MWM MS 3.9L Operation and Maintenance Manual

Type
Operation and Maintenance Manual

This manual is also suitable for

Operation and Maintenance ManualOperation and Maintenance Manual
MS 3.9lMS 3.9l
Engines
Operation and Maintenance ManualOperation and Maintenance Manual
MWM- MOTORES
INTERNATIONAL
Av. das Nações Unidas, 22.002
CEP 04795-915 - São Paulo - SP - Brasil
Phone: 55 (11) 3882-3318 / 3249 / 3541 - Fax: 55 (11) 3882-3573 / 3576
Phone: 55 (11) 3882-3323 / 3441 / 3442 - Fax: 55 (11) 3882-3594 / 5686-1554
Phone: 55 (11) 3882-3513 / 3759 / 3593 - Fax: 55 (11) 3882-3574
Printed in Brazil
Internet: E-mail: [email protected]
Engines Sales
Spare Parts
Customer Assistance Department
In Brazil Customer Assistance - MWM MOTORES Products Line (DDG) - 08000-110229
NP 085.70.69 - 01/06
www.mwm-international.com.br
MS 3.9lMS 3.9l
Engines
1
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A Few Words for the User
Congratulations!!!
You have just acquired a product of the highest technology and quality on the market.
For your convenience and satisfaction, we have elaborated this Operation and Maintenance Manual aiming to help you
about the correct using and maintenance of the MS 3.9l engines, in order to achieve their best performance, cost
effectiveness and durability, this way rising your equipment's retailing value.
We hope that you use this Manual as your main working tool, and consider it your daily working guide.
We recommend that you read the "Warranty Certificate" that is supplied with this Manual.
It is of equal importance that revision, adjustment and maintenance services be done at our Dealers and/or Authorized
Services Network.
MWM-
International
Motores Ltda. reserves its right of changing the technical contents of this publication without
previous notice and according with its criteria, at any moment that an innovation is introduced into its products.
MWM-
INTERNATIONAL
Motores Ltda.
Client Support Department
Av. das Nações Unidas, 22.002 - Santo Amaro
CEP 04795-915 - São Paulo - SP - Brasil
Tel: +55 (11) 3882-3200
Fax: +55 (11) 3882-3574
DDG: 08000-110229
Site: www.mwm-international.com.br
2NP 085.70.69 - 01/06
Index
A Few Words for the User ....................................................................................................................................... 1
Index....................................................................................................................................................................... 2
Safety Precautions ................................................................................................................................................... 4
Technical Features ................................................................................................................................................... 6
Location and identification of the engine number ..................................................................................................... 8
Engines View ........................................................................................................................................................... 9
Instruments panel.................................................................................................................................................. 10
Operation and Maintenance Recommendations ...................................................................................................... 13
Start and stop ....................................................................................................................................................... 13
Cold Start (for Engines with Start System Heating Kit) ........................................................................................... 14
Stop ...................................................................................................................................................................... 14
Running-in Period ................................................................................................................................................... 15
Revision Programs .................................................................................................................................................. 16
First Revision (Special) - 50 h.................................................................................................................................. 17
Periodic Maintenance ............................................................................................................................................. 19
Valves Adjustment ................................................................................................................................................. 21
Cooling System ...................................................................................................................................................... 23
Preventive Maintenance ......................................................................................................................................... 23
Level Check (Daily)................................................................................................................................................. 23
Cooling System Filling ............................................................................................................................................. 24
Coolant Circuit Drainage ......................................................................................................................................... 26
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Engine Coolant Refilling .......................................................................................................................................... 27
Coolant nozzle cap ................................................................................................................................................. 27
Fuel System ........................................................................................................................................................... 28
Preventive Maintenance ......................................................................................................................................... 28
Refueling ............................................................................................................................................................... 28
Fuel Filter and Pre-Filter.......................................................................................................................................... 29
Filter and Pre-Filter Drainage ................................................................................................................................... 30
Filters replacement................................................................................................................................................. 31
Supply pump ......................................................................................................................................................... 32
Filter screen cleaning ............................................................................................................................................. 32
Air Bleeding ........................................................................................................................................................... 33
Lubrication System................................................................................................................................................. 36
Preventive maintenance ........................................................................................................................................ 36
Level ..................................................................................................................................................................... 36
Lubricating Oil and Filter Change............................................................................................................................. 37
Belt ....................................................................................................................................................................... 39
Belt Tension Check ................................................................................................................................................ 39
Conservation of inactive engines ............................................................................................................................ 40
Engine preparation to return to operation.............................................................................................................. 42
Fuel storage........................................................................................................................................................... 44
Influence of altitude in engine performance ........................................................................................................... 45
4NP 085.70.69 - 01/06
Safety Precautions
Caution: The text marked with the symbol above presents direct or indirect risks to personal safety.
Read this Manual carefully and always maintain it close at hand to eliminate any doubts.
Don't try to operate the equipment without prior knowledge of all its controls and full
understanding of its functioning. Use always the following safety precautions before proceeding
with any work, because they are listed for your protection:
Do not change the original features of the engine;
Do not smoke when refueling the fuel tank;
Clean immediately any and all spilled fuel. Place all used material in a clean and safe area;
Do not refuel an operating engine, unless it is absolutely necessary;
Never clean, lubricate or adjust an engine while it is running;
Do not make any adjustment, if you do not know how to do it correctly;
Do not operate the engine within closed areas, because the exhaust gases are extremely poisonous;
Do not allow people or animals near the engine, vehicle or equipment while it is running;
Do not allow people with baggy clothing or with long, loosen hair to approach the movable parts;
Maintain a safe distance from any rotary parts. Remember that fans, for example, cannot be seen distinctly while the engine is running;
Do not remove the radiator cap if the engine is hot, because a spray of engine coolant, under pressure, is extremely dangerous and could
cause a serious burnings;
Do not use salty water or any other liquid that could cause corrosion in the cooling system;
Avoid sparks and flames near the batteries, especially when they are being charged, because they can cause explosions. The battery
electrolyte can boil and any contact with your skin and/or eyes is dangerous;
Disconnect the battery terminals before doing any repair to the electrical system;
Seek medical assistance immediately if the high-pressure diesel fuel penetrates into the skin.
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NP 085.70.69 - 01/06
NOTES
6NP 085.70.69 - 01/06
Technical Features
Type MS 3.9LL
LL
L
Aspiration Natural Turbocharger
Number of cylinders
and arrangement
Cylinders nominal
bore
Piston stroke
Cycle
Compression ratio
Total displacement
Direction of rotation
Firing order
MS 3.9T
4 in line 4 in line
98,43 mm 98,43 mm
127 mm (5 pol.) 127 mm (5 pol.)
Diesel 4 stroke Diesel 4 stroke
16:1 16:1
3,9 liters 3,9 liters
Clockwise Clockwise
1 - 3 - 4 - 2 1 - 3 - 4 - 2
LP number C72, C73, C47 C57, C48
Combustion system Direct injection Direct injection
Operating temperature 82 - 95 °C 82 - 95 °C
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67 cv @ 1800 rpm
DIN 6271 / ISO 3046
(LP C47)
Type MS 3.9LL
LL
L
Idle Speed
Cooling system
MS 3.9T
700 - 750 rpm 700 - 750 rpm
Liquid - Water pump Liquid - Water pump
Lubricant oil
pressure 2,1bar (min) 4,2 bar (max) 2,1bar (min) 5,9 bar (max)
Output
65 cv @ 2200 rpm
NBR 5484
(LP C72 / C73)
90 cv @ 1800 rpm DIN 6271 / ISO 3046
(LP C48 / C57)
26,5 m.kgf @ 1800 rpm
DIN 6271 / ISO 3046
(LP C47)
Torque
24 m.kgf @ 1400 rpm
NBR 5484
(LP C72 / C73)
36,2 m.kgf @ 1800rpm DIN 6271 / ISO 3046
(LP C48 / C57)
8NP 085.70.69 - 01/06
Location and identification of the engine number
Identification
I39T C65 XXXXXX B
Manufacturing
Year
Serial Number
Parts List
Number (LP)
Engine Model /
Type
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Engines View
Engine MS 3.9T
* Illustrative picture subject to changing
10 NP 085.70.69 - 01/06
Instruments panel
O Painel possui uma série de instrumentos que permite
observar, na partida e durante a operação, o bom
funcionamento do motor.
Portanto, é de fundamental importância que o operador fique
atento aos mesmos.
Tachometer (engine speed meter)
This instrument indicates engine's rotations per minute and
it should be monitored constantly to achieve the best output
and torque performance from the engine.
Engine coolant temperature indicator lamp
If engine coolant temperature exceeds the normal operating
temperature, this lamp will turn on simultaneously with fuel
cutoff and consequent engine stopping.
Note: Keep the coolant level correct and
check water pump belt's tension.
Oil pressure indicator lamp
This lamp will turn on when the ignition key is turned to
"ON" position, and it will turn off just after the engine is
running. In case of engine oil low pressure, this lamp will
turn on and there will be a fuel cutoff.
Note: Check lubricating oil on a daily basis.
Hour meter
It registers the total of running hours of the engine. The
rightmost numeral indicates tenths of an hour, corresponding
to six (6) minutes for each registered unit.
Battery charging indicator lamp
When turning the ignition key to "ON" position, this lamp
turns on, and it turns off when the engine is running, which
indicates that the alternator is charging the battery. The
correct level of electrolyte and tensioning of the alternator's
belt is of extreme importance for charging the battery.
Note: Keep the correct level of battery
electrolyte.
Air filter restriction indicator lamp
Whenever an air filter restriction occurs, which impairs
engine's performance, this lamp will turn on.
Clean or replace the element within the recommended
periods
Note: Keep the air filter element always clean.
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Acceleration control
1. Turn the acceleration control clockwise to achieve a gradual acceleration
of the engine, and turn it counterclockwise to decelerate it.
2. For a quick acceleration, depress the button and pull the control knob.
12 NP 085.70.69 - 01/06
4. After achieving the optimal engine speed, turn the control lock clockwise
to hinder it of changing the acceleration by itself while engine is running.
Turn it counterclockwise to change the engine speed regime.
Note: Apply the control lock only after you get the optimal
engine speed regime.
Keep the engine idling whenever the engine is turned
off.
3. To quickly get the engine idling or a fast deceleration, depress the button
and push the control knob.
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Operation and Maintenance Recommendations
Start and stop
Normal Start
Caution: Put the transmission shift in neutral (Agricultural).
1. Perform the "Daily Maintenance" routine.
Note: If the engine was inactive for a long period, bleed the
fuel system.
2. Actuate the throttle to approximately ¼ of its total stroke.
3. Turn the start key to position 4 during 7 (seven) seconds at most.
Caution: Do not keep the key turned on too long, because it
will damage the starter motor.
In turbocharged engines, after the start, wait for 30
(thirty) seconds in idling to avoid damage to the
turbocharger.
Illustration valid for agricultural application
Key positions
1. Off
2. Contact 3. Preheating
4. Start
14 NP 085.70.69 - 01/06
Cold Start (for Engines with Start System Heating Kit)
Caution: Put the transmission shift in neutral (Agricultural).
1. Perform the “Daily Maintenance” routine.
2. If the engine has a manual stopping control, make sure it is deactivated (start position).
3. Turn the start key to position 3 and keep it in this condition for 15 seconds.
4. Operate the throttle to position of maximum speed.
5. Turn the key to position 4 and start the engine.
6. If the engine doesn't run, turn the start key back to position 3 and keep it in this condition for 10 seconds. Then, try
to start the engine again.
Caution: Do not operate the key for a long time, this will damage the starter motor.
Stop
1. Keep the engine idling and the transmission shift in neutral.
2. Turn the start key to position 1.
Note: If the engine has manual stopping control, operate it and make sure it is deactivated.
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Running-in Period
During the running-in period, follow these recommendations:
It is not advisable to operate the engine at light loads for a long time.
Maximum load: It can be applied to a new engine as soon as it is in operation, since the engine's temperature is in the
ideal operation range.
Do not operate the engine at high speed without load.
Do not overload the engine.
Do not operate the engine with sudden accelerations, during the engine's lifetime.
Before starting the engine, check its lubricating oil, engine coolant and fuel levels.
Do not keep the engine idling for warming it. Instead, vary the engine speed.
Do not keep the engine idling without need.
Keep the operating temperature between 82 and 98 °C.
Note: The operator is responsible for the correct usage of this product during running-in period. To ignore the
recommendations above mentioned will cause a decrease of the product life duration, with consequent
increase of lubricating oil consumption to higher levels than those ones defined by project.
16 NP 085.70.69 - 01/06
Revision Programs
The engine warranty is conditioned to the accomplishment of the first revision (50 hours), and more revisions mentioned
in the Warranty Certificate.
All the operations of the obligatory and periodic revisions must be performed by our dealers and / or Authorized Service
Network according to the instructions in this Manual.
The installation of optional, unoriginal aftermarket parts will cancel warranty and may cause serious damages to the engine,
with consequent decreasing of its life duration. This procedure only will be allowed if genuine parts with normal versions of
factory are used.
For a better performance of your engine, always use genuine spare parts and equipments according to the factory
versions.
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First Revision (Special) - 50 h
Item
Lubricating oil and filter */** Change
Fuel filter and pre-filter Drain impurities
Cooling system Check level and complete if necessary
Water, oil and fuel * Check for leakages
Nuts, outer bolts and clamps Check tightening torque
Fan / alternator belt Check tension
Fuel lift pump Clean mesh filter
General performance Check engine speed, power output, etc
Service
* Service to be done with the engine at normal operating temperature.
** The oil and the lubricating oil filter must be obligatorily replaced (at most) each 6 months, even without reaching the period above
established.
Warning: The hot engine can cause burns.
18 NP 085.70.69 - 01/06
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MWM MS 3.9L Operation and Maintenance Manual

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Operation and Maintenance Manual
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