MTU 20V 4000 L62 Operating Instructions Manual
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MTU 20V 4000 L62 Operating Instructions Manual

MTU 20V 4000 L62 Operating Instructions Manual

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Operating Instructions

Gas engine
20V 4000 L62
MS150034/04E

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Summary of Contents for MTU 20V 4000 L62

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 20V 4000 L62 MS150034/04E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    3.4 Firing order 7.3.2 Spark plug – Removal 3.5 Technical Data 7.3.3 Spark plug – Installation 3.5.1 20V 4000 L62 engine data, fuel-optimized (TA- 7.3.4 Spark plug connector – Replacement Luft) 7.3.5 Spark plug connector – Removal 3.5.2 20V 4000 L62 engine data, emissions- 7.3.6 Spark plug connector –...
  • Page 4 Circuit 7.9.1 Engine coolant – Level check 8.1 Abbreviations 7.9.2 Engine coolant – Change 8.2 MTU Onsite Energy contact person / service 7.9.3 Engine coolant – Draining partner 7.9.4 Engine coolant – Filling 7.9.5 Vent line of engine coolant circuit –...

  • Page 5: Safety

    The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life.

  • Page 6: Correct Use Of All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...

  • Page 7: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 8: Safety Regulations For Initial Start-Up And Operation

    1.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 9 Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live. Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times. MS150034/04E 2016-11 | Safety | 9...

  • Page 10: Safety Regulations For Startup And Operation, Specific Information For Gaseous Fuel Or Dual Fuel Supply Applications

    1.5 Safety regulations for startup and operation, specific information for gaseous fuel or dual fuel supply applications General safety regulations Requirement for the user: Check the gas train every time the product is started. During operation, the surface temperature of the gas-bearing parts must not fall below 5 °C anywhere within the vicinity of the product.
  • Page 11 • a manual shut-off valve • a gas filter Gas trains feature the following components in the direction of flow (MTU scope of supply): • two gas shut-off valves (automatic) • a pressure regulating device • a manual shut-off valve...

  • Page 12: Safety Regulations For Maintenance And Repair Work

    1.6 Safety regulations for maintenance and repair work Safety regulations when preparing to perform 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 (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 13 Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g. components carrying oil, fuel, or air). Always seal connections with caps or covers if a line is removed or opened. Fit new seals when re-installing lines. Never bend lines and avoid damaging lines, particularly the fuel lines.
  • Page 14 Before starting work, pay attention to the following: • Vent the installation/removal device, the pumps and the pipework at the relevant designated points. • For hydraulic installation, screw on the tool with the piston retracted. • For hydraulic removal, screw on the tool with the piston extended. For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft end until correct sealing is established.
  • Page 15 Measuring component dimensions Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem- perature of 20 °C. MS150034/04E 2016-11 | Safety | 15...

  • Page 16: Safety Regulations For Maintenance And Servicing Work, Specific Information For Gaseous Fuel And Dual Fuel Supply Or Applications

    1.7 Safety regulations for maintenance and servicing work, specific information for gaseous fuel and dual fuel supply or applications Safety regulations for work prior to maintenance and servicing Assembly work shall be performed by specially trained/qualified and authorized personnel only. The gas supply shall be connected by trained/qualified and authorized personnel only.

  • Page 17: Fire Prevention And Environmental Protection, Fluids And Lubricants, Indirect Materials

    Indirect materials, fluids and lubricants may be hazardous or contain toxic substances. Observe the informa- tion provided in the safety data sheet for the product when using indirect materials and other chemical sub- stances. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Used oil Used oil contains harmful combustion residue.

  • Page 18: Compressed Air

    Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion. • Wear goggles when blowing off components or blowing away chips. • Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass) for drying purposes or to check for leaks risks bursting them.

  • Page 19: Fire Prevention And Environmental

    1.9 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials, specific information for gaseous fuel supply in gaseous-fuel or dual-fuel applications General notes on gas Observe the information contained in the safety data sheet of the gas used. Consult with gas supplier/utility. The gas used must comply with the (→...

  • Page 20: 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 21: Transport

    Setting the engine down after transport • Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. • Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

  • Page 22: Product Summary

    3 Product Summary 3.1 Engine – Overview 1 Air filter/air inlet 8 Coolant distribution housing 15 Flywheel 2 Engine coolant outlet con- 9 Capacitor ignition system 16 Starter (left side) nection from cooler 10 Spark plug 17 Engine governor/engine 3 Engine coolant inlet connec- 11 Cylinder head cover monitoring tion to cooler...
  • Page 23 9 Engine lifting eye, free end KGS Free end 5 Throttle (left side) 10 Engine mounting bracket, free end Engine model designation Key to the engine model designations 20V 4000 L62 Number of cylinders Cylinder arrangement: V engine 4000 Series Application: L = Gas engine...

  • Page 24: Engine Side And Cylinder Designations

    3.2 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

  • Page 25: Engine - Main Dimensions

    3.3 Engine – Main dimensions Main engine dimensions Length (A) approx. 3896 mm Width (B) approx. 1488 mm Height (C) approx. 2250 mm Crankshaft center to oil pan (D) approx. 636 mm Crankshaft center to engine mount (E) approx. 280.5 mm Table 2: Main engine dimensions MS150034/04E 2016-11 | Product Summary | 25...

  • Page 26: Firing Order

    3.4 Firing order Firing order Number of cylin- Firing order ders A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 26 | Product Summary | MS150034/04E 2016-11...

  • Page 27: Technical Data

    3.5 Technical Data 3.5.1 20V 4000 L62 engine data, fuel-optimized (TA-Luft) Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Reference value L Limit value up to which the engine can be operated without changes, e.g. to the power setting.
  • Page 28 Number of cylinders Gas type: natural gas Methane number, min. Table 5: General conditions (for max. power) Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh Table 6: 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...
  • Page 29 Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooling equipment) (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over LT mixture cooler (at nominal flow rate 8.56) Table 9: Coolant system (LT circuit) Lube oil system Number of cylinders...
  • Page 30 Number of cylinders Starter, current consumption, max. (standard design) 2 x 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 13: Starter (electric) Capacities Number of cylinders Engine coolant, engine side (w/o cooling equipment) Liters Engine coolant, mixture coolant side (w/o cooling equipment) Liters Total engine oil capacity for initial filling (standard oil system) Liters...

  • Page 31: 4000 L62 Engine Data, Emissions-Optimized (1/2 Ta-Luft)

    3.5.2 20V 4000 L62 engine data, emissions-optimized (1/2 TA-Luft) Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Reference value L Limit value up to which the engine can be operated without changes, e.g. to the power setting.
  • Page 32 Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh Table 21: 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 (°) Bore...
  • Page 33 Number of cylinders Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over LT mixture cooler (at nominal flow rate 8.56) Table 24: 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 34 Capacities Number of cylinders Engine coolant, engine side (w/o cooling equipment) Liters Engine coolant, mixture cooler side (w/o cooling equipment) Liters Total engine oil capacity for initial filling (standard oil system) Liters Oil change capacity, max. (standard oil system) Liters Table 29: Capacities Weights / main dimensions Number of cylinders...

  • Page 35: Monitoring, Control And Regulation Equipment

    3.6 Monitoring, Control and Regulation Equipment 3.6.1 Gas engine phase 3 system – Overview Overview 1 Unit system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 NOx sensor 10 Gas dosing unit 3 System 7 Compressor bypass 11 Throttles 4 Engine governor 8 Ignition...
  • Page 36 Compressor bypass (F-series) • Controls throttle reserve, blocks compressor pumps Ignition system IC922 • Adjusts ignition timing for cylinders Anti-knock control AKR • Controls monitored cylinders with regard to 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+ •...

  • Page 37: Control Cabinet Mis - Overview

    3.6.2 Control cabinet MIS – Overview Phase 3 gas engine control cabinet MIS – Overview A Control cabinet door, exter- 2 Automatic cutout 6A 5 Automatic cutout 32A nal side 3 Relay 6 Automatic cutout 16A B Mounting plate 4 Terminal block 7 Emergency stop (key 1 SAM switch)

  • Page 38: Purpose Of The Units

    3.6.3 Purpose of the units Engine governor ADEC (ECU 7) Central control and monitoring unit for the engine • Communication with other units and higher-level systems via CAN bus • Control of throttles (mixture and gas) • Acquisition and evaluation of engine operating states •...
  • Page 39 Service and Automation Module SAM 1 Module cassette, slots for 4 Control keys for Mini Dialog 7 Connector with spring-cage additional I/O PIM cards 5 Diagnostic lamp terminal connections 2 Compact Flash memory 6 Interface for dialog unit card 3 Display for fault code and Mini Dialog SAM functions •...
  • Page 40 Customer interface • 24 binary outputs • 3 PWM outputs • 8 display outputs • 28 channel binary input • 10 analog inputs (e.g. PT100, 4 to 20 mA, 0 to 10 V, etc.) • 4 frequency inputs • 1 dialog interface •...
  • Page 41 Engine Monitoring Unit EMU EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring MS150034/04E 2016-11 | Monitoring, Control and Regulation Equipment | 41...

  • Page 42: Operation

    4 Operation 4.1 Runtimes at partial load Gas engines are 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 range [kW Recommended max.

  • Page 43: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    4.2 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 44: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.3 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 167). Coolant circuit Check engine coolant level (→ Page 171); Check mixture coolant level (→...

  • Page 45: Control, Starting And Stopping Sequences

    4.4 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 start 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 requirement for gas engines, special procedures for engine start / stop are specified.
  • Page 46 Emergency stop sequence If an emergency stop command is activated, the following steps are carried out automatically: 1. Closing gas supply solenoid valves and mixture throttles 2. Mixture throttles close 3. Coasting down engine to standstill for a maximum coasting period 4.

  • Page 47: Engine - Start

    4.5 Engine – Start Preconditions ☑ Generator is not connected to network. ☑ Start interlock is 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 engine's danger zone.

  • Page 48: Operational Checks

    4.6 Operational checks DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Gaseous fuels are combustible/explosive.

  • Page 49: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas measuring and warning device (not stocked by MTU) WARNING Engine operation at high load/speed when measuring emissions. Risk of injury! • Conduct measuring in a room which offers safe protection from the engine if at all possible. If this is not feasible, keep the greatest possible distance away when measuring, e.g.
  • Page 50 Checking emission values Note: Open the exhaust gas test section and in- stall/remove measuring equipment only when the engine is at standstill. Apply the exhaust probe (1) at the measuring point (2). Start engine. Approach the measuring point until a stable operating state has been reached.

  • Page 51: Engine - Shutdown

    4.8 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 stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 52: Engine - Emergency Shutdown

    4.9 Engine – Emergency shutdown NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Engine – Emergency shutdown Item Measure Emergency stop pushbutton Press pushbutton. •...

  • Page 53: After Stopping The Engine - Engine Remains Ready For Operation

    4.10 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator controller Select operating mode, e.g. MANUAL, AUTOMATIC. (manufacturer-specific) MS150034/04E 2016-11 | Operation | 53...

  • Page 54: 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 Preservation and Represerva- tion Specifications A001070/..). The corrosion-inhibiting effect of the engine coolant may be used as an alter- native in case of out-of-service periods lasting for more than 1 month, by run- ning the engine for at least 2 hours at rated power once a month.

  • Page 55: Maintenance

    5 Maintenance 5.1 50-hours check 50-hours check One-time operations to be carried out after a test run or after the first 10 to 50 operating hours of the cylin- der head (with a new engine, after installation of new cylinder heads, after component maintenance or ex- tended component maintenance).

  • Page 56: Maintenance Task Reference Table [Ql1]

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

  • Page 57: Troubleshooting

    6 Troubleshooting 6.1 Fault indication on SAM display Explanation of the abbreviations used The following abbreviations are used in the texts for the fault messages: Abbreviation Meaning DL <number> Default Lost: The device with designation <number> has lost its connec- tion to the default CAN bus.
  • Page 58 Fault messages from the SAM are represented in the fault code list (→ Page 61). A prerequisite for performing the measures to rectify faults is a corresponding qualification/training at MTU. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
  • Page 59 OEM (see documentation of the genset manufacturer). A prerequisite for performing the measures to rectify faults is a corresponding qualification/training at MTU. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
  • Page 60 SE no. Error message text Download Server Collision not projected node Device specific error not projected node Device specific error Table 37: SE (System Error) alarms 60 | Troubleshooting | MS150034/04E 2016-11...

  • Page 61: Sam - Fault Messages

    6.2 SAM – Fault messages 112222 – HI T-Exhaust Mean Yellow alarm. Initiated by EMU. Cause Corrective action The average value of all individual 1. Check emission values. cylinder exhaust temperatures is 2. Check ignition timing (→ Page 154). too high. 3.
  • Page 62 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 154). with the average value. 3. Check valve drive (exhaust valves do not close). 112306 –...
  • Page 63 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 154). with the average value. 3. Check valve drive (exhaust valves do not close). 112312 –...
  • Page 64 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 154). with the average value. 3. Check valve drive (exhaust valves do not close). 112318 –...
  • Page 65 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 low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 154). 4.
  • Page 66 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 low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 154). 4.
  • Page 67 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 low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 154). 4.
  • Page 68 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 low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 154). 4.
  • Page 69 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 154). with the average value. 3. Check valve drive (exhaust valves do not close). 112505 –...
  • Page 70 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 154). with the average value. 3. Check valve drive (exhaust valves do not close). 112511 –...
  • Page 71 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 154). with the average value. 3. Check valve drive (exhaust valves do not close). 112517 –...
  • Page 72 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 154). 4.
  • Page 73 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 154). 4.
  • Page 74 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 154). 4.
  • Page 75 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 154). 4.
  • Page 76 112703 – HIHI T-Exhaust A3 (abs) Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 154). 3. Check valve drive (exhaust valves do not close). 112704 –...
  • Page 77 112709 – HIHI T-Exhaust A9 (abs) Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 154). 3. Check valve drive (exhaust valves do not close). 112710 –...
  • Page 78 112715 – HIHI T-Exhaust B5 (abs) Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 154). 3. Check valve drive (exhaust valves do not close). 112716 –...
  • Page 79 112923 – MD/SD T-Exhaust Red alarm. Initiated by EMU. Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm (for details, refer to the source alarm). 150176 – Lube Oil Min Red alarm. Initiated by SAM. Cause Corrective action Minimum engine oil level...
  • Page 80 150204 – Comm. Lost Mixer (TecJet) Red alarm. Initiated by SAM. Cause Corrective action No communication with mixer 1. Check supply voltage. (TecJet) CAN. 2. Check connecting line. 150352 – SS Release Circuit Breaker Red alarm. Initiated by SAM. Cause Corrective action Circuit breaker release detected.
  • Page 81 150402 – LO Oil Refill Yellow alarm. Initiated by SAM. Cause Corrective action u Check oil replenishment system. No oil replenishment within a configurable time. 150403 – AL Oil Refill Error Red alarm. Initiated by SAM. Cause Corrective action After initiation of the alarms 1.
  • Page 82 151021 – Warning Hold Position Yellow alarm. Initiated by TecJet. Cause Corrective action u Deactivate setting or interrupt serial communication. Hold position is activated. 151022 – Zero Pressure Detected Yellow alarm. Initiated by TecJet. Cause Corrective action u Check gas pressure. No gas pressure/gas flow detected.
  • Page 83 151029 – FGT Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 151030 – Delta P Fail High Red alarm. Initiated by TecJet. Cause Corrective action Excessive differential pressure 1. Check gas pressure. over TecJet detected.
  • Page 84 151038 – Delta P Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet and configuration. Differential pressure at TecJet is below the preset limit value. 151039 – FGP Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Gas pressure before TecJet is u Check TecJet and configuration.
  • Page 85 151051 – PWM Duty Cycle High Error Red alarm. Initiated by TecJet. Cause Corrective action PWM signal is beyond the valid 1. Check cabling. range. 2. Check frequency. 3. Check signal. 151052 – Battery Volt Low Error Red alarm. Initiated by TecJet. Cause Corrective action Supply voltage has reached...
  • Page 86 151058 – Delta P High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 151059 – FGP High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation.
  • Page 87 152011 – Error Missing Ring Gear Signal Red alarm. Initiated by IC922. Cause Corrective action u Check sensor B13.2, check sensor clearance and cabling, replace Crankshaft signal for ignition speed 182 teeth missing. if necessary. Restart of ignition system required to restart the engine.
  • Page 88 152019 – Global Timing out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adjust value. Specified global ignition timing is beyond the valid range. 152020 – Unknown Timing or Energy Level Red alarm. Initiated by IC922. Cause Corrective action No global ignition timing and u Check cabling and setting.
  • Page 89 152028 – Open Primary, Channel 3 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. 152029 – Open Primary, Channel 4 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 90 152035 – Open Primary, Channel 10 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. 152036 – Open Primary, Channel 11 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 91 152042 – Open Primary, Channel 17 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. 152043 – Open Primary, Channel 18 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 92 152054 – SCR Fault Odd Red alarm. Initiated by IC922. Cause Corrective action u Restart ignition system. Hardware not ready for operation. 152055 – SCR Fault Even Red alarm. Initiated by IC922. Cause Corrective action u Restart ignition system. Hardware not ready for operation. 152056 –...
  • Page 93 153104 – Error Camshaft Red alarm. Initiated by antiknock control. Cause Corrective action No signal from camshaft sensor 1. Check cabling. for antiknock control. 2. Check sensor B1.3, replace as necessary. 153111 – Knock Sensor Error A1 Red alarm. Initiated by antiknock control. Cause Corrective action No signal received from this...
  • Page 94 153117 – Knock Sensor Error A7 Red alarm. Initiated by antiknock control. Cause Corrective action No signal received from this 1. Check cabling. knock sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 153118 – Knock Sensor Error A8 Red alarm.
  • Page 95 153124 – Knock Sensor Error B4 Red alarm. Initiated by antiknock control. Cause Corrective action No signal received from this 1. Check cabling. knock sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 153125 – Knock Sensor Error B5 Red alarm.
  • Page 96 153221 – HI Knock Integrator A1 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 154). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 97 153226 – HI Knock Integrator A6 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 154). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 98 153231 – HI Knock Integrator B1 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 154). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 99 153236 – HI Knock Integrator B6 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 154). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 100 153241 – HIHI Knock Integrator A1 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 154). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153242 –...
  • Page 101 153246 – HIHI Knock Integrator A6 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 154). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153247 –...
  • Page 102 153251 – HIHI Knock Integrator B1 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 154). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153252 –...
  • Page 103 153256 – HIHI Knock Integrator B6 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 154). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153257 –...
  • Page 104 153262 – HI Misfire Integrator A2 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153263 – HI Misfire Integrator A3 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 105 153269 – HI Misfire Integrator A9 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153270 – HI Misfire Integrator A10 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 106 153276 – HI Misfire Integrator B6 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153277 – HI Misfire Integrator B7 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 107 153283 – HIHI Misfire Integrator A3 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153284 – HIHI Misfire Integrator A4 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 108 153290 – HIHI Misfire Integrator A10 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153291 – HIHI Misfire Integrator B1 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 109 153297 – HIHI Misfire Integrator B7 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153298 – HIHI Misfire Integrator B8 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...

  • Page 110: Engine Governor - Fault Messages

    6.3 Engine governor – Fault messages 015 – LO P-Lube Oil ZKP-Number: 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). Lack of engine oil, 2. Replace oil filter (→ Page 170). engine speed too low, oil lines, oil 3.
  • Page 111 020 – SS T-Exhaust A ZKP-Number: Yellow alarm. Associated parameter 2.0126.932 Cause Corrective action Exhaust gas temperature (A side) 1. Check exhaust turbocharger. after turbine too high (limit value 2. Check ignition timing (→ Page 154). 2). Incorrect ignition timing, 3.
  • Page 112 026 – HI P-Diff-Lube Oil ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0154.932 Cause Corrective action Pressure loss via oil filter too high 1. Replace oil filter (→ Page 170). (limit value 2). 2. If this fault message occurs again after unexpectedly short filter runtime, check oil filter for deposits, change oil if required (→...
  • Page 113 036 – HI ETC2 Overspeed ZKP-Number: Yellow alarm. Associated parameter 2.3013.931 Cause Corrective action Speed of 1st secondary u Turbocharger speed sensor is not fitted at present. Check ECU turbocharger too high (limit value setting for this input. 037 – SS ETC2 Overspeed ZKP-Number: Red alarm.
  • Page 114 053 – HI T-Intake Air ZKP-Number: Yellow alarm. Associated parameter 2.0123.931 Cause Corrective action Intake air temperature too high u Check ventilation system. (limit value 1). 054 – HIHI T-Intake Air ZKP-Number: Yellow alarm. Associated parameter 2.0123.932 Cause Corrective action Intake air temperature too high 1.
  • Page 115 063 – HI P-Crank Case ZKP-Number: Yellow alarm. Associated parameter 2.0106.931 Cause Corrective action Crankcase pressure too high (limit 1. Check crank drive: value 1). Restrictor valve in • Crank engine (→ Page 141). crankcase breather is closed too • Endoscope combustion chambers from bottom dead center to much, air filter is defective, oil top dead center.
  • Page 116 068 – SS T-Coolant ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0120.932 Cause Corrective action Coolant temperature after engine u Check engine coolant circuit. too high (limit value 2). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit.
  • Page 117 091 – SS Release Speed Not Reached ZKP-Number: Red alarm. Start terminated. Associated parameter 2.1090.924 Cause Corrective action The speed (starter DISENGAGE) 1. Check ignition. was not attained, ignition not 2. Check gas supply. working or no gas available. 3. Check mixture setting. 092 –...
  • Page 118 095 – AL Prelubrication Fault ZKP-Number: Red alarm. Start terminated. Associated parameter 2.1090.920 Cause Corrective action Oil priming fault. 1. Check oil pressure, oil temperature, oil level. 2. Check oil priming pump. 104 – AL Eng Hours Counter Defect ZKP-Number: Yellow alarm.
  • Page 119 121 – HIHI ECU Supply Voltage ZKP-Number: Red alarm. Associated parameter 2.0140.932 Cause Corrective action Supply voltage too high (limit 1. Check supply voltage. value 2). 2. Check cabling. 122 – HI T-ECU ZKP-Number: Yellow alarm. Associated parameter 2.0132.921 Cause Corrective action Electronics temperature too high u Improve cooling of governor.
  • Page 120 180 – AL CAN1 Node Lost ZKP-Number: Yellow alarm. Associated parameter 2.0500.680 Cause Corrective action Bus node (SAM or EMU) lost on u Check operation of nodes and cabling. Busses (CAN bus 1 and CAN bus 1. CAN bus 2) are redundant. 181 –...
  • Page 121 184 – AL CAN PU-Data Flash Error ZKP-Number: Red alarm. Associated parameter 2.0500.684 Cause Corrective action A programming error occurred u Contact Service (configuration fault). when attempting to copy a received PU data module into the Flash module. 186 – AL CAN1 Bus Off ZKP-Number: Yellow alarm.
  • Page 122 189 – AL CAN2 Error Passive ZKP-Number: Yellow alarm. Associated parameter 2.0500.689 Cause Corrective action CAN controller 2 has signaled a u Check operation of nodes (ECU, SAM or EMU) and cabling. warning. The cause may be e.g. missing listening nodes, minor malfunctions or temporary bus overload.
  • Page 123 206 – SD T-Exhaust A ZKP-Number: Yellow alarm. Associated parameter 1.8004.576 Cause Corrective action Exhaust temperature sensor on A u Check sensor and cabling (B4.21), replace if necessary. Fault is side defective, short circuit or rectified when engine is restarted. wire break.
  • Page 124 214 – SD P-Crank Case ZKP-Number: 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 when engine is restarted. break. 216 – SD T-Lube Oil ZKP-Number: Red alarm.
  • Page 125 227 – SD P- Lube Oil before Filter ZKP-Number: Yellow alarm. Associated parameter 1.8004.620 Cause Corrective action Engine oil pressure sensor before u Check sensor and cabling (B5.3), replace as necessary. Fault is filter defective, short circuit or rectified when engine is restarted. wire break.
  • Page 126 233 – SD Charger 2 Speed ZKP-Number: Yellow alarm. Associated parameter 1.3011.129 Cause Corrective action Speed sensor of secondary u Turbocharger speed sensor is not fitted at present. turbocharger defective, short circuit or wire break. 245 – SD ECU Power Supply Voltage ZKP-Number: Red alarm.
  • Page 127 382 – AL Wiring TOP 2 ZKP-Number: Red alarm. Associated parameter 2.8006.639 Cause Corrective action Short circuit or wire break on u Check cabling. transistor output, plant-side 2 (TOP 2). Activation of red combined alarm faulty. 383 – AL Wiring TOP 3 ZKP-Number: Red alarm.
  • Page 128 419 – SD T-Coolant b. Engine ZKP-Number: Red alarm. Associated parameter 1.8004.604 Cause Corrective action Coolant temperature sensor at u Check sensor and cabling (B6.3), replace if necessary. engine inlet defective, short circuit or wire break. 423 – LO P-Coolant Diff. ZKP-Number: Red alarm.
  • Page 129 431 – SS P-Coolant before Engine ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0168.922 Cause Corrective action Coolant pressure before engine u Check engine coolant circuit (pressure and volumetric flow). too low (limit value 2). Volumetric flow too low, static pressure too low.
  • Page 130 447 – HIHI P-Charge Mix Diff. ZKP-Number: 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 high 2. Check mixture lines for leakage. (limit value 2).
  • Page 131 454 – SS Power Reduction Active ZKP-Number: Yellow alarm. Associated parameter 2.7000.011 Cause Corrective action Power reduction activated. u Rectify limit value violation of the source alarm (e.g. reduce intake air temperature). 457 – LO T-Intake Air ZKP-Number: Yellow alarm. Associated parameter 2.0123.921 Cause Corrective action...
  • Page 132 472 – AL Stop SD ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.8006.593 Cause Corrective action Engine stop, since all shutdown u Combined alarm (for details, refer to the source alarm). channels detect “sensor defect". 473 – AL Wiring PWM_CM2 ZKP-Number: Red alarm.
  • Page 133 496 – SD P-Charge Mix A ZKP-Number: Red alarm. Engine shutdown. Associated parameter 1.8004.628 Cause Corrective action Mixture pressure sensor on A side u Check sensor and cabling (B79.21), replace if necessary. Fault is defective, short circuit or wire rectified when engine is restarted. break.
  • Page 134 511 – HIHI P-Charge Mix A ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0181.932 Cause Corrective action Mixture pressure on A side too 1. Check emissions. high (limit value 2). 2. Check ignition timing (→ Page 154). 3. Check exhaust back pressure. 4.
  • Page 135 517 – SD P-Charge Mix before Throttle ZKP-Number: Red alarm. Associated parameter 1.8004.631 Cause Corrective action Mixture pressure sensor before u Check sensor and cabling (B79.23), replace if necessary. Fault is throttle defective, short circuit or rectified when engine is restarted. wire break.
  • Page 136 532 – AL Wiring PWM1 ZKP-Number: Red alarm. Associated parameter 1.1046.900 Cause Corrective action Wire break or short circuit on u Check wiring to mixture throttle on A side, replace mixture throttle channel PWM1. on A side if necessary. 533 – AL Wiring PWM2 ZKP-Number: Red alarm.
  • Page 137 552 – AL GasControlCheck Fault ZKP-Number: Red alarm. Associated parameter 2.1090.118 Cause Corrective action Gas train test was not successful. 1. Check gas train. Alarm is activated if the gas train 2. Check cabling. does not report OK within a specified time-out period.
  • Page 138 557 – AL speed drop fault ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.1090.126 Cause Corrective action Speed drop. Alarm is activated if u Check gas train. engine speed drops during starting sequence. 559 – AL mixture throttle A fault ZKP-Number: Red alarm.
  • Page 139 566 – AL L2 P-Intake Air after Filter A ZKP-Number: Yellow alarm. Associated parameter 2.0186.931 Cause Corrective action Pressure loss over air filter on A u Replace air filter (→ Page 165). side is too high. 567 – AL L1 P-Intake Air after Filter B ZKP-Number: Yellow alarm.
  • Page 140 570 – L1 AI CAN Max Retarded Timing ZKP-Number: Yellow alarm. Associated parameter 2.1200.931 Cause Corrective action The cylinder set to maximum 1. Check emissions. retarded timing due to knocking 2. Check ignition timing (→ Page 154). has violated the first limit value. 3.

  • Page 141: Task Description

    7 Task Description 7.1 Engine 7.1.1 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 142: Machine Room - Check For Smell Of Gas

    7.1.2 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 143: Crankcase Breather

    7.2 Crankcase Breather 7.2.1 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 144 Remove locknut (1). Remove filter cover (3) with washer (2). Carefully lift out fine filter (6). Carefully lift out coalescer filter (5). Clean sealing faces and inside of housing. Check condition of gaskets on new fine filter and new coalescer filter. Note: The fine filter (6) must be installed in the cor- rect position in the housing.

  • Page 145: Ignition System

    7.3 Ignition System 7.3.1 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 146). Install new spark plug (→ Page 147). MS150034/04E 2016-11 | Ignition System | 145...

  • Page 146: Spark Plug - Removal

    7.3.2 Spark plug – Removal 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. Special wrench, 20.8 mm F30452574 DANGER Live components, flash-over.

  • Page 147: Spark Plug - Installation

    7.3.3 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 148 Note: Make sure that the color code of the spark plugs is identical. Screw spark plug into cylinder head (1). Note: The temperature of spark plug and cylinder head (1) must be the same prior to tightening. Use torque wrench to tighten spark plug to specified tightening torque. Name Size Type...

  • Page 149: Spark Plug Connector - Replacement

    7.3.4 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 150). Install spark plug connector (→ Page 152). MS150034/04E 2016-11 | Ignition System | 149...

  • Page 150: Spark Plug Connector - Removal

    7.3.5 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 151: Spark Plug Connector - Cleaning And Check

    7.3.6 Spark plug connector – Cleaning and check Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug connector with ignition cable (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Hot components/surfaces. Risk of burns! •...

  • Page 152: Spark Plug Connector - Installation

    7.3.7 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 cable (→...
  • Page 153 Push protective cap (3) onto ignition coil. MS150034/04E 2016-11 | Ignition System | 153...

  • Page 154: 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! • Always wear electrical gloves (class 4 minimum) when touching the ignition cable in operation.

  • Page 155: Valve Drive

    7.4 Valve Drive 7.4.1 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.

  • Page 156: Adjusting Valve Clearance

    Diagram – Two crankshaft posi- tions 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: •...
  • Page 157 Final steps Remove barring device (→ Page 141). Install cylinder head cover (→ Page 163). MS150034/04E 2016-11 | Valve Drive | 157...

  • Page 158: Valve Protrusion - Measurement

    7.4.2 Valve protrusion – 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 146). Remove cylinder head covers (→ Page 162). Remove sleeves (arrow).
  • Page 159 Valve protrusion – Measurement 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 protrusion for each valve in two crankshaft positions (firing TDC and overlap TDC cylinder A1) according to the diagram.
  • Page 160 Install sleeves (arrow). Install cylinder head covers (→ Page 163). Install spark plugs with new sealing rings (→ Page 147). 160 | Valve Drive | MS150034/04E 2016-11...

  • Page 161: Valve Gear - Lubrication

    7.4.3 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 162). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 162: Cylinder Head Cover - Removal

    7.4.4 Cylinder head cover ‒ Removal Preconditions ☑ Engine is stopped and starting disabled. Cylinder head cover ‒ Removal Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 150). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 163: Cylinder Head Cover - Installation

    7.4.5 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. Cylinder head cover ‒ Installa- tion Clean mounting surface.

  • Page 164: Gas System

    7.5 Gas System 7.5.1 Gas supply - Checking gas lines for leaks Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Leak identification spray Soap suds WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! •...

  • Page 165: Air Filter

    7.6 Air Filter 7.6.1 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 cor- responding fault message appears.

  • Page 166: Air Filter – Removal And Installation

    7.6.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installa- tion Loosen clamp (2). Remove air filter (3) and clamp (2) from con- necting flange (1) of intake housing. Clean connecting flange (1) of the intake housing and check for obstructions.

  • Page 167: Lube Oil System, Lube Oil Circuit

    7.7 Lube Oil System, Lube Oil Circuit 7.7.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Engine oil is hot. Engine oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! •...

  • Page 168: Engine Oil – Change

    7.7.2 Engine oil – Change Preconditions ☑ Engine is stopped 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 Engine oil is hot.

  • Page 169: Engine Oil – Sample Extraction And Analysis

    7.7.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine.

  • Page 170: Oil Filtration / Cooling

    7.8 Oil Filtration / Cooling 7.8.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Engine oil is hot.

  • Page 171: Circuit

    7.9 Coolant Circuit, General, High-Temperature Circuit 7.9.1 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 172: Engine Coolant – Change

    7.9.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 173). Fill with engine coolant (→ Page 175). 172 | Coolant Circuit, General, High-Temperature Circuit | MS150034/04E 2016-11...

  • Page 173: Engine Coolant – Draining

    7.9.3 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 174 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 174 | Coolant Circuit, General, High-Temperature Circuit | MS150034/04E 2016-11...

  • Page 175: Engine Coolant – Filling

    7.9.4 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 176: Vent Line Of Engine Coolant Circuit Replacement

    7.9.5 Vent line of engine coolant circuit – Replacement 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. Replacing coolant vent line Drain engine coolant (→...

  • Page 177: Low-Temperature Circuit

    7.10 Low-Temperature Circuit 7.10.1 Mixture 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! • Let the engine cool down.

  • Page 178: Mixture Coolant – Change

    7.10.2 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 179). Fill with fresh mixture coolant (→ Page 180). 178 | Low-Temperature Circuit | MS150034/04E 2016-11...

  • Page 179: Mixture Coolant – Draining

    7.10.3 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 180: Mixture Coolant – Filling

    7.10.4 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 181: Wiring (General) For Engine/Gearbox/Unit

    7.11 Wiring (General) for Engine/Gearbox/Unit 7.11.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.

  • Page 182: Sensors – Overview

    7.11.2 Sensors – Overview Sensors on B side Item Name Monitoring of B49.2 Intake air temperature B side B81.2 Intake air pressure after filter B side B4.XX Exhaust gas temperature after cylinder XX B79.22 Mixture pressure B side Mixture temperature Table 38: Sensors on B side The knocking sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads.
  • Page 183 Sensors on driving end Item Name Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.2 Crankshaft speed ignition Table 39: Sensors on driving end MS150034/04E 2016-11 | Wiring (General) for Engine/Gearbox/Unit | 183...
  • Page 184 Sensors on A side Item Name Monitoring of B4.21 Combined exhaust temperature A side B4.21 Combined exhaust temperature B side B49.1 Intake air temperature A side 81.1 Intake air pressure after filter A side B79.21 Mixture pressure A side Crankcase pressure B5.3 Engine oil pressure before filter Engine oil temperature...
  • Page 185 Sensors on free end Item Name Monitoring of B16.3 Coolant pressure before engine B1.3 Camshaft speed for antiknock control Engine oil level B1.2 Camshaft speed for ignition system B6.3 Coolant temperature before engine B16.1 Coolant pressure after engine Coolant temperature after engine Table 41: Sensors –...

  • Page 186: Sensors – Removal

    7.11.3 Sensors – Removal Preconditions ☑ Preparatory steps have been carried out. ☑ Provide containers for catching any fluids that escape. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ratchet adapter F30027340 WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 187 Removing NOx sensor (B88) Observe the following general information: • Arrangement and position of sensor (→ Page 182). Loosen and disconnect connector (2). Unscrew electronics box (1) at the eyelets. Remove sensor via nut (3). MS150034/04E 2016-11 | Wiring (General) for Engine/Gearbox/Unit | 187...

  • Page 188: Sensors – Installation

    7.11.4 Sensors – Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Kluthe Hakuform 30-15) X00067260 O-ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→...

  • Page 189: Abbreviations

    American National Standards Institute Association of American standardization organ- izations Exhaust turbocharger Series Betriebsstoffvorschrift MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Circuit Deutsches Institut für Normung e. V. At the same time identifier of German stand- ards (DIN = “Deutsche Industrie-Norm”)
  • Page 190 Abbreviation Meaning Explanation ORFS O-Ring Face Seal O-ring seal Top Dead Center Panel Control panel Peripheral Interface Module Peripheral interface module Pulse Width Modulation Modulated signal Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sicherheitsabsperrventil Sicherheitsabbalseventil Sensor Defect...

  • Page 191: 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.mtuonsiteenergy.com/haendlersuche/index.de.html 24-h Hotline...

  • Page 192: Special Tools

    9 Appendix B 9.1 Special Tools Angular screw driver Part No.: F30452765 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 155) Barring gear Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 141) Feeler gage Part No.: Y20098771...
  • Page 193 Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 7.1.2 Machine room – Check for smell of gas (→ Page 142) Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 4.7 Emission values –...
  • Page 194 Ratchet head with extension Part No.: F30006212 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 141) Sliding depth gauge, 200 mm Part No.: Y20000918 Qty.: Used in: 7.4.2 Valve protrusion – Measurement (→ Page 158) Socket wrench, 24 mm Part No.: F30029815 Qty.:...
  • Page 195 Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 7.3.8 Ignition system – Ignition timing check (→ Page 154) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 7.3.3 Spark plug – Installation (→ Page 147) Qty.: Used in: 7.3.7 Spark plug connector –...

  • Page 196: Index

    9.2 Index Numerics Engine coolant  – Change  172 20V 4000 L62 engine data  – Draining  173 – Emissions-optimized (1/2 TA-Luft)  31 – Filling  175 – Fuel-optimized (TA-Luft)  27 – Level check  171 50-hours check 55 Engine driving end  – Definition  24 Engine free end ...
  • Page 197 – Safety notices, standards  20 SAM  – Fault messages   – On the display  57 SAM – Fault messages 61 Sensors  – Installation  188 – Overview  182 – Removal  186 Service partner  – MTU Onsite Energy  191 MS150034/04E 2016-11 | Index | 197...
  • Page 198 Spark plug  – Installation  147 – Removal  146 – Replacement  145 Spark plug connector  – Check  151 – Cleaning  151 – Installation  152 – Removal  150 – Replacement  149 Starting sequence  – Control  45 Stopping sequence  – Control  45 transport 21 Valve clearance ...

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8 v 4000 l62

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