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12V4000G75S
MTU 12V4000G75S Manuals
Manuals and User Guides for MTU 12V4000G75S. We have
1
MTU 12V4000G75S manual available for free PDF download: Operating Instructions Manual
MTU 12V4000G75S Operating Instructions Manual (350 pages)
with Exhaust Gas Aftertreatment
Brand:
MTU
| Category:
Engine
| Size: 56.65 MB
Table of Contents
Table of Contents
5
1 Safety
8
Important Provisions for All Products
8
Important Requirements for Power Generation Application Products
10
Gendrive Engines - Intended Use
12
Personnel and Organizational Requirements
13
Safety Regulations for Initial Start-Up and Operation
14
Safety Regulations for Assembly, Maintenance, and Repair Work
16
Fire and Environmental Protection, Fluids and Lubricants
20
Standards for Warning Notices in the Text and Highlighted Information
22
Guards on the Engine - Overview
23
2 Transport
25
Transport 2.1 Transport
25
Lifting Specifications
26
RA Tank (Optional) - Transport
30
Crankshaft Transport Locking Device
31
Engine Mount Shipping Lock
34
3 General Information
35
Engine Side and Cylinder Designations
35
Product Summary
36
High-Pressure Points on Exhaust Gas Aftertreatment System - Overview
37
4 Functional Description
38
Diesel Engine with Exhaust Gas Aftertreatment
38
Diesel Engine with EGAT - Overview
38
Diesel Engine with EGAT - Standard Scope of Supply
40
Diesel Engine with EGAT - Nameplate and Designation
41
Series 4000 Engines
43
Engine Layout
43
Crankcase with Oil Pan
46
Gear Train
48
Running Gear
49
Cylinder Head with Injector
51
Valve Gear
53
Fuel System with Common Rail Injection
55
Charge-Air and Exhaust System
57
Lube Oil System
59
Fuel Cooler
61
Cooling System
63
Engine Management and Monitoring
66
Sensors and Actuators - Overview
69
Exhaust Gas Aftertreatment
73
Exhaust Gas Aftertreatment System - Overview
73
Diesel Particulate Filter (DPF) - Operating Principle
74
DPF System
74
Diesel Particulate Filter (DPF) - Overview
76
SCR Catalyst - Operating Principle
78
SCR System
78
SCR Catalytic Converter - Overview
79
RA Dosing System
81
RA Dosing System - Overview
81
Reducing Agent - Handling
83
Pre-Feed Module (PFM)
84
Supply Unit (SU)
86
Dosing Unit (DU)
87
RA Lines
88
RA Tank (Optional)
89
RA Heating System
90
EGAT Sensors - Overview
92
Monitoring, Control and Regulation Equipment
92
Exhaust Gas Aftertreatment Management and Monitoring
94
DCM CAN Connections
96
5 Technical Data
97
Product Data 12V4000G75S 12V4000G85S
97
Product Data 12V4000G15S 12V4000G25S
101
Product - Main Dimensions
105
Exhaust Gas Aftertreatment System - Main Dimensions
109
Firing Order
112
6 Operation
113
Putting the Engine into Operation after Extended Out-Of-Service Periods (>3 Months)
113
Putting into Operation after Scheduled Out-Of-Service-Period
114
Emission Label - Check
115
Engine - Starting in Manual Mode (Test Run)
116
Re-Starting the Engine Following an Automatic Safety Shutdown
118
Safety System - Override
119
Operational Monitoring
120
Emergency Engine Start (Override Mode)
121
Engine Shutdown in Manual Mode (Test Run)
122
Emergency Engine Stop
123
After Stopping the Engine - Engine Remains Ready for Operation
124
After Stopping the Engine - Putting the Engine out of Operation
125
Plant - Cleaning
126
Exhaust Gas Aftertreatment System - Regeneration Procedure
127
7 Troubleshooting
128
Fault Messages
128
Troubleshooting
186
8 Maintenance
189
Maintenance Task Reference Table [QL1]
189
Engine
191
Engine - Barring Manually
191
Engine - Cranking on Starting System
193
Engine - Test Run
194
9 Task Description
191
Cylinder Liner
195
Cylinder Liner - Endoscopic Examination
195
Cylinder Liner - Instructions and Comments on Endoscopic and Visual Examination
197
Crankcase Breather
199
Crankcase Breather - Filter Element Replacement
199
Valve Drive
201
Valve Protrusion - Measurement
201
Valve Gear - Lubrication
205
Valve Clearance - Check and Adjustment
206
Cylinder Head Cover - Removal and Installation
210
Injection Pump / HP Pump
211
HP Fuel Pump - Filling with Engine Oil
211
Injector
214
Injector - Replacement
214
Injector - Removal and Installation
215
Injector Rings - Replacement
221
Fuel System
227
Fuel System - Venting
227
Fuel Cooler - External Contamination and Leak-Tightness Check
229
Fuel Cooler - Cleaning
230
Fuel Filter
232
Fuel Filter - Replacement
232
Additional Fuel Filter - Replacement
233
Fuel Prefilter - Pressure Ratios
234
Fuel Prefilter (Non-Switchable) - Draining
235
Fuel Prefilter (Switchable) - Draining
237
Fuel Prefilter (Switchable) - Low Pressure Indicator Check
240
Fuel Prefilter (Non-Switchable) - Filter Element Replacement
241
Fuel Prefilter (Switchable) - Filter Element Replacement
243
Fuel Prefilter - Venting
246
Charge-Air Cooling
248
Charge-Air Cooler - Leak Check
248
Throttle Flap after Intercooler - Lever Position Check
249
Throttle Flap after Intercooler - Teach-In Routine Initiation
250
Air Filter
251
Air Filter - Replacement
251
Air Filter - Check
252
Air Filter - Removal and Installation
253
Heavy Duty Air Filter - Filter Insert and Filter Element Removal and Installation
254
Air Intake
256
Service Indicator - Signal Ring Position Check
256
Exhaust Gas Aftertreatment
257
Reducing Agent Lines - Replacement
257
Supply Unit - Filter Element Replacement
260
Dosing Unit - Replacement
263
Pre-Feed Module - Filter Element Replacement
265
Nox Sensor - Replacement
267
Lube Oil System, Lube Oil Circuit
270
Engine Oil - Change
270
Engine Oil Level - Check
273
Engine Oil - Sample Extraction and Analysis
274
Oil Priming Pump - Visual Inspection
276
Oil Filtration / Cooling
277
Engine Oil Filter - Replacement
277
Centrifugal Oil Filter - Cleaning and Filter Sleeve Replacement
279
Coolant System, General, High-Temperature Circuit
282
Engine Coolant Level - Check
282
Engine Coolant Change
284
Engine Coolant - Draining
285
Engine Coolant - Filling
287
Engine Coolant Pump - Relief Bore Check
291
Engine Coolant - Sample Extraction and Analysis
292
Preheater - Overview
294
Preheater - Function and Leak Check
295
Preheater - Overhaul
296
Preheater - Solenoid Switch Replacement
297
Preheater - Heating Element and Housing Check
299
Preheater Thermostats - Replacement
302
Coolant Expansion Tank Valve Cover - Replacement
305
Low-Temperature Circuit
306
Charge-Air Coolant Level - Check
306
Charge-Air Coolant - Change
308
Charge-Air Coolant - Draining
309
Charge-Air Coolant - Filling
311
Charge-Air Coolant Pump - Relief Bore Check
314
Belt Drive
315
Drive Belt - Condition Check
315
Battery-Charging Generator
316
Battery-Charging Generator - Drive Belt Tension Adjustment
316
Battery-Charging Generator Drive - Drive Belt Replacement
317
Engine Mounting / Support
318
Engine Mounting - Checking Resilient Element
318
Engine Mounting - Checking Securing Screws for Firm Seating
319
Generator Mounting - Check
321
Generator Mounting - Securing Screw Firm Seating Check
322
Wiring (General) for Engine/Gearbox/Unit
323
Engine Cabling - Check
323
Accessories for (Electronic) Engine Governor / Control System
324
Engine Governor and Connector - Cleaning
324
Engine Control Unit Plug Connections - Check
325
Engine Governor ECU 9 - Removal and Installation
326
Abbreviations
327
10 Appendix A
327
Conversion Tables
332
MTU Contact/Service Partners
336
11 Appendix B
337
Special Tools
337
Index
347
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