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MTU Diesel Engine 12 V 4000 G23 G43 12 V 4000 G63 G83 16 V 4000 G23 G43 16 V 4000 G63 G83 Operating Instructions Manual M015710-01E PDF DOWNLOAD
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MTU Diesel Engine 12 V 4000 G23 G43 12 V 4000 G63 G83 16 V 4000 G23 G43 16 V 4000 G63 G83 Operating Instructions Manual M015710-01E PDF DOWNLOAD
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Description
MTU Diesel Engine 12 V 4000 G23 G43 12 V 4000 G63 G83 16 V 4000 G23 G43 16 V 4000 G63 G83 Operating Instructions Manual M015710-01E PDF DOWNLOAD
FILE DETAILS:
MTU Diesel Engine 12 V 4000 G23 G43 12 V 4000 G63 G83 16 V 4000 G23 G43 16 V 4000 G63 G83 Operating Instructions Manual M015710-01E PDF DOWNLOAD
Language :English
Pages :180
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
MTU Diesel Engine 12 V 4000 G23 G43 12 V 4000 G63 G83 16 V 4000 G23 G43 16 V 4000 G63 G83 Operating Instructions Manual M015710-01E PDF DOWNLOAD
Title................................................................................................................................... 1 Commissioning Note...................................................................................................................... 3 Table of Contents....................................................................................................................... 5 1 Safety................................................................................................................................ 9 1.1 General conditions.............................................................................................................. 9 General......................................................................................................................... 9 Correct use..................................................................................................................... 9 Modifications or Conversions.................................................................................................... 9 Spare parts..................................................................................................................... 9 1.2 Personnel and organizational requirements ...................................................................................... 10 Personnel ...................................................................................................................... 10 Organization.................................................................................................................... 10 Working clothes and protective equipment........................................................................................ 10 1.3 Transport....................................................................................................................... 11 Engine transport................................................................................................................ 11 Setting the engine down after transport......................................................................................... 11 1.4 Safety requirements when working on the engine.................................................................................. 12 Safety precautions when putting the equipment into operation.................................................................... 12 Safety requirements for operators............................................................................................... 12 Engine operation................................................................................................................ 12 Maintenance and repair.......................................................................................................... 12 Welding work.................................................................................................................... 13 Hydraulic installation and removal.............................................................................................. 13 Working on electrical/electronic assemblies..................................................................................... 14 Working with laser equipment.................................................................................................... 14 Operation of electrical equipment............................................................................................... 14 1.5 Auxiliary materials, fire prevention and environmental protection............................................................... 15 Fire prevention................................................................................................................. 15 Noise........................................................................................................................... 15 Environmental protection........................................................................................................ 15 Auxiliary materials............................................................................................................. 15 Lead............................................................................................................................ 15 Acids and alkaline solutions.................................................................................................... 15 Paints.......................................................................................................................... 15 Liquid nitrogen................................................................................................................. 15 Compressed air.................................................................................................................. 16 Used oil........................................................................................................................ 16 1.6 Standards for warning notices in the publication................................................................................ 17 Warning notices................................................................................................................. 17 2 Product Summary....................................................................................................................... 19 2.1 Engine Layout................................................................................................................... 19 2.1.1 Engine layout............................................................................................................. 19 Illustration is also valid for 12V 4000 Gx3 engines......................................................................... 19 Engine model designation.................................................................................................... 20 Key to the engine model designations 12/16V 4000 Gx3........................................................................ 20 2.2 Engine Side and Cylinder Designations........................................................................................... 21 2.2.1 Engine side and cylinder designations..................................................................................... 21 2.3 Main Engine Dimensions.......................................................................................................... 22 2.3.1 Engine – Main dimensions.................................................................................................. 22 Engine – Main dimensions.................................................................................................... 22 Illustration is also valid for 12/16V engines............................................................................... 22 2.4 Firing Order.................................................................................................................... 23 2.4.1 Firing order.............................................................................................................. 23 Firing order................................................................................................................ 23 2.5 Final Compression Pressure...................................................................................................... 24 2.5.1 Final compression pressure................................................................................................ 24 Final compression pressure.................................................................................................. 24 2.6 Technical Data.................................................................................................................. 25 2.6.1 12V 4000 Gx3 engine data: Standby operation 3D, optimized fuel consumption ............................................... 25 REFERENCE CONDITIONS........................................................................................................ 25 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046).................................................. 25 GENERAL CONDITIONS (for maximum power)...................................................................................... 25 MODEL RELATED DATA (basic design)........................................................................................... 26 COMBUSTION AIR / EXHAUST GAS................................................................................................ 26 COOLANT SYSTEM (HT circuit)................................................................................................. 27 COOLING SYSTEM (LT circuit)................................................................................................. 27 LUBE-OIL SYSTEM............................................................................................................. 27 FUEL SYSTEM................................................................................................................. 28 GENERAL OPERATING DATA...................................................................................................... 28 CAPACITIES.................................................................................................................. 28 WEIGHTS / MAIN DIMENSIONS................................................................................................... 28 ACOUSTICS................................................................................................................... 29 2.6.2 16V 4000 Gx3 engine data: Standby operation 3D, optimized fuel consumption ............................................... 30 REFERENCE CONDITIONS........................................................................................................ 30 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046).................................................. 30 GENERAL CONDITIONS (for maximum power)...................................................................................... 30 MODEL RELATED DATA (basic design)........................................................................................... 31 COMBUSTION AIR / EXHAUST GAS................................................................................................ 31 COOLANT SYSTEM (HT circuit)................................................................................................. 32 COOLING SYSTEM (LT circuit)................................................................................................. 32 LUBE-OIL SYSTEM............................................................................................................. 32 FUEL SYSTEM................................................................................................................. 33 GENERAL OPERATING DATA...................................................................................................... 33 CAPACITIES.................................................................................................................. 33 WEIGHTS / MAIN DIMENSIONS................................................................................................... 33 ACOUSTICS................................................................................................................... 34 2.6.3 Engine data 12/16V 4000 Gx3: Standby operation 3D, optimized exhaust emissions (EPA stage 2).............................. 35 REFERENCE CONDITIONS........................................................................................................ 35 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046).................................................. 35 GENERAL CONDITIONS (for maximum power)...................................................................................... 35 MODEL RELATED DATA (basic design)........................................................................................... 36 COMBUSTION AIR / EXHAUST GAS................................................................................................ 36 COOLANT SYSTEM (HT circuit)................................................................................................. 37 COOLING SYSTEM (LT circuit)................................................................................................. 37 LUBE-OIL SYSTEM............................................................................................................. 37 FUEL SYSTEM................................................................................................................. 38 GENERAL OPERATING DATA...................................................................................................... 38 CAPACITIES.................................................................................................................. 38 WEIGHTS / MAIN DIMENSIONS................................................................................................... 38 ACOUSTICS................................................................................................................... 39 2.6.4 12V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized fuel consumption................................... 40 REFERENCE CONDITIONS........................................................................................................ 40 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046).................................................. 40 GENERAL CONDITIONS (for maximum power)...................................................................................... 40 MODEL RELATED DATA (basic design)........................................................................................... 41 COMBUSTION AIR / EXHAUST GAS................................................................................................ 41 COOLANT SYSTEM (HT circuit)................................................................................................. 42 COOLING SYSTEM (LT circuit)................................................................................................. 42 LUBE-OIL SYSTEM............................................................................................................. 42 FUEL SYSTEM................................................................................................................. 43 GENERAL OPERATING DATA...................................................................................................... 43 CAPACITIES.................................................................................................................. 43 WEIGHTS / MAIN DIMENSIONS................................................................................................... 43 ACOUSTICS................................................................................................................... 44 2.6.5 16V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized fuel consumption................................... 45 REFERENCE CONDITIONS........................................................................................................ 45 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046).................................................. 45 GENERAL CONDITIONS (for maximum power)...................................................................................... 45 MODEL RELATED DATA (basic design)........................................................................................... 46 COMBUSTION AIR / EXHAUST GAS................................................................................................ 46 COOLANT SYSTEM (HT circuit)................................................................................................. 47 COOLING SYSTEM (LT circuit)................................................................................................. 47 LUBE-OIL SYSTEM............................................................................................................. 47 FUEL SYSTEM................................................................................................................. 48 GENERAL OPERATING DATA...................................................................................................... 48 CAPACITIES.................................................................................................................. 48 WEIGHTS / MAIN DIMENSIONS................................................................................................... 48 ACOUSTICS................................................................................................................... 49 2.6.6 12/16 V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized exhaust emission (EPA stage 2)................ 50 REFERENCE CONDITIONS........................................................................................................ 50 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046).................................................. 50 GENERAL CONDITIONS (for maximum power)...................................................................................... 50 MODEL RELATED DATA (basic design)........................................................................................... 51 COMBUSTION AIR / EXHAUST GAS................................................................................................ 51 COOLANT SYSTEM (HT circuit)................................................................................................. 52 COOLING SYSTEM (LT circuit)................................................................................................. 52 LUBE-OIL SYSTEM............................................................................................................. 52 FUEL SYSTEM................................................................................................................. 53 GENERAL OPERATING DATA...................................................................................................... 53 CAPACITIES.................................................................................................................. 53 WEIGHTS / MAIN DIMENSIONS................................................................................................... 53 ACOUSTICS................................................................................................................... 54 2.6.7 12V 4000 Gx3 engine data: Continuous operation, variable 3B , optimized exhaust emissions (TA-Luft)....................... 55 REFERENCE CONDITIONS........................................................................................................ 55 POWER-RELATED DATA (performance refers to net brake power as per 3046)...................................................... 55 GENERAL CONDITIONS (for maximum power)...................................................................................... 55 MODEL RELATED DATA (basic design)........................................................................................... 56 COMBUSTION AIR / EXHAUST GAS................................................................................................ 56 COOLANT SYSTEM (HT circuit)................................................................................................. 56 COOLING SYSTEM (LT circuit)................................................................................................. 57 LUBE-OIL SYSTEM............................................................................................................. 57 FUEL SYSTEM................................................................................................................. 57 GENERAL OPERATING DATA...................................................................................................... 57 CAPACITIES.................................................................................................................. 58 WEIGHTS / MAIN DIMENSIONS................................................................................................... 58 ACOUSTICS................................................................................................................... 58 3 Operation............................................................................................................................. 59 3.1 Putting the engine into operation after extended out-of-service-periods (>3 months)............................................. 59 Putting the engine into operation after extended out-of-service-periods (>3 months)............................................. 59 3.2 Putting the engine into operation after scheduled out-of-service-period......................................................... 60 3.3 Starting the engine in manual mode.............................................................................................. 61 3.4 Emergency start (override mode)................................................................................................. 62 3.5 Operational checks.............................................................................................................. 63 3.6 Stopping the engine in manual mode.............................................................................................. 64 3.7 Emergency stop.................................................................................................................. 65 3.8 After stopping the engine – engine remains ready for operation.................................................................. 66 3.9 After stopping the engine – putting the engine out of service................................................................... 67 4 Maintenance........................................................................................................................... 69 4.1 Preface......................................................................................................................... 69 MTU maintenance concept......................................................................................................... 69 Preventive maintenance instructions............................................................................................. 69 Out-of-service periods.......................................................................................................... 69 Application group............................................................................................................... 69 4.2 Maintenance schedule matrix..................................................................................................... 70 Maintenance schedule matrix for application group 3B, 0-10,000 operating hours.................................................. 70 Maintenance schedule matrix for application group 3C, 0-6,000 operating hours................................................... 71 4.3 Maintenance tasks............................................................................................................... 72 5 Troubleshooting....................................................................................................................... 75 5.1 Troubleshooting................................................................................................................. 75 5.2 Engine governor ADEC (ECU 7) for Series 4000 genset engines - Fault messages ................................................... 78 The fault code numbers are generated by the Engine Control Unit and transmitted to the following display........................ 78 6 Task Description...................................................................................................................... 99 6.1 Engine.......................................................................................................................... 99 6.1.1 Engine – Barring manually................................................................................................. 99 6.1.2 Engine – Barring with starting system.....................................................................................100 6.1.3 Engine test run ..........................................................................................................101 6.2 Cylinder Liner..................................................................................................................102 6.2.1 Cylinder liner – Endoscopic examination...................................................................................102 6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners.........................................104 Terms used for endoscopic examination.......................................................................................104 Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report.....104 Evaluation of findings and further measures.................................................................................105 6.3 Crankcase Breather..............................................................................................................106 6.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement...........................................106 6.4 Valve Drive.....................................................................................................................108 6.4.1 Valve gear – Lubrication..................................................................................................108 6.4.2 Valve clearance – Check and adjustment....................................................................................109 6.4.3 Cylinder head cover – Remove and install..................................................................................112 6.5 Injector........................................................................................................................113 6.5.1 Injector – Replacement....................................................................................................113 6.5.2 Injector – Removal and Installation.......................................................................................114 6.6 Fuel System.....................................................................................................................118 6.6.1 Fuel system – Venting.....................................................................................................118 6.7 Fuel Filter.....................................................................................................................119 7 Special Tools.................................................................................................................163 7.1 Special tools...........................................................................................................163 6.7.1 Fuel filter – Replacement.................................................................................................119 6.7.2 Fuel prefilter cleaning...................................................................................................120 6.7.3 Fuel prefilter – differential pressure check and adjustment of gauge......................................................121 6.7.4 Fuel prefilter – draining.................................................................................................122 6.7.5 Fuel prefilter – flushing.................................................................................................124 6.7.6 Fuel prefilter – filter element replacement...............................................................................126 6.8 Charge-air Cooling, General, Left Side..........................................................................................128 6.8.1 Intercooler – Checking condensate drains for coolant disscharge and obstructions..........................................128 6.9 Air Filter......................................................................................................................129 6.9.1 Air filter replacement....................................................................................................129 6.9.2 Air filter – Check........................................................................................................130 6.9.3 Air filter removal and installation.......................................................................................131 6.9.4 Rubber sleeves between air intake elbow and turbocharger - Replacement....................................................132 6.10 Air Intake.....................................................................................................................133 6.10.1 Service indicator – Signal ring position check...........................................................................133 6.11 Staring Equipment..............................................................................................................134 6.11.1 Air starter – manual operation...........................................................................................134 6.11.2 Starter – Condition check ...............................................................................................135 6.12 Lube-oil System, Lube-oil Circuit..............................................................................................136 6.12.1 Engine oil – Change......................................................................................................136 6.12.2 Engine oil – Level check.................................................................................................138 6.12.3 Engine oil – Sample extraction and analysis..............................................................................139 6.13 Oil Filtration/Cooling.........................................................................................................140 6.13.1 Engine oil filter – Replacement..........................................................................................140 6.13.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement..........................................................141 6.14 Cooling Circuit, General, HT Circuit...........................................................................................143 6.14.1 Engine coolant – Change..................................................................................................143 6.14.2 Engine coolant – Filling ................................................................................................144 6.14.3 Engine coolant – Draining................................................................................................146 6.14.4 Engine coolant level – Check.............................................................................................147 6.14.5 Engine coolant pump – Relief bore check .................................................................................148 6.14.6 Engine coolant – Sample extraction and analysis..........................................................................149 6.15 LT Circuit.....................................................................................................................150 6.15.1 Charge-air coolant change................................................................................................150 6.15.2 Charge-air coolant – Filling.............................................................................................151 6.15.3 Charge-air coolant – Draining............................................................................................153 6.15.4 Charge-air coolant level check...........................................................................................154 6.15.5 Charge-air coolant pump – Relief bore check .............................................................................155 6.16 Belt Drive.....................................................................................................................156 6.16.1 Drive belt – Condition check.............................................................................................156 6.17 Battery-charging Generator.....................................................................................................157 6.17.1 Battery-charging generator drive – Drive belt tension adjustment.........................................................157 6.17.2 Battery-charging generator drive – Drive belt replacement................................................................158 6.18 Cabling, General for Engine / Gearbox / Plant..................................................................................159 6.18.1 Engine wiring – Check....................................................................................................159 6.19 Accessories for Engine Governor (Electronic) / Control System..................................................................160 6.19.1 ECU and connectors – Cleaning............................................................................................160 6.19.2 ECU – Checking plug-in connections.......................................................................................161 7 Special Tools.........................................................................................................................163 7.1 Special tools...................................................................................................................163 8 Annex.................................................................................................................................171 8.1 Manufacturer’s documentation........................................................................................................171 See Manufacturer’s documentation....................................................................................................171 8.2 MTU contact person/service partner..............................................................................................172 8.3 Abbreviations...................................................................................................................173 8.4 Index...........................................................................................................................177
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DESCRIPTION:
MTU Diesel Engine 12 V 4000 G23 G43 12 V 4000 G63 G83 16 V 4000 G23 G43 16 V 4000 G63 G83 Operating Instructions Manual M015710-01E PDF DOWNLOAD
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 must be observed.
- This engine is a state-of-the-art product and conforms with all applicable specifications and regulations.
- Nevertheless, persons and property may be at risk in the event of:
- Incorrect use
- Operation, maintenance, and repair by unqualified personnel
- Modifications or conversions
- Non-compliance with the Safety Instructions
Correct use:
- The engine is intended exclusively for the application specified in the contract or defined at the time of delivery.
- Any other use is considered improper use. The manufacturer will accept no liability for any resultant damage. The responsibility is borne by the user alone.
- Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions:
- Modifications made by the customer to the engine may affect safety.
- 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.
- In the event of any damage caused by the use of other spare parts, no liability nor warranty claims vis-à-vis the engine manufacturer will be accepted.
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- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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