MWM Acteon Instruction manual

Workshop Manual

MWM- Motores International
Assistência ao Cliente / Asistencia al Cliente / Customer Assistance
Fax:
Av.das Nações Unidas, 22.002
CEP- 04795-915 - São Paulo - SP - Brasil
[phone]
9.612.0.006.7160 - 11/06
Internet:
e-mail
Fone:
(DDG):
www.mwm-international.com.br
: [email protected]
[phone]
0800 0110229
Impresso no Brasil
Workshop Manual

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Presentation
Introduction....................................................................................................................................... 1-2
How to Use thisWorkshop Manual .................................................................................................. 1-2
ImportantSafety Remarks ................................................................................................................ 1-3
GeneralInstructions ......................................................................................................................... 1-4
Cleaning General Instructions ......................................................................................................... 1-5
Engine Serial Number Identification and Location ......................................................................... 1-6
Cylinder Numeration ......................................................................................................................... 1-7

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Introduction
This manual contains complete information and specification to assembly and disassembly MWM Acteon engines
andall componentsmanufactured byMWM Motores Diesel Ltda.
Read and follow all safety instructions.Consult the item ATTENTION in the Safety General Instructions, in the next
section.
Therepairing procedures, describedin this manual, consider thatthe engine ispositioned on an appropriate stand.
Some of the assembly and disassembly procedures require special tools.
Make sure that the correct tools are used according indicated in the procedures.
The assembly and disassembly specifications and information presented in this manual are the ones which is
effective in the moment of its print. MWM Motores Diesel Ltda. reserves the right of making any change, at any
moment.MWM Motores Diesel Ltda. reserves the rightof doingchanges inthe product atany momentwithout this
to incur in any further obligation. In case of any difference in the engine or information of this manual, contact an
MWM Authorized Distributor or the factory.
The components used in MWM engines production are produced with last generation technology components and
withhigh levelquality standards.Whenparts changes arenecessary, itis recommended touse only MWM genuine
spare parts.These parts can be identified by the following marks.
How to Use this Manual
To create this Manual ithas been takenasbase ageneric MWMActeon engine, whichoperationsand maintenance
procedures are the same for all models of this series.The illustrations therefore, could differ from application to
application.
InthisManual,allreferencestothecomponentsoftheenginearedividedin17specificsections.Foryourconvenience,
the organization of the Manual is consistent with MWM Service Bulletins.
Content of the Manual
The Manual contains an index that can be used as a quick reference to access each section.
Content of the Sections
Each section contains the following information:
• Page of index in the beginning of each section to help for the fast location of the desired information.
• Generalinformation aboutthe operationof thecomponent andthe explanationof theirmain changes.
• Componentdisassembly, cleaning,inspection anddimension instructions.
Remissive Index
In the end of the manual there is a remissive index to help the location of specific information.
Information on Metric System
All dimensions are expressed in the International Metric System (I.S.).

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Important Safety Remarks
Carefullyreadallsafetyproceduresandremarks beforeperforminganyrepairintheengine.Thefollowinglistpresents
the general cautions that must be followed to guarantee your personal safety. Special safety measures can be
presentedwith the procedures, ifnecessary.
• Make sure that the work area around the engine is dry, well lightened, ventilated, organized;without tools and
loosened parts, ignition sources and dangerous substances.Check for dangerous conditions can happen and
avoidthem.
• Always use individual protection equipments (safety eyeglasses, gloves, shoes, etc.) while you are working.
• Remember that parts in movement can cause cuts, mutilation and strangling.
• Donot useloosen orripped clothes.Remove jewelleryand watchesbefore working.
• Disconnectthe battery (negative cable first) and dischargethe capacitorsbefore beginningthe repairs.
• In case the repair is being made in the vehicle, disconnect the starter motor to avoid an accidental start of the
engine.In case of industrial engines, placea “Do Not Operate” warningin theoperator compartment oron the
controls.
• To manually rotate the engine, use ONLY the recommended procedures.Never try to rotate the crankshaft with
the fan.This practice can cause serious personal injuries or damages to the fan blades, causing the premature
failureof thecomponent.
• If the engine was in operation and the cooling fluid is hot, leave the engine to cold down before slowly open the
cover of the reservoir to relief the pressure of the cooling system.
•Do not work with materials that are lifted by jacks or cranes.
Always use correct blocks, stands or brackets to position the engine before performing any repair.
Relief the pressure of the pneumatic (brakes), lubrication and cooling systems before removing or disconnect
anypiping,connections orother elements.Payattentionto thepressure existencebeforetodisconnect anyitem
of a pressurized system. Do not check pressure leakages with the hand. Oil or fuel at high pressure can cause
injuries.
• To avoidinjuries,use acrane,or askforhelpto lift components which weightmore than20 kg.Makesure thatall
lift equipments as chains, hooks or belts are in good conditions and have the correct load capacity.Make sure
that hooks are correctly positioned.Always use an extension when necessary.The lift hooks must not receive
side loads.
• Never leave the engine operating in a closed and non ventilated area.The engine exhaust gases are harmful to
health.
• The MWM coolant has alkaline substances.Avoid the contact with the eyes.Avoid the prolonged or repetitive
contact with the skin. Do not ingest. In case of contact with the skin, wash immediately with water and soap. In
case of contact with the eyes, abundantly wash with water for, at least 15 minutes. CALL MEDICAL HELP
IMMEDIATELY.KEEP AWAY FROMTHE REACH OFTHE CHILDREN AND ANIMALS.
Attention
• Incorrect procedures and lack of care can cause burns, cuts, mutilation, asphyxia or other
injuries and even death.

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• Cleaning solutions and solvents are inflammable materials that must be handled with a lot of care. Follow the
manufacturerinstructionstousetheseproducts.KEEPAWAYFROMTHEREACHOFCHILDRENANDANIMALS.
• To avoid burns, pay attention to hot spots on engines that have just been stopped and to hot piping and
compartments.
•Always use tools in good conditions. Make sure that you know how to handle the tools before beginning any
repair.UseONLYgenuineMWMspare parts.
• Someinternationalpublic healthinstitutionsprove thatusedlubricant oilcanbe cancerousandcontaminates the
humanreproducersystem.Avoidinhalingvapours,ingestingorkeepingprolongedcontactwiththesesubstances.
• People with pacemaker must avoid standing close to the engine electronic injection system.
GeneralInstructions
Thisenginehas been manufacturedwiththe mostadvancedtechnology;nevertheless,it wasdesigned to berepaired
usingregular techniquescomplemented byquality standards.
• Use good quality fuel, free of water and impurities.
• Useonly recommendedlubricant oil.
• In case of any irregularity seek for a dealer or authorized service of the vehicle / equipment manufacturer or
MWM.Avoid that outsiders make any service in the engine, because this cancels the warranty.
• To use a parallel battery to start de engine, the amperages of both batteries must be the same to avoid tension
peaks.Thestandardprocedure isalways first to connect the cable on the negative pole and lateron thepositive
pole.Take care to do not invert the poles.
• The inadequate removal of the battery cables may cause the loss of data from ECM, erasing the saved errors
from the last start of the engine.It can also cause tension peak, provoking ECM to break down.

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MWM Motores Diesel Ltda.
ServiceDepartment
Av.das Nações Unidas, 22.002 - Santo Amaro
Zip Code:04795-915 - São Paulo - SP - Brazil
Phone:[phone] /3305
Fax:[phone]
DDG:0800-110229
Site:www.mwm.com.br
E-mail:[email protected]
Cleaning General Instructions
Cleaning with Acids and Solvents
Several solvents and acid substances can be used to clean the parts of the engine.
MWM Motores Diesel Ltda. does not recommend any specific substance. Always follow the instructions of
the manufacturer of the product.
Remove all gaskets, sealing rings, and with a brush of steel or rasper, the sludge deposits, carbon, etc., before
placing the parts in the cleaning tank.Be careful to do not damage the surfaces of the sealing elements seats.
Flush all parts with hot water after cleaning.Completely dry them with compressed air.Remove water from screw
holesand fromlubrication innergrooves.
Incasethe partsare nottobe used soonafter the cleaning,dipthem inanappropriate anti-oxidationcompound.That
compound must be removed of the parts before installation in the engine.
The following parts cannot be cleaned with vapour:
1. Electric and electronics components;
2. Electric harness;
3. Fuelinjectors;
4. Highpressurepump;
5. Belts, pipes and hoses;
6. Bearings.

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6.12TCE
Turbocharged
Cylinders numbers
Series
Aftercooler
Identification and Location of the Serial Number
The engine identification and serial number can be found in the following places:
1. Identification plate on the water pipe.
2. Engraving on the right side of the engine block, close to the cylinder head of the cylinder #3.
Electronic

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Cylinders Numeration
The numeration of the cylinders starts from the flywheel, according to the illustration below.
Duringthe assembly,checkthenumberson the block(A) and onthe bearings (B), whichindicates the right assembly
position.
B
A
Cylinder#1
Flywheel

NOTES
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Technical Data
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Technical Data
Technical Data ................................................................................................................................... 2-2
Fuel System ........................................................................................................................ 2-2
Lubrication System ............................................................................................................ 2-3
Cooling System .................................................................................................................. 2-3
Thermostat .......................................................................................................................... 2-3

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TechnicalData
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Fuel System
Description
Maximum fuel inlet
restriction (for gears
pump) 0.6 to 1.2 bar
Railpressure 350 to 1400bar
Fuel pressure strip in the
fuel filter outlet (at crank
speed)
Technical Data
Engine Data 4.12TCE 6.12TCE
Engine type Vertical cylinders in line, 4 strokes
Injection type Directwith electronicmanagement
Cylinder bore 105mm
Cylinderstroke 137mm
Unit displacement 1,2 l
4,745 litres 7,118 litres
Total displacement 46
Quantity of cylinders
Compressionrate
Firing order 1 - 3 - 4 - 2 1 - 5 - 3 - 6 - 2 - 4
Rotationsense Counter clockwise (seen by flywheel side)
~450Kg ~570 KgDry engine weight
16,8:1
4 Cylinders 6 Cylinders
150hp 260hp
Power
500NmTorque
210hp
105kW 191kW152kW 900Nm700Nm
0,2 to 0,4 mmValves clearance (cold)
Strip of fuel pressure in
fuel filter fuel inlet (at
operationspeed)
9.7 to 12.8 bar
Maximum pressure
reduction in fuel filter ≤0,8bar
10,5 to 13 bar

Technical Data
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Thermostat
Lubrication System
Description
Oil pressure
• Nominal speed
• Idling speed 4.5bar (hot engine)
1.0bar (hot engine)
Oil temperature
• Nominal
• Maximum 90 - 110 °C
120°C
Oil capacity
• Minimum
• Maximum(withoutfilter)
• Maximum (with filter)
Description
Volume of water in the
engine, without radiator
Watertemperature
• Nominal
• Maximum
Cooling System
4.12TCE 6.12TCE
5 l
8 l
9,2 l
4.12TCE 6.12TCE
80 - 90 °C
100°C
13 l
17 l
18,7 l
7 l9 l
• Variation pressure of the
filter to open by-pass 2,5 + 1,2 bar
- 0,3 bar
Openingbeginning Totalopening
17.210EOD
Thermostat
9.412.0.757.001.6 75 ± 2°C 90°C
Minimumoperationcourse
10.0mm
Openingbeginning Totalopening
9.150E / 17.260E OT
Thermostat
9.412.0.757.002.6 80 ± 2°C 95°C
Minimumoperationcourse
10.0mm
13 l
17 l
18,2 l
17 l
29 l
30,2 l
23 l
32 l
33,7 l

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NOTES

Operationand Maintenance
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Operation and Maintenance
Engine Operation .............................................................................................................................. 3-2
Cooling fluid and Coolant ................................................................................................................ 3-5
Level Check ............................................................................................................................. 3-5
Cooling Fluid Filling Procedure ...................................................................................................... 3-6
MaintenanceTable ............................................................................................................................ 3-7
MWM Acteon Engines -Vehicular .......................................................................................... 3-7
Conservation for Inactive Engines for Long Periods...................................................................... 3-8

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Operation and Maintenance
Engine operation
Start
Beforeoperating the MWM Acteon engine check:
• Waterlevel.
• Fuel level.
• Lubricantlevel.
• Soon after to start the engine, heat it up at medium speed, without load.Watch lubricant oil pressure and water
temperature.
• Itis recommendedto start theengine withoutaccelerating,keeping the engine at idling speedfor30 secondsin
ordertopre-lubricatetheturbocharger.
• Before stopping the engine, run about 30 seconds at idling speed so that the turbo decrease its speed.
ColdStart
Thedifficulty ofstartat verylowtemperaturescan happendue to thecollapse ofthe filter becauseparaffin formation
or lack of ignition of the fuel.
The following actions can be observed:
• Use winter fuel, which does not form paraffinic flakes at low temperatures, or;
• Case the winter fuel is not available, it is necessary that the filter has a heater on the cylinder head to allow fuel
flow before the start.
TurbochargerCares
Almost all failures in turbochargers are caused by lubrication deficiency (delay in lubrication,
restrictionorlackofoil,intakeofimpuritiesintheoil,etc.)orobjectsorimpuritiesentrancethrough
intake.
To maximize the turbo lifetime follow these cautions:
• Do not accelerate the engine immediately after the start.
• Wait 30 seconds with the engine at idling speed before stop it.
• Pre-lubricate the turbocharger after oil change or other service that evolves oil drain. Crank the engine a few
times before start the engine.Then run the engine and allow it to run at idling speed for a period of time to
establish a complete circulation and oil pressure before to perform high speeds and load.
• Inlowtemperaturesorwhenthe engine isbeingreactivatedafteralong periodwithout operation, start the engine
and let it running at idling speed before operating in high speeds.
• Avoid operating the engine at idling speed for long periods of time.

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Running-in
OAll MWM engines are assembled and tested in the factory, making sure its immediate operation.
However, it needs to be correctly ran-in, regarding that its performance and durability depend, largely, on the cares
takenduring firstoperation phase.
As general rule, it is considered as running-in period the first 2,000 km for vehicular engines or the firsts 50 service
hours for stationary, industrial and agriculture engines.The vehicle or equipment moderate operation has decisive
importance to its durability, service safety and economy.
During this period it is very important to follow these recommendations:
• Carefully check if engine oil level is correct;
• Carefully check if water level of the engine cooling system is correct;
• Avoid forcing the engine at high speeds, that is to say, to do not apply extreme conditions of load or, in the case
of the vehicular, to "stretch out" the speeds;
• Avoid forcing the engine at low speeds;
• Avoid forcing the engine while it has not reached the normal operation temperature yet;
• Avoid operating over the limit of 3/4 (75%) of the maximum load of the vehicle or equipment;
• Avoid operating the engine at constant speeds for long periods of time;
• Avoid leaving the engine running at idling speed for a long period of time;
Strictly follow the maintenance instructions.
Followingthese recommendationsthe usefullife ofthe engine will be prolonged.
FuelSpecifications
MWMActeon enginemust operatewith regularDiesel fuel.It isrecommended touse fuelof specificationaccording
tothe BrazilianResolution CNP nr.07/80of PetroleumNational Council.
Thefog point(beginning ofparaffin segregation)must bebelow theambient temperatureand theCetan indexmust
not be less than 40.
Lubricantoil
Oil Level Check
• Stop the engine and wait 30 minutes so that the oil can flow back to the carter.
• Make sure that the vehicle is levelled.
• Before pulling oil dipstick, clean the surroundings.
• If necessary complete up to the upper mark (MAXIMUM), without exceeding it. Use the same oil mark and type
to complete the level.
• Donot operate the engine withthe levelbelow the lower mark (MINIMUM).
• Useonly recommendedlubricant oil.
• Do not mix different oil brands.
• Chosen an oil type and brand, always use the same.

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Operationand Maintenance
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CheckLubricantoilCondition
The condition of the lubricant oil is very important for a good conservation of the inner components of the engine.
Attention
• Always use genuine MWM filter.
OilChange
• The oil must be hot to facilitate the drainage.
• Drain the oil removing the carter plug.
• Wait until not leaving oil anymore.
• Install the plug with a new washer and tighten according to the specification.
• Fill with recommended lubricant oil up to upper level mark (MAXIMUM) of the dipstick.
OilFilterChange
• Clean the sealing area of the filter with a clean and without threads cloth.
• Lubricate the filter gasket and manually screw until touch.
• Manuallytighten.
• Fill up with new oil. In a levelled vehicle, the oil level must reach the upper mark of the dipstick.
• Run the engine checking the sealing of the filter and carter plug.
• Stop the engine and, after 30 minutes, check oil level again, filling up if necessary.
LubricantOil
The lubricant oil is very important for a good conservation of the inner components of the engine. Lubricant oil
contaminated with sand, soil, dust, water or fuel cause problems to the engine.
Checkthe appearanceof theengine lubricantoil. A dark coloration andlow viscositycould meanpresence offuel in
the lubricant oil.The presence of bubbles or a milky coloration could indicate presence of water in the oil.
LubricantOilSpecifications
It must be used multi-viscous type lubricant oil that accomplish, at least, to the API CG4 (or upper) specifications
and to the recommended viscosities.
Attention
• Do not mix different oil brands. Chosen one oil type, always use the same in the filling.

Operationand Maintenance
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Cooling Fluid and Coolant
OilLevelCheck
Attention
• Do not open the expansion reservoir cap while the engine is hot.
• Check the level when the engine is cold.
• Check the level of the cooling system daily. If the level is not correct, add clean water +
MWM coolant according to the proportion recommended on the bottle.
• Carefully open the first stage of the cap relieving the vapour pressure.
• Check for leaks through cooling piping.
• Check the nominal pressure of the cap in case of change.
WaterPumpCheck
Check for leaks through the pump drain hole.

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Operationand Maintenance
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CoolingSystemCleaning
1. Remove the cap from the engine radiator or from the expansion reservoir of the vehicle;
2. Drain the cooling system fluid through the lateral plug of the engine block;
3. Flush the whole system until to leave only clean water;
4. Close the system and fill with clean water;
5. Operate the engine until to reach the normal operation temperature and leave it running for 15 minutes;
Remark: If the vehicle has hot air conditioning, turn the button in hot position.
6. Stop the engine and wait to cool down;
7. Open the drain, remove the radiator cap and leave the water to flow out all again;
8. ClosethedrainoutletandfillthesystemwithcleanwaterandMWMcoolantaccordingtotherecommendedproportion;
9. Operatethe engineup tothe normaloperation temperatureand leaveit runningfor 15minutes;
Remark: If the vehicle has hot air conditioning, turn the button in hot position.
10. Check the level of the cooling system completing if it is necessary.
Cooling Fluid Filling Procedure
Fill the system with the necessary amount of MWM coolant and complete with clean water. Put the engine in
operation up to the normal operation temperature. Only complete the level of the system with clean water + MWM
coolantin thecorrect proportion.
After filled the system, operate the engine checking for leaks.
Denomination ConcentrateCoolant
Properties Anticorrosive / Anti-boiling / Antifreeze
Application ModernDiesel Engines inGeneral
Colour Red
Proportion 50% ± 10%
ChangeInterval 50,000 km or 6 months
Composition Anticorrosive, Ethilenoglycol, Borates,
Silicatesand Colouring
Validity of the bottle 5 years
MWMCOOLANT