MTU 12 V 4000 G23 Guide

Technical Documentation
Diesel Engine
12 V 4000 G23, G43
12 V 4000 G63, G83
16 V 4000 G23, G43
16 V 4000 G63, G83
Operating Instructions
M015710/01E
TP-6503

Printed in Germany
© 2007 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, microfilming 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.

Wichtig – Important – Importante
Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH
zurücksenden.
Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik-
Support (Gewährleistung, Ersatzteile etc.).
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
(warranty, spare parts, etc.).
Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen
GmbH.
Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en
exploitation contractuelle (garantie, rechanges, etc.).
Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU
Friedrichshafen GmbH.
Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico
contractual (garantía, piezas de repuesto, etc.).
Ritagliare “Avviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen
GmbH.
Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).
É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU
Friedrichshafen.
Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças
sobressalentes, etc.) estabelecido contratualmente.
Postcard
MTU Friedrichshafen GmbH
Department MST
88040 Friedrichshafen
GERMANY


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Please use block capitals!
Prière de remplir en lettres capitales!
¡A rellenar en letras de imprenta!
Scrivere in stampatello!
Favor preencher com letras de forma!
Motornr.:
Engine No.:
Nodu moteur:
Node motor:
Motore N.:
No. do motor:
Auftragsnr.:
MTU works order No.:
N° de commande:
N° de pedido:
N. commessa:
No. do
p
edido:
Motortyp:
Engine model:
Type du moteur:
Tipo de motor:
Motore tipo:
Ti
p
o do motor:
Inbetriebnahmedatum:
Date put into operation:
Mise en service le:
Fecha de puesta en servicio:
Messa in servizio il:
Data da coloca
ç
ão em servi
ç
o:
Eingebaut in:
Installation site:
Lieu de montage:
Lugar de montaje:
Installato:
Incor
p
orado em:
Schiffstyp / Schiffshersteller:
Vessel/type/class / Shipyard:
Type du bateau / Constructeur:
Tipo de buque / Constructor:
Tipo di barca / Costruttore
Ti
p
o de embarca
ç
ão/estaleiro naval:
Endabnehmer/Anschrift:
End user`s address:
Adresse du client final:
Dirección del cliente final:
Indirizzo del cliente finale:
Usuário final/endere
ç
o:
Bemerkung:
Remarks:
Remarques:
Observaciones:
Commento:
Observa
ç
ões:
Inbetriebnahme-
meldung
Commissioning
Note
Notice de mise
en service
Aviso de puesta
en servicio
Avviso di messa
in servizio
Participação da
colocação em
serviço

Table of Contents 01
1 Safety ........................................................................ 05
1.1 Generalconditions ....................................................... 05
1.2 Personnel and organizational requirements .................................. 06
1.3 Transport ............................................................... 07
1.4 Safety requirements when workingontheengine ............................. 08
1.5 Auxiliary materials, fire prevention and environmental protection . . .............. 11
1.6 Standards for warning notices in thepublication .............................. 13
2 ProductSummary .............................................................. 15
2.1 EngineLayout ........................................................... 15
2.1.1 Enginelayout .................................................... 15
2.2 Engine Side and Cylinder Designations ...................................... 17
2.2.1 Engine side and cylinder designations . . . .............................. 17
2.3 MainEngineDimensions .................................................. 18
2.3.1 Engine – Main dimensions .......................................... 18
2.4 FiringOrder ............................................................. 19
2.4.1 Firingorder ...................................................... 19
2.5 Final Compression Pressure . .............................................. 20
2.5.1 Final compression pressure ......................................... 20
2.6 TechnicalData .......................................................... 21
2.6.1 12V 4000 Gx3 engine data: Standby operation 3D, optimized fuel consumption
............................................................... 21
2.6.2 16V 4000 Gx3 engine data: Standby operation 3D, optimized fuel consumption
............................................................... 26
2.6.3 Engine data 12/16V 4000 Gx3: Standby operation 3D, optimized exhaust
emissions(EPAstage2) ........................................... 31
2.6.4 12V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized fuel
consumption .................................................... 36
2.6.5 16V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized fuel
consumption .................................................... 41
2.6.6 12/16 V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized
exhaust emission (EPA stage 2) ...................................... 46
2.6.7 12V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized exhaust
emissions(TA-Luft) ................................................ 51
3 Operation ..................................................................... 55
3.1 Putting the engine into operation after extended out-of-service-periods (>3
months) ................................................................ 55
3.2 Putting the engine into operation after scheduled out-of-service-period ........... 56
3.3 Starting the engine in manual mode ......................................... 57
3.4 Emergency start (override mode) ........................................... 58
3.5 Operational checks ...................................................... 59
3.6 Stopping the engine in manual mode . . ...................................... 60
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02 Table of Contents
3.7 Emergencystop ......................................................... 61
3.8 After stopping the engine – engine remains ready for operation .................. 62
3.9 After stopping the engine – putting the engine out of service . . .................. 63
4 Maintenance .................................................................. 65
4.1 Preface ................................................................ 65
4.2 Maintenance schedule matrix .............................................. 66
4.3 Maintenance tasks . ...................................................... 68
5 Troubleshooting ............................................................... 71
5.1 Troubleshooting ......................................................... 71
5.2 Engine governor ADEC (ECU 7) for Series 4000 genset engines - Fault messages . . . 74
6 Task Description . .............................................................. 95
6.1 Engine ................................................................. 95
6.1.1 Engine – Barring manually .......................................... 95
6.1.2 Engine – Barring with starting system . . . .............................. 96
6.1.3 Enginetestrun .................................................. 97
6.2 CylinderLiner ........................................................... 98
6.2.1 Cylinder liner – Endoscopic examination . .............................. 98
6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners
............................................................... 100
6.3 Crankcase Breather ...................................................... 102
6.3.1 Crankcase breather – Oil separator replacement, diaphragm check and
replacement ..................................................... 102
6.4 ValveDrive ............................................................. 104
6.4.1 Valve gear – Lubrication . . .......................................... 104
6.4.2 Valve clearance – Check and adjustment ............................... 105
6.4.3 Cylinder head cover – Remove and install .............................. 108
6.5 Injector ................................................................ 109
6.5.1 Injector–Replacement ............................................. 109
6.5.2 Injector – Removal and Installation .................................... 110
6.6 FuelSystem ............................................................ 114
6.6.1 Fuel system – Venting . . . .......................................... 114
6.7 FuelFilter .............................................................. 115
6.7.1 Fuelfilter–Replacement ........................................... 115
6.7.2 Fuel prefilter cleaning .............................................. 116
6.7.3 Fuel prefilter – differential pressure check and adjustment of gauge .......... 117
6.7.4 Fuelprefilter–draining ............................................. 118
6.7.5 Fuel prefilter – flushing ............................................. 120
6.7.6 Fuel prefilter – filter element replacement .............................. 122
6.8 Charge-air Cooling, General, LeftSide ....................................... 124
6.8.1 Intercooler – Checking condensate drains for coolant discharge and
obstructions ..................................................... 124
6.9 AirFilter ................................................................ 125
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Table of Contents 03
6.9.1 Airfilterreplacement .............................................. 125
6.9.2 Airfilter–Check .................................................. 126
6.9.3 Air filter removal and installation ...................................... 127
6.9.4 Rubber sleeves between air intake elbow and turbocharger – Replacement . . . . 128
6.10 AirIntake ............................................................... 129
6.10.1 Service indicator – Signal ring position check . . .......................... 129
6.11 StaringEquipment ....................................................... 130
6.11.1 Air starter – manual operation . ...................................... 130
6.11.2 Starter – Condition check .......................................... 131
6.12 Lube-oil System, Lube-oil Circuit . .......................................... 132
6.12.1 Engine oil – Change . . ............................................. 132
6.12.2 Engineoil–Levelcheck ............................................ 134
6.12.3 Engine oil – Sample extraction and analysis . . .......................... 135
6.13 OilFiltration/Cooling ..................................................... 136
6.13.1 Engine oil filter – Replacement ....................................... 136
6.13.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement . . .............. 137
6.14 Cooling Circuit, General, HT Circuit ......................................... 139
6.14.1 Engine coolant – Change . . ......................................... 139
6.14.2 Enginecoolant–Filling ............................................ 140
6.14.3 Engine coolant – Draining .......................................... 142
6.14.4 Engine coolant level – Check ........................................ 143
6.14.5 Engine coolant pump – Relief borecheck .............................. 144
6.14.6 Engine coolant – Sample extraction and analysis . . ...................... 145
6.15 LTCircuit ............................................................... 146
6.15.1 Charge-air coolant change .......................................... 146
6.15.2 Charge-air coolant – Filling .......................................... 147
6.15.3 Charge-air coolant – Draining ........................................ 149
6.15.4 Charge-air coolant level check ....................................... 150
6.15.5 Charge-aircoolantpump–Reliefborecheck ........................... 151
6.16 BeltDrive ............................................................... 152
6.16.1 Drive belt – Condition check ......................................... 152
6.17 Battery-charging Generator ................................................ 153
6.17.1 Battery-charging generator drive – Drive belt tension adjustment . . .......... 153
6.17.2 Battery-charging generator drive – Drive belt replacement .................. 154
6.18 Cabling, General for Engine / Gearbox/Plant ................................. 155
6.18.1 Enginewiring–Check ............................................. 155
6.19 Accessories for Engine Governor (Electronic) / Control System . . . .............. 156
6.19.1 ECU and connectors – Cleaning . . . .................................. 156
6.19.2 ECU – Checking plug-in connections .................................. 157
7 SpecialTools .................................................................. 159
7.1 Specialtools ............................................................ 159
8 Annex ....................................................................... 167
8.1 Manufacturer’s documentation ............................................. 167
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04 Table of Contents
8.2 MTU contact person/service partner ......................................... 168
8.3 Abbreviations ........................................................... 169
8.4 Index .................................................................. 173
M015710/01E 07-02 ©MTU

Safety 05
1 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.
M015710/01E 07-02 ©MTU

06 Safety
1.2 Personnel and organizational requirements
Personnel
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organization
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
M015710/01E 07-02 ©MTU