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20 V 4000 G83
MTU 20 V 4000 G83 Technical Publication
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EDG TR
A
INI
NG M
A
NU
A
L JOB 6
608 REV
.0
2.
Engine
2.1.
MTU Manual
2.2.
P&ID
2.2.1.
Lube Oil System
2.2.2.
Fuel System
2.2.3.
Cooling System
2
Table of Contents
Default Chapter
6
Table of Contents
6
1 Safety
10
General Conditions
10
Personnel and Organizational Requirements
11
Transport
12
Safety Precautions When Working on the Engine
13
Auxiliary Materials, Fire Prevention and Environmental Protection
16
Standards for Warning Notices in the Publication
18
2 Product Summary
20
Engine Layout
20
Engine Side and Cylinder Designations
22
Main Engine Dimensions
23
Firing Order
24
Final Compression Pressure
25
Technical Data
26
4000 Gx3 Engine Data: Standby Operation 3D, Optimized Fuel Consumption
26
4000 Gx3 Engine Data: Standby Operation 3D, Optimized Exhaust Emissions
33
Consumption
37
Emissions (EPA)
44
Emissions (TA-Luft)
48
3 Operation
52
Putting the Engine into Operation after Extended Out-Of-Service-Periods (>3 Months)
52
Putting the Engine into Operation after Scheduled Out-Of-Service-Period
53
Starting the Engine in Manual Mode
54
Emergency Start (Override Mode)
55
Operational Checks
56
Stopping the Engine in Manual Mode
57
Emergency Stop
58
After Stopping the Engine - Engine Remains Ready for Operation
59
After Stopping the Engine - Putting the Engine out of Service
60
4 Maintenance
62
Preface
62
Maintenance Schedule Matrix
64
Maintenance Tasks
71
5 Troubleshooting
74
Engine Governor ADEC (ECU 7) for Series 4000 Genset Engines - Fault Messages
77
6 Task Description
98
Engine
98
Engine - Barring Manually
98
Engine - Barring with Starting System
99
Engine Test Run
100
Cylinder Liner
101
Cylinder Liner - Endoscopic Examination
101
Instructions and Comments on Endoscopic and Visual Examination of Cylinder Liners
102
Crankcase Ventilation
104
Crankcase Breather - Oil Separator Replacement, Diaphragm Check and Replacement
104
Valve Gear
106
Valve Gear - Lubrication
106
Valve Clearance - Check and Adjustment
107
Cylinder Head Cover - Remove and Install
110
Fuel Injector
111
Injector Replacement
111
Injector - Removal and Installation
112
Fuel System
116
Fuel System - Venting
116
Fuel Filter
117
Fuel Filter - Replacement
117
Fuel Prefilter Cleaning
118
Fuel Prefilter - Differential Pressure Check and Adjustment of Gauge
119
Fuel Prefilter - Draining
120
Fuel Prefilter - Flushing
122
Fuel Prefilter - Filter Element Replacement
124
Charge-Air Cooling General, Left Side
126
Intercooler - Checking Condensate Drains for Coolant Discharge and Obstructions
126
Air Filter
127
Air Filter Replacement
127
Air Filter - Check
128
Air Filter Removal and Installation
129
Air Intake
130
Service Indicator - Signal Ring Position Check
130
Starting System
131
Air Starter - Manual Operation
131
Starter - Condition Check
132
Lube Oil System / Lube Oil Circuit
133
Engine Oil - Change
133
Engine Oil - Level Check
135
Engine Oil - Sample Extraction and Analysis
136
Oil Cooling / Filtration
137
Engine Oil Filter - Replacement
137
Centrifugal Oil Filter - Cleaning and Filter-Sleeve Replacement
138
Coolant Circuit General, HT Circuit
140
Engine Coolant - Filling
140
Engine Coolant - Draining
142
Engine Coolant - Change
143
Engine Coolant Level - Check
144
Engine Coolant Pump - Relief Bore Check
145
Engine Coolant - Sample Extraction and Analysis
146
Circuit
147
Charge-Air Coolant Change
147
Charge-Air Coolant - Filling
148
Charge-Air Coolant - Draining
150
Charge-Air Coolant Level Check
151
Charge-Air Coolant Pump - Relief Bore Check
152
Belt Drive
153
Drive Belt - Condition Check
153
Battery-Charging Generator
154
Battery-Charging Generator Drive - Drive Belt Tension Adjustment
154
Battery-Charging Generator Drive - Drive Belt Replacement
155
Cabling, General for Engine / Transmission / Plant
156
Engine Wiring Check
156
Accessories for Engine Governor (Electronic) / Control System
157
ECU and Connectors - Cleaning
157
ECU - Checking Plug-In Connections
158
7 Special Tools
160
8 Annex
166
Manufacturer's Documentation
166
MTU Contact Person/Service Partner
167
Abbreviations
168
Index
172
Other manuals for MTU 20 V 4000 G83
Operating Instructions
199 pages
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MTU 20 V 4000 G83 Specifications
General
Engine Type
Diesel
Fuel Type
Diesel
Cooling System
Water-cooled
Compression Ratio
16.5:1
Bore
170 mm
Stroke
210 mm
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