Rolls-Royce mtu 20V4000B 4F Series Operating Instructions Manual
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Rolls-Royce mtu 20V4000B 4F Series Operating Instructions Manual

Rolls-Royce mtu 20V4000B 4F Series Operating Instructions Manual

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Operating Instructions
Diesel engine
20V4000Bx4F
20V4000Bx4S
20V4000Gx3F
20V4000Gx3S
20V4000Gx3Lx
20V4000Gx4F
20V4000Gx4S
MS15039/07E

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Summary of Contents for Rolls-Royce mtu 20V4000B 4F Series

  • Page 1 Operating Instructions Diesel engine 20V4000Bx4F 20V4000Bx4S 20V4000Gx3F 20V4000Gx3S 20V4000Gx3Lx 20V4000Gx4F 20V4000Gx4S MS15039/07E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. Rolls-Royce Solutions re‐ serves the right to change, delete or supplement the information provided as and when required.

  • Page 3: California Proposition

    California Proposition 65 This warning applies only to the State of California, USA, in compliance with Title 27 California Code of Regu‐ lations, Article 6, Clear and Reasonable Warnings. (→ www.P65warnings.ca.gov/diesel ) MS15039/07E 2023-09 | California Proposition 65 | 3...
  • Page 4 4 | California Proposition 65 | MS15039/07E 2023-09...

  • Page 5: Table Of Contents

    Table of Contents 1 Preface 6 Technical Data 1.1 Preface 6.1 Product data 20V4000B24F, 1.2 Applicability 20V4000B34F, 20V4000B24S, 20V4000B44S, application group 3A 6.2 Product data 20V4000G14F, application 2 Safety group 3B 2.1 Important provisions for all products 6.3 Product data 20V4000G14F, application 2.2 Important requirements for Power group 3E Generation application products...
  • Page 6 6.22 Product data 20V4000G23F, 10.3.1 Crankcase breather – Oil separator element 20V4000G63F, 20V4000G63LF, replacement 20V4000G43S, 20V4000G83S, 10.3.2 Crankcase breather – Oil separator element 20V4000G83LS replacement 6.23 Firing order 10.3.3 Crankcase breather – Oil mist separator 6.24 Engine – Main dimensions replacement 10.4 Valve Drive 7 Operation...
  • Page 7 10.13.1 Engine oil – Change 10.17.4 Battery-charging generator – Drive belt 10.13.2 Engine oil – Level check tension adjustment 10.13.3 Engine oil – Sample extraction and analysis 10.18 Storage 10.13.4 Oil priming pump – Visual inspection 10.18.1 Engine mounting – Checking resilient element 10.14 Oil Filtration / Cooling 10.18.2 Engine mounting –...

  • Page 8: Preface

    1.1 Preface These Operating Instructions contain general instructions for the proper and safe operation of your product from the manufacturer Rolls-Royce Solutions. The wording of this document is intended to encompass and address all genders equally. 8 | Preface | MS15039/07E 2023-09...

  • Page 9: Applicability

    1.2 Applicability Engine model Frequency Application group * 20V4000B24F 50 Hz 20V4000B34F 50 Hz 20V4000G14F 50 Hz 3B, 3G, 3E, 3F 20V4000G24F 50 Hz 3B, 3G, 3E, 3F 20V4000G34F 50 Hz 3B, 3G, 3E, 3F 20V4000G64F 50 Hz 20V4000G74F 50 Hz 20V4000G84F 50 Hz 20V4000B24S...

  • Page 10: Safety

    • Non-compliance with the safety notes and warnings • Only connect devices that are part of Rolls-Royce Solutions scope of delivery. • Contact the Rolls-Royce Solutions representative in the case of any system abnormalities (→ Page 348). Nameplates The product is identified by nameplate, model designation, or serial number. This data must match the specifi‐...

  • Page 11: Important Requirements For Power Generation Application Products

    2.2 Important requirements for Power Generation application products Project-specific operational environment During integration and use of the diesel engine, all currently valid and relevant standards and guidelines on safety and specified operation must be implemented and observed. This applies to persons responsible for: •...
  • Page 12 Incorrect synchronization Load application with incorrect synchronization (generator connection with phase offset) can cause considera‐ bly high torque pulses. The plant integrator must design the control system such that the possibility of a load application with incorrect synchronization is excluded. Emergency stop The diesel engine has inputs for Stop and Emergency stop.

  • Page 13: Intended Use Of Gendrive Engines

    • 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/Rolls-Royce Solutions contact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (also applies to engine control/parameters) •...

  • Page 14: Personnel And Organizational Requirements

    2.4 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installation, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, re‐ pair, assembly, installation, and transport personnel at all times.

  • Page 15: Safety Regulations For Commissioning And Operation

    2.5 Safety regulations for commissioning and operation Safety regulations for commissioning Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications be‐ fore commissioning the product. All necessary approvals must be granted by the relevant authorities and all requirements for commissioning must be fulfilled.
  • Page 16 Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed to do so following a written procedure. Do not inhale exhaust gases emitted by the product. The following requirements must be fulfilled before the product is started: •...

  • Page 17: Safety Regulations For Assembly, Maintenance, And Repair Work

    2.6 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/scalding).
  • Page 18 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 exterior components: 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 19 Welding work Welding work on the product or any installed equipment may only be carried out by personnel authorized by Rolls-Royce Solutions. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch.
  • Page 20 ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge must always be carried out with appropriate equipment. Appropriate equipment includes electrically conductive work surfaces or antistatic wristbands. Avoid damaging cabling during removal work. When reconnecting, ensure that cabling can not be damaged during operation by: •...

  • Page 21: Fire And Environmental Protection, Indirect Materials

    The safety data sheet may be obtained from the relevant manufacturer or from Rolls-Royce Solutions. Only fluids and lubricants approved by the manufacturer must be used in accordance with the Fluids and Lu‐...
  • Page 22 When operating with biodiesel fuel: Component corrosion during longer engine service life. Follow the special instructions in the Fluids and Lubricants Specifications. Contamination of indirect materials with reducing agent (e.g. AdBlue , DEF): Store indirect materials in sepa‐ ® rate containers and use separate drip trays. Even very slight contamination with reducing agent can lead to malfunctions in sensors and other components.
  • Page 23 Acids, alkaline solutions, reducing agents • Observe the relevant safety data sheet for all materials. • When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective clothing. • Do not inhale vapors. • If reducing agent is swallowed, rinse out mouth and drink plenty of water. •...

  • Page 24: Standards For Warning Messages In The Text And Highlighted Information

    2.8 Standards for warning messages 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 25: Transport

    Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set the engine down on the oil pan unless this has been expressly authorized by Rolls-Royce Solutions. MS15039/07E 2023-09 | Transport | 25...

  • Page 26: Lifting Specifications

    3.2 Lifting specifications Lifting specifications DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. Lifting by crane must only be carried out by qualified per‐ sonnel. • Never stand beneath a suspended load and keep a safe distance. •...

  • Page 27: Engine Mounting Transportation Lock

    3.3 Engine mounting transportation lock Preconditions ☑ The engine must have been filled with engine coolant and engine oil. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 300–800 Nm F30047798 Ratchet bit F30450902 Engine oil Transport locking device Note: The transportation lock protects the engine mounting from damage resulting from shock and vibration during...
  • Page 28 Installing transportation locks Insert screws (1) together with washers and nuts (2) (2 on each mount). Screw on and tighten nut (3). Tighten nuts (2) evenly in stages against en‐ gine foot and base mount. Tighten screws (1) and nuts (2, 3) to specified torque. Name Size Type...

  • Page 29: Transport Locking Device For Crankshaft

    3.4 Transport locking device for crankshaft Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027341 Engine oil Transport locking device Note: The transport locking device on both sides protects the crankshaft bearings from shocks and possible vibra‐ tion damage during engine transport.
  • Page 30 Installing the transport locking de‐ vice 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 31 Installing guard plates and engine supports (if applicable) on driving end (KS) Note: Screw on guard plates and engine support (where applicable) only with the screws supplied or with the screws removed from the guard plates or engine supports. Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten to speci‐ fied tightening torque tightening.

  • Page 32: General Information

    4 General Information 4.1 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 DIN ISO 1204 (KGS = Kupplungsgegen‐...

  • Page 33: Data Acquisition And Data Transmission

    4.2 Data acquisition and data transmission Data acquisition and data transmission Rolls-Royce Solutions products automatically capture and record data and transmit it to the manufacturer. This does not apply to Rolls-Royce Solutions products in military applications. The data transmitted includes operating data, GPS data, log files of malfunctions and fault messages. No per‐...

  • Page 34: Functional Description

    5 Functional Description 5.1 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 34 | Functional Description | MS15039/07E 2023-09...
  • Page 35 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 36: Crankcase With Oil Pan

    5.2 Crankcase with oil pan 1 Crankcase 7 Coolant transfer 13 Crankshaft bearing 2 Main oil gallery 8 Oil dipstick 14 Oil spray nozzle for piston 3 Upper end cover 9 Oil filler neck cooling 4 Coolant chamber 10 Inspection port cover 15 Camshaft bearing 5 Cylinder liner 11 Oil pan...
  • Page 37 Benefits • High level of rigidity • Low noise and vibration level Function The crankcase (1) is the component where the power generated by the combustion process of the fuel/air mixture in the cylinders is transmitted to the crankshaft. The crankcase is cast as a single solid unit to with‐ stand the forces involved.

  • Page 38: Gear Train

    5.3 Gear train 1 Gear train for coolant pump, 5 Drive gear for HP fuel pump 9 Drive gear for engine oil LT circuit and fuel delivery pump pump 2 Gear train for coolant pump, 6 Idler gear 10 Drive gear for oil replenish‐ HT circuit 7 Drive gear for battery-charg‐...

  • Page 39: Running Gear

    5.4 Running gear 1 Flywheel 4 Conrod 7 Crankshaft counterweight 2 Crankshaft 5 Vibration damper 8 Ring gear 3 Piston 6 Crankshaft gear KS = Driving end Running gear The running gear is installed in the crankcase. It is supported in sleeve bearings and locked in axial direction. Engine oil from the crankcase is used to lubricate the bearings, vibration damper, and pistons.
  • Page 40 Crankshaft • Forged • Bolt-on counterweights • Press-fitted crankshaft gear • Low-wear sleeve bearings, oil supply from lube-oil system • Axial fixing by thrust bearing • Radial-lip shaft seals for sealing against external influences (driving end and free end) Vibration damper (free end) •...

  • Page 41: Cylinder Head With Injector

    5.5 Cylinder head with injector 1 Cylinder head 6 Valve guide a Charge-air 2 Hold-down clamp 7 Inlet valves b Exhaust gas 3 Injector 8 Sealing ring c Coolant 4 HP fuel line 9 Exhaust valves d Engine oil 5 Fuel return line 10 Piston Cylinder head with injector The cylinder heads containing the valve gear and fuel injection equipment are mounted on the crankcase.
  • Page 42 Function Charge-air flows into the combustion chamber of the cylinder when the inlet valves (7) are open. The injector (3) injects fuel into the combustion chamber creating an air/fuel mixture which ignites spontane‐ ously under compression. When the exhaust valves (9) open, exhaust gas created by the combustion process flows via the outlet duct to the exhaust manifold leading to the exhaust turbochargers.

  • Page 43: Valve Gear

    5.6 Valve gear 1 Camshaft drive gear 6 Pushrod 11 Rocker arm (exhaust) 2 Swing follower shaft 7 Rocker shaft 12 Rocker arm bearing block 3 Swing follower (intake) 8 Rocker arm (intake) 13 Valve bridge 4 Swing follower (exhaust) 9 Locknut 5 Camshaft 10 Adjusting screw...
  • Page 44 Function The camshaft (5) controls opening and closing of the intake and exhaust valves. The motion applied from the cams of the camshaft to actuate the valves is transferred by swing followers (3, 4), pushrods (6) and rocker arms (8, 11) onto the valve bridges (13) of the intake and exhaust valves. The valves open against spring pressure and close with the pressure exerted by the valve springs.

  • Page 45: Fuel System With Common-Rail Injection

    5.7 Fuel system with Common-Rail injection 1 Injector 6 Common Rail 11 Fuel delivery pump 2 Connecting line, HP fuel line 7 Connection, fuel return to 12 HP fuel pump (only 16V/20V engines) tank 13 HP fuel distributor 3 Connecting line, return line 8 Connection, fuel supply from 14 Pressure limiting valve (only 16V/20V engines)
  • Page 46 High pressure The high-pressure fuel system (Common-Rail injection system) comprises: • HP fuel pump • HP distributor with pressure limiting valve • Common rails • Single-wall HP fuel lines • Injectors with integrated, individual injector accumulator and flow restrictor valve Return •...

  • Page 47: Charge-Air And Exhaust System

    5.8 Charge-air and exhaust system 1 Exhaust turbocharger, right 6 Charge-air pipe, right side 11 Air intake, connection for air side (free end) 7 Exhaust turbocharger, right filter 2 Exhaust outlet side (driving end) 12 Air supply pipe 3 Exhaust turbocharger, left 8 Exhaust turbocharger, left 13 Inlet duct side (free end)
  • Page 48 Benefits • Low exhaust emissions • Low fuel consumption • High degree of engine efficiency • Optimum load application characteristics • Straightforward connection to external exhaust gas system Function Exhaust system After the exhaust valves open, exhaust gases flow out of the cylinder combustion chambers through the ex‐ haust ducts (15) in the cylinder heads to the exhaust manifolds (14) leading to the exhaust turbochargers (1, 3, 7, 8).

  • Page 49: Lube Oil System

    5.9 Lube oil system 1 Exhaust turbocharger 10 Oil priming pump outlet con‐ 19 Pressure maintaining valve 2 Centrifugal oil filter nection 20 Conrod bearings 3 Engine oil heat exchanger 11 Suction basket 21 Crankshaft thrust bearing 4 Oil sampling connection 12 Pressure limiting valve be‐...
  • Page 50 The following components / assemblies are supplied directly: • HP fuel pump (6) • Vibration damper (13) • Crankshaft support bearing, free end (14) • Conrods (20) • Piston cooling nozzles (24) The following components / assemblies are supplied from the main oil gallery (17): •...

  • Page 51: Cooling System

    5.10 Cooling system Engine coolant circuit 1 Charge-air coolant vent line, 11 Charge-air coolant drain 21 Engine oil heat exchanger plug 22 Engine coolant preheater 2 Engine coolant vent line, HT 12 Charge-air coolant pump outlet (option) 3 Space heater supply con‐ 13 Charge-air coolant outlet to 23 Engine coolant drain plug nection (only 12/16V en‐...
  • Page 52 Technical data • Two separate circuits: – Engine coolant HT (high-temperature) – Charge-air coolant LT (low-temperature) • Coolant cooling by: – Electrically driven cooling fans – Mechanically driven cooling fans – Water/water heat exchanger (for example, plate-core heat exchanger) • Thermostat-controlled coolant circuit •...

  • Page 53: Engine Management And Monitoring

    5.11 Engine management and monitoring 1 Customer's control system 4 Data and signals 7 Connection of engines sen‐ 2 Power supply 24 V DC 5 EIL sory equipment 3 SmartConnect 6 ECU 9 P System E Engine electronics Engine management and monitoring The engine monitoring system continuously analyzes the operating data of the engine.
  • Page 54 Technology • High temperature resistance, power output, integration level and computing power than the predecessor • Larger program memory, data memory and RAM • Flat housing with three self-locking plug connectors • 24 V DC power supply • Communication with other devices and higher-level systems via CAN bus (to mtu devices via PCS-5 redun‐ dant, to external devices via J1939) •...
  • Page 55 Engine protection and safety features • Restricting engine operation to remain within admissible operating values • Engine protection with dual-level safety systems; The following responses by the governor including the output of an alarm message can be programmed: – Start interlock –...

  • Page 56: Cylinder Cutout

    5.12 Cylinder cutout Wet stacking Diesel engines do not reach the usual operating conditions when running at low load or in idle mode. With a lower pressure in the cylinders, the piston rings do not make full contact with the cylinder liner.This leads to an increased amount of oil in the combustion chamber and in the exhaust system.

  • Page 57: Engine - Quick-Start Function

    5.13 Engine – Quick-start function 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 58: Sensors And Actuators - Overview

    5.14 Sensors and actuators – Overview Designation Description Engine Ident label (EIL) Charge-air temperature sensor Pressure sensor, fuel after filter Temperature sensor, LP fuel pressure B48.1 Pressure sensor, HP fuel pressure, A-side Y39.A10 - Y39.A1 Injectors, left engine side 58 | Functional Description | MS15039/07E 2023-09...
  • Page 59 Designation Description Camshaft speed sensor Pressure sensor, lube oil after filter Temperature sensor, coolant at engine outlet Lube oil temperature sensor, engine inlet Charge-air coolant temperature sensor Crankcase pressure sensor Lube oil replenishment pump pressure sensor (optional) Control block of HP fuel pump (optional) XB54 Connection for oil replenishment pump (optional) MS15039/07E 2023-09 | Functional Description | 59...
  • Page 60 Designation Description Charge-air pressure sensor B48.2 Pressure sensor, HP fuel pressure, B-side XF33 Connection, engine coolant level sensor (external expansion tank) XF57 Connection, charge-air coolant level sensor (external expansion tank) Y39.B1 - Y39.B10 Injectors, right engine side 60 | Functional Description | MS15039/07E 2023-09...
  • Page 61 Designation Description Crankshaft speed sensor MS15039/07E 2023-09 | Functional Description | 61...
  • Page 62 Designation Description B44* Turbocharger speed sensor * Installed on 60 Hz engines only 62 | Functional Description | MS15039/07E 2023-09...

  • Page 63: Technical Data

    6 Technical Data 6.1 Product data 20V4000B24F, 20V4000B34F, 20V4000B24S, 20V4000B44S, application group 3A CP 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 64 Power-related data Rated engine speed 1500 1500 1800 1800 Continuous power ISO 3046 (10% over‐ 2000 2200 2230 2490 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2200 2420 2453 2739 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 65 Air / exhaust gas Combustion air volumetric flow – CP m³/s 3.45 Combustion air volumetric flow – BL m³/s 3.85 Exhaust gas volume (at exhaust gas tem‐ m³/s perature) – CP Exhaust gas volumetric flow (at exhaust m³/s gas temperature) – BL Exhaust gas temperature after engine –...

  • Page 66: (Standard Oil System) (Design: Max. Oper

    Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...

  • Page 67: Take Noise (Filter) - Cp (Sound Power Level

    Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 68: Product Data 20V4000G14F, Application Group 3B

    6.2 Product data 20V4000G14F, application group 3B CP 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 69: Liter

    Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2200 2200 2200 2200 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 70 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.12 7.12 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 7.74 7.74 gas temperature) –...

  • Page 71: Liter Liter Liter

    Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...

  • Page 72: Db(A)

    Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 73: Product Data 20V4000G14F, Application Group 3E

    6.3 Product data 20V4000G14F, application group 3E CP 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 74 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2200 2200 2200 2200 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 75 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.12 7.12 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 7.74 7.74 gas temperature) –...

  • Page 76: Db(A)

    Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 77 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 78: Product Data 20V4000G14F, Application Group 3F

    6.4 Product data 20V4000G14F, application group 3F CP 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 79 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2200 2200 2200 2200 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 80 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.12 7.12 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 7.74 7.74 gas temperature) –...
  • Page 81 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 82 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, + 2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 83: Product Data 20V4000G14F, Application Group 3G

    6.5 Product data 20V4000G14F, application group 3G CP 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 84 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2200 2200 2200 2200 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2420 2420 2420 2420 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 85 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.12 7.12 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 7.74 7.74 gas temperature) –...
  • Page 86 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 87 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 88: Product Data 20V4000G24F, Application Group 3B

    6.6 Product data 20V4000G24F, application group 3B CP 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 89 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2420 2420 2420 2420 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 90 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.68 7.68 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 10.1 8.44 8.44 gas temperature) –...
  • Page 91 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 92 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 93: Product Data 20V4000G24F, Application Group 3E

    6.7 Product data 20V4000G24F, application group 3E CP 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 94 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2420 2420 2420 2420 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 95 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.68 7.68 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 10.1 8.44 8.44 gas temperature) –...
  • Page 96 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 97 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 98: Product Data 20V4000G24F, Application Group 3F

    6.8 Product data 20V4000G24F, application group 3F CP 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 99 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2420 2420 2420 2420 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 100 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.68 7.68 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 10.1 8.44 8.44 gas temperature) –...
  • Page 101 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 102 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 103: Product Data 20V4000G24F, Application Group 3G

    6.9 Product data 20V4000G24F, application group 3G CP 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 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2420 2420 2420 2420 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2662 2662 2670 2670 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 105 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 7.68 7.68 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 10.1 8.44 8.44 gas temperature) –...
  • Page 106 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 107 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 108: Product Data 20V4000G34F, Application Group 3B

    6.10 Product data 20V4000G34F, application group 3B CP 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 109 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2590 2590 2590 2590 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 110 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 10.3 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 8.78 10.3 gas temperature) – BL Exhaust gas temperature after engine –...
  • Page 111 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 112 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 113: Product Data 20V4000G34F, Application Group 3E

    6.11 Product data 20V4000G34F, application group 3E CP 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 114 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2590 2590 2590 2590 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 115 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 10.3 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 8.78 10.3 gas temperature) – BL Exhaust gas temperature after engine –...
  • Page 116 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 117 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 118: Product Data 20V4000G34F, Application Group 3F

    6.12 Product data 20V4000G34F, application group 3F CP 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 119 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2590 2590 2590 2590 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 120 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 10.3 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 8.78 10.3 gas temperature) – BL Exhaust gas temperature after engine –...
  • Page 121 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 122 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 123: Product Data 20V4000G34F, Application Group 3G

    6.13 Product data 20V4000G34F, application group 3G CP 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 124 Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over‐ 2590 2590 2590 2590 load capability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 2849 2849 2849 2849 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max.
  • Page 125 Air / exhaust gas Combustion air volumetric flow – CP m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem‐ m³/s 10.3 perature) – CP Exhaust gas volumetric flow (at exhaust m³/s 8.78 10.3 gas temperature) – BL Exhaust gas temperature after engine –...
  • Page 126 Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) Capacities Engine coolant, engine side (w/o cooling liter 205 * 205 * 205 * 205 * system) Charge-air coolant, engine side liter Fuel, engine side liter Total engine oil capacity, initial filling liter 390 * 390 *...
  • Page 127 Engine surface noise with attenuated in‐ dB(A) take noise (filter) – CP (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with attenuated in‐...

  • Page 128: Product Data 20V4000G64F, Application Group 3D

    6.14 Product data 20V4000G64F, application group 3D CP 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 129 Site conditions (for max. power) Intake air depression (new filter) mbar Intake depression, max. mbar Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max (w/o °C power reduction) Fuel temperature at fuel feed connection, max. °C Consumption Specific fuel consumption (be) –...
  • Page 130 Exhaust gas temperature after engine – CP °C Exhaust gas temperature after engine – BL °C Coolant system (high-temperature 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 131 Oil pan capacity at dipstick mark “min.” (standard oil liter system) (design: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil liter system) (design: max. operating inclinations) Mass / main dimensions Engine mass, dry (basic engine configuration acc. to 9290 9290 9290...

  • Page 132: Product Data 20V4000G74F, Application Group 3D

    6.15 Product data 20V4000G74F, application group 3D CP 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 133 Site conditions (for max. power) Intake air 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 fuel feed connection, max. °C Consumption Specific fuel consumption (be) –...
  • Page 134 Exhaust gas temperature after engine – CP °C Exhaust gas temperature after engine – BL °C Coolant system (high-temperature 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 135 Oil pan capacity at dipstick mark “min.” (standard oil liter system) (design: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil liter system) (design: max. operating inclinations) Mass / main dimensions Engine mass, dry (basic engine configuration acc. to 9290 9290 9290...

  • Page 136: Product Data 20V4000G14S, 20V4000G24S, 20V4000G44S, Application Group 3B

    6.16 Product data 20V4000G14S, 20V4000G24S, 20V4000G44S, application group 3B CP 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 137 Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut- in / cut-out control) Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 2490 2490 2740 2740 3010 3010 3046 (10% overload ca‐ pability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 A 2739...
  • Page 138 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 angle (°) Bore Stroke Displacement of a cylin‐ liter 4.77 4.77 4.77...
  • Page 139 Coolant system (low-temperature circuit) Coolant temperature (at R °C engine connection: outlet to cooling system) Coolant temperature be‐ °C fore intercooler, limit 1 Coolant temperature be‐ °C fore intercooler, limit 2 Coolant antifreeze con‐ tent, max. Lube oil system Lube oil temperature be‐ °C fore engine, limit 1 Lube oil temperature be‐...
  • Page 140 Oil pan capacity at dip‐ liter stick mark “min.” (stand‐ ard oil system) (design: max. operating inclina‐ tions) Oil pan capacity at dip‐ liter stick mark “max.” (stand‐ ard oil system) (design: max. operating inclina‐ tions) Mass / main dimensions Engine mass, dry (basic R kg 9290...
  • Page 141 Engine surface noise with R dB(A) attenuated intake noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with R dB(A) attenuated intake noise (filter) - BL (sound power level LW, ISO 6798, +2dB(A) tolerance) MS15039/07E 2023-09 | Technical Data | 141...

  • Page 142: Product Data 20V4000G84F, Application Group 3D

    6.17 Product data 20V4000G84F, application group 3D CP 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 143 Site conditions (for max. power) Intake air 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 fuel feed connection, max. °C Consumption Specific fuel consumption (be) –...
  • Page 144 Exhaust gas temperature after engine – CP °C Exhaust gas temperature after engine – BL °C Coolant system (high-temperature 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 145 Oil pan capacity at dipstick mark “min.” (standard oil liter system) (design: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil liter system) (design: max. operating inclinations) Mass / main dimensions Engine mass, dry (basic engine configuration acc. to 9290 9290 9290...

  • Page 146: Product Data 20V4000G14S, 20V4000G24S, 20V4000G44S, Application 3E

    6.18 Product data 20V4000G14S, 20V4000G24S, 20V4000G44S, application 3E CP 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 147 Site conditions (for max. power) Intake air 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 fuel feed connection, max. °C Consumption Specific fuel consumption (be) –...
  • Page 148 Exhaust gas temperature after engine – CP °C Exhaust gas temperature after engine – BL °C Coolant system (high-temperature 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 149 Oil pan capacity at dipstick mark “min.” (standard oil liter system) (design: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil liter system) (design: max. operating inclinations) Mass / main dimensions Engine mass, dry (basic engine configuration acc. to 9290 9290 9290...

  • Page 150: Product Data 20V4000G14S, 20V4000G24S, 20V4000G44S, Application Group 3F

    6.19 Product data 20V4000G14S, 20V4000G24S, 20V4000G44S, application group 3F CP 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 151 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) Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 2490 2490...
  • Page 152 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 153 Coolant system (high-temperature 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 (low-temperature circuit) Coolant temperature (at R °C engine connection: outlet to cooling system)
  • Page 154 Capacities Engine coolant, engine R liter 205 * 205 * 205 * 205 * 205 * 205 * side (w/o cooling system) Charge-air coolant, en‐ R liter gine side Fuel, engine side R liter Total engine oil capacity, R liter 390 * 390 * 390 *...
  • Page 155 Exhaust noise, unsilenced R dB(A) - BL (sound power level LW, ISO 6798, +3dB tol‐ erance) Engine surface noise with R dB(A) attenuated intake noise (filter) – CP (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with R dB(A) attenuated intake noise...

  • Page 156: Product Data 20V4000G14S, 20V4000G24S, 20V4000G44S, Application Group 3G

    6.20 Product data 20V4000G14S, 20V4000G24S, 20V4000G44S, application group 3G CP 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 157 Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut- in / cut-out control) Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 2490 2490 2740 2740 3010 3010 3046 (10% overload ca‐ pability) (design power DIN 6280, ISO 8528) Fuel stop power ISO 3046 A 2739...
  • Page 158 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 angle (°) Bore Stroke Displacement of a cylin‐ liter 4.77 4.77 4.77...
  • Page 159 Coolant system (low-temperature circuit) Coolant temperature (at R °C engine connection: outlet to cooling system) Coolant temperature be‐ °C fore intercooler, limit 1 Coolant temperature be‐ °C fore intercooler, limit 2 Coolant antifreeze con‐ tent, max. Lube oil system Lube oil temperature be‐ °C fore engine, limit 1 Lube oil temperature be‐...
  • Page 160 Oil pan capacity at dip‐ liter stick mark “min.” (stand‐ ard oil system) (design: max. operating inclina‐ tions) Oil pan capacity at dip‐ liter stick mark “max.” (stand‐ ard oil system) (design: max. operating inclina‐ tions) Mass / main dimensions Engine mass, dry (basic R kg 9290...
  • Page 161 Engine surface noise with R dB(A) attenuated intake noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with R dB(A) attenuated intake noise (filter) - BL (sound power level LW, ISO 6798, +2dB(A) tolerance) MS15039/07E 2023-09 | Technical Data | 161...

  • Page 162: Product Data 20V4000G64S, 20V4000G74S, 20V4000G94S, Application Group 3D

    6.21 Product data 20V4000G64S, 20V4000G74S, 20V4000G94S, application group 3D CP 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 163 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) Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Fuel stop power ISO 3046 A 2740 2740...
  • Page 164 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 angle (°) Bore Stroke Displacement of a cylin‐ liter 4.77 4.77 4.77...
  • Page 165 Coolant system (low-temperature circuit) Coolant temperature (at R °C engine connection: outlet to cooling system) Coolant temperature be‐ °C fore intercooler, limit 1 Coolant temperature be‐ °C fore intercooler, limit 2 Coolant antifreeze con‐ tent, max. Lube oil system Lube oil temperature be‐ °C fore engine, limit 1 Lube oil temperature be‐...
  • Page 166 Oil pan capacity at dip‐ liter stick mark “min.” (stand‐ ard oil system) (design: max. operating inclina‐ tions) Oil pan capacity at dip‐ liter stick mark “max.” (stand‐ ard oil system) (design: max. operating inclina‐ tions) Mass / main dimensions Engine mass, dry (basic R kg 9290...
  • Page 167 Engine surface noise with R dB(A) attenuated intake noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) Engine surface noise with R dB(A) attenuated intake noise (filter) - BL (sound power level LW, ISO 6798, +2dB(A) tolerance) MS15039/07E 2023-09 | Technical Data | 167...

  • Page 168: Product Data 20V4000G23F

    6.22 Product data 20V4000G23F, 20V4000G63F, 20V4000G63LF, 20V4000G43S, 20V4000G83S, 20V4000G83LS Product type Frequency Application 20V4000G23F 50 Hz see Product data 20V4000G14F (→ Page 68) see Product data 20V4000G64F (→ Page 128) see Product data 20V4000G14F (→ Page 73) see Product data 20V4000G14F (→...
  • Page 169 Product type Frequency Application 20V4000G43S 60 Hz see Product data 20V4000G14S (→ Page 136) see Product data 20V4000G64S (→ Page 162) See Product data 20V4000G14S (→ Page 146) see Product data 20V4000G14S (→ Page 150) see Product data 20V4000G14S (→ Page 156) 20V4000G83S 60 Hz see Product data 20V4000B24S...

  • Page 170: Firing Order

    6.23 Firing order Number of cyl‐ Firing order inders A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 170 | Technical Data | MS15039/07E 2023-09...

  • Page 171: Engine - Main Dimensions

    6.24 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 MS15039/07E 2023-09 | Technical Data | 171...

  • Page 172: Operation

    7 Operation 7.1 Preparations for putting into operation after extended out-of- service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ Preservation and Represervation Specifications (A001070/..) are available. Putting into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...

  • Page 173: Preparations For Putting Into Operation After Scheduled Out-Of-Service-Period

    7.2 Preparations for 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 292); Coolant circuit Check engine coolant level (→ Page 300). Check charge-air coolant level (→...

  • Page 174: Starting The Engine In Manual Mode (Test Run)

    7.3 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 175: Re-Starting The Engine Following An Automatic Safety Shutdown

    7.4 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 176: Safety System - Override

    7.5 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. Preparation Note: This function is only available when a pushbutton is provided.

  • Page 177: Emergency Engine Start (Override Mode)

    7.6 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 178: Operational Monitoring

    7.7 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 A high level of noise is produced when the system is running.

  • Page 179: Emission Label - Check

    7.8 Emission label – Check Emission label – Check Note: If there are any irregularities, notify your Rolls-Royce Solutions contact person/service partner without delay. Check that emissions labels are present (there can be more than one). Check emission labels for intactness.

  • Page 180: Engine - Stopping In Manual Mode (Test Run)

    7.9 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 181 After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after engine shutdown. MS15039/07E 2023-09 | Operation | 181...

  • Page 182: Engine - Emergency Stop

    7.10 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 183: After Stopping The Engine - Engine Remains Ready For Operation

    7.11 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump con‐ Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. trol MS15039/07E 2023-09 | Operation | 183...

  • Page 184: After Shuting Down Engine - Putting Engine Out Of Operation

    7.12 After shuting down engine – Putting engine out of operation Preconditions ☑ Preservation and Represervation Specifications (A001070/..) are available. After shutdown Item Action Coolant circuit Drain engine coolant (→ Page 303); Drain charge-air coolant (→ Page 322) if: • freezing temperatures are to be expected and the engine is to remain out of service for an extended period but the coolant has no antifreeze addi‐...

  • Page 185: Plant - Cleaning

    7.13 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Concentrated cleaning agent (Hakupur 449) X00071179 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 186 Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec‐ tion). Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning units carefully and observe the safety precautions. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit: •...

  • Page 187: Troubleshooting

    8 Troubleshooting 8.1 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). Starter (electric): Engine cabling or u Check if cable connections are properly secured.
  • Page 188 Engine does not reach rated speed Cause Corrective action Fuel prefilter (not switchable) u Replace (→ Page 276). clogged Fuel prefilter (switchable) clogged u Replace (→ Page 278). Fuel filter contaminated u Replace (→ Page 265). Air filter contaminated u Check signal ring position of service indicator (→ Page 287). Injector defective u Replace (→...
  • Page 189 Blue exhaust gas Cause Corrective action Too much engine oil in the engine u Drain engine oil (→ Page 289). Oil separator of crankcase u Replace filter (→ Page 240). ventilation contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner faulty White exhaust gas Cause...

  • Page 190: Fault Messages Of Engine Control Unit Ecu9 For Series 4000, Genset Applications

    8.2 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 175) Note: Individual remedial measures require a higher qualification level to carry out the work.
  • Page 191 6 – SS T-Charge Air SPN: 105 – FMI: 0 The charge-air temperature at sensor B9 has exceeded limit value 2. Cause Corrective action Charge-air temperature too high. 1. Reduce power. 2. Check if alarm 9 and/or 10 is active. 3.
  • Page 192 23 – LO Coolant Level SPN: 111 – FMI: 17 Coolant level at level switch B533 in HT circuit is too low. Cause Corrective action Coolant level too low. 1. Check engine coolant level. (→ Page 300) 2. Check relief bore of engine coolant pump. (→ Page 308) 3.
  • Page 193 32 – SS ETC1 Overspeed SPN: 103 – FMI: 16 The speed of the A-side LP turbocharger at sensor B44 has exceeded limit value 2. The exhaust turbocharger speed is too high. Cause Corrective action Fault or malfunction of another 1.
  • Page 194 60 – SS T-Coolant L4 SPN: 110 – FMI: 0 The coolant temperature at sensor B6 has exceeded upper limit value 4. Cause Corrective action The coolant temperature is too 1. Check operation of cooler and fan (plant side). high. 2.
  • Page 195 67 – HI T-Coolant SPN: 110 – FMI: 15 The coolant temperature at sensor B6 has exceeded limit value 1. Cause Corrective action The coolant temperature is too 1. Reduce power. high. 2. Check operation of cooler and fan (plant side). 3.
  • Page 196 90 – SS Idle Speed Not Reached SPN: 188 – FMI: 1 The engine has failed to reach idle speed within the defined time after reaching starter disengagement speed. Cause Corrective action Engine speed has not reached 1. Check supply pressure (plant side) of starter. idling speed within the set time 2.
  • Page 197 95 – AL Prelubrication Fault SPN: 521092 – FMI: 31 The oil pressure at sensor B5 is below the specified value. Cause Corrective action The specified oil pressure was not 1. Check engine cabling. (→ Page 339) reached. The starting sequence 2.
  • Page 198 122 – HI T-ECU SPN: 1136 – FMI: 15 The temperature at the sensor inside the ECU has exceeded the limit value. Cause Corrective action Internal temperature too high. 1. Check if alarm 9 and/or 10 is active. 2. If ECU cooling is connected, check flow rate. 3.
  • Page 199 188 – AL CAN2 Bus Off SPN: 521013 – FMI: 31 CAN bus 2 to plant-side automation (e.g. Murphy Display) disrupted or faulty. Cause Corrective action CAN bus is interrupted or faulty. 1. Check connection between plant-side automation and mtu automation.
  • Page 200 208 – SD P-Charge Air SPN: 3563 – FMI: 11 The signal from the charge-air pressure sensor (B10) after the HP intercooler is faulty or missing. Cause Corrective action Charge-air pressure sensor (B10) 1. Check engine cabling. (→ Page 339) after the HP intercooler delivers an 2.
  • Page 201 229 – AL Stop Camshaft Sensor Defect SPN: 521016 – FMI: 31 Emergency engine stop following failure of the crankshaft sensor (B13) and camshaft sensor (B1). Cause Corrective action Emergency engine stop following u Contact Service. (→ Page 348) failure of the crankshaft sensor and camshaft sensor.
  • Page 202 266 – SD Speed Demand SPN: 898 – FMI: 11 Signal of analog speed setting missing. Cause Corrective action Signal missing. 1. Switch on plant-side automation. 2. Contact Service. (→ Page 348) 321 – AL Wiring Cylinder A1 SPN: 520900 – FMI: 31 Short circuit fault in the injector wiring for cylinder A1 or injector defective.
  • Page 203 325 – AL Wiring Cylinder A5 SPN: 520904 – FMI: 31 Short circuit fault in the injector wiring for cylinder A5 or injector defective. Cause Corrective action Short circuit fault in injector wiring 1. Check wiring of affected injector. (→ Page 339) of the cylinder or injector 2.
  • Page 204 330 – AL Wiring Cylinder A10 SPN: 520909 – FMI: 31 Short circuit fault in injector wiring cylinder A10 or injector defective. Cause Corrective action Short circuit fault in injector wiring 1. Check wiring of affected injector. (→ Page 339) of the cylinder or injector 2.
  • Page 205 335 – AL Wiring Cylinder B5 SPN: 520914 – FMI: 31 Short circuit fault in injector wiring for cylinder B5 or injector defective. Cause Corrective action Short circuit fault in injector wiring 1. Check wiring of affected injector. (→ Page 339) of the cylinder or injector 2.
  • Page 206 340 – AL Wiring Cylinder B10 SPN: 520919 – FMI: 31 Short circuit fault in injector wiring for cylinder B10 or injector defective. Cause Corrective action Short circuit fault in injector wiring 1. Check wiring of affected injector. (→ Page 339) of the cylinder or injector 2.
  • Page 207 346 – AL Open Load Cylinder A6 SPN: 520935 – FMI: 31 Disruption fault in injector wiring for cylinder A6. Cause Corrective action Open circuit in injector wiring of 1. Check wiring of affected injector. (→ Page 339) the cylinder. 2.
  • Page 208 352 – AL Open Load Cylinder B2 SPN: 520941 – FMI: 31 Disruption fault in injector wiring to cylinder B2. Cause Corrective action Open circuit in injector wiring of 1. Check wiring of affected injector. (→ Page 339) the cylinder. 2.
  • Page 209 358 – AL Open Load Cylinder B8 SPN: 520947 – FMI: 31 Disruption fault in injector wiring to cylinder B8. Cause Corrective action Open circuit in injector wiring of 1. Check wiring of affected injector. (→ Page 339) the cylinder. 2.
  • Page 210 365 – AL Stop MV-Wiring Ground SPN: 521023 – FMI: 31 Short circuit of injector positive connection to ground of one or more injectors. Cause Corrective action Short circuit of the negative 1. Check cabling. (→ Page 339) injector connection or of one or 2.
  • Page 211 412 – HI U-PDU SPN: 520982 – FMI: 15 The ECU voltage to control the injectors has exceeded limit value 1. Cause Corrective action The voltage of the ECU has 1. Check power supply (plant side). exceeded the limit value. 2.
  • Page 212 445 – SD P-Ambient Air SPN: 521060 – FMI: 11 Signal from ambient air pressure sensor in ECU faulty or missing. Cause Corrective action The ECU-internal ambient u Contact Service. (→ Page 348) pressure sensor delivers an incorrect signal or none at all. 446 –...
  • Page 213 470 – SD T-ECU SPN: 1136 – FMI: 11 Signal from ECU internal temperature sensor faulty or missing. Cause Corrective action The temperature sensor in the 1. Check engine cabling. (→ Page 339) ECU delivers an incorrect signal or 2. Contact Service. (→ Page 348) none at all.
  • Page 214 549 – AL Power Cut-Off detected SPN: 521031 – FMI: 31 ECU operating voltage was switched off while the engine was running. Only disconnect the voltage supply when the engine is stationary. Cause Corrective action ECU operating voltage was 1. If the voltage supply was not disconnected manually, check engine switched off while the engine was wiring.
  • Page 215 596 – AL Develop PR Set SPN: 966 – FMI: 31 The parameter set is used for trials. This alarm remains set until a series parameter set is loaded. Cause Corrective action The parameter set is used for u No action required. trials.
  • Page 216 745 – AL Emission Fault SPN: 521050 – FMI: 31 Emission fault summary alarm. Cause Corrective action Emission fault summary alarm. 1. Check for additional messages. 2. Contact Service. (→ Page 348) 759 – AL L1 T-Fuel b.Engine SPN: 6698 – FMI: 15 The fuel temperature before the engine measured at sensor B38 has exceeded limit value 1.
  • Page 217 851 – AL External Start and HD too high SPN: 521155 – FMI: 31 On starting the engine, but before the starter engages, the pressure in the HP accumulator measured at sensors B48.1, A-side, and/or B48.2, B-side, has exceeded the limit value. Cause Corrective action On starting the engine, but before...
  • Page 218 1025 – LOLO P-Fuel (Common RailB) SPN: 1349 – FMI: 1 The HP fuel pressure measured at sensor B48.2 has undershot limit value 2. Cause Corrective action Fuel pressure too low. u Contact Service. (→ Page 348) 1174 – HI T-Fuel f(T0) SPN: 174 –...
  • Page 219 1370 – SD P-HD Constant Value SPN: 157 – FMI: 2 The ECU has not detected any variation in pressure at A-side HP fuel sensor B48.1. Cause Corrective action HP fuel pressure sensor defective. u Contact Service. (→ Page 348) 1371 –...
  • Page 220 1595 – AL L2 P-HD Injection SPN: 157 – FMI: 0 This alarm is tripped when the rail pressure exceeds the defined value for a defined number of times. Cause Corrective action Rail pressure too high. 1. Check whether alarms 82 and/or 83 are active. 2.
  • Page 221 1804 – AL_Injector_defect_A4 SPN: 654 – FMI: 6 Summary alarms for injector A4. Cause Corrective action Possible fault states are: Short 1. For further information, see chapter "Fault conditions of the alarms circuit or open load in the injector 1801 to 1840". (→ Page 225) cabling, inadmissible injector 2.
  • Page 222 1809 – AL_Injector_defect_A9 SPN: 659 – FMI: 6 Summary alarms for injector A9. Cause Corrective action Possible fault states are: Short 1. For further information, see chapter "Fault conditions of the alarms circuit or open load in the injector 1801 to 1840". (→ Page 225) cabling, inadmissible injector 2.
  • Page 223 1814 – AL_Injector_defect_B4 SPN: 664 – FMI: 6 Summary alarms for injector B4. Cause Corrective action Possible fault states are: Short 1. For further information, see chapter "Fault conditions of the alarms circuit or open load in the injector 1801 to 1840". (→ Page 225) cabling, inadmissible injector 2.
  • Page 224 1819 – AL_Injector_defect_B9 SPN: 669 – FMI: 6 Summary alarms for injector B9. Cause Corrective action Possible fault states are: Short 1. For further information, see chapter "Fault conditions of the alarms circuit or open load in the injector 1801 to 1840". (→ Page 225) cabling, inadmissible injector 2.

  • Page 225: Fault Conditions Of The Alarms 1801 To 1840

    8.3 Fault conditions of the alarms 1801 to 1840 The alarms 1801 to 1820 (AL_Injector_defect_A1-B10) as well as 1821 to 1840 (AL_Injector_defect_critical_A1-B10) cover fault conditions (bit 0 to bit 17) each, which can - depending on the configuration of the engine - be active through the ECU9. When one of the mentioned alarms is active, the corresponding fault condition(s) is/are stored together with the alarm and may be read out through the diagnostic tool DiaSys.
  • Page 226 Bit 7 – No Injection Detected for Cylinder Xx The pressure variation measured at the injector accumulator pressure sensor and evaluated by the EXU indicates that despite correct energization no fuel is being injected at the affected cylinder. Cause Corrective action The signal from the injector u Check if a sensor defect alarm of the injector accumulator pressure accumulator pressure sensor in...
  • Page 227 Bit 12 – Critical Fuel Mass HI2 for Cylinder Xx The measured pressure in the injector indicates excessive fuel injection for an extended period of time. Cause Corrective action The number of detected injection 1. Replace injector (→ Page 254). faults exceeds limit 2.

  • Page 228: Maintenance

    9 Maintenance 9.1 Maintenance task reference table [QL1] The maintenance tasks and intervals required for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 229 Task Item Maintenance tasks WM02084 ENGINE CONTROL UNIT After replacement of fuel injection valve/injector: reset injector running (→ Page 343) time with Diasys WM00106 CRANKCASE VENTILATION Replace oil separator (impactor) (→ Page 242) Preheater WM00222 PREHEATING Check preheater function and inspect for leaks (→...

  • Page 230: Task Description

    10 Task Description 10.1 Engine 10.1.1 Barring engine manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring gear F6801820 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 231 Engage barring gear (2) in ring tool of fly‐ wheel and mount on flywheel housing. Fit ratchet (1) on barring gear. 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‐...

  • Page 232: Engine - Cranking On Starting System

    10.1.2 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 233: Engine - Test Run

    10.1.3 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 234: Cylinder Liner

    10.2 Cylinder Liner 10.2.1 Cylinder liner – Endoscopic inspection Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 251). Remove injector (→ Page 255). Positioning crankshaft at BDC Use barring gear to turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC (→...
  • Page 235 Final steps Install injector (→ Page 255). Install cylinder head cover (→ Page 251). MS15039/07E 2023-09 | Cylinder Liner | 235...

  • Page 236: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    10.2.2 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. Finding Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 237 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 en‐ gine.

  • Page 238: Crankcase Breather

    10.3 Crankcase Breather 10.3.1 Crankcase breather – Oil separator 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 Engine oil Filter element (→...
  • Page 239 Remove filter element (1) from oil separator housing (2). Insert new filter element in housing. Install cover with new O-ring. Tighten cover screws tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 8 Nm +1 Nm Replace further oil separator elements in the same way.

  • Page 240: Crankcase Breather - Oil Separator Element Replacement

    10.3.2 Crankcase breather – Oil separator 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 Engine oil Filter element (→ Spare Parts Catalog) O-ring (→...
  • Page 241 Remove filter element (1) from housing (2). Insert new filter element in housing. Install cover with new O-ring. Tighten cover screws tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 6 Nm +2 Nm Replace further oil separator elements in the same way.

  • Page 242: Crankcase Breather - Oil Mist Separator Replacement

    10.3.3 Crankcase breather – Oil mist separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil mist fine separator (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) WARNING Oil is hot.

  • Page 243: Valve Drive

    10.4 Valve Drive 10.4.1 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 gauge with hook, 200 mm Y20000918 Measuring jig 2, optional Y4350010 Torque wrench, 10–60 Nm F30452769...
  • Page 244 Calibrating measuring jigs 1 and 2 Place measuring unit (2) on calibration plate (3). Turn measuring unit screws (1) into threads and use torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque 20 Nm Set all dial gauges to 0.
  • Page 245 Determine values with all dial gauges. • The valve protrusion value must be ≤ 1.5 mm. • If the value is > 1.5 mm, measure with depth gauge or optionally with measuring jig 2. Unscrew measuring unit (2) from cylinder head (3). Step 2: Measure valve protrusion at valve stem with depth gauge Check TDC position of piston in cylinder A1: •...
  • Page 246 Note: Do not remove rocker arm (2). Loosen adjusting screw (1) and remove valve bridge. Place measuring unit 2 (2) on the cylinder head (3). Turn measuring unit screws (1) into threads provided for cylinder head cover and use torque wrench to tighten to specified tightening torque.

  • Page 247: Valve Gear - Lubrication

    10.4.2 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 251). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 248: Valve Clearance - Check And Adjustment

    10.4.3 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 249 Note: Risk of confusion: Additional OT/A1 mark (1) on flywheel, if fitted. The additional OT/A1 mark (1) on the perime‐ ter of the flywheel must not be used for refer‐ ence. Diagram for 20V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...
  • Page 250 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 251: Cylinder Head Cover - Removal And Installation

    10.4.4 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 252: Injection Pump / Hp Pump

    10.5 Injection Pump / HP Pump 10.5.1 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 253 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 254: Injector

    10.6 Injector 10.6.1 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 255). 254 | Injector | MS15039/07E 2023-09...

  • Page 255: Injector - Removal And Installation

    10.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
  • Page 256 WARNING Internal loads and residual pressures in the HP fuel system. Risk of flying parts when released. Risk of pressurized fuel spraying out. Risk of injury from flying parts and spraying fuel! • Never work on the HP fuel system when the engine is running. •...
  • Page 257 Install installation/removal jig (1) on cylinder head. Remove injector (2) with installation/removal jig (1). Remove installation/removal jig (1). 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 in‐ jector (1) when removed, use a self-made wire hook or magnet to extract it from the cyl‐...
  • Page 258 Note: Remove seal plugs on HP line only before in‐ stallation of the adapter. Remove seal 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)).
  • Page 259 Use 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 torque wrench and long socket to tighten adapter (3) to specified tightening torque. Name Size Type...

  • Page 260: Fuel System

    10.7 Fuel System 10.7.1 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 261 Note: See figure (a). Unlock hand pump: Hold sleeve (2). Turn handle (1) counterclockwise until the sleeve can be pushed backwards (arrow). 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 vent screw.

  • Page 262: Fuel Cooler - External Contamination And Leak-Tightness Check

    10.7.2 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 263: Fuel Cooler - Cleaning

    10.7.3 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 system to cool down to below 50 °C before beginning work. •...
  • Page 264 Cleaning with compressed-air gun 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 265: Fuel Filter

    10.8 Fuel Filter 10.8.1 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 266: Fuel Prefilter - Pressure Ratios

    10.8.2 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 267: Fuel Prefilter - Draining

    10.8.3 Fuel prefilter – Draining Note: The descriptions also apply to heavy-duty fuel prefilters Fuel prefilter (non-switchable) Drain water and contaminants from fuel prefilter (→ Page 268). Fuel prefilter (switchable) Drain water and contaminants from fuel prefilter (→ Page 271). MS15039/07E 2023-09 | Fuel Filter | 267...

  • Page 268: Fuel Prefilter (Non-Switchable) - Draining

    10.8.4 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 269 Draining fuel prefilter in case of low pressure, version A Note: The fuel prefilter must only be drained with the engine at a standstill! Provide a suitable container to collect the water. Stop engine and disable engine start. Close fuel supply if a shut-off valve is available. Open threaded vent plug (1) of filter to be serviced.
  • Page 270 Draining fuel prefilter in case of high pressure, version B Note: The fuel prefilter can be drained during engine operation or with the engine at a standstill! Provide a suitable container to collect the wa‐ ter. Take care when opening the drain screw (1) because fuel or water can spurt out.

  • Page 271: Fuel Prefilter (Switchable) - Draining

    10.8.5 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 272 Draining fuel prefilter in case of low pressure, version A Note: • During engine operation, only the cut-out filter module must be drained! • At engine standstill, both filter modules can be drained! Provide a suitable container to collect the water. During engine operation, turn the switchover level as far as the stop (arrowed) to cut out the filter module to be serviced.
  • Page 273 Open drain plug (1). Allow water to drain until fuel emerges. Close drain plug (2) again. Drain second filter to be serviced on module, from (→ Step 3). Close threaded vent plug again. Vent fuel prefilter (→ Page 281). Draining fuel prefilter in case of overpressure, version B Note: The filter modules can be drained without switchover during engine operation and at engine standstill! Provide a suitable container to collect the water.

  • Page 274: Fuel Prefilter (Switchable) - Low Pressure Indicator Check

    10.8.6 Fuel prefilter (switchable) – Low pressure indicator check Low pressure indicator on switcha‐ ble 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 filter element (→...

  • Page 275: Fuel Prefilter - Filter Element Replacement

    10.8.7 Fuel prefilter – Filter element replacement Note: The descriptions also apply to heavy-duty fuel prefilters Fuel prefilter (non-switchable) Fuel prefilter, replace filter element (→ Page 276). Fuel prefilter (switchable) Fuel prefilter, replace filter element (→ Page 278). MS15039/07E 2023-09 | Fuel Filter | 275...

  • Page 276: Fuel Prefilter (Non-Switchable) - Filter Element Replacement

    10.8.8 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 277 Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be changed! If fuel emerges continuously, check shut-off valve in fuel supply, notify Service. Note: • As soon as the filter housing is opened, ab‐ solute cleanness is imperative! •...

  • Page 278: Fuel Prefilter (Switchable) - Filter Element Replacement

    10.8.9 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 279 Preparatory steps Pressure ratios in the fuel prefilter, see (→ Page 266). • In case of low pressure, replace fuel prefilter according to version A, see (→ Page 279). • In case of overpressure, replace fuel prefilter according to version B, see (→ Page 280). Replacing fuel prefilter with low pressure, version A Note: •...
  • Page 280 Replace other filter elements in the same way. Close threaded vent plug again. Vent fuel prefilter (→ Page 281). Check fuel prefilter for leaks. Replacing fuel prefilter with overpressure, 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.

  • Page 281: Fuel Prefilter - Venting

    10.8.10 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 282 Venting fuel prefilter in case of low pressure, version A Open fuel supply as necessary. Loosen threaded vent plugs (2, 3) unscrewing at least one rotation. Note: • Only operate the fuel priming pump man‐ ually! • Move the pump plunger only vertically to avoid damaging the pump! Unlock fuel priming pump, screw out han‐...

  • Page 283: Charge-Air Cooling

    10.9 Charge-Air Cooling 10.9.1 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 system is running.

  • Page 284: Air Filter

    10.10 Air Filter 10.10.1 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 285). 284 | Air Filter | MS15039/07E 2023-09...

  • Page 285: Air Filter - Replacement

    10.10.2 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 286). Reset signal ring of service indicator (→ Page 287). MS15039/07E 2023-09 | Air Filter | 285...

  • Page 286: Air Filter - Removal And Installation

    10.10.3 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 287: Air Intake

    10.11 Air Intake 10.11.1 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 288: Starting Equipment

    10.12 Starting Equipment 10.12.1 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 289: Lube Oil System, Lube Oil Circuit

    10.13 Lube Oil System, Lube Oil Circuit 10.13.1 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No.
  • Page 290 Unscrew one of the drain screws (1 to 8) and drain engine oil. Fit drain screw (1 to 8) with new sealing ring. Engine oil filtration Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter sleeve (→...
  • Page 291 Filling 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 292). Note: Observe the following instructions to avoid en‐ gine damage: Adequate oil pressure for an engine start is only provided when the quick- start function is deactivated (→...

  • Page 292: Engine Oil Level Check

    10.13.2 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 293: Engine Oil - Sample Extraction And Analysis

    • Repair leaking exhaust pipework immediately. Engine oil sample extraction and analysis (engine without centrifugal oil filter) Important Rolls-Royce Solutions recommends the diesel engine test kit produced by CMT Technologie GmbH https:// www.cmtechnologies.de . MS15039/07E 2023-09 | Lube Oil System, Lube Oil Circuit | 293...
  • Page 294 • Dilution by fuel Engine oil – Sample extraction and analysis Important Rolls-Royce Solutions recommends the diesel engine test kit produced by CMT Technologie GmbH https:// www.cmtechnologies.de . Open screw (1) on centrifugal oil filter carrier by one to two rotations.

  • Page 295: Oil Priming Pump - Visual Inspection

    10.13.4 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 296: Oil Filtration / Cooling

    10.14 Oil Filtration / Cooling 10.14.1 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 297: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement

    10.14.2 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 adapter F30027340...
  • Page 298 Centrifugal oil filter – Disassembly Remove V-band clamp (17). Loosen cover nut (2) and take off cover (1). Carefully lift rotor unit (14), allow oil to drain and remove from housing. Note: Do not clamp rotor unit in a bench vise. Holding the rotor unit (14) firmly with an oil fil‐...
  • Page 299 Install V-band clamp (17) and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Clamp Tightening torque 20 Nm Use a torque wrench to tighten cover nut (2) to specified tightening torque. Name Size Type Lubricant Value/Standard...

  • Page 300: Coolant Circuit, General, High-Temperature Circuit

    10.15 Coolant Circuit, General, High-Temperature Circuit 10.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ Fluids and Lubricants Specifications (A001061/..) are available. DANGER Falling from great heights. Risk of serious injury – danger to life! •...
  • Page 301 Checking engine coolant level by means of level sensor Switch on engine control system and check readings on the display. Top up with treated coolant as necessary (→ Page 305). MS15039/07E 2023-09 | Coolant Circuit, General, High-Temperature Circuit | 301...

  • Page 302: Engine Coolant - Change

    10.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 303). Fill with engine coolant (→ Page 305). 302 | Coolant Circuit, General, High-Temperature Circuit | MS15039/07E 2023-09...

  • Page 303: Engine Coolant - Draining

    10.15.3 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 304 Final steps Tighten shutoff cocks (3) and (4) with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Spindle 11 A/F Tightening torque 12 Nm Close all other open drain points. Position valve cover on filler neck and close. 304 | Coolant Circuit, General, High-Temperature Circuit | MS15039/07E 2023-09...

  • Page 305: Engine Coolant - Filling

    10.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ 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. Risk of injury and scalding! •...
  • Page 306 Note: An empty engine must always be filled with coolant from below, i.e. using the drain valve connection of the engine coolant pump. Filling with coolant from below us‐ ing a pump Connect appropriate pump with hose to drain valve of engine coolant pump (arrow). Loosen vent line union at distributor (arrow).
  • Page 307 Alternatively: Filling coolant through filler neck Loosen vent line union at distributor (arrow). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck re‐ mains constant. Tighten union (arrow) if coolant leaks out at loose union.

  • Page 308: Engine Coolant Pump - Relief Bore Check

    10.15.5 Engine coolant pump – Relief bore check Preconditions ☑ Engine is stopped and starting disabled. 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 309: Engine Coolant - Sample Extraction And Analysis

    • Wear protective clothing, protective gloves and goggles/safety mask. • Wipe up escaped/spilled coolant immediately. Engine coolant – Sample extraction and analysis Important Rolls-Royce Solutions recommends the diesel engine test kit produced by CMT Technologie GmbH https:// www.cmtechnologies.de . Note: Take the sample immediately after shutting down the engine from partial or full load oper‐...

  • Page 310: Preheater - Overview

    10.15.7 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 311: Preheater - Function And Leak Check

    10.15.8 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. WARNING Coolant contains antifreeze and is toxic.

  • Page 312: Preheater - Solenoid Switch Replacement

    10.15.9 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 potentially fatal electric shock! •...
  • Page 313 Replacing solenoid switch Loosen screws on control box (1) and open control box. 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.

  • Page 314: Preheater Thermostats - Replacement

    10.15.10 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 potentially fatal electric shock! •...
  • Page 315 Replacing safety thermostat Loosen screws (1) on cover of electrical part (2) and remove cover. Mark cables prior to disconnection. Disconnect terminals from blade terminals of measuring unit (2). Loosen thermostat clip (1) and remove safety thermostat. Insert new safety thermostat in recess. Secure thermostat clip.
  • Page 316 Mark cables prior to disconnection. Disconnect wires. Remove screws (2) and control thermo‐ stat (1). Install new control thermostat (1) with screws (2). Connect cable. Fit housing cover and tighten screws. Final steps Connect preheater to power supply. Switch on preheater. 316 | Coolant Circuit, General, High-Temperature Circuit | MS15039/07E 2023-09...

  • Page 317: Coolant Expansion Tank - Valve Cover Replacement

    10.15.11 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) DANGER Falling from great heights. Risk of serious injury – danger to life! •...
  • Page 318 Replacing valve cover Note: Schematic diagram. Design may deviate. Turn valve cover (1) on coolant expansion tank counterclockwise until the first stop and allow pressure to escape. Continue to turn valve cover counterclockwise and remove. Remove chain with screw (4) and washer (3). Draw off separated corrosion inhibitor oil in expansion tank via filler neck (2).

  • Page 319: Low-Temperature Circuit

    10.16 Low-Temperature Circuit 10.16.1 Charge-air coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ 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 320 Note: Charge-air coolant must be visible at marker plate. Check charge-air coolant level. Top up charge-air coolant as necessary (→ Page 324). Check that cover is in serviceable condition. Clean sealing surfaces as necessary. Fit cover and close it. Checking charge-air coolant level by means of level sensor Note: The charge-air coolant level is monitored automatically by the engine control system.

  • Page 321: Charge-Air Coolant - Change

    10.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 322). Fill with charge-air coolant (→ Page 324). MS15039/07E 2023-09 | Low-Temperature Circuit | 321...

  • Page 322: Charge-Air Coolant - Draining

    10.16.3 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 323 Drain remaining coolant at intercooler (arrow). 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 324: Charge-Air Coolant - Filling

    10.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ 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. Risk of injury and scalding! •...
  • Page 325 Filling coolant using a pump Connect appropriate pump with hose to drain valve (1). Loosen vent line union at distributor (arrow). Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum. Tighten union (arrow) if coolant leaks out at loose union.
  • Page 326 Alternatively: Filling coolant through filler neck Loosen vent line union at distributor (arrow). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck re‐ mains constant. Tighten union (arrow) if coolant leaks out at loose union.

  • Page 327: Charge-Air Coolant Pump - Relief Bore Check

    10.16.5 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 328: Battery-Charging Generator

    10.17 Battery-Charging Generator 10.17.1 Battery-charging generator – Cleaning 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 329: Drive Belt - Condition Check

    10.17.2 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 330: Battery-Charging Generator Drive - Drive Belt Replacement

    10.17.3 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 Drive belt...

  • Page 331: Battery-Charging Generator - Drive Belt Tension Adjustment

    10.17.4 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 332: Engine Mounting - Checking Resilient Element

    10.18 Storage 10.18.1 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 333: Engine Mounting - Checking Securing Screws For Firm Seating

    10.18.2 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 adapter F30027341 Engine oil Version A –...
  • Page 334 Version B – rigid engine mounting with standalone generator Check that securing screws (1, 2, 3) and base frame screw connections (arrows) are tight. Use a torque wrench to tighten loose screw connections (1, 2) to specified tightening torque. Name Size Type Lubricant...
  • Page 335 10.18.3 Engine mounting – Measuring height of rubber element Engine mounting – Measuring height of rubber element Measure each resilient mount. Resilient mount Height (A) Unloaded 63 mm ±1 mm Loaded > 57 mm Table 4: Engine mounting – Measuring height of rubber element Measure height (A) of resilient mount: a) If the height (A) of all resilient mounts is not within a tolerance of ±1 mm of the average value: place rele‐...

  • Page 336: Generator Mounting - Check

    10.18.4 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 337: Generator Mounting - Securing Screw Firm Seating Check

    10.18.5 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. MS15039/07E 2023-09 | Storage | 337...
  • Page 338 10.18.6 Generator mounting – Measuring height of rubber element Preconditions ☑ Engine is stopped and starting disabled. Generator mounting – Measuring height of rubber element Measure each resilient mount. Resilient mount Height (A) Unloaded 63 mm ±1 mm Loaded > 57 mm Table 5: Generator mounting –...

  • Page 339: Wiring (General) For Engine/Gearbox/Unit

    10.19 Wiring (General) for Engine/Gearbox/Unit 10.19.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037/GET 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 340: Accessories For (Electronic) Engine Governor / Control System

    10.20 Accessories for (Electronic) Engine Governor / Control System 10.20.1 Еngine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Power supply to electronic engine management system is switched off. Special tools, Material, Spare parts Designation / Use Part No.

  • Page 341: Engine Control Unit Plug Connections - Check

    10.20.2 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 342: Engine Governor Ecu 9 - Removal And Installation

    10.20.3 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 343: Parameters For Drift Correction (Cdc) - Resetting With Diasys

    10.20.4 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 344 11 Appendix A 11.1 Abbreviations Abbre‐ Meaning Explanation viation Analog/Digital-Wandler Converter: converts sensor voltages into numeric val‐ ADEC Advanced Diesel Engine Controller Engine management system AFRS Air Filter Restriction Sensor Air filter differential pressure sensor Abgasrückführung Exhaust gas recirculation Abgasnachbehandlung Exhaust gas aftertreatment Alarm –...
  • Page 345 Abbre‐ Meaning Explanation viation Dieselpartikelfilter Diesel particulate filter Diagnostic Tool Diagnostic unit Electronic Control Modul Electronic control unit of the DDEC system Engine Control System Engine management system Engine Control Unit Engine governor Engine Data Module Memory module for engine data EE‐...
  • Page 346 Turbocharger Boost Sensor Charge-air pressure sensor Turbo Compressor Inlet – Turbo Compressor Outlet – Transmitter Deviation – Technical Evolution Network Technical data for products from Rolls-Royce Solu‐ tions Throttle Position Sensor – Timing Reference Sensor – T-xyz Temperature-xyz Temperature measuring point xyz...
  • Page 347 Abbre‐ Meaning Explanation viation Unterer Totpunkt Bottom Dead Center Variable Nozzle Turbine – Variable Speed Governor – Vehicle Speed Sensor – Werkzeugkatalog Tool Catalog Zuordnung - Kategorie - Parameter A number allocated to a parameter describing its function and assignment MS15039/07E 2023-09 | Appendix A | 347...
  • Page 348 11.2 Contact person / Service partner Service Our worldwide sales organization network with subsidiaries, sales offices, representatives and customer serv‐ ice centers ensures fast and direct support on site and assures the high operational availability of our prod‐ ucts. Local support Experienced and qualified specialists place their knowledge and expertise at your disposal.
  • Page 349 12 Appendix B 12.1 Standard Tools and Special Tools Barring gear Part No.: F6801820 Qty.: Used in: 10.1.1 Barring engine manually (→ Page 230) Crossbeam Part No.: T80091826 Qty.: Used in: 3.1 Transport (→ Page 25) Crossbeam Part No.: T80092360 Qty.: Used in: 3.1 Transport (→...
  • Page 350 Depth gauge with hook, 200 mm Part No.: Y20000918 Qty.: Used in: 10.4.1 Valve protrusion – Measurement (→ Page 243) Endoscope Part No.: Y20097353 Qty.: Used in: 10.2.1 Cylinder liner – Endoscopic inspection (→ Page 234) Feeler gage Part No.: Y20098771 Qty.: Used in:...
  • Page 351 Fuel suction device Part No.: F30378207 Qty.: Used in: 10.5.1 HP fuel pump – Filling with engine oil (→ Page 252) Installation/removal jig Part No.: F6789889 Qty.: Used in: 10.6.2 Injector – Removal and installation (→ Page 255) Measuring jig 1 Part No.: Y4350009 Qty.:...
  • Page 352 Milling cutter Part No.: F30452739 Qty.: Used in: 10.6.2 Injector – Removal and installation (→ Page 255) Oil filter wrench Part No.: F30455924 Qty.: Used in: 10.14.2 Centrifugal oil filter – Cleaning and filter sleeve re‐ placement (→ Page 297) Ratchet adapter Part No.: F30027340...
  • Page 353 Ratchet bit Part No.: F30450902 Qty.: Used in: 3.3 Engine mounting transportation lock (→ Page 27) Ratchet bit Part No.: F30027340 Qty.: Used in: 3.4 Transport locking device for crankshaft (→ Page 29) Qty.: Used in: 10.3.1 Crankcase breather – Oil separator element re‐ placement (→...
  • Page 354 Ratchet bit Part No.: F30027341 Qty.: Used in: 3.4 Transport locking device for crankshaft (→ Page 29) Qty.: Used in: 10.4.3 Valve clearance – Check and adjustment (→ Page 248) Qty.: Used in: 10.6.2 Injector – Removal and installation (→ Page 255) Qty.: Used in: 10.13.1 Engine oil –...
  • Page 355 Torque screwdriver, 1–5 Nm Part No.: F30452774 Qty.: Used in: 10.6.2 Injector – Removal and installation (→ Page 255) Qty.: Used in: 10.10.3 Air filter – Removal and installation (→ Page 286) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 3.4 Transport locking device for crankshaft (→...
  • Page 356 Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 10.3.1 Crankcase breather – Oil separator element re‐ placement (→ Page 238) Qty.: Used in: 10.3.2 Crankcase breather – Oil separator element re‐ placement (→ Page 240) Qty.: Used in: 10.14.2 Centrifugal oil filter –...
  • Page 357 Torque wrench, 6–50 Nm Part No.: F30027336 Qty.: Used in: 10.8.8 Fuel prefilter (non-switchable) – Filter element re‐ placement (→ Page 276) Qty.: Used in: 10.8.9 Fuel prefilter (switchable) – Filter element replace‐ ment (→ Page 278) MS15039/07E 2023-09 | Standard Tools and Special Tools | 357...
  • Page 358 12.2 Index Contamination indicator  – Signal ring position check  287 Abbreviations 344 Coolant  Actuators  – Change  302, 321 – Overview  58 – Filling  305, 324 ADEC 53 Coolant expansion tank  After shuting down engine  – Valve cover replacement  317 – Putting engine out of operation  184 Cooling system 51...
  • Page 359 Engine  Engine sides  – Barring   – Designation  32 – Manually  230 – Cranking   Fault conditions  – On starting system  232 – Alarms 1801 to 1840  225 – Emergency start (Override mode)  177 Fault messages  – Emergency stop  182 –...
  • Page 360 Product data 20V400034F  – 3B continuous service   Lifting instructions 26 – China III NRMM compliant (stationary)  108 Lube oil system 49 – Fuel optimized  108 – NEA Singapore for ORDE  108 – NOx emissions-optimized  108 Maintenance Schedule  – 3E standby power   –...
  • Page 361 Product data 20V4000G14S  Product data 20V4000G34F  – 3B continuous service   – 3F heavy duty   – EPA Nonroad T2 Comp (40CFR89)  136 – China III NRMM compliant (stationary)  118 – Fuel optimized  136 – Fuel optimized  118 – 3E standby power   –...
  • Page 362 Product data 20V4000G84F  Transport  – 3D standby power   – Description  25 – China III NRMM compliant (stationary)  142 – Lifting requirements  26 – Fuel optimized  142 Transport locking device  – 3D standby power 3D   – Crankshaft   – NEA Singapore for ORDE  142 –...

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