MTU 12 V 4000 G21R User manual

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

Printed in Germany
© 2011 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Commissioning Note
Important
Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐
ranty, spare parts, etc.).

Table of Contents
1 Safety
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 13
1.6 Explosion hazard when removing
inspection port cover on engine 14
1.7 Safety regulations for maintenance and
repair work 15
1.8 Fluids and lubricants, fire prevention and
environmental protection 18
1.9 Conventions for safety instructions in the
text 20
2 General Information
2.1 Engine side and cylinder designations 21
2.2 Engine layout 22
3 Technical Data
3.1 12V 4000 engine data, continuous
operation, variable 3B, optimized fuel
consumption 23
3.2 12V 4000 engine data, continuous
operation, variable 3B, emissions optimized
w/o certificate 27
3.3 12V 4000 engine data, continuous
operation, variable 3B, emissions optimized
(TA-Luft) 31
3.4 Final compression pressure 34
3.5 Firing order 35
3.6 Engine – Main dimensions 36
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 37
4.2 Putting the engine into operation after
scheduled out-of-service-period 38
4.3 Start engine in manual mode (testing
mode) 39
4.4 Starting the engine in emergency situations
(override mode) 40
4.5 Operational checks 41
4.6 Stop engine in manual mode (testing
mode) 42
4.7 Emergency stop 43
4.8 After stopping the engine – Engine remains
ready for operation 44
4.9 After stopping the engine – putting the
engine out of service 45
4.10 Plant – Cleaning 46
5 Maintenance
5.1 Maintenance task reference table [QL1] 47
6 Troubleshooting
6.1 Troubleshooting 48
6.2 Fault messages on engine governor 51
7 Task Description
7.1 Engine 63
7.1.1 Engine – Barring manually 63
7.1.2 Engine – Barring with starting system 64
7.1.3 Engine – Test run 65
7.2 Cylinder Liner 66
7.2.1 Cylinder liner – Endoscopic examination 66
7.2.2 Cylinder liner - Instructions and comments on
endoscopic and visual examination 68
7.3 Crankcase Breather 70
7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 70
7.4 Valve Drive 72
7.4.1 Valve gear – Lubrication 72
7.4.2 Valve clearance – Check and adjustment 73
7.4.3 Cylinder head cover – Removal and
installation 75
7.5 Injection Pump / HP Pump 76
7.5.1 HP pump – Relief bore check 76
7.6 Injection Valve / Injector 77
7.6.1 Injector – Replacement 77
7.6.2 Injector – Removal and installation 78
7.7 Fuel System 83
7.7.1 Fuel system – Venting 83
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7.8 Fuel Filter 84
7.8.1 Fuel filter – Replacement 84
7.8.2 Fuel prefilter cleaning 85
7.8.3 Fuel prefilter – Differential pressure gauge
check and adjustment 86
7.8.4 Fuel prefilter – Draining 87
7.8.5 Fuel prefilter ‒ Flushing 88
7.8.6 Fuel prefilter – Filter element replacement 90
7.9 Charge-Air Cooling 92
7.9.1 Intercooler – Check drain for coolant leakage
and obstruction 92
7.10 Air Filter 93
7.10.1 Air filter – Replacement 93
7.10.2 Air filter – Removal and installation 94
7.11 Air Intake 95
7.11.1 Contamination indicator – Signal ring position
check 95
7.12 Starting Equipment 96
7.12.1 Air starter – Manual operation 96
7.12.2 Starter – Condition check 97
7.13 Lube Oil System, Lube Oil Circuit 98
7.13.1 Engine oil level – Check 98
7.13.2 Engine oil – Change 99
7.13.3 Engine oil – Sample extraction and analysis 101
7.14 Oil Filtration / Cooling 102
7.14.1 Engine oil filter – Replacement 102
7.14.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 103
7.15 Coolant Circuit, General, High-
Temperature Circuit 105
7.15.1 Coolant level - Check 105
7.15.2 Engine coolant – Change 106
7.15.3 Engine coolant – Draining 107
7.15.4 Engine coolant – Filling 108
7.15.5 Engine coolant pump – Relief bore check 111
7.15.6 Coolant – Sample extraction and analysis 112
7.16 Low-Temperature Circuit 113
7.16.1 Charge-air coolant – Level check 113
7.16.2 Charge-air coolant – Change 114
7.16.3 Charge-air coolant – Draining 115
7.16.4 Charge-air coolant – Filling 116
7.16.5 Charge-air coolant – Sample extraction and
analysis 119
7.16.6 Charge-air coolant pump – Relief bore check 120
7.17 Belt Drive 121
7.17.1 Drive belt – Condition check 121
7.18 Battery-Charging Generator 122
7.18.1 Battery-charging generator drive – Drive belt
tension adjustment 122
7.18.2 Battery-charging generator drive – Drive belt
tension check 123
7.18.3 Battery-charging generator drive – Drive belt
replacement 124
7.19 Wiring (General) for Engine/Gearbox/Unit 125
7.19.1 Engine wiring – Check 125
7.20 Accessories for (Electronic) Engine
Governor / Control System 126
7.20.1 Engine control unit and connectors – Cleaning 126
7.20.2 Engine control unit plug connections – Check 127
8 Appendix A
8.1 Abbreviations 128
8.2 MTU contacts/service partners 131
9 Appendix B
9.1 Special Tools 132
9.2 Index 135
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory 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 use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged 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 mainte‐
nance and repair specifications.
Modifications or conversions
Unauthorized 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 parts
Only 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 components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.
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1.3 Transport
Engine transport
Lift the engine only with the lifting eyes provided.
Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans‐
port pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and
engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured against
slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
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1.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Torque wrench, 60-320 Nm F30047446 1
Engine oil
Transport locking device
Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine
transport.
For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device must remain installed as long as possible during engine installation in order
to avoid damage.
2. Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is also re‐
moved.
3. Prior to every engine transport, the transport locking device must be reinstalled on both sides according
to the instructions.
4. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
Removing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
1. Remove screws (4) om both sides and take
off with washers (3), guard plates (1) and
engine mounting brackets (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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Fitting the transport locking device
on driving end (KS)
Note: Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
1. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Screw nut (3) onto screws (4) up to the end of the thread.
3. Fit the locks (1) through the openings of plates (2) and fasten with the screws (4).
4. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
5. Screw on nuts (3) of both screws (4) at plates (2) and secure.
6. Fit label (7) to mark the engine as "Fitted with transport locking device".
Removing the transport locking
device from driving end (KS)
1. Release the locknuts (3) on both sides of
the flywheel housing, remove screws (4)
and take off the two locks (1).
2. Remove screws (6) with washers (5), label
(7) and plates (2)..
3. Store the removed parts of the transport
locking device carefully for possible reuse.
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Installing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
Note: Always use the screws supplied with the or
removed from the guard plates and engine
mounting brackets to secure them on the
engine.
1. Install engine mounting brackets (2) on both
sides with guard plates (1) washers (3), and
screws (4).
2. Tighten screws (4).
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1.5 Safety regulations for startup and operation
Safety requirements for initial operation
Prior to initial operation of the unit, install the assembly or unit according to the specifications and check
the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that nobody is in the danger area of moving machine parts.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the signaling and alarm systems work properly.
Safety requirements for operators
The procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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1.6 Explosion hazard when removing inspection port cover on
engine
DANGER Explosion hazard due to oil vapors.
Risk of serious injury – danger to life!
• Allow the engine to cool down before opening the crankcase!
• Avoid open flames, electrical sparks and ignition sources.
Safety instructions
uBefore starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion
due to oil vapors).
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1.7 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
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For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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1.8 Fluids and lubricants, fire prevention and environmental
protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their
use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal
Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-
relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Fluids and lubricants
Use only fluids and lubricants that have been tested and approved by MTU.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
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Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.
Painting
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective
clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water.
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1.9 Conventions for safety instructions in the text
DANGER In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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