MTU 20V4000L63 Operating Instructions Manual Download Page 31

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2.6 Monitoring, Control and Regulation Equipment

2.6.1 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

individual cylinders

MS150059/02E 2013-10

| Product Summary | 31

TIM-ID: 0000017542 - 003

Summary of Contents for 20V4000L63

Page 1: ...Operating Instructions Gas engine 20 V 4000 Lx3 MS150059 02E...

Page 2: ...n 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 or...

Page 3: ...ice period 40 3 4 Control starting and stopping sequences 41 3 5 Engine Start 43 3 6 Operational checks 44 3 7 Emission values Check 45 3 8 Engine Shutdown 46 3 9 Emergency stop 47 3 10 After stopping...

Page 4: ...Temperature Circuit 171 6 10 1 Mixture coolant level Check 171 6 10 2 Mixture coolant Change 172 6 10 3 Mixture coolant Draining 173 6 10 4 Mixture coolant Filling 174 6 11 Wiring General for Engine G...

Page 5: ...nfiguration approved by the manufacturer in writ ing including engine control parameters In compliance with all safety regulations and in adherence with all warning notices in this manual In accordanc...

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: ...th the consequences of any operations performed During operation the display instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit v...

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: ...work 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 Observe the safety data sheet Safe...

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

Page 12: ...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 f...

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: ...roduct 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 facturer Nonc...

Page 15: ...y 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 painting...

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

Page 19: ...Engine mounting bracket free end 11 Engine oil filter 12 Engine oil sampling port 13 Oil level switch 14 Engine coolant inlet con nection to cooler KGS Free end Engine model designation Key to the en...

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: ...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 3 Main engine dimensions MS1500...

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 MS150059 02E 2013 10 TIM ID 0000010710 001...

Page 23: ...efernce data 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 as per ISO 3046 A kW 2200...

Page 24: ...l 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 co...

Page 25: ...l pressure after oil filter bar 5 0 Lube oil pressure after oil filter warning R bar 5 0 Lube oil pressure after oil filter shutdown L bar 4 5 Table 11 Lube oil system Fuel system Number of cylinders...

Page 26: ...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 16 Weights main dimensions Exhaust emissio...

Page 27: ...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 power ISO...

Page 28: ...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 29: ...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 30: ...lifted during extended component maintenance QL3 R kg 440 Table 31 Weights main dimensions Exhaust emissions Number of cylinders 20 Exhaust emission before catalytic converter at 100 DL nitric oxides...

Page 31: ...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 t...

Page 32: ...knock characteristics 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 Contro...

Page 33: ...y 4 Terminal block 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 Ant...

Page 34: ...rge number of inputs 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 memo...

Page 35: ...g de sign 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...

Page 36: ...V etc 4 frequency 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...

Page 37: ...Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring MS150059 02E 2013 10 Product Summary 37 TIM ID 0000017541 001...

Page 38: ...oad 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 N...

Page 39: ...137 Valve gear Standstill 6 months Lubricate valve gear Page 156 Lube oil system Check engine oil level Page 162 Check oil level in oil storage tank Page 162 Coolant circuit Standstill 1 year Change e...

Page 40: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 162 Coolant circuit Check engine coolant level Page 166 Check mixture coolant level Page...

Page 41: ...ld gas A 24V digital output is provided to activate such systems Start sequence If a start command is activated with the engine being at standstill the following steps are carried out automatically 1...

Page 42: ...activa tion 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 en...

Page 43: ...aught 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 High level of engine noise when the engine is running Risk of...

Page 44: ...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 smell of gas...

Page 45: ...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 ventilated Repair leaki...

Page 46: ...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 47: ...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 cause for emergenc...

Page 48: ...Engine remains ready for operation After stopping the engine Item Action Engine generator control manufacturer specific Select operating mode e g HAND MANUAL AUTO AUTOMATIC 48 Operation MS150059 02E...

Page 49: ...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 service for more than 1 week sea...

Page 50: ...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 51: ...e oil filter when changing engine oil or when the interval years is reached at the latest Page 165 W1089 Check gas lines for leaks repair as required Page 159 W1091 Check ignition timing adjust as nec...

Page 52: ...ty 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 53: ...from the SAM This code is always followed by a 6 digit number indicating the fault code from the SAM EC This is an alarm message from the engine governor This code is always followed by a 3 digit num...

Page 54: ...oviding that automatic engine shutdown to protect the engine has not been configured or is not tripped Contact Service immediately start fault rectification Red alarm Caution the engine is running at...

Page 55: ...ect 25 I O Module Slot7 Defect 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 Table 38 SE System...

Page 56: ...gnition timing Page 149 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 57: ...tion timing Page 149 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 58: ...tion timing Page 149 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 59: ...Check ignition timing Page 149 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 60: ...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 149 4 Check valve drive 1...

Page 61: ...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 149 4 Check valve drive...

Page 62: ...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 149 4 Check valve drive 1...

Page 63: ...es 3 Check ignition timing Page 149 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 64: ...tion timing Page 149 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 65: ...ition timing Page 149 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 66: ...ignition timing Page 149 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 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 149 4 Check valve drive 1...

Page 68: ...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 149 4 Check valve drive 11...

Page 69: ...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 149 4 Check valve drive 1...

Page 70: ...k spark plug 2 Check emission values 3 Check ignition timing Page 149 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this c...

Page 71: ...tion timing Page 149 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 72: ...ition timing Page 149 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 73: ...tion timing Page 149 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 74: ...ystem Page 162 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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...Readjustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas qua...

Page 92: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality...

Page 93: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality...

Page 94: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality...

Page 95: ...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 149 3 Check combustion chambe...

Page 96: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Page 97: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Page 98: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Page 99: ...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 100: ...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 Y...

Page 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 02E 2013 10 Troubleshoo...

Page 106: ...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 107: ...er 2 Check ignition timing Page 149 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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...ions 2 Check ignition timing Page 149 3 Check exhaust back pressure 4 Check valve clearance Page 150 5 Check throttle 6 Check mixture coolant system 513 SD P Coolant Diff ZKP Number Red alarm Associat...

Page 131: ...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 132: ...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 133: ...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 134: ...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 135: ...ameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Page 160 569 AL SAM Missing Data Fault ZKP Number Red alarm Associated parameter 2 10...

Page 136: ...uction is initiated 1 Check emissions 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 572 L3 AI CAN Max Retarded Timing ZKP Number Red alarm...

Page 137: ...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 138: ...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 139: ...il 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 140: ...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 141: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 142 2 Install new spark plug Page 143 MS150059 02E 2013...

Page 142: ...ar protective gloves WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wea...

Page 143: ...able in operation 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 risk of ruptur...

Page 144: ...k 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 Molycote P 37 50 5 Nm 9 Fit spark plug conn...

Page 145: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 146 2 Install spark plug connector Page 147 MS150...

Page 146: ...gloves WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety gogg...

Page 147: ...hing the ignition cable in operation 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 hea...

Page 148: ...5 Push protective cap 3 onto ignition coil 148 Task Description MS150059 02E 2013 10 TIM ID 0000042718 001...

Page 149: ...RNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note The service tool Diasys and a dongle with access ri...

Page 150: ...se 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 Pa...

Page 151: ...gram 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 lo...

Page 152: ...Final steps 1 Remove barring device Page 137 2 Install cylinder head cover Page 158 152 Task Description MS150059 02E 2013 10 TIM ID 0000012227 003...

Page 153: ...depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 142 2 Remove cylinder head covers Page 157 3 Remove sleeves arrow 4 Install barring device Page 137 5 Rotate crankshaft with...

Page 154: ...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 specified value for a...

Page 155: ...3 Install sleeves arrow 4 Install cylinder head covers Page 158 5 Install spark plugs with new sealing rings Page 143 MS150059 02E 2013 10 Task Description 155 TIM ID 0000012015 003...

Page 156: ...ls Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 157 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install...

Page 157: ...disabled Removing cylinder head cover 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 146 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 158: ...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 159: ...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 160: ...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 161: ...alla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from connecting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air fil...

Page 162: ...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 by up to 2 cm Note Toppin...

Page 163: ...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 in extrac...

Page 164: ...sk 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 WARN...

Page 165: ...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 166: ...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 167: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 168 2 Fill with engine coolant Page 170 MS150059 02E 2013 10 Task Description...

Page 168: ...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 169: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points MS150059 02E 2013 10 Task Description 169 TIM ID 0000006751 002...

Page 170: ...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 171: ...lant 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 pressu...

Page 172: ...l tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 173 2 Fill with fresh mixture coolant Page 174 172 Task Description MS15005...

Page 173: ...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 174: ...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 175: ...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 176: ...essure after filter B side 3 B4 XX Exhaust gas temperature after cylinder XX 4 B79 22 Mixture pressure B side 5 B73 Mixture temperature Table 39 Sensors on B side The knocking sensors B80 XX are arran...

Page 177: ...Monitoring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset ignition system 3 B13 2 Crankshaft speed ignition Table 40 Sensors on driving end MS150059 02E 2013 10 Task Descri...

Page 178: ...1 Intake air 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 temper...

Page 179: ...ed for antiknock 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...

Page 180: ...her during operation for preventive maintenance corrective work in case of malfunction or changed oper ating conditions or for spare parts supply For our locally available support go to MTU s Internet...

Page 181: ...High Alarm Measured value exceeds 1st maxi mum limit value HIHI High High Alarm Measured value exceeds 2nd maxi mum limit value HT High Temperature ICFN ISO Continuous Fuel stop Net brake power Fuel...

Page 182: ...ff valve SBV Sicherheitsabbalseventil Safety discharge valve SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische Anleitung zur Reinhaltung der Luft General ad...

Page 183: ...4 1 Valve clearance Check and adjustment Page 150 Barring gear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 137 Feeler gage Part No Y20098771 Qty Used in 1 6 4 1 Valve clearance C...

Page 184: ...or smell of gas Page 138 Gas measuring and warning device not stocked by MTU Part No Qty Used in 3 7 Emission values Check Page 45 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Eng...

Page 185: ...l Page 142 Qty Used in 1 6 3 3 Spark plug Installation Page 143 Stroboscope not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 149 Torque wrench 10 60 Nm Part No F...

Page 186: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 1 Valve clearance Check and adjustment Page 150 186 Appendix B MS150059 02E 2013 10 DCL ID 0000016447 004...

Page 187: ...s 21 Shutdown 46 Start 43 Wiring check 175 Engine coolant Change 167 Draining 168 Filling 170 Level check 166 Engine governor Fault messages 106 Engine layout 18 Engine oil Change 163 Sample extractio...

Page 188: ...5 Maintenance work 10 Maintenance work special instructions for applica tions with gaseous fuel 13 Operation 8 Operation special instructions for applications with gaseous fuel 9 Organizational requir...

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MTU 20V4000L63, Operating Instructions Manual

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