MTU 20 V 4000 C22 Instructions d'exploitation

Operating InstructionsDiesel engine20V 4000 C22M015675/06E

1.5 Safety regulations for startup and operationSafety regulations for startupInstall the product correctly and carry out acceptance in accordance the

Checking strainerItem Findings MeasureStrainer Metallic residues •Clean•Monitor engine operation•Check strainer daily•Contact ServiceStrainer Damaged

7.14.3 Cleaning centrifugal oil filter and replacing filter sleevePreconditions☑Engine shut down and secured against being restarted.Special tools, Ma

Cleaning centrifugal oil filterand replacing filter sleeve1. Remove clamp (14).2. Undo cover screw (2) and take off cov-er (1).3. Carefully lift rotor

7.15 Coolant Circuit, General, High-Temperature Circuit7.15.1 Engine coolant – Level checkPreconditions☑Engine is stopped and starting disabled.☑MTU F

7.15.2 Engine coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantEngine coolant change1. Drain engine coolant (

7.15.3 Engine coolant – DrainingPreconditions☑Engine is stopped and starting disabled.WARNINGCoolant is hot and under pressure.Risk of injury and scal

7.15.4 Engine coolant – FillingPreconditions☑Engine is stopped and starting disabled.☑MTU Fluids and Lubricants Specifications (A001061/..) are availa

Filling with coolant using apump1. Connect appropriate pump with hose todrain valve.2. Open drain valve and pump coolant into en-gine at 0.5 bar minim

7.15.5 Engine coolant pump – Checking pressure relief portDANGERRotating and moving engine parts.Risk of crushing, danger of parts of the body being c

7.15.6 Engine coolant – Sample extraction and analysisPreconditions☑MTU Fluids and Lubricants Specifications (A001061/..) are available.Special tools,

1.6 Safety regulations for maintenance and repair workSafety regulations prior to maintenance and repair workHave maintenance or repair work carried o

7.15.7 Engine coolant filter – ReplacementPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

7.16 Low-Temperature Circuit7.16.1 Charge-air coolant – Level checkPreconditions☑Engine is stopped and starting disabled.☑MTU Fluids and Lubricants Sp

7.16.2 Charge-air coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantCharge-air coolant – Change1. Drain charge

7.16.3 Charge-air coolant – DrainingPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part N

7.16.4 Charge-air coolant system – FillingPreconditions☑Engine is stopped and starting disabled.☑MTU Fluids and Lubricants Specification (A001061/..)

Charge-air coolant system – Fill-ing1. Pour treated coolant via the filling point onthe coolant line from and to the intercoolerand via the filler nec

7.16.5 Charge-air coolant pump – Checking pressure relief portDANGERRotating and moving engine parts.Risk of crushing, danger of parts of the body bei

7.17 Engine Mounting / Support7.17.1 Engine mounting – CheckEngine mounting – CheckItem Findings ActionVisually inspect mounts. •Damage•Brittleness•De

7.18 Belt Drive7.18.1 Drive belt – Check conditionPreconditions☑Engine is stopped and starting disabled.☑Protective cover is removedItem Findings Meas

7.19 Battery-Charging Generator7.19.1 Battery-charging generator – RemovalPreconditions☑Engine is stopped and starting disabledWARNINGHeavy object.Ris

Ensure particular cleanness during maintenance and repair work on the product. After completion ofmaintenance and repair work, make sure that no loose

7.19.2 Battery-charging generator – CheckPreconditions☑Engine is stopped and starting disabled.WARNINGCompressed airRisk of injury!• Do not direct com

7.19.3 Generator – CleaningSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Cleaner (Snow-White 11-0)40460 1Cleaner (Hakupur 312)303

7.19.4 Battery-charging generator drive – Drive belt tension adjustmentPreconditions☑Engine is stopped and starting disabled.Adjusting belt tension1.

7.19.5 Battery-charging generator drive – Drive belt tension checkPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare

7.19.6 Battery-charging generator drive – Drive belt replacementPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare p

7.20 Fan Drive7.20.1 Fan drive – Drive belt tension check / adjustmentPreconditions☑Engine is stopped and starting disabled.Special tools, Material, S

Checking V-belt tension – Rock-ford S370 fan clutch1. Switch on belt tension tester.2. Hold measuring tip of belt tension testerover belt drive. Tap d

7.20.2 Fan drive – Drive belt replacementPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use P

7.21 Wiring (General) for Engine/Gearbox/Unit7.21.1 Engine wiring – CheckPreconditions☑Engine is stopped and starting disabled.Special tools, Material

7.22 Accessories for (Electronic) Engine Governor / Control System7.22.1 Engine governor and connectors – CleaningPreconditions☑Engine is stopped and

Working on electrical and electronic assembliesAlways obtain the permission of the person in charge before commencing maintenance and repair workor sw

7.22.2 Checking engine control unit plug connectionsPreconditions☑Engine shut down and starting disabled.Special tools, Material, Spare partsDesignati

8 Appendix A8.1 AbbreviationsAbbre-viationMeaning ExplanationA/D Analog/Digital Transformer: transforms sensor voltages into numer-ic valuesADEC Advan

Abbre-viationMeaning ExplanationEDM Engine Data Module Memory module for engine dataEE-PROMElectrically Erasable Programmable ReadOnly MemoryElectrica

Abbre-viationMeaning ExplanationNN Normal Null Reference surface for height above sea levelNT NiedertemperaturOEM Original Equipment ManufacturerOI Op

8.2 MTU contact persons/service partnersOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters

9 Appendix B9.1 Special ToolsAdapterPart No.: F6558528Qty.:Used in:1 7.1.1 Engine – Barring manually (→ Page 52)Allen keyPart No.: F30002817Qty.:Used

Barring gearPart No.: F6783293Qty.:Used in:1 7.1.1 Engine – Barring manually (→ Page 52)Belt tension testerPart No.: Y4345711Qty.:Used in:1 7.19.5 Bat

Cranking toolPart No.: F6555766Qty.:Used in:1 7.2.1 Endoscopically examining cylinder liner(→ Page 55)EndoscopePart No.: Y20097353Qty.:Used in:1 7.2.1

Installation and removal tool for injectorPart No.: F6790161Qty.:Used in:1 7.7.2 Injector – Removal and installation (→ Page 78)Milling cutterPart No.

RatchetPart No.: F30027340Qty.:Used in:1 7.3.1 Crankcase breather – Oil separator element re-placement, diaphragm check and replacement(→ Page 59)Ratc

1.7 Fire prevention and environmental protection, consumablefluids and materialsFire preventionRectify any fuel or oil leaks immediately. Oil or fuel

Socket wrenchPart No.: F30039518Qty.:Used in:1 7.5.2 Valve clearance – Check and adjustment(→ Page 69)Steam jet cleanerPart No.: -Qty.:Used in:1 4.7 C

Torque wrench, 10-60NmPart No.: F30452769Qty.:Used in:1 7.3.4 Crankcase breather – Filter element replacement(→ Page 63)Torque wrench, 10-60 NmPart No

Torque wrench, 6-50 NmPart No.: F30027336Qty.:Used in:1 7.3.1 Crankcase breather – Oil separator element re-placement, diaphragm check and replacement

9.2 IndexNumerics20V 4000 C22 engine data 24AAbbreviations 131After shutting down the engine 35Air filter – Replacement  90Air filter element – Cleani

Fuel filter – Replacing  84Fuel prefilter – Draining  85Fuel system – Venting  83GGenerator  – Cleaning  121Grounding device – Carbon brush check  65G

Lead• Adopt suitable measures to avoid the formation of lead dust.• Switch on extraction system.• When working with lead or pastes that contain lead,

1.8 Standards for safety notices in the textDANGERIn the event of immediate danger.Consequences: Death, serious or permanent injury.• Remedial actionW

2 General Information2.1 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS) (4).For designati

2.2 Engine layout1 Centrifugal oil filter2 Engine lifting eye3 Fan drive4 Drive belt5 Charge-air coolant inlet6 Engine coolant outlet7 Starter (A side

1 Engine lifting eye2 Cylinder head cover / cyl-inder head3 Oil heat exchanger4 Intercooler5 Flywheel6 Charge-air coolant outlet7 Engine coolant inlet

Printed in Germany© 2013 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole

1 Air supply downstream ofintercooler (A side)2 Exhaust system connec-tion (A side)3 Exhaust turbocharger (Aside)4 Combustion air inlet (Aside)5 Crank

2.3 Sensors and actuators – Overview1 B07 (T-Lube oil)2 Injectors Y39.1 to Y39.10(A side cylinders)3 B34 (P-Fuel after filter)4 B48 (P-Fuel)5 B33 (T-F

1 Injectors Y39.11 toY39.20 (B side cylinders)2 B16 (P-Coolant)3 B10 (P-Charge Air)4 B09 (T-Charge Air)1 B44 (N-Turbocharger) 2 B03 (T-Intake Air)22 |

1 B13 (N-Crankshaft)1 B50 (P-Crankcase)2 F25 (P-Lube Oil Diff.afterFilter)3 B05 (P-Lube Oil)4 B01 (N-Camshaft)5 B43 (P-Coolant Intercool-er)6 B26 (T-C

3 Technical Data3.1 20V 4000 C22 engine dataExplanation:DL Ref. value: Continuous power (CP)BL Ref. value: Fuel stop power (FSP)A Design valueG Guaran

MODEL-RELATED DATA (basic design)Number of cylinders 20V 4000Number of cylinders 20Cylinder configuration: V angle degrees 90Bore mm 165Stroke mm 210C

Number of cylinders 20V 4000Lube oil pressure before engine, alarm R bar 4.5Lube oil pressure before engine, shutdown L bar 3.9FUEL SYSTEMNumber of cy

ACOUSTICSNumber of cylinders 16Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m dis-tance, ISO 6798)R db(A) 118Engine surface no

3.2 Firing orderFiring orderNumber of cylin-dersFiring order8V A1-B4-A4-A2-B3-A3-B2-B112V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B616 V A1-A7-B4-B6-A4-B8-A2

3.3 Main engine dimensionsMain engine dimensionsLength (A) approx. 3630 mmWidth (B) approx. 1450 mmHeight (C) approx. 2252 mmM015675/06E 2013-04 | Tec

Table of Contents1 Safety1.1 Important provisions for all products 51.2 Personnel and organizational requirements 61.3 Transport 71.4 Crankshaft trans

4 Operation4.1 Putting the engine into operation after extended out-of-serviceperiods (>3 months)Preconditions☑Engine is stopped and starting disab

4.2 Putting the engine into operation after scheduled out-of-service-periodPreconditions☑Engine is stopped and starting disabled.StartupItem ActionLub

4.3 Engine – Starting in manual modePreconditions☑Engine is not under load.☑External start interlock is not activated.DANGERRotating and moving engine

4.4 Operational checksDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special care when working o

4.5 Engine – Stopping in manual modePreconditions☑Engine is not under load.☑Engine is running in manual mode.NOTICEStopping the engine when it is runn

4.6 After shutting down the enginePreconditions☑MTU Corrosion-proofing and Reproofing Regulations (A001070/..) are available.After shutting down the e

4.7 Cleaning the plantPreconditions☑Engine shut down and secured against being restarted.☑Power supply not connected.Special tools, Material, Spare pa

5 Maintenance5.1 Maintenance Schedule task reference table [QL1]The maintenance tasks and intervals for this product are defined in the Maintenance Sc

6 Troubleshooting6.1 TroubleshootingEngine does not turn over when starter is operatedComponent Cause ActionBattery Discharged or defective Charge or

Engine speed not steadyComponent Cause ActionFuel injection system Injector defective Replace (→ Page 77).Speed sensor Defective Notify Service.Fuel s

7.13 Lube Oil System, Lube Oil Circuit 947.13.1 Checking engine oil level 947.13.2 Engine oil – Change 957.14 Oil Filtration / Cooling 967.14.1 Automa

Component Cause ActionDrain water from fuel prefilter.Intercooler Leaking Notify Service.40 | Troubleshooting | M015675/06E 2013-04TIM-ID: 0000002541

6.2 ECU 4 alarmsFaults in the overall system are indicated as a four-digit code on the PIM display. The fault code num-bers are generated by the ECU.T

Fault code Alarm text Meaning Task016 L2 P-LUBE OIL Lube-oil pressure too low(2nd limit)Automatic engine shutdown.1.Check engine-oil level and topup,

Fault code Alarm text Meaning Task065 L1 P-FUEL Fuel supply pressure too low(1st limit)1.Check fuel lines for leaks; re-pair defective lines.2.Clean f

Fault code Alarm text Meaning Task090 IDLE SPEED LOW Idle speed not reached with-in a specified period;Termination of starting pro-cedure.Note further

Fault code Alarm text Meaning TaskAutomatic engine shutdown(depending on project de-sign).122 L1 T-ELECTRONIC Temperature in ECU housingtoo high (1st

Fault code Alarm text Meaning Task170 MI MODULE FAIL Module in maintenance pre-dictor either defective ormissing.Contact Service.171 MI NOT ACTIVE Mai

Fault code Alarm text Meaning Task215 SD P-RAIL FUEL Sensor defect (common railpressure);HP controller in emergencymode.1.Check wiring.2.Contact Servi

Fault code Alarm text Meaning Task310 TIMING CYLINDERA10Injection timing fault cylin-der A10If fault occurs repeatedly: ContactService.311 TIMING CYLI

Fault code Alarm text Meaning Task330 WIRING CYLINDERA10Faulty wiring to solenoidvalve cylinder A10;Misfiring1.Check wiring2.Contact Service:331 WIRIN

1 Safety1.1 Important provisions for all productsNameplateThe product is identified by nameplate, model designation or serial number and must match wi

Fault code Alarm text Meaning Task347 OPEN_LOAD CYL. A7 Disconnection in wiring tosolenoid valve cylinder A7;Misfiring1.Check wiring.2.Contact Service

Fault code Alarm text Meaning Task364 STOP POWER STAGE2Solenoid valve or wiring orECU defectiveAutomatic engine shutdown.1.Check wiring.2.Try to re-st

7 Task Description7.1 Engine7.1.1 Engine – Barring manuallyPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsD

Barring engine manually (toolmounted underneath)1. Remove grounding device or guard plate.2. Engage barring gear (2) in ring gear (1) andmount on flyw

7.1.2 Engine – Barring with starting systemSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Connector pliers0135315483 1DANGERRotati

7.2 Cylinder Liner7.2.1 Endoscopically examining cylinder linerPreconditions☑Engine shut down and secured against being restarted.Special tools, Mater

1. Compile endoscopy report with the aid of the table.2. Use technical terms for description of the liner surface (→ Page 57).3. Depending on findings

7.2.2 Instructions and comments on endoscopic and visual examination of cylinderlinersTerms used for endoscopic examinationUse the terms listed below

Findings MeasureLiners with heat discoloration starting in the TDC-ring 1 have to be replaced.Seizures, Seizure marks Seizure marks are of irregular c

7.3 Crankcase Breather7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check andreplacementPreconditions☑Engine is stopped and

1.2 Personnel and organizational requirementsOrganizational measures of the operatorThis manual must be issued to all personnel involved in operation,

Checking diaphragm1. Remove cover (4).2. Remove spring (5), gasket (2) and dia-phragm (3).3. Check diaphragm (3) for damage, fit newdiaphragm if used

7.3.2 Crankcase breather – CleaningSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Cleaner (Snow-White 11-0)40460 1Cleaner (Hakupur

7.3.3 Crankcase breather (open-circuit crankcase ventilation) – Filter elementcleaningPreconditions☑Engine is stopped and starting disabled.WARNINGCom

7.3.4 Crankcase breather – Filter element replacementPreconditions☑Engine shut down and starting disabled.Special tools, Material, Spare partsDesignat

Crankcase breather (open-circuitcrankcase ventilation) – Filter el-ement cleaning or replacement1. Clean filter externally.2. Release vent hose on oil

7.4 Running Gear7.4.1 Grounding device – Carbon brush checkPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsD

Cleaning running surface on adapter1. Clean running surface of carbon brushes on adapter with cold cleaner.2. Remove stubborn deposits with soft brush

7.4.2 Grounding device – Carbon brush replacementPreconditions☑Engine shut down and starting disabled.Special tools, Material, Spare partsDesignation

7.5 Valve Drive7.5.1 Valve gear – LubricationPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / U

7.5.2 Valve clearance – Check and adjustmentPreconditions☑Engine is stopped and starting disabled.☑Engine coolant temperature is max. 40 °C.☑Valves ar

1.3 TransportTransportAlways use the lifting eyes on the engine and generator/gearbox when transporting gensets.Always use the lifting eyes on the eng

Checking valve-bridge balanceX Valve bridge with guideY Flying valve bridgeNote: Not applicable for engines with flying valvebridge.1. Prior to adjust

3. Insert feeler gauge with determined valuebetween valve bridge and valve-stem end(A).4. At the opposite valve-stem end (B), a feelergauge thicker by

7. Tighten locknut (2) to 35 Nm +5 Nm, hold-ing valve bridge (1) in position with open-end spanner.8. Check valve bridge balance again.9. Adjust valve

Adjusting valve clearance1. Release locknut (1).2. Insert feeler gauge between valve bridgeand rocker arm.3. Using Allen key, set adjusting screw (2)

7.5.3 Cylinder head cover – Removal and installationPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignat

7.6 Injection Pump / HP Pump7.6.1 HP pump – Filling with engine oilPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spar

7.6.2 HP pump – Relief bore checkDANGERRotating and moving engine parts.Risk of crushing, danger of parts of the body being caught or pulled in.• Only

7.7 Injection Valve / Injector7.7.1 Injector – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Injector(→ Spare Parts Ca

7.7.2 Injector – Removal and installationPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use P

Remove injectorNote: Always replace the first and last injectorsof one engine side first. Replace the innerinjectors only after the installation of th

1.4 Crankshaft transport locking device – For transport withflanged-on generatorTransportThis locking device protects the crankshaft bearings from sho

7. Remove sealing ring (1) from injector oruse a self-made hook to take it out of thecylinder head.8. Remove O-rings (2) from injector.9. Cover all co

9. Use slotted screwdriver to check thrustring at both line ends for secure seating.10. Tighten loose thrust ring to the specified tightening torque.N

16. Tighten union nut of adapter (limiting valve) with torque wrench to the specified tightening torque.Name Size Type Lubricant Value/StandardUnion n

7.8 Fuel System7.8.1 Fuel system – VentingPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

7.9 Fuel Filter7.9.1 Fuel filter – ReplacementPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation /

7.9.2 Draining fuel prefilterPreconditions☑Engine shut down and secured against being restarted.Special tools, Material, Spare partsDesignation / Use

7.9.3 Edge-type fuel filter – DrainingPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part

7.9.4 Auxiliary fuel filter – ReplacementPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use P

7.10 Charge-Air Cooling7.10.1 Intercooler – Check water drain for coolant leakage and absence of restrictionsDANGERRotating and moving engine parts.Ri

7.11 Air Filter7.11.1 Air filter element and dust bowl (optional) – CleaningPreconditions☑Engine is stopped and starting disabled.Special tools, Mater

Fitting the transport locking device on driving end (KS)• Remove protective cover from flywheel housing (5).Keep guard plate and screws on the engine.

7.11.2 Air filter – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Air filter(→ Spare Parts Catalog)Air filter – Replac

7.11.3 Air filter element – Removal and installation (optional)Preconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare pa

7.11.4 Service indicator – Signal ring position check (optional)Preconditions☑Engine is stopped and starting disabled.Checking signal ring position1.

7.12 Starting Equipment7.12.1 Starter – Condition checkPreconditions☑Engine is stopped and starting disabled.Checking starter condition1. Check securi

7.13 Lube Oil System, Lube Oil Circuit7.13.1 Checking engine oil levelChecking oil level before start-ing engine1. Withdraw oil dipstick from guide tu

7.13.2 Engine oil – ChangePreconditions☑Engine is stopped and starting disabled.☑Engine is at operating temperature.☑MTU Fluids and Lubricants Specifi

7.14 Oil Filtration / Cooling7.14.1 Automatic oil filter – Oil filter candles replacementPreconditions☑Engine is stopped and starting disabled.Special

3. Withdraw oil filter element (1).4. Remove O-ring.5. Remove screw (2).6. Withdraw plastic spinner (1) with spring.7. Remove nut (3).8. Take off spri

Installing oil filter candles1. For installation follow reverse sequence of working steps.2. Additionally, the following instructions are to be observ

7.14.2 Oil indicator filter – Cleaning and checkPreconditions☑Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation