MWM MS 3.9L Operation and Maintenance Manual

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

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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

E-mail: [email protected]

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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

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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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NOTES

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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)

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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

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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.

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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

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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.

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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.

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NOTES

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