MTU 20V4000G44F User manual

Operating Instructions
Diesel engine
20V4000Gx4F
MS15058/01E

Engine model Power Frequency Application group
20V4000G44F 140 kW/cyl. 50 Hz 3B, continuous operation, variable load, ICXN
20V4000G94F 154 kW/cyl. 50 Hz 3D, standby power, fuel stop power, IFN
Load factor: < 75 % (3B)
< 85 % (3D)
Operating hours: No limit for operating hours (3B)
500 h per year or for the duration of an emergency (3D)
Time between overhaul: 30,000 h to 24,000 h (3B)
8,000 h or 18 years (3D)
Table 1: Applicability
© 2017 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 the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Correct use of all products 6
1.3 Personnel and organizational requirements 7
1.4 Safety regulations for initial start-up and
operation 8
1.5 Safety regulations for assembly,
maintenance, and repair work 10
1.6 Fire prevention and environmental
protection, fluids and lubricants, indirect
materials 14
1.7 Standards for safety notices in the text 16
2 Transport
2.1 Transportation 17
2.2 Lifting requirements 18
2.3 Crankshaft transport locking device 19
2.4 Engine mount shipping lock 22
3 General Information
3.1 Engine side and cylinder designations 23
3.2 Engine layout 24
3.3 Sensors and actuators – Overview 25
4 Technical Data
4.1 Product data 20V4000G44F, 20V4000G94F 29
4.2 Firing order 34
4.3 Engine – Main dimensions 35
5 Operation
5.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 36
5.2 Putting into operation after scheduled out-
of-service-period 37
5.3 Engine – Starting in manual mode (test run) 38
5.4 Safety system – Override 39
5.5 Operational monitoring 40
5.6 Starting the engine in emergency situations
(override mode) 41
5.7 Engine – Stopping in manual mode (test
run) 42
5.8 Emergency engine stop 43
5.9 After stopping the engine – Engine remains
ready for operation 44
5.10 After stopping the engine – Putting the
engine out of operation 45
5.11 Plant – Cleaning 46
6 Maintenance
6.1 Maintenance task reference table [QL1] 47
7 Troubleshooting
7.1 Troubleshooting 49
7.2 Fault messages of the engine governor (ECU
9) for Series 4000 genset engines
(preliminary) 52
8 Task Description
8.1 Engine 101
8.1.1 Engine – Barring manually 101
8.1.2 Engine – Turning on starting system 103
8.1.3 Engine – Test run 104
8.2 Cylinder Liner 105
8.2.1 Cylinder liner – Endoscopic examination 105
8.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 107
8.3 Crankcase Breather 109
8.3.1 Crankcase breather – Oil mist fine separator
replacement 109
8.3.2 Crankcase breather – Filter element
replacement 110
8.4 Valve Drive 112
8.4.1 Valve protrusion – Measurement 112
8.4.2 Valve gear – Lubrication 116
8.4.3 Valve clearance – Check and adjustment 117
8.4.4 Cylinder head cover – Removal and
installation 120
8.5 Injection Pump / HP Pump 121
8.5.1 HP fuel pump – Filling with engine oil 121
8.6 Injector 123
8.6.1 Injector – Replacement 123
8.6.2 Injector – Removal and installation 124
8.7 Fuel System 130
8.7.1 Fuel system – Venting 130
8.8 Fuel Filter 132
8.8.1 Fuel filter – Replacement 132
8.8.2 Additional fuel filter – Replacement 133
8.8.3 Fuel prefilter – Pressure ratios 134
8.8.4 Fuel prefilter (non-switchable) – Draining 135
8.8.5 Fuel prefilter (switchable) – Draining 137
8.8.6 Fuel prefilter (switchable) – Contamination
indicator check 140
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8.8.7 Fuel prefilter (non-switchable) – Filter element
replacement 141
8.8.8 Fuel prefilter (switchable) – Filter element
replacement 143
8.8.9 Fuel prefilter – Venting 146
8.9 Charge-Air Cooling 148
8.9.1 Charge-air cooler – Check water drain for
coolant leakage and obstruction 148
8.10 Air Filter 149
8.10.1 Air filter ‒ Replacement 149
8.10.2 Air filter – Check 150
8.10.3 Air filter – Removal and installation 151
8.10.4 Heavy duty air filter – Filter insert and filter
element removal and installation 152
8.11 Air Intake 154
8.11.1 Service indicator – Signal ring position check 154
8.12 Lube Oil System, Lube Oil Circuit 155
8.12.1 Engine oil – Change 155
8.12.2 Engine oil level – Check 157
8.12.3 Engine oil – Sample extraction and analysis 158
8.12.4 Oil priming pump – Visual check 160
8.13 Oil Filtration / Cooling 161
8.13.1 Engine oil filter – Replacement 161
8.13.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 162
8.14 Coolant Circuit, General, High-Temperature
Circuit 164
8.14.1 Engine coolant – Level check 164
8.14.2 Engine coolant – Change 165
8.14.3 Engine coolant – Draining 166
8.14.4 Engine coolant – Filling 168
8.14.5 Engine coolant pump – Relief bore check 172
8.14.6 Engine coolant – Sample extraction and
analysis 173
8.14.7 Preheater – Overview 175
8.14.8 Preheater – Overhaul 176
8.14.9 Electrical operation of heating elements –
Check 178
8.14.10 Preheater – Function and leak-tightness check 179
8.14.11 Valve cover – Replacement 180
8.15 Low-Temperature Circuit 181
8.15.1 Charge-air coolant – Level check 181
8.15.2 Charge-air coolant – Change 182
8.15.3 Charge-air coolant – Draining 183
8.15.4 Charge-air coolant – Filling 185
8.15.5 Charge-air coolant pump – Relief bore check 188
8.16 Belt Drive 189
8.16.1 Drive belt – Condition check 189
8.17 Battery-Charging Generator 190
8.17.1 Battery-charging generator – Drive belt
tension adjustment 190
8.17.2 Battery-charging generator drive – Drive belt
replacement 191
8.18 Wiring (General) for Engine/Gearbox/Unit 192
8.18.1 Engine cabling – Check 192
8.19 Engine Mounting / Support 193
8.19.1 Engine mounting – Check 193
8.20 Accessories for (Electronic) Engine
Governor / Control System 194
8.20.1 Engine governor and connector – Cleaning 194
8.20.2 Engine governor plug connections – Check 195
8.20.3 Engine governor ECU 9 – Removal and
installation 196
9 Appendix A
9.1 Conversion tables 197
9.2 Abbreviations 202
9.3 MTU Contact/Service Partners 205
10 Appendix B
10.1 Special Tools 206
10.2 Index 214
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1 Safety
1.1 Important provisions for all products
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 6).
Replacing components with emission labels
On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Exception: Engines used exclusively in land-based, 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.
• Emission labels shall not be transferred from the replaced part to the spare part.
• The emission labels must be removed from the replaced part and destroyed.
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1.2 Correct use of all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions 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
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product must not be operated in explosive atmospheres, unless the engine fulfills the conditions for such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment
Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
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1.4 Safety regulations for initial start-up and operation
Safety regulations for initial start-up
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• The product must be free of any damage, this applies in particular to lines and cabling.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/urea solution line, sup-
ply/return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• respond by taking any necessary emergency action, e.g. emergency stop.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.
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Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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1.5 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
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 work on CaPoS, if used:
• Switch of the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Before working on the exhaust gas treatment system close the shut-off valve on the urea solution tank. Take
into consideration that the urea solution pumps continue to run for a certain period when the engine was
stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work
Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Setting down, lifting and climbing
Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down.
Ensure safe stand when performing assembly work.
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