

6.2 TroubleshootingEngine does not turn when starter is actuatedComponent Probable Cause TaskBattery Low or defective Charge or replace (see manufactu

Engine speed not steadyComponent Probable Cause TaskFuel injection equip‐mentInjector defective Replace (→ Page 85).Speed sensor Defective Replace.Fue

Exhaust gas whiteComponent Probable Cause TaskEngine Not at operating temperature Run engine to reach operating temper‐ature.Fuel system Water in fuel

7 Task Description7.1 SOLAS7.1.1 SOLAS shielding as per MTN 5233 – InstallationPreconditions☑ Engine is stopped and starting disabled.Special tools, M

7.1.2 SOLAS shielding – InstallationPreconditions☑ Engine is stopped and starting disabled.☑ Engine is cooled down to ambient temperature.Special tool

7.1.3 Installation locations for SOLAS shieldingGeneral informationPrimarily fit SOLAS shielding as per MTN 5233 (→ Page 65).Free end B-sideItem Type

Item Type of shielding Comments1 (free end) Shield (A8) On fuel filter2 (free end) Shield (A7) Above fuel priming pump3 (free end) Shield (A7) Below f

Item Type of shielding Comments1 (driving end, A-side) Shield (A5) To turbocharger lubrication2 (driving end, A-side) Shield (A5) On valve plateDrivin

1 Safety1.1 General conditionsGeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other com‐pu

Driving end B-sideItem Type of shielding Comments1 (driving end, B-side) Shield (A5) Turbocharger flap2 (driving end, B-side) Shield (A5) Turbocharger

Driving end A-sideItem Type of shielding Comments1 (driving end, A-side) Shield (A5) To flap controlDriving end B-sideItem Type of shielding Comments1

7.2 Engine7.2.1 Engine – Barring manuallyPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

7.2.2 Engine – Barring with starting systemPreconditions☑ Clutch is disengaged.☑ Engine start is disabled.☑ LOP is accessible and open.DANGERUnguarded

7.3 Cylinder Liner7.3.1 Cylinder liner – Endoscopic examinationPreconditions☑ Engine is stopped and starting disabledSpecial tools, Material, Spare pa

Final steps1. Install injector (→ Page 86).2. Install cylinder head cover (→ Page 84).M015650/04E 2012-02 | Task Description | 75TIM-ID: 0000000015 -

7.3.2 Cylinder liner – Instructions and comments on endoscopic and visualexaminationTerms used for endoscopic examinationUse the terms listed below to

Findings MeasureBurn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they runover the whole ring-travel area (TDC/BDC),

7.4 Crankcase Breather7.4.1 Crankcase breather – Cleaning oil pre-separator elementPreconditions☑ Engine is stopped and starting disabled.WARNINGFuels

7.4.2 Crankcase breather – Oil separator replacement, diaphragm check andreplacementPreconditions☑ Engine is stopped and starting disabled.Special too

1.2 Personnel and organizational requirementsPersonnel requirementsWork on the engine must only be carried out by appropriately qualified and instruct

Checking diaphragm1. Remove cover (4).2. Take off spring (5), seal (2) and diaphragm(3).3. Check diaphragm (3) for damage.4. Fit new diaphragm if used

7.5 Valve Drive7.5.1 Valve clearance – Check and adjustmentPreconditions☑ Engine is stopped and starting disabled.☑ Engine coolant temperature is max.

10V2000Position Cylinder 1 2 3 4 5 6 7 8 9Firing TDC in cylinder A1 Bank A E A - - - - - A E -Bank B E - - - - A E A E -Overlap TDC in cylinder A1 Ban

Valve clearance adjustment1. Loosen locknut (1) and unscrew adjustingscrew (2) by a few threads.2. Insert feeler gauge between valve bridgeand rocker

7.5.2 Cylinder-head cover – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesigna

7.6 Injection Valve / Injector7.6.1 Injector – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Injector(→ Spare Parts Ca

7.6.2 Injector – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

Installing injector1. Remove all plugs before installation.2. Fit new O-rings onto injector and coat with grease.3. Fit new sealing ring with grease o

7.7 Fuel System7.7.1 Fuel system – VentingPreconditions☑ Engine is stopped and starting disabled.WARNINGFuels are combustible.Risk of fire and explosi

7.8 Fuel Filter7.8.1 Fuel filter – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Oil filter wrenchF30379104 1Diesel fu

1.3 TransportTransportOnly use the lifting eyes provided to lift the engine.Only use transport and lifting devices approved by MTU.Take the engine&apo

Easy-change fuel filter replacementwith the engine stopped1. Stop engine and disable engine start.2. Cut out the filter to be replaced.B Left filter c

7.8.2 Fuel prefilter – Differential pressure check and adjustment of gaugeDANGERUnguarded rotating and moving engine components.Risk of serious injury

7.8.3 Fuel prefilter – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Q

7.8.4 Fuel prefilter – FlushingSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelSeal(→ Spare Parts Catalog)DANGERUnguarde

2. Open threaded vent plug (5) of the filter tobe flushed.3. Unlock drain valve (6) by pressing toggle,open it and drain fuel.Result: Fuel flows from

7.8.5 Fuel prefilter – Filter element replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignatio

2. Open threaded vent plug (5) of contaminat‐ed filter.3. Unlock drain valve (6) by pressing toggleand open it.4. Drain water and contaminants from th

7.9 Charge-Air Cooling7.9.1 Intercooler – Checking condensate drain line for coolant discharge andobstructionDANGERUnguarded rotating and moving engin

7.10 Air Filter7.10.1 Air filter – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Air filter(→ Spare Parts Catalog)Air

7.10.2 Air filter – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Air filter – Removal and installation1. Release cla