MTU 20V4000Bx4 Operating Instructions Manual Download Page 198

Page: 198 / 304

8.6 Injector

8.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

Remove injector and install new one (→ Page 196).

196 | Injector | MS15039/01E 2018-11

TIM-ID: 0000042329 - 002

Summary of Contents for 20V4000Bx4

Page 1: ...Operating Instructions Diesel engine 20V4000Bx4 20V4000Gx4 MS15039 01E...

Page 2: ...Standby power overload capability to ICXN 3F Mains backup mode unlimited ICXN 3G Prime power time limited ICXN Table 1 Applicability 2018 Copyright MTU Friedrichshafen GmbH This publication is protect...

Page 3: ...an enclosed area vent the exhaust to the outside x Do not modify or tamper with the exhaust system x Do not idle the engine except as necessary WA WAR W W W W W W W W W W W W W W W W W W W W W W W W W...

Page 4: ......

Page 5: ...4F application group 3E 82 4 12 Product data 20V4000G34F application group 3F 87 4 13 Product data 20V4000G34F application group 3G 92 4 14 Product data 20V4000G64F application group 3D 97 4 15 Produc...

Page 6: ...lter 229 8 10 1 Air filter Check 229 8 10 2 Air filter Replacement 230 8 10 3 Air filter Removal and installation 231 8 11 Air Intake 232 8 11 1 Contamination indicator Signal ring position check 232...

Page 7: ...for Electronic Engine Governor Control System 283 8 21 1 Engine governor and connector Cleaning 283 8 21 2 Engine Control Unit plug connections Check 284 8 21 3 Engine governor ECU 9 Removal and insta...

Page 8: ...ns Emission related components must only be serviced ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these specifications will invali...

Page 9: ...sed military applications other than by US government agen cies Please note the following when replacing components with emission labels The relevant emission labels must be affixed to the spare part...

Page 10: ...lfills the conditions for such use and approval has been granted The section below applies to applications deployed in regions under the jurisdiction of the EPA Use of EPA Tier 2 and Tier 3 certified...

Page 11: ...lified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering and also for work with...

Page 12: ...battery terminals generator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediatel...

Page 13: ...ids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrica...

Page 14: ...e fitted Attach Do not operate sign in the operating area or to control equipment Disconnect the battery cables or actuate the battery isolating switch if fitted Lock circuit breakers Before starting...

Page 15: ...ent contact with other components Do not place fuel or oil lines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection a...

Page 16: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 17: ...properly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrap...

Page 18: ...Ensure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always w...

Page 19: ...tands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smokin...

Page 20: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in...

Page 21: ...5 Remove any loose parts on engine generator 6 Raise and lower engine generator slowly Do not allow hoist slings or chains to contact engine generator or any of their component parts Adjust lifting g...

Page 22: ...distance Wear personal protective equipment e g protective helmet safety shoes 1 Center of gravity A Max permissible diagonal pull 10 Taking note of the engine center of gravity Refer to the installat...

Page 23: ...must be reinstalled on both engine sides accord ing to the instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be installe...

Page 24: ...the ring gear 4 Screw in screw 1 in bores of holder 3 until holder 3 is locked in position Note Screw 1 must be tightened stepwise and alternately on both sides of the flywheel housing 5 Tighten scre...

Page 25: ...om the guard plates and engine supports to secure them on the engine u Install engine supports 2 on both sides with guard plates 1 washers 3 and screws 4 and tighten to specified tightening torque tig...

Page 26: ...gnated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 27: ...Oil heat exchanger 3 Cylinder head cover 4 Engine mounting 5 Charge air pipework 6 Oil pan 7 Engine governor 8 Starter 9 Flywheel housing 10 Flywheel 11 Intercooler 12 Air filter MS15039 01E 2018 11 G...

Page 28: ...mostat housing 12 Coolant distribution housing 13 Centrifugal oil filter option 14 Exhaust turbocharger Engine model designation Explanation of engine model designation 20V4000Gx4y 20 Number of cylind...

Page 29: ...9 Engine Ident Label EIL B48 1 High pressure fuel A side Y39 A1 A10 Injectors cylinders A1 A10 B38 Fuel temperature LP system B34 Differential fuel pressure across filter B9 Charge air temperature MS1...

Page 30: ...oil pressure M8 Control block of HP fuel pump option B1 Camshaft speed XB54 Connector for oil refill pump option B54 Lube oil pressure of refill pump option B26 Charge air coolant temperature B6 Coola...

Page 31: ...Injectors cylinders B1 B10 B48 2 High pressure fuel B side B10 Charge air pressure XF57 LT coolant level remote expansion tank XF33 HT coolant level remote expansion tank MS15039 01E 2018 11 General I...

Page 32: ...Designation Description B13 Crankshaft speed 30 General Information MS15039 01E 2018 11 TIM ID 0000082053 003...

Page 33: ...Designation Description B44 Turbocharger speed Installed on 60 Hz engines only MS15039 01E 2018 11 General Information 31 TIM ID 0000082053 003...

Page 34: ...ecified value Not sufficiently validated value 10 tolerance Not sufficiently validated value 5 tolerance ID Product type Application Speed Nominal pow er 1 20V4000B24F Power generation 3A continuous o...

Page 35: ...nsumption ID 1 2 3 4 Specific fuel consumption be 100 DL 5 EN 590 42 8 MJ kg R g kWh 194 191 195 195 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg...

Page 36: ...ant temperature at engine connec tion outlet to cooling system A C 100 100 100 100 Coolant temperature after engine limit 1 L C 102 102 102 102 Coolant temperature after engine limit 2 L C 104 104 104...

Page 37: ...340 340 340 340 Oil pan capacity at dipstick mark min standard oil system option max oper ating inclinations L Liters 268 268 268 268 Oil pan capacity at dipstick mark max standard oil system option...

Page 38: ...take noise filter DL sound power lev el LW ISO 6798 2 dB A tolerance R dB A 123 123 126 125 Engine surface noise with attenuated in take noise filter BL free field sound pressure level Lp 1 m distance...

Page 39: ...d tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G14F Power generation 3B continuous opera tion variable load ICXN 1500 rpm 50 Hz 2200...

Page 40: ...42 8 MJ kg R g kWh 192 221 199 199 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine wi...

Page 41: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 62 69 55 55 Coolant temperature before...

Page 42: ...ss dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 43: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 44: ...tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G14F Power generation 3E standby power overload capability to ICXN 1500 rpm 50 Hz 2200...

Page 45: ...0 42 8 MJ kg R g kWh 192 221 199 199 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine...

Page 46: ...ant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 62 69 55 55 Coolant temperature before intercooler...

Page 47: ...ss dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 48: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 49: ...dequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G14F Power generation 3F mains backup mode unlimited ICXN 1500 rpm 5...

Page 50: ...42 8 MJ kg R g kWh 192 221 199 199 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine wi...

Page 51: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 62 69 55 55 Coolant temperature before...

Page 52: ...ss dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 53: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 54: ...not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G14F Power generation 3G prime power time limited ICXN 1500 rp...

Page 55: ...42 8 MJ kg R g kWh 192 221 199 199 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine wi...

Page 56: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 62 69 55 55 Coolant temperature before...

Page 57: ...ss dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 58: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 59: ...ed tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G24F Power generation 3B continuous opera tion variable load ICXN 1500 rpm 50 Hz 242...

Page 60: ...42 8 MJ kg R g kWh 190 221 197 197 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine wi...

Page 61: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 64 73 60 60 Coolant temperature before...

Page 62: ...s dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 63: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 64: ...tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G24F Power generation 3E standby power overload capability to ICXN 1500 rpm 50 Hz 2420...

Page 65: ...42 8 MJ kg R g kWh 190 221 197 197 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine wi...

Page 66: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 64 73 60 60 Coolant temperature before...

Page 67: ...s dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 68: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 69: ...dequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G24F Power generation 3F mains backup mode unlimited ICXN 1500 rpm 5...

Page 70: ...42 8 MJ kg R g kWh 190 221 197 197 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine wi...

Page 71: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 64 73 60 60 Coolant temperature before...

Page 72: ...s dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 73: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 74: ...not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G24F Power generation 3G prime power time limited ICXN 1500 rp...

Page 75: ...42 8 MJ kg R g kWh 190 221 197 197 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine wi...

Page 76: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 64 73 60 60 Coolant temperature before...

Page 77: ...s dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 78: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 79: ...ed tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G34F Power generation 3B continuous opera tion variable load ICXN 1500 rpm 50 Hz 259...

Page 80: ...8 MJ kg R g kWh 192 221 198 198 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine with...

Page 81: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 66 75 60 60 Coolant temperature before...

Page 82: ...ss dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 83: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 84: ...tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G34F Power generation 3E standby power overload capability to ICXN 1500 rpm 50 Hz 2590...

Page 85: ...8 MJ kg R g kWh 192 221 198 198 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine with...

Page 86: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 66 75 60 60 Coolant temperature before...

Page 87: ...ss dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 88: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 89: ...dequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G34F Power generation 3F mains backup mode unlimited ICXN 1500 rpm 5...

Page 90: ...8 MJ kg R g kWh 192 221 198 198 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine with...

Page 91: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 66 75 60 60 Coolant temperature before...

Page 92: ...dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO 67...

Page 93: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 94: ...not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G34F Power generation 3G prime power time limited ICXN 1500 rp...

Page 95: ...8 MJ kg R g kWh 192 221 198 198 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh Fuel consumption at zero load R kg h 35 38 35 35 Model related data basic design ID 1 2 3 4 Engine with...

Page 96: ...104 104 Coolant antifreeze content max L 50 50 50 50 Coolant system LT circuit ID 1 2 3 4 Coolant temperature at engine connec tion outlet to cooling system R C 66 75 60 60 Coolant temperature before...

Page 97: ...ss dry basic engine configura tion acc to scope of delivery specifica tion R kg 9290 9290 9290 9290 Acoustics ID 1 2 3 4 Exhaust noise unsilenced CP free field sound pressure level Lp 1 m distance ISO...

Page 98: ...lter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A Engine surface noise with attenuated in take noise filter BL sound power level LW ISO 6798 2 dB A tolerance R d...

Page 99: ...specified value Value not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G64F Power generation 3D standby power f...

Page 100: ...ETC and charge air cooling intercooler X X X Uncooled exhaust lines X X X Operating method four stroke cycle diesel single acting X X X Combustion method direct injection X X X Cooling method treated...

Page 101: ...system ID 1 2 3 Lube oil temperature before engine limit 1 L C 99 99 99 Lube oil temperature before engine limit 2 L C 101 101 101 General operating data ID 1 2 3 High idling speed max static L rpm 1...

Page 102: ...lenced BL free field sound pres sure level Lp 1 m distance ISO 6798 3 dB A toler ance R dB A 113 113 113 Exhaust noise unsilenced BL sound power level LW ISO 6798 3 dB A tolerance R dB A 126 126 126 E...

Page 103: ...specified value Value not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G74F Power generation 3D standby power fu...

Page 104: ...ETC and charge air cooling intercooler X X X Uncooled exhaust lines X X X Operating method four stroke cycle diesel single acting X X X Combustion method direct injection X X X Cooling method treated...

Page 105: ...system ID 1 2 3 Lube oil temperature before engine limit 1 L C 99 99 99 Lube oil temperature before engine limit 2 L C 101 101 101 General operating data ID 1 2 3 High idling speed max static L rpm 1...

Page 106: ...lenced BL free field sound pres sure level Lp 1 m distance ISO 6798 3 dB A toler ance R dB A 115 115 115 Exhaust noise unsilenced BL sound power level LW ISO 6798 3 dB A tolerance R dB A 127 127 127 E...

Page 107: ...specified value Value not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G84F Power generation 3D standby power fu...

Page 108: ...TC and charge air cooling intercooler X X X Uncooled exhaust lines X X X Operating method four stroke cycle diesel single acting X X X Combustion method direct injection X X X Cooling method treated w...

Page 109: ...system ID 1 2 3 Lube oil temperature before engine limit 1 L C 99 99 99 Lube oil temperature before engine limit 2 L C 101 101 101 General operating data ID 1 2 3 High idling speed max static L rpm 1...

Page 110: ...lenced BL free field sound pres sure level Lp 1 m distance ISO 6798 3 dB A toler ance R dB A 116 116 116 Exhaust noise unsilenced BL sound power level LW ISO 6798 3 dB A tolerance R dB A 129 129 129 E...

Page 111: ...nce 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 20V4000G14S Power generation 3B continuous opera tion variable load ICXN 1800 rpm 60 Hz 2490 kW 3339...

Page 112: ...1800 1800 1800 1800 1800 1800 Continuous power ISO 3046 10 overload capa bility power range DIN 6280 ISO 8528 A kW 2490 2490 2740 2740 3010 3010 Fuel stop power ISO 3046 A kW 2739 2739 3014 3014 3311...

Page 113: ...ction of rotation c c w facing driving end X X X X X X Number of cylinders 20 20 20 20 20 20 Cylinder arrangement V angle Degrees 90 90 90 90 90 90 Bore mm 170 170 170 170 170 170 Stroke mm 210 210 21...

Page 114: ...tem R C 66 60 70 62 73 65 Coolant temperature be fore intercooler limit 1 L C 75 75 75 75 75 75 Coolant temperature be fore intercooler limit 2 L C Coolant antifreeze con tent max L 50 50 50 50 50 50...

Page 115: ...ers 268 268 268 268 268 268 Oil pan capacity at dip stick mark max stand ard oil system option max operating inclina tions L Liters 315 315 315 315 315 315 Masses main dimensions ID 1 2 3 4 5 6 Engine...

Page 116: ...107 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A 125 125 125 125 128 126 Engine surface noise with attenuated intake noise filter B...

Page 117: ...ce 5 ID Product type Application Speed Nominal pow er 1 20V4000G64S Power generation 3D standby power fuel stop power IFN 1800 rpm 60 Hz 2740 kW 3674 bhp Ref 25 C 55 C Optimized fuel con sumption 2 20...

Page 118: ...wer ID 1 2 3 4 5 6 Intake depression new filter A mbar 15 15 15 15 15 15 Intake depression max L mbar 50 50 50 50 50 50 Fuel temperature at en gine inlet connection R C 25 25 25 25 25 25 Fuel temperat...

Page 119: ...Bore mm 170 170 170 170 170 170 Stroke mm 210 210 210 210 210 210 Cylinder displacement Liters 4 77 4 77 4 77 4 77 4 77 4 77 Total displacement Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio...

Page 120: ...C 75 75 75 75 75 75 Coolant temperature be fore intercooler limit 2 L C Coolant antifreeze con tent max L 50 50 50 50 50 50 Lube oil system ID 1 2 3 4 5 6 Lube oil temperature be fore engine limit 1...

Page 121: ...na tions L Liters 268 268 268 268 268 268 Oil pan capacity at dip stick mark max stand ard oil system option max operating inclina tions L Liters 315 315 315 315 315 315 Masses main dimensions ID 1 2...

Page 122: ...urface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A Engine surface noise with attenuated intake noise filter BL free field sound pressure level Lp...

Page 123: ...rance 5 ID Product type Application Speed Nominal pow er 1 20V4000G14S Power generation 3F mains backup mode unlimited ICXN 1800 rpm 60 Hz 2490 kW 3339 bhp Ref 25 C 55 C Optimized fuel con sumption 2...

Page 124: ...2739 2739 3014 3014 3311 3311 Site conditions for max power ID 1 2 3 4 5 6 Intake depression new filter A mbar 15 15 15 15 15 15 Intake depression max L mbar 50 50 50 50 50 50 Fuel temperature at en...

Page 125: ...e mm 210 210 210 210 210 210 Cylinder displacement Liters 4 77 4 77 4 77 4 77 4 77 4 77 Total displacement Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio 16 4 16 4 16 4 16 4 16 4 16 4 Air exha...

Page 126: ...C 75 75 75 75 75 75 Coolant temperature be fore intercooler limit 2 L C Coolant antifreeze con tent max L 50 50 50 50 50 50 Lube oil system ID 1 2 3 4 5 6 Lube oil temperature be fore engine limit 1...

Page 127: ...iters 268 268 268 268 268 268 Oil pan capacity at dip stick mark max stand ard oil system option max operating inclina tions L Liters 315 315 315 315 315 315 Masses main dimensions ID 1 2 3 4 5 6 Engi...

Page 128: ...107 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A 125 125 125 125 128 126 Engine surface noise with attenuated intake noise filter B...

Page 129: ...5 tolerance ID Product type Application Speed Nominal pow er 1 20V4000G14S Power generation 3G prime power time limited ICXN 1800 rpm 60 Hz 2490 kW 3339 bhp Ref 25 C 55 C Optimized fuel con sumption 2...

Page 130: ...1 2 3 4 5 6 Intake depression new filter A mbar 15 15 15 15 15 15 Intake depression max L mbar 50 50 50 50 50 50 Fuel temperature at en gine inlet connection R C 25 25 25 25 25 25 Fuel temperature at...

Page 131: ...e mm 210 210 210 210 210 210 Cylinder displacement Liters 4 77 4 77 4 77 4 77 4 77 4 77 Total displacement Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio 16 4 16 4 16 4 16 4 16 4 16 4 Air exha...

Page 132: ...C 75 75 75 75 75 75 Coolant temperature be fore intercooler limit 2 L C Coolant antifreeze con tent max L 50 50 50 50 50 50 Lube oil system ID 1 2 3 4 5 6 Lube oil temperature be fore engine limit 1...

Page 133: ...iters 268 268 268 268 268 268 Oil pan capacity at dip stick mark max stand ard oil system option max operating inclina tions L Liters 315 315 315 315 315 315 Masses main dimensions ID 1 2 3 4 5 6 Engi...

Page 134: ...107 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A 125 125 125 125 128 126 Engine surface noise with attenuated intake noise filter B...

Page 135: ...4 21 Firing order Number of cylinders Firing order 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 MS15039 01E 2018 11 Technical Data 133 TIM ID 0000035068 003...

Page 136: ...ne Main dimensions Engine model Length A Width B Height C 20V4000Gx4y Anwen dung 3D 3E 3486 mm 1701 mm 2172 mm 20V4000Gx4y Anwen dung 3A 3B 3F 3G 3560 8 mm 1701 mm 2172 mm 134 Technical Data MS15039 0...

Page 137: ...conds at a pressure of at least 0 3 bar Only for engines without oil priming pump Crank engine on starting system without injecting fuel Page 177 Fuel prefilter Fill with fuel Page 221 Page 223 Fuel p...

Page 138: ...circuit Check engine coolant level Page 244 Check charge air coolant level Page 265 Coolant circuit Heat engine coolant with coolant preheater Fuel prefilter Drain water Page 215 Page 217 Monitoring s...

Page 139: ...inated contact Service Preparation Item Action Operating mode switch if fitted Change to manual mode Preheating pump if fitted Switch on Starting the engine Item Action Control cabinet operator statio...

Page 140: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Page 141: ...when a pushbutton is provided Safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown crite...

Page 142: ...ms will be disregarded Severe material damage Initiate emergency start only in emergency situations Preparation Item Action Operating mode selector switch Change to Override mode Manual mode if applic...

Page 143: ...may be red hot If the maximum exhaust temperatures are not exceeded no restrictions in en gine operation are required Check for abnormal running noises and vibration Fuel prefilter Check fuel prefilt...

Page 144: ...emission label for intactness 3 Check that emission label is fully legible 4 Check content of emission label Does the label on the engine match the label document in the Business Portal Equipment Does...

Page 145: ...extreme thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and cons...

Page 146: ...After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping 144 Operation MS15039 01E 2018 11 TIM ID 0000002285 005...

Page 147: ...from LOP Item Action Emergency stop pushbutton Press pushbutton Engine is stopped by disconnecting the power supply to the ECU Signaling e g by horn flashing lamp is tripped After emergency engine sto...

Page 148: ...he engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION 146 Operation MS15039 01E 2018 11...

Page 149: ...o the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is...

Page 150: ...gun directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental prot...

Page 151: ...ENGINE GENERAL Check relief bore of coolant pump Page 250 Page 273 WM00063 OIL CONDITIONING Automatic centrifugal oil filter automatic Measure thickness of oil residue lay er clean replace paper eleme...

Page 152: ...0110 CRANKCASE Perform endoscopic examination of cylinder liner Page 179 WM00090 FUEL INJECTOR Replace fuel injection valve injector Page 196 WM00089 FUEL INJECTOR Reset drift compensation CDC paramet...

Page 153: ...nspection manufacturer s documentation Engine governor Plug in connections loose u Check plug in connections Page 284 Running gear blocked engine cannot be barred manually u Contact Service Engine tur...

Page 154: ...re too high Cause Corrective action Engine coolant treatment incorrect u Check MTU test kit Intercooler dirty u Contact Service Engine room Air intake temperature too high u Check fans and intake exha...

Page 155: ...ngs or cylinder liner defective u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Check fue...

Page 156: ...power 2 Check fuel cooling system if applicable 3 Contact Service 5 HI T Charge Air Cause Corrective action The charge air temperature at sensor B9 has violated limit value 1 The charge air temperatu...

Page 157: ...s too low 1 Check engine oil level Page 237 2 Contact Service 23 LO Coolant Level Cause Corrective action Coolant level at level switch B533 in HT circuit is too low 1 Check engine coolant level Page...

Page 158: ...haust turbocharger 1 Reduce power 2 Contact Service 32 SS ETC1 Overspeed Cause Corrective action The speed of the A side LP turbocharger at sensor B44 1 has violated limit value 2 The exhaust turbocha...

Page 159: ...ne coolant level Page 244 3 Contact Service 63 HI P Crank Case Cause Corrective action The crankcase pressure at sensor B50 has violated limit value 1 The crankcase pressure is too high 1 Stop engine...

Page 160: ...lated the limit value Fuel pressure is too low u Contact Service 89 SS Engine Speed too low Cause Corrective action The engine speed has violated the limit value An emergency engine shutdown has been...

Page 161: ...orrective action The oil pressure at sensor B5 1 has violated the set value The set oil pressure was not reached The starting sequence was terminated 1 Check engine cabling Page 282 2 Contact Service...

Page 162: ...r A3 Cause Corrective action Short circuit fault in the injector wiring for cylinder A3 or injector defective 1 Check wiring of affected injector Page 282 2 Replace injector Page 196 3 Contact Service...

Page 163: ...action Short circuit fault in injector wiring cylinder A10 or injector defective 1 Check wiring of affected injector Page 282 2 Replace injector Page 196 3 Contact Service 331 AL Wiring Cylinder B1 C...

Page 164: ...ive action Short circuit fault in the injector wiring for cylinder B7 or injector defective 1 Check wiring of affected injector Page 282 2 Replace injector Page 196 3 Contact Service 338 AL Wiring Cyl...

Page 165: ...er A4 1 Check wiring of affected injector Page 282 2 Contact Service 345 AL Open Load Cylinder A5 Cause Corrective action Disruption fault in injector wiring for cylinder A5 1 Check wiring of affected...

Page 166: ...der B2 1 Check wiring of affected injector Page 282 2 Contact Service 353 AL Open Load Cylinder B3 Cause Corrective action Disruption fault in injector wiring to cylinder B3 1 Check wiring of affected...

Page 167: ...ed injector Page 282 2 Contact Service 365 AL Stop MV Wiring Ground Cause Corrective action Short circuit of injector positive connection to ground of one or more injectors Short circuit of injector n...

Page 168: ...mary emission fault alarm 1 Observe any other messages 2 Contact Service 759 AL L1 T Fuel b Engine Cause Corrective action The charge air pressure at sensor B33 has violated upper limit value 1 The fu...

Page 169: ...u Schedule an injector replacement 1033 AL Inj Drift Limit 1 Cyl A2 Cause Corrective action The drift correction for energization start and duration of injector A2 has violated limit 1 The injector wi...

Page 170: ...reach its maximum drift limit u Schedule an injector replacement 1039 AL Inj Drift Limit 1 Cyl A8 Cause Corrective action The drift correction for energization start and duration of injector A8 has vi...

Page 171: ...reach its maximum drift limit u Schedule an injector replacement 1045 AL Inj Drift Limit 1 Cyl B4 Cause Corrective action The drift correction for energization start and duration of injector B4 has v...

Page 172: ...injector will soon reach its maximum drift limit u Schedule an injector replacement 1051 AL Inj Drift Limit 1 Cyl B10 Cause Corrective action The drift correction for energization start and duration...

Page 173: ...ctor has reached its maximum drift limit u Replace injector Page 196 1057 AL Inj Drift Limit 2 Cyl A6 Cause Corrective action The drift correction for energization start and duration of injector A6 ha...

Page 174: ...injector has reached its maximum drift limit u Replace injector Page 196 1063 AL Inj Drift Limit 2 Cyl B2 Cause Corrective action The drift correction for energization start and duration of injector...

Page 175: ...has reached its maximum drift limit u Replace injector Page 196 1069 AL Inj Drift Limit 2 Cyl B8 Cause Corrective action The drift correction for energization start and duration of injector B8 has vio...

Page 176: ...uel temperature has violated the critical upper limit value 1 Reduce power 2 Check fuel cooling system if applicable 3 Contact Service 1376 AL Refdrive Impossibl Ubat Low Cause Corrective action The E...

Page 177: ...chet with extension F30006212 1 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...

Page 178: ...sistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resistance exceeds the normal com pression resistance contact Service...

Page 179: ...ge 135 Before starting the engine in a contingency situation to maintain operation of a leaking intercooler Page 228 Cranking engine on starting system Note The engine must not start and no fuel may b...

Page 180: ...isoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of heari...

Page 181: ...top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lowe...

Page 182: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 183: ...It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be interrup...

Page 184: ...ks 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 inspectio...

Page 185: ...substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Av...

Page 186: ...r sleeve 2 and remove hose from cover 3 2 Loosen clamp 6 and remove cover 3 3 Remove air filter 5 with filter mounts 4 4 Remove O ring 7 from adapter 5 Coat new O ring 7 with assembly compound and ins...

Page 187: ...th gage 200 mm Y20000918 1 Measuring jig 2 optional Y4350010 1 Preparatory steps 1 Remove cylinder head covers Page 193 2 Install barring tool Page 175 3 Turn crankshaft in direction of rotation using...

Page 188: ...er head 3 4 Turn measuring unit screws 1 into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10 T...

Page 189: ...95 8 mm 5 Install valve bridge 6 Adjusting valve clearance Page 190 Step 2 optional Measure valve protrusion at the valve stem with measuring jig 2 1 Check TDC position of piston in cylinder A1 If roc...

Page 190: ...ze Type Lubricant Value Standard Screw M10 Tightening torque 20 Nm 6 Determine the values with all dial gages The valve protrusion value must be 2 mm Have the affected cylinder head replaced by expert...

Page 191: ...rts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 193 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting...

Page 192: ...320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Ratchet bit F30027341 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 193 2 Install barring device Page 175 Note Pointer 1 is locat...

Page 193: ...re under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 2 mm 0 05 mm Exhaust valves short rocker arm 0 5 0 05 mm 3 Check all v...

Page 194: ...pass through the gap 4 Pull feeler gauge 3 between valve bridge and rocker arm Note Hold adjusting screw 2 firmly in position 5 Tighten lock nut 1 to specified tightening torque using a torque wrench...

Page 195: ...prior to removal 2 Remove screws 2 together with wash ers 3 3 Remove cylinder head cover together with profile gasket 4 from cylinder head Installing cylinder head cover 1 Clean installation surface...

Page 196: ...y through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing pr...

Page 197: ...ox 2 Use fuel suction device to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standar...

Page 198: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 196 196 Injector MS15039 01E 20...

Page 199: ...Liquid or gaseous media e g fuel are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to ey...

Page 200: ...upply to engine 3 Remove cylinder head cover Page 193 Injector Removal 1 Disconnect cable connectors on injector Note Be aware of system pressure 2 Slowly loosen nuts 4 6 and remove HP fuel line 5 Not...

Page 201: ...t from the cylinder head and dispose accordingly 9 Dispose of injector 1 with O rings in place 10 Clean all mating and sealing surfaces 11 Cover all connections and bores or seal with suitable plugs I...

Page 202: ...sert injector 1 in the cylinder head ensur ing that it is correctly aligned with the HP line connection 8 Press in injector with installation removal de vice 9 Remove the installation removal device 1...

Page 203: ...damage 19 Tighten nuts 4 6 by hand as far as possible 20 Use a torque wrench to tighten nuts 4 6 to specified tightening torque in the following order Tightening sequence 1 Nut on adapter 4 2 Nut on...

Page 204: ...e 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...

Page 205: ...nstructions Check components for special cleanliness Preparatory steps 1 Allow HP system to cool down 2 Shut off fuel supply to engine 3 Remove cylinder head cover Page 193 Removing injector removing...

Page 206: ...g ring 4 from injector or use a self made wire hook or magnet to take it out of the cylinder head and dispose properly 9 Remove O rings 5 O ring 3 and damper ring 2 from injector 1 and dispose accord...

Page 207: ...the CE ring must face the combustion chamber A multi purpose grease without solids must be used 3 Install new sealing ring 1 abutted to Multi purpose grease and ensure that the installa tion position...

Page 208: ...ze Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 16 Use a torque wrench and long socket to tighten adapter 3 to specified tightening torque Name Size Type Lubricant...

Page 209: ...Do not reset drift correction CDC after re in stalling a used injector 22 After fitting new injectors Page 197 Final steps 1 Install cylinder head cover Page 193 2 Open fuel supply to engine MS15039...

Page 210: ...ve 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 Venting LP fuel syst...

Page 211: ...ed vent plug 6 Close threaded vent plug 7 Continue to operate the pump until resist ance is noticeable at least 50 times to ach ieve full filling height Note See figure c 8 Lock hand pump Slide sleeve...

Page 212: ...el are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attent...

Page 213: ...ugh inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If conta...

Page 214: ...o avoid damage to cooling elements only aim water jet parallel to the cooling fins applying moderate pressure To improve the cleaning effect add a suitable degreasing agent to the water in accordance...

Page 215: ...fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective...

Page 216: ...f with water and soap Pressure ratios Note If the fuel prefilter is above the full level of the fuel tank during engine operation the fuel pressure in the filter is lower than ambient pressure vacuum...

Page 217: ...ith water and soap WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework...

Page 218: ...11 Vent fuel prefilter Page 226 Draining fuel prefilter with high pressure version B Note The fuel prefilter can be drained during engine operation or with the engine at a standstill 1 Provide a suit...

Page 219: ...ash off with water and soap WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust...

Page 220: ...lter module 2 is cut out 3 Open threaded vent plug 1 of filter to be serviced 4 Open drain plug 1 5 Allow water to drain until fuel emerges 6 Close drain plug 2 again 7 Drain the second filter on the...

Page 221: ...chover during engine operation and at engine stand still 1 Provide a suitable container to collect the water 2 Take care when opening drain plug 1 be cause fuel or water can spurt out 3 Allow water to...

Page 222: ...eading 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 2 Switch over the fuel prefilter or replace a fil ter element Page 223 when...

Page 223: ...through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If...

Page 224: ...element 3 from filter housing 4 7 Unclip filter element 3 from filter cover 1 8 Install new O ring 2 on filter cover 1 9 Coat new O rings on filter cover and filter ele ment with fuel 10 Clip new filt...

Page 225: ...nhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is...

Page 226: ...is opened absolute cleanness is imperative Carefully extract the filter element straight up avoiding contact with the upper edge of the cylinder if at all possible to prevent contamination of the fuel...

Page 227: ...ible to prevent contamination of the fuel remaining in the filter housing 6 Unscrew filter cover 1 and withdraw with fil ter element 3 from filter housing 4 7 Unclip filter element 3 from filter cover...

Page 228: ...NING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A...

Page 229: ...threaded vent plugs 2 3 Note Never actuate the handle with the threaded vent plugs closed 5 Move handle 1 of fuel priming pump back and screw in 6 Close threaded vent plugs 2 3 and tighten by hand Ve...

Page 230: ...irect air jet at people Always wear safety goggles face mask and hearing protection Intercooler Checking conden sate drain for coolant leak and obstruction 1 With the engine running verify that air es...

Page 231: ...Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Checking air filter 1 Check entire circumference of air filter for damage 2 Fit new air filter if damaged Page 230 MS15...

Page 232: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 231 2 Reset signal ring of service indicator Page 232 230 A...

Page 233: ...r filter 1 Loosen clamp 2 2 Remove air filter 4 with attached heat shield 1 and clamp 2 from connecting flange of intake elbow 3 3 Clean connecting flange of intake elbow 3 and check for obstructions...

Page 234: ...r if opening of the entrance door can be prevented Only operate the engine with installed air filters Never open air carrying components during operation Ensure that the engine room is well ventilated...

Page 235: ...sure that there are no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear suitable hearing protection Air starter Manual...

Page 236: ...the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Inadequate oil pressu...

Page 237: ...th un scheduled engine oil change 1 Provide a suitable container in which to col lect the engine oil 2 Remove drain plug 1 and drain engine oil from engine oil heat exchanger and from en gine oil filt...

Page 238: ...ck engine oil level Page 237 Note Observe the following instructions to avoid engine damage Adequate oil pressure for an engine start is only provided when the quick start function is deactivated 5 Ma...

Page 239: ...o 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changers flowing back into the oil pan After extended standstill the oil level 2 cm above mark 2 is the minimum oil level...

Page 240: ...il vapor WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediatel...

Page 241: ...sludge 3 Drain approx 1 liter engine oil into a clean container 4 Close screw 1 and tighten to specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 2...

Page 242: ...ect oil priming pump and connections for firm seating and leaks Retighten loose threaded connections as necessary 2 Check leak telltale bore 2 for oil discharge Result If oil emerges the gear pump 1 u...

Page 243: ...ick start function is deactivated before starting the engine For engines with lube oil priming pump Prime the engine for 20 seconds at a pressure of at least 0 3 bar Engine oil filter Replacement 1 Re...

Page 244: ...k Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct...

Page 245: ...eal ing ring 4 in rotor cover 3 Note Do not clamp rotor unit in a bench vise Use an oil filter wrench 5 Screw on rotor cover 3 by turning at hexa gon 6 Tighten rotor cover 3 with torque wrench to spec...

Page 246: ...nd goggles safety mask Checking coolant level at re mote cooler 1 Check coolant level coolant must be visible at marking plate 2 Top up with treated coolant as necessary Page 248 3 Check and clean bre...

Page 247: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 246 2 Fill with engine coolant Page 248 MS15039 01E 2018 11 Coolant Circuit General High Tem...

Page 248: ...les safety mask Wipe up escaped spilled coolant immediately Preparatory steps 1 Provide a suitable container to catch the coolant 2 Switch off preheater Draining engine coolant 1 Turn valve cover of c...

Page 249: ...2 Close all other open drain points 3 Position valve cover on filler neck and close MS15039 01E 2018 11 Coolant Circuit General High Temperature Circuit 247 TIM ID 0000000960 005...

Page 250: ...the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant...

Page 251: ...required 8 Fit valve cover and close it 9 Start engine Page 137 10 After 10 seconds of running the engine without load shut down the engine Page 143 11 Turn valve cover on coolant expansion tank count...

Page 252: ...hearing protection Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drop...

Page 253: ...RNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when workin...

Page 254: ...Nm 5 Using the equipment and chemicals from the MTU test kit examine coolant for antifreeze concentration Amount of corrosion protection oil pH value 6 For engine coolant change intervals refer to MT...

Page 255: ...t 6 Intake 7 Safety thermostat 8 Housing cover 9 Pump Arrow Flow direction Variant Heating output Rated voltage Frequency Phases 1 9 kW 400 V 50 Hz 3 2 9 kW 480 V 60 Hz 3 3 12 kW 400 V 50 Hz 3 4 12 kW...

Page 256: ...protection Function check Note The preheater operates properly if the measured value of the coolant temperature is within the control range of the thermostat 1 Check coolant preheating temperature 2 C...

Page 257: ...onnected Replacing solenoid switch u Replace solenoid switch Page 256 Cleaning heating element and replacing gasket u Clean heating element and housing and check Page 258 Replacing thermostat u Replac...

Page 258: ...jury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before begi...

Page 259: ...noid switch off the rail 5 Fit a new solenoid switch on the rail and fully engage the spring clip 6 Connect up all wires as marked previously 7 Close the control box and tighten the screws Final steps...

Page 260: ...ssure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid...

Page 261: ...d or new heating element into housing 7 Install electrical part 2 and tighten screws 1 Installing coolant lines 1 Clean drain plug and screw in thread arrow at preheater 2 Coat drain plug with screw l...

Page 262: ...Final steps 1 Connect preheater power sources 2 Switch on preheater 260 Coolant Circuit General High Temperature Circuit MS15039 01E 2018 11 TIM ID 0000081913 004...

Page 263: ...es Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot...

Page 264: ...e 8 Fit cover and tighten screws Replacing control thermostat 1 Undo screws 1 on housing cover 2 of con trol thermostat and remove cover 2 Mark cables prior to disconnection 3 Disconnect wires 4 Remov...

Page 265: ...Final steps 1 Connect preheater to power supply 2 Switch on preheater MS15039 01E 2018 11 Coolant Circuit General High Temperature Circuit 263 TIM ID 0000081762 001...

Page 266: ...ety mask Preparatory steps u Switch off preheater Replacing valve cover Note Schematic diagram Design may deviate 1 Turn valve cover 1 on coolant expansion tank counterclockwise until the first stop a...

Page 267: ...and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and...

Page 268: ...rge air coolant level is monitored automatically by the engine control system 1 Switch on engine control system and check readings on the display 2 Top up with charge air coolant as necessary Page 270...

Page 269: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 268 2 Fill with charge air coolant Page 270 MS15039 01E 2018 11 Low Temperat...

Page 270: ...coolant Draining 1 Provide a suitable container to catch the coolant 2 Turn valve cover on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn va...

Page 271: ...a torque wrench Name Size Type Lubricant Value Standard Spindle 11A F Tightening torque 12 Nm 9 Close the remaining drain valves and screw in drain plugs with new sealing rings 10 Position valve cover...

Page 272: ...lding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up...

Page 273: ...ealing faces if required 8 Position valve cover on filler neck and close 9 Start engine Page 137 10 After 10 seconds of running the engine without load shut down the engine Page 143 11 Turn valve cove...

Page 274: ...load shut down the engine Page 143 8 Turn valve cover on coolant expansion tank counterclockwise to first stop and release pressure 9 Turn valve cover counterclockwise and re move 10 Check coolant lev...

Page 275: ...ation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suita...

Page 276: ...onents Never operate the engine without protective covers or safety guards which meet applicable accident prevention regulations Ensure that the safety guards can prevent body parts from being drawn i...

Page 277: ...ator drive Drive belt replacement 1 Remove protective cover 2 Loosen screws 2 and 3 by half a turn 3 Mount socket or box wrench on screw 1 and press belt tensioner in direction of arrow as far as the...

Page 278: ...tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Adjusting belt tension 1 Slacken screws 1 and 2 by half a turn Result...

Page 279: ...ife or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounting Check Item...

Page 280: ...a torque wrench to tighten loose screw connections 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torque wrench to ti...

Page 281: ...fied tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torque wrench to tighten loose screw connections 3 to specified tightening torqu...

Page 282: ...ll Risk of shorter service life or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them...

Page 283: ...ing check Preconditions Engine is stopped and starting disabled Generator mounting securing screw firm seating check 1 Check securing screws for firm seating 2 Tighten loose screws MS15039 01E 2018 11...

Page 284: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector...

Page 285: ...propyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible lab...

Page 286: ...management system is de energized Checking plug connections at Engine Control Unit 1 Check all plug connections for firm seating 2 Lock loose connectors 3 Check dust cap on ECU connectors for damage a...

Page 287: ...1 Note or mark assignment of cables and plugs 2 Remove all screws 2 3 Undo clips 3 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Installing engine governor on...

Page 288: ...CDC Resetting with DiaSys Note The engine will lose its emissions certification of the drift correction parameters CDC if not reset 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E5319...

Page 289: ...level sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant pressure sensor Monitors coolant pressure CR Common Rail CTS Coolant temperature sensor Monitors coolant t...

Page 290: ...t HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interface Data Module Memory module for interface data IIG Initial injector equalization Initial input of inject...

Page 291: ...p 1st function Warning lamp stop engine and rectify fault 2nd function Read out fault codes SID System Identifier SPC Spare Parts Catalog SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety Syst...

Page 292: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 293: ...ngine Barring manually Page 175 Qty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 179 Crossbeam Part No T80091826 Qty Used in 1 2 1 Transport Page 19 Crossbeam Part No T80092360 Qty Used...

Page 294: ...linder liner Endoscopic examination Page 179 Feeler gage Part No Y20098771 Qty Used in 1 8 4 3 Valve clearance Check and adjustment Page 190 Filter wrench Part No F30379104 Qty Used in 1 8 8 1 Fuel fi...

Page 295: ...1 5 13 Plant Cleaning Page 148 Installation removal device Part No F6789889 Qty Used in 1 8 6 2 Injector Removal and installation Page 197 Qty Used in 1 8 6 3 Injector rings Replacement Page 202 Measu...

Page 296: ...8 6 3 Injector rings Replacement Page 202 MTU test kit Part No F6798833 Qty Used in 1 8 13 3 Engine oil Sample extraction and analysis Page 238 Qty Used in 1 8 15 6 Engine coolant Sample extraction a...

Page 297: ...generator drive Drive belt re placement Page 275 Qty Used in 1 8 18 2 Battery charging generator Drive belt tension ad justment Page 276 Ratchet bit Part No F30027341 Qty Used in 1 8 4 3 Valve cleara...

Page 298: ...mm Part No F30039526 Qty Used in 1 8 4 3 Valve clearance Check and adjustment Page 190 Torque screwdriver 1 5 Nm Part No F30452774 Qty Used in 1 8 6 2 Injector Removal and installation Page 197 Qty U...

Page 299: ...242 Qty Used in 1 8 18 1 Battery charging generator drive Drive belt re placement Page 275 Qty Used in 1 8 18 2 Battery charging generator Drive belt tension ad justment Page 276 Torque wrench 300 800...

Page 300: ...Cleaning and filter sleeve re placement Page 242 Qty Used in 1 8 18 1 Battery charging generator drive Drive belt re placement Page 275 Qty Used in 1 8 18 2 Battery charging generator Drive belt tensi...

Page 301: ...expansion tank Valve cover replacement 264 Crankcase breather Filter element replacement 184 Oil mist separator Replacement 183 Crankshaft Transport locking device Installation removal 21 Cylinder Des...

Page 302: ...g Non switchable 215 Switchable 217 Filter element replacement Non switchable 221 Switchable 223 Low pressure indicator check Switchable 220 Pressure ratios 214 Venting 226 Fuel system Venting 208 G G...

Page 303: ...oduct data 20V4000G14S Continuous operation 3B EPA Nonroad T2 Comp 40CFR89 109 EPA Stationary EMERG T2 40CFR60 109 Fuel optimized 109 Mains backup mode 3F EPA Nonroad T2 Comp 40CFR89 121 EPA Stationar...

Page 304: ...tandby power 3D EPA Stationary EMERG T2 40CFR60 115 EPA Stationary EMERG T2 40CFR89 115 Fuel optimized 115 Pump Charge air coolant Relief bore check 273 Engine coolant Relief bore check 250 Putting th...

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MTU 20V4000Bx4, Operating Instructions Manual

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