MTU 20 V 4000 C22 Operations Instructions

Operating InstructionsDiesel engine20 V 4000 C22M015675/05E

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

11. Turn filter insert upside down and use ap‐propriate tool to push out filter candles (1).12. Turn filter insert by 180°and insert new filtercandles

7.14.2 Oil indicator filter – CheckPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part N

Checking strainerItem Findings TaskStrainer Metallic residues • Clean• Monitor engine operation• Check strainer daily• Contact Service.Strainer Damage

7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material,

Centrifugal oil filter – Cleaning andfilter-sleeve replacement1. Remove clamp (3).2. Release cover screw (1) and take off cover(2).3. Carefully lift r

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

7.15.2 Engine coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Engine coolantDrain engine coolant.u (→ Page 107)Fill

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

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

Filling coolant with pump1. Connect appropriate pump with hose todrain valve.2. Open drain valve and pump coolant into en‐gine at 0.5 bar minimum.3. F

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

7.15.5 Engine coolant pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take spe

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

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

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

7.16.2 Charge-air coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Charge-air coolantDrain charge-air coolant.u (→ P

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

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

Charge-air coolant system – Filling1. Pour treated coolant via the filling point onthe coolant line from and to the intercoolerand via the filler neck

7.16.5 Charge-air coolant pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take

7.17 Belt Drive7.17.1 Drive belt – Condition checkPreconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.Item Findings TaskDrive be

1.5 Safety regulations for startup and operationSafety requirements for initial operationPrior to initial operation of the unit, install the assembly

7.18 Battery-Charging Generator7.18.1 Battery-charging generator – RemovalPreconditions☑ Engine is stopped and starting disabledWARNINGHeavy object.Ri

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

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

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

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

7.19 Fan Drive7.19.1 Fan drive belt– Tension check / adjustmentPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare p

Adjusting drive belt tension1. Release screws (2) until fan coupling canbe moved.2. Tighten stud (1) until the required frequencyis achieved.3. Tighte

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

7.20 Wiring (General) for Engine/Gearbox/Unit7.20.1 Engine wiring – CheckPreconditions☑ Engine is stopped and starting disabled.Special tools, Materia

7.21 Accessories for (Electronic) Engine Governor / ControlSystem7.21.1 Engine control unit and connectors – CleaningPreconditions☑ Engine shut down a

1.6 Explosion hazard when removing inspection port cover onengineDANGERExplosion hazard due to oil vapors.Risk of serious injury – danger to life!• Al

7.21.2 Engine governor plug-in connections – CheckPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignati

8 Appendix A8.1 AbbreviationsAbbreviation Meaning ExplanationA/D Analog/Digital Transformer: transforms sensor voltages intonumeric valuesADEC Advance

Abbreviation Meaning ExplanationEGR Exhaust Gas RecirculationEMU Engine Monitoring UnitETK Ersatzteilkatalog Spare Parts Catalog (SPC)EUI Electronic U

Abbreviation Meaning ExplanationSAE Society of Automotive Engineers U.S. standardization organizationSD Sensor Defect Alarm: Sensor failureSEL Stop En

8.2 MTU contacts/service partnersServiceOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters

9 Appendix B9.1 Special ToolsAir filterPart No.:Qty.:Used in: 7.11.2 Air filter – Replacement (→ Page 92)Coolant filterPart No.:Qty.:Used in: 7.15.7 C

GasketPart No.:Qty.:Used in: 7.5.3 Cylinder head cover – Removal and installation (→ Page 76)Grounding devicePart No.:Qty.:Used in: 7.4.2 Grounding de

Sealing ringPart No.:Qty.:Used in: 7.9.2 Edge-type fuel filter – Draining (→ Page 87)Qty.:Used in: 7.13.2 Engine oil – Change (→ Page 97)Qty.:Used in:

9.2 Index 9820V 4000 C22 engine data 27AAbbreviations 131After stopping the engine 38Air filter– Replacement  92Air filter element– Cleaning  90– Remo

IInjector– Removal and installation  79– Replacement  78Inspection port cover– Explosion hazard  13Instructions and comments on endoscopic and visual

1.7 Safety precautions when working on the engineSafety requirements for maintenance and repair work• Maintenance and repair work may only be carried

If welding has to be carried out on components (e.g. exhaust manifold), these components must first beremoved from the engine.Hydraulic installation a

1.8 Fluids and lubricants, fire prevention and environmentalprotectionFire preventionCorrect fuel or oil leaks immediately. Quantities of oil or fuel

Lead• When working with lead or lead-containing compounds, avoid direct contact to the skin and do notinhale lead vapors.• Prevent the buildup of whit

1.9 Conventions for safety instructions in the textDANGERIn the event of immediate danger.Consequences: Death or serious injury• Remedial actionWARNIN

2 General Information2.1 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS).The cylinders of

Printed in Germany© 2011 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole

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

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, actuators and injectors – 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

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)24 |

1 B13 (N-Crankshaft)M015675/05E 2011-10 | General Information | 25TIM-ID: 0000012921 - 002

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-Coolant Intercool‐er)

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

LUBE OIL SYSTEMNumber of cylinders 20V 4000Lube oil operating temperature before engine, from R °C 86Lube oil operating temp. before engine, to R °C 9

Commissioning NoteImportantPlease complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.The Commissioning Note informati

CAPACITIESNumber of cylinders 20V 4000Engine coolant capacity (without cooling equipment) R liter 205Engine oil capacity, initial filling (standard oi

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 mm32 | Technical Data | M01

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

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

4.3 Engine – Start in manual modePreconditions☑ Engine with no load.☑ External start interlock is not activated.DANGERUnguarded rotating and moving en

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 – Shutdown in manual modePreconditions☑ Engine is not under load☑ Engine in manual modeCAUTIONStopping the engine when it is running at ful

4.6 After stopping the enginePreconditions☑ MTU Fluids and Lubricants Specification (A001061/..) is available.After stopping the engineItem TaskCoolan

4.7 Plant – CleaningPreconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not applied.Special tools, Material, Spare partsDesi

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

6 Troubleshooting6.1 TroubleshootingEngine does not turn when starter is actuatedComponent Probable Cause TaskBattery Low or defective Charge or repla

Component Probable Cause TaskEngine wiring Defective Check (→ Page 128).Engine Overloaded Contact Service.Engine speed not steadyComponent Probable Ca

Exhaust gas whiteComponent Probable Cause TaskEngine Not at operating temperature Run engine to reach operating temper‐ature.Fuel system Water in fuel

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

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

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

Fault code Alarm text Meaning Task089 ENGINE SPEEDLOWEngine speed lower than200 rpm;Automatic engine shut‐down.Re-start the engine (→ Page 35).090 IDL

Fault code Alarm text Meaning Task119 L2 SUPPLY VOLT.LOWSupply voltage too low(2nd limit)Check ECU supply voltage.120 L1 SUPPLY VOLT.HIGHSupply voltag

Fault code Alarm text Meaning Task147 AD-TEST1 ECU DE‐FECTElectronic equipment de‐fective;Automatic engine shut‐down.Contact Service.148 L1 AD-TEST2 S

Table of Contents1 Safety1.1 General conditions 71.2 Personnel and organizational requirements 81.3 Transport 91.4 Crankshaft transport locking device

Fault code Alarm text Meaning Task189 CAN2 ERROR PAS‐SIVELight fault on RedundantCAN bus (e.g. short-timeoverload)(none)201 SD T-COOLANT Sensor defect

Fault code Alarm text Meaning Task246 SD T-ELECTRONIC Sensor defect (temperaturein ECU)Contact Service.266 SD SPEED DE‐MAND AN.Sensor defect (analogsp

Fault code Alarm text Meaning Task322 WIRING CYLINDERA2Faulty wiring to solenoidvalve cylinder A2;Misfiring1. Check wiring.2. Contact Service.323 WIRI

Fault code Alarm text Meaning Task337 WIRING CYLINDERB7Faulty wiring to solenoidvalve cylinder B7;Misfiring1. Check wiring.2. Contact Service.338 WIRI

Fault code Alarm text Meaning Task351 OPEN_LOAD CYL.B1Disconnection in wiring tosolenoid valve cylinder B1;Misfiring1. Check wiring.2. Contact Service

Fault code Alarm text Meaning Task365 STOP SOLENOID-WIRINGSolenoid-valve wiring faul‐ty;Automatic engine shut‐down.1. Check wiring.2. Try to re-start

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

Barring engine manually(installation on lower side)1. Remove grounding device or guard plate.2. Engage barring device (2) with ring gear (1)and mount

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

7.2 Cylinder Liner7.2.1 Cylinder liner – Endoscopic examinationPreconditions☑ Engine is stopped and starting disabledSpecial tools, Material, Spare pa

7.11.3 Air filter element – Removal and installation 937.11.4 Service indicator - Signal ring position check 947.12 Starting Equipment 957.12.1 Starte

Final steps1. Install injector (→ Page 79).2. Install cylinder head cover (→ Page 76).60 | Task Description | M015675/05E 2011-10TIM-ID: 0000003304 -

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

Findings MeasureDiscolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually theyrun over the whole ring-travel ar

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

Crankcase breather – Replacingfilter element (variant B)1. Remove cover (2) with O-ring (3).2. Remove filter element (1) from housing (4).3. Insert ne

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 – Filter element replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesign

Crankcase breather (open-circuitcrankcase ventilation) – Filterelement cleaning or replacement1. Clean filter (6) outside.2. Undo clamp (2) and screw

7.4 Running Gear7.4.1 Grounding device – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Removing grounding device1. Cl

7.4.2 Grounding device – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Grounding device(→ Spare Parts Catalog)Remove g

1 Safety1.1 General conditionsGeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other com‐pu

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

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

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

Adjusting valve-bridge balanceNote: Not applicable for engines with flying valvebridge.1. Hold valve bridge (1) firmly in position withopen-end spanne

Checking valve clearance at twocrankshaft positions1. Check TDC position of piston in cylinderA1:• If the rocker arms are unloaded on cylin‐der A1, th

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

7.6 Injection Pump / HP Pump7.6.1 HP fuel pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – dange

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

1.2 Personnel and organizational requirementsPersonnel requirementsWork on the engine must only be carried out by appropriately qualified and instruct

Removing injectorNote: Always replace the first and last injectors ofone engine side first. Replace the inner in‐jectors only after the installation o

7. Remove sealing ring (1) from injector or usea self-made wire hook to extract it from thecylinder head.8. Remove O-rings (2) from injector.9. Cover

Installing injector1. Remove all plugs before installing.2. Coat nozzle retaining nut area of injectorwith assembly paste.3. Fit new O-rings on inject

10. Tighten loose thrust ring to the specified tightening torque.Name Size Type Lubricant Value/StandardThrust ring Tightening torque 5 Nm to 10 Nm11.

18. Twist cable several times.19. Insert cable terminals (arrowed) underneath screws on injector and tighten screws to specified torqueusing a torque

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

7.9.3 Fuel prefilter – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Q

7.10 Charge-Air Cooling7.10.1 Intercooler – Check drain for coolant leakage and obstructionDANGERUnguarded rotating and moving engine components.Risk

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

7.11 Air Filter7.11.1 Air filter element and dust bowl – CleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare

Visual inspection1. Use inspection lamp to check cleaned filterelement for damage.2. Fit new filter element if old one is damaged(→ Page 92).M015675/0

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

7.11.3 Air filter element – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesigna

7.11.4 Service indicator - Signal ring position checkPreconditions☑ Engine is stopped and starting disabled.Checking signal ring position1. If the sig

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

7.13 Lube Oil System, Lube Oil Circuit7.13.1 Engine oil level – CheckChecking engine oil level prior toengine start1. Withdraw oil dipstick from guide

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

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

Oil filter candles – Removal1. Remove nuts (2) from oil filter cover (1).2. Remove oil filter cover.3. Withdraw filter insert (1).4. Remove O-ring.5.