Page 1 Operating Instructions Diesel engine 20V4000Bx4 20V4000Gx4 MS15039/01E...
Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.
Page 3 WARNING WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.
Page 5: Table Of Contents
Table of Contents 1 Safety 4.12 Product data 20V4000G34F, application group 3F 1.1 Important provisions for all products 4.13 Product data 20V4000G34F, application 1.2 Gendrive engines – Intended use group 3G 1.3 Personnel and organizational requirements 4.14 Product data 20V4000G64F, application 1.4 Safety regulations for initial start-up and group 3D operation...
Page 6 7 Troubleshooting 8.10 Air Filter 8.10.1 Air filter – Check 7.1 Troubleshooting 8.10.2 Air filter ‒ Replacement 7.2 Fault messages of Engine Control Unit ECU9 8.10.3 Air filter – Removal and installation for Series 4000, genset applications 8.11 Air Intake 8.11.1 Contamination indicator –...
Page 7 8.19.4 Generator mounting – Securing screw firm 9 Appendix A seating check 9.1 Abbreviations 8.20 Wiring (General) for Engine/Gearbox/Unit 9.2 MTU Contact/Service Partners 8.20.1 Engine cabling – Check 8.21 Accessories for (Electronic) Engine 10 Appendix B Governor / Control System 8.21.1 Engine governor and connector –...
Page 8: Safety
Nameplates, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv- ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system is not visible without the removal of components, the system integrator must install the second nameplate in a clearly visible area on the vehicle/system.
Page 9 Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life. Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies.
Page 10: Gendrive Engines - Intended Use
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...
Page 11: Personnel And Organizational Requirements
1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.
Page 12: Safety Regulations For Initial Start-Up And Operation
1.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
Page 13 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.
Page 14: Safety Regulations For Assembly, Maintenance, And Repair Work
1.5 Safety regulations for assembly, maintenance, and repair work Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants, risk of burning).
Page 15 Assume a safe standing position when performing assembly work. Never use the product as a climbing aid. When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing. Removing, installing and cleanliness Pay particular attention to cleanliness at all times.
Page 16 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
Page 17 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.
Page 18: Fire And Environmental Protection, Fluids And Lubricants
Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
Page 19 Particularly hazardous substances used with our products are named in a list: • For drive systems: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products • For power generation: www.mtuonsiteenergy.com/technische-infos → Tools and Downloads → SVHC ACC. REACH IN MTU PRODUCTS Compressed air •...
Page 20: Standards For Warning Notices In The Text And Highlighted Information
1.7 Standards for warning notices in the text and highlighted information DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...
Page 21: Transport
Set system down on a firm, flat surface only. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set the engine down on its oil pan unless expressly authorized to do so by MTU. MS15039/01E 2018-11 | Transport | 19...
Page 22: Lifting Instructions
2.2 Lifting instructions Lifting instructions DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. • Never stand beneath a suspended load and keep a safe distance. • Wear personal protective equipment (e.g. protective helmet, safety shoes). 1 Center of gravity A Max.
Page 23: Crankshaft Transport Locking Device
2.3 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Engine oil Transport locking devices Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam- age during engine transport.
Page 24 Installing the transport locking device on driving end (KS) Note: Install plate (6) on the upper part of the openings only. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel housing and tighten to the specified tightening torque.
Page 25 Installing guard plates and en- gine mounting brackets (if appli- cable) on driving end (KS) Note: Always use the screws supplied with the equipment or removed from the guard plates and engine supports to secure them on the engine. Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten to specified tightening torque tightening.
Page 26: General Information
3 General Information 3.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)
Page 27: Engine - Overview
3.2 Engine – Overview 1 Crankcase breather 5 Charge-air pipework 9 Flywheel housing 2 Oil heat exchanger 6 Oil pan 10 Flywheel 3 Cylinder head cover 7 Engine governor 11 Intercooler 4 Engine mounting 8 Starter 12 Air filter MS15039/01E 2018-11 | General Information | 25...
Page 28 1 Exhaust pipe bellows 6 Fuel filter 11 Thermostat housing 2 Emissions label (EPA) (op- 7 Fuel priming pump 12 Coolant distribution housing tion) 8 Oil filter 13 Centrifugal oil filter (option) 3 Starter 9 HP fuel pump 14 Exhaust turbocharger 4 Oil filler neck 10 Vibration damper 5 Oil dipstick...
Page 29: Sensors And Actuators - Overview
3.3 Sensors and actuators – Overview Designation Description Engine Ident Label (EIL) B48.1 High-pressure fuel, A side Y39.A1 – A10 Injectors, cylinders A1 - A10 Fuel temperature, LP system Differential fuel pressure across filter Charge-air temperature MS15039/01E 2018-11 | General Information | 27...
Page 30 Designation Description Crankcase pressure Lube oil temperature, engine inlet Engine oil pressure Control block of HP fuel pump (option) Camshaft speed XB54 Connector for oil refill pump option Lube oil pressure of refill pump (option) Charge-air coolant temperature Coolant temperature, engine outlet 28 | General Information | MS15039/01E 2018-11...
Page 31 Designation Description Y39.B1 – B10 Injectors, cylinders B1 - B10 B48.2 High-pressure fuel, B side Charge-air pressure XF57 LT coolant level (remote expansion tank) XF33 HT coolant level (remote expansion tank) MS15039/01E 2018-11 | General Information | 29...
Page 32 Designation Description Crankshaft speed 30 | General Information | MS15039/01E 2018-11...
Page 33 Designation Description B44 * Turbocharger speed * Installed on 60 Hz engines only MS15039/01E 2018-11 | General Information | 31...
Page 34: Technical Data
4 Technical Data 4.1 Product data 20V4000B24F, 20V4000B34F, 20V4000B24S, 20V4000B44S, application group 3A DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 35 Rating Rated engine speed 1500 1500 1800 1800 Continuous power ISO 3046 (10% over- 2000 2200 2230 2490 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2200 2420 2453 2739 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 36 Total displacement Liters 95.4 95.4 95.4 95.4 Compression ratio 16.4 16.4 16.4 16.4 Air / exhaust gas Combustion air volumetric flow – DL m³/s 3.45 Combustion air volumetric flow – BL m³/s 3.85 Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 37 General operating data High idling speed, max. (static) 1700 1700 1900 1900 Limit speed for overspeed alarm/emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 *...
Page 38 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 39: Product Data 20V4000G14F, Application Group 3B
4.2 Product data 20V4000G14F, application group 3B DL Reference value: Continuous power; continuously attainable power under standard conditions BL Reference value: Fuel stop power; Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value: Value required to design an external system (plant). R Guideline value: Typical average value for information, only partially suitable for design purposes.
Page 40 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2200 2200 2200 2200 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 41 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.12 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 7.74 perature) – BL Exhaust gas temperature after engine –...
Page 42 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 43 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) MS15039/01E 2018-11 | Technical Data | 41...
Page 44: Product Data 20V4000G14F, Application Group 3E
4.3 Product data 20V4000G14F, application group 3E DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 45 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2200 2200 2200 2200 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 46 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.12 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 7.74 perature) – BL Exhaust gas temperature after engine –...
Page 47 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 48 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) 46 | Technical Data | MS15039/01E 2018-11...
Page 49: Product Data 20V4000G14F, Application Group 3F
4.4 Product data 20V4000G14F, application group 3F DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 50 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2200 2200 2200 2200 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 51 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.12 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 7.74 perature) – BL Exhaust gas temperature after engine –...
Page 52 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 53 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) MS15039/01E 2018-11 | Technical Data | 51...
Page 54: Product Data 20V4000G14F, Application Group 3G
4.5 Product data 20V4000G14F, application group 3G DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 55 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2200 2200 2200 2200 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 56 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.12 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 7.74 perature) – BL Exhaust gas temperature after engine –...
Page 57 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 58 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) 56 | Technical Data | MS15039/01E 2018-11...
Page 59: Product Data 20V4000G24F, Application Group 3B
4.6 Product data 20V4000G24F, application group 3B DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 60 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2420 2420 2420 2420 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 61 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.68 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 10.1 8,44 perature) –...
Page 62 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 63 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) MS15039/01E 2018-11 | Technical Data | 61...
Page 64: Product Data 20V4000G24F, Application Group 3E
4.7 Product data 20V4000G24F, application group 3E DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 65 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2420 2420 2420 2420 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 66 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.68 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 10.1 8.44 perature) –...
Page 67 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 68 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) 66 | Technical Data | MS15039/01E 2018-11...
Page 69: Product Data 20V4000G24F, Application Group 3F
4.8 Product data 20V4000G24F, application group 3F DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 70 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2420 2420 2420 2420 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 71 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.68 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 10.1 8.44 perature) –...
Page 72 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 73 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) MS15039/01E 2018-11 | Technical Data | 71...
Page 74: Product Data 20V4000G24F, Application Group 3G
4.9 Product data 20V4000G24F, application group 3G DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 75 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2420 2420 2420 2420 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 76 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 7.68 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 10.1 8,44 perature) –...
Page 77 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 78 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB (A) tolerance) 76 | Technical Data | MS15039/01E 2018-11...
Page 79: Product Data 20V4000G34F, Application Group 3B
4.10 Product data 20V4000G34F, application group 3B DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 80 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2590 2590 2590 2590 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 81 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 10.3 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 8.78 10.3 perature) –...
Page 82 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 83 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) MS15039/01E 2018-11 | Technical Data | 81...
Page 84: Product Data 20V4000G34F, Application Group 3E
4.11 Product data 20V4000G34F, application group 3E DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 85 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2590 2590 2590 2590 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 86 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 10.3 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 8.78 10.3 perature) –...
Page 87 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 88 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) 86 | Technical Data | MS15039/01E 2018-11...
Page 89: Product Data 20V4000G34F, Application Group 3F
4.12 Product data 20V4000G34F, application group 3F DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 90 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2590 2590 2590 2590 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 91 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 10.3 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 8.78 10.3 perature) –...
Page 92 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 93 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) MS15039/01E 2018-11 | Technical Data | 91...
Page 94: Product Data 20V4000G34F, Application Group 3G
4.13 Product data 20V4000G34F, application group 3G DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 95 Rating Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2590 2590 2590 2590 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 96 Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s 10.3 perature) – DL Exhaust gas volume (at exhaust gas tem- m³/s 8.78 10.3 perature) –...
Page 97 Capacities Engine coolant, engine side (w/o cooling Liters 205 * 205 * 205 * 205 * equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Total engine oil capacity, initial filling Liters 390 * 390 * 390 * 390 * (standard oil system) (option: max.
Page 98 Engine surface noise with attenuated in- dB(A) take noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - BL (sound power level LW, ISO 6798, +2 dB(A) tolerance) 96 | Technical Data | MS15039/01E 2018-11...
Page 99: Product Data 20V4000G64F, Application Group 3D
4.14 Product data 20V4000G64F, application group 3D DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 100 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max. °C (w/o power reduction) Fuel temperature at engine inlet connection, max. °C Consumption Specific fuel consumption (be) –...
Page 101 Exhaust gas temperature after engine – DL °C Exhaust gas temperature after engine – BL °C Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to °C cooling system) Coolant temperature after engine. limit 1 °C Coolant temperature after engine, limit 2 °C Coolant antifreeze content, max.
Page 102 Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil Liters system) (option: max. operating inclinations) Masses / main dimensions Engine mass, dry (basic engine configuration acc. to 9290 9290 9290...
Page 103: Product Data 20V4000G74F, Application Group 3D
4.15 Product data 20V4000G74F, application group 3D DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 104 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max. °C (w/o power reduction) Fuel temperature at engine inlet connection, max. °C Consumption Specific fuel consumption (be) –...
Page 105 Exhaust gas temperature after engine – DL °C Exhaust gas temperature after engine – BL °C Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to °C cooling system) Coolant temperature after engine. limit 1 °C Coolant temperature after engine, limit 2 °C Coolant antifreeze content, max.
Page 106 Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil Liters system) (option: max. operating inclinations) Masses / main dimensions Engine mass, dry (basic engine configuration acc. to 9290 9290 9290...
Page 107: Product Data 20V4000G84F, Application Group 3D
4.16 Product data 20V4000G84F, application group 3D DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 108 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max. °C (w/o power reduction) Fuel temperature at engine inlet connection, max. °C Consumption Specific fuel consumption (be) –...
Page 109 Exhaust gas temperature after engine – DL °C Exhaust gas temperature after engine – BL °C Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to °C cooling system) Coolant temperature after engine. limit 1 °C Coolant temperature after engine, limit 2 °C Coolant antifreeze content, max.
Page 110 Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil Liters system) (option: max. operating inclinations) Masses / main dimensions Engine mass, dry (basic engine configuration acc. to 9290 9290 9290...
Page 111: Product Data 20V4000G14S, 20V4000G24S, 20V4000G44S, Application Group 3B
4.17 Product data 20V4000G14S, 20V4000G24S, 20V4000G44S, application group 3B DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 112 Reference conditions Intake air temperature °C Charge-air coolant tem- °C perature Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) Rating Rated engine speed 1800 1800...
Page 113 Consumption Specific fuel consumption g/kWh (be) – 100% DL (+5%; EN 590; 42.8 MJ/kg) Specific fuel consumption g/kWh (be) – 100% BL (+5%; EN 590; 42.8 MJ/kg) Fuel consumption at zero kg/h load Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (inter- cooler)
Page 114 Exhaust gas temperature °C after engine – DL Exhaust gas temperature °C after engine – BL Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine. limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con-...
Page 115 Capacities Engine coolant, engine Liters 205 * 205 * 205 * 205 * 205 * 205 * side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters 390 * 390 * 390 * 390 * 390 *...
Page 116 Exhaust noise, unsilenced dB(A) - BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 117: Product Data 20V4000G64S, 20V4000G74S, 20V4000G94S, Application Group 3D
4.18 Product data 20V4000G64S, 20V4000G74S, 20V4000G94S, application group 3D DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 118 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) Rating Rated engine speed 1800 1800 1800 1800 1800 1800 Fuel stop power ISO 2740 2740 3010...
Page 119 Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (inter- cooler) Uncooled exhaust lines Operating method: four- stroke cycle, diesel, sin- gle-acting Combustion method: di- rect injection Cooling method: treated water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V Degrees...
Page 120 Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine. limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con- tent, max. Coolant system (LT circuit) Coolant temperature (at °C engine connection: outlet to cooling system)
Page 121 Capacities Engine coolant, engine Liters 205 * 205 * 205 * 205 * 205 * 205 * side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters 390 * 390 * 390 * 390 * 390 *...
Page 122 Exhaust noise, unsilenced dB(A) - BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 123: Product Data 20V4000G14S, 20V4000G24S, 20V4000G44S, Application Group 3F
4.19 Product data 20V4000G14S, 20V4000G24S, 20V4000G44S, application group 3F DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 124 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) Rating Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 2490 2490 2740...
Page 125 Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (inter- cooler) Uncooled exhaust lines Operating method: four- stroke cycle, diesel, sin- gle-acting Combustion method: di- rect injection Cooling method: treated water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V Degrees...
Page 126 Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine. limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con- tent, max. Coolant system (LT circuit) Coolant temperature (at °C engine connection: outlet to cooling system)
Page 127 Capacities Engine coolant, engine Liters 205 * 205 * 205 * 205 * 205 * 205 * side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters 390 * 390 * 390 * 390 * 390 *...
Page 128 Exhaust noise, unsilenced dB(A) - BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 129: Product Data 20V4000G14S, 20V4000G24S, 20V4000G44S, Application Group 3G
4.20 Product data 20V4000G14S, 20V4000G24S, 20V4000G44S, application group 3G DL Reference value: Continuous power. continuously attainable power at standard conditions BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 130 Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) Rating Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 2490 2490 2740 2740 3010 3010 3046 (10% overload capa- bility) (power range DIN 6280, ISO 8528) Fuel stop power ISO 2739...
Page 131 Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (inter- cooler) Uncooled exhaust lines Operating method: four- stroke cycle, diesel, sin- gle-acting Combustion method: di- rect injection Cooling method: treated water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V Degrees...
Page 132 Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine. limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con- tent, max. Coolant system (LT circuit) Coolant temperature (at °C engine connection: outlet to cooling system)
Page 133 Capacities Engine coolant, engine Liters 205 * 205 * 205 * 205 * 205 * 205 * side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters 390 * 390 * 390 * 390 * 390 *...
Page 134 Exhaust noise, unsilenced dB(A) - BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 135: Firing Order
4.21 Firing order Number of Firing order cylinders A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS15039/01E 2018-11 | Technical Data | 133...
Page 136: Engine - Main Dimensions
4.22 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 20V4000Gx4y, Anwen- 3486 mm 1701 mm 2172 mm dung 3D, 3E 20V4000Gx4y, Anwen- 3560.8 mm 1701 mm 2172 mm dung 3A, 3B, 3F, 3G 134 | Technical Data | MS15039/01E 2018-11...
Page 137: Operation
5.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...
Page 138: Putting Into Operation After Scheduled Out-Of-Service-Period
5.2 Putting into operation after scheduled out-of-service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 237); Coolant circuit Check engine coolant level (→ Page 244). Check charge-air coolant level (→ Page 265). Coolant circuit Heat engine coolant with coolant preheater.
Page 139: Starting The Engine In Manual Mode (Test Run)
5.3 Starting the engine in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network ☑ External start interlock is not activated. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 140: Re-Starting The Engine Following An Automatic Safety Shutdown
5.4 Re-starting the engine following an automatic safety shutdown NOTICE Re-starting the engine following an automatic safety shutdown. Risk of severe engine damage! • Before starting the engine, make sure the root cause of the safety shutdown was eliminated. • If the root cause cannot be identified or eliminated, contact Service. Note: •...
Page 141: Safety System - Override
5.5 Safety system – Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! • Use override function only in hazardous situations to ensure full capability in the event of engine faults.
Page 142: Emergency Engine Start (Override Mode)
5.6 Emergency engine start (Override mode) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.
Page 143: Operational Monitoring
5.7 Operational monitoring DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
Page 144: Emission Label - Check
5.8 Emission label – Check Emission label – Check Note: If there are any irregularities, notify your MTU contact person/service partner without delay. Check that emission labels are present (there can be more than one). Check emission label for intactness.
Page 145: Engine - Stopping In Manual Mode (Test Run)
5.9 Engine – Stopping in Manual mode (test run) Preconditions ☑ Generator (if applicable) is not connected to network ☑ Engine is in Manual mode DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 146 After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping. 144 | Operation | MS15039/01E 2018-11...
Page 147: Engine - Emergency Stop
5.10 Engine – Emergency stop NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Emergency engine stop from LOP Item Action Emergency stop pushbutton Press pushbutton.
Page 148: After Stopping The Engine - Engine Remains Ready For Operation
5.11 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control 146 | Operation | MS15039/01E 2018-11...
Page 149: After Stopping The Engine - Putting The Engine Out Of Operation
5.12 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 246); Drain charge-air coolant (→ Page 268) if: •...
Page 150: Plant - Cleaning
5.13 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaner (→ Tools Catalog) Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...
Page 151: Maintenance
6 Maintenance 6.1 Maintenance task reference table [QL1] The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a separate publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Page 152 Task Item Maintenance tasks WM00106 CRANKCASE BREATHER Replace oil separator (→ Page 183) WM00119 CRANKCASE BREATHER Replace filter or filter element (→ Page 184) WM00110 CRANKCASE Perform endoscopic examination of cylinder liner (→ Page 179) WM00090 FUEL INJECTOR Replace fuel injection valve/injector (→...
Page 153: Troubleshooting
7 Troubleshooting 7.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (→ manufacturer's documentation). Cable connections faulty u Check cable connections for secure seating (→ manufacturer's documentation). u Check whether cable connections are properly secured. Starter (electric): Engine cabling or starter faulty Contact Service.
Page 154 Engine governor defective u Contact Service. Charge-air temperature too high Cause Corrective action Engine coolant treatment u Check (→ MTU test kit). incorrect u Contact Service. Intercooler dirty u Check fans and intake/exhaust lines. Engine room: Air-intake temperature too high...
Page 155 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 234). Too much engine oil in the engine u Replace filter (→ Page 183). Oil separator of crankcase breather contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner defective White exhaust gas Cause...
Page 156: Fault Messages Of Engine Control Unit Ecu9
7.2 Fault messages of Engine Control Unit ECU9 for Series 4000, genset applications Possible engine responses to yellow alarm: Warning, power limitation/reduction, speed limitation, engine shutdown Possible engine responses to red alarm: Engine shutdown, power limitation/reduction, speed limitation, warning Procedure following an automatic safety shutdown (→ Page 138) 3 –...
Page 157 10 – SS T-Coolant Intercooler Cause Corrective action The intercooler coolant 1. Reduce power. temperature measured at sensor 2. Check whether alarm 23 is signaled. B26 has violated limit value 2. The 3. Check cooler (plant) for contamination. intercooler coolant temperature is 4.
Page 158 27 – HI Level Leakage Fuel Cause Corrective action u Contact Service. Switch F46 in the collecting tank has been tripped. The HP fuel system is leaking. 30 – SS Engine Overspeed Cause Corrective action Engine speed has violated the 1.
Page 159 52 – SS T-Lube Oil Cause Corrective action The lube oil temperature at sensor 1. Check operation of cooler and fan (plant). B7 has exceeded limit value 2. 2. Check engine coolant level (→ Page 244). The lube oil temperature is too 3.
Page 160 67 – HI T-Coolant Cause Corrective action The coolant temperature at 1. Reduce power. sensor B6 has exceeded limit 2. Check operation of cooler and fan (plant). value 1. The coolant temperature 3. Check engine coolant level (→ Page 244). is too high.
Page 161 92 – SS Starter Speed Not Reached Cause Corrective action The engine has failed to reach the 1. Check pressure supply (plant) of starter. defined speed threshold within 2. Observe any other messages. the defined time. 3. Contact Service. 93 – SS T-Preheat Cause Corrective action The engine coolant temperature...
Page 162 120 – HI ECU Power Supply Voltage Cause Corrective action The supply voltage of the ECU has 1. Check condition of batteries (plant). violated set limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 284). 3. Check battery charging-generator. 4.
Page 163 327 – AL Wiring Cylinder A7 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 282). wiring for cylinder A7 or injector 2. Replace injector (→ Page 196). defective. 3. Contact Service. 328 –...
Page 164 334 – AL Wiring Cylinder B4 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 282). wiring for cylinder B4 or injector 2. Replace injector (→ Page 196). defective. 3. Contact Service. 335 –...
Page 165 341 – AL Open Load Cylinder A1 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 282). to cylinder A1. 2. Contact Service. 342 – AL Open Load Cylinder A2 Cause Corrective action Disruption fault in injector wiring 1.
Page 166 349 – AL Open Load Cylinder A9 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 282). to cylinder A9. 2. Contact Service. 350 – AL Open Load Cylinder A10 Cause Corrective action Disruption fault in injector wiring 1.
Page 167 357 – AL Open Load Cylinder B7 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 282). to cylinder B7. 2. Contact Service. 358 – AL Open Load Cylinder B8 Cause Corrective action Disruption fault in injector wiring 1.
Page 168 454 – SS Power Reduction Active Cause Corrective action Power reduction activated. A main 1. Observe any other messages. alarm activating power reduction 2. Contact Service. has been tripped. 510 – AL Override applied Cause Corrective action The Override function was u No action required.
Page 169 834 – AL Gas Path Warning Cause Corrective action Summary emission fault alarm 1. Observe any other messages. 2. Contact Service. 835 – AL Gas Path Fault Cause Corrective action Summary emission fault alarm 1. Observe any other messages. 2. Contact Service. 1024 –...
Page 170 1036 – AL Inj. Drift Limit 1 Cyl. A5 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector A5 has violated limit value 1. The injector will soon reach its maximum drift limit. 1037 –...
Page 171 1042 – AL Inj. Drift Limit 1 Cyl. B1 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector B1 has violated limit value 1. The injector will soon reach its maximum drift limit. 1043 –...
Page 172 1048 – AL Inj. Drift Limit 1 Cyl. B7 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector B7 has violated limit 1. The injector will soon reach its maximum drift limit. 1049 –...
Page 173 1054 – AL Inj. Drift Limit 2 Cyl. A3 Cause Corrective action u Replace injector (→ Page 196). The drift correction for energization (start and duration) of injector A3 has violated limit 2. The injector has reached its maximum drift limit. 1055 –...
Page 174 1060 – AL Inj. Drift Limit 2 Cyl. A9 Cause Corrective action u Replace injector (→ Page 196). The drift correction for energization (start and duration) of injector A9 has violated limit 2. The injector will soon reach its maximum drift limit. 1061 –...
Page 175 1066 – AL Inj. Drift Limit 2 Cyl. B5 Cause Corrective action u Replace injector (→ Page 196). The drift correction for energization (start and duration) of injector B5 has violated limit 2. The injector has reached its maximum drift limit. 1067 –...
Page 176 1170 – AL Permanent Injection Cause Corrective action u Contact Service. The ECU has detected continuous injection at one or more injectors based on the pressure gradient in the HP fuel system (B48). 1174 – HI T-Fuel f(T0) Cause Corrective action The charge-air pressure at sensor 1.
Page 177: Task Description
8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 178 Engage barring tool (2) in ring gear of fly- wheel and mount on flywheel housing. Fit ratchet (1) on barring tool. Note: No resistance other than compression resist- ance must be encountered. Rotate crankshaft in engine direction of rota- tion. Result: If the resistance exceeds the normal com- pression resistance, contact Service.
Page 179: Engine - Cranking On Starting System
8.1.2 Engine – Cranking on starting system DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before barring the engine, make sure that there are no persons in the engine's danger zone. •...
Page 180: Engine - Test Run
8.1.3 Engine – Test run DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Exhaust gases are harmful to health and may cause cancer.
Page 181: Cylinder Liner
8.2 Cylinder Liner 8.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 193). Remove injector (→...
Page 182 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 181). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...
Page 183: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination
8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
Page 184 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.
Page 185: Crankcase Breather
8.3 Crankcase Breather 8.3.1 Crankcase breather – Oil mist separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist separator (→ Spare Parts Catalog) O-ring (→...
Page 186: Crankcase Breather - Filter Element Replacement
8.3.2 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet bit F30027340 Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil Filter element (→...
Page 187: Valve Drive
8.4 Valve Drive 8.4.1 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Measuring jig 1 Y4350009 Depth gage, 200 mm Y20000918 Measuring jig 2, optional Y4350010 Preparatory steps Remove cylinder head covers (→...
Page 188 Turn measuring unit screws (1) into the threads and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque 20 Nm Set all dial gages to 0. Unscrew measuring unit (2) from calibration plate (3). Step 1: Measure valve protrusion at the valve head with measuring jig 1 Check TDC position of piston in cylinder A1: •...
Page 189 Release adjusting screw (1) and remove valve bridge. Do not remove rocker arm (2). Measure distance (A) between valve stem end and cylinder head top at the injector bore with depth gage. • The specified value for a new cylinder head: 93.8 mm.
Page 190 Note: Do not remove rocker arm (2). Release adjusting screw (1) and remove valve bridge. Place measuring unit 2 (2) on the cylinder head (3). Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench.
Page 191: Valve Gear - Lubrication
8.4.2 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 193). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.
Page 192: Valve Clearance - Check And Adjustment
8.4.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Torque wrench, 60–320 Nm F30452768...
Page 193 Note: Risk of confusion: Additional OT/A1 mark (1) on flywheel, if fitted. The additional OT/A1 mark (1) on the perim- eter of the flywheel must not be used for ref- erence. Diagram for 20V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...
Page 194 Adjusting valve clearance Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Note: Replace or rectify adjusting screws and/or locknuts which do not move freely. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provided. Note: Feeler gauge must just pass through the gap.
Page 195: Cylinder Head Cover - Removal And Installation
8.4.4 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-15) X00067260 Profile gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.
Page 196: Injection Pump / Hp Pump
8.5 Injection Pump / HP Pump 8.5.1 HP fuel pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Fuel suction device F30378207 Engine oil WARNING...
Page 197 Preparatory steps Loosen nut (2) and remove oil line (1) from HP pump. HP pump – Filling Remove union (1). Note: Excess engine oil runs into gear box. Use fuel suction device to fill HP pump with 2 liters of clean engine oil. Screw in union (1) and use torque wrench to tighten to specified tightening torque.
Page 198: Injector
8.6 Injector 8.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 196). 196 | Injector | MS15039/01E 2018-11...
Page 199: Injector - Removal And Installation
8.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal device F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
Page 200 NOTICE Contamination of components. Damage to component! • Observe manufacturer's instructions. • Check components for special cleanliness. Preparatory steps Allow HP system to cool down. Shut off fuel supply to engine. Remove cylinder head cover (→ Page 193). Injector – Removal Disconnect cable connectors on injector.
Page 201 Install installation/removal device on the cyl- inder head. Remove injector with installation/removal tool. Remove the installation/removal device. Note: The sealing ring (2) for sealing the combus- tion chamber must only be used once. If the sealing ring (2) did not remain on the injector (1) when removed, use a self-made wire hook or magnet to extract it from the cylinder head and dispose accordingly.
Page 202 Note: Remove plugs on HP line only before installa- tion of the adapter. Remove plug. Use milling cutter to remove oil carbon from sealing face on cylinder head and protective sleeve. Coat damper ring (2) with (Assembly com- pound (Molykote P 37)). Coat O-rings (3) and (5) with (Assembly com- pound (Kluthe Hakuform 30-15)).
Page 203 Use a torque wrench to tighten hold-down clamp screw (2) to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm+10 Nm Use a torque wrench and long socket to tighten adapter (3) to specified tightening torque. Name Size Type...
Page 204: Injector Rings - Replacement
8.6.3 Injector rings – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal device F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Torque wrench, 60–320 Nm...
Page 205 WARNING Internal load and residual pressure in the HP fuel system. Parts may be expelled at high speed on re- lease. Fuel may spurt out. Risk of injury by flying parts and sprayed fuel! • Only use specified tools and devices. •...
Page 206 Install installation/removal device on the cyl- inder head. Remove injector with installation/removal tool. Remove the installation/removal device. Remove sealing ring (4) from injector or use a self-made wire hook or magnet to take it out of the cylinder head and dispose properly. Remove O-rings (5), O-ring (3) and damper ring (2) from injector (1) and dispose accord- ingly.
Page 207 Replacing rings, installing injec- Note: Remove plugs on HP line only before installa- tion of the adapter. Remove plug. Use milling cutter to remove oil carbon from sealing face on cylinder head and protective sleeve. Note: • Replace sealing ring (1) between injector and water sleeve whenever the injector is disassembled.
Page 208 Press in injector with installation/removal de- vice. Remove installation/removal device. Coat screw head mating face and thread of hold-down clamp (2) with engine oil. Fit hold-down clamp (1) in correct position, fit screw (2) and tighten by hand. Note: Make sure parts are perfectly clean. Apply engine oil to thread, sealing taper and thrust ring of adapter (3).
Page 209 Fit cable connector on injector (arrowed). Note: Do not reset drift correction (CDC) after re-in- stalling a used injector. After fitting new injectors (→ Page 197). Final steps Install cylinder head cover (→ Page 193). Open fuel supply to engine. MS15039/01E 2018-11 | Injector | 207...
Page 210: Fuel System
8.7 Fuel System 8.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 211 Note: See figure (a). Unlock hand pump: Hold sleeve (2). Turn han- dle (1) counterclockwise until sleeve can be moved back (arrowed). Note: • See figure (b). • After pulling the handle, wait briefly until the chamber is optimally filled. Operate pump with handle (1) until bubble- free fuel emerges from threaded vent plug.
Page 212: Fuel Cooler - External Contamination And Leak-Tightness Check
8.7.2 Fuel cooler – External contamination and leak-tightness check Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...
Page 213: Fuel Cooler - Cleaning
8.7.3 Fuel cooler – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Hot components/surfaces. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. •...
Page 214 Cleaning with a compressed-air pistol Blow out cooler elements with a jet of compressed air working against the direction of the cooling air parallel to the cooling fins. Remove and dispose of dirt before putting engine into operation. Use industrial high-pressure cleaner to clean fuel cooler in case of stubborn contamination. Cleaning with industrial high-pressure cleaner Note: •...
Page 215: Fuel Filter
8.8 Fuel Filter 8.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 216: Fuel Prefilter - Pressure Ratios
8.8.2 Fuel prefilter – Pressure ratios WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g.
Page 217: Fuel Prefilter (Non-Switchable) - Draining
8.8.3 Fuel prefilter (non-switchable) – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
Page 218 Open threaded vent plug (1) of filter to be serviced. Open drain plug (1). Allow water to drain until fuel emerges. Close drain plug (2) again. Drain second filter on module, from (→ Step 4). Close threaded vent plug again. Open fuel supply.
Page 219: Fuel Prefilter (Switchable) - Draining
8.8.4 Fuel prefilter (switchable) – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
Page 220 During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: • Filter module (1) is cut in • Filter module (2) is cut out Open threaded vent plug (1) of filter to be serviced.
Page 221 Draining fuel prefilter in case of gauge pressure, version B Note: The filter modules can be drained without switchover during engine operation and at engine stand- still! Provide a suitable container to collect the water. Take care when opening drain plug (1) be- cause fuel or water can spurt out.
Page 222: Fuel Prefilter (Switchable) - Low Pressure Indicator Check
8.8.5 Fuel prefilter (switchable) – Low pressure indicator check Low pressure indicator on switchable fuel prefilter Check low pressure indicator reading at low pressure gauge (3): • Red zone (1): -1.0 bar to -0.4 bar (low pressure) • Green zone (2): -0.4 bar to +0.5 bar (nor- mal operation) Switch over the fuel prefilter or replace a fil- ter element (→...
Page 223: Fuel Prefilter (Non-Switchable) - Filter Element Replacement
8.8.6 Fuel prefilter (non-switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet bit F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 224 Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be changed! If fuel emerges continuously, check shutoff valve in fuel supply, notify Service. Note: • As soon as the filter housing is opened, absolute cleanness is imperative! •...
Page 225: Fuel Prefilter (Switchable) - Filter Element Replacement
8.8.7 Fuel prefilter (switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet bit F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 226 Replacing fuel prefilter with low pressure, version A Note: • During engine operation, the filter elements must only be replaced on the cut-out filter module! • At engine standstill, the filter elements on both filter modules can be replaced! Provide a suitable container in which to collect the fuel. During engine operation, turn the switchover level as far as the stop (arrowed) to cut out the filter module to be serviced.
Page 227 Replacing fuel prefilter with high pressure, version B Note: The filter modules must only be replaced with the engine at a standstill! Provide a suitable container in which to collect the fuel. Stop engine and disable engine start. Close fuel inlet. Open threaded vent plug and ensure that fuel does not emerge continuously.
Page 228: Fuel Prefilter - Venting
8.8.8 Fuel prefilter – Venting DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
Page 229 Loosen threaded vent plugs (2, 3) and un- screw at least one rotation. Note: • Only operate the fuel priming pump man- ually! • Move the piston of the pump only vertical- ly to avoid damaging the pump! Unlock fuel priming pump, screw out han- dle (1).
Page 230: Charge-Air Cooling
8.9 Charge-Air Cooling 8.9.1 Intercooler – Checking condensate drain for coolant leak and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING A high level of noise is produced when the engine is running.
Page 231: Air Filter
8.10 Air Filter 8.10.1 Air filter – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Checking air filter Check entire circumference of air filter for damage. Fit new air filter if damaged (→ Page 230). MS15039/01E 2018-11 | Air Filter | 229...
Page 232: Air Filter - Replacement
8.10.2 Air filter ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter ‒ Replacement Remove air filter and install new one (→ Page 231). Reset signal ring of service indicator (→ Page 232). 230 | Air Filter | MS15039/01E 2018-11...
Page 233: Air Filter - Removal And Installation
8.10.3 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque screwdriver, 1–5 Nm F30452774 Air filter (→ Spare Parts Catalog) WARNING Hot components/surfaces. Risk of burns! •...
Page 234: Air Intake
8.11 Air Intake 8.11.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. WARNING The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac- uum. Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door can be prevented! •...
Page 235: Starting Equipment
8.12 Starting Equipment 8.12.1 Air starter – Manual operation DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.
Page 236: Lube Oil System, Lube Oil Circuit
8.13 Lube Oil System, Lube Oil Circuit 8.13.1 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty.
Page 237 Unscrew one of the drain plugs (1 to 8) and drain engine oil. Screw in drain plug (1 to 8) with new sealing ring. Engine oil treatment Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter sleeve (→...
Page 238 Filling with new engine oil Open cover (1) on filler neck. Pour oil in at filler neck up to 'max.' mark at oil dipstick. Close cover (1) on filler neck. Check engine oil level (→ Page 237). Note: Observe the following instructions to avoid engine damage: Adequate oil pressure for an engine start is only provided when the quick- start function is deactivated.
Page 239: Engine Oil Level - Check
8.13.2 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Oil is hot. Oil can contain residue/substances which are harmful to health. Risk of injury and poisoning! • Allow the product to cool to below 50 °C before beginning work. •...
Page 240: Engine Oil - Sample Extraction And Analysis
8.13.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit F6798833 Engine oil DANGER Components are moving or rotating.
Page 241 Screw Tightening torque (Engine oil) 20 Nm +2 Nm Use equipment and chemicals in MTU test kit to analyze engine oil for: • Dispersing capacity (spot test) • Proportion of water • Dilution by fuel MS15039/01E 2018-11 | Lube Oil System, Lube Oil Circuit | 239...
Page 242: Oil Priming Pump - Visual Inspection
8.13.4 Oil priming pump – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Visually inspecting oil priming pump Inspect oil priming pump and connections for firm seating and leaks. Retighten loose threaded connections as necessary. Check leak telltale bore (2) for oil discharge. Result: If oil emerges, the gear pump (1) usually has to be replaced (→...
Page 243: Oil Filtration / Cooling
8.14 Oil Filtration / Cooling 8.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Oil is hot.
Page 244: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement
8.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027340...
Page 245 Cleaning centrifugal oil filter Wash rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with cold cleaner. Blow out rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with compressed air. Assembling centrifugal oil filter Coat new sealing rings (9) and (10) with as- sembly compound and insert in grooves on bearing shaft (11).
Page 246: Coolant Circuit, General, High-Temperature Circuit
8.15 Coolant Circuit, General, High-Temperature Circuit 8.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
Page 247: Engine Coolant Change
8.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 246). Fill with engine coolant (→ Page 248). MS15039/01E 2018-11 | Coolant Circuit, General, High-Temperature Circuit | 245...
Page 248: Engine Coolant - Draining
8.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms. •...
Page 249 Close all other open drain points. Position valve cover on filler neck and close. MS15039/01E 2018-11 | Coolant Circuit, General, High-Temperature Circuit | 247...
Page 250: Engine Coolant - Filling
8.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
Page 251 Filling with coolant from below using a pump Note: Important: Fill engine only from below! Connect appropriate pump with hose to drain valve of engine coolant pump (arrow). Open venting point on distributor (arrow). Open drain valve and pump coolant into en- gine at 0.5 bar minimum.
Page 252: Engine Coolant Pump - Relief Bore Check
8.15.5 Engine coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING A high level of noise is produced when the engine is running.
Page 253: Engine Coolant - Sample Extraction And Analysis
8.15.6 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit F6798833 DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 254 Using the equipment and chemicals from the MTU test kit, examine coolant for: • antifreeze concentration • Amount of corrosion protection oil • pH value For engine coolant change intervals, refer to (→ MTU Fluids and Lubricants Specifications (A001061/..)). 252 | Coolant Circuit, General, High-Temperature Circuit | MS15039/01E 2018-11...
Page 255: Preheater - Overview
8.15.7 Preheater – Overview 1 Outlet 5 Control thermostat 9 Pump 2 24 VDC input 6 Intake Arrow Flow direction 3 Main power supply input 7 Safety thermostat 4 Control box 8 Housing cover Variant Heating output Rated voltage Frequency Phases 9 kW 400 V...
Page 256: Preheater - Function And Leak Check
8.15.8 Preheater – Function and leak check Preconditions ☑ Preheater is switched on. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Function check Note: The preheater operates properly if the measured value of the coolant temperature is within the control range...
Page 257: Preheater - Overhaul
8.15.9 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. ☑ All preheater power sources are disconnected. Replacing solenoid switch Replace solenoid switch (→ Page 256). Cleaning heating element and replacing gasket Clean heating element and housing and check (→ Page 258). Replacing thermostat Replace thermostat (→...
Page 258: Preheater - Solenoid Switch Replacement
8.15.10 Preheater – Solenoid switch replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solenoid switch (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 259 Mark all cables (4) prior to disconnection. Disconnect all cables (4) from solenoid switch (1). Note: The solenoid switch is secured to the rail (2) by a spring clip (3). Pull out the spring clip with a screwdriver and slide the solenoid switch off the rail. Fit a new solenoid switch on the rail and fully engage the spring clip.
Page 260: Preheater - Heating Element And Housing Check
8.15.11 Preheater – Heating element and housing check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Screw locking compound (Loctite 586) 40033 O-ring (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 261 Open drain plug at coolant inlet (arrow) and drain coolant. Undo clamps on both lines on preheater side. Checking heating element and housing for contamination Undo screws (1) between electrical part (2) and housing. Pull electrical part (2) with heating element out of housing.
Page 262 Final steps Connect preheater power sources. Switch on preheater. 260 | Coolant Circuit, General, High-Temperature Circuit | MS15039/01E 2018-11...
Page 263: Preheater Thermostats - Replacement
8.15.12 Preheater thermostats – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Thermostat (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 264 Mark cables prior to disconnection. Disconnect terminals from blade terminals of measuring unit (2). Undo thermostat clip (1) and remove safety thermostat. Insert new safety thermostat in recess. Secure thermostat clip. Connect cable. Fit cover and tighten screws. Replacing control thermostat Undo screws (1) on housing cover (2) of con- trol thermostat and remove cover.
Page 265 Final steps Connect preheater to power supply. Switch on preheater. MS15039/01E 2018-11 | Coolant Circuit, General, High-Temperature Circuit | 263...
Page 266: Coolant Expansion Tank Valve Cover - Replacement
8.15.13 Coolant expansion tank valve cover – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Valve cover (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
Page 267: Low-Temperature Circuit
8.16 Low-Temperature Circuit 8.16.1 Charge-air coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms.
Page 268 Checking charge-air coolant level by means of level sensor Note: The charge-air coolant level is monitored automatically by the engine control system. Switch on engine control system and check readings on the display. Top up with charge-air coolant as necessary (→ Page 270). 266 | Low-Temperature Circuit | MS15039/01E 2018-11...
Page 269: Charge-Air Coolant - Change
8.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 268). Fill with charge-air coolant (→ Page 270). MS15039/01E 2018-11 | Low-Temperature Circuit | 267...
Page 270: Charge-Air Coolant - Draining
8.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
Page 271 Drain remaining coolant at intercooler (ar- row). Tighten drain valve to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Spindle 11A/F Tightening torque 12 Nm Close the remaining drain valves and screw in drain plugs with new sealing rings. Position valve cover on filler neck and close.
Page 272: Charge-Air Coolant - Filling
8.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
Page 273 Filling coolant using a pump Connect appropriate pump with hose to drain valve (1). Loosen the vent line union at the distributor piece (arrow). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Tighten union (arrowed) if coolant leaks out at loose union.
Page 274 Alternatively: Filling coolant through filler neck Loosen the vent line union at the distributor piece (arrow). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Tighten union (arrowed) if coolant leaks out at loose union.
Page 275: Charge-Air Coolant Pump - Relief Bore Check
8.16.5 Charge-air coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Hot components/surfaces.
Page 276: Belt Drive
8.17 Belt Drive 8.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. WARNING Exposed rotating parts can eject drawn-in components or draw in body parts. Risk of crushing, limbs or extremities may be pinched, trapped or entangled! Risk of injury due to flying parts! •...
Page 277: Battery-Charging Generator
8.18 Battery-Charging Generator 8.18.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
Page 278: Battery-Charging Generator - Drive Belt Tension Adjustment
8.18.2 Battery-charging generator – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 WARNING...
Page 279: Engine Mounting / Support
8.19 Engine Mounting / Support 8.19.1 Engine mounting – Checking resilient element NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! • Cover engine mounts when working with fuel or oil. •...
Page 280 8.19.2 Engine mounting – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Torque wrench, 300–800 Nm F30047798 Ratchet bit F30027341 Engine oil Version A –...
Page 281 Version B – rigid engine mount- ing with standalone generator Check that securing screws (1, 2, 3) and base frame screw connections (arrowed) are tight. Use a torque wrench to tighten loose screw connections (1, 2) to specified tightening torque. Name Size Type...
Page 282 8.19.3 Generator mounting – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Resilient element (→ Spare Parts Catalog) NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! •...
Page 283 8.19.4 Generator mounting – Securing screw firm seating check Preconditions ☑ Engine is stopped and starting disabled. Generator mounting, securing screw firm seating check Check securing screws for firm seating. Tighten loose screws. MS15039/01E 2018-11 | Engine Mounting / Support | 281...
Page 284 8.20 Wiring (General) for Engine/Gearbox/Unit 8.20.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
Page 285 8.21 Accessories for (Electronic) Engine Governor / Control System 8.21.1 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g.
Page 286 8.21.2 Engine Control Unit plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ Electronic engine management system is de-energized. Checking plug connections at Engine Control Unit Check all plug connections for firm seating. Lock loose connectors. Check dust cap on ECU connectors for damage and correct seating.
Page 287 8.21.3 Engine governor ECU 9 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Protective cover over connectors on Heavy-Duty version removed. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.
Page 288 8.21.4 Parameters for drift correction (CDC) – Resetting with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Parameters for drift correction (CDC) – Resetting with DiaSys® Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset. Use DiaSys®...
Page 289 American National Standards Institute Association of American standardization organiza- tions Air Temperature Sensor Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A001061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-...
Page 290 Abbre- Meaning Explanation viation Electrically Erasable Programmable Read PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal Exhaust Gas Recirculation Engine Ident Label EIM-ID Emission Identification Number Engine Monitoring Unit ESCM Extreme Site Condition Management Power reduction for operation in extreme conditions Einzelspeicherdruck Injector accumulator pressure Exhaust turbocharger/exhaust turbocharg-...
Page 291 Abbre- Meaning Explanation viation Maximum Continuous Rating Torque limitation curve Not Applicable Normal Null Reference surface for heights above sea level Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil pressure sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Oberer Totpunkt Top Dead Center (TDC)
Page 292 Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h Hotline With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.
Page 293 10 Appendix B 10.1 Special Tools Barring tool Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 175) Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 179) Crossbeam Part No.: T80091826 Qty.: Used in: 2.1 Transport (→...
Page 294 Depth gage, 200 mm Part No.: Y20000918 Qty.: Used in: 8.4.1 Valve protrusion – Measurement (→ Page 185) Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 179) Feeler gage Part No.: Y20098771 Qty.: Used in: 8.4.3 Valve clearance –...
Page 295 Fuel suction device Part No.: F30378207 Qty.: Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 194) High-pressure cleaner Part No.: Qty.: Used in: 5.13 Plant – Cleaning (→ Page 148) Installation/removal device Part No.: F6789889 Qty.: Used in: 8.6.2 Injector –...
Page 296 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 197) Qty.: Used in: 8.6.3 Injector rings – Replacement (→ Page 202) MTU test kit Part No.: F6798833 Qty.: Used in: 8.13.3 Engine oil – Sample extraction and analysis (→...
Page 297 Ratchet bit Part No.: F30027340 Qty.: Used in: 8.3.2 Crankcase breather – Filter element replacement (→ Page 184) Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 197) Qty.: Used in: 8.6.3 Injector rings – Replacement (→ Page 202) Qty.: Used in: 8.8.6 Fuel prefilter (non-switchable) –...
Page 298 Ratchet with extension Part No.: F30006212 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 175) Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 179) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→...
Page 299 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 21) Qty.: Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 194) Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 197) Qty.: Used in: 8.6.3 Injector rings –...
Page 300 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 21) Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→ Page 190) Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 197) Qty.: Used in: 8.6.3 Injector rings –...
Page 301 10.2 Index Crankshaft – Transport locking device Abbreviations 287 – Installation/removal 21 Actuators Cylinder – Overview 27 – Designation 24 After stopping the engine Cylinder head cover – Engine remains ready for operation 146 – Installation 193 – Putting the engine out of operation 147 –...
Page 302 Engine oil level – Check 237 Engine sides Maintenance Schedule – Designation 24 – Maintenance task reference table [QL1] 149 MTU contact persons 290 Fault messages – ECS with ECU9 154 Oil priming pump Firing order 133 – Visual inspection 240 Fuel cooler ...
Page 303 Preheater Product data 20V4000G14S – Check – Continuous operation 3B – Heating element 258 – EPA Nonroad T2 Comp (40CFR89) 109 – Housing 258 – EPA Stationary EMERG T2 (40CFR60) 109 – Function check 254 – Fuel optimized 109 –...
Page 304 Product data 20V4000G44S – Continuous operation 3B Safety regulations – EPA Nonroad T2 Comp (40CFR89) 109 – Assembly work 12 – EPA Stationary EMERG T2 (40CFR60) 109 – Auxiliary materials 16 – Fuel optimized 109 – Environmental protection 16 –...

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20v4000gx4

MTU 20V4000Bx4 Operating Instructions Manual

1 Safety

2 Transport

3 General Information

4 Technical Data

5 Operation

6 Maintenance

7 Troubleshooting

8 Task Description

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