Page 1 EDG TRAINING MANUAL JOB 6608 REV.0 Engine 2.1. MTU Manual 2.2. P&ID 2.2.1. Lube Oil System 2.2.2. Fuel System 2.2.3. Cooling System...
Page 2 Technical Publication Diesel Engine 20 V 4000 G23 20 V 4000 G43 20 V 4000 G63 20 V 4000 G83 Operating Instructions M015715/00E...
Page 3 © 2006 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services.
Page 4 The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.). Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen GmbH. Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en exploitation contractuelle (garantie, rechanges, etc.).
Page 5 Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma! Motornr.: Auftragsnr.: Inbetriebnahme- Engine No.: MTU works order No.: meldung du moteur: N° de commande: de motor: N° de pedido: Motore N.: N. commessa: Commissioning No.
Page 6: Table Of Contents
After stopping the engine – engine remains ready for operation ....After stopping the engine – putting the engine out of service ....M015715/00E 06-08 © MTU...
Page 8 MTU contact person/service partner ........
Page 10: Safety
Modifications or Conversions Modifications made by the customer to the engine may affect safety. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. In the event of any damage caused by the use of other spare parts, no liability nor warranty claims vis-à-vis the engine manufacturer will be accepted.
Page 11: Personnel And Organizational Requirements
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron. Work clothing must be tight fitting so that it does not catch on rotating or projecting components. Do not wear jewelry (e.g. rings, chains etc.). M015715/00E 06-08 © MTU...
Page 12: Transport
Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so. M015715/00E 06-08...
Page 13: Safety Precautions When Working On The Engine
Safety precautions when working on the engine Safety precautions when putting the equipment into operation Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications. Before putting the device or the system into operation, always ensure •...
Page 14 Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
Page 15 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes. Operation of electrical equipment When operating electrical equipment, certain components of this equipment are live. Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property. M015715/00E 06-08 © MTU...
Page 16: Auxiliary Materials, Fire Prevention And Environmental Protection
Only fuels of the specified quality required to achieve emission limits must be used. In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is such a company). Auxiliary materials Use only fluids and lubricants that have been tested and approved by MTU.
Page 17 • Do not use compressed air to clean contaminated clothing whilst it is being worn. Used oil Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil. M015715/00E 06-08 © MTU...
Page 18: Standards For Warning Notices In The Publication
ANSI Z535, which begin with one of the above signal words according to the degree of danger: Warning notices 1. Read and become acquainted with all cautions and symbols before operating or repairing this product. 2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel! M015715/00E 06-08 © MTU...
Page 20: Product Summary
230 Mounting / support 080 Fuel system (low-pressure) 250 PTO systems, driving end and 100 Exhaust turbocharger free end (coupling) 110 Intercooler 500 Monitoring and control system, 120 Air intake / air supply general electric devices M015715/00E 06-08 © MTU...
Page 21 Product Summary Engine model designation Key to the engine model designation 20V 4000 Gx3 Number of cylinders Cylinder arrangement: V engine 4000 Series Application Application segment (2, 4, 6, 8) Design index M015715/00E 06-08 © MTU...
Page 22: Engine Side And Cylinder Designations
The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. The numbering of engine components is also from the driving end, starting with No. 1. 1 KGS = Free end 3 KS = Driving end 2 Right side 4 Left side M015715/00E 06-08 © MTU...
Page 23: Main Engine Dimensions
Product Summary Main Engine Dimensions 2.3.1 Main engine dimensions Main engine dimensions approx. 3520 mm Length (A) Width (B) approx. 1620 mm Height (C) approx. 2490 mm M015715/00E 06-08 © MTU...
Page 24: Firing Order
Product Summary Firing Order 2.4.1 Firing order Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 M015715/00E 06-08 © MTU...
Page 25: Final Compression Pressure
Product Summary Final Compression Pressure 2.5.1 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar M015715/00E 06-08 © MTU...
Page 26: Technical Data
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Number of cylinders Rated engine 1500 1800 1500 1500 1800 1800 speed Fuel stop power 2420 2740 2670 2850 3010 3490 ISO 3046 M015715/00E 06-08 © MTU...
Page 27 Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder Degrees arrangement: V angle Bore Stroke Displacement, liters 4.77 4.77 4.77 4.77 4.77 4.77 cylinder Displacement, liters 95.4 95.4 95.4 95.4 95.4 95.4 total M015715/00E 06-08 © MTU...
Page 28 Number of cylinders Coolant °C temperature (at engine connection: outlet to cooling equipment) Coolant °C temperature after engine, alarm Coolant °C temperature after engine, shutdown Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. M015715/00E 06-08 © MTU...
Page 29 Lube-oil °C temperature before engine, alarm Lube-oil °C temperature before engine, shutdown Lube-oil operating pressure before engine, from Lube-oil operating pressure before engine, to Lube-oil pressure before engine, alarm Lube-oil pressure before engine, shutdown M015715/00E 06-08 © MTU...
Page 30 (during engine starting) GENERAL OPERATING DATA Number of cylinders Cold start °C capability: Air temperature (w/o start aid, w/o preheating) - (case Coolant °C preheating, preheating temperature (min.) Firing speed, from Firing speed, to M015715/00E 06-08 © MTU...
Page 31 "max." (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, 9640 9640 9640 9640 9640 9640 dry (basic engine configuration acc. to scope of supply specification) M015715/00E 06-08 © MTU...
Page 32 Product Summary ACOUSTICS Number of cylinders Exhaust noise, dB(A) unsilenced, BL, (sound power level LW, ISO 6798) Engine surface dB(A) noise with attenuated intake noise (filter), BL (sound power level LW, ISO 6798) M015715/00E 06-08 © MTU...
Page 33: 4000 Gx3 Engine Data: Standby Operation 3D, Optimized Exhaust Emissions
1800 1800 2740 3010 3490 Fuel stop power ISO 3046 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar Intake air depression, max. mbar Exhaust pressure mbar Exhaust pressure, max. mbar M015715/00E 06-08 © MTU...
Page 34 Cylinder liners: Wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder, BL bar abs M015715/00E 06-08 © MTU...
Page 35 Lube-oil pressure before engine, alarm Lube-oil pressure before engine, shutdown FUEL SYSTEM Number of cylinders Fuel pressure at engine inlet connection, min. (during -0.1 -0.1 -0.1 engine starting) Fuel pressure at engine inlet connection, max. (during engine starting) M015715/00E 06-08 © MTU...
Page 36 9640 scope of supply specification) ACOUSTICS Number of cylinders Exhaust noise, unsilenced, BL, (sound power level LW, dB(A) ISO 6798) Engine surface noise with attenuated intake noise (filter), dB(A) BL (sound power level LW, ISO 6798) M015715/00E 06-08 © MTU...
Page 37: Consumption
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Number of cylinders Rated engine 1500 1800 1500 1500 1800 1800 speed Continuous 2200 2490 2420 2590 2740 3010 power ISO 3046 (10% overload capability) (design power DIN 6280, ISO 8528) M015715/00E 06-08 © MTU...
Page 38 Number of cylinders Cylinder degrees arrangement: V angle Bore Stroke Displacement per liter 4.77 4.77 4.77 4.77 4.77 4.77 cylinder Total displacement liter 95.4 95.4 95.4 95.4 95.4 95.4 Compression ratio 16.5 16.5 16.5 16.5 16.5 16.5 M015715/00E 06-08 © MTU...
Page 39 Number of cylinders Coolant °C temperature (at engine connection: outlet to cooling equipment) Coolant °C temperature after engine, alarm Coolant °C temperature after engine, shutdown Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. M015715/00E 06-08 © MTU...
Page 40 Lube-oil °C temperature before engine, alarm Lube-oil °C temperature before engine, shutdown Lube-oil operating pressure before engine, from Lube-oil operating pressure before engine, to Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown M015715/00E 06-08 © MTU...
Page 41 (during engine starting) GENERAL OPERATING DATA Number of cylinders Cold start °C capability: Air temperature (w/o start aid, w/o preheating) - (case Coolant °C preheating, preheating temperature (min.) Firing speed, from Firing speed, to M015715/00E 06-08 © MTU...
Page 42 "max." (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, 9640 9640 9640 9640 9640 9640 dry (basic engine configuration acc. to scope of supply specification) M015715/00E 06-08 © MTU...
Page 43 Product Summary ACOUSTICS Number of cylinders Exhaust noise, dB(A) unsilenced - DL (sound power level LW, ISO 6798) Engine surface dB(A) noise with attenuated intake noise (filter), DL (sound power level LW, ISO 6798) M015715/00E 06-08 © MTU...
Page 44: Emissions (Epa)
Continuous power ISO 3046 (10% overload capability) (design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders mbar Intake air depression (new filter) Intake air depression, max. mbar Exhaust pressure mbar Exhaust pressure, max. mbar M015715/00E 06-08 © MTU...
Page 45 Cylinder liners: Wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder - DL bar abs M015715/00E 06-08 © MTU...
Page 46 Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown FUEL SYSTEM Number of cylinders Fuel pressure at engine inlet connection, min. (during -0.1 -0.1 -0.1 engine starting) Fuel pressure at engine inlet connection, max. (during engine starting) M015715/00E 06-08 © MTU...
Page 47 ACOUSTICS Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, dB(A) ISO 6798) Engine surface noise with attenuated intake noise (filter), dB(A) DL (sound power level LW, ISO 6798) M015715/00E 06-08 © MTU...
Page 48: Emissions (Ta-Luft)
Continuous power ISO 3046 (10% overload capability) (design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders mbar Intake air depression (new filter) Intake air depression, max. mbar Exhaust pressure mbar Exhaust pressure, max. mbar M015715/00E 06-08 © MTU...
Page 49 Cylinder liners: Wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder - DL bar abs M015715/00E 06-08 © MTU...
Page 50 Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown FUEL SYSTEM Number of cylinders Fuel pressure at engine inlet connection, min. (during -0.1 -0.1 -0.1 engine starting) Fuel pressure at engine inlet connection, max. (during engine starting) M015715/00E 06-08 © MTU...
Page 51 ACOUSTICS Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, dB(A) ISO 6798) Engine surface noise with attenuated intake noise (filter), dB(A) DL (sound power level LW, ISO 6798) M015715/00E 06-08 © MTU...
Page 52: Operation
Putting the engine into operation after extended out-of-service-periods (>3 months) Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Task Engine Depreserve (→MTU Fluids and Lubricants Specifications A001061/..).
Page 53: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period
Check charge-air coolant level (→ Page 146). Cooling system Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 115). Monitoring equipment Carry out lamp test (see manufacturer’s documentation). Engine/generator control system Switch ON; Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION. M015715/00E 06-08 © MTU...
Page 54: Starting The Engine In Manual Mode
Close the generator circuit breaker. (depending on manufacturer) Engine Run engine at 10 to 15 % of rated power to reach operating temperature. Apply full load only after engine has reached operating temperature (coolant temperature approx. 75 °C). M015715/00E 06-08 © MTU...
Page 55: Emergency Start (Override Mode)
• After the starting procedure is completed, engine is running at rated speed. Connecting the generator to network Item Task Switching cabinet, control panel etc. If generator is not connected to network: Close the generator circuit (depending on manufacturer) breaker. Engine Run at rated power. M015715/00E 06-08 © MTU...
Page 56: Operational Checks
Charge-air coolant pump Check relief bore (→ Page 147). Compressed-air system (if Check operating pressure on pressure gauge; applicable) Always fill compressed-air tank to max. pressure; Drain condensate from compressed-air tank, pressure drop must not exceed 1 bar. M015715/00E 06-08 © MTU...
Page 57: Stopping The Engine In Manual Mode
Switching cabinet, control panel etc. Press stop button. (depending on manufacturer) • Automatic stopping procedure is performed; • Engine is stopped. After stopping the engine Item Task Cooling pump Operate for approx. 5 minutes after engine stop. M015715/00E 06-08 © MTU...
Page 58: Emergency Stop
• Engine is stopped by switching off power supply to ECU; • Signalization (e.g. by horn, flashing lamp) is released. After emergency stop from LOP Item Task Switching cabinet, control panel etc. Press button for alarm acknowledgement. (depending on manufacturer) • Audible and visual signalization stops. M015715/00E 06-08 © MTU...
Page 59: After Stopping The Engine - Engine Remains Ready For Operation
Operation After stopping the engine – engine remains ready for operation After stopping the engine Item Task Engine/generator control system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION. M015715/00E 06-08 © MTU...
Page 60: After Stopping The Engine - Putting The Engine Out Of Service
If the engine is to remain out of service for more than 1 week, seal the engine’s air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation (→MTU Fluids and Lubricants Specification A001061/..).
Page 62: Maintenance
The various Qualification Levels QL1 to QL4 reflect the levels of training offered in MTU courses and the contents of the tool kits required: QL1: Operational monitoring and maintenance which can be carried out during a break in operation without disassembling the engine.
Page 63 Corresponding operating time Load profile table, application group 3B Power 110% 100% Corresponding operating time Load profile table, application group 3C Power 110% 100% Corresponding operating time Load profile table, application group 3D Power 100% Corresponding operating time M015715/00E 06-08 © MTU...
Page 64: Maintenance Schedule Matrix
X X X X X X X X X X X X X X X X X X X X X Fuel filter Valve gear Belt drive Air filter Fuel injector Cylinder chambers Exhaust turbocharger Component maintenance Fuel delivery pump Cylinder head Crankcase breather Extended component maintenance M015715/00E 06-08 © MTU...
Page 65 X X X X X X X X X X X X X X X X X X X X X X Fuel filter Valve gear Belt drive Air filter Fuel injector Cylinder chambers Exhaust turbocharger Component maintenance Fuel delivery pump Cylinder head Crankcase breather Extended component maintenance M015715/00E 06-08 © MTU...
Page 66 X X X X X X X X X X X X X X X X X Fuel filter Valve gear Belt drive Air filter Fuel injector Cylinder chambers Exhaust turbocharger Component maintenance Fuel delivery pump Cylinder head Crankcase breather Extended component maintenance M015715/00E 06-08 © MTU...
Page 67 X X X X X X X X X X X X X X X X X X X X X Valve gear Fuel filter Belt drive Air filter Fuel injector Cylinder chambers Exhaust turbocharger Component maintenance Fuel delivery pump Cylinder head Crankcase breather Extended component maintenance M015715/00E 06-08 © MTU...
Page 68 X X X X X X X X X X X X X X X Valve gear Fuel filter Belt drive Air filter Fuel injector Cylinder chambers Exhaust turbocharger Component maintenance Fuel delivery pump Cylinder head Crankcase breather Extended component maintenance M015715/00E 06-08 © MTU...
Page 69 X X X X X X X X X X X X X X X X X X Valve gear Fuel filter Belt drive Air filter Fuel injector Cylinder chambers Crankcase breather Exhaust turbocharger Component maintenance Fuel delivery pump Cylinder head Extended component maintenance M015715/00E 06-08 © MTU...
Page 70 Centrifugal oil filter X X X X X X X X X X X X Valve gear Fuel filter Belt drive Air filter Fuel injector Crankcase breather Exhaust turbocharger Component maintenance Cylinder head Extended component maintenance Cylinder chambers M015715/00E 06-08 © MTU...
Page 71: Maintenance Tasks
Check charge-air coolant thermostat and replace thermostat element W2007 (→Workshop Manual). Overhaul engine coolant preheating (if fitted) (→Workshop Manual). W2008 W2009 Check centrifugal oil filter for wear (if fitted) (→Workshop Manual). Overhaul starter (→Workshop Manual). W2010 M015715/00E 06-08 © MTU...
Page 72 Replace conrod bearings (→Workshop Manual). W3003 W3004 Replace crankshaft bearings (→Workshop Manual). Replace cylinder liners (→Workshop Manual). W3005 Replace auxiliary PTO antifriction bearing (→Workshop Manual). W3006 Replace high-pressure fuel pump (→Workshop Manual). W3007 Overhaul battery-charging generator (→Workshop Manual). W3042 M015715/00E 06-08 © MTU...
Page 74: Troubleshooting
Engine fires unevenly Component Probable Cause Task Fuel injection equipment Injector defective Replace (→ Page 106). Engine wiring Defective Check (→ Page 151). Fuel system Not vented Vent fuel system (→ Page 111). Defective Contact Service. M015715/00E 06-08 © MTU...
Page 75 Contact Service. Charge-air temperature too high Component Probable Cause Task Engine coolant Incorrect coolant concentration Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge air pressure too low...
Page 76 Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating temperature. Fuel system Water in fuel Check fuel system on fuel prefilter. Drain fuel prefilter (→ Page 115). Intercooler Leaking Contact Service. M015715/00E 06-08 © MTU...
Page 77: Engine Governor Adec (Ecu 7) For Series 4000 Genset Engines - Fault Messages
AL L2 T-Coolant Main warning: Charge-air Reduce power. 2.0124.932 Intercooler coolant temperature too high; Engine stop. Preliminary warning: Lube oil 2.0100.921 LO P-Lube Oil Check oil level, top pressure too low. up as necessary (→ Page 130). M015715/00E 06-08 © MTU...
Page 78 HI ETC 2 idle speed Idle speed of ETC 2 too high. Contact Service. SS Engine Speed Alarm configuration limit value 1. Acknowledge 2.2510.932 2; Engine overspeed; reduced alarm. 2. Attempt to fuel injection. restart engine. M015715/00E 06-08 © MTU...
Page 79 Engine stop engine or reduced fuel injection. shutdown. 2. Check coolant level (→ Page 139). HI P-Crankcase Preliminary warning: 1. Reduce power. 2.0106.931 Crankcase pressure too 2. Replace oil high. separator element (→ Page 99). M015715/00E 06-08 © MTU...
Page 80 3. Restart engine (→ Page 49). 4. Contact Service. AL Rail Leakage Pressure gradient in rail is too 1.8004.046 low during starting or too high during stopping; HP system leaky, air in system). Contact Service. M015715/00E 06-08 © MTU...
Page 81 1.8004.623 AL Eng Hours Counter Alarm configuration; Defect Hourmeter faulty. Contact Service. 2.0140.921 LO ECU Supply Voltage Alarm configuration limit value 1. Check ECU 1; Preliminary warning: Supply supply voltage. voltage too low. 2. Contact Service. M015715/00E 06-08 © MTU...
Page 82 Replace ECU. Supply voltage A/D converter L1 AD-TEST1 SUPPLY too low. Replace ECU. AD-TEST1 ECU Electronic fault; automatic DEFECT engine shutdown. Replace ECU. Supply voltage A/D converter L1 AD-TEST2 SUPPLY too low. Replace ECU. M015715/00E 06-08 © MTU...
Page 83 AL CAN1 Bus Off Alarm configuration; CAN 1. Inspect CAN 2.0500.686 controller 1 is in "Bus-Off" bus for short status. circuit and rectify short circuit as necessary. 2. Check shielding, improve as necessary. 3. Contact Service. M015715/00E 06-08 © MTU...
Page 84 Error cleared after restarting the engine. SD T-Charge Air SD alarm configuration; Check sensor and 1.8004.571 Charge-air temperature sensor cabling (B9), replace faulty; short circuit or wire as necessary. break. Error cleared after restarting the engine. M015715/00E 06-08 © MTU...
Page 85 SD P-HD SD alarm configuration; Rail Check sensor and 1.8004.567 pressure sensor faulty; HP cabling (B48), regulator in emergency mode, replace as necessary. short circuit or wire break. Error cleared after restarting the engine. M015715/00E 06-08 © MTU...
Page 86 Error cleared after operating cycle). restarting the engine. SD crankshaft SD alarm configuration; Check sensor and 1.8004.498 Crankshaft sensor faulty; short cabling (B13), circuit or wire break. replace as necessary. Error cleared after restarting the engine. M015715/00E 06-08 © MTU...
Page 87 SD Loadp.Analog filt SD alarm configuration; Check cabling, 2.8006.588 Filtered analog signal of load replace as necessary. pulse missing; short circuit or Error cleared after wire break. restarting the engine. M015715/00E 06-08 © MTU...
Page 88 1.8004.512 AL Timing Cylinder B4 1.8004.513 AL Timing Cylinder B5 1.8004.514 AL Timing Cylinder B6 1.8004.515 AL Timing Cylinder B7 1.8004.516 1.8004.517 AL Timing Cylinder B8 AL Timing Cylinder B9 1.8004.518 AL Timing Cylinder B10 1.8004.519 M015715/00E 06-08 © MTU...
Page 89 1.8004.532 AL Wiring Cylinder B4 1.8004.533 1.8004.534 AL Wiring Cylinder B5 AL Wiring Cylinder B6 1.8004.535 AL Wiring Cylinder B7 1.8004.536 AL Wiring Cylinder B8 1.8004.537 AL Wiring Cylinder B9 1.8004.538 AL Wiring Cylinder B10 1.8004.539 M015715/00E 06-08 © MTU...
Page 90 AL Open Load Cylinder 1.8004.553 AL Open Load Cylinder 1.8004.554 AL Open Load Cylinder AL Open Load Cylinder 1.8004.555 AL Open Load Cylinder 1.8004.556 AL Open Load Cylinder 1.8004.557 AL Open Load Cylinder 1.8004.558 AL Open Load Cylinder 1.8004.559 M015715/00E 06-08 © MTU...
Page 91 Alarm configuration; Short 1.8004.637 circuit or wire break on transistor output 4 (TO 4). AL Wiring TOP 1 Alarm configuration; Short Check cabling to 2.8006.638 circuit or wire break on plant. transistor output, plant-side 1 (TOP 1). M015715/00E 06-08 © MTU...
Page 92 2. Contact Service. AL Open Load Digital Alarm configuration; Line 1. Check cabling 2.8006.625 Input 1 disruption on digital input 1; 2. Check input of Cabling faulty or no resistance target device. over switch. 3. Contact Service. M015715/00E 06-08 © MTU...
Page 93 1; Preliminary warning: 2. Check power Injector voltage too low. supply. 3. Contact Service. LOLO U-PDU Alarm configuration limit value 1. Check cabling 2.0141.922 2; Main warning: Injector 2. Check power voltage too low. supply. 3. Contact Service. M015715/00E 06-08 © MTU...
Page 94 L1 T-Aux 2 Alarm configuration limit 2.0131.921 value 1; Preliminary warning: Temperature signal of Aux 2 has exceeded / not attained Determine and rectify limit value 1, depending on reason for limit value configuration. violation. M015715/00E 06-08 © MTU...
Page 95 Contact Service. SD Idle/End-Torque SD alarm configuration; Input Check signal 2.8006.592 Input [%] signal for initial/final torque transmitter and faulty; short circuit or wire cabling, replace as break. necessary. Error cleared after restarting the engine. M015715/00E 06-08 © MTU...
Page 96 1.8004.586 SD T-AUX 2 SD alarm configuration; Check temperature Analog input signal for Aux 2 sensor and cabling, temperature faulty; short circuit replace as necessary. or wire break. Error cleared after restarting the engine. M015715/00E 06-08 © MTU...
Page 97 DiaSys. AL Comb. Alarm Yel Alarm configuration; Combined Note further fault 2.8006.001 (Plant) alarm YELLOW from plant. messages. AL Comb. Alarm Red Alarm configuration; Combined Note further fault 2.8006.002 (Plant) alarm RED from plant. messages. M015715/00E 06-08 © MTU...
Page 98: Task Description
3. Set ratchet (1) onto barring tool (2). 4. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there should be no abnormal resistance. 5. For barring-tool removal follow reverse sequence of working steps. M015715/00E 06-08 © MTU...
Page 99: Engine - Barring With Starting System
4. Let the crankshaft rotate until oil pressure is indicated. 5. Engine start is automatically interrupted when specified starting period is expired. If necessary, re-start the engine after approx. 20 seconds. 6. Connect connector X4 to ECU and latch in position. M015715/00E 06-08 © MTU...
Page 100: Engine Test Run
1. Start engine (→ Page 49). 2. Perform test run at not below 1/3 load and at least until steady-state temperature is reached. 3. Carry out operational checks (→ Page 51). 4. Stop engine (→ Page 52). M015715/00E 06-08 © MTU...
Page 101: Cylinder Liner
• Do not take any action or • carry out further endoscopic examination as part of maintenance work or • contact Service: cylinder liner must be replaced. Final steps 1. Install injector (→ Page 107). 2. Install cylinder-head cover (→ Page 105). M015715/00E 06-08 © MTU...
Page 102: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners
Liners with heat discoloration starting in the TDC-ring 1 have to be replaced. Seizures, Seizure marks Irregular circumference lengths and depths. Can be caused by either the piston skirt or the piston crown. Material deposits on the liner (smear), heavy discoloration. Severe, visible scoring. Replace liner. M015715/00E 06-08 © MTU...
Page 103 The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine. M015715/00E 06-08 © MTU...
Page 104: Crankcase Ventilation
3. Insert new filter element in housing (4). 4. Fit cover (2) with new O-ring. 5. Use torque wrench to tighten the screws of cover (2) to specified torque 10 Nm -2 Nm. 6. Replace further oil separator elements in the same way. M015715/00E 06-08 © MTU...
Page 105 5. Install new seal (2) and spring (5) together with cover (4). 6. Use torque wrench to tighten the screws of cover (4) to specified torque 10 Nm -2 Nm. 7. Check diaphragms in further oil separators in the same way. M015715/00E 06-08 © MTU...
Page 106: Valve Gear
1. Remove cylinder head covers (→ Page 105). 2. Fill oil chambers of valve bridges with oil. 3. Fill oil chambers of rocker arms and adjusting screws with oil. 4. Install cylinder head covers (→ Page 105). M015715/00E 06-08 © MTU...
Page 107: Valve Clearance - Check And Adjustment
1. Remove cylinder head cover (→ Page 105). 2. Install barring tool (→ Page 93). 3. Rotate crankshaft with barring tool in engine direction of rotation until marking "OT-A1" and pointer are aligned. Diagram • Two crankshaft positions • Applicable to 12V engines M015715/00E 06-08 © MTU...
Page 108 3. Check all valve clearances at two crankshaft positions (firing and overlap TDC for cylinder A1) as per diagram. 4. Use feeler gauge to determine the distance between valve bridge and rocker arm. 5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance. M015715/00E 06-08 © MTU...
Page 109 (2) firm. 6. Replace or rectify adjusting screws and/or locknuts which do not move freely. 7. Check valve clearance. Final steps 1. Remove barring tool (→ Page 93). 2. Install cylinder head cover (→ Page 105). M015715/00E 06-08 © MTU...
Page 110: Cylinder Head Cover - Remove And Install
Install cylinder head cover 1. Clean mating faces. 2. Check condition of gasket, replace if necessary. 3. Place gasket and cylinder head cover on cylinder head. 4. Install screws and tighten to 42 Nm. M015715/00E 06-08 © MTU...
Page 111: Fuel Injector
Task Description Fuel Injector 6.5.1 Injector replacement Spare parts Designation / Use Part No. Qty. Injector Remove injector and install new one (→ Page 107). M015715/00E 06-08 © MTU...
Page 112: Injector - Removal And Installation
Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Preparatory steps 1. Shut off fuel supply to engine. 2. Remove cylinder head cover (→ Page 105). M015715/00E 06-08 © MTU...
Page 113 4. Unscrew adapter (3) until only the last two to three courses of the thread are engaged. 5. Allow the fuel to drain off and collect it in a suitable container. 6. Unscrew adapter completely. 7. Fit puller and withdraw injector. M015715/00E 06-08 © MTU...
Page 114 5. Insert injector into cylinder head, ensuring that correct adapter connection alignment. 6. Lock press-in tool in position between the rocker arms in the cylinder head recess (arrowed). 7. Use press-in tool to insert injector into cylinder head. M015715/00E 06-08 © MTU...
Page 115 • Injector side (4): 20 Nm +5 Nm • Rail side (6): 30 Nm +5 Nm 15. Fit cable connector. Final steps 1. Install cylinder head cover (→ Page 105). 2. Open fuel supply to engine. M015715/00E 06-08 © MTU...
Page 116: Fuel System
3. Operate the pump with the handle (2) until bubble-free fuel emerges from the vent plug (1). 4. Close vent plug (1). 5. Screw in handle, turning it clockwise. 6. Verify that fuel priming pump (2) is locked: Handle must be tightened. M015715/00E 06-08 © MTU...
Page 117: Fuel Filter
1. Remove easy-change filter using filter wrench. 2. Clean the sealing surface of the filter head. 3. Slightly lubricate seal on the easy-change filter. 4. Screw on easy-change filter by hand until the seal connects and tighten manually. M015715/00E 06-08 © MTU...
Page 118: Fuel Prefilter Cleaning
7. Insert filter element into filter housing and secure with nut. 8. Place new sealing ring into groove in filter head. 9. Fit cover with seal and secure it with nuts crosswise. 10. Open fuel supply. M015715/00E 06-08 © MTU...
Page 119: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge
1. With the engine running at full load or rated power, read off pressure at gauge (1). 2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 117). M015715/00E 06-08 © MTU...
Page 120: Fuel Prefilter - Draining
Part No. Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Gasket Fuels are combustible. Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. M015715/00E 06-08 © MTU...
Page 121 7. Fill filter housing with clean fuel. 8. Place new gasket in cover (2). 9. Fit cover with gasket and secure it with screws. 10. Cut the cut-out filter in again. 11. When fuel emerges from system, close vent plug (5). M015715/00E 06-08 © MTU...
Page 122: Fuel Prefilter - Flushing
Fuels are combustible. Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! WARNING • Wear ear protectors. M015715/00E 06-08 © MTU...
Page 123 5. Fit cover with gasket and secure it with screws. 6. Check differential pressure (→ Page 114). Result: If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 119). M015715/00E 06-08 © MTU...
Page 124: Fuel Prefilter - Filter Element Replacement
Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Filter element Gasket Fuels are combustible. Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. M015715/00E 06-08 © MTU...
Page 125 11. Fit cover with gasket and secure it with screws. 12. Cut the cut-out filter in again. 13. Close vent plug (5) when fuel emerges. 14. Align adjustable pointer of differential pressure gauge with pressure-indicating pointer. (→ Page 114). M015715/00E 06-08 © MTU...
Page 126: Charge-Air Cooling General, Left Side
Emergency measures prior to engine start with a leaking intercooler 1. Remove injectors (→ Page 107). 2. Bar engine manually (→ Page 93). 3. Bar engine with starting system to blow out combustion chambers (→ Page 94). 4. Install injectors (→ Page 107). M015715/00E 06-08 © MTU...
Page 127: Air Filter
Task Description Air Filter 6.9.1 Air filter replacement Spare parts Designation / Use Part No. Qty. Air filter Remove air filter and install new one (→ Page 124). Reset signal ring of service indicator (→ Page 125). M015715/00E 06-08 © MTU...
Page 128: Air Filter - Check
Air filter – Check Spare parts Designation / Use Part No. Qty. Air filter Air filter – Check 1. Check entire circumference of air filter for damage. 2. Fit new air filter if damaged (→ Page 124). M015715/00E 06-08 © MTU...
Page 129: Air Filter Removal And Installation
(1). 3. Verify that there are no objects in the flange of the intake housing (1) and clean it. 4. Place new air filter (3) with clamp (2) onto intake housing (1). 5. Tighten clamp (2). M015715/00E 06-08 © MTU...
Page 130: Air Intake
1. If the signal ring is completely visible in the control window (2), replace air filter (→ Page 122). 2. After installation of new filter, press reset button (1). Result: Engaged piston with signal ring moves back to initial position. M015715/00E 06-08 © MTU...
Page 131: Starting System
WARNING • Wear ear protectors. Air starter – manual operation 1. Press pushbutton for manual start and hold it. 2. Allow compressed air to enter the air starter until the engine fires evenly. 3. Release pushbutton. M015715/00E 06-08 © MTU...
Page 132: Starter - Condition Check
6.11.2 Starter – Condition check Preconditions • Engine is stopped and starting disabled. Starter – Condition check 1. Check starter securing screws for secure seating. 2. Tighten loose screw connections. 3. Check wiring (→ Page 151). M015715/00E 06-08 © MTU...
Page 133: Lube Oil System / Lube Oil Circuit
Lube Oil System / Lube Oil Circuit 6.12.1 Engine oil – Change Preconditions • Engine is stopped and starting disabled. • Engine is at operating temperature. • MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools Designation / Use Part No. Qty. Torque wrench...
Page 134 2. Pour oil in at filler neck up to "max." mark at oil dipstick. 3. Close cover of filler neck. 4. Check engine oil level (→ Page 130). 5. After oil change and oil filter replacement, bar engine with starting system (→ Page 94). M015715/00E 06-08 © MTU...
Page 135: Engine Oil - Level Check
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. 3. Oil level must be between marks (1) and (2). 4. If necessary, top up to the mark (1) (→ Page 128). 5. Insert dipstick into guide tube up to the stop. M015715/00E 06-08 © MTU...
Page 136: Engine Oil - Sample Extraction And Analysis
Task Description 6.12.3 Engine oil – Sample extraction and analysis Preconditions • MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools Designation / Use Part No. Qty. MTU test kit 5605892099/00 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER •...
Page 137: Oil Cooling / Filtration
4. Screw on and tighten new oil filter by hand. 5. Replace further oil filters in the same way. 6. After each oil change and filter replacement, bar engine with starting system (→ Page 94). 7. Check oil level (→ Page 130). M015715/00E 06-08 © MTU...
Page 138: Centrifugal Oil Filter - Cleaning And Filter-Sleeve Replacement
8. If maximum layer thickness of oil residues exceeds 45 mm, shorten maintenance interval. 9. Disassemble rotor tube (11), conical disk (12) and rotor base (14). 10. Wash rotor cover (8), rotor tube (11), conical disk (12) and rotor base (14) with cleaner. M015715/00E 06-08 © MTU...
Page 139 20. Fit sealing ring (4) on housing (5). 21. Fit cover (2). 22. Tighten Tommy nut (1) by hand. 23. Fit clamp (3) and tighten with 8 Nm to 10 Nm. 24. Tighten cover nut (1) with 5 Nm to 7 Nm. M015715/00E 06-08 © MTU...
Page 140: Coolant Circuit General, Ht Circuit
6.14 Coolant Circuit General, HT Circuit 6.14.1 Engine coolant – Filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specifications (A001061/..) are available. Material Designation / Use Part No. Qty. Engine coolant Coolant is hot and under pressure.
Page 141 7.3. Set breather valve onto filler neck and close it. Final steps 1. Start the engine and operate it at unloaded condition for some minutes. 2. Check coolant level (→ Page 139) and top up if required. M015715/00E 06-08 © MTU...
Page 142: Engine Coolant - Draining
• Preheating unit; • Thermostat housing (arrow) • U-bend (arrow) • HT coolant pump elbow; • Crankcase, left and right side. 5. Close all open drain points. 6. Place breather valve on filler neck and close. M015715/00E 06-08 © MTU...
Page 143: Engine Coolant - Change
Task Description 6.14.3 Engine coolant – Change Material Designation / Use Part No. Qty. Engine coolant Drain engine coolant (→ Page 137). Fill engine coolant system (→ Page 135). M015715/00E 06-08 © MTU...
Page 144: Engine Coolant Level - Check
6.14.4 Engine coolant level – Check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down.
Page 145: Engine Coolant Pump - Relief Bore Check
3. Clean the relief bore with a wire if it is dirty. • Permissible coolant discharge: up to 10 drops per hour; • Permissible oil discharge: up to 5 drops/hour; 4. If discharge exceeds the specified limits: Contact Service. M015715/00E 06-08 © MTU...
Page 146: Engine Coolant - Sample Extraction And Analysis
Task Description 6.14.6 Engine coolant – Sample extraction and analysis Preconditions • MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools Designation / Use Part No. Qty. MTU test kit 5605892099/00 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! DANGER •...
Page 147: Circuit
Task Description 6.15 LT Circuit 6.15.1 Charge-air coolant change Material Designation / Use Part No. Qty. Coolant Drain charge-air coolant system (→ Page 145). Fill charge-air coolant system (→ Page 143). M015715/00E 06-08 © MTU...
Page 148: Charge-Air Coolant - Filling
Task Description 6.15.2 Charge-air coolant – Filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specifications (A001061/..) are available. Material Designation / Use Part No. Qty. Charge-air coolant Coolant is hot and under pressure. Risk of injury and scalding! WARNING •...
Page 149 7.3. Place breather valve on filler neck and close. Final steps 1. Start the engine and operate it at unloaded condition for some minutes. 2. Check coolant level (→ Page 146) and top up if required. M015715/00E 06-08 © MTU...
Page 150: Charge-Air Coolant - Draining
• at the LT thermostat housing. 6. Draining of residual coolant: • at the intercooler 7. Close all drain valves and install drain plugs with new sealing rings. 8. Place breather valve on filler neck and close. M015715/00E 06-08 © MTU...
Page 151: Charge-Air Coolant Level Check
6.15.4 Charge-air coolant level check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down.
Page 152: Charge-Air Coolant Pump - Relief Bore Check
3. Clean the relief bore with a wire if it is dirty. • Permissible coolant discharge: up to 10 drops per hour; • Permissible oil discharge: up to 5 drops per hour; 4. If discharge exceeds the specified limits: Contact Service. M015715/00E 06-08 © MTU...
Page 153: Belt Drive
None Breaks in a few individual places Drive belt Belt is oily, shows signs of Replace (→ Page 150) overheating Drive belt B Breaks around the entire circumference Drive belt C Areas of belt material missing M015715/00E 06-08 © MTU...
Page 154: Battery-Charging Generator
Result: Belt tensioner moves against the drive belt and tensions it. 3. Use torque wrench to tighten screw (1) to the specified torque 42 Nm and screw (2) to 60 Nm up to 65 Nm. 4. Install guard cover. M015715/00E 06-08 © MTU...
Page 155: Battery-Charging Generator Drive - Drive Belt Replacement
8. Use torque wrench to tighten screw (1) to the specified torque 42 Nm and screw (2) to 60 Nm up to 65 Nm. 9. Install guard cover. 10. Readjust belt tension after 30 minutes and again after 8 hours engine runtime. (→ Page 149) M015715/00E 06-08 © MTU...
Page 156: Cabling, General For Engine / Transmission / Plant
5. Inspect electrical components visually for damage: • connector housings; • contacts; • connector sockets; • cables and terminals; • plug-in contacts. 6. If conductors are damaged, contact Service. 7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. M015715/00E 06-08 © MTU...
Page 157: Accessories For Engine Governor (Electronic) / Control System
Cleaning severely contaminated connectors on ECU 1. Release latches of connectors and withdraw connectors. 2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol. 3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches. M015715/00E 06-08 © MTU...
Page 158: Ecu - Checking Plug-In Connections
Task Description 6.19.2 ECU – Checking plug-in connections Preconditions • Engine is stopped and starting disabled. ECU – Checking plug-in connections 1. Verify that all plug-in connections are securely seated. 2. Secure loose connectors and latch. M015715/00E 06-08 © MTU...
Page 160: Special Tools
Special Tools Special Tools Special tools Part No. Designation / Use Qty. F6555766 Barring tool F30006212 Ratchet M015715/00E 06-08 © MTU...
Page 161 Special Tools Part No. Designation / Use Qty. Y20097353 Rigid endoscope F30027336 Torque wrench 6-50 Nm Y20010128 Feeler gauge F30047446 Torque wrench 60-320 Nm F30039526 Ring socket, 24 mm M015715/00E 06-08 © MTU...
Page 162 Special Tools Part No. Designation / Use Qty. F30510423 Torque wrench 10-60 Nm F6784183 Puller M015715/00E 06-08 © MTU...
Page 163 Special Tools Part No. Designation / Use Qty. F6784167 Press-in tool F30510423 Torque wrench 10-60 Nm F30025896 Socket wrench, 17 mm F30025897 Socket wrench, 19 mm F30027341 Ratchet adapter F30379104 Filter wrench M015715/00E 06-08 © MTU...
Page 164 Special Tools Part No. Designation / Use Qty. F30027337 Torque wrench 5605892099/00 MTU test kit M015715/00E 06-08 © MTU...
Page 167: Mtu Contact Person/Service Partner
Annex MTU contact person/service partner You will find the MTU contact person/service partner for your region at www.mtu-online.com, worldwide, in the left-hand navigation margin. M015715/00E 06-08 © MTU...
Page 168: Abbreviations
Engine Data Module EEPROM Electrically Erasable Programmable Read Only Memory EFPA Electronic Foot Pedal Assembly Exhaust Gas Recirculation Engine Monitoring Unit Electronic Unit Injector Fluids and Lubricants Specification MTU Publication No. A01061/.. Fuel Pressure Sensor Monitors fuel pressure M015715/00E 06-08 © MTU...
Page 169 Oberer Totpunkt Top dead center (TDC) Panel Peripheral Interface Module Pulsewidth modulated P-xyz Pressure-xyz Pressure measuring point xyz Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure M015715/00E 06-08 © MTU...
Page 170 Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Alarm: Sensor-comparison failure Throttle Position Sensor Timing Reference Sensor T-xyz Temperature-xyz Temperature measuring point xyz Unterer Totpunkt Bottom dead center (BDC) Variable nozzle turbine Variable Speed Governor Vehicle Speed Sensor M015715/00E 06-08 © MTU...
Page 173 ... MTU contact person/service partner ..Fuel prefilter – draining ... . .
Page 176 Demo version (http://www.verypdf.com)
Page 177 Demo version (http://www.verypdf.com)
Page 178 Demo version (http://www.verypdf.com)

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20 v 4000 g43 20 v 4000 g63 20 v 4000 g83 20 v 4000 g63l 20 v 4000 g83l

MTU 20 V 4000 G23 Technical Publication

1 Safety

2 Product Summary

3 Operation

4 Maintenance

5 Troubleshooting

6 Task Description

7 Special Tools

8 Annex

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Summary of Contents for MTU 20 V 4000 G23

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