MTU Diesel Engine 16 V 4000 E20 Operating Instructions Manual M015241-03E PDF DOWNLOAD

MTU Diesel Engine 16 V 4000 E20 Operating Instructions Manual M015241-03E PDF DOWNLOAD

FILE DETAILS:

MTU Diesel Engine 16 V 4000 E20 Operating Instructions Manual M015241-03E PDF DOWNLOAD

Language : English
Pages : 140
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

MTU Diesel Engine 16 V 4000 E20 Operating Instructions Manual M015241-03E 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............................................... 12
        1.6 Explosion hazard when removing inspection port cover on engine............................. 13
        1.7 Safety regulations for maintenance and repair work......................................... 14
        1.8 Fluids and lubricants, fire prevention and environmental protection........................ 17
        1.9 Engine – Barring with starting system...................................................... 19
        1.10 Conventions for safety instructions in the text........................................... 20
    2 General Information.............................................................................. 21
        2.1 Engine layout.............................................................................. 21
        2.2 Engine side and cylinder designations...................................................... 25
        2.3 Sensors and actuators – Overview........................................................... 26
    3 Technical Data................................................................................... 28
        3.1 16V 4000 E20 engine data................................................................... 28
        3.2 Firing order............................................................................... 32
    4 Operation........................................................................................ 33
        4.1 Putting the engine into operation after extended out-of-service periods (>3 months)........ 33
        4.2 Putting the engine into operation after scheduled out-of-service-period.................... 34
        4.3 Engine – Start in manual mode.............................................................. 35
        4.4 Operational checks......................................................................... 36
        4.5 Engine – Shutdown in manual mode........................................................... 37
        4.6 After stopping the engine.................................................................. 38
        4.7 Plant – Cleaning........................................................................... 39
    5 Maintenance...................................................................................... 40
        5.1 Maintenance task reference table [QL1]..................................................... 40
    6 Troubleshooting.................................................................................. 41
        6.1 Troubleshooting............................................................................ 41
        6.2 DDEC alarms................................................................................ 44
    7 Task Description................................................................................. 64
        7.1 Engine..................................................................................... 64
            7.1.1 Engine – Barring manually............................................................ 64
            7.1.2 Engine – Barring with starting system................................................ 66
        7.2 Cylinder Liner............................................................................. 67
            7.2.1 Cylinder liner – Endoscopic examination.............................................. 67
            7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners.... 69
        7.3 Crankcase Breather......................................................................... 71
            7.3.1 Crankcase breather – Oil separator check............................................. 71
            7.3.2 Crankcase breather – Filter element replacement...................................... 72
            7.3.3 Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning.... 74
        7.4 Valve Drive................................................................................ 75
            7.4.1 Valve gear – Lubrication............................................................. 75
            7.4.2 Valve clearance – Check and adjustment............................................... 76
            7.4.3 Cylinder head cover – Removal and installation....................................... 80
        7.5 Injection Pump / HP Pump................................................................... 81
            7.5.1 HP pump – Relief bore check.......................................................... 81
        7.6 Injection Valve / Injector................................................................. 82
            7.6.1 Injector – Replacement............................................................... 82
            7.6.2 Injector – Removal and installation.................................................. 83
        7.7 Fuel System................................................................................ 88
            7.7.1 Fuel system – Venting................................................................ 88
        7.8 Fuel Filter................................................................................ 89
            7.8.1 Fuel filter – Replacement............................................................ 89
            7.8.2 Fuel prefilter – Draining............................................................ 90
            7.8.3 Edge-type fuel filter – Draining..................................................... 91
        7.9 Charge-Air Cooling......................................................................... 92
            7.9.1 Intercooler – Check drain for coolant leakage and obstruction........................ 92
        7.10 Air Intake................................................................................ 93
            7.10.1 Service indicator – Check........................................................... 93
        7.11 Starting Equipment........................................................................ 94
            7.11.1 Starter – Condition check........................................................... 94
            7.11.2 Cold start system with ether injection – Check...................................... 95
        7.12 Lube Oil System, Lube Oil Circuit......................................................... 96
            7.12.1 Engine oil level – Check............................................................ 96
            7.12.2 Engine oil – Change................................................................. 97
            7.12.3 Engine oil – Sample extraction and analysis......................................... 99
        7.13 Oil Filtration / Cooling..................................................................100
            7.13.1 Engine oil filter – Replacement.....................................................100
            7.13.2 Centrifugal oil filter – Cleaning and filter sleeve replacement.....................101
        7.14 Coolant Circuit, General, High-Temperature Circuit........................................103
            7.14.1 Coolant level - Check...............................................................103
            7.14.2 Engine coolant – Change.............................................................104
            7.14.3 Engine coolant – Draining...........................................................105
            7.14.4 Engine coolant – Filling............................................................106
            7.14.5 Engine coolant pump – Relief bore check.............................................108
            7.14.6 Coolant – Sample extraction and analysis............................................109
        7.15 Low-Temperature Circuit...................................................................110
            7.15.1 Charge-air coolant – Level check....................................................110
            7.15.2 Charge-air coolant – Change.........................................................111
            7.15.3 Charge-air coolant – Draining.......................................................112
            7.15.4 Charge-air coolant – Filling........................................................113
            7.15.5 Charge-air coolant pump – Relief bore check.........................................116
        7.16 Belt Drive................................................................................117
            7.16.1 Drive belt – Condition check........................................................117
        7.17 Battery-Charging Generator................................................................118
            7.17.1 Battery-charging generator – Condition check........................................118
            7.17.2 Battery-charging generator – Check..................................................119
            7.17.3 Battery-charging generator – Removal and installation...............................120
            7.17.4 Battery-charging generator drive – Drive belt and belt tensioner replacement........122
            7.17.5 Battery-charging generator drive – Drive belt tension adjustment....................123
        7.18 Fan Drive.................................................................................124
            7.18.1 Fan drive belt– Tension check / adjustment..........................................124
            7.18.2 Fan drive – Drive belt replacement..................................................126
        7.19 Wiring (General) for Engine/Gearbox/Unit..................................................127
            7.19.1 Engine wiring – Check...............................................................127
        7.20 Accessories for (Electronic) Engine Governor / Control System.............................128
            7.20.1 DDEC and connectors – Cleaning......................................................128
            7.20.2 DDEC – Checking plug-in connections.................................................130
    8 Appendix A.......................................................................................131
        8.1 Abbreviations..............................................................................131
        8.2 MTU contacts/service partners..............................................................134
    9 Appendix B.......................................................................................135
        9.1 Special Tools..............................................................................135
        9.2 Index......................................................................................139

DESCRIPTION:

MTU Diesel Engine 16 V 4000 E20 Operating Instructions Manual M015241-03E PDF DOWNLOAD

SAFETY:
General Conditions

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 UseThe 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 case. 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 ConversionsUnauthorized 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 PartsOnly 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 case.Reworking ComponentsRepair or engine overhaul must be carried out in workshops authorized by MTU.