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MTU Diesel Engine 8 V 4000 R41 R41L R41R 12 V 4000 R41 R41L R41R 16 V 4000 R41 R41L R41R Operating Instruction Manual M015575-06E PDF DOWNLOAD
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MTU Diesel Engine 8 V 4000 R41 R41L R41R 12 V 4000 R41 R41L R41R 16 V 4000 R41 R41L R41R Operating Instruction Manual M015575-06E PDF DOWNLOAD
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Description
MTU Diesel Engine 8 V 4000 R41 R41L R41R 12 V 4000 R41 R41L R41R 16 V 4000 R41 R41L R41R Operating Instruction Manual M015575-06E PDF DOWNLOAD
FILE DETAILS:
MTU Diesel Engine 8 V 4000 R41 R41L R41R 12 V 4000 R41 R41L R41R 16 V 4000 R41 R41L R41R Operating Instruction Manual M015575-06E PDF DOWNLOAD
Language : English
Pages : 152
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
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DESCRIPTION:
MTU Diesel Engine 8 V 4000 R41 R41L R41R 12 V 4000 R41 R41L R41R 16 V 4000 R41 R41L R41R Operating Instruction Manual M015575-06E 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..
TABLE OF CONTENTS:
MTU Diesel Engine 8 V 4000 R41 R41L R41R 12 V 4000 R41 R41L R41R 16 V 4000 R41 R41L R41R Operating Instruction Manual M015575-06E PDF DOWNLOAD
Title................................................................................................................................... 1 Inbetriebnahmemeldung................................................................................................................... 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 Transport....................................................................................................................... 11 Placement after transport....................................................................................................... 11 1.4 Crankshaft transport locking device............................................................................................. 12 Transport locking device........................................................................................................ 12 Removing the transport locking device from driving end (KS)..................................................................... 12 Fitting the transport locking device on driving end (KS)........................................................................ 12 1.5 Safety requirements when working on the engine.................................................................................. 14 Safety precautions when putting the equipment into operation.................................................................... 14 Safety requirements for operators............................................................................................... 14 Engine operation................................................................................................................ 14 Maintenance and repair.......................................................................................................... 14 Welding work.................................................................................................................... 15 Hydraulic installation and removal.............................................................................................. 15 Working on electrical/electronic assemblies..................................................................................... 16 Working with laser equipment.................................................................................................... 16 Operation of electrical equipment............................................................................................... 16 1.6 Auxiliary materials, fire prevention and environmental protection............................................................... 17 Fire prevention................................................................................................................. 17 Noise........................................................................................................................... 17 Environmental protection........................................................................................................ 17 Auxiliary materials............................................................................................................. 17 Lead............................................................................................................................ 17 Acids and alkaline solutions.................................................................................................... 17 Paints.......................................................................................................................... 17 Liquid nitrogen................................................................................................................. 17 Compressed air.................................................................................................................. 18 Used oil........................................................................................................................ 18 1.7 Standards for warning notices in the publication................................................................................ 19 2 Product Overview...................................................................................................................... 21 2.1 Engine Overview................................................................................................................. 21 2.1.1 Engine layout............................................................................................................. 21 Engine model designation.................................................................................................... 22 Key to the engine model designation 8/12/16V 4000 R41, R41L, R41R........................................................... 22 2.1.2 Sensors, actuators and injectors – Overview............................................................................... 23 Overview of sensors and actuators........................................................................................... 24 Overview of injectors....................................................................................................... 25 2.2 Engine Side and Cylinder Designations........................................................................................... 26 2.2.1 Engine side and cylinder designations..................................................................................... 26 2.3 Main Engine Dimensions.......................................................................................................... 27 2.3.1 Main engine dimensions.................................................................................................... 27 Main engine dimensions...................................................................................................... 27 2.4 Firing Order.................................................................................................................... 28 2.4.1 Firing order.............................................................................................................. 28 Firing order................................................................................................................ 28 2.5 Technical Data.................................................................................................................. 29 2.5.1 8/12/16 V 4000 R41 engine data........................................................................................... 29 REFERENCE CONDITIONS........................................................................................................ 29 POWER-RELATED DATA (power ratings are net brake power to ISO 3046).......................................................... 29 GENERAL CONDITIONS (for maximum power)...................................................................................... 29 CONSUMPTION................................................................................................................. 30 MODEL-RELATED DATA (basic design)........................................................................................... 30 COMBUSTION AIR / EXHAUST GAS................................................................................................ 30 COOLING SYSTEM (HT circuit)................................................................................................. 30 COOLING SYSTEM (LT circuit)................................................................................................. 31 LUBE OIL SYSTEM............................................................................................................. 31 FUEL SYSTEM................................................................................................................. 31 GENERAL OPERATING DATA...................................................................................................... 32 INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline) ................................................................... 32 CAPACITIES.................................................................................................................. 32 WEIGHTS / MAIN DIMENSIONS................................................................................................... 32 ACOUSTICS................................................................................................................... 32 2.5 2 8/12/16 V 4000 R41 L engine data......................................................................................... 33 REFERENCE CONDITIONS........................................................................................................ 33 POWER-RELATED DATA (power ratings are net brake power to ISO 3046).......................................................... 33 GENERAL CONDITIONS (for maximum power)...................................................................................... 33 CONSUMPTION................................................................................................................. 34 MODEL-RELATED DATA (basic design)........................................................................................... 34 COMBUSTION AIR / EXHAUST GAS................................................................................................ 34 COOLING SYSTEM (HT circuit)................................................................................................. 34 COOLING SYSTEM (LT circuit)................................................................................................. 35 LUBE OIL SYSTEM............................................................................................................. 35 FUEL SYSTEM................................................................................................................. 35 GENERAL OPERATING DATA...................................................................................................... 36 INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline) ................................................................... 36 CAPACITIES.................................................................................................................. 36 WEIGHTS / MAIN DIMENSIONS................................................................................................... 36 ACOUSTICS................................................................................................................... 36 2.5.3 8/12/16 V 4000 R41 R engine data......................................................................................... 37 REFERENCE CONDITIONS........................................................................................................ 37 POWER-RELATED DATA (power ratings are net brake power to ISO 3046).......................................................... 37 GENERAL CONDITIONS (for maximum power)...................................................................................... 37 CONSUMPTION................................................................................................................. 38 MODEL-RELATED DATA (basic design)........................................................................................... 38 COMBUSTION AIR / EXHAUST GAS................................................................................................ 38 COOLING SYSTEM (HT circuit)................................................................................................. 38 COOLING SYSTEM (LT circuit)................................................................................................. 39 LUBE OIL SYSTEM............................................................................................................. 39 FUEL SYSTEM................................................................................................................. 39 GENERAL OPERATING DATA...................................................................................................... 40 INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline) ................................................................... 40 CAPACITIES.................................................................................................................. 40 WEIGHTS / MAIN DIMENSIONS................................................................................................... 40 ACOUSTICS................................................................................................................... 40 3 Operation............................................................................................................................. 41 3.1 Putting the engine into operation after extended out-of-service periods (> 3 months)............................................ 41 3.2 Putting the engine into operation after scheduled out-of-service-period......................................................... 42 3.3 Starting the engine in manual mode.............................................................................................. 43 3.4 Operational checks.............................................................................................................. 44 3.5 Stopping the engine in manual mode.............................................................................................. 45 3.6 After stopping the engine....................................................................................................... 46 3.7 Plant – Cleaning................................................................................................................ 47 4 Maintenance........................................................................................................................... 49 4.1 Preface......................................................................................................................... 49 MTU maintenance concept......................................................................................................... 49 Preventive maintenance instructions............................................................................................. 49 Out-of-service periods.......................................................................................................... 49 Application group............................................................................................................... 49 Load profile.................................................................................................................... 50 4.2 Maintenance schedule matrix..................................................................................................... 51 Maintenance schedule matrix V 4000 R41/R41 R, 0-21,000 operating hours.......................................................... 51 Maintenance schedule matrix V 4000 R41/R41 R, 22,000-30,000 operating hours..................................................... 52 Maintenance schedule matrix V 4000 R41 L, 0-21,000 operating hours.............................................................. 53 Maintenance schedule matrix V 4000 R41 L, 22,000 – 24,000 operating hours....................................................... 54 4.3 Maintenance tasks............................................................................................................... 55 V 4000 R41, R41 R............................................................................................................... 55 V 4000 R41 L.................................................................................................................... 57 5 Troubleshooting....................................................................................................................... 59 5.1 Troubleshooting................................................................................................................. 59 Engine does not turn when starter is actuated................................................................................... 59 Engine turns but does not fire.................................................................................................. 59 Engine fires unevenly........................................................................................................... 59 Engine does not reach nominal speed............................................................................................. 60 Engine speed not steady......................................................................................................... 60 Charge-air temperature too high................................................................................................. 60 Charge air pressure too low..................................................................................................... 60 Coolant leaks on intercooler.................................................................................................... 61 Exhaust gas black............................................................................................................... 61 Exhaust gas blue................................................................................................................ 61 Exhaust gas white............................................................................................................... 61 5.2 ECU alarms...................................................................................................................... 62 6 Task Description...................................................................................................................... 75 6.1 Engine.......................................................................................................................... 75 6.1.1 Engine – Barring manually................................................................................................. 75 6.1.2 Engine – Barring with starting system..................................................................................... 76 6.1.3 Engine test run........................................................................................................... 77 6.2 Cylinder Liner.................................................................................................................. 78 6.2.1 Cylinder liner - Endoscopic examination................................................................................... 78 6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners......................................... 80 Terms used for endoscopic examination....................................................................................... 80 Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report..... 80 Evaluation of findings and further measures................................................................................. 81 6.3 Crankcase Breather.............................................................................................................. 82 6.3.1 Crankcase breather – Checking oil seperator .............................................................................. 82 6.3.2 Crankcase breather – Filter element replacement........................................................................... 83 6.4 Valve Drive..................................................................................................................... 84 6.4.1 Valve gear – Lubrication.................................................................................................. 84 6.4.2 Valve clearance – Check and adjustment.................................................................................... 85 6.4.3 Cylinder head cover – Removal and installation............................................................................ 88 6.5 Injection Pump / HP Pump........................................................................................................ 89 6.5.1 HP fuel pump – Relief bore check.......................................................................................... 89 6.6 Injector........................................................................................................................ 90 6.6.1 Injector – Replacement.................................................................................................... 90 6.6.2 Injector – Removal and installation....................................................................................... 91 6.7 Fuel System..................................................................................................................... 97 6.7.1 Fuel system venting....................................................................................................... 97 6.8 Fuel Filter..................................................................................................................... 98 6.8.1 Fuel filter – Replacement................................................................................................. 98 6.9 Charge-air Cooling.............................................................................................................. 99 6.9.1 Intercooler – Checking condensate drains for coolant discharge and obstructions........................................... 99 6.10 Air Filter.....................................................................................................................100 6.10.1 Air filter and dust bowl – Cleaning......................................................................................100 6.10.2 Air filter replacement...................................................................................................101 6.10.3 Air filter element – Removal and installation............................................................................102 6.11 Air Intake.....................................................................................................................103 6.11.1 Service indicator – Signal ring position check...........................................................................103 6.12 Starting System................................................................................................................104 6.12.1 Starter – Condition check ...............................................................................................104 6.13 Lube Oil System, Lube Oil Circuit..............................................................................................105 6.13.1 Check engine oil level...................................................................................................105 6.13.2 Engine oil – Change......................................................................................................106 6.13.3 Engine oil – Sample extraction and analysis..............................................................................108 6.14 Oil Conditioning...............................................................................................................109 6.14.1 Engine oil filter – Replacement .........................................................................................109 6.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement..........................................................110 6.15 Coolant Circuit, General, High-temperature Circuit.............................................................................112 6.15.1 Engine coolant level – Check.............................................................................................112 6.15.2 Engine coolant – Change..................................................................................................113 6.15.3 Engine coolant – Draining................................................................................................114 6.15.4 Engine coolant – Filling.................................................................................................115 6.15.5 Engine coolant pump – Relief bore check..................................................................................118 6.15.6 Engine coolant – Sample extraction and analysis..........................................................................119 6.15.7 Coolant filter – Replacement.............................................................................................120 6.16 Low-temperature Circuit........................................................................................................121 6.16.1 Charge-air coolant level check...........................................................................................121 6.16.2 Charge-air coolant change................................................................................................122 6.16.3 Charge-air coolant system – Draining.....................................................................................123 6.16.4 Charge-air coolant – Filling.............................................................................................124 6.16.5 Charge-air coolant pump – Relief bore check .............................................................................127 6.17 Engine Mounting................................................................................................................128 6.17.1 Engine mounts – Resilient element check..................................................................................128 6.18 General Wiring for Engine / Gearbox / Genset...................................................................................130 6.18.1 Engine wiring – Check....................................................................................................130 6.19 Accessories for (electronic) Engine Governor / Control System..................................................................131 6.19.1 Engine governor and connectors – Cleaning................................................................................131 6.19.2 Engine governor plug-in connections – Check..............................................................................132 7 Special Tools.........................................................................................................................133 7.1 Special tools...................................................................................................................133 8 Appendix..............................................................................................................................145 8.1 MTU contact person/service partner..............................................................................................145 8.2 Abbreviations...................................................................................................................146 8.3 Index...........................................................................................................................149
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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