MTU 20 V 4000 C22 Manuale utente
Operating Instructions
Diesel engine
20 V 4000 C22
M015675/05E
Printed in Germany
© 2011 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
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Commissioning Note
Important
Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐
ranty, spare parts, etc.).
Table of Contents
1 Safety
1.1 General conditions 7
1.2 Personnel and organizational requirements 8
1.3 Transport 9
1.4 Crankshaft transport locking device – For
transport with flanged-on generator 10
1.5 Safety regulations for startup and operation 12
1.6 Explosion hazard when removing
inspection port cover on engine 13
1.7 Safety precautions when working on the
engine 14
1.8 Fluids and lubricants, fire prevention and
environmental protection 16
1.9 Conventions for safety instructions in the
text 18
2 General Information
2.1 Engine side and cylinder designations 19
2.2 Engine layout 20
2.3 Sensors, actuators and injectors –
Overview 23
3 Technical Data
3.1 20V 4000 C22 engine data 27
3.2 Firing order 31
3.3 Main engine dimensions 32
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 33
4.2 Putting the engine into operation after
scheduled out-of-service-period 34
4.3 Engine – Start in manual mode 35
4.4 Operational checks 36
4.5 Engine – Shutdown in manual mode 37
4.6 After stopping the engine 38
4.7 Plant – Cleaning 39
5 Maintenance
5.1 Maintenance task reference table [QL1] 40
6 Troubleshooting
6.1 Troubleshooting 41
6.2 ECU 4 alarms 44
7 Task Description
7.1 Engine 56
7.1.1 Engine – Barring manually 56
7.1.2 Engine – Barring with starting system 58
7.2 Cylinder Liner 59
7.2.1 Cylinder liner – Endoscopic examination 59
7.2.2 Instructions and comments on endoscopic
and visual examination of cylinder liners 61
7.3 Crankcase Breather 63
7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 63
7.3.2 Crankcase breather – Cleaning 65
7.3.3 Crankcase breather – Filter element
replacement 66
7.4 Running Gear 68
7.4.1 Grounding device – Removal and installation 68
7.4.2 Grounding device – Replacement 69
7.5 Valve Drive 70
7.5.1 Valve gear – Lubrication 70
7.5.2 Valve clearance – Check and adjustment 71
7.5.3 Cylinder head cover – Removal and
installation 76
7.6 Injection Pump / HP Pump 77
7.6.1 HP fuel pump – Relief bore check 77
7.7 Injection Valve / Injector 78
7.7.1 Injector – Replacement 78
7.7.2 Injector – Removal and installation 79
7.8 Fuel System 85
7.8.1 Fuel system – Venting 85
7.9 Fuel Filter 86
7.9.1 Fuel filter – Replacement 86
7.9.2 Edge-type fuel filter – Draining 87
7.9.3 Fuel prefilter – Draining 88
7.10 Charge-Air Cooling 89
7.10.1 Intercooler – Check drain for coolant leakage
and obstruction 89
7.11 Air Filter 90
7.11.1 Air filter element and dust bowl – Cleaning 90
7.11.2 Air filter – Replacement 92
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7.11.3 Air filter element – Removal and installation 93
7.11.4 Service indicator - Signal ring position check 94
7.12 Starting Equipment 95
7.12.1 Starter – Condition check 95
7.13 Lube Oil System, Lube Oil Circuit 96
7.13.1 Engine oil level – Check 96
7.13.2 Engine oil – Change 97
7.14 Oil Filtration / Cooling 98
7.14.1 Automatic oil filter – Filter candles
replacement 98
7.14.2 Oil indicator filter – Check 101
7.14.3 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 103
7.15 Coolant Circuit, General, High-
Temperature Circuit 105
7.15.1 Coolant – Level check 105
7.15.2 Engine coolant – Change 106
7.15.3 Engine coolant – Draining 107
7.15.4 Engine coolant – Filling 108
7.15.5 Engine coolant pump – Relief bore check 110
7.15.6 Coolant – Sample extraction and analysis 111
7.15.7 Coolant filter – Replacement 112
7.16 Low-Temperature Circuit 113
7.16.1 Charge-air coolant – Level check 113
7.16.2 Charge-air coolant – Change 114
7.16.3 Charge-air coolant – Draining 115
7.16.4 Charge-air coolant system – Filling 116
7.16.5 Charge-air coolant pump – Relief bore check 118
7.17 Belt Drive 119
7.17.1 Drive belt – Condition check 119
7.18 Battery-Charging Generator 120
7.18.1 Battery-charging generator – Removal 120
7.18.2 Battery-charging generator – Check 121
7.18.3 Battery-charging generator drive – Drive belt
tension adjustment 122
7.18.4 Battery-charging generator drive – Drive belt
tension check 123
7.18.5 Battery-charging generator drive – Drive belt
replacement 124
7.19 Fan Drive 125
7.19.1 Fan drive belt– Tension check / adjustment 125
7.19.2 Fan drive – Drive belt replacement 127
7.20 Wiring (General) for Engine/Gearbox/Unit 128
7.20.1 Engine wiring – Check 128
7.21 Accessories for (Electronic) Engine
Governor / Control System 129
7.21.1 Engine control unit and connectors – Cleaning 129
7.21.2 Engine governor plug-in connections – Check 130
8 Appendix A
8.1 Abbreviations 131
8.2 MTU contacts/service partners 134
9 Appendix B
9.1 Special Tools 135
9.2 Index 138
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the operating instructions and mainte‐
nance and repair specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.
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1.3 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
Transport the engine/genset in the installation position only, maximum admissible inclination is 10°.
Remove any loose parts on the genset.
Hoist the engine/genset slowly ensuring that lifting cables/chains do not touch the engine or any of its
component parts. Readjust lifting device as necessary.
Pay attention to the center of gravity of the engine/genset.
When specially wrapped in aluminum foil, suspend the engine/genset by the lifting eyes on the bearing
pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Fit the crankshaft shipping lock on the engine and fit the engine mount locking devices prior to transport.
Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip‐
ping and tipping when driving up or down inclines and ramps.
Placement after transport
Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
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1.4 Crankshaft transport locking device – For transport with
flanged-on generator
Transport
This locking device protects the crankshaft bearings from shocks and vibration damage during unit trans‐
port.
For removal of the transport locking device follow the following instructions:
• The transport locking device should remain installed as long as possible during unit installation in or‐
der to avoid damage.
• Starting or barring the engine is allowed only with the transport locking device removed. Make sure
that the transport locking device of the generator is removed.
• Prior to every unit transport, this transport locking device must be reinstalled according to the instruc‐
tions. The transport locking device of the generator is also to be fitted.
Removing the transport locking device from driving end (KS)
• Remove screw (4) on both sides. Remove retainer (2) and washer (3).
• Remove guard plate from flywheel housing.
Store the removed parts of the transport locking device carefully for possible reuse!
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