1. Manuals
  2. Brands
  3. MTU Manuals
  4. Engine
  5. 20V4000L33F
  6. Operating instructions manual

MTU 20V4000L33F Operating Instructions Manual

Hide thumbs Also See for 20V4000L33F:
Table of Contents

Advertisement

Quick Links

Operating Instructions

Gas Engine
20 V 4000 Lx3x
MS150108/00E

Advertisement

Table of Contents
loading

Related Manuals for MTU 20V4000L33F

Summary of Contents for MTU 20V4000L33F

  • Page 1: Operating Instructions

    Operating Instructions Gas Engine 20 V 4000 Lx3x MS150108/00E...
  • Page 2 This Publication is protected by copyright and may not be used 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 or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 3.7 Engine – Shutdown 3.8 Emergency engine shutdown 1.1 Important provisions for all products 3.9 After stopping the engine – Engine remains 1.2 Personnel and organizational requirements ready for operation 1.3 Transport 3.10 After stopping the engine – Putting the 1.4 Safety regulations for startup and operation engine out of operation 1.5 Safety regulations for startup and operation,...
  • Page 4 6.9.2 Engine coolant – Change 7 Appendix A 6.9.3 Engine coolant – Draining 7.1 Abbreviations 6.9.4 Engine coolant – Filling 7.2 MTU Onsite Energy contact / service 6.10 Low-Temperature Circuit partner 6.10.1 Mixture coolant level - Check 6.10.2 Mixture coolant – Change 8 Appendix B 6.10.3 Mixture coolant –...

  • Page 5: Safety

    1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. General information This product may pose a risk of injury or damage in the following cases: •...

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 7: Transport

    Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis.

  • Page 8: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.

  • Page 9: Safety Regulations For Startup And Operation, Special Instructions For Applications With Gaseous Fuel

    1.5 Safety regulations for startup and operation, special instructions for applications with gaseous fuel Gas system Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device. This must be designed by the plant designer according to site conditions. The connection to the gas supply network is made by the plant designer in accordance with regulations of the DVGW (DVGW490, G490/I).

  • Page 10: Safety Regulations For Maintenance And Repair Work

    1.6 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 11 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and cable ties) Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
  • Page 12 Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work.

  • Page 13: Safety Regulations For Maintenance And Repair Work, Special Instructions For Applications With Gaseous Fuel

    1.7 Safety regulations for maintenance and repair work, special instructions for applications with gaseous fuel Safety regulations prior to maintenance and repair work Installation and connection of the gas supply must only be carried out by a specialized company with staff that has been trained and authorized for this task.

  • Page 14: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The latest version can be found on the website on the "Technical Info" tab at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety instructions that apply to the product.

  • Page 15: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 16: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials, Special Instructions For Applications With Gaseous Fuel

    1.9 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials, special instructions for applications with gaseous fuel Natural gas Observe the safety data sheet. Caution: Highly flammable gas, forms an explosive mixture with air/oxygen. Caution: Weak narcotic gas, risk of suffocation at very high concentration. All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during operation.

  • Page 17: Standards For Safety Notices In The Text

    1.10 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury. • Remedial action WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury. •...

  • Page 18: Product Summary

    2 Product Summary 2.1 Engine – Overview 1 Air filter/air inlet 6 Capacitor ignition system 11 Throttle 2 Mixture cooler 7 Engine mounting bracket, 12 Flywheel 3 Exhaust turbocharger, left- free end 13 Engine Control Unit/ hand side 8 Oil pan Engine Monitoring Unit 4 Exhaust turbocharger, 9 Engine mounting bracket,...
  • Page 19 1 Crankcase breather, oil 6 Throttle 11 Engine oil filter separator 7 Spark plug 12 Oil level switch 2 Exhaust outlet 8 Cylinder head cover 13 Engine oil heat exchanger 3 Gas control valve 9 Cylinder head KGS Free end 4 Gas inlet connection 10 Engine oil sampling con- 5 Ignition coil...

  • Page 20: Engine Side And Cylinder Designations

    2.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B"...

  • Page 21: Engine - Main Dimensions

    2.3 Engine – Main dimensions Main engine dimensions Length (A) for 20V 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.

  • Page 22: Firing Order

    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...

  • Page 23: Technical Data

    2.5 Technical Data 2.5.1 Runtimes at partial load Gas engines were designed and optimized for continuous operation at 100 % load. The following restrictions apply to ensure maximum operational availability of the engine plant and to reduce maintenance to a minimum: Power, referenced to nominal Recommended maximum run- Recommended minimum run-...

  • Page 24: Engine Data 20V 4000 L33F, Fuel-Optimized ("Ta-Luft")

    2.5.2 Engine data 20V 4000 L33F, fuel-optimized (“TA-Luft”) Explanation: DL Reference value: Continuous power (CP) BL Reference value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 25 Consumption Number of cylinders Lube oil consumption after 1000 h run time g/kWh Table 7: Consumption Model related data (basic design) Number of cylinders Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders Cylinder arrangement: V angle Degrees (°)
  • Page 26 Number of cylinders Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler LT (at nominal flow rate 8.56) Table 10: Coolant system (LT circuit) Lube oil system Number of cylinders Lube oil operating temperature after oil heat exchanger, from °C Lube oil operating temperature after oil heat exchanger, to °C...
  • Page 27 Capacities Number of cylinders Engine coolant, engine-side (without cooling system) Liters Mixture coolant, engine side (without cooling system) Liters Total engine oil capacity for initial filling (standard oil system) Liters Oil change capacity, max. (standard oil system) Liters Table 15: Capacities Weights/main dimensions Number of cylinders Dry engine weight (basic-configuration engine)

  • Page 28: Engine Data 20 V 4000 L33F, Emissions-Optimized (1/2 "Ta-Luft")

    2.5.3 Engine data 20 V 4000 L33F, emissions-optimized (1/2 “TA-Luft”) Explanation: DL Reference value: Continuous power (CP) BL Reference value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 29 Consumption Number of cylinders Lube oil consumption after 1000 h run time g/kWh Table 22: Consumption Model related data (basic design) Number of cylinders Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders Cylinder arrangement: V angle Degrees (°)
  • Page 30 Number of cylinders Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler LT (at nominal flow rate 8.56) Table 25: Coolant system (LT circuit) Lube oil system Number of cylinders Lube oil operating temperature after oil heat exchanger, from °C Lube oil operating temperature after oil heat exchanger, to °C...
  • Page 31 Capacities Number of cylinders Engine coolant, engine-side (without cooling system) Liters Mixture coolant, engine side (without cooling system) Liters Total engine oil capacity for initial filling (standard oil system) Liters Oil change capacity, max. (standard oil system) Liters Table 30: Capacities Weights/main dimensions Number of cylinders Dry engine weight (basic-configuration engine)

  • Page 32: Monitoring, Control And Regulation Equipment

    2.6 Monitoring, Control and Regulation Equipment 2.6.1 Gas engine phase 3 system – Overview General overview 1 Plant system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 Humidity sensor 10 Ignition 3 Plant 7 Throttles 11 Compressor bypass 4 Engine Control Unit 8 Gas dosing unit 12 NOx sensor (optional)
  • Page 33 Anti-knock control AKR • Controls monitored cylinders with regard to knock characteristics. If knocking is detected, ignition is delayed 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) •...

  • Page 34: Purpose Of The Units

    2.6.2 Purpose of the units ECU 9 engine governor Central control and monitoring unit for the engine • Communication with other devices and higher-level systems via CAN bus • Control of throttles (mixture and gas) • Registration and analysis of engine operating states •...
  • Page 35 Engine Monitoring 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...

  • Page 36: Operation

    3.1 Putting the engine into operation after extended out-of- service-periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item...

  • Page 37: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    3.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine shut down and 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 38: Control, Starting And Stopping Sequences

    3.3 Control, starting and stopping sequences NOTICE Risk of engine damage due to incorrect action. Risk of severe damage to property! • Ensure engine is ready for operation before starting. See engine documentation. Starting and stopping sequences The starting sequence is software-controlled and depends on the place of start command input. To ensure that no mixture is in the engine when ignition is switched on or off, which is a specific re- quirement for gas engines, special procedures for engine start / stop are specified.
  • Page 39 Emergency stop sequence If an emergency stop command is activated, the following steps are carried out automatically: 1. Closing gas supply solenoid valves 2. Closing mixture throttles 3. Engine running down to standstill 4. Deactivating ignition 5. Requesting external ventilation by contact Restarting after emergency stop A scavenging phase and a request for external ventilation by contact ensue following a start request after emergency shutdown.

  • Page 40: Engine - Start

    3.4 Engine – Start Preconditions ☑ Generator not connected to network. ☑ Start interlock not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body 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.

  • Page 41: Operational Checks

    3.5 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Only run the engine at low power. Keep away from the engine's danger zone. WARNING A high level of noise is produced when the engine is running. Risk of damage to hearing.

  • Page 42: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas measuring and warning device (not stocked by MTU) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in.
  • Page 43 Compare measured value with limit value (tolerance = − 10 %), make adjustments if the limit value is exceeded. • NO limit value, fuel optimized (TA-Luft) (→ Page 24). • NO limit value, emissions-optimized (1/2 TA-Luft) (→ Page 28). MS150108/00E 2013-06 | Operation | 43...

  • Page 44: Engine - Shutdown

    3.7 Engine – Shutdown Preconditions ☑ Generator is not connected to network. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses. Overheating of and, therefore, damage to components is possible. •...

  • Page 45: Emergency Engine Shutdown

    3.8 Emergency engine shutdown WARNING Escaping residual gas may create an explosive atmosphere in case of emergency stop. Explosion hazard! • Ensure that any escaping residual gas is routed out by means of appropriate facility ventilation and use of an SBV (safety blow-off valve) to prevent any risk of explosive atmosphere. •...
  • Page 46 Item Action A contact is provided to request the ventilation system in the scaveng- • ing phase. Note: • The gas control system must be equipped with an SAV (safety shut-off Gas train valve) when using gas control systems with inlet pressures in excess of 0.1 bar.

  • Page 47: After Stopping The Engine - Engine Remains Ready For Operation

    3.9 After stopping the engine – Engine remains ready for operation After stopping the engine Item Task Engine/generator control Set operating mode, e.g. HAND, MANUAL, AUTO, AUTOMATIC (manufacturer-specific) MS150108/00E 2013-06 | Operation | 47...

  • Page 48: After Stopping The Engine - Putting The Engine Out Of Operation

    If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Fluids and Lubricants Specifi- cations A001061/..). The preservative effect of the engine coolant may be used as an alternative in case of out-of-service periods lasting for more than 1 month, by running the engine for at least 2 hours at rated power once a month.

  • Page 49: Maintenance

    4 Maintenance 4.1 50-hours check 50-hours check One-time operations to be carried out after the first 50 operating hours of the cylinder head (with a new engine, after installation of new cylinder heads, after component maintenance or extended component maintenance). When installing a cylinder head with run-in mating faces (e.g.

  • Page 50: Maintenance Task Reference Table [Ql1]

    4.2 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 51: Troubleshooting

    OEM (see documentation of the genset man- ufacturer). A prerequisite for performing the measures to rectify faults is corresponding qualification/training at MTU. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful. Recommended action in case of alarm...
  • Page 52 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 signaled. 52 | Troubleshooting | MS150108/00E 2013-06...

  • Page 53: Fault Messages In Genset Control System Log

    5.2 Fault messages in genset control system log 112222 – HI T-Exhaust Mean Yellow alarm. Initiated by EMU. Cause Corrective action Weighted average of all 1. Check emission values. individual exhaust gas 2. Check ignition timing (→ Page 141). temperatures is too high. 3.
  • Page 54 112305 – HI T-Exhaust A5 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 141). with the average value. 3. Check valve drive (exhaust valves do not close). 112306 –...
  • Page 55 112311 – HI T-Exhaust B1 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 141). with the average value. 3. Check valve drive (exhaust valves do not close). 112312 –...
  • Page 56 112317 – HI T-Exhaust B7 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 141). with the average value. 3. Check valve drive (exhaust valves do not close). 112318 –...
  • Page 57 112403 – LO T-Exhaust A3 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 58 112408 – LO T-Exhaust A8 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 59 112413 – LO T-Exhaust B3 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 60 112418 – LO T-Exhaust B8 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 61 112504 – HIHI T-Exhaust A4 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 141). with the average value. 3. Check valve drive (exhaust valves do not close). 112505 –...
  • Page 62 112510 – HIHI T-Exhaust A10 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 141). with the average value. 3. Check valve drive (exhaust valves do not close). 112511 –...
  • Page 63 112516 – HIHI T-Exhaust B6 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 141). with the average value. 3. Check valve drive (exhaust valves do not close). 112517 –...
  • Page 64 112602 – LOLO T-Exhaust A2 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 65 112607 – LOLO T-Exhaust A7 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 66 112612 – LOLO T-Exhaust B2 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 67 112617 – LOLO T-Exhaust B7 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 141). 4.
  • Page 68 112703 – HIHI T-Exhaust A3 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing(→ Page 141). too high. 3. Check valve drive (exhaust valves do not close). 112704 –...
  • Page 69 112709 – HIHI T-Exhaust A9 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 141). too high. 3. Check valve drive (exhaust valves do not close). 112710 –...
  • Page 70 112715 – HIHI T-Exhaust B5 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 141). too high. 3. Check valve drive (exhaust valves do not close). 112716 –...
  • Page 71 112923 – MD/SD T-Exhaust Red alarm. Initiated by EMU. Cause Corrective action Combined alarm (for details, u Combined alarm (for details, refer to the source alarm). refer to the source alarm). 113200 – Communication Lost ECU Red alarm. Initiated by SAM. Cause Corrective action No communication with ECU...
  • Page 72 1.4510.188 – Internal Error Red alarm. Initiated by anti-knock control. Cause Corrective action Hardware not ready for u Restart knock module. operation. 1.4510.189 – Error Camshaft Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from camshaft sensor u Check cabling.
  • Page 73 1.4510.196 – Knock Sensor Error A5 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.197 – Knock Sensor Error A6 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 74 1.4510.202 – Knock Sensor Error B1 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.203 – Knock Sensor Error B2 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 75 1.4510.208 – Knock Sensor Error B7 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.209 – Knock Sensor Error B8 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 76 1.4520.234 – Error Missing Camshaft Signal Red alarm. Initiated by IC922. Cause Corrective action No camshaft signal. u Check sensor, sensor distance and cabling, replace as necessary. 1.4520.235 – Error Number of Teeth Red alarm. Initiated by IC922. Cause Corrective action Incorrect number of teeth on 1.
  • Page 77 1.4520.241 – Individual Timing out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified individual ignition u Adjust value. timing is beyond the valid range. 1.4520.242 – Selftest Shutdown Yellow alarm. Initiated by IC922. Cause Corrective action Self-test is active with the u Restart ignition.
  • Page 78 1.4520.249 – Open Primary, Channel 5 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.250 – Open Primary, Channel 6 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 79 1.4520.256 – Open Primary, Channel 12 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.257 – Open Primary, Channel 13 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 80 1.4520.264 – Open Primary, Channel 19 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.265 – Open Primary, Channel 20 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 81 1.4520.275 – Odd Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified energy level is beyond u Adjust value. the valid range. 1.4520.276 – Even Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified energy level is beyond...
  • Page 82 1.4530.012 – Analog Input High Error Yellow alarm. Initiated by F-series. Cause Corrective action F-series setting is incorrect. u Check setting. 1.4530.013 – Analog Input Low Error Yellow alarm. Initiated by F-series. Cause Corrective action F-series setting is incorrect. u Check setting. 1.4530.014 –...
  • Page 83 1.4530.019 – Run Enable not active Yellow alarm. Initiated by F-series. Cause Corrective action F-series setting is incorrect. u Check setting. 1.4530.020 – Spring Check Failed Yellow alarm. Initiated by F-series. Cause Corrective action F-series setting is incorrect. u Check setting. 1.4530.021 –...
  • Page 84 1.4540.012 – Valve Position Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 1.4540.013 – High Elec Temp Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 85 1.4540.019 – Position Fail High Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 1.4540.020 – Elec Temp Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 86 1.4540.026 – Analog Input Low Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting. 1.4540.027 – Analog Input High Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting.
  • Page 87 1.4540.033 – Battery Volt High Error Red alarm. Initiated by TecJet. Cause Corrective action Supply voltage has reached 1. Check supply voltage. maximum limit value. 2. Check cabling. 1.4540.034 – FGT High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet.
  • Page 88 1.4540.041 – TecJet Internal Fault Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 1.4540.042 – Keyswitch State Red alarm. Initiated by TecJet. Cause Corrective action Keyswitch cabling missing. u Check cabling. 1.4540.043 – Parameter Error Red alarm.
  • Page 89 1.4540.048 – SPI ADC Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 1.4540.049 – Sense 5V Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 90 1.4540.055 – Factory CAL Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 1.4540.056 – PWM Duty Cycle High Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting.
  • Page 91 1.4550.036 – A - Temperature derating active Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action The internal temperature is 1. Check temperature in room. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.037 – A - Temperature above 120 °C Red alarm.
  • Page 92 1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by ProAct A-Bank. Cause Corrective action CAN bus connection faulty. u Check cabling and setting. 1.4550.044 – A - CAN Stop Command Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action “Stop”...
  • Page 93 1.4550.136 – B - Temperature derating active Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action The internal temperature is 1. Check temperature in room. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.137 – A - Temperature above 120 °C Red alarm.
  • Page 94 1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by ProAct B-Bank. Cause 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”...

  • Page 95: Fault Messages - Engine Control Unit

    5.3 Fault messages – Engine Control Unit 015 – LO P-Lube Oil Yellow alarm. Associated parameter 2.0100.921 Cause Corrective action Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger. value 1). No oil in engine, engine 2.
  • Page 96 021 – HI T-Exhaust B Yellow alarm. Associated parameter 2.0127.931 Cause Corrective action Exhaust gas temperature (B 1. Check exhaust turbocharger. side) after turbine too high (limit 2. Check ignition timing (→ Page 141). value 1). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4.
  • Page 97 030 – SS Engine Overspeed Red alarm. Engine shutdown. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. 1. Check governor. This usually fault message 2. Check throttle closing position. usually follows other fault messages. Check governor, throttle closing position. 031 –...
  • Page 98 051 – HI T-Lube Oil Yellow alarm. Associated parameter 2.0125.931 Cause Corrective action Engine oil temperature after oil 1. Check engine coolant circuit. heat exchanger too high (limit 2. Check oil heat exchanger. value 1). Oil heat exchanger 3. Check oil level (→ Page 154). contaminated, coolant temperature too high.
  • Page 99 058 – SS P-Coolant Red alarm. Engine shutdown. Associated parameter 2.0101.922 Cause Corrective action Coolant pressure after engine u Check engine coolant circuit (pressure and flow). too low (limit value 2). Insufficient volume flow, static pressure too low. 063 – HI P-Crankcase Yellow alarm.
  • Page 100 068 – SS T-Coolant Red alarm. Engine shutdown. Associated parameter 2.0120.932 Cause Corrective action Coolant temperature after u Check engine coolant circuit. engine too high (limit value 2). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit. 089 –...
  • Page 101 092 – SS Starter Speed Not Reached Red alarm. Start terminated. Associated parameter 2.1090.923 Cause Corrective action Minimum speed for flushing u Check starter system. process and ignition release was not attained. 093 – SS T-Preheat Red alarm. Engine shutdown. Associated parameter 2.1090.922 Cause Corrective action...
  • Page 102 118 – LO ECU Power Supply Voltage Yellow alarm. Associated parameter 2.0140.921 Cause Corrective action Supply voltage too low (limit 1. Check supply voltage. value 1). 2. Check cabling. 119 – LOLO ECU Power Supply Voltage Red alarm. Associated parameter 2.0140.922 Cause Corrective action Supply voltage too low (limit...
  • Page 103 181 – AL CAN2 Node Lost Yellow alarm. Associated parameter 2.0500.681 Cause Corrective action Bus node (SAM or EMU) lost on u Check operation of bus stations and cabling. Buses (CAN bus 1 CAN bus 2. and CAN bus 2) are redundant. 182 –...
  • Page 104 187 – AL CAN1 Error Passive Yellow alarm. Associated parameter 2.0500.687 Cause Corrective action CAN controller 1 has indicated a u Check operation of bus stations and cabling. warning. Bus users (ECU, SAM or EMU) are faulty. 188 – AL CAN2 Bus Off Yellow alarm.
  • Page 105 204 – SD Level Lube Oil Red alarm. Engine shutdown. Associated parameter 1.8004.602 Cause Corrective action Engine oil level sensor defective, u Check sensor and cabling (B24), replace as necessary. Fault is short circuit or wire break. rectified following engine restart. 206 –...
  • Page 106 214 – SD P-Crankcase Red alarm. Associated parameter 1.8004.568 Cause Corrective action Crankcase pressure sensor u Check sensor and cabling (B50), replace as necessary. Fault is defective, short circuit or wire rectified following engine restart. break. 216 – SD T-Lube Oil Red alarm.
  • Page 107 229 – AL Stop Camshaft Sensor Defect Red alarm. Engine shutdown. Associated parameter 1.8004.562 Cause Corrective action Engine stop due to camshaft u Check sensor and cabling (B1.1), replace as necessary. Fault is sensor fault (and a previous rectified following engine restart. crankshaft sensor fault in the same operating cycle).
  • Page 108 266 – SD Speed Demand Red alarm. Associated parameter 2.8006.586 Cause Corrective action Speed setting signal can no u Check signal and cabling between plant and ADEC. longer be transmitted from plant. 381 – AL Wiring TOP 1 Yellow alarm. Associated parameter 2.8006.638 Cause Corrective action...
  • Page 109 418 – SD T-Intake Air B Yellow alarm. Associated parameter 1.8004.603 Cause Corrective action Intake air temperature sensor u Check sensor and cabling (B49.2), replace as necessary. defective, short circuit or wire break. 419 – SD T-Coolant before Engine Red alarm. Associated parameter 1.8004.604 Cause Corrective action...
  • Page 110 431 – SS P-Coolant before Engine Red alarm. Engine shutdown. Associated parameter 2.0168.922 Cause Corrective action Coolant pressure before engine u Check engine coolant circuit (pressure and flow). too low (limit value 2). Insufficient volume flow, static pressure too low. 434 –...
  • Page 111 447 – HIHI P-Charge Mix Diff. Red alarm. Engine shutdown. Associated parameter 2.0183.932 Cause Corrective action Difference in mixture pressures 1. Check throttles for varying positions and malfunction. sensed on A and B side is too 2. Check mixture lines for leakage. high (limit value 2).
  • Page 112 457 – LO T-Intake Air Yellow alarm. Associated parameter 2.0123.921 Cause Corrective action Intake air temperature is too low u Check ventilation system. (limit value 3). 458 – LOLO T-Intake Air Red alarm. Engine shutdown. Associated parameter 2.0123.922 Cause Corrective action Intake air temperature is too low u Check ventilation system.
  • Page 113 478 – AL Comb. Alarm Yel (Plant) Yellow alarm. Associated parameter 2.8006.001 Cause Corrective action Combined YELLOW alarm from u Combined alarm (for details, refer to the source alarm). plant. 479 – AL Comb. Alarm Red (Plant) Red alarm. Engine shutdown. Associated parameter 2.8006.002 Cause Corrective action...
  • Page 114 499 – SD T-Charge Mix Red alarm. Associated parameter 1.8004.632 Cause Corrective action Mixture temperature sensor u Check sensor and cabling (B73), replace as necessary. Fault is defective, short circuit or wire rectified following engine restart. break. 511 – HIHI P-Charge Mix A Red alarm.
  • Page 115 517 – SD P-Charge Mix before Throttle Red alarm. Associated parameter 1.8004.631 Cause Corrective action Mixture pressure sensor before u Check sensor and cabling (B79.23), replace as necessary. Fault throttle defective, short circuit is rectified following engine restart. or wire break. 520 –...
  • Page 116 554 – AL Ignition Fault Red alarm. Associated parameter 2.1090.122 Cause Corrective action Ignition failure. Alarm is 1. Check ignition system. activated if the feedback signal 2. Check cabling. from ignition system is not received within a specified time- out period. Either the ignition could not be activated, the timeout period is set too short, or communication is faulty.
  • Page 117 560 – Mixture throttle B Red alarm. Engine shutdown. Associated parameter 1.1450.013 Cause Corrective action A problem related to mixture u Check mixture throttle on B side and cabling. Replace mixture throttle on B side occurred. throttle on B side as necessary. Possible causes: Mixture throttle defective, no power supply to throttle, cabling of feedback...
  • Page 118 569 – AL SAM Missing Data Fault Red alarm. Associated parameter 2.1090.128 Cause Corrective action This alarm is activated if the u Check the cabling/connectors of the devices connected to ECU does not receive some SAM and ECU bus. Replace devices as necessary. messages to be transmitted from SAM.
  • Page 119 583 – AL GLS closed Red alarm. Engine shutdown. Associated parameter 2.0451.115 Cause Corrective action Generator load switch does not 1. Check generator load switch. open when engine stops. Engine 2. Manually disconnect generator switch. is motoring. 3. Open any existing mains circuit breaker. 4.
  • Page 120 620 – HIHI Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.009 Cause Corrective action Fuel calorific value has u Check gas quality if feasible. undershot the second limit value. 621 – LO NOx Value Yellow alarm. Associated parameter 2.3050.024 Cause Corrective action NOx emissions have undershot...
  • Page 121 633 – SD P-Ambient Air (HDT2800) none Associated parameter 1.0700.087 Cause Corrective action Air humidity sensor defect. u Sensor currently not in standard scope of delivery. 634 – SD T0-Ambient Air (HDT2800) none Associated parameter 1.0700.089 Cause Corrective action Air humidity sensor defect. u Sensor currently not in standard scope of delivery.
  • Page 122 650 – Al Req Angle Throttle B Red alarm. Associated parameter 2.1200.936 Cause Corrective action Opening angle of throttles B 1. Check charge-air pressure reserve. exceeded. 2. Intake air temperature outside TVU data. 3. Check compressor for contamination. 4. Reduce power. 651 –...
  • Page 123 655 – AL TecJet Comm Lost Red alarm. Associated parameter 1.4540.996 Cause Corrective action CAN bus communication for gas 1. Check cabling. control valve faulty 2. Check power supply. (alternatively, a stepper motor 3. Carry out restart of ECU, EMU & gas control valve. with gas mixer can be installed).
  • Page 124 664 – AL Oil Refill Error Red alarm. Associated parameter 1.1480.305 Cause Corrective action Combined alarm for automatic u After initiation of the alarms “HI Oil Refill” and oil replenishment faulty. “HI Lube Oil Level refill” a programmable timeout period starts. The engine is stopped when this time expires.
  • Page 125 669 – AL ProActA Yellow Yellow alarm. Associated parameter 1.4550.093 Cause Corrective action An internal combined alarm in u An exact fault designation is transmitted via CAN bus to the throttle A was detected. genset control system. 670 – AL ProActB Yellow Yellow alarm.
  • Page 126 677 – AL FSeries Red Red alarm. Associated parameter 1.4530.991 Cause Corrective action An internal combined alarm in u An exact fault designation is transmitted via CAN bus to the the bypass flap was detected. genset control system. 678 – AL TecJet Red Red alarm.
  • Page 127 685 – AL Lube Oil Min Red alarm. Associated parameter 1.1480.307 Cause Corrective action Minimum engine oil filling level 1. Check engine oil level (→ Page 154). detected. 2. Check replenishment system. 3. Fill oil. 686 – AL Lube Oil Max Red alarm.
  • Page 128 694 – SD T-Gas Yellow alarm. Associated parameter 1.8004.123 Cause Corrective action Gas temperature sensor 1. Not installed in all engine versions (optional). defective, short circuit or wire 2. Check sensor and cabling (B38), replace as necessary. break. 719 – AL T-Gas L1 Yellow alarm.

  • Page 129: Task Description

    6 Task Description 6.1 Engine 6.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring gear F6555766 Ratchet head with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in.

  • Page 130: Machine Room - Check For Smell Of Gas

    6.1.2 Machine room – Check for smell of gas Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas detection and alarm unit (not stocked by MTU) WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources.

  • Page 131: Crankcase Breather

    6.2 Crankcase Breather 6.2.1 Oil separator – Filter replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter element (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) O-ring (→...
  • Page 132 Remove locknut (1). Remove filter cover (3) with washer (2). Carefully lift out fine filter (6). Carefully lift out coalescence filter (5). Clean sealing faces and inside of housing. Check condition of gaskets on new fine fil- ter and new coalescence filter. Note: The fine filter (6) must be installed in the correct position in the housing.

  • Page 133: Ignition System

    6.3 Ignition System 6.3.1 Spark plug – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug (→ Spare Parts Catalog) Replacing spark plug Remove spark plug (→ Page 134). Install new spark plug (→ Page 135). MS150108/00E 2013-06 | Task Description | 133...

  • Page 134: Spark Plug - Removal

    6.3.2 Spark plug – Removal Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug just immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Special wrench, 20.8 mm F30452574 DANGER Live components, flash-over.

  • Page 135: Spark Plug - Installation

    6.3.3 Spark plug – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Special wrench, 20.8 mm F30452574...
  • Page 136 Screw spark plug into cylinder head. Note: The temperature of spark plug and cylinder head must be the same prior to tightening. 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 50 +5 Nm...

  • Page 137: Spark Plug Connector - Replacement

    6.3.4 Spark plug connector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug connector (→ Spare Parts Catalog) Replacing spark plug connector Remove spark plug connector (→ Page 138). Install spark plug connector (→ Page 139). MS150108/00E 2013-06 | Task Description | 137...

  • Page 138: Spark Plug Connector - Removal

    6.3.5 Spark plug connector – Removal Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug connector only immediately prior to installation. DANGER Live components, flash-over. Risk of serious injury - danger to life! •...

  • Page 139: Spark Plug Connector - Installation

    6.3.6 Spark plug connector – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug connector only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Spark plug connector with ignition lead (→...
  • Page 140 Installing spark plug connector Remove lower sealing ring from ignition lead and fit new sealing ring as necessary. Clean dust and dirt on outside of Teflon body of ignition lead connector and inside on spark plug end. Install new spark plug isolator sealing ring when performing maintenance (→...

  • Page 141: Ignition System - Ignition Timing Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Stroboscope (Not stocked by MTU) DANGER Live components, flash-over. Risk of serious injury - danger to life! • During operation, do not touch ignition cable except with insulated glove (at least class 4)! DANGER Rotating and moving engine parts.

  • Page 142: Valve Drive

    6.4 Valve Drive 6.4.1 Valve depth – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sliding depth gauge, 200 mm Y20000918 Preparatory steps Remove spark plugs (→ Page 134). Remove cylinder head covers (→...
  • Page 143 Measuring valve depth Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. Measure valve depth for each valve in two crankshaft positions (firing TDC and overlap TDC for cylinder A1) according to the diagram.
  • Page 144 Install sleeves (arrow). Install cylinder head covers (→ Page 150). Install spark plugs with new sealing rings (→ Page 135). 144 | Task Description | MS150108/00E 2013-06...

  • Page 145: Valve Clearance - Check And Adjustment

    6.4.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Angular screw driver F30452765...

  • Page 146: Adjusting Valve Clearance

    Diagram for 20V engines 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. •...
  • Page 147 Final steps Remove barring device (→ Page 129). Install cylinder head cover (→ Page 150). MS150108/00E 2013-06 | Task Description | 147...

  • Page 148: Valve Gear - Lubrication

    6.4.3 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear Remove cylinder head covers (→ Page 149). Fill oil chambers of rocker arms and adjust- ing screws with oil.

  • Page 149: Cylinder Head Cover - Removal

    6.4.4 Cylinder head cover – Removal Preconditions ☑ Engine is stopped and starting disabled. Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 138). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 150: Cylinder Head Cover - Installation

    6.4.5 Cylinder head cover – Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) NOTICE Contamination of components. Damage to component! • Observe manufacturer's instructions. • Check components for special cleanliness. Installing cylinder head cover Clean mounting surface.

  • Page 151: Gas System

    6.5 Gas System 6.5.1 Gas supply – Checking gas lines for leaks Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Leakage detection spray Soap solution WARNING Natural gas is combustible. Risk of fire and explosion! •...

  • Page 152: Air Filter

    6.6 Air Filter 6.6.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Prefilter 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.

  • Page 153: Air Filter - Removal And Installation

    6.6.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installa- tion Loosen clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3). Verify that there are no objects in the flange of the intake housing (3) and clean Place new air filter (1) with clamp (2) onto intake housing (3).

  • Page 154: Lube Oil System, Lube Oil Circuit

    6.7 Lube Oil System, Lube Oil Circuit 6.7.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. WARNING Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. •...

  • Page 155: Engine Oil - Change

    6.7.2 Engine oil - Change Preconditions ☑ Engine shut down and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Hot oil.

  • Page 156: Engine Oil - Sample Extraction And Analysis

    6.7.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Only run the engine at low power. Keep away from the engine's danger zone.

  • Page 157: Oil Filtration / Cooling

    6.8 Oil Filtration / Cooling 6.8.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 158: Circuit

    6.9 Coolant Circuit, General, High-Temperature Circuit 6.9.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 159: Engine Coolant – Change

    6.9.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 160). Fill with engine coolant (→ Page 162). MS150108/00E 2013-06 | Task Description | 159...

  • Page 160: Engine Coolant – Draining

    6.9.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 161 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS150108/00E 2013-06 | Task Description | 161...

  • Page 162: Engine Coolant – Filling

    6.9.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and under pressure.

  • Page 163: Low-Temperature Circuit

    6.10 Low-Temperature Circuit 6.10.1 Mixture coolant level - Check Preconditions ☑ Engine shut down and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 164: Mixture Coolant – Change

    6.10.2 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Changing mixture coolant Drain mixture coolant. (→ Page 165) Fill with fresh mixture coolant. (→ Page 166) 164 | Task Description | MS150108/00E 2013-06...

  • Page 165: Mixture Coolant – Draining

    6.10.3 Mixture coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. 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. Draining mixture coolant Provide a suitable receptacle to catch the coolant.

  • Page 166: Mixture Coolant – Filling

    6.10.4 Mixture coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant WARNING Coolant is hot and under pressure.

  • Page 167: Wiring (General) For Engine/Gearbox/Unit

    6.11 Wiring (General) for Engine/Gearbox/Unit 6.11.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Checking engine wiring Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 168: Sensors – Overview

    6.11.2 Sensors – Overview Sensors on right engine side, 20 V Item Description Monitors B49.2 Intake air temperature B81.2 Intake air pressure after filter B16.1 Coolant pressure after engine B4.XX Exhaust temperature after cylinder XX B79.22 Mixture pressure, B-side Mixture temperature Table 36: Sensors on right engine side, 20 V The knock sensors (B80.XX) are mounted on the crankcase on the right and left sides below the cylin- der heads.
  • Page 169 Sensors on driving end, 20V Item Description Monitors B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.2 Crankshaft speed ignition Table 37: Sensors on driving end MS150108/00E 2013-06 | Task Description | 169...
  • Page 170 Sensors on left engine side, 20 V Item Description Monitors B4.21 Exhaust bulk temperature after turbocharger B79.21 Mixture pressure, A-side Crankcase pressure B5.3 Engine oil pressure before filter Engine oil temperature B5.1 Engine oil pressure after filter Table 38: Sensors on left engine side 170 | Task Description | MS150108/00E 2013-06...
  • Page 171 Sensors on engine free end, 20V Item Description Monitors B4.21 Combined exhaust temperature B16.3 Coolant pressure before engine B1.3 Camshaft speed for anti-knock control B1.1 Camshaft speed for engine governor Engine oil level B6.3 Coolant temperature before engine B6.1 Coolant temperature after engine Table 39: Sensors on engine free end MS150108/00E 2013-06 | Task Description | 171...

  • Page 172: Appendix A 7.1 Abbreviations

    Association of American standardization organ- izations Abgasturbolader Exhaust turbocharger Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Pub- lication No. A01061/.. Controller Area Network Data bus system, bus standard Circuit Deutsches Institut für Normung e. V. German national standards institute. At the...
  • Page 173 Abbreviation Meaning Explanation Pulse Width Modulation Modulated signal Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure Safety System Safety system alarm TA-Luft Technische Anleitung zur Reinhaltung General administrative instruction for federal der Luft emission control law in Germany Transmitter Deviation...

  • Page 174: Partner

    Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For our locally available support, go to MTU's Internet site: http://www.mtu-online.com/mtuonsitee- nergy/kontakt 24h Hotline With our 24h hotline and the flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed oper- ating conditions, or for spare parts supply.

  • Page 175: Special Tools

    8 Appendix B 8.1 Special Tools Angular screw driver Part No.: F30452765 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 145) Barring gear Part No.: F6555766 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 129) Feeler gauge Part No.: Y20098771...
  • Page 176 Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 157) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 6.1.2 Machine room – Check for smell of gas (→ Page 130) Gas measuring and warning device (not stocked by MTU) Part No.:...
  • Page 177 Used in: 6.3.2 Spark plug – Removal (→ Page 134) Qty.: Used in: 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.:...
  • Page 178 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 145) 178 | Appendix B | MS150108/00E 2013-06...

  • Page 179: Index

    – Filling  166 Engine  Mixture coolant level  – Barring manually  129 – Check  163 – Emergency shutdown  45 MTU Onsite Energy contact / service partner 174 – Main dimensions  21 – Shutdown  44 – Start  40 Oil separator  – Wiring check  167...
  • Page 180 Safety regulations  – Auxiliary materials, special instructions for applica- tions with gaseous fuel  16 – Consumables  14 – Environmental protection  14 – Environmental protection, special instructions for ap- plications with gaseous fuel  16 – Fire prevention  14 – Fire prevention, special instructions for applications with gaseous fuel  16 –...

This manual is also suitable for:

20v4000l32f

Table of Contents