MTU 20V4000Lx2x User manual
Operating Instructions
Gas engine
20V4000Lx2x
MS150122/00E
Engine model kW/cyl. Application group
20V4000L32FNER 100/110 kW/cyl. 3A, continuous power, unrestricted
Table 1: Applicability
© 2015 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
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.
Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Personnel and organizational requirements 7
1.3 Transport 8
1.4 Safety regulations for startup and operation 9
1.5 Safety requirements for startup and
operation, special instructions for
applications with gaseous fuel 10
1.6 Safety regulations for maintenance and
repair work 11
1.7 Safety requirements for maintenance and
repair work, special instructions for
applications with gaseous fuel 14
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 15
1.9 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel 17
1.10 Standards for safety notices in the text 18
2 Product Summary
2.1 Engine overview 19
2.2 Engine side and cylinder designations 21
2.3 Engine – Main dimensions 22
2.4 Firing order 23
2.5 Technical Data 24
2.5.1 20V4000L32FNER engine data, optimized fuel
consumption (TA-Luft), 100 kW/cylinder 24
2.5.2 20V4000L32FNER engine data, optimized fuel
consumption (TA-Luft), 110 kW/cylinder 29
2.6 Monitoring, Control and Regulation
Equipment 34
2.6.1 Gas engine phase 3 system – Overview 34
2.6.2 Purpose of the units 36
3 Operation
3.1 Runtimes at partial load 38
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 39
3.3 Putting the engine into operation after
scheduled out-of-service-period 40
3.4 Control, starting and stopping sequences 41
3.5 Engine – Start 43
3.6 Operational checks 44
3.7 Emission values – Check 45
3.8 Engine – Shutdown 46
3.9 Emergency engine shutdown 47
3.10 After stopping the engine – Engine remains
ready for operation 49
3.11 After stopping the engine – Putting the
engine out of operation 50
4 Maintenance
4.1 50-hours check 51
4.2 Maintenance task reference table [QL1] 52
5 Troubleshooting
5.1 Fault messages - Key 53
5.2 Fault messages in log for genset controller 55
5.3 Fault messages – Engine Control Unit 97
6 Task Description
6.1 Engine 131
6.1.1 Engine – Barring manually 131
6.1.2 Machine room – Check for smell of gas 132
6.2 Crankcase Breather 133
6.2.1 Oil separator – Filter replacement 133
6.3 Ignition System 135
6.3.1 Spark plug – Replacement 135
6.3.2 Spark plug – Removal 136
6.3.3 Spark plug – Installation 137
6.3.4 Spark plug connector – Replacement 139
6.3.5 Spark plug connector – Removal 140
6.3.6 Spark plug connector – Installation 141
6.3.7 Ignition system – Ignition timing check 143
6.4 Valve Drive 144
6.4.1 Valve projection – Measurement 144
6.4.2 Valve gear – Lubrication 147
6.4.3 Valve clearance – Check and adjustment 148
6.4.4 Cylinder head cover ‒ Removal 150
6.4.5 Cylinder head cover ‒ Installation 151
6.5 Gas System 152
6.5.1 Gas supply - Checking gas lines for leaks 152
6.6 Air Filter 153
6.6.1 Air filter – Replacement 153
6.6.2 Air filter – Removal and installation 154
6.7 Lube Oil System, Lube Oil Circuit 155
6.7.1 Engine oil – Level check 155
6.7.2 Engine oil – Change 156
6.7.3 Engine oil – Sample extraction and analysis 157
6.8 Oil Filtration / Cooling 158
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6.8.1 Engine oil filter – Replacement 158
6.9 Coolant Circuit, General, High-Temperature
Circuit 159
6.9.1 Engine coolant – Level check 159
6.9.2 Engine coolant – Change 160
6.9.3 Engine coolant – Draining 161
6.9.4 Engine coolant – Filling 163
6.10 Low-Temperature Circuit 164
6.10.1 Mixture coolant level – Check 164
6.10.2 Mixture coolant level – Check 165
6.10.3 Mixture coolant – Change 166
6.10.4 Mixture coolant – Draining 167
6.10.5 Mixture coolant – Filling 168
6.11 Wiring (General) for Engine/Gearbox/Unit 169
6.11.1 Engine cabling – Check 169
6.11.2 Sensors – Overview 170
6.11.3 Sensors – Removal 174
6.11.4 Sensor – Installation 176
7 Appendix A
7.1 Abbreviations 177
7.2 MTU Onsite Energy contact person / service
partner 179
8 Appendix B
8.1 Special Tools 180
8.2 Index 184
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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 infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
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 (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the use-
ful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use. Such improper use increases the risk of injury and damage when
working with the product. The manufacturer shall not be held liable for any damage resulting from improper,
non-intended use.
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.
Replacing components with emission labels
Emission labels are attached to all MTU engines. These must remain on the engine throughout its operational
life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• Appropriate emission labels must be affixed on spare parts.
• Emission labels may not be transferred from old components to new ones.
• Emission labels on old components must be removed and destroyed.
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1.2 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, and
transport.
Personnel must not be under the influence of alcohol, drugs, or strong medication.
Working clothes and personal protective equipment
When working, always wear the necessary personal protective equipment (for example safety shoes, ear pro-
tectors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
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1.3 Transport
Taking the engine's center of gravity into account
For information regarding the center of gravity of the engine, refer to the installation/arrangement drawing
of the engine/genset/system.
Transport
• Lift the engine/genset/system only with the lifting eyes provided.
• Only use transport and lifting devices approved by MTU.
• The engine/genset/system must only be transported in installation position.
• Max. permissible diagonal pull 10°.
• If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes of the
trestle or use a means of transportation which is appropriate for the given weight (forklift truck).
• Prior to transporting the engine/genset/system, it is imperative to install the transport locking device for
the crankshaft.
• Prior to transporting the engine/genset/system, it is imperative to install the transport locks for the en-
gine mounts.
• Secure the engine/genset/system such as to preclude tipping during transport.
• Secure the engine/system/genset as to preclude slipping and tipping when driving up or down inclines
and ramps.
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.
• Place the engine/genset/system on a firm, flat surface only.
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1.4 Safety regulations for startup and operation
Safety regulations for startup
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.
When putting the product into operation, always ensure that
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• Keep clear of the service room during the first operating hours. Hazardous gases may occur as a result of
the combustion of paints or oils.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems are working properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
The procedures for emergencies, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.
Operation of electrical equipment
During operation of electrical devices, certain elements of these devices are live/under high voltage.
Observe the warning information applicable to the devices.
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1.5 Safety requirements for startup and operation, special
instructions for applications with gaseous fuel
Safety requirements for startup
Whenever the product is started, always ensure that:
• The operator has fulfilled the requirement to: Check the gas train.
• The temperature in the area of the product must not fall below 5 °C at any point.
Gas system, requirements
Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device. This must be
realized by the plant designer to suit site conditions.
The connection to the gas supply network is established by the plant designer in accordance with require-
ments of the DVGW (DVGW490, G490/I). The plant designer must use certified gas trains for the fuel supply
to the product and connection to the gas supply network. The connection conditions and dimensions must
be coordinated with the manufacturer.
In flow direction, gas trains have:
• a manual shutoff valve
• a gas filter
• two gas shutoff valves
• a pressure regulating device
The gas train must be fitted with an automatic leak check.
The gas shutoff valves are activated via two different paths from the control system, whereby one gas shutoff
valve respectively is activated via one of the paths.
Gas trains must be monitored to detect minimum pressure.
The plant designer must ensure that the gas train is positioned directly in front of the engine, yet a maximum
of 3 meters before the interface of the engine. The interface is the flange in front of the gas volume regulator
of the product.
In the case of network supply pressures higher than 100 mbar, additional equipment is required on the gas
train.
The gas pressure regulator must be equipped with an approved safety shut-off valve and a safety discharge
valve to ensure safety in case of excessive outlet pressure at the pressure regulator. Gas discharge must be
routed to a safe area (to atmosphere).
If the gas supply is connected to a vessel or if gases containing oxygen are used, the gas train must be
equipped with a temperature-monitored flame arrester.
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