MTU 20V4000G*3 series Operating Instructions Manual Download Page 212

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9.6 Injector

9.6.1 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 211).

210 | Injector | MS150093/05E 2018-12

TIM-ID: 0000042329 - 002

Summary of Contents for 20V4000G*3 series

Page 1: ...Operating Instructions Diesel engine 20V4000Gx3x 6 exhaust turbochargers MS150093 05E...

Page 2: ...eration time limited ICXN Table 1 Applicability 2018 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in part without th...

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: ...20V4000Gx3x standby operation 3D EPA Stationary EMERG T2 40CFR60 and EPA Nonroad T2 Comp 40CFR89 69 5 8 Product data 20V4000Gx3x standby operation mode 3D NEA Singapore for ORDE and China Nonroad Mob...

Page 6: ...System 217 9 7 1 Fuel system Venting 217 9 8 Fuel Filter 219 9 8 1 Fuel filter Replacement 219 9 8 2 Fuel prefilter Pressure ratios 220 9 8 3 Fuel prefilter non switchable Draining 221 9 8 4 Fuel pre...

Page 7: ...tery charging generator Drive belt tension adjustment 284 9 18 2 Battery charging generator drive Drive belt replacement 285 9 19 Engine Mounting Support 286 9 19 1 Engine mounting Checking resilient...

Page 8: ...al Chapter MS150093 04 MS150093 05 2 Chapter Safety Chapter updated to the latest status Revision overview Maintenance schedule Task No Revision overview Task description Chapter MS150093 04 MS150093...

Page 9: ...s 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 invalid...

Page 10: ...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 11: ...ons contained in this manual in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair The...

Page 12: ...ified 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 13: ...attery 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 Immediately...

Page 14: ...ds 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 electrical...

Page 15: ...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 w...

Page 16: ...nt 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 ag...

Page 17: ...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 18: ...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 19: ...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 20: ...ands 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 smoking...

Page 21: ...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 o...

Page 22: ...ts 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 gear as necessary 7 For...

Page 23: ...istance 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 installati...

Page 24: ...port locking device must be installed on all resilient mounts according to the instructions before transporting Removing engine mount trans portation locks 1 Slacken nuts 2 2 Undo nut 3 and unscrew an...

Page 25: ...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 installed...

Page 26: ...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 screw...

Page 27: ...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 28: ...orques MA are specified for screws of strength class 8 8 surface condition bare phosphatized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a fricti...

Page 29: ...s for studs Thread screwed into Steel M A Nm Gray cast iron MA Nm AI alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setsc...

Page 30: ...e based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is perm...

Page 31: ...n tightening MA tightening torques Tightening torques for plug screws as per MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852 Form...

Page 32: ...ightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35 30 M...

Page 33: ...l gray cast iron M A Nm AI alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torque for banjo screws as p...

Page 34: ...ns during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x 1 5 25 M18...

Page 35: ...nd oiled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable d...

Page 36: ...ng the union nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm...

Page 37: ...valves see ISO 6149 47 and ISO 7789 Tightening torques for screwed plugs with O ring as per ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M22...

Page 38: ...RFS fittings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting metallic sealing with union...

Page 39: ...2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37 UNF...

Page 40: ...Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 38 General Informa...

Page 41: ...cordance 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 and letter...

Page 42: ...ead 13 Exhaust system 14 Fuel filter 15 Gear train 16 Power supply 17 HP fuel pump 18 Vibration damper 19 Coolant distribution housing Engine model designation Key to the engine model designation 20V4...

Page 43: ...ators Overview 1 B44 turbocharger speed 2 B10 charge air pressure 3 Sensor B34 fuel pressure after filter 4 M8 HP fuel pump 5 B09 charge air tempera ture MS150093 05E 2018 12 General Information 41 TI...

Page 44: ...e oil pressure 5 B48 fuel pressure rail 6 B01 camshaft speed 7 XB54 oil replenishment pump 8 B33 fuel temperature rail 9 B26 charge air coolant temperature 10 B06 coolant temperature 1 X2 Engine Contr...

Page 45: ...1 B13 crankshaft speed MS150093 05E 2018 12 General Information 43 TIM ID 0000019859 005...

Page 46: ...value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated power 1 20V4000G63 Pow...

Page 47: ...5 4 95 4 Compression ratio 16 4 16 4 16 4 16 4 Number of inlet valves per cylinder 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 Air exhaust gas ID 1 2 3 4 Charge air pressure before cylinder...

Page 48: ...from R bar 3 9 3 8 4 5 4 4 Lube oil operating pressure before en gine to R bar 6 7 6 6 7 3 7 2 Fuel system ID 1 2 3 4 Fuel pressure at engine inlet connection min when engine is starting L bar 0 1 0 1...

Page 49: ...at dipstick mark max standard oil system option max oper ating inclinations L Liters 315 315 315 315 Weights main dimensions ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of de...

Page 50: ...plication Engine speed Listed rated power 1 20V4000G23 Power generation 3B continuous opera tion variable load ICXN 1500 rpm 50 Hz 2200 kW 2950 bhp Ref 25 C 55 C 6 ETC 6 Optimized fuel con sumption 2...

Page 51: ...e mm 170 170 170 170 170 170 Stroke mm 210 210 210 210 210 210 Displacement cylinder Liters 4 77 4 77 4 77 4 77 4 77 4 77 Displacement total Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio 16 4...

Page 52: ...be oil operating tem perature before engine from R C 88 88 88 88 88 88 Lube oil operating tem perature before engine to R C 98 98 98 98 98 98 Lube oil temperature be fore engine limit 1 L C 99 99 99 9...

Page 53: ...itial filling standard oil sys tem option max oper ating inclinations R Liters 390 390 390 390 390 390 Oil change quantity max standard oil system op tion max operating incli nations R Liters 340 340...

Page 54: ...evel LW ISO 6798 3dB A tolerance R dB A 124 127 126 127 128 129 Engine surface noise with attenuated intake noise filter DL power sound power level LW ISO 6798 2dB A tolerance R dB A 123 125 123 124 1...

Page 55: ...alue Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated power 1 20...

Page 56: ...ant system HT circuit ID 1 2 3 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 100 Coolant temperature after engine limit 1 L C 102 102 102 Coolant temperature after e...

Page 57: ...05 205 Charge air coolant engine side R Liters 50 50 50 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 390 390 390 Oil change quantity max standard...

Page 58: ...gher than specified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Li...

Page 59: ...2 2 2 Air exhaust gas ID 1 2 3 Charge air pressure before cylinder DL R bar abs 3 0 3 1 3 3 Charge air pressure before cylinder BL R bar abs 3 1 3 3 3 5 Coolant system HT circuit ID 1 2 3 Coolant tem...

Page 60: ...oolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 80 80 80 Firing speed to R rpm 120 120 120 Capacities ID 1 2 3 Engine coolant capacity engine side without cooling equ...

Page 61: ...power level LW ISO 6798 3 dB A tolerance R dB A 128 128 129 Engine surface noise with attenuated intake noise fil ter DL power sound power level LW ISO 6798 2 dB A tolerance R dB A 125 125 126 MS1500...

Page 62: ...an specified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed ra...

Page 63: ...2 2 2 Air exhaust gas ID 1 2 3 Charge air pressure before cylinder DL R bar abs 2 5 2 7 2 9 Charge air pressure before cylinder BL R bar abs 2 7 2 9 3 2 Coolant system HT circuit ID 1 2 3 Coolant tem...

Page 64: ...oolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 80 80 80 Firing speed to R rpm 120 120 120 Capacities ID 1 2 3 Engine coolant capacity engine side without cooling equ...

Page 65: ...d power level LW ISO 6798 3dB A tolerance R dB A 129 129 127 Engine surface noise with attenuated intake noise fil ter DL power sound power level LW ISO 6798 2dB A tolerance R dB A 125 125 124 MS15009...

Page 66: ...5 ID Product type Application Engine speed Listed rated power 1 20V4000G23 Power generation 3D standby power fuel stop power IFN 1500 rpm 50 Hz 2420 kW 3245 bhp Ref 25 C 55 C 6 ETC 6 Optimized fuel c...

Page 67: ...re mm 170 170 170 170 170 170 Stroke mm 210 210 210 210 210 210 Displacement cylinder Liters 4 77 4 77 4 77 4 77 4 77 4 77 Displacement total Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio 16...

Page 68: ...re engine from R C 88 88 88 88 88 88 Lube oil operating tem perature before engine to R C 98 98 98 98 98 98 Lube oil temperature be fore engine limit 1 L C 99 99 99 99 99 99 Lube oil temperature be fo...

Page 69: ...nitial filling standard oil sys tem option max oper ating inclinations R Liters 390 390 390 390 390 390 Oil change quantity max standard oil system op tion max operating incli nations R Liters 340 340...

Page 70: ...evel LW ISO 6798 3dB A tolerance R dB A 126 128 127 129 129 131 Engine surface noise with attenuated intake noise filter BL sound power level LW ISO 6798 2dB A tolerance R dB A 123 125 125 125 126 127...

Page 71: ...ust be higher than specified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine...

Page 72: ...of exhaust valves per cylinder 2 2 2 Air exhaust gas ID 1 2 3 Charge air pressure before cylinder BL R bar abs 3 1 3 3 3 6 Coolant system HT circuit ID 1 2 3 Coolant temperature at engine connection o...

Page 73: ...Coolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 80 80 80 Firing speed to R rpm 120 120 120 Capacities ID 1 2 3 Engine coolant capacity engine side without cooling s...

Page 74: ...power level LW ISO 6798 3 dB A tolerance R dB A 128 129 131 Engine surface noise with attenuated intake noise fil ter BL sound power level LW ISO 6798 2 dB A tolerance R dB A 125 126 127 72 Technical...

Page 75: ...ently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated power 1 20V4000G23 Power generation 3D standby power fuel stop power IFN...

Page 76: ...ore mm 170 170 170 170 170 Stroke mm 210 210 210 210 210 Displacement cylinder Liters 4 77 4 77 4 77 4 77 4 77 Displacement total Liters 95 4 95 4 95 4 95 4 95 4 Compression ratio 16 4 16 4 16 4 16 4...

Page 77: ...98 98 Lube oil temperature before engine limit 1 L C 99 99 99 99 99 Lube oil temperature before engine limit 2 L C 101 101 101 101 101 Lube oil operating pressure upstream of engine from R bar 4 3 4...

Page 78: ...apacity at dipstick mark min standard oil system option max oper ating inclinations L Liters 268 268 268 268 268 Oil pan capacity at dipstick mark max standard oil system option max oper ating inclina...

Page 79: ...lue must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated power 1 20V4000G23 Power...

Page 80: ...e before cylinder BL R bar abs 2 5 2 9 3 2 Coolant system HT circuit ID 1 2 3 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 100 Coolant temperature after engine limi...

Page 81: ...ooling equipment r Liter 205 205 205 Charge air coolant engine side r Liter 50 50 Engine oil capacity initial filling standard oil system Option max operating inclinations r Liter 390 390 390 Oil chan...

Page 82: ...lue Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated power 1 20V...

Page 83: ...ant system HT circuit ID 1 2 3 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 100 Coolant temperature after engine limit 1 L C 102 102 102 Coolant temperature after e...

Page 84: ...side R Liters 50 50 50 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 390 390 390 Oil change quantity max standard oil system op tion max operating...

Page 85: ...specified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rate...

Page 86: ...2 2 2 Air exhaust gas ID 1 2 3 Charge air pressure before cylinder DL R bar abs 2 5 2 7 2 9 Charge air pressure before cylinder BL R bar abs 2 7 2 9 3 2 Coolant system HT circuit ID 1 2 3 Coolant tem...

Page 87: ...oolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 80 80 80 Firing speed to R rpm 120 120 120 Capacities ID 1 2 3 Engine coolant capacity engine side without cooling equ...

Page 88: ...d power level LW ISO 6798 3dB A tolerance R dB A 129 129 127 Engine surface noise with attenuated intake noise fil ter DL power sound power level LW ISO 6798 2dB A tolerance R dB A 125 125 124 86 Tech...

Page 89: ...type Application Engine speed Listed rated power 1 20V4000G23 Power generation 3F standby operation mode unlimited ICXN 1500 1 min 50 Hz 2200 kW 2950 bhp Ref 25 C 55 C 6 ETC 1 Optimized fuel con sumpt...

Page 90: ...mm 170 170 170 170 170 170 Stroke mm 210 210 210 210 210 210 Displacement cylinder Liters 4 77 4 77 4 77 4 77 4 77 4 77 Displacement total Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio 16 4...

Page 91: ...be oil operating tem perature before engine from R C 88 88 88 88 88 88 Lube oil operating tem perature before engine to R C 98 98 98 98 98 98 Lube oil temperature be fore engine limit 1 L C 99 99 99 9...

Page 92: ...itial filling standard oil sys tem option max oper ating inclinations R Liters 390 390 390 390 390 390 Oil change quantity max standard oil system op tion max operating incli nations R Liters 340 340...

Page 93: ...evel LW ISO 6798 3dB A tolerance R dB A 124 127 126 127 128 129 Engine surface noise with attenuated intake noise filter DL power sound power level LW ISO 6798 2dB A tolerance R dB A 123 125 123 124 1...

Page 94: ...ified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated pow...

Page 95: ...ant system HT circuit ID 1 2 3 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 100 Coolant temperature after engine limit 1 L C 102 102 102 Coolant temperature after e...

Page 96: ...05 205 Charge air coolant engine side R Liters 50 50 50 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 390 390 390 Oil change quantity max standard...

Page 97: ...be higher than specified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine sp...

Page 98: ...2 2 2 Air exhaust gas ID 1 2 3 Charge air pressure before cylinder DL R bar abs 3 0 3 1 3 3 Charge air pressure before cylinder BL R bar abs 3 1 3 3 3 5 Coolant system HT circuit ID 1 2 3 Coolant tem...

Page 99: ...Coolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 80 80 80 Firing speed to R rpm 120 120 120 Capacities ID 1 2 3 Engine coolant capacity engine side without cooling eq...

Page 100: ...power level LW ISO 6798 3 dB A tolerance R dB A 128 128 129 Engine surface noise with attenuated intake noise fil ter DL power sound power level LW ISO 6798 2 dB A tolerance R dB A 125 125 126 98 Tec...

Page 101: ...her than specified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Lis...

Page 102: ...2 2 2 Air exhaust gas ID 1 2 3 Charge air pressure before cylinder DL R bar abs 2 5 2 7 2 9 Charge air pressure before cylinder BL R bar abs 2 7 2 9 3 2 Coolant system HT circuit ID 1 2 3 Coolant temp...

Page 103: ...oolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 80 80 80 Firing speed to R rpm 120 120 120 Capacities ID 1 2 3 Engine coolant capacity engine side without cooling equ...

Page 104: ...power level LW ISO 6798 3dB A tolerance R dB A 129 129 127 Engine surface noise with attenuated intake noise fil ter DL power sound power level LW ISO 6798 2dB A tolerance R dB A 125 125 124 102 Tech...

Page 105: ...plication Engine speed Listed rated power 1 20V4000G23 Power generation 3G continuous opera tion time limited ICXN 1500 1 min 50 Hz 2200 kW 2950 bhp Ref 25 C 55 C 6 ETC 1 Optimized fuel con sumption 2...

Page 106: ...mm 170 170 170 170 170 170 Stroke mm 210 210 210 210 210 210 Displacement cylinder Liters 4 77 4 77 4 77 4 77 4 77 4 77 Displacement total Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio 16 4 1...

Page 107: ...be oil operating tem perature before engine from R C 88 88 88 88 88 88 Lube oil operating tem perature before engine to R C 98 98 98 98 98 98 Lube oil temperature be fore engine limit 1 L C 99 99 99 9...

Page 108: ...tial filling standard oil sys tem option max oper ating inclinations R Liters 390 390 390 390 390 390 Oil change quantity max standard oil system op tion max operating incli nations R Liters 340 340 3...

Page 109: ...evel LW ISO 6798 3dB A tolerance R dB A 124 127 126 127 128 129 Engine surface noise with attenuated intake noise filter DL power sound power level LW ISO 6798 2dB A tolerance R dB A 123 125 123 124 1...

Page 110: ...d value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated power 1...

Page 111: ...nt system HT circuit ID 1 2 3 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 100 Coolant temperature after engine limit 1 L C 102 102 102 Coolant temperature after en...

Page 112: ...05 205 Charge air coolant engine side R Liters 50 50 50 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 390 390 390 Oil change quantity max standard...

Page 113: ...e Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed rated power 1 20V40...

Page 114: ...nt system HT circuit ID 1 2 3 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 100 Coolant temperature after engine limit 1 L C 102 102 102 Coolant temperature after en...

Page 115: ...5 205 Charge air coolant engine side R Liters 50 50 50 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 390 390 390 Oil change quantity max standard o...

Page 116: ...than specified value Actual value must be lower than specified value Insufficiently assured value tolerance 10 Insufficiently assured value tolerance 5 ID Product type Application Engine speed Listed...

Page 117: ...2 2 2 Air exhaust gas ID 1 2 3 Charge air pressure before cylinder DL R bar abs 2 5 2 7 2 9 Charge air pressure before cylinder BL R bar abs 2 7 2 9 3 2 Coolant system HT circuit ID 1 2 3 Coolant temp...

Page 118: ...oolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 80 80 80 Firing speed to R rpm 120 120 120 Capacities ID 1 2 3 Engine coolant capacity engine side without cooling equ...

Page 119: ...power level LW ISO 6798 3dB A tolerance R dB A 129 129 127 Engine surface noise with attenuated intake noise fil ter DL power sound power level LW ISO 6798 2dB A tolerance R dB A 125 125 124 MS150093...

Page 120: ...5 20 Final compression pressure Final compression pressure At 120 rpm 24 bar to 28 bar 118 Technical Data MS150093 05E 2018 12 TIM ID 0000002820 002...

Page 121: ...ng order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V 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 B8 MS1500...

Page 122: ...5 22 Engine Main dimensions Engine Main dimensions Engine model Length A Width B Height C 20V4000Gx3 3560 mm 1671 mm 2163 mm 120 Technical Data MS150093 05E 2018 12 TIM ID 0000019845 002...

Page 123: ...ilter Fill with fuel Page 227 Page 229 Fuel prefilter pressure gauge Check low pressure indicator on switchable fuel prefilter Page 226 Coolant circuit If engine is out of service for more than one ye...

Page 124: ...circuit Check engine coolant level Page 252 Check charge air coolant level Page 274 Coolant circuit Heat engine coolant with coolant preheater Fuel prefilter Drain water Page 221 Page 223 Monitoring s...

Page 125: ...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 126: ...fied 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 a...

Page 127: ...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 128: ...s 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 applica...

Page 129: ...ratures are not exceeded no restrictions in en gine operation are required Check for abnormal running noises and vibration Fuel prefilter Check reading on differential pressure gauge to ensure that ma...

Page 130: ...mission 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 131: ...o 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 con...

Page 132: ...After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping 130 Operation MS150093 05E 2018 12 TIM ID 0000002285 006...

Page 133: ...rom 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 stop...

Page 134: ...e engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION 132 Operation MS150093 05E 2018 12...

Page 135: ...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 136: ...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 137: ...nspection manufacturer s documentation Engine governor Plug in connections loose u Check plug in connections Page 289 Running gear blocked engine cannot be barred manually u Contact Service Engine tur...

Page 138: ...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 139: ...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 140: ...1 Limit value 1 Cause Corrective action Fuel temperature too high u Contact Service 004 SS T Fuel ZKP Number 2 0122 932 Limit value 2 Cause Corrective action Fuel temperature too high Engine stop u Co...

Page 141: ...l top up as necessary Page 242 016 SS P Lube Oil ZKP Number 2 0100 922 Limit value 2 Cause Corrective action Lube oil pressure too low Automatic engine shutdown u Engine must not be started risk of en...

Page 142: ...ve action Coolant level too low u Check coolant level in expansion tank Page 252 025 HI P Diff Lube Oil ZKP Number 2 0154 931 Limit value 1 Cause Corrective action Oil filter differential pressure too...

Page 143: ...ocharger too high u Contact Service 032 SS ETC1 Overspeed ZKP Number 2 3012 932 Limit value 2 Cause Corrective action Speed of primary turbocharger too high 1 Automatic power reduction by Engine Contr...

Page 144: ...on Synchro fault between primary turbocharger and one of the secondary turbochargers 1 Reduce power 2 Contact Service 039 AL ETC2 Cutin Failure ZKP Number 1 8004 204 Cause Corrective action ETC 2 fail...

Page 145: ...sure too low Engine stop or reduced injection quantity 1 Automatic engine shutdown 2 Check coolant level Page 252 059 SS T Coolant L3 ZKP Number 20 120 933 Limit value 3 Cause Corrective action Coolan...

Page 146: ...nlet pressure too low 1 Check fuel lines for leaks 2 Drain fuel prefilter Page 221 Page 223 3 Replace filter element of fuel prefilter Page 227 Page 229 4 Replace fuel filter Page 219 066 SS P Fuel ZK...

Page 147: ...KP Number 2 0104 931 Cause Corrective action Rail pressure set value DBR fuel limitation start of injection readjusted towards late Suction restrictor of HP fuel block jamming or HP fuel control block...

Page 148: ...Speed Not Reached ZKP Number 2 1090 924 Cause Corrective action Runup speed was not attained u Contact Service 092 SS Starter Speed Not Reached ZKP Number 2 1090 923 Cause Corrective action Starter sp...

Page 149: ...mption meter faulty u Contact Service 104 AL Eng Hours Counter Defect ZKP Number 1 8004 623 Cause Corrective action Hour meter faulty u Contact Service 118 LO ECU Power Supply Voltage ZKP Number 2 014...

Page 150: ...ECU ZKP Number 2 0132 921 Limit value 1 Cause Corrective action Temperature in ECS too high 1 Reduce power 2 Improve engine room ventilation 141 AL Power too high ZKP Number 11 088 007 Cause Correcti...

Page 151: ...se Corrective action Connection to a node on CAN bus 1 failed u Contact Service 181 AL CAN2 Node Lost ZKP Number 2 0500 681 Cause Corrective action Connection to a node on CAN bus 2 failed u Contact S...

Page 152: ...ding improve shielding as necessary 3 Contact Service 188 AL CAN2 Bus Off ZKP Number 2 0500 688 Cause Corrective action CAN controller 2 is in Bus Off status automatic changeover to CAN 1 Short circui...

Page 153: ...bling B9 replace as necessary Error cleared after restarting the engine 204 SD Level Lube Oil ZKP Number 1 8004 602 Cause Corrective action Lube oil level sensor faulty Short circuit or wire break u C...

Page 154: ...ary Error cleared after restarting the engine 212 SD P Coolant ZKP Number 1 8004 564 Cause Corrective action Coolant pressure sensor faulty Short circuit or wire break u Check sensor and cabling B16 r...

Page 155: ...cabling B3 replace as necessary Error cleared after restarting the engine 220 SD Coolant Level ZKP Number 1 8004 584 Cause Corrective action Coolant level sensor faulty Short circuit or wire break u...

Page 156: ...nsor and cabling B5 3 replace as necessary 229 AL Stop Camshaft Sensor Defect ZKP Number 1 8004 562 Cause Corrective action Engine stop due to camshaft sensor fault and a previous crankshaft sensor fa...

Page 157: ...ination with the alarm SD P Fuel before Filter or SD P Fuel after Filter u Observe additional message 240 SD P Fuel ZKP Number 1 8004 565 Cause Corrective action Fuel pressure sensor faulty Short circ...

Page 158: ...break 1 Check cabling 2 Check speed setpoint 268 SD Spinning Value ZKP Number 28 006 591 Cause Corrective action Analog skid signal faulty Short circuit or wire break u Check sensor and cabling repla...

Page 159: ...ctive action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 210 304...

Page 160: ...ctive action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 210 309...

Page 161: ...ctive action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 210 314...

Page 162: ...ctive action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 210 319...

Page 163: ...der A4 ZKP Number 1 8004 523 Cause Corrective action Short circuit in injector cabling to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 325 AL Wiring Cylinder A5 ZKP Number 1 8004...

Page 164: ...der B1 ZKP Number 1 8004 530 Cause Corrective action Short circuit in injector cabling to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 332 AL Wiring Cylinder B2 ZKP Number 1 8004...

Page 165: ...er B8 ZKP Number 1 8004 537 Cause Corrective action Short circuit in injector cabling to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 339 AL Wiring Cylinder B9 ZKP Number 1 8004...

Page 166: ...inder A5 ZKP Number 1 8004 544 Cause Corrective action Open circuit in injector wiring to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 346 AL Open Load Cylinder A6 ZKP Number 1 8...

Page 167: ...linder B2 ZKP Number 1 8004 551 Cause Corrective action Open circuit in injector wiring to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 353 AL Open Load Cylinder B3 ZKP Number 1...

Page 168: ...Contact Service 359 AL Open Load Cylinder B9 ZKP Number 1 8004 558 Cause Corrective action Open circuit in injector wiring to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 360 AL...

Page 169: ...021 Power Stage Failure Stop engine is set engine is additionally stopped in this case Short circuit of injector positive connection to ground of one or more injectors Short circuit of the negative i...

Page 170: ...e TOP 1 u Check cabling to plant 382 AL Wiring TOP 2 ZKP Number 2 8006 639 Cause Corrective action Short circuit or wire break at transistor output 2 plant side TOP 2 u Check cabling to plant 383 AL W...

Page 171: ...ant temperature reading too high Engine stop 1 Check wiring and sensor 2 Contact Service 394 LO P Lube Oil Red ZKP Number 2 0112 921 Limit value 1 Cause Corrective action Redundant lube oil pressure r...

Page 172: ...arget device input 3 Contact Service 402 AL Open Load Digital Input 3 ZKP Number 2 8006 627 Cause Corrective action Line disruption on digital input 3 Cabling faulty or no resistance over switch 1 Che...

Page 173: ...isruption on digital input 8 Cabling faulty or no resistance over switch 1 Check cabling 2 Check target device input 3 Contact Service 408 AL Open Load Emerg Stop Input ESI ZKP Number 2 8006 633 Cause...

Page 174: ...efilter ZKP Number 2 0156 931 Limit value 1 Cause Corrective action Water level in fuel prefilter too high u Drain water Page 221 Page 223 415 LO P Coolant Intercooler ZKP Number 2 0107 921 Limit valu...

Page 175: ...ated limit value 1 depending on configuration u Determine cause of limit value violation and rectify fault 421 AL L2 Aux 1 ZKP Number 2 0160 922 Limit value 2 Cause Corrective action Input signal of A...

Page 176: ...1 P Aux 1 ZKP Number 2 0110 921 Limit value 1 Cause Corrective action Pressure signal of Aux 1 has violated limit value 1 depending on configuration u Determine cause of limit value violation and rect...

Page 177: ...ion Input signal for initial final torque faulty Short circuit or wire break u Check signal transmitter and cabling replace as necessary Error cleared after restarting the engine 454 SS Power Reductio...

Page 178: ...aust EMU ZKP Number 2 8006 653 Limit value 1 Cause Corrective action EMU exhaust gas temperature value too low 1 Check cabling 2 Contact Service 462 HI T Coolant EMU ZKP Number 2 8006 654 Limit value...

Page 179: ...ng replace as necessary Error cleared after restarting the engine 470 SD T ECU ZKP Number 1 8004 587 Cause Corrective action Temperature sensor for ECU faulty Short circuit or wire break u Check senso...

Page 180: ...tdown 476 AL Crash Rec Init Error ZKP Number 1 8010 007 Cause Corrective action Initialization error of crash recorder u Check setting with DiaSys 478 AL Comb Alarm Yel Plant ZKP Number 2 8006 001 Cau...

Page 181: ...it value 1 Cause Corrective action Exhaust gas temperature C side too high 1 Reduce power 2 Contact Service 485 SS T Exhaust C ZKP Number 20 133 932 Limit value 2 Cause Corrective action Exhaust gas t...

Page 182: ...ive action Speed of the third secondary turbocharger too high u Reduce power 491 SS ETC4 Overspeed ZKP Number 23 015 932 Limit value 2 Cause Corrective action Speed of the third secondary turbocharger...

Page 183: ...OM Alternator ZKP Number 14 500 902 Cause Corrective action A line interruption was detected at the battery charging connection for the POM u Check connection between POM and battery charging generato...

Page 184: ...e engaged Start is canceled when the number of automatic start attempts from PR 2 1090 134 Number of Start Attempts has been used up Check CPM starter and cabling 1 Repeat starting attempt 2 Check CPM...

Page 185: ...uit or wire break u Check sensor and cabling replace as necessary 526 SD T Coolant R2 ZKP Number 18 004 639 Cause Corrective action Redundant coolant pressure sensor faulty Short circuit or wire break...

Page 186: ...3 Cause Corrective action This alarm is activated when the system configuration was changed e g because the ECU or SAM was replaced u Fault remains active until changes are revoked or data have been t...

Page 187: ...FDH feature that results in a change of engine parameters This fault remains active even after switching off and back on until a valid enabling code is entered via the SAM display and key controls Th...

Page 188: ...Cause Corrective action MD forced idle demand node failure node 3 4 or 5 u 580 AL MD CAN Speed Limitation ZKP Number 21 063 513 Cause Corrective action MD speed limitation demand node failure node 3 4...

Page 189: ...Page 235 W1006 Replace fuel injectors Page 210 W1008 X Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 246 W1009 X Measure thickness of oil...

Page 190: ...8 X Check preheater for leaks and operation Page 263 W1864 X Check and clean oil indicator filter Page 247 W4172 X Check general condition of rubber mounts visual inspection Page 286 Table 2 Maintenan...

Page 191: ...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 192: ...istance 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 193: ...place and all tools are removed from the engine Turning engine on starting system 1 Release latch of connector X4 2 Remove connector from Engine Control Unit 3 Turn engine in unloaded condition Press...

Page 194: ...soning 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 hearin...

Page 195: ...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 196: ...pending 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 P...

Page 197: ...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 198: ...s are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspection...

Page 199: ...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 Avo...

Page 200: ...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 inse...

Page 201: ...mm Y20000918 1 Measuring jig 2 optional Y4350010 1 Preparatory steps 1 Remove cylinder head covers Page 207 2 Remove guard plate and install barring tool Page 189 3 Turn crankshaft in direction of ro...

Page 202: ...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 Tig...

Page 203: ...sured value is 95 8 mm 5 Install valve bridge 6 Adjust valve clearance Page 204 Step 2 optional Measure valve protrusion at the valve stem with measuring jig 2 1 Check TDC position of piston in cylind...

Page 204: ...ricant 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 personnel...

Page 205: ...rts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 207 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting...

Page 206: ...320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Ratchet bit F30027341 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 207 2 Install barring device Page 189 Note Pointer 1 is locate...

Page 207: ...e 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 va...

Page 208: ...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 209: ...4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surface 2 Check O ring 6 for damage replace as necessary 3 Coa...

Page 210: ...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 211: ...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 212: ...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 211 210 Injector MS150093 05E 20...

Page 213: ...cial protection WARNING 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 inha...

Page 214: ...engine 3 Remove cylinder head cover Page 207 Removing injector 1 Disconnect cable connector at injector ar rowed Note Observe system pressure 2 Slowly release union on HP line 4 3 Remove HP fuel line...

Page 215: ...hamber must only be used once 10 Dispose of sealing ring 4 and injector 11 Clean all mating and sealing surfaces 12 Cover all connections and bores or seal with suitable plugs Installing new injector...

Page 216: ...ring 4 is correctly seated 7 Insert injector into cylinder head ensuring that the HP line connection is correctly aligned 8 Press in injector with installation removal de vice 9 Remove installation re...

Page 217: ...Nm Note Do not hold in place by hand 6 Tighten HP line 5 to specified final tightening torque in the same order 1 Adapter 4 2 Rail 6 Name Size Type Lubricant Value Standard Union nut thrust screw Tigh...

Page 218: ...emissions certification of the engine 2 Reset drift compensation CDC with Dia Sys Dialog system DiaSys E531920 If DiaSys is not available con tact Service Final steps 1 Install cylinder head cover Pa...

Page 219: ...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 c...

Page 220: ...7 Turn handle 2 clockwise to screw it in 8 Verify that fuel priming pump is locked Handle 2 must be tightened firmly 218 Fuel System MS150093 05E 2018 12 TIM ID 0000081190 001...

Page 221: ...edia e g fuel or ether Risk of 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...

Page 222: ...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 223: ...th 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 i...

Page 224: ...11 Vent fuel prefilter Page 232 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 suita...

Page 225: ...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 226: ...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 227: ...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 228: ...ading 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 229 when t...

Page 229: ...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 c...

Page 230: ...lement 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 filte...

Page 231: ...halation 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 232: ...s 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 233: ...ble 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 234: ...ING 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 h...

Page 235: ...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 236: ...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 237: ...Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 237 2 Reset signal ring of service indicator Page 23...

Page 238: ...l 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 235 236 Air Filt...

Page 239: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Page 240: ...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 241: ...sure that there are no persons in the engine s danger zone WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable hearing protection Air starter Manual...

Page 242: ...ive gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining engine oil at drain plug s on oil pan 1 Provide a suitable container...

Page 243: ...ain plug s with new sealing ring 5 Use torque wrench to tighten drain plugs 2 and 3 to specified tightening torque Name Size Type Lubricant Value Standard Screw M26 x 1 5 Tightening torque Engine oil...

Page 244: ...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 245: ...inhale oil 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 i...

Page 246: ...he oil 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...

Page 247: ...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 248: ...ive gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing engine oil filter 1 Remove engine oil filter using the filter wrench 2 Clean the sealing surface on the con...

Page 249: ...tective gloves and goggles safety mask 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 r...

Page 250: ...er 6 with engine oil and install strainer 6 2 Coat O ring 3 with engine oil and install in filter housing 3 Install spring 4 4 Fill housing with new engine oil 5 Install cover 2 and secure with screws...

Page 251: ...ged Replace Spring Damaged Replace O ring Damaged Replace Installing strainer 1 Coat square section ring on basket strainer 5 with engine oil and install basket strainer 5 2 Coat O ring 3 with engine...

Page 252: ...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 253: ...al 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 speci...

Page 254: ...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 256 3 Check and clean bre...

Page 255: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 254 2 Fill with engine coolant Page 256 MS150093 05E 2018 12 Coolant Circuit General High Tem...

Page 256: ...es 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 co...

Page 257: ...2 Close all other open drain points 3 Position valve cover on filler neck and close MS150093 05E 2018 12 Coolant Circuit General High Temperature Circuit 255 TIM ID 0000000960 005...

Page 258: ...ct 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 goggles safety mask Wipe...

Page 259: ...ing torque 12 Nm 7 Check satisfactory condition of valve cover on coolant expansion tank clean sealing faces if required 8 Fit valve cover and close it 9 Start engine Page 123 10 After 10 seconds of r...

Page 260: ...9 8 Turn valve cover on coolant expansion tank counterclockwise to the first stop and release pressure 9 Turn valve cover counterclockwise and re move 10 Check coolant level Page 252 and top up with c...

Page 261: ...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 262: ...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 263: ...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 264: ...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 265: ...rotection 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 Co...

Page 266: ...nnected Replacing solenoid switch u Replace solenoid switch Page 265 Cleaning heating element and replacing gasket u Clean heating element and housing and check Page 267 Replacing thermostat u Replace...

Page 267: ...ury 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 begin...

Page 268: ...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 269: ...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 270: ...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 lo...

Page 271: ...Final steps 1 Connect preheater power sources 2 Switch on preheater MS150093 05E 2018 12 Coolant Circuit General High Temperature Circuit 269 TIM ID 0000081913 004...

Page 272: ...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 273: ...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 Remove...

Page 274: ...Final steps 1 Connect preheater to power supply 2 Switch on preheater 272 Coolant Circuit General High Temperature Circuit MS150093 05E 2018 12 TIM ID 0000081762 002...

Page 275: ...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 276: ...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 277: ...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 279...

Page 278: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 277 2 Fill with charge air coolant Page 279 276 Low Temperature Circuit MS15...

Page 279: ...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 280: ...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 281: ...ding 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 282: ...ealing faces if required 8 Position valve cover on filler neck and close 9 Start engine Page 123 10 After 10 seconds of running the engine without load shut down the engine Page 129 11 Turn valve cove...

Page 283: ...oad shut down the engine Page 129 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 leve...

Page 284: ...Wear suitable hearing protection Charge air coolant pump Re lief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 129 and disable engine start observe general safety in...

Page 285: ...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 286: ...0 1 WARNING Belt 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 ha...

Page 287: ...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 stop 4 Tighten sc...

Page 288: ...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 289: ...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 h...

Page 290: ...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 291: ...The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seatin...

Page 292: ...ine governor from engine 1 Note or mark assignment of cables and plugs 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Inst...

Page 293: ...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 294: ...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 295: ...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 Syste...

Page 296: ...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 297: ...ngine Barring manually Page 189 Qty Used in 1 9 2 1 Cylinder liner Endoscopic examination Page 193 Crossbeam Part No T80091826 Qty Used in 1 3 1 Transport Page 20 Crossbeam Part No T80092360 Qty Used...

Page 298: ...linder liner Endoscopic examination Page 193 Feeler gage Part No Y20098771 Qty Used in 1 9 4 3 Valve clearance Check and adjustment Page 204 Filter wrench Part No F30379104 Qty Used in 1 9 8 1 Fuel fi...

Page 299: ...cleaner Part No Qty Used in 1 6 13 Plant Cleaning Page 134 Installation removal jig Part No F6789889 Qty Used in 1 9 6 2 Injector Removal and installation Page 211 Measuring jig 1 Part No Y4350009 Qt...

Page 300: ...tion Page 211 MTU test kit Part No F6798833 Qty Used in 1 9 13 3 Engine oil Sample extraction and analysis Page 243 Qty Used in 1 9 15 6 Engine coolant Sample extraction and analysis Page 260 Oil filt...

Page 301: ...sed in 1 9 18 1 Battery charging generator Drive belt tension ad justment Page 284 Qty Used in 1 9 18 2 Battery charging generator drive Drive belt re placement Page 285 Ratchet bit Part No F30027341...

Page 302: ...193 Socket wrench 24 mm Part No F30039526 Qty Used in 1 9 4 3 Valve clearance Check and adjustment Page 204 Torque screwdriver 1 5 Nm Part No F30452774 Qty Used in 1 9 6 2 Injector Removal and install...

Page 303: ...18 1 Battery charging generator Drive belt tension ad justment Page 284 Qty Used in 1 9 18 2 Battery charging generator drive Drive belt re placement Page 285 Torque wrench 10 60 Nm Part No F30510423...

Page 304: ...gal oil filter Cleaning and filter sleeve re placement Page 250 Qty Used in 1 9 18 1 Battery charging generator Drive belt tension ad justment Page 284 Qty Used in 1 9 18 2 Battery charging generator...

Page 305: ...ment 273 Crankcase breather Filter element replacement 198 Oil mist separator Replacement 197 Crankshaft Transport locking device Installation removal 23 Cylinder Designation 39 Cylinder head cover In...

Page 306: ...ssure indicator check Switchable 226 Pressure ratios 220 Venting 232 Fuel system Venting 217 H Heating element Check Preheater 267 Hotline 294 Housing Check Preheater 267 HP pump Filling with engine o...

Page 307: ...I 60 NEA Singapore for ORDE 60 Optimized exhaust gas emission TA Luft 53 Optimized fuel consumption 48 Continuous operation 3G China Nonroad Mobile Machinery Stage III 114 NEA Singapore for ORDE 114 O...

Page 308: ...ized exhaust gas emission 87 Pump Engine coolant Relief bore check 259 Putting the engine generator set into operation after ex tended out of service periods 3 months 121 Putting the engine generator...

Page 309: ...Valve cover Replacement 273 Valve gear Lubrication 203 Valve protrusion Measurement 199 W Warning notices standards 19 MS150093 05E 2018 12 Index 307 DCL ID 0000005896 007...

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MTU 20V4000G*3 series, Operating Instructions Manual

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