MTU 20 V 4000 G23 Technical Publication Download Page 173

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168

Annex

Engine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine – Barring manually

. . . . . . . . . .

Engine – Barring with starting
system

. . . . . . . . . . . . . . . . . . . . . . . . .

Engine test run

. . . . . . . . . . . . . . . . . . .

Engine – Barring manually

. . . . . . . . . . . . . . .

Engine – Barring with starting system . . . . . . .

Engine coolant – Change

. . . . . . . . . . . . . . . .

138

Engine coolant – Draining . . . . . . . . . . . . . . . .

137

Engine coolant – Filling . . . . . . . . . . . . . . . . . .

135

Engine coolant – Sample extraction and
analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141

Engine coolant level – Check

. . . . . . . . . . . . .

139

Engine coolant pump – Relief bore check . . . .

140

Engine governor ADEC (ECU 7) for Series 4000
genset engines - Fault messages . . . . . . . . . .

Engine layout

. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . .

Engine layout

. . . . . . . . . . . . . . . . . . . .

Engine oil – Change

. . . . . . . . . . . . . . . . . . . .

128

Engine oil – Level check . . . . . . . . . . . . . . . . .

130

Engine oil – Sample extraction and
analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131

Engine oil filter – Replacement . . . . . . . . . . . .

132

Engine side and cylinder designations

. . . . . .

Engine Side and Cylinder Designations

. . . . .

Engine side and cylinder
designations

. . . . . . . . . . . . . . . . . . . . .

Engine test run

. . . . . . . . . . . . . . . . . . . . . . . .

Engine wiring check

. . . . . . . . . . . . . . . . . . . .

151

Final compression pressure

. . . . . . . . . . . . . .

Final Compression Pressure . . . . . . . . . . . . . .

Final compression pressure

. . . . . . . . .

Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . .

Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . .

Firing order . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

Fuel filter – Replacement

. . . . . . . . . . .

112

Fuel prefilter – differential pressure check
and adjustment of gauge

. . . . . . . . . . .

114

Fuel prefilter – draining . . . . . . . . . . . . .

115

Fuel prefilter – filter element
replacement

. . . . . . . . . . . . . . . . . . . . .

119

Fuel prefilter – flushing

. . . . . . . . . . . . .

117

Fuel prefilter cleaning . . . . . . . . . . . . . .

113

Fuel filter – Replacement

. . . . . . . . . . . . . . . .

112

Fuel Injector

. . . . . . . . . . . . . . . . . . . . . . . . . .

106

Injector – Removal and Installation . . . .

107

Injector replacement . . . . . . . . . . . . . . .

106

Fuel prefilter – differential pressure check and
adjustment of gauge . . . . . . . . . . . . . . . . . . . .

114

Fuel prefilter – draining . . . . . . . . . . . . . . . . . .

115

Fuel prefilter – filter element replacement . . . .

119

Fuel prefilter – flushing

. . . . . . . . . . . . . . . . . .

117

Fuel prefilter cleaning

. . . . . . . . . . . . . . . . . . .

113

Fuel System

. . . . . . . . . . . . . . . . . . . . . . . . . .

111

Fuel system – Venting

. . . . . . . . . . . . .

111

Fuel system – Venting . . . . . . . . . . . . . . . . . . .

111

General conditions

. . . . . . . . . . . . . . . . . . . . .

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167

Injector – Removal and Installation . . . . . . . . .

107

Injector replacement . . . . . . . . . . . . . . . . . . . .

106

Instructions and comments on endoscopic and
visual examination of cylinder liners

. . . . . . . .

Intercooler – Checking condensate drains for
coolant discharge and obstructions . . . . . . . . .

121

LT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

Charge-air coolant – Draining . . . . . . . .

145

Charge-air coolant – Filling . . . . . . . . . .

143

Charge-air coolant change

. . . . . . . . . .

142

Charge-air coolant level check

. . . . . . .

146

Charge-air coolant pump – Relief bore
check

. . . . . . . . . . . . . . . . . . . . . . . . . .

147

Lube Oil System / Lube Oil Circuit

. . . . . . . . .

128

Engine oil – Change . . . . . . . . . . . . . . .

128

Engine oil – Level check . . . . . . . . . . . .

130

Engine oil – Sample extraction and
analysis . . . . . . . . . . . . . . . . . . . . . . . . .

131

Main engine dimensions . . . . . . . . . . . . . . . . .

Main Engine Dimensions

. . . . . . . . . . . . . . . .

Main engine dimensions . . . . . . . . . . . .

Maintenance schedule matrix . . . . . . . . . . . . .

Maintenance tasks

. . . . . . . . . . . . . . . . . . . . .

Manufacturer’s documentation

. . . . . . . . . . . .

161

MTU contact person/service partner . . . . . . . .

162

Oil Cooling / Filtration

. . . . . . . . . . . . . . . . . . .

132

Centrifugal oil filter – Cleaning and
filter-sleeve replacement . . . . . . . . . . . .

133

Engine oil filter – Replacement . . . . . . .

132

Operational checks . . . . . . . . . . . . . . . . . . . . .

M015715/00E 06-08

Summary of Contents for 20 V 4000 G23

Page 1: ...EDG TRAINING MANUAL JOB 6608 REV 0 2 Engine 2 1 MTU Manual 2 2 P ID 2 2 1 Lube Oil System 2 2 2 Fuel System 2 2 3 Cooling System...

Page 2: ...Technical Publication Diesel Engine 20 V 4000 G23 20 V 4000 G43 20 V 4000 G63 20 V 4000 G83 Operating Instructions M015715 00E...

Page 3: ...l entretien et de la conduite Modifications r serv es Impreso en Alemania 2006 Copyright MTU Friedrichshafen GmbH Esta publicaci n se encuentra protegida en toda su extensi n por los derechos de auto...

Page 4: ...base pour l assistance en exploitation contractuelle garantie rechanges etc Rogamos separen la tarjeta Aviso de puesta en servicio y la devuelvan rellenada a MTU Friedrichshafen GmbH Las informaciones...

Page 5: ...ta en servicio Messa in servizio il Data da coloca o em servi o Eingebaut in Installation site Lieu de montage Lugar de montaje Installato Incorporado em Schiffstyp Schiffshersteller Vessel type class...

Page 6: ...fuel consumption 21 2 6 2 20V 4000 Gx3 engine data Standby operation 3D optimized exhaust emissions EPA stage 2 28 2 6 3 20V 4000 Gx3 engine data Continuous operation variable 3B optimized fuel consu...

Page 7: ...101 6 4 1 Valve gear Lubrication 101 6 4 2 Valve clearance Check and adjustment 102 6 4 3 Cylinder head cover Remove and install 105 6 5 Fuel Injector 106 6 5 1 Injector replacement 106 6 5 2 Injecto...

Page 8: ...lant Sample extraction and analysis 141 6 15 LT Circuit 142 6 15 1 Charge air coolant change 142 6 15 2 Charge air coolant Filling 143 6 15 3 Charge air coolant Draining 145 6 15 4 Charge air coolant...

Page 9: ...04 Table of Contents M015715 00E 06 08 MTU...

Page 10: ...the application specified in the contract or defined at the time of delivery Any other use is considered improper use The manufacturer will accept no liability for any resultant damage The responsibil...

Page 11: ...d in operation maintenance repair or transportation The personnel must be instructed on engine operation and repair by means of this publication and in particular the safety instructions must be expla...

Page 12: ...nsporting the engine it is imperative to install transportation locking devices for crankshaft and engine mounts Secure the engine against tilting during transportation The engine must be especially s...

Page 13: ...s or cables Inadequate protection of electrical components can lead to electric shocks and serious injuries When the engine is running never release coolant oil fuel compressed air or hydraulic lines...

Page 14: ...ounted units Never use the engine as a ground connection This prevents the welding current passing through the engine resulting in burnt scorched bearings sliding surfaces and tooth flanks which may l...

Page 15: ...o properly support the wires For this purpose no cable binders must be used as during maintenance and or repair work the binders can be removed but not installed a second time Spare parts shall be pro...

Page 16: ...s governing the use of materials that may affect water quality is applicable which means work must only be carried out by authorized specialist companies MTU is such a company Auxiliary materials Use...

Page 17: ...set to permitted pressure must form an intermediate connection Hose coupling and connections must be securely attached Always wear protective goggles when blowing off tools or chips The snout of the...

Page 18: ...ions Consequences Slight injury or material damage Preventive measures Note This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535 which...

Page 19: ...14 Safety M015715 00E 06 08 MTU...

Page 20: ...tem high pressure 080 Fuel system low pressure 100 Exhaust turbocharger 110 Intercooler 120 Air intake air supply 140 Exhaust system 170 Starting equipment 180 Lube oil system lube oil circuit 200 Coo...

Page 21: ...ngine model designation Key to the engine model designation 20V 4000 Gx3 20 Number of cylinders V Cylinder arrangement V engine 4000 Series G Application x Application segment 2 4 6 8 3 Design index M...

Page 22: ...end KS The cylinders of the left engine side are designated A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving...

Page 23: ...18 Product Summary 2 3 Main Engine Dimensions 2 3 1 Main engine dimensions Main engine dimensions Length A approx 3520 mm Width B approx 1620 mm Height C approx 2490 mm M015715 00E 06 08 MTU...

Page 24: ...iring Order 2 4 1 Firing order Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9...

Page 25: ...20 Product Summary 2 5 Final Compression Pressure 2 5 1 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar M015715 00E 06 08 MTU...

Page 26: ...gine model 20V 4000 G23 20V 4000 G43 20V 4000 G63 20V 4000 G63L 20V 4000 G83 20V 4000 G83L Application group 3D 3D 3D 3D 3D 3D Intake air temperature C 25 25 25 25 25 25 Charge air coolant temperature...

Page 27: ...g ETC and charge air cooling CAC X X X X X X Exhaust piping non cooled X X X X X X Working method four cycle diesel single acting X X X X X X Combustion method Direct fuel injection X X X X X X Coolin...

Page 28: ...OMBUSTION AIR EXHAUST GAS Number of cylinders 20 20 20 20 20 20 Charge air pressure before cylinder BL R bar abs 2 5 3 1 2 7 2 9 3 3 3 6 COOLANT SYSTEM HT circuit Number of cylinders 20 20 20 20 20 20...

Page 29: ...20 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 88 88 88 Lube oil operating temperature before engine to R C 98 98 98 98 98 98 Lube oil temperature before engine alarm R C 9...

Page 30: ...nection max during engine starting L bar 1 5 1 5 1 5 1 5 1 5 1 5 GENERAL OPERATING DATA Number of cylinders 20 20 20 20 20 20 Cold start capability Air temperature w o start aid w o preheating case A...

Page 31: ...390 390 Oil change quantity max standard oil system Option max operating inclinations R liters Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L liters 245...

Page 32: ...20 20 20 20 20 20 Exhaust noise unsilenced BL sound power level LW ISO 6798 R dB A 131 134 130 131 136 136 Engine surface noise with attenuated intake noise filter BL sound power level LW ISO 6798 R d...

Page 33: ...Application group 3D 3D 3D Intake air temperature C 25 25 25 Charge air coolant temperature C 45 45 45 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea le...

Page 34: ...s 20 20 20 Cylinder arrangement V angle Degrees 90 90 90 Bore mm 170 170 170 Stroke mm 210 210 210 Displacement cylinder liters 4 77 4 77 4 77 Displacement total liters 95 4 95 4 95 4 Compression rati...

Page 35: ...off engine cooling system max L bar 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temperature before engine...

Page 36: ...linations R liters 390 390 390 Oil change quantity max standard oil system Option max operating inclinations R liters Oil pan capacity at dipstick mark min standard oil system Option max operating inc...

Page 37: ...0 G43 20V 4000 G63 20V 4000 G63L 20V 4000 G83 20V 4000 G83L Application group 3B 3B 3B 3B 3B 3B Intake air temperature C 25 25 25 25 25 25 Charge air coolant temperature C 55 55 55 55 55 55 Raw water...

Page 38: ...CAC X X X X X X Exhaust piping non cooled X X X X X X Working method four cycle diesel single acting X X X X X X Combustion method Direct fuel injection X X X X X X Cooling system conditioned water X...

Page 39: ...S Number of cylinders 20 20 20 20 20 20 Charge air pressure before cylinder DL R bar abs 2 3 2 8 2 5 2 6 3 1 3 3 COOLANT SYSTEM HT circuit Number of cylinders 20 20 20 20 20 20 Coolant temperature at...

Page 40: ...20 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 88 88 88 Lube oil operating temperature before engine to R C 98 98 98 98 98 98 Lube oil temperature before engine alarm R C 9...

Page 41: ...nection max during engine starting L bar 1 5 1 5 1 5 1 5 1 5 1 5 GENERAL OPERATING DATA Number of cylinders 20 20 20 20 20 20 Cold start capability Air temperature w o start aid w o preheating case A...

Page 42: ...390 390 Oil change quantity max standard oil system Option max operating inclinations R liter Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L liter 245 24...

Page 43: ...20 20 20 20 20 20 Exhaust noise unsilenced DL sound power level LW ISO 6798 R dB A 130 133 131 132 134 136 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 R d...

Page 44: ...B Intake air temperature C 25 25 25 Charge air coolant temperature C 45 45 45 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 POWER RE...

Page 45: ...20 20 20 Cylinder arrangement V angle degrees 90 90 90 Bore mm 170 170 170 Stroke mm 210 210 210 Displacement per cylinder liter 4 77 4 77 4 77 Total displacement liter 95 4 95 4 95 4 Compression rat...

Page 46: ...off engine cooling system max L bar 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temperature before engine...

Page 47: ...clinations R liter 390 390 390 Oil change quantity max standard oil system Option max operating inclinations R liter Oil pan capacity at dipstick mark min standard oil system Option max operating incl...

Page 48: ...3B Intake air temperature C 25 25 25 Charge air coolant temperature C 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 POWER...

Page 49: ...20 20 20 Cylinder arrangement V angle degrees 90 90 90 Bore mm 170 170 170 Stroke mm 210 210 210 Displacement per cylinder liter 4 77 4 77 4 77 Total displacement liter 95 4 95 4 95 4 Compression rat...

Page 50: ...off engine cooling system max L bar 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temperature before engine...

Page 51: ...clinations R liter 390 390 390 Oil change quantity max standard oil system Option max operating inclinations R liter Oil pan capacity at dipstick mark min standard oil system Option max operating incl...

Page 52: ...e oil level Page 130 Fuel prefilter Prime Page 119 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 114 Coolant circuit If engine is out of service for m...

Page 53: ...m Check oil level Page 130 Cooling system Check engine coolant level Page 139 Check charge air coolant level Page 146 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 115...

Page 54: ...t control panel etc depending on manufacturer If coolant temperature is 40 C with preheating pump or 10 C 60 Hz generator without preheating pump or 5 C 50 Hz generator without preheating pump Press s...

Page 55: ...utton for override input of ECU Switching cabinet control panel etc depending on manufacturer Press start button Automatic starting procedure is performed All safety functions are deactivated and engi...

Page 56: ...are within the limit restricted engine operation is not required Check for abnormal running noises and vibration Fuel prefilter Check if suction side pressure indicated at the fuel prefilter pressure...

Page 57: ...le speed until operating temperatures decrease and stable values are indicated Preparation Item Task Engine After the generator circuit breaker has been opened allow the engine to cool down by running...

Page 58: ...tuations Emergency stop from LOP Item Task EMERGENCY STOP button Press Engine is stopped by switching off power supply to ECU Signalization e g by horn flashing lamp is released After emergency stop f...

Page 59: ...8 After stopping the engine engine remains ready for operation After stopping the engine Item Task Engine generator control system Select operating mode e g MANUAL OPERATION AUTOMATIC OPERATION M01571...

Page 60: ...antifreeze additive the engine room is not heated the coolant is not maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room temperature antifreeze conce...

Page 61: ...56 Operation M015715 00E 06 08 MTU...

Page 62: ...be done action to be taken indicate the relevant maintenance item They serve as a reference for the scope of parts needed and also appear on the labels of the corresponding spare parts Preventive main...

Page 63: ...oad factor 85 Load profile Load profile table application group 3A Power 110 100 Corresponding operating time 1 99 Load profile table application group 3B Power 110 100 70 Corresponding operating time...

Page 64: ...7 500 8 000 8 500 9 000 9 500 10 000 10 500 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X X Fuel filter 2 X X X X X X X X X X Valve gear X X...

Page 65: ...000 21 500 Engine oil filter 2 Engine operation Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X X X Fuel filter 2 X X X X X X X X X X X Valve gear X X X X X X X Belt drive 2 X X X X X...

Page 66: ...0 Engine oil filter 2 Engine operation Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X Fuel filter 2 X X X X X X X X X Valve gear X X X X X X Belt drive 2 X X X X X X Air filter 3 X X X Fue...

Page 67: ...000 9 500 10 000 10 500 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X X Valve gear X X X X X X X X X X Fuel filter 2 X X X X X X X X X X Belt...

Page 68: ...ne oil filter 2 Engine operation Centrifugal oil filter 2 X X X X X X X X X X X X X X X Valve gear X X X X X X X X Fuel filter 2 X X X X X X X X Belt drive 2 X X X X X Air filter 3 X X X Fuel injector...

Page 69: ...00 8 500 9 000 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X Valve gear X X X X X X X X X Fuel filter 2 X X X X X X X X X Belt drive 2 X X X X X X...

Page 70: ...500 5 000 5 500 6 000 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X Valve gear X X X X X X Fuel filter 2 X X X X X X Belt drive 2 X X X X X X Air filter 3 X...

Page 71: ...W1002 QL1 Belt drive Check drive belt condition and tension replace if necessary Page 148 adjust belt tension Page 149 W1003 QL1 Air filter Replace air filter Page 122 W1005 QL1 Fuel injector Replace...

Page 72: ...linder liners visually Workshop Manual W1063 QL4 Extended component maintenance Disassemble engine completely Inspect engine components acc to assembly instructions repair or replace as necessary Work...

Page 73: ...68 Maintenance M015715 00E 06 08 MTU...

Page 74: ...erform visual inspection see manufacturer s documentation ECU Plug in connections are loose Check plug in connections Page 153 Engine Running gear blocked engine cannot be barred manually Contact Serv...

Page 75: ...ive Contact Service Fuel system Not vented Vent fuel system Page 111 ECU Defective Contact Service Charge air temperature too high Component Probable Cause Task Engine coolant Incorrect coolant concen...

Page 76: ...sk Too much oil in engine Drain engine oil Page 128 Engine oil Oil separator of crankcase breather contaminated Replace Page 99 Exhaust turbocharger cylinder head piston rings cylinder liner Defective...

Page 77: ...warning Fuel temperature too high Contact Service 2 0122 931 004 SS T Fuel Main warning Fuel temperature too high Engine stop Contact Service 2 0122 932 005 HI T Charge Air Preliminary warning Charge...

Page 78: ...Coolant Level Alarm configuration limit value 1 Coolant level too low Check coolant level in expansion tank Page 139 2 0152 921 024 SS Coolant Level Alarm configuration limit value 2 Coolant level too...

Page 79: ...ynchro Fault Synchronization error between ETCs 1 and 2 1 Reduce power 2 Contact Service 1 8004 205 039 AL ETC 2 cut in failure ETC2 failed to cut in 1 Reduce power 2 Contact Service 1 8004 204 044 L1...

Page 80: ...pressure too low Engine stop 1 Check fuel lines for leaks 2 Clean fuel prefilter Page 113 3 Fuel prefilter Flushing Page 117 4 Replace filter element of fuel prefilter Page 119 5 Replace fuel filter P...

Page 81: ...p Speed Alarm configuration limit value Runup speed was not attained Contact Service 2 1090 924 092 SS No Starter Speed Alarm configuration limit value Starter speed was not attained Termination of st...

Page 82: ...lty automatic engine shutdown Replace ECU 136 15V NEG ECU DEFECT Internal voltage 15 VDC missing automatic engine shutdown Contact Service 139 L1 TE BUFFER TEST Supply voltage of temperature sensors f...

Page 83: ...ction to one node on CAN bus 1 failed Contact Service 2 0500 680 181 AL CAN2 Node Lost Alarm configuration Connection to one node on CAN bus 2 failed Contact Service 2 0500 681 182 AL CAN Wrong Parame...

Page 84: ...a warning 1 Inspect CAN bus for short circuit and rectify short circuit as necessary 2 Check shielding improve as necessary 3 Contact Service 2 0500 689 190 AL EMU Parameter Not Supported Alarm config...

Page 85: ...r restarting the engine 1 8004 566 211 SD P Lube Oil SD alarm configuration Lube oil pressure sensor faulty short circuit or wire break Check sensor and cabling B5 replace as necessary Error cleared a...

Page 86: ...D alarm configuration Leak off fuel level sensor faulty short circuit or wire break Check sensor and cabling F46 replace as necessary Error cleared after restarting the engine 1 8004 582 223 SD Level...

Page 87: ...culation SD alarm configuration Recirculation sensor faulty short circuit or wire break Check sensor and cabling B49 replace as necessary Error cleared after restarting the engine 1 8004 581 242 SD T...

Page 88: ...506 308 AL Timing Cylinder A8 1 8004 507 309 AL Timing Cylinder A9 1 8004 508 310 AL Timing Cylinder A10 1 8004 509 311 AL Timing Cylinder B1 1 8004 510 312 AL Timing Cylinder B2 1 8004 511 313 AL Ti...

Page 89: ...iring Cylinder A9 1 8004 528 330 AL Wiring Cylinder A10 1 8004 529 331 AL Wiring Cylinder B1 1 8004 530 332 AL Wiring Cylinder B2 1 8004 531 333 AL Wiring Cylinder B3 1 8004 532 334 AL Wiring Cylinder...

Page 90: ...Cylinder A9 1 8004 548 350 AL Open Load Cylinder A10 1 8004 549 351 AL Open Load Cylinder B1 1 8004 550 352 AL Open Load Cylinder B2 1 8004 551 353 AL Open Load Cylinder B3 1 8004 552 354 AL Open Loa...

Page 91: ...bit 1 1020 021 Power Stage Failure Stop Engine is set engine will be shut down as additional measure 1 Short circuit of positive connection of one or more injectors to ground 2 Short circuit of negati...

Page 92: ...31 393 SS T Coolant Redundant Alarm configuration limit value 1 Main warning Redundant coolant temperature reading too high Engine stop 1 Check cabling and sensor 2 Contact Service 2 0129 932 394 LO P...

Page 93: ...rm configuration Line disruption on digital input 6 Cabling faulty or no resistance over switch 1 Check cabling 2 Check input of target device 3 Contact Service 2 8006 630 406 AL Open Load Digital Inp...

Page 94: ...lter SD alarm configuration Sensor for water level in fuel prefilter faulty short circuit or wire break Check sensor and cabling replace as necessary Error cleared after restarting the engine 1 8004 5...

Page 95: ...attained limit value 1 depending on configuration Determine and rectify reason for limit value violation 2 0110 921 442 L2 P Aux 1 Alarm configuration limit value 2 Preliminary warning Pressure signa...

Page 96: ...value too low 1 Check cabling 2 Contact Service 2 8006 653 462 AL Coolant EMU L1 Alarm configuration limit value EMU coolant temperature value too high low Check configuration with DiaSys 2 8006 654...

Page 97: ...faulty short circuit or wire break Check sensor and cabling replace as necessary Error cleared after restarting the engine 1 8004 592 472 Al Stop SD Alarm configuration Engine shutdown since all shutd...

Page 98: ...of serious injury danger to life Before barring the engine ensure that nobody is in the danger zone Engine Barring manually 1 Remove guard plate 2 Engage barring tool 2 with ring gear 3 and mount on...

Page 99: ...es have been reinstalled and all tools removed from the engine Engine Barring with starting system 1 Release latch of connector X4 2 Disconnect connector from ECU 3 Bar engine in unloaded condition Pr...

Page 100: ...rting the engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine test run 1 Start engine Page 49 2 Perform test run at...

Page 101: ...r cooling bores Running pattern seems darker No actions required Darker areas of even or varying color intensity Beginning and end of the discoloration are not sharply defined and do not cover the ent...

Page 102: ...rature differences around the liner It appears rather darker within the honed structure in contrast to the bright metallic running surface The honing pattern is undisturbed Discolorations extend in st...

Page 103: ...n discoloration and heat discoloration are similar Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation To avoid unnecessary disassembly work it is rec...

Page 104: ...Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil...

Page 105: ...agm 3 for damage fit new diaphragm if used one is damaged 4 Mount diaphragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4...

Page 106: ...starting disabled Material Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 105 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of roc...

Page 107: ...ation Use Part No Qty Feeler gauge Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Ring socket 24 mm F30039526 1 Preparatory steps 1 Remove cylinder head cover Page 105 2 Install barring tool Page 93...

Page 108: ...rms are unloaded on cylinder A1 the piston is in firing TDC If the rocker arms are loaded on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker...

Page 109: ...so that the specified valve clearance is provided 4 Feeler gauge must just pass through the gap 5 Tighten locknut 1 to 90 9 Nm holding adjusting screw 2 firm 6 Replace or rectify adjusting screws and...

Page 110: ...Designation Use Part No Qty Gasket Remove cylinder head cover 1 Clean very dirty cylinder head covers prior to removal 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head Insta...

Page 111: ...106 Task Description 6 5 Fuel Injector 6 5 1 Injector replacement Spare parts Designation Use Part No Qty Injector Remove injector and install new one Page 107 M015715 00E 06 08 MTU...

Page 112: ...10423 1 Socket wrench 17 mm F30025896 1 Socket wrench 19 mm F30025897 1 Torque wrench 60 320 Nm F30047446 1 Ratchet adapter F30027341 1 Material Designation Use Part No Qty Petroleum jelly WARNING Fue...

Page 113: ...ve HP fuel line 4 Note The injector accumulator will be emptied when removing the adapter 4 Unscrew adapter 3 until only the last two to three courses of the thread are engaged 5 Allow the fuel to dra...

Page 114: ...new O rings scope of supply of injector with petroleum jelly and fit on injector 3 Fit new sealing ring with petroleum jelly on injector observe installation position of sealing ring 4 Clean sealing s...

Page 115: ...3 and use torque wrench to pretighten to between 5 Nm and 10 Nm 12 Tighten screw 2 and adapter 3 to specified tightening torque of 100 Nm 10 Nm using a torque wrench 13 Coat thread and sealing cone o...

Page 116: ...id naked flames electrical sparks and ignition sources Do not smoke Venting LP fuel system 1 Open vent plug 1 2 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 3 Operate the...

Page 117: ...esignation Use Part No Qty Easy change filter WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1...

Page 118: ...l prefilter cleaning 1 Shut off fuel supply 2 Remove nuts from filter head 3 Take off filter housing and drain fuel into appropriate container 4 Remove filter element securing nut and remove filter el...

Page 119: ...erential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within the...

Page 120: ...stopped and starting disabled Material Designation Use Part No Qty Diesel fuel Spare parts Designation Use Part No Qty Gasket WARNING Fuels are combustible Risk of fire and explosion Avoid naked flame...

Page 121: ...ssing toggle and open it 4 Drain water and contaminants from the filter until pure fuel emerges 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with...

Page 122: ...ed rotating and moving engine components Risk of serious injury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid naked f...

Page 123: ...the filter deposits downwards out of the filter 4 Close vent plug 5 and drain cock 6 Fuel prefilter filling fuel 1 Stop engine Page 52 and disable engine start 2 Remove screws securing the cover and...

Page 124: ...stopped and starting disabled Material Designation Use Part No Qty Diesel fuel Spare parts Designation Use Part No Qty Filter element Gasket WARNING Fuels are combustible Risk of fire and explosion A...

Page 125: ...ilter 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Remove spring 4 and filter element 3 8 Insert new filter element 3 and spring 4 9 Fill filter housing with clean fu...

Page 126: ...ive goggles safety mask and ear protectors Intercooler Checking condensate drains for coolant discharge and obstructions 1 With the engine running verify that air emerges from the condensate drain s a...

Page 127: ...tion 6 9 Air Filter 6 9 1 Air filter replacement Spare parts Designation Use Part No Qty Air filter Remove air filter and install new one Page 124 Reset signal ring of service indicator Page 125 M0157...

Page 128: ...on 123 6 9 2 Air filter Check Spare parts Designation Use Part No Qty Air filter Air filter Check 1 Check entire circumference of air filter for damage 2 Fit new air filter if damaged Page 124 M015715...

Page 129: ...abled Air filter removal and installation 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 an...

Page 130: ...ine is stopped and starting disabled Signal ring position check 1 If the signal ring is completely visible in the control window 2 replace air filter Page 122 2 After installation of new filter press...

Page 131: ...o life Before barring or starting the engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Air starter manual operation 1 Pr...

Page 132: ...arter Condition check Preconditions Engine is stopped and starting disabled Starter Condition check 1 Check starter securing screws for secure seating 2 Tighten loose screw connections 3 Check wiring...

Page 133: ...g ring WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do n...

Page 134: ...ters at drain plug 3 approx 5 liters 4 Replace engine oil filter Page 132 5 Install drain plug s with new sealing ring 6 Tighten drain plugs 2 and 3 with torque wrench to the specified torque 100 Nm 1...

Page 135: ...e g oil filter or heat exchanger back to the oil pan 3 The oil level must reach the mark 1 or exceed the mark 1 by up to 2 cm 4 If necessary top up to the mark 1 Page 128 5 Insert dipstick into guide...

Page 136: ...nd poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors En...

Page 137: ...e harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filt...

Page 138: ...le oil vapor WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors Centrifugal oil filter Cleaning and filter sleeve...

Page 139: ...ce facing the wall 15 Check sealing ring 9 fit new one if necessary 16 Mount rotor cover 8 with sealing ring 9 17 Tighten rotor cover nut 7 with 35 Nm to 45 Nm 18 Place rotor 6 in housing 5 and check...

Page 140: ...under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cr...

Page 141: ...o filler neck and close it 11 3 Repeat the steps from Start engine 7 until coolant is no longer needed to be topped up 11 4 Disconnect pump and hose Filling coolant through filler neck 1 Alternatively...

Page 142: ...ine coolant Draining 1 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3...

Page 143: ...138 Task Description 6 14 3 Engine coolant Change Material Designation Use Part No Qty Engine coolant Drain engine coolant Page 137 Fill engine coolant system Page 135 M015715 00E 06 08 MTU...

Page 144: ...terclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye...

Page 145: ...k of damage to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and water discharge 2 Stop the engine Page 52 and disable engine start observe general safe...

Page 146: ...et the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine coolant Sample extraction and an...

Page 147: ...Description 6 15 LT Circuit 6 15 1 Charge air coolant change Material Designation Use Part No Qty Coolant Drain charge air coolant system Page 145 Fill charge air coolant system Page 143 M015715 00E 0...

Page 148: ...ure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in comp...

Page 149: ...er valve on filler neck and close 11 3 Repeat the steps from Start engine 7 until coolant is no longer needed to be topped up 11 4 Disconnect pump and hose Filling coolant through filler neck 1 Altern...

Page 150: ...nt into 2 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 3 Continue to turn breather valve counterclockwise and remove 4 Draw off segr...

Page 151: ...nsion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at marking plate 4 If...

Page 152: ...of damage to hearing Wear ear protectors Charge air coolant pump Relief bore check 1 Check relief bore for oil and water discharge 2 Stop the engine Page 52 and disable engine start observe general sa...

Page 153: ...ped and starting disabled Guard is removed Item Findings Task Drive belt A Breaks in a few individual places None Drive belt Belt is oily shows signs of overheating Drive belt B Breaks around the enti...

Page 154: ...ing circlip tensioning roller preload Risk of injury Only use specified tool and equipment Adjusting belt tension 1 Remove guard cover 2 Slacken screws 1 and 2 by half a turn Result Belt tensioner mov...

Page 155: ...cken screws 1 and 2 by half a turn 3 Place socket adapter or box wrench on screw 3 and press belt tensioner in the direction indicated by the arrow as far as it will go 4 Tighten screw 2 5 Remove the...

Page 156: ...ten loose screw connections 2 Make certain that cables are securely seated in clamps and cannot move freely 3 Check cable binders for secure seating tighten loose cable binders 4 Replace defective cab...

Page 157: ...ce using a cloth moistened with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning s...

Page 158: ...Checking plug in connections Preconditions Engine is stopped and starting disabled ECU Checking plug in connections 1 Verify that all plug in connections are securely seated 2 Secure loose connectors...

Page 159: ...154 Task Description M015715 00E 06 08 MTU...

Page 160: ...Special Tools 155 7 Special Tools 7 1 Special tools Part No Designation Use Qty F6555766 Barring tool 1 F30006212 Ratchet 1 M015715 00E 06 08 MTU...

Page 161: ...l Tools Part No Designation Use Qty Y20097353 Rigid endoscope 1 F30027336 Torque wrench 6 50 Nm 1 Y20010128 Feeler gauge 1 F30047446 Torque wrench 60 320 Nm 1 F30039526 Ring socket 24 mm 1 M015715 00E...

Page 162: ...Special Tools 157 Part No Designation Use Qty F30510423 Torque wrench 10 60 Nm 1 F6784183 Puller 1 M015715 00E 06 08 MTU...

Page 163: ...No Designation Use Qty F6784167 Press in tool 1 F30510423 Torque wrench 10 60 Nm 1 F30025896 Socket wrench 17 mm 1 F30025897 Socket wrench 19 mm 1 F30027341 Ratchet adapter 1 F30379104 Filter wrench 1...

Page 164: ...Special Tools 159 Part No Designation Use Qty F30027337 Torque wrench 1 5605892099 00 MTU test kit 1 M015715 00E 06 08 MTU...

Page 165: ...160 Special Tools M015715 00E 06 08 MTU...

Page 166: ...Annex 161 8 Annex 8 1 Manufacturer s documentation See Manufacturer s documentation M015715 00E 06 08 MTU...

Page 167: ...Annex 8 2 MTU contact person service partner You will find the MTU contact person service partner for your region at www mtu online com worldwide in the left hand navigation margin M015715 00E 06 08...

Page 168: ...ant temperature DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel DDL Diagnostic Data Link DDR Diagnostic Data Reader DIN Deutsches Institut f r Normung e V German S...

Page 169: ...ght Emitting Diode LO LOW Alarm Measured value lower than 1st minimum limit LOLO Low Low Alarm Measured value lower than 2nd minimum limit LSG Limiting Speed Governor N A Not Applicable OEM Original E...

Page 170: ...m is initiated by the safety system TBS Turbocharger Boost Sensor Monitors charge air pressure TC Tools Catalog TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Se...

Page 171: ...166 Annex M015715 00E 06 08 MTU...

Page 172: ...t 149 Battery charging generator drive Drive belt replacement 150 Battery charging generator drive Drive belt tension adjustment 149 Belt Drive 148 Drive belt Condition check 148 C Cabling General for...

Page 173: ...efilter cleaning 113 Fuel filter Replacement 112 Fuel Injector 106 Injector Removal and Installation 107 Injector replacement 106 Fuel prefilter differential pressure check and adjustment of gauge 114...

Page 174: ...pping the engine in manual mode 52 T Technical Data 21 20V 4000 Gx3 engine data Continuous operation variable 3B optimized exhaust emissions EPA 39 20V 4000 Gx3 engine data Continuous operation variab...

Page 175: ......

Page 176: ...Demo version http www verypdf com...

Page 177: ...Demo version http www verypdf com...

Page 178: ...Demo version http www verypdf com...

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MTU 20 V 4000 G23, Technical Publication

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Summary of Contents for 20 V 4000 G23

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