MTU 20 V 4000 L63 Operating Instructions Manual Download Page 30

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3 Monitoring, Control and Regulation

Equipment

3.1 Gas engine phase 3 system – Overview

Overview

1 Genset system

2 Engine system

3 Genset

4 Engine governor

5 Engine monitoring

6 NOx sensor

7 Compressor bypass

8 Ignition

9 Knock module

10 Gas metering unit

11 Throttles

Governing/control/monitoring

Engine governor ADEC (ECU-7)

• Controls engine starting, stopping and emergency stop

• Monitors engine operating parameters

• Controls throttles and sets gas mixture for requested speed/power

• Monitors first gas solenoid in gas train to engine

SAM

• Interface module to unit control

• Monitors second gas solenoid in gas train to engine

• Diagnostic interface

30 | Monitoring, Control and Regulation Equipment | MS150059/01E 2012-07

TIM-ID: 0000017542 - 002

Summary of Contents for 20 V 4000 L63

Page 1: ...Operating Instructions Gas engine 20 V 4000 L63 MS150059 01E...

Page 2: ...ten 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 on...

Page 3: ...topping the engine Engine remains ready for operation 44 4 9 After stopping the engine Putting the engine out of operation 45 5 Maintenance 5 1 50 hours check 46 5 2 Maintenance task reference table Q...

Page 4: ...ature Circuit 165 7 10 1 Mixture coolant level Check 165 7 10 2 Mixture coolant Change 166 7 10 3 Mixture coolant Draining 167 7 10 4 Mixture coolant Filling 168 7 11 Wiring General for Engine Gearbox...

Page 5: ...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 alon...

Page 6: ...to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety relevant i...

Page 7: ...or the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transport...

Page 8: ...ion the display instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must...

Page 9: ...and vent the compressed air line when air starters are fitted Disconnect the control device from the assembly or plant Only use adequate calibrated tools During assembly and disassembly observe the s...

Page 10: ...re starting the pressing procedure Bleed air from the device for force fitting removing parts pumps and piping at the points provided for the system concerned e g open threaded vent plugs pump until n...

Page 11: ...es When working with laser equipment always wear special laser protection goggles eye injury through strongly concentrated beam Laser devices must be equipped in accordance with their class and usage...

Page 12: ...main tained exchanged or repaired if the components used for this purpose are approved by MTU Noncom pliance with these guidelines might represent a violation of the Clean Air Act and could involve th...

Page 13: ...gregate In low lying areas of the plant carbon dioxide enrichment is possible All gas carrying lines must be checked for leaks prior to commissioning and at regular intervals during operation Procedur...

Page 14: ...oses or to check for leaks results in a risk of bursting Carry out the leak check as specified Painting When carrying out painting work outside the spray stands provided with fume extraction systems e...

Page 15: ...on involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety warnings in accordance...

Page 16: ...ir inlet 5 Throttle 6 Ignition coil 7 Spark plug 8 Cylinder head cover 9 Engine suspension 10 Oil pan 11 Cylinder head 12 Engine oil filter 13 Engine oil sampling connection 14 Oil level switch 15 Eng...

Page 17: ...nting bracket 9 Flywheel 10 Starter 11 Engine governor engine monitoring KS Driving end Engine model designation Key to the engine model designations 20 V 4000 L63 20 Number of cylinders V Cylinder ar...

Page 18: ...d A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end Other components are numbered in the same way i e star...

Page 19: ...rox 3800 mm Width B approx 1487 mm Height C approx 2250 mm Crankshaft center to oil pan D approx 636 mm Crankshaft center to engine mount E approx 281 mm Table 2 Main dimensions MS150059 01E 2012 07 P...

Page 20: ...2 4 Firing order Firing order 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 20 Product Summary MS150059 01E 2012 07 TIM ID 0000010710 001...

Page 21: ...tional availability of the engine plant and to re duce maintenance to a minimum Power referenced to nominal load Recommended maximum run time at this load Recommended minimum runtime in subsequent ope...

Page 22: ...t brake power to ISO 3046 Number of cylinders 20 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 2200 Mean effective pressure pme continuous power ISO 30...

Page 23: ...reeze A C 90 Coolant temperature at engine connection inlet from cooling equipment w o antifreeze A C 78 Coolant temperature after engine warning R C 95 Coolant temperature after engine shutdown L C 9...

Page 24: ...l system Number of cylinders 20 Gas temperature before engine min L C 10 Gas temperature before engine max L C 40 Gas flow pressure before Tecjet min L mbar 80 Gas flow pressure before Tecjet max L mb...

Page 25: ...ifted during extended component maintenance QL3 R kg 440 Table 15 Weights main dimensions Exhaust emissions Number of cylinders 20 Exhaust emission before catalytic converter at 100 DL nitric oxides N...

Page 26: ...s are net brake power to ISO 3046 Number of cylinders 20 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 2200 Mean effective pressure pme continuous powe...

Page 27: ...freeze A C 90 Coolant temperature at engine connection inlet from cooling equipment w o antifreeze A C 78 Coolant temperature after engine warning R C 95 Coolant temperature after engine shutdown L C...

Page 28: ...l system Number of cylinders 20 Gas temperature before engine min L C 10 Gas temperature before engine max L C 40 Gas flow pressure before Tecjet min L mbar 80 Gas flow pressure before Tecjet max L mb...

Page 29: ...lifted during extended component maintenance QL3 R kg 440 Table 30 Weights main dimensions Exhaust emissions Number of cylinders 20 Exhaust emission before catalytic converter at 100 DL nitric oxides...

Page 30: ...s Governing control monitoring Engine governor ADEC ECU 7 Controls engine starting stopping and emergency stop Monitors engine operating parameters Controls throttles and sets gas mixture for requeste...

Page 31: ...k control AKR Controls monitored cylinders with regard to knock characteristics If knocking is found the ignition tim ing is retarded on the cylinder in question If this does not result in an improvem...

Page 32: ...ck 5 Automatic cutout 32A 6 Automatic cutout 16A 7 Emergency stop key switch Fuses F001 Starter A bank starter B bank F002 Throttle A bank throttle B bank F003 Ignition system F004 Anti knock control...

Page 33: ...nputs outputs provided Genset side 14 inputs 7 outputs 2 serial interfaces Engine side 39 inputs 28 outputs 1 serial interface Engine and genset related parameter settings in flash memory In case of i...

Page 34: ...unctions Display of fault codes from engine governor and SAM 3 Backup function engine life data are stored every hour after every engine stop after every emergency engine stop Interface for dialog uni...

Page 35: ...ncy inputs 1 dialog interface Extendable with MCS 5 PIM I O cards CANOpen and SAE J1939 interface For CANOpen and J1939 interface a type CCB2 printed circuit board 1 is inserted in slot 3 of the SAM u...

Page 36: ...Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 36 Monitoring Control and Regulation Equipment MS150059 01E 2012 07 TIM ID 0000017541 001...

Page 37: ...e Out of service period 6 months Grease valve drive Page 144 Lube oil system Check engine oil level Page 155 Checking oil level in oil storage tank Page 155 Coolant circuit Out of service period more...

Page 38: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 155 Coolant circuit Check engine coolant level Page 159 Check mixture coolant level Page...

Page 39: ...for starter disengagement speed 9 Disengaging starter 10 Waiting for idling speed 11 Runup to rated speed Stop sequence If a stop command is activated the following steps are carried out automatically...

Page 40: ...components Risk of serious injury danger to life Before barring or starting the engine make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear...

Page 41: ...ay SAM Check for fault messages If fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Operation log if provided Docume...

Page 42: ...ses extreme stress to the engine Risk of overheating damage to components Before stopping the engine operate it at idle speed until operating temperatures decrease and stable values are indicated Stop...

Page 43: ...Emergency stop button Press Engine is stopped Safety measures Item Task Emergency stop button Remove key Rectifying cause Item Task Engine control system Determine cause for emergency stop and take re...

Page 44: ...emains ready for operation After stopping the engine Item Measure Engine genset control system Engine is in stop mode For engine restart refer to documentation Genset control system 44 Operation MS150...

Page 45: ...antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Power supply to engine control system Switch OFF Gas...

Page 46: ...ylinder heads after component maintenance or extended component maintenance When installing a cylinder head with run in mating faces e g after piston replacement a repeated check after the first 50 op...

Page 47: ...ge tank Page 155 W1002 Check valve clearance Page 145 W1005 Replace air filter Page 153 W1008 Replace engine oil filter at each oil change or when the time limit years is reached at the latest Page 15...

Page 48: ...esponded in one of the specified ways TD Transmitter Deviation Two sensors which acquire the measured val ues of the same medium provide different measured values HI High The first limit value has bee...

Page 49: ...ult code from the SAM EC This is an alarm message from the engine governor This code is always followed by a 3 digit number 3 indicating the fault code from the engine governor 2nd line plain text mes...

Page 50: ...immediately start fault rectification Red alarm Caution the engine is running at its limits Shut down manually without further delay if the engine does not shut itself down immediately after a red al...

Page 51: ...e text 26 I O Module Slot8 Defect 27 Download Server Collision 28 not projected node 29 Device specific error 30 not projected node 31 Device specific error MS150059 01E 2012 07 Troubleshooting 51 TIM...

Page 52: ...gnition timing Page 137 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hig...

Page 53: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112308 HI T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 54: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112314 HI T Exhaust B4 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 55: ...Check ignition timing Page 137 3 Check valve drive exhaust valves do not close 112320 HI T Exhaust B10 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is...

Page 56: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Page 57: ...orrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive...

Page 58: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Page 59: ...es 3 Check ignition timing Page 137 4 Check valve drive 112501 HIHI T Exhaust A1 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared wit...

Page 60: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112507 HIHI T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as...

Page 61: ...ition timing Page 137 3 Check valve drive exhaust valves do not close 112513 HIHI T Exhaust B3 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 62: ...ignition timing Page 137 3 Check valve drive exhaust valves do not close 112519 HIHI T Exhaust B9 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hi...

Page 63: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Page 64: ...rective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 11...

Page 65: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Page 66: ...k spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this c...

Page 67: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hig...

Page 68: ...ition timing Page 137 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hi...

Page 69: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hig...

Page 70: ...ystem Page 155 150200 Communication Lost ECU Red alarm Initiated by SAM Cause Corrective action No communication with ECU CAN 1 Check supply voltage 2 Check connecting line 150201 Communication Lost E...

Page 71: ...s pressure applied 1 Check initial gas pressure and gas line 2 Check cabling 150399 SS Coolant too Low Red alarm Initiated by SAM Cause Corrective action Lack of coolant in cooling system feedback sig...

Page 72: ...Initiated by SAM Cause Corrective action Actual power signal out of valid range 1 Check cabling 2 Check signal 150504 LO Engine Power Yellow alarm Initiated by SAM Cause Corrective action The engine...

Page 73: ...ot Reached Red alarm Initiated by TecJet Cause Corrective action No gas flow detected 1 Check inlet and outlet 2 Check gas pressure gas quality gas filter gas line for obstruction 3 Check engine for o...

Page 74: ...151032 Coil Current Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151035 Position Fail High Red alarm Initiated by TecJet Cause Cor...

Page 75: ...Low Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151048 Analog Input Low Error Red alarm Initiated by TecJet Cause Corrective action TecJet s...

Page 76: ...TecJet 151054 Delta P Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151055 FGP Low Limit Error Red alarm Initiated by TecJet...

Page 77: ...arm Initiated by TecJet Cause Corrective action TecJet setting is not correct u Switch over setting to PWM input Check PWM signal 151066 TecJet Shutdown Red alarm Initiated by TecJet Cause Corrective...

Page 78: ...ion Camshaft signal for ignition is missing u Check sensor B1 2 check sensor clearance and cabling replace if necessary Restart of ignition system required to restart the engine 152014 Error Number of...

Page 79: ...value 152023 Selftest Shutdown Cause Corrective action Self test is active with the engine rotating u Restart ignition system 152024 Open Primary Rate Exceeded Red alarm Initiated by IC922 Cause Corre...

Page 80: ...Channel 6 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152032 Open Primary Channel 7 Yellow alarm...

Page 81: ...Channel 13 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152039 Open Primary Channel 14 Yellow alar...

Page 82: ...Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152050 Warn Missing Ring Gear Signal Yellow alarm Initiated by IC922 Cause Corrective actio...

Page 83: ...22 Cause Corrective action Specified energy level is beyond the valid range u Adjust value 153101 Error Status Red alarm Initiated by antiknock control Cause Corrective action AKR combined alarm At le...

Page 84: ...2 Check sensor tightening torque damage replace as necessary 153113 Knock Sensor Error A3 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock sensor 1 C...

Page 85: ...cabling 2 Check sensor tightening torque damage replace as necessary 153119 Knock Sensor Error A9 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock se...

Page 86: ...cabling 2 Check sensor tightening torque damage replace as necessary 153125 Knock Sensor Error B5 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock se...

Page 87: ...Readjustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas qua...

Page 88: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality...

Page 89: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality...

Page 90: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality...

Page 91: ...grator A1 Red alarm Initiated by SAM Cause Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chambe...

Page 92: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Page 93: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Page 94: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Page 95: ...by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153262 HI Misfire Integrator A2 Yellow alarm Initiated by...

Page 96: ...8 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153269 HI Misfire Integrator A9...

Page 97: ...5 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153276 HI Misfire Integrator B6...

Page 98: ...or A2 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153283 HIHI Misfire Integrator...

Page 99: ...A9 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153290 HIHI Misfire Integrator A1...

Page 100: ...B6 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153297 HIHI Misfire Integrator B7...

Page 101: ...B10 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system MS150059 01E 2012 07 Troubleshoo...

Page 102: ...Corrective action Engine oil pressure too low limit value 2 Lack of engine oil engine speed too low oil lines oil heat exchanger clogged oil pump defective 1 Check oil system oil heat exchanger 2 Repl...

Page 103: ...er 2 Check ignition timing Page 137 3 Check mixture setting 4 Check spark plugs 022 SS T Exhaust B ZKP Number Yellow alarm Associated parameter 2 0127 932 Cause Corrective action Exhaust gas temperatu...

Page 104: ...lue 2 This usually fault message usually follows other fault messages 1 Check governor 2 Check throttle closing position 031 HI ETC1 Overspeed ZKP Number Yellow alarm Associated parameter 2 3011 931 C...

Page 105: ...be Oil ZKP Number Yellow alarm Associated parameter 2 0125 931 Cause Corrective action Engine oil temperature after oil heat exchanger too high limit value 1 Oil heat exchanger clogged coolant tempera...

Page 106: ...ant ZKP Number Yellow alarm Associated parameter 2 0101 921 Cause Corrective action Coolant pressure after engine too low limit value 1 Volumetric flow too low static pressure too low u Check engine c...

Page 107: ...ameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restrictor valve in crankcase breather is closed too much air filter is defective oil separator is clogged piston ri...

Page 108: ...ator and coupling for damage 2 In isolated operation Check throttle position Check throttles for implausible closing If throttles are fully open Check if load step values are admissible Check bypass p...

Page 109: ...d u Check starter system 093 SS T Preheat ZKP Number Red alarm Engine shutdown Associated parameter 2 1090 922 Cause Corrective action Preheating temperature too low limit value 2 Coolant temperature...

Page 110: ...CU Supply Voltage ZKP Number Yellow alarm Associated parameter 2 0140 921 Cause Corrective action Supply voltage too low limit value 1 1 Check supply voltage 2 Check cabling 119 LOLO ECU Supply Voltag...

Page 111: ...ber Red alarm Associated parameter 2 4000 004 Cause Corrective action No suitable LifeData backup system available after expiry of timeout following ECU reset Backup system has no LifeData feature or...

Page 112: ...ing Busses CAN bus 1 and CAN bus 2 are redundant 182 AL CAN Wrong Parameters ZKP Number Red alarm Associated parameter 2 0500 682 Cause Corrective action Incorrect parameter values entered in data rec...

Page 113: ...CAN bus 2 Bus users ECU SAM or EMU faulty u Check operation of nodes and cabling 187 AL CAN1 Error Passive ZKP Number Yellow alarm Associated parameter 2 0500 687 Cause Corrective action CAN controll...

Page 114: ...ice configuration fault 201 SD T Coolant ZKP Number Red alarm Engine shutdown Associated parameter 1 8004 570 Cause Corrective action Coolant temperature sensor at engine outlet defective short circui...

Page 115: ...eplace if necessary Fault is rectified when engine is restarted 211 SD P Lube Oil ZKP Number Red alarm Engine shutdown Associated parameter 1 8004 563 Cause Corrective action Engine oil pressure senso...

Page 116: ...eplace as necessary Fault is rectified when engine is restarted 219 SD T Intake Air ZKP Number Yellow alarm Associated parameter 1 8004 573 Cause Corrective action Intake air temperature sensor defect...

Page 117: ...ult in the same operating cycle u Check sensor and cabling B1 1 replace if necessary Fault is rectified when engine is restarted 231 SD Camshaft Speed ZKP Number Red alarm Engine shutdown Associated p...

Page 118: ...nal governor fault u Replace ADEC engine governor 266 SD Speed Demand ZKP Number Red alarm Associated parameter 2 8006 586 Cause Corrective action Speed setting signal can no longer be transmitted fro...

Page 119: ...ctivation of gas supply solenoid valve No 1 faulty u Check cabling 384 AL Wiring TOP 4 ZKP Number Red alarm Associated parameter 2 8006 641 Cause Corrective action Short circuit or wire break on trans...

Page 120: ...Check engine coolant circuit pressure and volumetric flow 429 HI P Coolant ZKP Number Red alarm Engine shutdown Associated parameter 2 0101 931 Cause Corrective action Coolant pressure after engine to...

Page 121: ...coolant circuit pressure and volumetric flow 435 SS T Coolant before Engine ZKP Number Red alarm Engine shutdown Associated parameter 2 0173 932 Cause Corrective action Coolant temperature before eng...

Page 122: ...ng system inlet temperature too high mixture cooler clogged 1 Check mixture cooling circuit 2 Check mixture cooler for dirt 452 HIHI T Charge Mix ZKP Number Red alarm Engine shutdown Associated parame...

Page 123: ...Corrective action Intake air temperature is too low limit value 4 u Check ventilation system 459 SD P Coolant b Engine ZKP Number Red alarm Associated parameter 1 8004 627 Cause Corrective action Coo...

Page 124: ...ttle if necessary 476 AL Crash Rec Init Fault ZKP Number Red alarm Associated parameter 1 8010 007 Cause Corrective action Crash recorder initialization error u Contact Service 478 AL Comb Alarm Yel P...

Page 125: ...ing B79 22 replace if necessary Fault is rectified when engine is restarted 498 SD P Charge Mix Diff ZKP Number Red alarm Associated parameter 1 8004 630 Cause Corrective action Mixture differential p...

Page 126: ...ions 2 Check ignition timing Page 137 3 Check exhaust back pressure 4 Check valve clearance Page 145 5 Check throttle 6 Check mixture coolant system 513 SD P Coolant Diff ZKP Number Red alarm Associat...

Page 127: ...break u Check sensor and cabling B81 1 replace if necessary Fault is rectified when engine is restarted 522 SD P Intake Air after Filter B ZKP Number Yellow alarm Associated parameter 1 0187 900 Cause...

Page 128: ...xture throttle on B side replace mixture throttle on B side if necessary 543 AL Multiple FDH Slaves ZKP Number Yellow alarm Associated parameter 2 0555 005 Cause Corrective action More than one device...

Page 129: ...1090 122 Cause Corrective action Ignition failure Alarm is activated if the feedback signal from ignition system is not received within a specified time out period Either the ignition could not be act...

Page 130: ...ttle on A side and cabling Replace mixture throttle on A side if necessary 560 AL mixture throttle B fault ZKP Number Red alarm Engine shutdown Associated parameter 1 1450 013 Cause Corrective action...

Page 131: ...ameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Page 153 569 AL SAM Missing Data Fault ZKP Number Red alarm Associated parameter 2 10...

Page 132: ...uction is initiated 1 Check emissions 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane number 572 L3 AI CAN Max Retarded Timing ZKP Number Red alarm...

Page 133: ...sk of serious injury Danger to life Before barring the engine ensure that nobody is in the danger zone Engine barring manually 1 Remove guard plate 2 Engage barring tool 2 with ring gear 3 and install...

Page 134: ...of gas 1 Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit 2 If smell of gas is detected or the gas detection and alarm unit is triggered Avoid naked...

Page 135: ...log 2 O ring Spare Parts Catalog 4 WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask...

Page 136: ...rings arrowed at oil drain nip ple 9 Replace sealing ring in oil separator hous ing 10 Fit oil separator upper section 2 with filter element 11 Close clamping ring 3 12 Align clamp 1 and secure Repla...

Page 137: ...ger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note For the specified ignition timing contact your Service partner 1 St...

Page 138: ...ement Special tools Material Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Remove spark plug connector and install new one u Page 139 138 Task Description MS150059 0...

Page 139: ...Catalog Sealing ring Spare Parts Catalog WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protecti...

Page 140: ...eve of ignition line 2 Fit spark plug connector 6 with ignition ca ble 4 on spark plug 3 Fit locking plate 7 on cylinder head cover 4 Screw screw 2 with spring washer onto ig nition coil 1 5 Push prot...

Page 141: ...eplacement Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Remove spark plug and install new one u Page 139 MS150059 01E 2012 07 Task Description 141 TIM...

Page 142: ...pare Parts Catalog WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask...

Page 143: ...g 6 Fit new sealing ring 2 on spark plug 1 positioning it correctly 7 Screw spark plug into cylinder head Note The temperature of spark plug and cylinder head must be the same prior to tightening 8 Ti...

Page 144: ...cial tools Material Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 151 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3...

Page 145: ...o Qty Feeler gauge Y20098771 1 Offset screwdriver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Cylinder head cover removal Page 151 2...

Page 146: ...A1 as per diagram 4 Check distance between valve bridge and rocker arm using a feeler gauge 5 If the deviation from the desired value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1...

Page 147: ...Final steps 1 Barring tool removal Page 133 2 Cylinder head cover installation Page 151 MS150059 01E 2012 07 Task Description 147 TIM ID 0000012227 002...

Page 148: ...Depth gauge Y20095775 1 Preparatory steps 1 Remove spark plugs Page 139 2 Remove cylinder head covers Page 151 3 Remove sleeves arrow 4 Install barring device Page 133 5 Rotate crankshaft with barrin...

Page 149: ...1 and remove valve bridge Do not remove rocker arm 2 4 Measure distance between valve stem end and cylinder head top at the spark plug bore with depth gauge see figure The specified value for a new cy...

Page 150: ...3 Install sleeves arrow 4 Install cylinder head covers Page 151 5 Install spark plugs with new sealing rings Page 139 150 Task Description MS150059 01E 2012 07 TIM ID 0000012015 002...

Page 151: ...plug connector Page 139 3 Unscrew screws 2 4 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1 Clean mounting surface 2 Check condition of gasket replace if d...

Page 152: ...as is combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Gas supply Checking gas lines for leaks 1 Coat all connections of the gas supply line...

Page 153: ...e Parts Catalog Fleece prefilter optional Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the corresponding fault messag...

Page 154: ...tallation 1 Release clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and clean it 4 Place new air filt...

Page 155: ...ceed the mark 1 by up to 2 cm The cause of this may be that oil e g from the oil filter and oil heat exchanger flows back into the oil pan 3 The oil level must reach the mark 2 or ex ceed the mark 1 b...

Page 156: ...gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Extracting engine oil 1 Open shut off valve s in extraction line from engine and waste oil tank 2 Extract all oil from o...

Page 157: ...Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear e...

Page 158: ...health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filter with filte...

Page 159: ...lable WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant Level check 1 Read off syste...

Page 160: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 161 2 Fill with engine coolant Page 163 160 Task Description MS150059 01E 201...

Page 161: ...e Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch o...

Page 162: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 162 Task Description MS150059 01E 2012 07 TIM ID 0000006751 001...

Page 163: ...es and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Engine coolant filling 1 Fill with tr...

Page 164: ...of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 161 2 Release union nuts 1 and 3 3 Remov...

Page 165: ...Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Checking mixture coolant level 1 Read off system pressur...

Page 166: ...Change Special tools Material Spare parts Designation Use Part No Qty Mixture coolant Drain mixture coolant u Page 167 Fill mixture coolant system u Page 168 166 Task Description MS150059 01E 2012 07...

Page 167: ...ding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining charge air coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve in the coolant...

Page 168: ...goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Filling with coolant 1 Fill with treated co...

Page 169: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Page 170: ...r filter B side 3 B4 XX Exhaust gas temperature after cylinder XX 4 B79 22 Mixture pressure B side 5 B73 Mixture temperature Table 34 Sensors on right engine side The knocking sensors B80 XX are arran...

Page 171: ...nitoring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset 3 B13 2 Crankshaft speed ignition Table 35 Sensors on engine driving end MS150059 01E 2012 07 Task Description 171 TI...

Page 172: ...de 3 B79 21 Mixture pressure A side 4 B50 Crankcase pressure 5 B5 3 Engine oil pressure before filter 6 B7 Engine oil temperature 7 B5 1 Engine oil pressure after filter 8 B4 21 Combined exhaust tempe...

Page 173: ...24 Engine oil level 4 B1 2 Camshaft speed for ignition system 5 B6 3 Coolant temperature before engine 6 B6 1 Coolant temperature after engine 7 B16 1 Coolant pressure after engine 8 B4 22 Combined ex...

Page 174: ...the flexibility of our service staff we are always ready to assist you either during operation for preventive maintenance corrective work in case of malfunction or changed operat ing conditions or for...

Page 175: ...ICFN ISO Continuous Fuel stop brake power Fuel stop power ISO International coding for power output of combustion engines ISO International Organization for Stand ardization International umbrella org...

Page 176: ...S Safety System Safety system alarm TA Luft Technische Anleitung zur Reinhaltung der Luft General administrative instruction for federal emission control law in Germany TD Transmitter Deviation Alarm...

Page 177: ...auge Part No Y20095775 Qty Used in 1 7 4 3 Valve depth Measurement Page 148 Feeler gauge Part No Y20098771 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 145 Filter wrench Part No F3037...

Page 178: ...analysis Page 157 Offset screwdriver Part No F30452765 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 145 Ratchet head with extension Part No F30006212 Qty Used in 1 7 1 1 Engine Barrin...

Page 179: ...roboscope Part No Qty Used in 7 3 1 Ignition system Ignition timing check Page 137 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 7 3 3 Spark plug connector Removal and installation Page 139 Q...

Page 180: ...ty Used in 7 4 2 Valve clearance Check and adjustment Page 145 Qty Used in 7 7 2 Engine oil Change Page 156 Qty Used in 7 8 1 Engine oil filter Replacement Page 158 Isopropyl alcohol Part No X00058037...

Page 181: ...Soap solution Part No Qty Used in 7 5 1 Gas supply Checking gas lines for leaks Page 152 MS150059 01E 2012 07 Appendix B 181 DCL ID 0000016447 003...

Page 182: ...asket Part No Qty Used in 7 4 4 Cylinder head cover Removal and installation Page 151 Locking plate Part No Qty Used in 7 3 3 Spark plug connector Removal and installation Page 139 Qty Used in 7 3 5 S...

Page 183: ...o Qty Used in 7 3 4 Spark plug Replacement Page 141 Qty Used in 7 3 5 Spark plug Removal and installation Page 142 Spark plug connector Part No Qty Used in 7 3 2 Spark plug connector Replacement Page...

Page 184: ...ually 133 F Fault indication on SAM display 48 Fire and environmental protection 12 Firing order 20 Fluids and lubricants 12 G Gas engine phase 3 system Overview 30 Gas supply Checking gas lines for l...

Page 185: ...earance Check and adjustment 145 Valve depth Measurement 148 Valve gear Lubrication 144 Vent line of engine coolant circuit Replacement 164 W Wiring engine Check 169 MS150059 01E 2012 07 Appendix B 18...

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MTU 20 V 4000 L63, Operating Instructions Manual

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