MTU Diesel Engine 12 V 4000 G21R 12 V 4000 G41R Operating Instructions Manual MS150064-01E PDF DOWNLOAD
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MTU Diesel Engine 12 V 4000 G21R 12 V 4000 G41R Operating Instructions Manual MS150064-01E PDF DOWNLOAD
Language :English
Pages :136
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
MTU Diesel Engine 12 V 4000 G21R 12 V 4000 G41R Operating Instructions Manual MS150064-01E PDF DOWNLOAD
Operating Instructions...................................................................................... 1 Table of Contents....................................................................................... 5 1 Safety................................................................................................ 7 1.1 General conditions.............................................................................. 7 1.2 Personnel and organizational requirements....................................................... 8 1.3 Transport....................................................................................... 9 1.4 Crankshaft transport locking device............................................................. 10 1.5 Safety regulations for startup and operation.................................................... 13 1.6 Explosion hazard when removing inspection port cover on engine.................................. 14 1.7 Safety regulations for maintenance and repair work.............................................. 15 1.8 Fluids and lubricants, fire prevention and environmental protection............................. 18 1.9 Conventions for safety instructions in the text................................................. 20 2 General Information................................................................................... 21 2.1 Engine side and cylinder designations........................................................... 21 2.2 Engine layout................................................................................... 22 3 Technical Data........................................................................................ 23 3.1 12V 4000 engine data, continuous operation, variable 3B, optimized fuel consumption............. 23 3.2 12V 4000 engine data, continuous operation, variable 3B, emissions optimized w/o certificate.... 27 3.3 12V 4000 engine data, continuous operation, variable 3B, emissions optimized (TA-Luft).......... 31 3.4 Final compression pressure...................................................................... 34 3.5 Firing order.................................................................................... 35 3.6 Engine – Main dimensions........................................................................ 36 4 Operation............................................................................................. 37 4.1 Putting the engine into operation after extended out-of-service periods (>3 months)............. 37 4.2 Putting the engine into operation after scheduled out-of-service-period......................... 38 4.3 Start engine in manual mode (testing mode)...................................................... 39 4.4 Starting the engine in emergency situations (override mode)..................................... 40 4.5 Operational checks.............................................................................. 41 4.6 Stop engine in manual mode (testing mode)....................................................... 42 4.7 Emergency stop.................................................................................. 43 4.8 After stopping the engine – Engine remains ready for operation.................................. 44 4.9 After stopping the engine – putting the engine out of service................................... 45 4.10 Plant – Cleaning............................................................................... 46 5 Maintenance........................................................................................... 47 5.1 Maintenance task reference table [QL1].......................................................... 47 6 Troubleshooting....................................................................................... 48 6.1 Troubleshooting................................................................................. 48 6.2 Fault messages on engine governor............................................................... 51 7 Task Description...................................................................................... 63 7.1 Engine.......................................................................................... 63 7.1.1 Engine – Barring manually................................................................. 63 7.1.2 Engine – Barring with starting system..................................................... 64 7.1.3 Engine – Test run......................................................................... 65 7.2 Cylinder Liner.................................................................................. 66 7.2.1 Cylinder liner – Endoscopic examination................................................... 66 7.2.2 Cylinder liner - Instructions and comments on endoscopic and visual examination........... 68 7.3 Crankcase Breather.............................................................................. 70 7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement........... 70 7.4 Valve Drive..................................................................................... 72 7.4.1 Valve gear – Lubrication.................................................................. 72 7.4.2 Valve clearance – Check and adjustment.................................................... 73 7.4.3 Cylinder head cover – Removal and installation............................................ 75 7.5 Injection Pump / HP Pump........................................................................ 76 7.5.1 HP pump – Relief bore check............................................................... 76 7.6 Injection Valve / Injector...................................................................... 77 7.6.1 Injector – Replacement.................................................................... 77 7.6.2 Injector – Removal and installation....................................................... 78 7.7 Fuel System..................................................................................... 83 7.7.1 Fuel system – Venting..................................................................... 83 7.8 Fuel Filter..................................................................................... 84 7.8.1 Fuel filter – Replacement................................................................. 84 7.8.2 Fuel prefilter cleaning................................................................... 85 7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment......................... 86 7.8.4 Fuel prefilter – Draining................................................................. 87 7.8.5 Fuel prefilter ‒ Flushing................................................................. 88 7.8.6 Fuel prefilter – Filter element replacement............................................... 90 7.9 Charge-Air Cooling.............................................................................. 92 7.9.1 Intercooler – Check drain for coolant leakage and obstruction............................. 92 7.10 Air Filter..................................................................................... 93 7.10.1 Air filter – Replacement................................................................. 93 7.10.2 Air filter – Removal and installation.................................................... 94 7.11 Air Intake..................................................................................... 95 7.11.1 Contamination indicator – Signal ring position check..................................... 95 7.12 Starting Equipment............................................................................. 96 7.12.1 Air starter – Manual operation........................................................... 96 7.12.2 Starter – Condition check................................................................ 97 7.13 Lube Oil System, Lube Oil Circuit.............................................................. 98 7.13.1 Engine oil level – Check................................................................. 98 7.13.2 Engine oil – Change...................................................................... 99 7.13.3 Engine oil – Sample extraction and analysis..............................................101 7.14 Oil Filtration / Cooling.......................................................................102 7.14.1 Engine oil filter – Replacement..........................................................102 7.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement..........................103 7.15 Coolant Circuit, General, High-Temperature Circuit.............................................105 7.15.1 Coolant level - Check....................................................................105 7.15.2 Engine coolant – Change..................................................................106 7.15.3 Engine coolant – Draining................................................................107 7.15.4 Engine coolant – Filling.................................................................108 7.15.5 Engine coolant pump – Relief bore check..................................................111 7.15.6 Coolant – Sample extraction and analysis.................................................112 7.16 Low-Temperature Circuit........................................................................113 7.16.1 Charge-air coolant – Level check.........................................................113 7.16.2 Charge-air coolant – Change..............................................................114 7.16.3 Charge-air coolant – Draining............................................................115 7.16.4 Charge-air coolant – Filling.............................................................116 7.16.5 Charge-air coolant – Sample extraction and analysis......................................119 7.16.6 Charge-air coolant pump – Relief bore check..............................................120 7.17 Belt Drive.....................................................................................121 7.17.1 Drive belt – Condition check.............................................................121 7.18 Battery-Charging Generator.....................................................................122 7.18.1 Battery-charging generator drive – Drive belt tension adjustment.........................122 7.18.2 Battery-charging generator drive – Drive belt tension check..............................123 7.18.3 Battery-charging generator drive – Drive belt replacement................................124 7.19 Wiring (General) for Engine/Gearbox/Unit.......................................................125 7.19.1 Engine wiring – Check....................................................................125 7.20 Accessories for (Electronic) Engine Governor / Control System..................................126 7.20.1 Engine control unit and connectors – Cleaning............................................126 7.20.2 Engine control unit plug connections – Check.............................................127 8 Appendix A............................................................................................128 8.1 Abbreviations...................................................................................128 8.2 MTU contacts/service partners...................................................................131 9 Appendix B............................................................................................132 9.1 Special Tools...................................................................................132 9.2 Index...........................................................................................135
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DESCRIPTION:
1 Safety
1.1 General conditions
General:
- In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations.
- The engine may nevertheless present 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
Correct use:
- The engine is intended solely for use in accordance with contractual agreements and the purpose envisaged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such cases. The responsibility is borne by the user alone.
- Correct use also includes observation of and compliance with the operating instructions and maintenance and repair specifications.
Modifications or conversions:
- Unauthorized modifications to the engine represent a safety risk.
- MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts:
- Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts, and the warranty shall be voided in such cases.
Reworking components:
- Repair or engine overhaul must be carried out in workshops authorized by MTU.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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