MTU 12 V 4000 G21R User manual

Operating Instructions
Diesel engine
12 V 4000 G21R
12 V 4000 G41R
MS150064/01E

2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end of
the engine.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 KGS = Free end
2 Right engine side
3 KS = Driving end
4 Left engine side
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2.2 Engine layout
Illustration valid for 8/12/16V 4000 Gxy engines
1 Coolant line
2 Exhaust system
3 Exhaust turbocharger
4 Air intake
5 Intercooler
6 Engine governor
7 PTO systems, driving end
and free end (coupling)
8 Air supply
9 Starting equipment
10 Oil filler neck
11 Mounting / support
12 Oil pan
13 Fuel line (high pressure)
14 Inspection port cover
15 Cylinder head
16 Fuel line (low pressure)
17 Lube oil filter
18 Fuel pump (high pres‐
sure)
19 Gear train
20 Running gear
21 Coolant system
22 Lube oil system
Engine model designation
Key to the engine model designations 8/12/16V 4000 Gxy
Designation Meaning
8/12/16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
G Application
x Application segment (2, 4, 6, 8)
y Design index (1, 2,...)
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3 Technical Data
3.1 12V 4000 engine data, continuous operation, variable 3B,
optimized fuel consumption
Explanation
Abbr. Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated without changes (e.g. of power set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V
4000 G21R
12V
4000 G21R
12V
4000 G41R
Application group 3B 3B 3B
Intake air temperature °C 25 25 25
Charge-air coolant temperature °C 55 55 55
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 12 12
Engine rated speed A rpm 1500 1800 1800
Continuous power ISO 3046 (10%
overload capability) (design power
DIN 6280, ISO 8528)
A kW 1102 1246 1246
GENERAL CONDITIONS (for maximum power)
Number of cylinders 12 12 12
Intake air depression (new filter) A mbar 30 30 30
Intake air depression, max. L mbar 50 50 60
Exhaust pressure A mbar 30 30 30
Exhaust pressure, max. L mbar 51 51 51
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CONSUMPTION
Number of cylinders 12 12 12
Lube oil consumption after engine
run-in (B = hourly fuel consumption)
R % of B 0.5 0.5 0.5
MODEL RELATED DATA (basic design)
Number of cylinders 12 12 12
Cylinder arrangement: V angle Degrees (°) 90 90 90
Bore mm 165 165 165
Stroke mm 190 190 190
Displacement per cylinder liter 4.06 4.06 4.06
Displacement, total liter 48.7 48.7 65.0
Compression ratio 15.5 15.5 15.5
Number of inlet valves per cylinder 2 2 2
Number of exhaust valves per cylin‐
der
2 2 2
Standard flywheel housing flange (en‐
gine main PTO)
SAE 00 00 00
COMBUSTION AIR / EXHAUST GAS
Number of cylinders 12 12 12
Charge air pressure before cylinder,
BL
R bar ABS 2.4 2.8 2.8
COOLING SYSTEM (HT circuit)
Number of cylinders 12 12 12
Coolant temperature (at engine outlet
to cooling equipment)
A °C 95 95 95
Coolant temperature after engine,
alarm
R °C 97 97 97
Coolant temperature after engine,
shutdown
L °C 99 99 99
Coolant antifreeze content, max. L % 50 50 50
Pressure loss in external raw water
system, max.
L bar 0.7 0.7 0.7
COOLING SYSTEM (LT circuit)
Number of cylinders 12 12 12
Coolant temperature before intercool‐
er (at engine inlet from cooling equip‐
ment)
A °C 55 55 55
Coolant antifreeze content, max. L % 50 50 50
Pressure loss in external raw water
system, max.
L bar 0.7 0.7 0.7
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LUBE OIL SYSTEM
Number of cylinders 12 12 12
Lube oil temperature before engine,
from
R °C 85 85 85
Lube oil operating temperature before
engine, to
R °C 95 95 95
Lube oil temperature before engine,
alarm
R °C 95 95 95
Lube oil operating pressure before
engine, from
R bar 5.0 5.0 5.0
Lube oil operating pressure before
engine, to
R bar 6.0 6.0 6.0
Lube oil pressure before engine,
alarm
R bar 4.5 4.5 4.5
Lube oil pressure before engine,
shutdown
L bar 4.0 4.0 4.0
FUEL SYSTEM
Number of cylinders 12 12 12
Fuel pressure at supply connection to
engine, min. (when engine is starting)
L bar -0.1 -0.1 -0.1
Fuel pressure at engine supply con‐
nection, max. (when engine is start‐
ing)
L bar 1.5 1.5 1.5
GENERAL OPERATING DATA
Number of cylinders 12 12 12
Cold start capability: air temperature
(w/o start aid, w/o preheating) (case
A)
R °C 5 10 10
Coolant preheating, preheating tem‐
perature (min.)
R °C 32 32 32
Firing speed, from R rpm 80 80 80
Firing speed, to R rpm 120 120 120
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CAPACITIES
Number of cylinders 12 12 12
Engine coolant capacity (without cool‐
ing equipment)
R liter 160 160 160
Charge-air coolant capacity, engine
side
R liter 40 40 40
Engine oil at initial filling (standard oil
system) (Option: max. operating incli‐
nations)
R liter 260 260 260
Oil pan capacity at dipstick mark
"min." (standard oil system) (Option:
max. operating inclinations)
L liter 160 160 160
Oil pan capacity at dipstick mark
"max." (standard oil system) (Option:
max. operating inclinations)
L liter 200 200 200
WEIGHTS / MAIN DIMENSIONS
Number of cylinders 12 12 12
Engine weight, dry (basic engine con‐
figuration acc. to scope of supply
specification)
R kg 5650 5650 5650
ACOUSTICS
Number of cylinders 12 12 12
Exhaust noise, unsilenced, BL (free-
field sound pressure level Lp, 1m dis‐
tance, ISO 6798, +3dB(A) tolerance)
R dB(A) 115 118 115
Engine surface noise with attenuated
intake noise (filter), BL, (free-field
sound-pressure level Lp, 1m dis‐
tance, ISO 6798+2dB(A) tolerance)
R dB(A) 106 108 106
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3.2 12V 4000 engine data, continuous operation, variable 3B,
emissions optimized w/o certificate
Explanation
Abbr. Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated without changes (e.g. of power set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V
4000 G21R
12V
4000 G41R
Application group 3B 3B
Intake air temperature °C 25 25
Charge-air coolant temperature °C 55 55
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 12
Engine rated speed A rpm 1800 1800
Continuous power ISO 3046 (10% overload
capability, design power DIN 6280, ISO
8528)
A kW 1246 1246
GENERAL CONDITIONS (for maximum power)
Number of cylinders 12 12
Intake air depression (new filter) A mbar 30 30
Intake air depression, max. L mbar 50 50
Exhaust pressure A mbar 30 30
Exhaust pressure, max. L mbar 51 51
CONSUMPTION
Number of cylinders 12 12
Lube oil consumption after engine run-in (B
= hourly fuel consumption)
R % of B 0.5 0.5
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MODEL RELATED DATA (basic design)
Number of cylinders 12 12
Number of cylinders 12 12
Cylinder arrangement: V angle Degrees (°) 90 90
Bore mm 165 165
Stroke mm 190 190
Displacement per cylinder liter 4.06 4.06
Displacement, total liter 48.7 48.7
Compression ratio 15.5 15.5
Number of inlet valves per cylinder 2 2
Number of exhaust valves per cylinder 2 2
Standard flywheel housing flange (engine
main PTO)
SAE 00 00
COMBUSTION AIR / EXHAUST GAS
Number of cylinders 12 12
Charge air pressure before cylinder, BL R bar ABS 3.1 3.1
COOLING SYSTEM (HT circuit)
Number of cylinders 12 12
Coolant temperature (at engine outlet to
cooling equipment)
A °C 95 95
Coolant temperature after engine, alarm R °C 97 97
Coolant temperature after engine, shutdown L °C 99 99
Coolant antifreeze content, max. L % 50 50
Pressure loss in external raw water system,
max.
L bar 0.7 0.7
COOLING SYSTEM (LT circuit)
Number of cylinders 12 12
Coolant temperature before intercooler (at
engine inlet from cooling equipment)
A °C 55 55
Coolant antifreeze content, max. L % 50 50
Pressure loss in external raw water system,
max.
L bar 0.7 0.7
LUBE OIL SYSTEM
Number of cylinders 12 12
Lube oil temperature before engine, from R °C 85 85
Lube oil operating temperature before en‐
gine, to
R °C 95 95
Lube oil temperature before engine, alarm R °C 95 95
Lube oil operating pressure before engine,
from
R bar 5.0 5.0
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Number of cylinders 12 12
Lube oil operating pressure before engine,
to
R bar 6.0 6.0
Lube oil pressure before engine, alarm R bar 4.5 4.5
Lube oil pressure before engine, shutdown L bar 4.0 4.0
FUEL SYSTEM
Number of cylinders 12 12
Fuel pressure at supply connection to en‐
gine, min. (when engine is starting)
L bar -0.1 -0.1
Fuel pressure at engine supply connection,
max. (when engine is starting)
L bar 1.5 1.5
GENERAL OPERATING DATA
Number of cylinders 12 12
Cold start capability: air temperature (w/o
start aid, w/o preheating) (case A)
R °C 5 10
Coolant preheating, preheating temperature
(min.)
R °C 32 32
Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
CAPACITIES
Number of cylinders 12 12
Engine coolant capacity (without cooling
equipment)
R liter 160 160
Charge-air coolant capacity, engine side R liter 40 40
Engine oil at initial filling (standard oil sys‐
tem) (Option: max. operating inclinations)
R liter 260 260
Oil pan capacity at dipstick mark "min."
(standard oil system) (Option: max. operat‐
ing inclinations)
L liter 160 160
Oil pan capacity at dipstick mark "max."
(standard oil system) (Option: max. operat‐
ing inclinations)
L liter 200 200
WEIGHTS / MAIN DIMENSIONS
Number of cylinders 12 12
Engine weight, dry (basic engine configura‐
tion acc. to scope of supply specification)
R kg 5650 5650
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ACOUSTICS
Number of cylinders 12 12
Exhaust noise, unsilenced, BL (free-field
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
R dB(A) 117 117
Engine surface noise with attenuated intake
noise (filter), BL, (free-field sound-pressure
level Lp, 1m distance, ISO 6798+2dB(A) tol‐
erance)
R dB(A) 107 107
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3.3 12V 4000 engine data, continuous operation, variable 3B,
emissions optimized (TA-Luft)
Explanation
Abbr. Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated without changes (e.g. of power set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V
4000 G21R
Application group 3B
Intake air temperature °C 25
Charge-air coolant temperature °C 55
Barometric pressure mbar 1000
Site altitude above sea level m 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12
Engine rated speed A rpm 1500
Continuous power ISO 3046 (10% overload capabili‐
ty) (design power DIN 6280, ISO 8528)
A kW 1102
GENERAL CONDITIONS (for maximum power)
Number of cylinders 12
Intake air depression (new filter) A mbar 30
Intake air depression, max. L mbar 50
Exhaust pressure A mbar 30
Exhaust pressure, max. L mbar 51
CONSUMPTION
Number of cylinders 12
Lube oil consumption after engine run-in (B = hourly
fuel consumption)
R % of B 0.5
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MODEL RELATED DATA (basic design)
Number of cylinders 12
Number of cylinders 12
Cylinder arrangement: V angle Degrees (°) 90
Bore mm 165
Stroke mm 190
Displacement per cylinder liter 4.06
Displacement, total liter 48.7
Compression ratio 15.5
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
Standard flywheel housing flange (engine main PTO) SAE 00
COMBUSTION AIR / EXHAUST GAS
Number of cylinders 12
Charge air pressure before cylinder, BL R bar ABS 3.0
COOLING SYSTEM (HT circuit)
Number of cylinders 12
Coolant temperature (at engine outlet to cooling
equipment)
A °C 95
Coolant temperature after engine, alarm R °C 97
Coolant temperature after engine, shutdown L °C 99
Coolant antifreeze content, max. L % 50
Pressure loss in external raw water system, max. L bar 0.7
COOLING SYSTEM (LT circuit)
Number of cylinders 12
Coolant temperature before intercooler (at engine in‐
let from cooling equipment)
A °C 55
Coolant antifreeze content, max. L % 50
Pressure loss in external raw water system, max. L bar 0.7
LUBE OIL SYSTEM
Number of cylinders 12
Lube oil temperature before engine, from R °C 85
Lube oil operating temperature before engine, to R °C 95
Lube oil temperature before engine, alarm R °C 95
Lube oil operating pressure before engine, from R bar 5.0
Lube oil operating pressure before engine, to R bar 6.0
Lube oil pressure before engine, alarm R bar 4.5
Lube oil pressure before engine, shutdown L bar 4.0
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FUEL SYSTEM
Number of cylinders 12
Fuel pressure at supply connection to engine, min.
(when engine is starting)
L bar -0.1
Fuel pressure at engine supply connection, max.
(when engine is starting)
L bar 1.5
GENERAL OPERATING DATA
Number of cylinders 12
Cold start capability: air temperature (w/o start aid, w/
o preheating) (case A)
R °C 5
Coolant preheating, preheating temperature (min.) R °C 32
Firing speed, from R rpm 80
Firing speed, to R rpm 120
CAPACITIES
Number of cylinders 12
Engine coolant capacity (without cooling equipment) R liter 160
Charge-air coolant capacity, engine side R liter 40
Engine oil at initial filling (standard oil system) (Op‐
tion: max. operating inclinations)
R liter 260
Oil pan capacity at dipstick mark "min." (standard oil
system) (Option: max. operating inclinations)
L liter 160
Oil pan capacity at dipstick mark "max." (standard oil
system) (Option: max. operating inclinations)
L liter 200
WEIGHTS / MAIN DIMENSIONS
Number of cylinders 12
Engine weight, dry (basic engine configuration acc. to
scope of supply specification)
R kg 5650
ACOUSTICS
Number of cylinders 12
Exhaust noise, unsilenced, BL (free-field sound pres‐
sure level Lp, 1m distance, ISO 6798, +3dB(A) toler‐
ance)
R dB(A) 115
Engine surface noise with attenuated intake noise (fil‐
ter), BL, (free-field sound-pressure level Lp, 1m dis‐
tance, ISO 6798+2dB(A) tolerance)
R dB(A) 106
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3.4 Final compression pressure
Final compression pressure
Final compression pressure at 120 rpm 24 bar to 28 bar
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3.5 Firing order
Firing order
Number of cylin‐
ders
Firing order
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
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3.6 Engine – Main dimensions
Engine – Main dimensions
Engine model Length (A) Width (B) Height (C)
8 V 4000 Gxy approx. 1940 mm approx. 1550 mm approx. 1760 mm
12 V 4000 Gxy approx. 2410 mm approx. 1550 mm approx. 1760 mm
16 V 4000 Gxy approx. 2880 mm approx. 1550 mm approx. 1760 mm
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4 Operation
4.1 Putting the engine into operation after extended out-of-
service periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specification (A001061/..) is available.
Putting the engine into operation after extended out-of-service-periods (>3 months)
Item Task
Engine Depreserve (→ MTU Fluids and Lubricants Specification A001061/..).
Valve Gear Lubricate valve gear (→ Page 72);
Lube oil system Check oil level (→ Page 98);
Fuel prefilter Prime (→ Page 90).
Fuel prefilter, pressure
gauge
Align adjustable pointer with position of pressure indicator (→ Page 86).
Fuel system Vent (→ Page 83).
Cooling system If engine is out of service for more than one year, change engine coolant
(→ Page 106);
Change charge-air coolant (→ Page 114).
Cooling system Check engine coolant level (→ Page 105);
Check charge-air coolant level (→ Page 113).
Cooling system Preheat coolant with preheating unit.
ECU Check plug-in connections (→ Page 127).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control
system
Switch ON;
Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER‐
ATION.
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4.2 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
☑ Engine is stopped and starting disabled.
Putting the engine into operation
Item Task
Lube oil system Check oil level (→ Page 98);
Cooling system Check engine coolant level (→ Page 105);
Check charge-air coolant level (→ Page 113).
Cooling system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 87).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control
system
Switch ON;
Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER‐
ATION.
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4.3 Start engine in manual mode (testing mode)
Preconditions
☑ Generator (if provided) not connected to network.
☑ External start interlock is not activated.
DANGER Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Task
Operating mode selector
switch (if provided)
Change to manual mode.
Preheating pump (if provid‐
ed)
Switch ON.
Starting the engine
Item Task
Switchgear cabinet, control
panel etc. (depending on
manufacturer)
If coolant temperature is
• > 40 °C (with preheating equipment), or
• > 5 °C (without preheating equipment):
Press start button.
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing crankshaft speed;
• After the starting sequence is completed, engine is running at rated
speed.
Connect generator to network (if provided), run engine to reach operating
temperature )
Item Task
Switchgear cabinet, control
panel etc. (depending on
manufacturer)
Close the generator circuit breaker.
Engine Apply full load only after engine has reached operating temperature (cool‐
ant temperature approx. 75 °C).
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