MTU 20V4000G*3 series, Operating Instructions Manual

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6.2 Putting into operation after scheduled out-
of-service-period 122
6.3 Starting the engine in manual mode (test
run) 123
6.4 Re-starting the engine following an
automatic safety shutdown 124
6.5 Safety system – Override 125
6.6 Emergency engine start (Override mode) 126
6.7 Operational monitoring 127
6.8 Emission label – Check 128
6.9 Engine – Stopping in Manual mode (test
run) 129
6.10 Engine – Emergency stop 131
6.11 After stopping the engine – Engine remains
ready for operation 132
6.12 After stopping the engine – Putting the
engine out of operation 133
6.13 Plant – Cleaning 134
7 Troubleshooting
7.1 Troubleshooting 135
7.2 Engine Control Unit ADEC (ECU 7) for
Series 4000 genset engines – Fault
messages
138
8 Maintenance
8.1 Maintenance task reference table [QL1] 187
9 Task Description
9.1 Engine 189
9.1.1 Engine – Barring manually 189
9.1.2 Engine – Turning on starting system 191
9.1.3 Engine – Test run 192
9.2 Cylinder Liner 193
9.2.1 Cylinder liner – Endoscopic examination 193
9.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 195
9.3 Crankcase Breather 197
9.3.1 Crankcase breather – Oil mist separator
replacement 197
9.3.2 Crankcase breather – Filter element
replacement 198
9.4 Valve Drive 199
9.4.1 Valve protrusion – Measurement 199
9.4.2 Valve gear – Lubrication 203
9.4.3 Valve clearance – Check and adjustment 204
9.4.4 Cylinder head cover – Removal and
installation 207
9.5 Injection Pump / HP Pump 208
9.5.1 HP fuel pump – Filling with engine oil 208
9.6 Injector 210
9.6.1 Injector – Replacement 210
9.6.2 Injector – Removal and installation 211
9.7 Fuel 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 prefilter (switchable) – Draining 223
9.8.5 Fuel prefilter (switchable) – Low pressure
indicator check 226
9.8.6 Fuel prefilter (non-switchable) – Filter element
replacement 227
9.8.7 Fuel prefilter (switchable) – Filter element
replacement 229
9.8.8 Fuel prefilter – Venting 232
9.9 Charge-Air Cooling 234
9.9.1 Intercooler – Checking condensate drain for
coolant leak and obstruction 234
9.10 Air Filter 235
9.10.1 Air filter ‒ Replacement 235
9.10.2 Air filter – Check 236
9.10.3 Air filter – Removal and installation 237
9.11 Air Intake 238
9.11.1 Contamination indicator – Signal ring position
check 238
9.12 Starting Equipment 239
9.12.1 Air starter – Manual operation 239
9.13 Lube Oil System, Lube Oil Circuit 240
9.13.1 Engine oil – Change 240
9.13.2 Engine oil level – Check 242
9.13.3 Engine oil – Sample extraction and analysis 243
9.13.4 Oil priming pump – Visual inspection 245
9.14 Oil Filtration / Cooling 246
9.14.1 Engine oil filter – Replacement 246
9.14.2 Oil indicator filter – Cleaning and check 247
9.14.3 Centrifugal oil filter – Cleaning and filter
sleeve replacement 250
9.15 Coolant Circuit, General, High-Temperature
Circuit 252
9.15.1 Engine coolant – Level check 252
9.15.2 Engine coolant – Change 253
9.15.3 Engine coolant – Draining 254
9.15.4 Engine coolant – Filling 256
9.15.5 Engine coolant pump – Relief bore check 259
9.15.6 Engine coolant – Sample extraction and
analysis 260
9.15.7 Preheater – Overview 262
9.15.8 Preheater – Function and leak check 263
9.15.9 Preheater – Overhaul 264
9.15.10 Preheater – Solenoid switch replacement 265
4 | Table of Contents | MS150093/05E 2018-12
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