MTU 12V2000 Service Manual.pdf

Technical Publication

Diesel Engine 12 V 2000 P62, P82 16 V 2000 P62, P82 Application group 3B

Operating Instructions

MS15009/00E

Printed in Germany © 2006 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten.

Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen.

Änderungen bleiben vorbehalten.

Printed in Germany

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, microfilming and storage or processing on electronic systems including data bases and online services.

This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.

Subject to alterations and amendments.

Imprimé en Allemagne

Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.

Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.

Modifications réservées.

Impreso en Alemania

Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.

El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio.

Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania

Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.

II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla manutenzione e alla condotta.

Con riserva di modifiche.

Impresso na Alemanha

A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line.

Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.

Salvo alterações.

Wichtig – Important – Importante

Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH zurücksenden.

Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik- Support (Gewährleistung, Ersatzteile etc.).

Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.

The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.).

Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen GmbH.

Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en exploitation contractuelle (garantie, rechanges, etc.).

Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU Friedrichshafen GmbH.

Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico contractual (garantía, piezas de repuesto, etc.).

Ritagliare “Avviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen GmbH.

Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).

É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU Friedrichshafen.

Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças sobressalentes, etc.) estabelecido contratualmente.

Postcard

MTU Friedrichshafen GmbH

Department SCSD

88040 Friedrichshafen

GERMANY

Bitte in Blockschrift ausfüllen!

Please use block capitals!

Prière de remplir en lettres capitales!

¡A rellenar en letras de imprenta!

Scrivere in stampatello!

Favor preencher com letras de forma!

Motornr.:

Engine No.:

No du moteur:

No de motor:

Motore N.:

No. do motor:

Auftragsnr.:

MTU works order No.:

N° de commande:

N° de pedido:

N. commessa:

No. do pedido:

Motortyp:

Engine model:

Type du moteur:

Tipo de motor:

Motore tipo:

Tipo do motor:

Inbetriebnahmedatum:

Date put into operation:

Mise en service le:

Fecha de puesta en servicio:

Messa in servizio il:

Data da colocação em serviço:

Eingebaut in:

Installation site:

Lieu de montage:

Lugar de montaje:

Installato:

Incorporado em:

Schiffstyp / Schiffshersteller:

Vessel/type/class / Shipyard:

Type du bateau / Constructeur:

Tipo de buque / Constructor:

Tipo di barca / Costruttore Tipo de embarcação/estaleiro naval:

Endabnehmer/Anschrift:

End user`s address:

Adresse du client final:

Dirección del cliente final:

Indirizzo del cliente finale:

Usuário final/endereço:

Bemerkung:

Remarks:

Remarques:

Observaciones:

Commento:

Observações:

Inbetriebnahme-meldung

Commissioning Note

Notice de mise en service

Aviso de puesta en servicio

Avviso di messa in servizio

Participação da colocação em serviço

Table of Contents 01

1 Safety

1.1 General conditions

1.2 Personnel and organizational requirements

1.3 Transport

1.4 Safety precautions when working on the engine

1.5 Auxiliary materials, fire prevention and environmental protection

1.6 Standards for warning notices in the publication

2 Product Summary

2.1 Plant Overview

2.1.1 Use

2.1.2 ECS-5 – Use of devices

2.1.3 MDEC – Functions

2.1.4 Peripheral Interface Modules (PIMs)

2.1.5 Printed circuit board SCB 3

2.2 Engine Overview

2.2.1 Engine layout

2.3 Engine Side and Cylinder Designations

2.3.1 Engine side and cylinder designations

2.4 Final Compression Pressure

2.4.1 Final compression pressure

2.5 Technical Data

2.5.1 12/16V 2000 P62/82 engine data

2.5.2 SAM – Technical data

2.5.3 SCB 3 – Technical data

3 Operation

3.1 LOP controls

3.2 Putting the engine into operation after extended out-of-service-periods (>3 months)

3.3 Putting the engine into operation after scheduled out-of-service-period

3.4 Starting the engine in manual mode

3.5 Emergency start (override mode)

3.6 Operational checks

3.7 Stopping the engine in manual mode

3.8 Emergency stop

3.9 After stopping the engine – engine remains ready for operation

3.10 After stopping the engine – putting the engine out of service

4 Maintenance

4.1 Preface

MS15009/00E 06-09 © MTU

02 Table of Contents

4.2 Maintenance schedule matrix

4.3 Maintenance tasks

5 Troubleshooting

5.1 Troubleshooting

5.2 Fault indication on printed circuit board SAM

5.3 ECU alarms

6 Task Description

6.1 Engine

6.1.1 Engine – Barring manually

6.1.2 Engine – Barring with starting system

6.1.3 Engine test run

6.2 Cylinder Liner

6.2.1 Cylinder liner – Endoscopic examination

6.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners

6.3 Crankcase Ventilation

6.3.1 Crankcase breather – Wire mesh cleaning

6.3.2 Crankcase breather – Oil separator replacement, diaphragm check and replacement

6.4 Valve Drive

6.4.1 Valve clearance – Check and adjustment

6.4.2 Cylinder-head cover – Removal and installation

6.5 Injection Pump/ HP Pump

6.5.1 Injection pump replacement

6.5.2 Injection pump – Removal and installation

6.6 Injector

6.6.1 Injector replacement

6.6.2 Injector – Removal and installation

6.7 Fuel System

6.7.1 Fuel pressure relief valve – Replacement

6.7.2 Fuel – Draining

6.8 Fuel Filter

6.8.1 Fuel filter – Replacement

6.8.2 Fuel prefilter cleaning

6.8.3 Fuel prefilter – differential pressure check and adjustment of gauge

6.8.4 Fuel prefilter – draining

6.8.5 Fuel prefilter – flushing

6.8.6 Fuel prefilter – filter element replacement

6.9 Charge-air Cooling, General, Left Side

6.9.1 Intercooler – Checking condensate drains for coolant discharge and obstructions

6.10 Air Filter

6.10.1 Air filter – Replacement

Table of Contents 03

6.11 Air Intake

6.11.1 Service indicator – Signal ring position check

6.12 Starting System

6.12.1 Air starter – manual operation

6.12.2 Starter – Condition check

6.13 Lube Oil System / Lube Oil Circuit

6.13.1 Engine oil change

6.13.2 Engine oil – Level check

6.14 Oil Filtration / Cooling

6.14.1 Engine oil filter – Replacement

6.15 Cooling Circuit, General, HT Circuit

6.15.1 Drain and venting points

6.15.2 Engine coolant filling

6.15.3 Engine coolant draining

6.15.4 Engine coolant – Change

6.15.5 Engine coolant level – Check

6.15.6 Coolant pump – Relief bore check

6.16 LT Circuit

6.16.1 Charge-air coolant change

6.16.2 Charge-air coolant filling

6.16.3 Charge-air coolant – Draining

6.16.4 Charge-air coolant level check

6.17 General Cabling for Engine / Gearbox / Unit

6.17.1 Engine wiring check

6.17.2 Sensors and actuators

6.18 Accessories for Engine Governor (Electronic) / Control System

6.18.1 ECU and connectors – Cleaning

6.18.2 EMU and connectors – Cleaning

6.18.3 ECU – Checking plug-in connections

6.18.4 EMU – Checking plug-in connections

6.18.5 ECU – Removal and installation

6.19 Emergency Instrumentation (LOP)

6.19.1 LOP – visual inspection

6.19.2 LOP test procedures

7 Engine Governor Assignment and Circuitry

7.1 Engine Governor

7.1.1 Engine governor channel circuitry

7.1.2 MDEC governor assignment

7.2 Connector Assignment

7.2.1 Connector pin assignment

8 Special Tools

8.1 Special tools

9 Annex

04 Table of Contents

9.1 Manufacturer’s documentation

9.2 MTU contact person/service partner

9.3 Abbreviations

9.4 Index

Safety 05

1 Safety

1.1 General conditions

General In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Non-compliance with the Safety Instructions

Correct use The engine is intended exclusively for the application specified in the contract or defined at the time of delivery. Any other use is considered improper use. The manufacturer will accept no liability for any resultant damage. The responsibility is borne by the user alone.

Correct use also includes observation of and compliance with the maintenance specifications.

Modifications or Conversions Modifications made by the customer to the engine may affect safety.

MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.

Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. In the event of any damage caused by the use of other spare parts, no liability nor warranty claims vis-à-vis the engine manufacturer will be accepted.

06 Safety

1.2 Personnel and organizational requirements

Personnel Work on the engine must only be carried out by properly qualified and instructed personnel.

The specified legal minimum age must be observed.

Responsibilities of the operating, maintenance and repair personnel must be specified.

Organization This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.

It must be kept at hand near the engine and accessible at any time to all personnel involved in operation, maintenance, repair or transportation.

The personnel must be instructed on engine operation and repair by means of this publication, and in particular the safety instructions must be explained.

This is especially important for personnel who work on the engine only on an occasional basis.

Such personnel must be given instructions repeatedly.

Working clothes and protective equipment Wear proper work clothing for all work.

Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.

Work clothing must be tight fitting so that it does not catch on rotating or projecting components.

Do not wear jewelry (e.g. rings, chains etc.).

Safety 07

1.3 Transport

Transport

Lift the engine only with the lifting eyes provided.

Use only the transport and lifting equipment approved by MTU.

Take note of the engine center of gravity.

The engine must only be transported in installation position, max. permissible diagonal pull 10°.

In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck).

Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and engine mounts.

Secure the engine against tilting during transport. The engine must be especially secured against slipping or tilting when going up or down inclines and ramps.

Setting the engine down after transport Place the engine only on an even, firm surface.

Ensure appropriate consistency and load-bearing capacity of the ground or support surface.

Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

08 Safety

1.4 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.

Before putting the device or the system into operation, always ensure

• that all maintenance and repair work is completed

• that all loose components have been removed from rotating parts

• that nobody is standing in the danger zone of moving engine components.

Immediately after putting the device or system into operation, make sure that all control and display instruments as well as the signaling and alarm systems work properly.

Safety requirements for operators Procedures for cases of emergency must be practised regularly.

The operator must be familiar with the controls and displays.

The operator must know the consequences of each operation to be carried out.

The operator must carry out the individual operations according to the documentation.

During operation, the displays and monitoring units must be permanently observed with regard to present operating status, violation of limit values and warning or alarm messages.

The following steps must be taken if a malfunction of the system is recognized or reported by the system:

• notify the supervisory personnel in charge

• analyze the message

• if required, carry out emergency operations e.g. emergency engine stop.

Engine operation When the engine is running, always wear ear protectors.

Ensure that the engine room is well ventilated.

Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.

Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.

During engine operation, do not touch battery terminals, generator terminals or cables.

Inadequate protection of electrical components can lead to electric shocks and serious injuries.

When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Maintenance and repair Strict adherence to the maintenance and repair schedule is an essential safety factor.

Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.

Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted.

Close the main valve on the compressed-air system and vent the compressed air line when air starters are fitted. Post the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.

Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. Have maintenance and repair work carried out by qualified and authorized personnel only.

Use only proper, calibrated tools.

Do not work on engines or components which are only held by lifting equipment or crane. Always support by suitable means which conform with the applicable regulations before commencing maintenance or repair work.

Before barring the engine, make sure that nobody is standing in the danger zone. After completing work on the engine, check that all protective devices/safety guards have been installed and that all tools and loose parts have been removed from the engine.

Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before starting work, relieve pressure in systems and H.P. lines which are to be opened.

Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.

Always seal connections with caps or covers if a line is removed or opened.

Take care not to damage fuel lines during maintenance and repair work. To tighten the connections when installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.

Safety 09

Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other components to avoid contact with them. Do not place fuel or oil lines near hot components, except when necessary for design reasons during installation.

Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes when exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!

Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!

Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!

Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!

Take special care when removing ventilation or plugs from engine. In order to avoid discharge of highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently been shut down, as the liquids can still be hot.

Take special care when draining hot fluids. ⇒ Risk of injury!

When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or soak them with a suitable bonding agent.

When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.

When working high on the engine, always use suitable ladders and work platforms. Make sure components are placed on stable surfaces.

In order to prevent back injuries when lifting heavy components adults, depending on age and sex, should only lift weights between max. 10 kg and 30 kg, therefore:

• Use lifting gear or seek assistance.

• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that hooks are correctly positioned. Lifting eyes must not be unevenly loaded.

Welding work Never carry out welding work on the engine or engine-mounted units.

Never use the engine as a ground connection. This prevents the welding current passing through the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may lead to bearing seizure and/or other material damage.

Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.

The welding unit ground connection must not be more than 60 cm from the weld point.

If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.

It is not necessary to remove the connector and the connections when carrying out welding operation on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire is disconnected from the negative and positive poles on the battery.

Hydraulic installation and removal Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly instructions must be used.

The max. permissible push-on pressure specified for the equipment must not be exceeded.

The H.P. lines for hydraulic installation and removal are tested with 3800 bar.

Do not attempt to bend or apply force to lines.

Before starting work, pay attention to the following:

• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).

• 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 tool with central expansion pressure supply, screw spindle into shaft end until correct sealing is achieved.

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the component to be installed/removed. As long as the system is under pressure, there is the risk that the component to be installed/removed may be suddenly released from the pressure connection.

Before use, the tools must be checked at regular intervals (crack test).

10 Safety

Working on electrical/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. Any measures requiring a power supply are expressly defined as such at the appropriate place in the manual.

Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body.

Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.

Do not secure wiring to fluid-carrying lines.

On completion of the maintenance and repair work, any cables which have become loose must be correctly connected and secured.

On completion of all repair work, the component and system must be subjected to a function check.

Separate testing of the repaired component without system integration is insufficient.

If wires are installed beside mechanical components and there is a risk of chafing, use cable clamps to properly support the wires.

For this purpose, no cable binders must be used as, during maintenance and / or repair work, the binders can be removed but not installed a second time.

Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipment When working with laser equipment, always wear special laser-protection goggles.

Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.

Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application.

For conducting light-beam procedures and measurement work, only the following laser devices must be used:

• Laser devices of classes 1, 2 or 3A,

• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

Operation of electrical equipment When operating electrical equipment, certain components of this equipment are live.

Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property.

Safety 11

1.5 Auxiliary materials, fire prevention and environmental

protection

Fire prevention Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around on the engine. Do not store combustible materials near the engine.

Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a noncombustible fluid.

When starting the engine with a foreign power source, connect the ground lead last and remove it first.

To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of the engine or to the ground terminal of the starter.

Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.

Noise Noise can lead to an increased risk of accident if acoustic signals, warning shouts or sounds indicating danger are drowned.

At all workplaces with a sound pressure level over 85 dB (A), always wear ear protectors (protective wadding, plugs or capsules).

Environmental protection Dispose of used fluids, lubricants, materials and filters in accordance with local regulations.

Manipulation of the injection control system can influence the engine performance and exhaust emissions.

As a result, compliance with environmental regulations may no longer be guaranteed.

Only fuels of the specified quality required to achieve emission limits must be used.

In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is such a company).

Auxiliary materials Use only fluids and lubricants that have been tested and approved by MTU.

Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions applicable to the product. Take care when handling hot, chilled or caustic materials. When using inflammable materials, avoid sparks, flames and do not smoke.

Lead

• When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors.

• Adopt suitable measures to avoid the formation of lead dust!

• Switch on fume extraction system.

• After coming into contact with lead or lead-containing materials, wash hands!

Acids and alkaline solutions

• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.

• Immediately remove clothing wetted by acids and alkalis!

• Rinse injuries with plenty of water!

• Rinse eyes immediately with eyedrops or clean tap water.

Paints

• When painting anywhere other than in spray booths equipped with extractors, ensure good ventilation. Make sure that adjacent work areas are not affected.

• No naked flames!

• No smoking.

• Observe fire prevention regulations!

• Wear masks providing protection against paint and solvent fumes.

Liquid nitrogen

• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.

• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and loss of tissue.

• Wear protective clothing, including gloves, closed shoes and protective goggles!

12 Safety

• Ensure that the room is well ventilated. Nitrogen concentration exceeding 88% of breathing air leads to suffocation.

• Avoid all knocks and jars to the containers, fixtures or workpieces.

Compressed air Compressed air is air compressed at excess pressure and is stored in vessels from which it can be extracted.

The pressure at which the air is kept can be read off at pressure gauges which must be connected to the compressed air vessels and the compressed air lines.

When working with compressed air, safety precautions must be constantly observed:

• Pay special attention to the pressure level in the compressed air network and pressure vessel!

• Devices and equipment connected must either be designed for this pressure or, if the permitted pressure for the connected elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose coupling and connections must be securely attached!

• Always wear protective goggles when blowing off tools or chips!

• The snout of the air nozzle should be provided with a protective disc (e.g. rubber disc), which prevents air-borne particles being deflected and thereby prevents injury to eyes.

• First shut off compressed air lines before compressed air equipment is disconnected from the supply line or before equipment or tools are exchanged!

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of containers, carries the risk of explosion!

• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of shattering!

• Do not use compressed air to clean contaminated clothing whilst it is being worn.

Used oil Used oil may contain health-threatening combustion residues.

Rub barrier cream into hands!

Wash hands after contact with used oil.

Safety 13

1.6 Standards for warning notices in the publication

DANGER

In the event of immediate danger.

Consequences: Death or serious injury.

• Preventive measures

WARNING

In the event of possibly dangerous situations.

Consequences: Death or serious injury.

• Preventive measures

CAUTION

In the event of dangerous situations.

Consequences: Slight injury or material damage.

• Preventive measures

Note: This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:

Warning notices

1. Read and become acquainted with all cautions and symbols before operating or repairing this product.

2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

14 Safety

Product Summary 15

2 Product Summary

2.1 Plant Overview

2.1.1 Use

1 Service and Automation Module (SAM)

2 Peripheral Interface Module 601 (option)

3 Peripheral Interface Module 602 (option)

4 CAN bus 5 Engine with generator

6 Engine governor 7 Engine monitoring (optional) 8 LOP (optional)

Up to 8 additional Peripheral Interface Modules can be connected for linking to higher-level systems.

Functions

• Control of the engine.

• Monitoring of operating states.

• Closed-loop control of fuel injection and engine speed (depending on operating state).

• Indication of faulty operating states (display SAM (1)).

Features

• Electronic engine governing and control.

• Monitoring of inadmissible engine operating states.

• Display of fault messages and fault codes.

• Connecting cable for power supply to engine governor.

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• Connecting cable for connection to a higher-level genset control system.

• Hardware interfaces to a higher-level control system (option).

• Inputs for plant sensors (option).

• Engine safety features including engine shutdown.

• Integral fault diagnosis system ITS.

• Integral load profile recorder.

• Speed droop switching possible with engine running.

• Straightforward engine governor replacement.

• Engine and interface data stored in SAM.

• Complete automatic software download following connection of a new, unprogrammed engine governor.

Design of the overall MDEC system

1 Monitoring and Control System MCS-5 (PIMs optional)

2 CAN bus between ECS-5 and MCS-5

3 Engine Control System ECS-5 4 RS422 interface and RS232 interface to an external controller 5 External controller

The design of the overall MDEC system comprising the ECS-5 and MCS-5 subsystems depends on customer requirements and the higher-level control system.

Product Summary 17

Design of Engine Control System ECS-5

1 Engine with generator 2 Engine interface 3 Power supply +Ub

4 Signal connection to the MCS devices and the higher-level control systems

5 Engine governor 6 System boundary ECS-5

The Engine Control System comprises the following devices:

• Engine governor

• Sensors on engine

• Actuators on engine

• Injectors on engine

• Wiring harnesses on engine

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Basic scope of Monitoring and Control System MCS-5

1 Monitoring and Control System

MCS-5

2 Power supply +Ub 3 Signal connection to ECS devices

4 System boundary MCS-5

5 SAM

Product Summary 19

Service and Automation Module (SAM)

1 Module cassette, slots for additional I/O PIM cards

2 Compact flash memory card

3 Display for fault codes and minidialog

4 Control keys for minidialog

5 Diagnostic lamp 6 Interface for dialog unit 7 Connector with spring design

Functions SAM functions

• Display of fault codes from engine governor and SAM (3).

• Backup function, engine life data are stored,

• every hour,

• after every engine stop

• after every emergency engine stop.

• Interface for dialog unit.

Diagnosis

• Straightforward diagnosis by fault code display.

• Self-diagnosis by diagnostic lamp (5).

• Steady = SAM is OK.

• Flashing = SAM is faulty, contact Service.

• Dark = Supply voltage missing.

Customer interface

• 24 binary outputs

• 3 PWM outputs

• 8 display outputs

• 28 channel binary input

• 10 analog inputs (e.g. PT100, 4–20 mA, 0-10 V, etc.)

• 4 frequency inputs

• 1 dialog interface

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• Extendable with MCS 5 PIM I/O cards

Data connections

1 Engine governor

2 SAM

3 PIM 601 (option) serial interface / slave

4 PIM 602 (option) serial interface / master

Data transmission The devices are equipped with a CAN bus for transmitting data between the individual subsystems. This CAN bus is in redundant design.

The CAN bus is a standardized automation technology field bus which allows various systems and devices to communicate with each other providing they are equipped with a CAN bus interface.

Tasks of the CAN bus:

CAN bus Tasks:

• Receiving plant signals (desired speed) and commands from higher-level control systems.

• Outputting all measured values/limit values for the Monitoring and Control System.

• Outputting alarms for signaling and evaluation in the Monitoring and Control System.

• Outputting relevant signals for engine control.

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Grounding

1 PIM

2 SAM

3 Engine governor 4 Battery 5 To engine sensors 6 Generating set 7 Equipotential bonding strip

8 Grounding 9 Equipotential bonding strip

10 Equipotential bonding strip 11 Mounting frame

12 GND (-)

13 +24 V VDC (+)

X! Inadmissible connection!

Grounding Both the engine and the generator are connected to ground (8) via equipotential bonding strips (7, 9, 10) on the mounting frame (11).

EMC

EMC design of the overall system is based on a two-pole ungrounded power supply. This is particularly relevant to CE labeling as per EMC directive.

Ground connection The ground of the power supply (battery negative) and all electronic devices (-) should not be connected to ground (8). The entire electronic system is electrically isolated from ground. This also applies to the sensors (5). All sensor signal lines and/or supply lines are not connected to the corresponding sensor housings.

Signal-to-noise ratio Electrical isolation of the mechanical and electronic components significantly increases the signal-to-noise ratio. This high signal-to-noise ratio on all electrical lines is necessary for satisfactory transmission of all data on the CAN bus and also all analog and binary sensor signals.

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2.1.2 ECS-5 – Use of devices

Engine governor

Central control and monitoring device for the engine

• Communication with other devices and higher-level systems via CAN bus.

• Control of injection system.

• Control of up to 20 injectors.

• Acquisition and evaluation of engine operating states.

• Monitoring of limit values.

• Self-monitoring and diagnosis,

• integral status/fault display

• fault memory

• Extensive I/O features:

• Plant side 13 inputs, 10 outputs, 2 serial interfaces,

• engine side 26 inputs, 26 outputs.

• Engine and plant-related setting variables in exchangeable memory modules.

• In case of inadmissible states and limit value violations: Initiation of power reduction, engine stop and emergency engine stop (configurable).

• Diagnosis via RS232 interface for dialog unit.

Software structure:

Name Meaning

Download software For downloading firmware and configuration data.

Dialog software For the dialog with a PC or notebook.

Automation software for open-loop control. E.g. to control injection quantity.

Automation software for monitoring. E.g. for engine stop and emergency engine stop.

Communication software For communication with other devices and via the CAN bus.

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Hardware structure

Item. Name Meaning

1 Cover –

2 Housing –

3 Rating plate Part and serial number Data record and engine number

4 Screws –

5 Connector X6 Connection for dialog unit

6 Connector X4 Connection for injector wiring harness

7 Connector X5 Connection for power supply

8 Connector X2 Connection for sensor/actuator wiring harness

9 Connector X3 BR 2000: Not used BR 4000: HP controller

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Item. Name Meaning

10 Connector X1 Connection for CAN bus

11 Mounting lugs –

Technical data

Dimensions (width x height x depth) 455 mm x 277 mm x 91 mm Draw-out clearance: +230 mm

Weight 7 kg

Operating voltage Rated voltage: 24 VDC Continuous voltage:

16.5 VDC to 32 VDC

Temporarily restricted operation:

11 VDC to 36 VDC Residual ripple: Max. 8 Vpp

Power consumption Max. 30 A

Heat loss Max. 35 W

Operating temperature range 0 °C to +75 °C

Storage temperature range –10 °C to +75 °C

Relative air humidity 0% to 95 % condensing

Degree of protection IP 65 DIN 40 050

Shock 15 g/11 ms semi-sinusoidal shock

Vibration 2 Hz to 13 Hz: Xpp= ±1.6 mm 25 Hz to 100 Hz: a= ±4 g 100 Hz to 2000 Hz: Electrical noise 1.3 g rms

EMC DIN EN 50081–2

DIN EN 50082–2

IEC 1000–4–2

IEC 1000–4–3

IEC 1000–4–4

IEC 1000–4–5

IEC 1000–4–6

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2.1.3 MDEC – Functions

Control functions Following engine functions are controlled:

• Engine start

• Engine stop

• Emergency start

• Restart response

• Sequences with activated “Override” function (safety system bypass).

• Nominal speed switching between two set values (optional operation as 50 Hz or 60 Hz genset).

• Injection quantity as a function of engine loading and speed.

Engine start The starting sequence is controlled by the software integrated in the engine governor as follows.

1. Engine start

2. Start lockout time t>16 seconds.

• Starting terminated if start lockout time is t<16.

3. Start interlock.

• Start terminated if start interlock applied.

4. Emergency air-shutoff flaps open.

• Start terminated if emergency air-shutoff flaps closed.

5. Starter on.

6. Speed n>n1 (configurable) reached within t1 (configurable).

• Start terminated if speed is n<n1 within t1. Start speed is too low “Start speed low”.

7. Start injection quantity

8. Speed n>300 reached within t2 (configurable).

• Start terminated if speed is n<300 within t2 (configurable). Start speed is too low “Run up speed low”.

9. Starter off.

10. Idling speed reached.

• Start terminated if idling speed not reached, “Idle speed low”.

11. Engine running at idling speed.

Restart response The response of the engine is determined by the following factors on receiving a start request when the engine is running down following a stop command:

• The engine immediately runs up to nominal speed if the engine speed is > 80 rpm;

• the engine is shut down if the engine speed is < 80 rpm. Restarting is only possible on expiry of the start lockout time.

Emergency start The following start interlock criteria are bypassed when override is active on starting the engine:

• Low coolant temperature (configurable).

• High coolant temperature (configurable).

• Coolant level (configurable).

Engine stop An engine stop is tripped by activation of binary input BE1 at the engine governor or by the engine protection system. Fuel is no longer injected as injector activation is disrupted.

Any starting procedure which has been initiated is interrupted.

Override (safety system bypass) The “Override” feature is used to bypass safety functions tripped by limit value violations or sensor faults and to bypass start interlocks.

Operating states which would normally lead to engine shutdown are ignored when the “Override” function is activated. The following operating states can also be configured to shut the engine down in override mode:

• Coolant level

• Coolant temperature

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• Coolant pressure

• Charge air coolant level

• Lube oil pressure

• Lube oil temperature

Monitoring functions The engine management system for engines used in Oil&Gas applications fulfills the following monitoring tasks:

• Control of analog instruments;

• engine speed (default)

• engine lube oil pressure (default)

• engine lube oil temperature (default)

• engine coolant temperature (default)

• Transmission of all measurands, warnings and alarms to monitoring system via CAN bus.

• Automatic shutdown in case of limit value violations.

Refer to the measuring-point list for order-specific configuration data.

Engine monitoring can basically be divided into two different areas:

• Engine protection system, monitors the engine during operation,

• Safety system, generates automatic engine shutdown in case of limit value violation.

These two functional areas are constantly monitored by the internal “Integral Test System (ITS)” to ensure operational availability.

Engine protection system The engine governor incorporates an integral engine protection system. It monitors the operational data of the engine.

Tasks of the engine protection system are:

• Safeguarding the engine from critical operating states.

• Signaling alarms to operating personnel.

• Restricting engine operation to remain within admissible operating values.

Action is taken such as warning, start interlock, power reduction or engine shutdown by reducing the quantity of fuel injected depending on the values measured.

Closed-loop control functions Closed-loop engine control functions:

• Speed

• Injection control with mapped commencement of injection.

• Two adjustable speed droops.

• Desired speed via:

• Analog or binary speed setting on the CAN bus.

• Analog speed setting 0 V to 10 VDC / 0 V to 5 VDC / 4 mA to 20 mA.

• Binary speed setting via Up/Down signal, frequency CAN bus.

• Frequency speed setting.

• Acquisition of a load pulse signal (analog or CAN bus) in preparation for load application.

• HP fuel governor.

Speed - injection control Functions of the closed-loop engine speed control integrated in the engine governor:

• Maintaining the desired engine speed under changing load conditions.

• Adjusting the engine speed when the setting is changed by the operator.

Additional tasks with an effect on closed-loop engine speed control:

• Setting a defined fuel injection quantity on starting the engine.

• Engine safety shutdown.

• Optimizing operation, exhaust emissions and fuel consumption.

• Protecting the engine against overloading.

Speed droop calculation Speed droop influences the effective setpoint speed depending on engine power. Maximum, speed-dependent engine power is limited by the DBR curve. The setpoint speed is not influenced by speed droop at 100% power. The effective setpoint speed increases at lower power. This allows power to be balanced when operating a number of engines in a network.

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Switchable speed droop Two different speed droops may be selected at the engine governor for stationary genset engines.

Which speed droop is active depends on whether the genset is running in isolated operation or in a parallel network with other gensets feeding a common busbar.

The speed droop is selected by a binary input (BE4) at the engine governor.

Speed droop is required to balance the load of coupled prime movers. Speed droop can be adjusted to meet plant requirements via the dialog unit.

Dynamic quantity limitation Dynamic quantity limits protect the engine against overloading and optimize exhaust emission values. The engine governor determines the maximum injection quantity based on preset and stored engine performance maps.

Following limits are applied:

• Speed-sensitive fuel quantity limitation (DBR).

• Fuel quantity limitation as a function of fuel temperature.

Fixed quantity limitation Fixed quantity limitations are used for power limitation and power reduction to protect the engine in case of:

• Electronic malfunctions.

• Supply voltage out of tolerance.

Fuel quantity control during engine start The quantity of fuel injected during engine start increases along a time ramp from a set initial value to a specified value. This value is calculated by the function qinject = f(speed). This limits the quantity of fuel injected as a function of speed. This fuel quantity limitation is effective until idling speed has been reached.

Cylinder cutout Only half of the injectors are activated when cylinder cutout is active. The other half of the injectors are activated on expiry of a switchover time. This prevents white smoke being emitted when the engine is running.

Desired speed handling The desired speed is the command variable for the engine speed control loop.

When the engine is started it runs up to an internally programmed desired speed (for 50 Hz network frequency: 1500 rpm, for 60 Hz network frequency: 1800 rpm).

Switching to an external speed setting takes place automatically once the nominal speed has been reached.

The following speed setting variants are possible:

• Desired speed setting via an analog input:

The setpoint speed can be adjusted within a (configurable) range around the preset synchronous speed (depending on the set network frequency).

In this case the voltage can either control the speed window only or cover the entire speed range.

The internal setpoint speed follows the applied speed setting value along a configurable acceleration/deceleration curve (speed ramp). The setting value last applied is maintained or the engine is throttled back to idling speed should the applied signal fail.

The response can be configured as desired:

• Speed setting via CAN bus.

• Speed setting via an analog speed setting input (0 V to 10 V).

• Speed setting via an analog speed setting input (4 mA to 20 mA).

• Frequency input.

• Setpoint processing via binary inputs “Setpoint speed up” (BE5)/ “Setpoint speed down” (BE6):

The setpoint speed can be adjusted within a (configurable) range around the preset synchronous speed (depending on the set network frequency). Briefly actuating the appropriate optocoupler input for less than 0.3 s increases or decreases the setpoint speed by 1 rpm.

The setpoint speed is automatically adjusted at a configurable rate if the input is activated for longer than 0.3 seconds.

Safety functions Safety shutdowns Safety shutdowns are initiated by the engine protection system in case of:

• Limit value violations;

• Sensor faults (depending of specific configuration).

This applies to the following measuring points:

• Engine speed/overspeed (configurable)

• Engine lube oil pressure (configurable)

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• Coolant level (configurable)

• Charge-air coolant temperature (configurable)

• Coolant temperature (configurable)

• Charge-air temperature (configurable)

• Engine lube oil temperature (configurable)

All safety shutdowns can be suppressed by activating the “Override” input (BE8, default).

The occurrence of safety-relevant alarms is still logged when the “Override” input has been activated.

Fault number 500 is added to the current fault number.

Integral Test System (ITS) The ITS monitors all important functions of the engine governor and connected electrical components:

• Electronics inside the engine governor itself,

• sensors,

• actuators,

• bus communication,

• power supply.

The ITS detects any faults which occur, pinpoints them and signals accordingly by combined alarms. Furthermore, a fault message is output via the CAN bus to a higher-level monitoring system (if applicable) and can visualized there for the operator.

Fault messages are stored in two memories:

• Chronological memory The fault message numbers are stored in a ring memory in chronological order of their occurrence or cancellation together with the hour meter reading. The ring memory stores the last 80 setting and cancellation procedures.

• Statistical memory Fault message…