Geko 12V 4000 G 41 Operating Instructions Manual Download Page 57

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Table of Contents

Task Description

6.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 1

6.1.1

Engine barring manually

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 1

6.1.2

Engine barring with starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 1

6.1.3

Engine test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 2

6.2 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 3

6.2.1

Cylinder-liner endoscopic examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 3

6.2.2

Instructions and comments on endoscopic and visual examination of cylinder liner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 5

6.3 Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 7

6.3.1

Crankcase breather oil separator replacement

. . . . . . . . . . . . . . . . . . . . . . . . . .

6 7

6.4 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 8

6.4.1

Valve gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 8

6.4.2

Valve clearance check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 8

6.4.3

Cylinder-head cover removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 12

6.5 Injection pump / HP pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 14

6.5.1

HP pump relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 14

6.6 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 15

6.6.1

Injector replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 15

6.6.2

Injector removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 15

6.7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 21

6.7.1

Fuel system venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 21

6.8 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 22

6.8.1

Fuel filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 22

6.8.2

Fuel prefilter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 23

6.8.3

Fuel prefilter differential pressure check and adjustment of gauge . . . . . . . . . . . . 6 23

6.8.4

Fuel prefilter draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 24

6.8.5

Fuel prefilter flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 25

6.8.6

Fuel prefilter filter element replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 27

6.9 Charge-Air Cooling, General, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 29

6.9.1

Intercooler checking condensate drains for coolant discharge and

obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 29

6.10 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 30

6.10.1 Air filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 30

6.10.2 Air filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.1 Service indicator signal ring position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 31

6.12 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 32

6.12.1 Starter condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 32

6.12.2 Air starter manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 32

M015403/00E 02-09

www.generent.ru

Summary of Contents for 12V 4000 G 41

Page 1: ...Dieselmotor Diesel Engine 8V 4000 G 61 81 12V 16V 4000 G 21 41 61 81 Operating instructions M015403 00 E Technical Publication w w w g e n e r e n t r u...

Page 2: ...nstructions Product Summary Engine layout technical data Operation Task descriptions Maintenance and Servicing Maintenance schedule Troubleshooting Malfunctions causes measures Task Description Inspec...

Page 3: ...erved Responsibilities of the operating maintenance and repair personnel must be specified Modifications or conversions Modifications made by the customer to the engine may affect safety MTU will acce...

Page 4: ...timulated emission in the range of visible light or in the infrared or ultraviolet spectral range The photochemical thermal and optomechanical effects of the laser can cause damage The main danger is...

Page 5: ...jection lines and connections clean Always seal connections with caps or covers if a line is removed or opened During maintenance and repair work take care not to damage the fuel lines To tighten the...

Page 6: ...ith 3800 bar 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 poi...

Page 7: ...e always keep the engine in a clean condition Do not leave cloths soaked with fluids and lubricants lying around on the engine Do not store combustible fluids near the engine Do not weld pipes and com...

Page 8: ...es immediately with eyedrops or clean tap water Painting When painting in other than spray booths equipped with extractors ensure good ventilation Make sure that adjacent work areas are not affected I...

Page 9: ...r than the pressure required a pressure reducing valve and safety valve set to permitted pressure must form an intermediate connection Hose coupling and connections must be securely attached Always we...

Page 10: ...one of the following signal words according to the degree of danger DANGER In event of immediate danger Consequences Death or serious injury WARNING In event of dangerous situations Consequences Deat...

Page 11: ...210 Power supply 070 Fuel system high pressure 230 Mounting support 080 Fuel system low pressure 250 PTO systems driving end and free end 100 110 120 Exhaust turbocharger Intercooler Air intake air su...

Page 12: ...the driving end starting with No 1 Applicable designations and abbreviations Driving end KS Free end KGS Left side Right side Main engine dimensions Engine model Overall length A Overall width B Overa...

Page 13: ...port and lifting equipment approved by MTU Transport the engine only in the installation position Lift only the engine by the lifting eyes provided Lifting eyes are designed only for the weight of the...

Page 14: ...ection system Electronic engine management Bore Stroke Cylinder displacement Total displacement 8 12 16V Compression ratio Direction of rotation facing driving end Firing order 8V Firing order 12V Fir...

Page 15: ...000 G61 985 895 895 735 12V 4000 G21 1330 1205 1205 12V 4000 G61 1465 1330 1330 1095 16V 4000 G21 1760 1600 1600 16V 4000 G61 1940 1760 1760 1450 Engine model kW at 1800 rpm 60 Hz Optimizations 1 8V 4...

Page 16: ...12V 4000 G41 Engine surface noise dB A approx 128 Exhaust noise unsilenced dB A approx 128 12V 4000 G61 Engine surface noise dB A approx 127 approx approx approx 126 Exhaust noise unsilenced dB A app...

Page 17: ...approx 12V 4000 G41 Engine surface noise dB A Exhaust noise unsilenced dB A 12V 4000 G61 Engine surface noise dB A approx 126 approx approx 123 approx Exhaust noise unsilenced dB A approx 127 approx...

Page 18: ...re loss in the external cooling system max permissible bar 0 7 Lube Oil System Lube oil operating temperature from to C 85 95 Lube oil operating pressure before engine bar 6 0 4 0 For 8 12 16V 4000 G6...

Page 19: ...bar ABS 2 7 3 1 16V 4000 G61 bar ABS 2 9 3 3 Application group 3B 8V 4000 G61 bar ABS 3 1 3 5 continuous power at variable load 8V 4000 G81 bar ABS 2 9 12V 4000 G21 bar ABS 2 8 3 3 12V 4000 G61 bar AB...

Page 20: ...16V 4000 G Initial filling approx 290 lit Oil dipstick mark min approx 160 lit Oil dipstick mark max approx 230 lit Coolant capacity internal engine cooling system without external cooling system Engi...

Page 21: ...f service period 3 2 3 3 Starting the engine in manual mode 3 2 3 4 Emergency start override mode 3 3 3 5 Operational checks 3 4 3 6 Stopping the engine in manual mode 3 5 3 7 Emergency stop 3 5 3 8 A...

Page 22: ...II Table of Contents M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 23: ...ressure gauge Align adjustable pointer with position of pressure indicator Page 6 23 Fuel system Vent Page 6 21 Cooling system If engine is out of service for more than one year change engine coolant...

Page 24: ...tation Engine generator control system Switch ON Select operating mode e g MANUAL OPERATION AUTOMATIC OPERATION 3 3 Starting the engine in manual mode Preconditions Generator is not connected to netwo...

Page 25: ...g temperature Apply full load only after engine has reached operating temperature coolant temperature approx 75 C 3 4 Emergency start override mode CAUTION Safety functions and engine shutdown alarms...

Page 26: ...e at nominal speed Check all pipework for leaks rectify any leaks with the engine stopped Check for abnormal running noises and vibrations Fuel prefilter Check if suction side pressure indicated at th...

Page 27: ...own by running it idle for approx 5 minutes Stopping the engine Item Task Switching cabinet control panel etc depending on manufacturer Press stop button Automatic stopping procedure is performed Engi...

Page 28: ...coolant Page 6 40 Drain charge air coolant Page 6 46 if freezing temperatures are expected and the engine is to remain out of service for an extended period and coolant has no antifreeze additive the...

Page 29: ...1 4 2 Maintenance Schedule Application Groups 3C and 3D 4 2 4 2 1 Maintenance schedule 4 2 4 3 Maintenance Schedule Application Group 3B 4 4 4 3 1 Maintenance schedule 4 4 4 4 Maintenance Schedule Ap...

Page 30: ...II Table of Contents M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 31: ...lanning and increases availability The maintenance schedule refers to the specified load profile The time intervals according to which the maintenance operations are to be performed and the relevant i...

Page 32: ...k W2 Air system Check air intake for leaks W2 Engine oil Take sample of used oil and analyze Page 6 33 W2 Engine oil Change Page 6 34 Every 2 years At the latest With oil category 1 every 250 operatin...

Page 33: ...Air filter Replace Page 6 30 W4 Starter Check condition Page 6 32 W4 Battery charging generator drive Check belt condition Page 6 50 W4 Battery charging generator drive Check and adjust belt tension...

Page 34: ...Engine oil Change Page 6 34 With oil category 1 without additional oil filter every 250 operating hours With oil category 1 with additional oil filter every 500 operating hours With oil category 2 wit...

Page 35: ...rer s information W4 HP pump Check relief bore for oil and fuel discharge and obstructions Page 6 14 W4 Air filter Replace Page 6 30 W4 Starter Check condition Page 6 32 W4 Battery charging generator...

Page 36: ...Fuel prefilter Clean Page 6 23 W2 Air system Check air intake for leaks W2 Engine oil Take sample of used oil and analyze Page 6 33 W2 Engine oil Change Page 6 34 With oil category 1 without addition...

Page 37: ...endoscopic examination Page 6 3 W4 HP fuel pump Check relief bore for oil and fuel discharge and obstructions Page 6 14 W4 Injectors Replace Page 6 15 W4 Air filter Replace Page 6 30 W4 Starter Check...

Page 38: ...8 Maintenance Schedule Application Group 3A M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 39: ...Table of Contents I 5 Troubleshooting 5 1 Troubleshooting 5 1 5 2 ECU alarms 5 4 M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 40: ...II Table of Contents M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 41: ...inspection see manufacturer s documentation ECU Plug in connections are loose Check plug in connections Page 6 57 Engine Running gear blocked engine cannot be barred manually Contact Service Engine t...

Page 42: ...ctive Contact Service Fuel system Not vented Vent Page 6 21 ECU Defective Contact Service Charge air temperature too high Component Probable Cause Task Engine coolant Incorrect coolant concentration C...

Page 43: ...gine Drain engine oil Page 6 34 Engine oil Oil separator of crankcase breather contaminated Replace filter element Page 6 7 Exhaust turbocharger cylinder head piston rings cylinder liner Defective Con...

Page 44: ...also be caused by defective sensors actuators If troubleshooting in accordance with the following table is not successful contact Service to have the sensors actuators checked and if required replace...

Page 45: ...ct Service 065 L1 P FUEL Fuel supply pressure too low 1st limit 1 Check fuel lines for leaks repair defective lines 2 Clean fuel prefilter Page 6 23 3 Flush fuel prefilter Page 6 25 4 Replace filter e...

Page 46: ...us 075 L1 P EXTERN 2 Violation of first limit for external pressure channel 2 Depending on the corresponding measuring point which is read via CAN bus 076 L2 P EXTERN 2 Violation of second limit for e...

Page 47: ...ote further alarms 093 PREHEAT TEMP LIMIT2 Coolant preheating temperature too low during starting 2nd limit Termination of starting procedure depending on project design Check preheating pump preheati...

Page 48: ...eck ECU supply voltage If engine was stopped Start engine Page 3 2 122 L1 T ELECTRONIC Temperature in ECU housing too high 1st limit 1 Improve engine room ventilation 2 Reduce engine power 134 15V POS...

Page 49: ...e 170 MI MODULE FAIL Module in maintenance predictor either defective or missing Contact Service 171 MI NOT ACTIVE Maintenance predictor no more activated Contact Service 173 MODULE WRITE LIMIT EEPROM...

Page 50: ...ect lube oil pressure 1 Check wiring 2 Contact Service 215 SD P RAIL FUEL Sensor defect common rail pressure HP controller in emergency mode 1 Check wiring 2 Contact Service 216 SD T LUBE OIL Sensor d...

Page 51: ...evice defective CAN P EXTERN 2 Contact Service 275 SD EXT COOLANT LEVEL External coolant level monitoring defective CAN Contact Service 276 SD INTERCOOLER LEVEL External charge air coolant level monit...

Page 52: ...rs repeatedly Contact Service 316 TIMING CYLINDER B6 Injection timing fault cylinder B6 If fault occurs repeatedly Contact Service 317 TIMING CYLINDER B7 Injection timing fault cylinder B7 If fault oc...

Page 53: ...RING CYLINDER B2 Faulty wiring to solenoid valve cylinder B2 Misfiring 1 Check wiring 2 Contact Service 333 WIRING CYLINDER B3 Faulty wiring to solenoid valve cylinder B3 Misfiring 1 Check wiring 2 Co...

Page 54: ...6 Disconnection in wiring to solenoid valve cylinder A6 Misfiring 1 Check wiring 2 Contact Service 347 OPEN_LOAD CYL A7 Disconnection in wiring to solenoid valve cylinder A7 Misfiring 1 Check wiring 2...

Page 55: ...ing 1 Check wiring 2 Contact Service 361 POWER STAGE FAIL 1 Defect in ECU solenoid valve power stage Contact Service 362 POWER STAGE FAIL 2 Defect in ECU solenoid valve power stage Contact Service 363...

Page 56: ...m text Meaning Task 385 TRAN OUT5 PLANT DEF Binary transistor output plant 5 defective Contact Service 386 TRAN OUT6 PLANT DEF Binary transistor output plant 6 defective Contact Service M015403 00E 02...

Page 57: ...placement 6 15 6 6 2 Injector removal and installation 6 15 6 7 Fuel system 6 21 6 7 1 Fuel system venting 6 21 6 8 Fuel Filter 6 22 6 8 1 Fuel filter replacement 6 22 6 8 2 Fuel prefilter cleaning 6...

Page 58: ...raining 6 46 6 16 3 Charge air coolant change 6 47 6 16 4 Charge air coolant level check 6 48 6 16 5 Charge air coolant sample extraction and analysis 6 48 6 16 6 LT cooling pump relief bore check 6 4...

Page 59: ...otate crankshaft in engine direction of rotation Apart from the normal compression resistance there should be no abnormal resistance 5 For barring tool removal follow reverse sequence of working steps...

Page 60: ...3 and use connector pliers 2 to secure the bayonet ring 4 by turning it clockwise until it latches into place 6 1 3 Engine test run DANGER Unguarded rotating and moving engine components Risk of serio...

Page 61: ...s Wear pattern appears to be darker No measures necessary Oxidation discoloration of even or uneven intensity Start and end of discolored areas have no clear edges and do not extend over the whole str...

Page 62: ...4 Cylinder Liner Final steps 1 Install injector Page 6 15 2 Install cylinder head cover Page 6 12 M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 63: ...ature differences around the liner It appears rather darker within the honed structure in contrast to the bright metallic running surface The honing pattern is undisturbed Discolorations extend in str...

Page 64: ...n and heat discoloration are similar A definite opinion can first be made after a careful inspection and reference to the above criteria To avoid unnecessary disassembly work it is recommended that an...

Page 65: ...f oil separator clamps 7 washers 5 and spacer sleeves 6 3 Loosen clamp 8 remove guide sleeve 9 from oil separator by turning it 4 Coat O ring in the new oil separator with denatured ethanol 5 Press gu...

Page 66: ...ers of rocker arms and adjusting screws with oil 4 Install cylinder head covers Page 6 12 6 4 2 Valve clearance check and adjustment Preconditions Engine is stopped and starting disabled Engine coolan...

Page 67: ...learance check valve bridge balance on all valve bridges 2 Use feeler gauge to determine the distance between valve bridge and rocker arm 3 Insert feeler gauge with determined value between valve brid...

Page 68: ...ween valve bridge and the two valve stem ends A and B 4 Turn adjusting screw so that both feeler gauges can be just pulled through 5 Hold adjusting screw securely in position with Allen key and fit lo...

Page 69: ...rms are loaded on cylinder A the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 2 mm Exhaust valves short rocker arm 0 5 mm 3 Check all valve clearanc...

Page 70: ...Nm holding adjusting screw 2 firm 6 Replace or rectify adjusting screws and or locknuts which do not move freely 7 Check valve clearance Final steps 1 Remove barring tool Page 6 1 2 Install cylinder h...

Page 71: ...rews 3 Remove cylinder head cover with gasket from cylinder head Cylinder head cover installation 1 Clean mating faces 2 Check condition of gasket replace if necessary 3 Place gasket and cylinder head...

Page 72: ...hearing Wear ear protectors HP pump relief bore check 1 Check relief bore for oil and fuel discharge by visual inspection 2 If relief bore is found dirty stop the engine disable engine start and clean...

Page 73: ...or injector removal TC Puller bracket TC Force in lever for injector installation TC Lever for force in lever TC Injector installation jig TC Slotted screwdriver TC Torque wrench TC Material Designati...

Page 74: ...terminals 2 Remove screw 2 and take off hold down clamp 1 3 Remove HP fuel line 5 4 Install puller for injector removal For this purpose fit part 4 onto injector 1 5 Slide part 2 over part 4 and turn...

Page 75: ...val 10 Turn nut 1 clockwise and withdraw injector 11 Remove puller bracket from injector 12 Remove sealing ring 1 from injector or use a self made hook to take it out of the cylinder head 13 Remove O...

Page 76: ...n sealing surface on cylinder head and protective sleeve 5 Insert injector 1 into cylinder head ensuring that the HP fuel line connection is aligned correctly 6 Fit injector installation jig 2 7 Lock...

Page 77: ...n screw 2 with torque wrench preliminary tightening torque 5 Nm to 10 Nm 15 Coat new O rings 4 and 6 on with petroleum jelly and fit on HP fuel line 5 16 Install HP line 5 and tighten preliminarily ti...

Page 78: ...20 Fuel Injector Final steps 1 Install cylinder head cover Page 6 12 2 Open fuel supply to engine M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 79: ...gnition sources Do not smoke LP fuel system venting 1 Loosen flushing return line of HP pump at connection 1 2 Unlock fuel priming pump 2 unscrew handle 3 Operate the fuel priming pump 2 with the hand...

Page 80: ...lter SPC WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel filter replacement 1 Remove easy change filter using the s...

Page 81: ...ement securing nut and remove filter element by pulling it downwards 5 Wash filter element in clean fuel using a smooth brush 6 Wash filter housing with clean fuel 7 Insert filter element into filter...

Page 82: ...e at gauge 1 2 If differential pressure as indicated between position of adjustable pointer 2 and pressure indicating pointer 3 of pressure gauge is 0 3 bar flush filter element of the cut in filter P...

Page 83: ...fuel emerges 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with clean fuel 8 Place new gasket in cover 2 9 Fit cover with gasket and secure it with...

Page 84: ...er cut in II Right filter cut in Fuel prefilter flushing 1 Cut out the contaminated filter 2 Open vent plug 5 of the filter to be flushed 3 Unlock drain cock 6 by pressing toggle open it and drain fue...

Page 85: ...eplacement Preconditions Engine is stopped and starting disabled Material Designation Use Part No Qty Diesel fuel FLS Spare parts Designation Use Part No Qty Filter element SPC Gasket SPC WARNING Fuel...

Page 86: ...ver 2 7 Remove spring 4 and filter element 3 8 Insert new filter element 3 and spring 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and secure it with...

Page 87: ...gles safety mask and ear protectors Intercooler checking condensate drains for coolant discharge and obstructions 1 With the engine running verify that air emerges from the condensate drain s at drivi...

Page 88: ...10 2 Air filter removal and installation Preconditions Engine is stopped and starting disabled Air filter removal and installation 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from flange of in...

Page 89: ...d starting disabled Signal ring position check 1 If the signal ring is completely visible in the control window 2 replace air filter Page 6 30 2 After installation of new filter press reset button 1 R...

Page 90: ...peration DANGER Unguarded rotating and moving engine components Risk of serious injury danger to life Before barring or starting the engine ensure that nobody is in the danger zone WARNING Engine nois...

Page 91: ...and scalding Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors En...

Page 92: ...in plug on oil pan 1 Provide a suitable container in which to collect the oil 2 Remove drain plug and drain oil 3 Install drain plug with new sealing ring 4 Replace engine oil filter Page 6 36 Oil cha...

Page 93: ...tube to stop withdraw and check oil level 3 Oil level must be between min and max marks 4 If necessary top up to max mark Page 6 34 5 Insert dipstick into guide tube to stop Oil level check after the...

Page 94: ...ul to health Risk of injury and scalding Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter replacement 1 Remove oil filter using...

Page 95: ...Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors Centrifugal oil filter cleaning and filter sleeve replacement 1 Remove clamp 3 2 Release Tommy nut 1...

Page 96: ...0 into rotor cap 8 and fit on standpipe 12 14 Install knurled nut 7 and tighten 15 Place rotor 5 in housing 6 and check for ease of movement 16 Fit new sealing ring 4 on housing 6 17 Fit cover 2 18 Ti...

Page 97: ...er pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks...

Page 98: ...plate 2 Check proper condition of breather valve clean sealing faces if required 3 Set breather valve onto filler neck and close it Final steps 1 Start the engine and operate it at idle speed for som...

Page 99: ...it HT coolant pump elbow Crankcase left and right side 5 Seal all open drain points 6 Set breather valve onto filler neck and close it 6 15 3 Engine coolant change Material Designation Use Part No Qty...

Page 100: ...If required top up with treated engine coolant Page 6 39 3 Check proper condition of breather valve clean sealing faces if required 4 Set breather valve onto filler neck and close it Coolant level ch...

Page 101: ...extraction point by draining approx 1 liter coolant 3 Drain approx 1 liter coolant into a clean container 4 Close drain valve 5 Using the equipment and chemicals of the MTU test kit examine coolant f...

Page 102: ...harge 2 Stop engine Page 3 5 and disable engine start 3 Clean the relief bore with a wire if it is dirty Permissible water discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per...

Page 103: ...e noise above 85 dB A Risk of damage to hearing Wear ear protectors CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold eng...

Page 104: ...alve clean sealing faces if required 4 Set breather valve onto filler neck and close it Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 6 48 6 1...

Page 105: ...sion tank through filler neck 5 Open drain cocks and drain plugs and drain coolant at the following points at the LT cooling pump at the coolant lines to and from the intercooler 6 Draining of residua...

Page 106: ...ck proper condition of breather valve clean sealing faces if required 6 Set breather valve onto filler neck and close it Charge air coolant level check by means of level sensor 1 Switch engine control...

Page 107: ...operating times specified in the MTU Fluids and Lubricants Specification Page 6 47 6 16 6 LT cooling pump relief bore check DANGER Unguarded rotating and moving engine components Risk of serious inju...

Page 108: ...3 Replace drive belt If belt is oily If belt shows signs of overheating If ribs are broken around the entire circumference A If ribs are broken around the entire circumference and material is broken...

Page 109: ...on arm 6 Read off measuring value at the intersection of indication arm and KG scale 7 If the measured value deviates from the specified belt tension 57 kg to 70 kg readjust belt tension Belt tension...

Page 110: ...nut 3 and check belt tension Page 6 50 7 Tighten locknut 2 8 Tighten screws 1 9 Install guard cover 10 Check drive belt tension after 30 minutes and again after 8 hours engine run time 6 17 4 Battery...

Page 111: ...ne mounting for secure seating 2 Check securing screws 2 and 3 of generator mounting for secure seating 3 Tighten loose screw connections 6 18 2 Engine generator mounting resilient elements check Prec...

Page 112: ...2 Check resilient elements for crack formation and deformation by visual inspection 3 Have cracked elements replaced contact Service Setting dimension check 1 Measure dimension a with Vernier caliper...

Page 113: ...ose screw connections 2 Make certain that cables are securely seated in clamps and cannot move freely 3 Check cable binders for secure seating tighten loose cable binders 4 Replace defective cable bin...

Page 114: ...propyl alcohol 2 Remove dirt from surface of connectors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or replace ille...

Page 115: ...nnector pliers TC ECU checking plug in connections 1 Use connector pliers 3 to make certain that all plug in connections of ECU are securely seated 2 Tighten loose bayonet union nuts 2 with connector...

Page 116: ...58 Engine Governor Electronic Control System M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 117: ...Table of Contents I 7 Annex 7 1 Abbreviations 7 1 7 2 Index 7 3 M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 118: ...II Table of Contents M015403 00E 02 09 MTU w w w g e n e r e n t r u...

Page 119: ...d Lubricants Specification MTU Publication No A01061 HI High Alarm Measured value exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interf...

Page 120: ...S standardization organization SD Sensor Defect Alarm Sensor failure SS Safety System Alarm initiated by safety system SPC Spare Parts Catalog T xyz Temperature xyz Temperature measuring point xyz TC...

Page 121: ...ins for coolant discharge and obstructions 6 29 Cooling System General HT Circuit 6 39 Engine coolant sample extraction and analysis 6 42 Engine coolant change 6 41 Engine coolant draining 6 40 Engine...

Page 122: ...al Wiring Engine Gearbox Plant 6 55 Engine wiring check 6 55 H HP pump relief bore check 6 14 HT cooling pump relief bore check 6 43 I Index 7 3 Injection pump HP pump 6 14 HP pump relief bore check 6...

Page 123: ...the engine in manual mode 3 2 Stopping the engine in manual mode 3 5 T Technical Data 2 2 Technical Data 2 2 Troubleshooting 5 1 V Valve clearance check and adjustment 6 8 Valve Gear 6 8 Cylinder head...

Page 124: ...w w w g e n e r e n t r u...

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Summary of Contents for 12V 4000 G 41

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Geko 12V 4000 G 41, Operating Instructions Manual

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Summary of Contents for 12V 4000 G 41

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