MTU Diesel Engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R Operating instructions Manual MS150066-02E PDF DOWNLOAD
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MTU Diesel Engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R Operating instructions Manual MS150066-02E PDF DOWNLOAD
Language : English
Pages : 239
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
MTU Diesel Engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R Operating instructions Manual MS150066-02E PDF DOWNLOAD
Operating Instructions.................................................................................. 1 Table of Contents................................................................................... 3 1 Safety............................................................................................ 5 1.1 Important provisions for all products....................................................... 5 1.2 Personnel and organizational requirements................................................... 6 1.3 Safety regulations for startup and operation................................................ 7 1.4 Safety regulations for maintenance and repair work.......................................... 8 1.5 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials.... 11 1.6 Standards for warning notices in the text................................................... 13 1.7 Transport................................................................................... 14 2 General Information............................................................................... 15 2.1 Engine side and cylinder designations....................................................... 15 2.2 Product description......................................................................... 16 2.3 Engine layout............................................................................... 36 2.4 Sensors, actuators and injectors – Overview................................................. 40 2.5 Sensors, actuators and injectors on 16V engines – Overview.................................. 50 3 Technical Data.................................................................................... 70 3.1 12V 4000 M63 engine data, EPA Tier 2, EU Stage IIIA, IMO Tier II............................ 70 3.2 16V 4000 M63 engine data, EPA Tier 2, EU Stage IIIA, IMO Tier II............................ 74 3.3 16V 4000 M63R engine data, IMO Tier II...................................................... 78 3.4 Firing order................................................................................ 82 3.5 Engine – Main dimensions.................................................................... 83 4 Operation......................................................................................... 85 4.1 Controls.................................................................................... 85 4.2 Putting the engine into operation after extended out-of-service periods (>3 months)......... 86 4.3 Putting the engine into operation after scheduled out-of-service-period..................... 87 4.4 Starting the engine......................................................................... 88 4.5 Operational checks.......................................................................... 89 4.6 Tasks after extended out-of-service periods (>3 weeks)...................................... 90 4.7 Checks prior to start-up.................................................................... 91 4.8 Fuel treatment system – Putting into operation.............................................. 92 4.9 Fuel treatment system – Switching on........................................................ 94 4.10 Fuel treatment system – Shutdown........................................................... 95 4.11 Stopping the engine........................................................................ 96 4.12 Emergency engine stop...................................................................... 97 4.13 After stopping the engine.................................................................. 98 4.14 Plant cleaning............................................................................. 99 5 Maintenance.......................................................................................100 5.1 Maintenance task reference table [QL1]......................................................100 6 Troubleshooting...................................................................................102 6.1 Troubleshooting.............................................................................102 6.2 Fuel treatment system – Troubleshooting.....................................................105 6.3 ADEC (ECU 7) fault codes for Series 4000 engines, marine application........................106 6.4 ADEC engine governor – Fault codes..........................................................107 7 Task Description..................................................................................133 7.1 Engine......................................................................................133 7.1.1 Engine – Barring manually.............................................................133 7.1.2 Engine – Barring with starting system.................................................134 7.2 Cylinder Liner..............................................................................135 7.2.1 Cylinder liner – Endoscopic examination...............................................135 7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners.....137 7.3 Valve Drive.................................................................................139 7.3.1 Valve gear – Lubrication..............................................................139 7.3.2 Valve clearance – Check and adjustment................................................140 7.3.3 Cylinder head cover – Removal and installation........................................143 7.4 Injection Pump / HP Pump....................................................................144 7.4.1 HP pump – Filling with engine oil.....................................................144 7.4.2 HP pump – Relief bore check...........................................................145 7.5 Injection Valve / Injector..................................................................146 7.5.1 Injector – Replacement................................................................146 7.5.2 Injector – Removal and installation...................................................147 7.6 Fuel Filter.................................................................................152 7.6.1 Supplementary fuel filter – Overview..................................................152 7.6.2 Supplementary fuel filter – Replacement...............................................153 7.6.3 Fuel filter – Replacement.............................................................154 7.6.4 Fuel prefilter – Differential pressure gauge check and adjustment.....................156 7.6.5 Fuel prefilter – Draining.............................................................157 7.6.6 Fuel prefilter – Flushing.............................................................159 7.6.7 Fuel prefilter with water separator – Filter element replacement......................161 7.6.8 Fuel prefilter with water separator – O-ring replacement in rotary slide valve........164 7.7 Exhaust Turbocharger........................................................................165 7.7.1 Compressor wheel – Cleaning...........................................................165 7.8 Charge-Air Cooling..........................................................................173 7.8.1 Intercooler – Checking condensate drain for water discharge and obstruction...........173 7.9 Air Filter..................................................................................174 7.9.1 Air filter – Replacement..............................................................174 7.9.2 Air filter – Removal and installation.................................................175 7.10 Air Intake.................................................................................176 7.10.1 Service indicator – Signal ring position check (optional)............................176 7.11 Starting Equipment.........................................................................177 7.11.1 Starter – Condition check............................................................177 7.12 Lube Oil System, Lube Oil Circuit..........................................................178 7.12.1 Engine oil – Level check.............................................................178 7.12.2 Engine oil – Change..................................................................179 7.12.3 Engine oil – Sample extraction and analysis..........................................181 7.13 Oil Filtration / Cooling...................................................................183 7.13.1 Engine oil filter – Replacement......................................................183 7.13.2 Oil indicator filter – Check.........................................................185 7.13.3 Centrifugal oil filter – Cleaning and filter sleeve replacement......................187 7.14 Coolant Circuit, General, High-Temperature Circuit.........................................190 7.14.1 Drain and vent points................................................................190 7.14.2 Engine coolant level – Check.........................................................194 7.14.3 Engine coolant – Change..............................................................195 7.14.4 Engine coolant – Draining............................................................196 7.14.5 Engine coolant – Filling.............................................................199 7.14.6 HT coolant pump — Relief bore check..................................................201 7.14.7 Engine coolant – Sample extraction and analysis......................................202 7.14.8 Engine coolant filter – Replacement..................................................203 7.14.9 Preheating unit......................................................................204 7.15 Raw Water Pump with Connections............................................................207 7.15.1 Raw water pump – Relief bore check...................................................207 7.16 Battery-Charging Generator.................................................................208 7.16.1 Battery-charging generator drive – Coupling condition check..........................208 7.17 Auxiliary PTO..............................................................................209 7.17.1 Bilge pump – Relief bore check.......................................................209 7.18 Fuel Supply System.........................................................................210 7.18.1 Water drain valve – Check............................................................210 7.18.2 Differential pressure gauge – Check..................................................211 7.18.3 Water level probe (3-in-1 rod electrode) – Check.....................................212 7.18.4 Pump capacity – Check................................................................213 7.18.5 Coalescer filter element – Replacement...............................................214 7.19 Wiring (General) for Engine/Gearbox/Unit...................................................216 7.19.1 Engine wiring – Check................................................................216 7.20 Accessories for (Electronic) Engine Governor / Control System..............................217 7.20.1 CDC parameters – Reset with DiaSys®..................................................217 7.20.2 Limit switch for start interlock ‒ Check.............................................218 7.20.3 Engine Control Unit ECU 7 – Checking plug connections................................219 7.20.4 Engine monitoring unit EMU – Plug connection check...................................220 7.20.5 Interface module plug connections – Check............................................221 7.20.6 ECU 7 engine governor – Removal and installation.....................................222 7.20.7 EMU 7 – Removal and installation.....................................................223 7.20.8 Engine Interface Module EIM – Removal and installation...............................224 7.20.9 Diagnostic features of EIM...........................................................225 8 Appendix A........................................................................................228 8.1 Abbreviations...............................................................................228 8.2 MTU contact persons/service partners........................................................230 9 Appendix B........................................................................................231 9.1 Special Tools...............................................................................231 9.2 Index.......................................................................................237
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MTU Diesel Engine 12 V 4000 M63 16 V 4000 M63 16 V 4000 M63R Operating instructions Manual MS150066-02E PDF DOWNLOAD
SAFETY INSTRUCTIONS:Important Provisions for All Products
Nameplate
The product is identified by a nameplate, model designation, or serial number, and it must match the information on the title page of this manual. The nameplate, model designation, or serial number can be found on the product.
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 exclusively for the application specified in the contract or defined at the time of delivery. This means that the equipment must be operated:
- Within the permissible operating parameters in accordance with the product data
- With fluids and lubricants approved by the manufacturer in accordance with Fluids and Lubricants Specifications of the manufacturer
- With spare parts approved by the manufacturer in accordance with the applicable Spare Parts Catalog
- In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (including engine control/parameters)
- In compliance with all safety instructions and in adherence to all warning notices in this manual
- In accordance with the maintenance requirements over the entire service life of the product (Maintenance Schedule)
- 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 repair
- By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage in product operation. The manufacturer will accept no liability for such damage.
Modifications or Conversions
Unauthorized modifications to the product compromise safety. The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare Parts
Only genuine spare parts must be used to replace components or assemblies. The manufacturer will accept no liability or warranty claims for any damage caused by the use of other spare parts.
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