MTU 12V4000G34F, Operating Instructions Manual

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Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Important requirements for Power
Generation application products 7
1.3 Gendrive engines – Intended use 9
1.4 Personnel and organizational requirements 10
1.5 Safety regulations for initial start-up and
operation 11
1.6 Safety regulations for assembly,
maintenance, and repair work 13
1.7 Fire and environmental protection, fluids
and lubricants 17
1.8 Standards for warning notices in the text
and highlighted information 19
2 Transport
2.1 Transport 20
2.2 Lifting specifications 21
2.3 Crankshaft transport locking device 22
2.4 Engine mount shipping lock 25
3 General Information
3.1 Engine side and cylinder designations 26
4 Technical Data
4.1 Product data 12V4000G34F, 12V4000G94F 27
4.2 Product data 16V4000G34F / 16V4000G94F 33
4.3 Firing order 39
4.4 Engine – Main dimensions 40
5 Functional Description
5.1 Engine models 12/16V4000G34F and
12/16V4000G94F – Overview 41
5.2 Crankcase with oil pan 44
5.3 Gear train 46
5.4 Running gear 47
5.5 Cylinder head with injector 49
5.6 Valve gear 51
5.7 Fuel system with Common Rail injection 53
5.8 Charge-air and exhaust system 55
5.9 Lube oil system 57
5.10 Cooling system 59
5.11 Fuel cooler 62
5.12 Engine management and monitoring 64
5.13 Sensors and actuators – Overview 67
6 Operation
6.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 71
6.2 Putting into operation after scheduled out-
of-service-period 72
6.3 Starting the engine in manual mode (test
run) 73
6.4 Re-starting the engine following an
automatic safety shutdown 74
6.5 Safety system – Override 75
6.6 Operational monitoring 76
6.7 Emergency engine start (Override mode) 77
6.8 Stopping the engine in manual mode (test
run) 78
6.9 Emergency engine stop 79
6.10 After stopping the engine – Engine remains
ready for operation 80
6.11 After stopping the engine – Putting the
engine out of operation 81
6.12 Plant – Cleaning 82
7 Maintenance
7.1 Maintenance task reference table [QL1] 83
8 Troubleshooting
8.1 Troubleshooting 85
8.2 Fault messages of the ADEC (ECU 9) engine
governor for Series 4000 genset engines 88
9 Task Description
9.1 Engine 112
9.1.1 Engine – Barring manually 112
9.1.2 Engine – Cranking on starting system 114
9.1.3 Engine – Test run 115
9.2 Cylinder Liner 116
9.2.1 Cylinder liner – Endoscopic examination 116
9.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 118
9.3 Crankcase Breather 120
9.3.1 Crankcase breather – Oil mist separator
replacement 120
9.4 Valve Drive 121
9.4.1 Valve protrusion – Measurement 121
9.4.2 Valve gear – Lubrication 125
9.4.3 Valve clearance – Check and adjustment 126
9.4.4 Cylinder head cover – Removal and
installation 130
MS15060/01E 2018-12 | Table of Contents | 3
DCL-ID: 0000044539 - 002