MTU 20V 4000 L62 Operating Instructions Manual Download Page 35

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3.6 Monitoring, Control and Regulation Equipment

3.6.1 Gas engine phase 3 system – Overview

Overview

1 Unit system
2 Engine system
3 System
4 Engine governor

5 Engine Monitoring Unit
6 NOx sensor
7 Compressor bypass
8 Ignition

9 Knock module

10 Gas dosing 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

Engine Monitoring Unit EMU

• Evaluation unit for PT 1000 temperature sensor to determine and monitor exhaust temperatures of indi-

vidual cylinders

MS150034/04E 2016-11

| Monitoring, Control and Regulation Equipment | 35

TIM-ID: 0000017542 - 003

Summary of Contents for 20V 4000 L62

Page 1: ...Operating Instructions Gas engine 20V 4000 L62 MS150034 04E...

Page 2: ...hout the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and storage or processing in electronic systems...

Page 3: ...2 4 2 Putting the engine into operation after extended out of service periods 3 months 43 4 3 Putting the engine into operation after scheduled out of service period 44 4 4 Control starting and stoppi...

Page 4: ...coolant Draining 173 7 9 4 Engine coolant Filling 175 7 9 5 Vent line of engine coolant circuit Replacement 176 7 10 Low Temperature Circuit 177 7 10 1 Mixture coolant level Check 177 7 10 2 Mixture...

Page 5: ...the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex ch...

Page 6: ...regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops authorized by the man...

Page 7: ...se personnel must be instructed repeatedly Personnel requirements All work on the product must be carried out by trained instructed and qualified personnel only Training at the Training Center of the...

Page 8: ...that all connections have been correctly allocated e g polarity direction Immediately after putting the product into operation make sure that all control and display instruments as well as the signali...

Page 9: ...quipment is in operation certain components of these appliances are electrically live Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times...

Page 10: ...control system with one path assigned to each of the gas shut off valves The gas train shall feature minimum pressure monitoring Additional equipment may be necessary in the gas train e g maximum pres...

Page 11: ...f flow plant manufacturer user scope of sup ply a manual shut off valve a gas filter Gas trains feature the following components in the direction of flow MTU scope of supply two gas shut off valves au...

Page 12: ...mer components e g engine mounts damping elements couplings and V belts must not be painted Only install them after painting the engine or mask them prior to painting The following applies to starters...

Page 13: ...installed and that all tools and loose parts have been removed especially the barring tool Ensure that no unattached parts have been left in on the product e g including rags and cable straps Ensure...

Page 14: ...prior to working on assemblies ESD Work on electrostatically endangered components which could be damaged by electrostatic discharge ESD must always be carried out with appropriate equipment Appropri...

Page 15: ...easuring component dimensions Workpieces components and measuring equipment lie in the specified tolerance range at a reference tem perature of 20 C MS150034 04E 2016 11 Safety 15 TIM ID 0000040535 01...

Page 16: ...nnel only The gas supply shall be connected by trained qualified and authorized personnel only Work on the gas bearing parts of the product shall be performed by specially trained qualified and author...

Page 17: ...always available and that staff are familiar with their correct handling Noise Wear ear protectors in work areas with a sound pressure level in excess of 85 dB A Noise can lead to an increased risk of...

Page 18: ...stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not impaired Avoid open flames in the vicinity No smoking Observe fire p...

Page 19: ...emergency stop Cordon off danger zone Ensure sufficient ventilation Do not enter the hazard zone until it has been established via measurement of the gas concentration with a suitable gas detector tha...

Page 20: ...n NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with...

Page 21: ...en weight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking device for the crankshaft Prior to transporting the engine genset system it is...

Page 22: ...as control valve 6 Gas outlet 7 Engine oil heat exchanger 8 Coolant distribution housing 9 Capacitor ignition system 10 Spark plug 11 Cylinder head cover 12 Ignition coil 13 Cylinder head 14 Starter r...

Page 23: ...ng eye free end 10 Engine mounting bracket free end 11 Engine oil filter 12 Engine oil sampling port 13 Oil level switch 14 Engine coolant inlet connec tion to cooler KGS Free end Engine model designa...

Page 24: ...accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and lette...

Page 25: ...h A approx 3896 mm Width B approx 1488 mm Height C approx 2250 mm Crankshaft center to oil pan D approx 636 mm Crankshaft center to engine mount E approx 280 5 mm Table 2 Main engine dimensions MS1500...

Page 26: ...3 4 Firing order Firing order Number of cylin ders Firing order 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 26 Product Summary MS150034 04E 2016 11 TIM ID 0000010710 003...

Page 27: ...Table 3 Reference conditions Power related data power ratings 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 ISO 3046...

Page 28: ...el related data basic design Coolant system HT circuit Number of cylinders 20 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 Coolant temperature at engine c...

Page 29: ...ter oil filter bar 5 0 Lube oil pressure after oil filter warning R bar 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 Table 10 Lube oil system Fuel system Number of cylinders 20 Gas temper...

Page 30: ...f cylinders 20 Dry engine weight basic configuration engine R kg 9217 Heaviest component to be lifted during extended component maintenance QL3 R kg 440 Table 15 Weights main dimensions Exhaust emissi...

Page 31: ...wer ratings 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 ISO 3046 A kW 2000 Mean effective pressure pme continuous p...

Page 32: ...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 33: ...ber of cylinders 20 Gas temperature before engine min L C 10 Gas temperature before engine max L C 30 Gas flow pressure before gas control valve min L mbar 80 Gas flow pressure before gas control valv...

Page 34: ...mponent to be 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...

Page 35: ...ine 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 I...

Page 36: ...eristics If knocking is found the ignition timing is retarded on the cylinder in question If this does not result in an improvement the power is reduced Gas control valve TecJet50 Controls the require...

Page 37: ...lock 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 contro...

Page 38: ...ensive I O features Plant side 14 inputs 7 outputs 2 serial interfaces Engine side 39 inputs 28 outputs 1 serial interface Engine and plant related parameter settings in Flash memory In the event of i...

Page 39: ...ections SAM functions 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 f...

Page 40: ...to 20 mA 0 to 10 V etc 4 frequency inputs 1 dialog interface Extendable with MCS 5 PIM I O cards CANOpen and J1939 interface For CANOpen and J1939 interface a type CCB2 printed circuit board 1 is ins...

Page 41: ...U EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring MS150034 04E 2016 11 Monitoring Control and Regulation Equipment...

Page 42: ...d Recommended min time in subsequent op eration at load 50 kWmech cyl Emission compliance as specified in technical data 0 to 30 30 minutes 120 minutes No 30 to 50 120 minutes 120 minutes No 50 to ful...

Page 43: ...e 161 Lube oil system Check engine oil level Page 167 Check oil level in oil storage tank Page 167 Coolant circuit Standstill 1 year Change engine coolant Page 172 Change mixture coolant Page 178 Cool...

Page 44: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 167 Coolant circuit Check engine coolant level Page 171 Check mixture coolant level Page...

Page 45: ...gas A 24V digital output is pro vided to activate such systems Start sequence If a start command is activated with the engine being at standstill the following steps are carried out auto matically 1...

Page 46: ...activation request for external ventilation is sent via the 24V digital output 1 Activation request for external ventilation via contact 2 Activating starter 3 Waiting for starting speed 4 Purging eng...

Page 47: ...High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Starting the engine Note A max of 5 engine starting attempts are permitted at a max fuel supply open...

Page 48: ...n sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Operational checks Item Measure Machine room Check machine room for s...

Page 49: ...l of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well ventilated...

Page 50: ...1 at the measuring point 2 2 Start engine 3 Approach the measuring point until a stable operating state has been reached 4 Carry out measurement and read off meas ured value for NOx rel ppm 5 Compare...

Page 51: ...nd mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are in...

Page 52: ...Emergency stop pushbutton Press pushbutton Engine will be shut down Safety measures Item Measure Emergency stop pushbutton Remove key Rectifying cause Item Measure Engine control system Determine caus...

Page 53: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC MS150034 04E 2016 11 Operatio...

Page 54: ...below 40 C Operating voltage for engine management Switch off Gas supply Close manual gas shutoff valve Air intake and exhaust sys tems If the engine is to remain out of service for more than 1 week...

Page 55: ...linder heads after component maintenance or ex tended 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 56: ...age 170 W1089 Check gas lines for leaks seal if required Page 164 W1091 Check ignition timing adjust as necessary Page 154 W1207 Check valve clearance and adjust if necessary IMPORTANT First adjustmen...

Page 57: ...ety system has reacted in some way TD Transmitter Deviation Two sensors that record the measured values for the same medium are sending different measured values HI High The first limit value has been...

Page 58: ...fault 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...

Page 59: ...tart 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 alarm is signale...

Page 60: ...ext 27 Download Server Collision 28 not projected node 29 Device specific error 30 not projected node 31 Device specific error Table 37 SE System Error alarms 60 Troubleshooting MS150034 04E 2016 11 T...

Page 61: ...gnition timing Page 154 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 62: ...tion timing Page 154 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 63: ...tion timing Page 154 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 64: ...Check ignition timing Page 154 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 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 154 4 Check valve drive 1...

Page 66: ...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 154 4 Check valve drive...

Page 67: ...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 154 4 Check valve drive 1...

Page 68: ...es 3 Check ignition timing Page 154 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 69: ...tion timing Page 154 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 70: ...ition timing Page 154 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 71: ...ignition timing Page 154 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 72: ...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 154 4 Check valve drive 1...

Page 73: ...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 154 4 Check valve drive 11...

Page 74: ...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 154 4 Check valve drive 1...

Page 75: ...k spark plug 2 Check emission values 3 Check ignition timing Page 154 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this c...

Page 76: ...tion timing Page 154 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 77: ...ition timing Page 154 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 78: ...tion timing Page 154 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 79: ...ystem Page 167 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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...ted by antiknock control Cause Corrective action No signal received from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 153114 Knock Sensor Error A4 Red...

Page 94: ...m Initiated by antiknock control Cause Corrective action No signal received from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 153121 Knock Sensor Erro...

Page 95: ...Initiated by antiknock control Cause Corrective action No signal received from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 153128 Knock Sensor Error...

Page 96: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality...

Page 97: ...ustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality i...

Page 98: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality...

Page 99: ...ustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality i...

Page 100: ...rrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality if feasible methane num...

Page 101: ...rrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality if feasible methane num...

Page 102: ...rrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality if feasible methane num...

Page 103: ...Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality if feasible methane number 153259 HIHI Knock Integrator B9 Red alarm Initiated by SAM Cause Corrective action Emergency st...

Page 104: ...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 153266 HI Misfire Integrator A6...

Page 105: ...2 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 153273 HI Misfire Integrator B3...

Page 106: ...9 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 153280 HI Misfire Integrator B10...

Page 107: ...A6 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 153287 HIHI Misfire Integrator A7...

Page 108: ...r B3 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 153294 HIHI Misfire Integrator B...

Page 109: ...eck emission values 2 Check spark plug energy level ignition system 153299 HIHI Misfire Integrator B9 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check...

Page 110: ...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 111: ...er 2 Check ignition timing Page 154 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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...ions 2 Check ignition timing Page 154 3 Check exhaust back pressure 4 Check valve clearance Page 155 5 Check throttle 6 Check mixture coolant system 513 SD P Coolant Diff ZKP Number Red alarm Associat...

Page 135: ...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 136: ...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 137: ...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 138: ...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 139: ...ameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Page 165 569 AL SAM Missing Data Fault ZKP Number Red alarm Associated parameter 2 10...

Page 140: ...uction is initiated 1 Check emissions 2 Check ignition timing Page 154 3 Check combustion chamber 4 Check gas quality if feasible methane number 572 L3 AI CAN Max Retarded Timing ZKP Number Red alarm...

Page 141: ...ody being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the engine s danger zone Barring engine manually 1 Remove guard plate 2 Engage barri...

Page 142: ...not smoke Checking machine room for smell 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 detecti...

Page 143: ...ues which are harmful to health Risk of injury and poisoning Allow the engine to cool to below 50 C before beginning work Wear protective clothing protective gloves and safety glasses facial protectio...

Page 144: ...filter 5 must be installed in the correct position in the housing 10 Place coalescer filter 5 in housing ensuring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12 Screw on w...

Page 145: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 146 2 Install new spark plug Page 147 MS150034 04E 2016...

Page 146: ...ble protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupt...

Page 147: ...gine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressuriz...

Page 148: ...wrench to tighten spark plug to specified tightening torque Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molycote P 37 50 5 Nm 9 Fit spark plug conn...

Page 149: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 150 2 Install spark plug connector Page 152 MS150...

Page 150: ...rotective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing...

Page 151: ...ning and check 1 Remove spark plug connector Page 150 2 Remove spark plug isolator sealing ring Page 152 3 Check spark plug connector 1 and ignition line 2 visually for kinks pinching points and britt...

Page 152: ...k of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ej...

Page 153: ...5 Push protective cap 3 onto ignition coil MS150034 04E 2016 11 Ignition System 153 TIM ID 0000042718 003...

Page 154: ...en the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition check Note The DiaSys service tool in conjunction with a dongle with access rights 1A or higher and the...

Page 155: ...Use Part No Qty Feeler gage Y20098771 1 Angular screw driver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head cover...

Page 156: ...diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation from the set value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release...

Page 157: ...Final steps 1 Remove barring device Page 141 2 Install cylinder head cover Page 163 MS150034 04E 2016 11 Valve Drive 157 TIM ID 0000012227 003...

Page 158: ...Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 146 2 Remove cylinder head covers Page 162 3 Remove sleeves arrow 4 Install barring tool Page 141 5 Rotate crankshaf...

Page 159: ...ew 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 sliding depth gauge see figure The specified value f...

Page 160: ...3 Install sleeves arrow 4 Install cylinder head covers Page 163 5 Install spark plugs with new sealing rings Page 147 160 Valve Drive MS150034 04E 2016 11 TIM ID 0000012015 004...

Page 161: ...tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 162 2 Fill oil chambers of rocker arms and adjusting screws with oil 3 Insta...

Page 162: ...ing disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 150 3 Remove screws 2 4 Remove cylinder head cover with gasket fr...

Page 163: ...omponents for special cleanliness Cylinder head cover Installa tion 1 Clean mounting surface 2 Check condition of gasket replace if dam aged 3 Position gasket and cylinder head cover 1 on cylinder hea...

Page 164: ...part of the personal safety equipment Do not smoke WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment th...

Page 165: ...efilter made of fleece option Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the cor responding fault message appears R...

Page 166: ...stalla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from con necting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air...

Page 167: ...e oil level may ex 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 e...

Page 168: ...contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Extracting en...

Page 169: ...ctive gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electri...

Page 170: ...protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion...

Page 171: ...is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Checking engine coolant level 1 Read off fuel optimized Page 27 o...

Page 172: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 173 2 Fill with engine coolant Page 175 172 Coolant Circuit General High Temperature Circuit...

Page 173: ...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 off preheater if i...

Page 174: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 174 Coolant Circuit General High Temperature Circuit MS150034 04E 2016 11 TIM ID 0000006751 002...

Page 175: ...es safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with coolant 1 Fill with treated...

Page 176: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 173 2 Release union nuts 1 and 3 3 Remove coolant vent l...

Page 177: ...t is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Mixture coolant level Check 1 Read off system filling pressure...

Page 178: ...ools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 179 2 Fill with fresh mixture coolant Page 180 178 Low Temperature Circuit MS1...

Page 179: ...ry and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining mixture coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve at dra...

Page 180: ...clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with coo...

Page 181: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector h...

Page 182: ...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 38 Sensors on B side The knocking sensors B80 XX are arranged on the...

Page 183: ...of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset ignition system 3 B13 2 Crankshaft speed ignition Table 39 Sensors on driving end MS150034 04E 2016 11 Wiring General for Eng...

Page 184: ...r temperature A side 4 81 1 Intake air pressure after filter A side 5 B79 21 Mixture pressure A side 6 B50 Crankcase pressure 7 B5 3 Engine oil pressure before filter 8 B7 Engine oil temperature 9 B5...

Page 185: ...knock control 3 B24 Engine oil level 4 B1 2 Camshaft speed for ignition system 5 B6 3 Coolant temperature before engine 6 B16 1 Coolant pressure after engine 7 6 1 Coolant temperature after engine Tab...

Page 186: ...g work Wear protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Coolant is hot and under pressure Risk of injury and scal...

Page 187: ...eral information Arrangement and position of sensor Page 182 2 Loosen and disconnect connector 2 3 Unscrew electronics box 1 at the eyelets 4 Remove sensor via nut 3 MS150034 04E 2016 11 Wiring Genera...

Page 188: ...re assembly Note Do not wipe off thread grease of manufactur er If necessary coat thread with high tem perature anti corrosion thread grease Too much grease can contaminate the sensor during operation...

Page 189: ...ximum limit value HIHI High High Alarm Measured value exceeds 2nd maximum limit value HT High Temperature High temperature ICFN ISO Continuous Fuel stop brake power Fuel stop power acc to ISO internat...

Page 190: ...otive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische...

Page 191: ...r during operation for preventive maintenance corrective work in case of malfunction or changed operating condi tions or for spare parts supply For our locally available support go to MTU s Internet s...

Page 192: ...4 1 Valve clearance Check and adjustment Page 155 Barring gear Part No F6555766 Qty Used in 1 7 1 1 Engine Barring manually Page 141 Feeler gage Part No Y20098771 Qty Used in 1 7 4 1 Valve clearance C...

Page 193: ...stocked by MTU Part No Qty Used in 4 7 Emission values Check Page 49 Oil filter wrench Part No F30379104 Qty Used in 1 7 8 1 Engine oil filter Replacement Page 170 Ratchet adapter Part No F30027340 Qt...

Page 194: ...n 1 7 4 2 Valve protrusion Measurement Page 158 Socket wrench 24 mm Part No F30029815 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 155 Special wrench 20 8 mm Part No F30452574 Qty Use...

Page 195: ...2769 Qty Used in 1 7 3 3 Spark plug Installation Page 147 Qty Used in 1 7 3 7 Spark plug connector Installation Page 152 Qty Used in 1 7 11 4 Sensors Installation Page 188 Torque wrench 60 320 Nm Part...

Page 196: ...manually 141 Emergency shutdown 52 Main dimensions 25 Shutdown 51 Start 47 Engine cabling Check 181 Engine coolant Change 172 Draining 173 Filling 175 Level check 171 Engine driving end Definition 24...

Page 197: ...ific information for dual fuel applications 19 Fluids and lubricants specific information for gaseous fuel supply applications 19 Important provisions 5 6 Indirect materials 17 Initial start up 8 Main...

Page 198: ...152 Removal 150 Replacement 149 Starting sequence Control 45 Stopping sequence Control 45 T transport 21 V Valve clearance Adjustment 155 Check 155 Valve gear Lubrication 161 Valve protrusion Measurem...

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MTU 20V 4000 L62, Operating Instructions Manual

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Summary of Contents for 20V 4000 L62

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