MTU 20V4000L32F Operating Instructions Manual Download Page 32

Page: 32 / 180

2.6 Monitoring, Control and Regulation Equipment

2.6.1 Gas engine phase 3 system – Overview

General overview

1 Plant system

2 Engine system

3 Plant

4 Engine Control Unit

5 Engine Monitoring Unit

6 Humidity sensor

7 Throttles

8 Gas dosing unit

9 Knock module

10 Ignition

11 Compressor bypass

12 NOx sensor (optional)

Governing/control/monitoring

Engine Control Unit ECU-9

• 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

Engine Monitoring Unit EMU 8

• Monitors second gas solenoid in gas train to engine

Compressor bypass (F-series)

• Controls throttle reserve, blocks compressor pumps

Ignition system IC922

• Adjusts ignition timing for cylinders

32 | Product Summary | MS150108/00E 2013-06

TIM-ID: 0000043155 - 001

Summary of Contents for 20V4000L32F

Page 1: ...Operating Instructions Gas Engine 20 V 4000 Lx3x MS150108 00E...

Page 2: ...in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation mi crofilming and storage o...

Page 3: ...ing sequences 38 3 4 Engine Start 40 3 5 Operational checks 41 3 6 Emission values Check 42 3 7 Engine Shutdown 44 3 8 Emergency engine shutdown 45 3 9 After stopping the engine Engine remains ready f...

Page 4: ...cuit 163 6 10 1 Mixture coolant level Check 163 6 10 2 Mixture coolant Change 164 6 10 3 Mixture coolant Draining 165 6 10 4 Mixture coolant Filling 166 6 11 Wiring General for Engine Gearbox Unit 167...

Page 5: ...on approved by the manufacturer in writ ing including engine control parameters In compliance with all safety instructions and in adherence to all warning notices in this manual In accordance with the...

Page 6: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

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: ...ts and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages Malfunctions and emergency stop The procedures for...

Page 9: ...lves are activated via two different paths from the control system whereby one gas shutoff valve respectively is activated via one of the paths Gas trains must be monitored to detect minimum pressure...

Page 10: ...llium containing pinion Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device as an additional...

Page 11: ...roduct beforehand Hydraulic installation and removal Check the function and safe operating condition of tools and fixtures to be used Use only the specified devices for hydraulic removal installation...

Page 12: ...cy stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched...

Page 13: ...that has been trained and authorized for this task Have all work on gas carrying components carried out by authorized specialized companies Prior to starting maintenance work shut off the gas supply...

Page 14: ...ics of the product are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu f...

Page 15: ...e supply line or before device or tool is to be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When pa...

Page 16: ...n be life threatening depending on concentration Some gases can no longer be detected by sense of smell in higher concentrations Caution Risk of poisoning due to hazardous byproducts The absorption of...

Page 17: ...event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequ...

Page 18: ...turbocharger right hand side 5 Engine lifting equipment 6 Capacitor ignition system 7 Engine mounting bracket free end 8 Oil pan 9 Engine mounting bracket driving end 10 Starter 11 Throttle 12 Flywhe...

Page 19: ...con nection 11 Engine oil filter 12 Oil level switch 13 Engine oil heat exchanger KGS Free end Engine model designation Key to engine model designation 20V 4000 L33F 20 Number of cylinders V Cylinder...

Page 20: ...he left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at the driving end The numb...

Page 21: ...approx 3894 mm Width B for 20V approx 1584 mm Height C for 20V approx 2240 mm Crankshaft center to oil pan D approx 636 mm Crankshaft center to engine mount E approx 280 5 mm Table 2 Main engine dimen...

Page 22: ...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 22 Product Summary MS150108 00E 2013 06 TIM ID 0000010710 001...

Page 23: ...load Recommended maximum run time at this load Recommended minimum run time in subsequent operation at load 50 0 to 30 30 minutes 120 minutes 30 to 50 120 minutes 120 minutes 50 to 100 No restriction...

Page 24: ...net brake power as per 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...

Page 25: ...eze 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 98...

Page 26: ...ystem Number of cylinders 20 Gas temperature before engine min L C 10 Gas temperature before engine max L C 50 Gas flow pressure before TecJet min L mbar 80 Gas flow pressure before TecJet max L mbar...

Page 27: ...ifted during extended component mainte nance QL3 R kg 450 Table 16 Weights main dimensions Exhaust emissions Number of cylinders 20 Exhaust emission before catalytic converter at 100 DL nitric oxides...

Page 28: ...s are net brake power as per 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...

Page 29: ...eeze 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 98...

Page 30: ...ystem 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 mbar...

Page 31: ...t part to be lifted during extended component mainte nance QL3 R kg 450 Table 31 Weights main dimensions Exhaust emissions Number of cylinders 20 Exhaust emission before catalytic converter at 100 DL...

Page 32: ...ol monitoring Engine Control Unit ECU 9 Controls engine starting stopping and emergency stop Monitors engine operating parameters Controls throttles and sets gas mixture for requested speed power Moni...

Page 33: ...ayed for the cylinder concerned The power is reduced if this does not lead to improvement Gas control valve TecJet52 Controls the required amount of gas Mixture throttles P Series Mixture throttles in...

Page 34: ...cs Integral status fault display Fault memory Extensive I O features Engine and genset related parameter settings in flash memory In the event of inadmissible states and limit value violations Initiat...

Page 35: ...oring Unit EMU 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring MS150108 00E 2013 06 Product Summary 35 TIM ID 00...

Page 36: ...ve Out of service period 6 months Grease valve drive Page 148 Lube oil system Check engine oil level Page 154 Checking oil level in oil storage tank Page 154 Coolant circuit Out of service period more...

Page 37: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 154 Coolant circuit Check engine coolant level Page 158 Check mixture coolant level Page...

Page 38: ...by means of suitable systems in the facility A contact is provided to activate such sys tems Starting sequence The following steps are performed automatically when a start command is activated with t...

Page 39: ...ing a start request after emergency shutdown 1 Requesting external ventilation by contact 2 Activating starter 3 Waiting for starting speed 4 Flushing the engine 5 Disengaging starter 6 Engine running...

Page 40: ...ht or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone WARNING A high level of noise is produced when the engine is running Ris...

Page 41: ...hine room for smell of gas Page 130 ECU Check for fault messages if fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures...

Page 42: ...ot and pressurized Risk of injury and burning Wear protective clothing gloves and goggles safety mask WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well...

Page 43: ...limit value tolerance 10 make adjustments if the limit value is exceeded NOx limit value fuel optimized TA Luft Page 24 NOxlimit value emissions optimized 1 2 TA Luft Page 28 MS150108 00E 2013 06 Oper...

Page 44: ...nd mechanical stresses 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 ind...

Page 45: ...order to safely burn off uncombust ed fuel air mixture The ignition is only switched off in case of an overspeed violation or an internal ignition fault Throttles The throttles are always closed in ca...

Page 46: ...t be equipped with an SAV safety shut off valve when using gas control systems with inlet pressures in excess of 0 1 bar If the SAV is tripped by an EMERGENCY STOP it must be reset manually SAV trippi...

Page 47: ...ne Engine remains ready for operation After stopping the engine Item Task Engine generator control manufacturer specific Set operating mode e g HAND MANUAL AUTO AUTOMATIC MS150108 00E 2013 06 Operatio...

Page 48: ...and engine room temperature is be low 40 C Power supply to engine con trol system Switch off Gas supply Close gas shut off valve Air intake and exhaust sys tems If the engine is to remain out of servi...

Page 49: ...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 50: ...e oil filter when changing engine oil or when the interval years is reached at the latest Page 157 W1089 Check gas lines for leaks repair as required Page 151 W1091 Check ignition timing adjust as nec...

Page 51: ...mit value has not been attained MG Message General message SE System Error Warning due to node failure on the default field bus PB Push Button Status indication due to activation of certain control ke...

Page 52: ...he 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 signaled 52 Troubleshooting MS150108 00E 2013 06 TI...

Page 53: ...Check ignition timing Page 141 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...

Page 54: ...tion timing Page 141 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 55: ...tion timing Page 141 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 56: ...heck ignition timing Page 141 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 57: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive...

Page 58: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive...

Page 59: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive...

Page 60: ...lues 3 Check ignition timing Page 141 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 w...

Page 61: ...tion timing Page 141 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 62: ...ition timing Page 141 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 63: ...ignition timing Page 141 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 64: ...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 141 4 Check valve drive 1...

Page 65: ...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 141 4 Check valve drive 11...

Page 66: ...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 141 4 Check valve drive 1...

Page 67: ...g 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is...

Page 68: ...tion timing Page 141 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 69: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinde...

Page 70: ...tion timing Page 141 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 71: ...cabling 113902 SS Local Initiated Emerg Stop Red alarm Initiated by SAM Cause Corrective action Emergency stop detected Emergency stop was released manually button or ignition system reported overspee...

Page 72: ...g torque damage replace as necessary 1 4510 193 Knock Sensor Error A2 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor...

Page 73: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 199 Knock Sensor Error A8 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 74: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 205 Knock Sensor Error B4 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 75: ...m this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 211 Knock Sensor Error B10 Red alarm Initiated by anti knock control Cause Corrective action No...

Page 76: ...OverSpeed Shutdown Red alarm Initiated by IC922 Cause Corrective action Genset has exceeded admissible speed u Restart ignition 1 4520 238 E2PROM Checksum Error Red alarm Initiated by IC922 Cause Cor...

Page 77: ...Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 246 Open Primary Channel 2 Yellow alarm Initia...

Page 78: ...y Channel 8 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 253 Open Primary Channel 9 Yellow...

Page 79: ...y Channel 15 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 260 Open Primary Channel 16 Yello...

Page 80: ...ce as necessary 1 4520 271 Warning Missing Reset Signal Yellow alarm Initiated by IC922 Cause Corrective action Reset signal from crankshaft is missing u Sensor B 75 check sensor sensor distance and c...

Page 81: ...F series Cause Corrective action Combined alarm for details refer to the source alarm u Combined alarm for details refer to the source alarm 1 4530 009 Derating Active Yellow alarm Initiated by F ser...

Page 82: ...Error Yellow alarm Initiated by F series Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4530 016 Electronics Temperature High Error Red...

Page 83: ...ies Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4540 009 Zero Pressure Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow de...

Page 84: ...T Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 016 Delta P Fail High Red alarm Initiated by TecJet Cause Corrective action D...

Page 85: ...22 Delta P Fail Low Red alarm Initiated by TecJet Cause Corrective action Delta p via TecJet below set limit value u Check TecJet and configuration 1 4540 023 FGP Fail Low Red alarm Initiated by TecJe...

Page 86: ...Red alarm Initiated by TecJet Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJe...

Page 87: ...t TecJet 1 4540 036 FGP High Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 037 Watchdog Reset Red alarm Initiated by TecJet...

Page 88: ...044 Parameter Version Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 045 Main EEP Read Fail Red alarm Initiated by TecJet Cause C...

Page 89: ...1 Sense 12V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 052 ADC Test Error Red alarm Initiated by TecJet Cause Corrective actio...

Page 90: ...ct A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action Supply voltage has...

Page 91: ...ng or is outside the range 1 Check setting 2 Check cabling 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is incorrect u Check settin...

Page 92: ...Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action S...

Page 93: ...ng or is outside the range 1 Check setting 2 Check cabling 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check settin...

Page 94: ...Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 144 B CAN Stop Command Yellow alarm Initiated by ProAct B Bank Cause Corrective action Stop input signal received via CA...

Page 95: ...l system oil heat exchanger 2 Replace oil filter Page 157 3 Take oil sample and analyze Page 156 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas tem...

Page 96: ...charger 2 Check ignition timing Page 141 3 Check mixture setting 4 Check spark plugs 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective action Pressure loss via oil f...

Page 97: ...ne shutdown Associated parameter 2 3012 932 Cause Corrective action Speed of primary turbocharger too high limit value 2 u Turbocharger speed sensor is not fitted at present Check ECU setting for this...

Page 98: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 154 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...

Page 99: ...Check oil separator condition replace as necessary Page 131 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value...

Page 100: ...ly open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 152 Check exhaust back pressure Check differential pr...

Page 101: ...ellow alarm Associated parameter 2 1090 921 Cause Corrective action Preheating temperature too low limit value 1 Coolant temperature too low for engine start 1 Check preheating 2 Check differential co...

Page 102: ...supply voltage 2 Check cabling 121 HIHI ECU Power Supply Voltage Red alarm Associated parameter 2 0140 932 Cause Corrective action Supply voltage too high limit value 2 1 Check supply voltage 2 Check...

Page 103: ...N mode initializes communication by means of the PU data module However the necessary PU data module is not present or is invalid u Contact Service configuration fault 184 AL CAN PU Data Flash Error R...

Page 104: ...0500 689 Cause Corrective action CAN controller 2 has indicated a warning Possible causes may be e g missing node minor malfunctions or temporary bus overload u Check operation of bus stations and cab...

Page 105: ...use Corrective action Exhaust temperature sensor on B side defective short circuit or wire break u Check sensor and cabling B4 22 replace as necessary Fault is rectified following engine restart 211 S...

Page 106: ...ective action Intake air temperature sensor defective short circuit or wire break u Check sensor and cabling B49 2 replace as necessary Fault is rectified when engine is restarted 221 SD P Diff Lube O...

Page 107: ...s necessary Fault is rectified following engine restart 232 SD ETC Speed 1 Yellow alarm Associated parameter 1 3011 128 Cause Corrective action Speed sensor of primary turbocharger defective short cir...

Page 108: ...8006 639 Cause Corrective action Short circuit or wire break at transistor output plant side 2 TOP 2 Activation of red combined alarm faulty u Check cabling 383 AL Wiring TOP 3 Red alarm Associated p...

Page 109: ...sociated parameter 2 0180 921 Cause Corrective action Coolant differential pressure too low limit value 1 Insufficient volume flow u Check engine coolant circuit pressure and flow 429 HI P Coolant Red...

Page 110: ...ameter 2 0173 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure volumetric flow too low air in engine coolant circuit u Check engine cool...

Page 111: ...xture cooler for dirt 452 HIHI T Charge Mix Red alarm Engine shutdown Associated parameter 2 0169 932 Cause Corrective action Mixture temperature too high limit value 2 Mixture coolant pump failure vo...

Page 112: ...replace as necessary Fault is rectified following engine restart 470 SD T ECU Red alarm Associated parameter 1 8004 587 Cause Corrective action Temperature sensor for Engine Control Unit defective sh...

Page 113: ...t or wire break u Check sensor and cabling B79 21 replace as necessary Fault is rectified following engine restart 497 SD P Charge Mix B Red alarm Engine shutdown Associated parameter 1 8004 629 Cause...

Page 114: ...2 0182 932 Cause Corrective action Mixture pressure on B side too high limit value 2 1 Check emissions 2 Check ignition timing Page 141 3 Check exhaust back pressure 4 Check valve clearance Page 145...

Page 115: ...ed parameter 1 0187 900 Cause Corrective action Intake air pressure sensor after filter on B side defective short circuit or wire break u Check sensor and cabling B81 2 replace as necessary Fault is r...

Page 116: ...ply solenoid valves are faulty the timeout period is set too short or communication is faulty 1 Check gas train 2 Check cabling 557 AL speed drop fault Red alarm Engine shutdown Associated parameter 2...

Page 117: ...over air filter on A side is too high u Replace air filter Page 152 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure loss over air f...

Page 118: ...emissions 2 Check ignition timing Page 141 3 Check combustion chamber 4 Check gas quality if feasible methane number 571 L2 Al CAN Max Retarded Timing Yellow alarm Power reduction Associated parameter...

Page 119: ...ling to NOx sensors and air humidity sensor 617 LO Current Heat Value of Fuel Yellow alarm Associated parameter 2 1210 006 Cause Corrective action Fuel calorific value has undershot the first limit va...

Page 120: ...parameter 2 3050 025 Cause Corrective action NOx emissions have undershot the second limit value 1 Check gas quality if feasible 2 Check gas pressure 3 Check NOx sensor 4 Check emissions 623 HI NOx V...

Page 121: ...ause Corrective action Engine power sensor defect analog input 2 1 Generator eff power not correctly transmitted 2 Generator eff power can also be transmitted via CAN bus as an option 3 Check configur...

Page 122: ...n for knock control faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU knock control 4 Check settings with device specific dialog software XD10 653 AL IC92x Comm Lost Red alarm...

Page 123: ...log software XD50 1 657 AL ProActB Comm Lost Red alarm Associated parameter 1 4550 196 Cause Corrective action CAN bus communication for throttle B faulty 1 Check cabling 2 Check power supply 3 Carry...

Page 124: ...llow alarm Associated parameter 1 4520 993 Cause Corrective action An internal combined alarm in the ignition system was detected u An exact fault designation is transmitted via CAN bus to the genset...

Page 125: ...ult designation is transmitted via CAN bus to the genset control system 672 AL NOxB Yellow Yellow alarm Associated parameter 1 4560 193 Cause Corrective action An internal combined alarm at NOx sensor...

Page 126: ...ct fault designation is transmitted via CAN bus to the genset control system 680 AL ProActB Red Red alarm Associated parameter 1 4550 191 Cause Corrective action An internal combined alarm in throttle...

Page 127: ...Yellow alarm Associated parameter 1 1480 301 Cause Corrective action No oil replenishment within a programmable time u Check oil replenishment system 689 HI Oil Refill Yellow alarm Associated paramet...

Page 128: ...Limit value 2 exceeded u Check gas supply 842 AL Fuel Throttle Pos L1 Yellow alarm Associated parameter 2 8006 038 Cause Corrective action TecJet throttle position has exceeded limit value 1 u Check...

Page 129: ...ody being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Barring engine manually 1 Remove guard plate 2 Engage barr...

Page 130: ...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 detection an...

Page 131: ...oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor...

Page 132: ...escence filter 5 must be installed in the correct position in the housing 10 Place coalescence filter 5 in housing en suring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12...

Page 133: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 134 2 Install new spark plug Page 135 MS150108 00E 2013...

Page 134: ...lated glove at least class 4 WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing ris...

Page 135: ...ring operation do not touch ignition cable except with insulated glove at least class 4 WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of press...

Page 136: ...to tightening 6 Tighten spark plug to specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molykote P 37...

Page 137: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 138 2 Install spark plug connector Page 139 MS150...

Page 138: ...y to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Removing spark plug connector 1 Undo screws 4 on...

Page 139: ...Parts Catalog Sealing ring Spare Parts Catalog DANGER Live components flash over Risk of serious injury danger to life During operation do not touch ignition cable except with insulated glove at leas...

Page 140: ...ore press ignition lead flange 6 down against spring pressure and turn screw fixture in until screws 4 are aligned on both sides Part number on flange faces 6 o clock 5 Tighten screws 4 on ignition le...

Page 141: ...when the engine is running Risk of damage to hearing Wear ear defenders Ignition system Ignition timing check Note The service tool Diasys and a dongle with access rights 1A or higher is required to...

Page 142: ...y Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 134 2 Remove cylinder head covers Page 149 3 Remove sleeves arrow 4 Install barring device Page 129 5 Rotate cranks...

Page 143: ...ase adjusting screw 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 specifie...

Page 144: ...3 Install sleeves arrow 4 Install cylinder head covers Page 150 5 Install spark plugs with new sealing rings Page 135 144 Task Description MS150108 00E 2013 06 TIM ID 0000043220 001...

Page 145: ...No Qty Feeler gauge 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 149...

Page 146: ...feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation from the specified value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release locknu...

Page 147: ...Final steps 1 Remove barring device Page 129 2 Install cylinder head cover Page 150 MS150108 00E 2013 06 Task Description 147 TIM ID 0000043600 001...

Page 148: ...ls Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 149 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install...

Page 149: ...disabled Removing cylinder head cover 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 138 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 150: ...mponents for special cleanliness Installing cylinder head cover 1 Clean mounting surface 2 Check condition of gasket replace if dam aged 3 Position gasket and cylinder head cover 1 on cylinder head 4...

Page 151: ...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 152: ...lter 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 corresponding fault message appears Repla...

Page 153: ...tion 1 Loosen clamp 2 2 Remove air filter 1 and clamp 2 from connecting flange of intake housing 3 3 Verify that there are no objects in the flange of the intake housing 3 and clean it 4 Place new ai...

Page 154: ...level may exceed 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...

Page 155: ...l vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Engine oil extraction 1 Open shut off valve s i...

Page 156: ...Avoid 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 WARNING...

Page 157: ...oves and goggles safety mask Avoid 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...

Page 158: ...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 Checking engine coolant level 1 Read off fuel opt...

Page 159: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 160 2 Fill with engine coolant Page 162 MS150108 00E 2013 06 Task Description...

Page 160: ...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 of...

Page 161: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points MS150108 00E 2013 06 Task Description 161 TIM ID 0000006751 002...

Page 162: ...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 coolant 1 Fi...

Page 163: ...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 164: ...tools Material Spare parts Designation Use Part No Qty Mixture coolant Changing mixture coolant 1 Drain mixture coolant Page 165 2 Fill with fresh mixture coolant Page 166 164 Task Description MS1501...

Page 165: ...injury 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...

Page 166: ...ive 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...

Page 167: ...swing freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Conta...

Page 168: ...B16 1 Coolant pressure after engine 4 B4 XX Exhaust temperature after cylinder XX 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 36 Sensors on right engine side 20 V The knock senso...

Page 169: ...cription Monitors 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset ignition system 3 B13 2 Crankshaft speed ignition Table 37 Sensors on driving end MS150108 00E 2013 06 Task Des...

Page 170: ...re after turbocharger 2 B79 21 Mixture pressure A side 3 B50 Crankcase pressure 4 B5 3 Engine oil pressure before filter 5 B7 Engine oil temperature 6 B5 1 Engine oil pressure after filter Table 38 Se...

Page 171: ...essure before engine 3 B1 3 Camshaft speed for anti knock control 4 B1 1 Camshaft speed for engine governor 5 B24 Engine oil level 6 B6 3 Coolant temperature before engine 7 B6 1 Coolant temperature a...

Page 172: ...High Alarm Measured value exceeds 2nd maxi mum limit value HT Hochtemperatur High temperature ICFN ISO Continuous Fuel stop brake power Fuel stop power ISO International coding for power output of co...

Page 173: ...t Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische Anleitung zur Reinhaltung der Luft General administrative instruction for federal emission control law in Germany TD Tran...

Page 174: ...exibility 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 oper ating conditions or for spare...

Page 175: ...2 Valve clearance Check and adjustment Page 145 Barring gear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 129 Feeler gauge Part No Y20098771 Qty Used in 1 6 4 2 Valve clearance C...

Page 176: ...or smell of gas Page 130 Gas measuring and warning device not stocked by MTU Part No Qty Used in 3 6 Emission values Check Page 42 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Eng...

Page 177: ...l Page 134 Qty Used in 1 6 3 3 Spark plug Installation Page 135 Stroboscope Not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 141 Torque wrench 10 60 Nm Part No F...

Page 178: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 145 178 Appendix B MS150108 00E 2013 06 DCL ID 0000028442 001...

Page 179: ...6 Engine oil filter Replacement 157 Engine oil level Check 154 Engine sides Designation 20 Engine wiring Check 167 Engine Overview 18 F Fault messages Engine Control Unit 95 Genset control system log...

Page 180: ...al instructions for applica tions with gaseous fuel 13 Operation 8 Operation special instructions for applications with gaseous fuel 9 Organizational requirements 6 Personnel requirements 6 Repair wor...

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MTU 20V4000L32F, Operating Instructions Manual

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