MTU MS150033/05E Operating Instructions Manual
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MTU MS150033/05E Operating Instructions Manual

MTU MS150033/05E Operating Instructions Manual

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Operating Instructions

Gas Engine
12 V 4000 Lx2
16 V 4000 Lx2
MS150033/05E

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Summary of Contents for MTU MS150033/05E

  • Page 1: Operating Instructions

    Operating Instructions Gas Engine 12 V 4000 Lx2 16 V 4000 Lx2 MS150033/05E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    6.7.1 Engine oil – Level check 3.4 Control, starting and stopping sequences 6.7.2 Engine oil – Change 3.5 Engine – Start 6.7.3 Engine oil – Sample extraction and analysis 3.6 Operational checks MS150033/05E 2013-10 | Table of Contents | 3...
  • Page 4 7.2 MTU Onsite Energy contacts / service Replacement partners 6.10 Low-Temperature Circuit 6.10.1 Mixture coolant level – Check 8 Appendix B 6.10.2 Mixture coolant – Change 8.1 Special Tools 6.10.3 Mixture coolant – Draining 8.2 Index 4 | Table of Contents | MS150033/05E 2013-10...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...

  • Page 6: Personnel And Organizational Requirements

    Wear proper protective clothing for all work. When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec- tive gloves, goggles, breathing protection). Observe the information on personal protective equipment in the respective activity description. 6 | Safety | MS150033/05E 2013-10...

  • Page 7: Transport

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

  • Page 8: Safety Regulations For Startup And Operation

    • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live. Observe the safety instructions for these devices. 8 | Safety | MS150033/05E 2013-10...

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

    (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. MS150033/05E 2013-10 | Safety | 9...

  • Page 10: Safety Regulations For Maintenance And Repair Work

    Note cooling time for components which are heated for installation or removal (risk of burning). When working high on the equipment, always use suitable ladders and work platforms. Make sure com- ponents or assemblies are placed on stable surfaces. 10 | Safety | MS150033/05E 2013-10...
  • Page 11 Never place tools on the battery. Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. MS150033/05E 2013-10 | Safety | 11...
  • Page 12 • 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. 12 | Safety | MS150033/05E 2013-10...

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

    Prior to starting maintenance work, shut off the gas supply to the product. Activate the emergency stop at the interface switchgear cabinet or by turning the key switch (if fitted). In case of scheduled shutdowns of the product, coolant pump operation must continue for a certain time. MS150033/05E 2013-10 | Safety | 13...

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

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

  • Page 15: Compressed Air

    • If spilled onto clothing, remove the affected clothing immediately. • After contact with skin, rinse affected parts of the body with plenty of water. • Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi- ble. MS150033/05E 2013-10 | Safety | 15...

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

    • If safely feasible: Carry out emergency stop. • Cordon off danger zone. • Ensure sufficient ventilation! • Do not enter danger zone before measurements with a suitable gas detector have confirmed that gas concentration is not hazardous. 16 | Safety | MS150033/05E 2013-10...

  • Page 17: Standards For Safety Notices In The Text

    Consequences: Material damage! • Remedial action. • Additional product information. Safety notices This manual with all safety instructions and safety notices must be issued to all personnel involved in operation, maintenance, repair or transportation. MS150033/05E 2013-10 | Safety | 17...

  • Page 18: Product Summary

    7 Capacitor ignition system 12 Flywheel monitoring 8 Engine mounting bracket, KS Driving end 3 Air filter/air inlet free end 4 Mixture cooler 9 Oil pan 5 Exhaust turbocharger 10 Engine mounting bracket, driving end 18 | Product Summary | MS150033/05E 2013-10...
  • Page 19 Key to the engine model designation 12/16V 4000 L62 12/16 Number of cylinders Cylinder arrangement: V engine 4000 Series Application: L = Gas engine Load profile Design index Table 2: Engine model designation MS150033/05E 2013-10 | Product Summary | 19...

  • Page 20: Engine Side And Cylinder Designations

    No. 1 at the driving end. The numbering of other engine components also starts with no. 1 at the driving end. 1 Left-hand side of engine 3 Right-hand side of engine 2 Free end 4 Driving end 20 | Product Summary | MS150033/05E 2013-10...

  • Page 21: Main Engine Dimensions

    Approx. 2156 mm Height (C) for 16V Approx. 2166 mm Crankshaft center to oil pan (D) Approx. 636 mm Crankshaft center to engine mount (E) Approx. 281 mm Table 3: Main engine dimensions MS150033/05E 2013-10 | Product Summary | 21...

  • Page 22: Ignition Order

    2.4 Ignition order Ignition order 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 22 | Product Summary | MS150033/05E 2013-10...

  • Page 23: Technical Data

    Intake air temperature, min. °C Intake air temperature, max. °C Mixture temperature after mixture cooler °C Ambient intake depression, max. mbar Pressure loss over air filter, max. mbar Exhaust back pressure, max. mbar MS150033/05E 2013-10 | Product Summary | 23...
  • Page 24 Pressure in cooling system, max. Pressure loss over engine (at nominal flow rate 7.27) Thermostat: Starts to open °C Thermostat: Opening stops (thermostat fully open and bypass °C closed) Table 9: Coolant system (HT circuit) 24 | Product Summary | MS150033/05E 2013-10...
  • Page 25 1500 1500 Limit speed for overspeed alarm/emergency shutdown 1900 1900 Table 13: General operating data Starting (electric) Number of cylinders Starter, rated power (standard design) 2 x 9 Rated starter voltage (standard design) MS150033/05E 2013-10 | Product Summary | 25...

  • Page 26: Exhaust Emissions

    Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise filter) - DL dB(A) (sound power level LW, ISO 8528-10) Table 18: Acoustics 26 | Product Summary | MS150033/05E 2013-10...

  • Page 27: 4000 L62, 16V 4000 L62 Engine Data, Emissions-Optimized (1/2 Ta-Luft)

    Mixture temperature after mixture cooler °C Ambient intake depression, max. mbar Pressure loss over air filter, max. mbar Exhaust back pressure, max. mbar Gas type: natural gas Methane number, min. Table 21: General conditions (for max. power) MS150033/05E 2013-10 | Product Summary | 27...
  • Page 28 Pressure in cooling system, max. Pressure loss over engine (at nominal flow rate 7.27) Thermostat: Starts to open °C Thermostat: Opening stops (thermostat fully open and bypass °C closed) Table 24: Coolant system (HT circuit) 28 | Product Summary | MS150033/05E 2013-10...
  • Page 29 1500 1500 Limit speed for overspeed alarm/emergency shutdown 1900 1900 Table 28: General operating data Starting (electric) Number of cylinders Starter, rated power (standard design) 2 x 9 Rated starter voltage (standard design) MS150033/05E 2013-10 | Product Summary | 29...
  • Page 30 Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise filter) - DL dB(A) (sound power level LW, ISO 8528-10) Table 33: Acoustics 30 | Product Summary | MS150033/05E 2013-10...

  • Page 31: Monitoring, Control And Regulation Equipment

    • Monitors second gas solenoid in gas train to engine • Diagnostic interface Engine Monitoring Unit EMU • Evaluation unit for PT 1000 temperature sensor to determine and monitor exhaust temperatures of individual cylinders MS150033/05E 2013-10 | Product Summary | 31...
  • Page 32 If this does not result in an improvement, the power is reduced. Gas control valve TecJet50+ • Controls the required amount of gas Mixture throttles ProAct • The mixture throttles in the mixture lines which are controlled by the engine governor 32 | Product Summary | MS150033/05E 2013-10...

  • Page 33: Control Cabinet Mis - Overview

    Starter A bank, starter B bank F002 Throttle A bank, throttle B bank F003 Ignition system F004 Anti knock control AKR F005 Emergency stop system F006 TecJet50+ F007 F008 ADEC (ECU 7), EMU F009 Bypass throttle MS150033/05E 2013-10 | Product Summary | 33...

  • Page 34: Purpose Of The Units

    (configurable) • Diagnostic function via CAN interface (Default CAN1, connection for dialog unit provided) Software structure: • One data record for engine software • One data record for genset software 34 | Product Summary | MS150033/05E 2013-10...
  • Page 35 • 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. MS150033/05E 2013-10 | Product Summary | 35...
  • Page 36 CANOpen and SAE-J1939 interface For CANOpen and J1939 interface, a type CCB2 printed circuit board (1) is inserted in slot 3 of the SAM unit. Engine Monitoring Unit EMU EMU = Engine Monitoring Unit 36 | Product Summary | MS150033/05E 2013-10...
  • Page 37 Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring MS150033/05E 2013-10 | Product Summary | 37...

  • Page 38: Operation

    No restriction Table 34: Runtimes at partial load A minimum operating time of 2 hours per start is recommended to counteract increased engine loading resulting from temperature changes (cold start to engine operating temperature). 38 | Operation | MS150033/05E 2013-10...

  • Page 39: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    3.2 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 PowerPack into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...

  • Page 40: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    Lube oil system Check oil level in oil storage tank (→ Page 162). Coolant circuit Check engine coolant level (→ Page 166); Check mixture coolant level (→ Page 172) Engine management system Check for fault messages. 40 | Operation | MS150033/05E 2013-10...

  • Page 41: Control, Starting And Stopping Sequences

    1. Gas supply solenoid valves close 2. Mixture throttles open, residual gas is purged with air 3. Engine coasts down to standstill or for a maximum coasting period 4. Deactivation of ignition 5. Mixture throttles close MS150033/05E 2013-10 | Operation | 41...
  • Page 42 2. Engine running for a minimum (parameterized) time period 3. Oil refilling enabled 4. When oil refill request is received 5. Refilling oil (automatically) 6. Oil refill request is canceled 7. Stopping oil refilling (automatically) 42 | Operation | MS150033/05E 2013-10...

  • Page 43: Engine - Start

    WARNING High level of engine noise when the engine is running. Risk of damage to hearing! • Wear ear protectors. Starting engine Start engine in accordance with starting sequence specifications (→ Page 41). MS150033/05E 2013-10 | Operation | 43...

  • Page 44: Operational Checks

    • This is especially useful for fault localization and fast remedial action. Engine under load, Check engine/plant and all pipework visually for leaks, rectify any leaks with Engine at nominal speed the engine stopped; Check for abnormal running noises and vibration. 44 | Operation | MS150033/05E 2013-10...

  • Page 45: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas measuring and warning device (not stocked by MTU) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 46: Engine - Shutdown

    • Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant levels are indicated. Shutting down engine Shut down engine in accordance with stopping sequence specifications (→ Page 41). 46 | Operation | MS150033/05E 2013-10...

  • Page 47: Emergency Stop

    Measure Engine Control System Determine cause for emergency stop and take remedial action; if the fault cannot be corrected, contact Service. Prior to re-starting the engine Item Measure Emergency stop button (key Unlock. switch) MS150033/05E 2013-10 | Operation | 47...

  • Page 48: After Stopping The Engine - Engine Remains Ready For Operation

    3.10 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator control Select operating mode, e.g. HAND, MANUAL, AUTO, AUTOMATIC. (manufacturer-specific) 48 | Operation | MS150033/05E 2013-10...

  • Page 49: 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 50: Maintenance

    When installing a cylinder head with run-in mating faces (e.g. after piston replacement), a repeated check after the first 50 operating hours is not necessary. Qualifi- Interval Item Tasks Task cation [hours] [years] Valve gear Check valve clearance (→ Page 153) 50 | Maintenance | MS150033/05E 2013-10...

  • Page 51: Maintenance Task Reference Table [Ql1]

    Replace spark plug connector. (→ Page 145) W1689 Measure valve depth. (→ Page 150) W1798 Replace fine filter. (→ Page 139) W1799 Replace coarse filter (coalescer filter). (→ Page 139) Table 36: Maintenance task reference table [QL1] MS150033/05E 2013-10 | Maintenance | 51...

  • Page 52: Troubleshooting

    Table 37: Explanation of the abbreviations used Fault indication on SAM display The fault messages are generated by the engine governor ADEC (ECU) and by the SAM unit and trans- mitted to the SAM display (4). 52 | Troubleshooting | MS150033/05E 2013-10...
  • Page 53 Fault messages from the SAM are represented in the fault code list (→ Page 56). 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. MS150033/05E 2013-10 | Troubleshooting | 53...
  • Page 54 Serial Conection Lost CAN Bus- 3 Error/Bus Defec CAN Bus- 3 Overrun S/A Bus Faulty PAN 1 Defect PAN 2 Defect PAN 3 Defect PAN 4 Defect PAN 5 Defect PAN 6 Defect I/O-Module Slot1 Defect 54 | Troubleshooting | MS150033/05E 2013-10...
  • Page 55 Error message text I/O-Module Slot5 Defect I/O-Module Slot6 Defect I/O-Module Slot7 Defect I/O-Module Slot8 Defect Download Server Collision not projected node Device specific error not projected node Device specific error Table 38: SE (System Error) alarms MS150033/05E 2013-10 | Troubleshooting | 55...

  • Page 56: Sam - Fault Messages

    The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 56 | Troubleshooting | MS150033/05E 2013-10...
  • Page 57 The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). MS150033/05E 2013-10 | Troubleshooting | 57...
  • Page 58 The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 58 | Troubleshooting | MS150033/05E 2013-10...
  • Page 59 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 149). 4. Check valve drive. MS150033/05E 2013-10 | Troubleshooting | 59...
  • Page 60 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 149). 4. Check valve drive. 60 | Troubleshooting | MS150033/05E 2013-10...
  • Page 61 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 149). 4. Check valve drive. MS150033/05E 2013-10 | Troubleshooting | 61...
  • Page 62 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 149). 4. Check valve drive. 62 | Troubleshooting | MS150033/05E 2013-10...
  • Page 63 The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). MS150033/05E 2013-10 | Troubleshooting | 63...
  • Page 64 The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 64 | Troubleshooting | MS150033/05E 2013-10...
  • Page 65 The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). MS150033/05E 2013-10 | Troubleshooting | 65...
  • Page 66 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 149). 4. Check valve drive. 66 | Troubleshooting | MS150033/05E 2013-10...
  • Page 67 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 149). 4. Check valve drive. MS150033/05E 2013-10 | Troubleshooting | 67...
  • Page 68 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 149). 4. Check valve drive. 68 | Troubleshooting | MS150033/05E 2013-10...
  • Page 69 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 149). 4. Check valve drive. MS150033/05E 2013-10 | Troubleshooting | 69...
  • Page 70 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 149). 3. Check valve drive (exhaust valves do not close). 70 | Troubleshooting | MS150033/05E 2013-10...
  • Page 71 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 149). 3. Check valve drive (exhaust valves do not close). MS150033/05E 2013-10 | Troubleshooting | 71...
  • Page 72 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 149). 3. Check valve drive (exhaust valves do not close). 72 | Troubleshooting | MS150033/05E 2013-10...
  • Page 73 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 149). 3. Check valve drive (exhaust valves do not close). MS150033/05E 2013-10 | Troubleshooting | 73...
  • Page 74 1. Check supply voltage. knocking module CAN. 2. Check connecting line. 150203 – Comm. Lost Ignition Red alarm. Initiated by SAM. Cause Corrective action No communication with ignition 1. Check supply voltage. CAN. 2. Check connecting line. 74 | Troubleshooting | MS150033/05E 2013-10...
  • Page 75 150401 – HI Oil Refill Yellow alarm. Initiated by SAM. Cause Corrective action Too many pulses received for 1. Check engine oil level (→ Page 162). lube oil replenishment. 2. Check oil supply (→ Page 162). MS150033/05E 2013-10 | Troubleshooting | 75...
  • Page 76 150902 – SS Local Initiated Emerg. Stop Red alarm. Initiated by SAM. Cause Corrective action Emergency stop detected. Emergency stop was released manually (button), or ignition system reported overspeed. 76 | Troubleshooting | MS150033/05E 2013-10...
  • Page 77 Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 151028 – Elec Temp Fail High Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. MS150033/05E 2013-10 | Troubleshooting | 77...
  • Page 78 Hardware not ready for u Restart TecJet. operation. 151037 – FGT Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet and configuration. Gas temperature before TecJet is below the preset limit value. 78 | Troubleshooting | MS150033/05E 2013-10...
  • Page 79 Check setting and switch over to PWM input. Check PWM signal. 151050 – PWM Duty Cycle Low 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. MS150033/05E 2013-10 | Troubleshooting | 79...
  • Page 80 Supply voltage has reached 1. Check supply voltage. maximum limit value. 2. Check cabling. 151057 – FGT High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 80 | Troubleshooting | MS150033/05E 2013-10...
  • Page 81 Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 151069 – Keyswitch State Red alarm. Initiated by TecJet. Cause Corrective action u Check cabling. Keyswitch cabling missing. MS150033/05E 2013-10 | Troubleshooting | 81...
  • Page 82 Cause Corrective action Genset has exceeded admissible u Restart ignition system. speed. 152018 – E2PROM Checksum Error Red alarm. Initiated by IC922. Cause Corrective action u Restart ignition system. Hardware not ready for operation. 82 | Troubleshooting | MS150033/05E 2013-10...
  • Page 83 2. Check ignition coil. 152027 – Open Primary, Channel 2 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. MS150033/05E 2013-10 | Troubleshooting | 83...
  • Page 84 2. Check ignition coil. 152034 – Open Primary, Channel 9 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. 84 | Troubleshooting | MS150033/05E 2013-10...
  • Page 85 2. Check ignition coil. 152041 – Open Primary, Channel 16 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. MS150033/05E 2013-10 | Troubleshooting | 85...
  • Page 86 152052 – Warn. Missing Camshaft Signal Yellow alarm. Initiated by IC922. Cause Corrective action u Check sensor B1.2, check sensor clearance and cabling, Missing camshaft signal for ignition system. replace if necessary. 86 | Troubleshooting | MS150033/05E 2013-10...
  • Page 87 Combined alarm (for details, refer to the source alarm). Combined alarm (for details, refer to the source alarm). 153103 – Internal Error Red alarm. Initiated by antiknock control. Cause Corrective action Hardware not ready for u Restart antiknock control system. operation. MS150033/05E 2013-10 | Troubleshooting | 87...
  • Page 88 153115 – Knock Sensor Error A5 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. 88 | Troubleshooting | MS150033/05E 2013-10...
  • Page 89 153121 – Knock Sensor Error B1 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. MS150033/05E 2013-10 | Troubleshooting | 89...
  • Page 90 153127 – Knock Sensor Error B7 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. 90 | Troubleshooting | MS150033/05E 2013-10...
  • Page 91 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder. 4. Check gas quality if feasible (methane number). MS150033/05E 2013-10 | Troubleshooting | 91...
  • Page 92 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder. 4. Check gas quality if feasible (methane number). 92 | Troubleshooting | MS150033/05E 2013-10...
  • Page 93 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder. 4. Check gas quality if feasible (methane number). MS150033/05E 2013-10 | Troubleshooting | 93...
  • Page 94 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder. 4. Check gas quality if feasible (methane number). 94 | Troubleshooting | MS150033/05E 2013-10...
  • Page 95 Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). MS150033/05E 2013-10 | Troubleshooting | 95...
  • Page 96 Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 96 | Troubleshooting | MS150033/05E 2013-10...
  • Page 97 Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). MS150033/05E 2013-10 | Troubleshooting | 97...
  • Page 98 Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 98 | Troubleshooting | MS150033/05E 2013-10...
  • Page 99 2. Check spark plug (energy level ignition system). 153264 – HI Misfire Integrator A4 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). MS150033/05E 2013-10 | Troubleshooting | 99...
  • Page 100 2. Check spark plug (energy level ignition system). 153271 – HI Misfire Integrator B1 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). 100 | Troubleshooting | MS150033/05E 2013-10...
  • Page 101 2. Check spark plug (energy level ignition system). 153278 – HI Misfire Integrator B8 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). MS150033/05E 2013-10 | Troubleshooting | 101...
  • Page 102 2. Check spark plug (energy level ignition system). 153285 – HIHI Misfire Integrator A5 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). 102 | Troubleshooting | MS150033/05E 2013-10...
  • Page 103 2. Check spark plug (energy level ignition system). 153292 – HIHI Misfire Integrator B2 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). MS150033/05E 2013-10 | Troubleshooting | 103...
  • Page 104 2. Check spark plug (energy level ignition system). 153299 – HIHI Misfire Integrator B9 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). 104 | Troubleshooting | MS150033/05E 2013-10...
  • Page 105 153300 – HIHI Misfire Integrator B10 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). MS150033/05E 2013-10 | Troubleshooting | 105...

  • Page 106: Engine Governor - Fault Messages

    (limit 2. Check ignition timing (→ Page 149). value 1). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4. Check spark plugs. rich, damage to turbine. 106 | Troubleshooting | MS150033/05E 2013-10...
  • Page 107 1. Replace oil filter (→ Page 165). high (limit value 1). 2. If this fault message occurs again after unexpectedly short filter runtime, check oil filter for deposits, change oil if required (→ Page 163). MS150033/05E 2013-10 | Troubleshooting | 107...
  • Page 108 Red alarm. Engine shutdown. Associated parameter 2.3012.932 Cause Corrective action u Turbocharger speed sensor is not fitted at present. Check ECU Speed of primary turbocharger too high (limit value 2). setting for this input. 108 | Troubleshooting | MS150033/05E 2013-10...
  • Page 109 1. Check engine coolant circuit. heat exchanger too high (limit 2. Check oil heat exchanger. value 2). Oil heat exchanger 3. Check oil level (→ Page 162). clogged, coolant temperature too high, oil flow too low. MS150033/05E 2013-10 | Troubleshooting | 109...
  • Page 110 Red alarm. Engine shutdown. Associated parameter 2.0101.922 Cause Corrective action Coolant pressure after engine u Check engine coolant circuit (pressure and volumetric flow). too low (limit value 2). Volumetric flow too low, static pressure too low. 110 | Troubleshooting | MS150033/05E 2013-10...
  • Page 111 Yellow alarm. Associated parameter 2.0120.931 Cause Corrective action Coolant temperature after u Check engine coolant circuit. engine too high (limit value 1). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit. MS150033/05E 2013-10 | Troubleshooting | 111...
  • Page 112 090 – SS Idle Speed Not Reached ZKP-Number: Red alarm. Start terminated. Associated parameter 2.1090.925 Cause Corrective action Idling speed not attained. 1. Check ignition. 2. Check gas supply. 3. Check mixture setting. 112 | Troubleshooting | MS150033/05E 2013-10...
  • Page 113 Associated parameter 2.1090.921 Cause Corrective action Preheating temperature too low 1. Check preheating. (limit value 1). Coolant 2. Check differential coolant pressure. temperature too low for engine 3. Check heating elements. start. 4. Check cabling. MS150033/05E 2013-10 | Troubleshooting | 113...
  • Page 114 2). 2. Check cabling. 120 – HI ECU Supply Voltage ZKP-Number: Yellow alarm. Associated parameter 2.0140.931 Cause Corrective action Supply voltage too high (limit 1. Check supply voltage. value 1). 2. Check cabling. 114 | Troubleshooting | MS150033/05E 2013-10...
  • Page 115 Power up ECU, contact Service. This fault message is generated if a CRC is faulty (is indicated for each module) during a restore data upload (in the ADEC) or if the upload is incomplete. MS150033/05E 2013-10 | Troubleshooting | 115...
  • Page 116 Corrective action A CAN mode has been selected u Contact Service (configuration fault). in which communication with the PU data module is initialized. However, the required PU data module is not available or not valid. 116 | Troubleshooting | MS150033/05E 2013-10...
  • Page 117 Yellow alarm. Associated parameter 2.0500.688 Cause Corrective action CAN controller 2 is in “Bus-Off” u Check operation of nodes and cabling. status. Automatic switching to CAN bus 1. Bus users (ECU, SAM or EMU) faulty. MS150033/05E 2013-10 | Troubleshooting | 117...
  • Page 118 Red alarm. Engine shutdown. Associated parameter 1.8004.602 Cause Corrective action u Check sensor and cabling (B24), replace as necessary. Fault is Engine oil level sensor defective, short circuit or wire break. rectified when engine is restarted. 118 | Troubleshooting | MS150033/05E 2013-10...
  • Page 119 Red alarm. Associated parameter 1.8004.564 Cause Corrective action Coolant pressure sensor after u Check sensor and cabling (B16.1), replace if necessary. Fault is engine defective, short circuit or rectified when engine is restarted. wire break. MS150033/05E 2013-10 | Troubleshooting | 119...
  • Page 120 Corrective action u Check sensor and cabling before filter (B5.3) and after Engine oil pressure sensors defective, short circuit or wire filter (B5.1), replace as necessary. Fault is rectified when engine break. is restarted. 120 | Troubleshooting | MS150033/05E 2013-10...
  • Page 121 232 – SD Charger 1 Speed ZKP-Number: Yellow alarm. Associated parameter 1.3011.128 Cause Corrective action Speed sensor of primary u Turbocharger speed sensor is not fitted at present. turbocharger defective, short circuit or wire break. MS150033/05E 2013-10 | Troubleshooting | 121...
  • Page 122 381 – AL Wiring TOP 1 ZKP-Number: Yellow alarm. Associated parameter 2.8006.638 Cause Corrective action u Check cabling. Short circuit or wire break on transistor output, plant-side 1 (TOP 1). Activation of yellow combined alarm faulty. 122 | Troubleshooting | MS150033/05E 2013-10...
  • Page 123 418 – SD T-Intake Air B ZKP-Number: Yellow alarm. Associated parameter 1.8004.603 Cause Corrective action u Check sensor and cabling (B49.2), replace if necessary. Intake air temperature sensor defective, short circuit or wire break. MS150033/05E 2013-10 | Troubleshooting | 123...
  • Page 124 Yellow alarm. Associated parameter 2.0168.921 Cause Corrective action u Check engine coolant circuit (pressure and volumetric flow). Coolant pressure before engine too low (limit value 1). Volumetric flow too low, static pressure too low. 124 | Troubleshooting | MS150033/05E 2013-10...
  • Page 125 Difference in mixture pressures 1. Check throttles for varying positions and malfunction. sensed on A and B side is too 2. Check mixture lines for leakage. high (limit value 1). 3. Check sensors and cabling (B79.22, B79.21). MS150033/05E 2013-10 | Troubleshooting | 125...
  • Page 126 453 – LO T-Charge Mix ZKP-Number: Yellow alarm. Associated parameter 2.0169.921 Cause Corrective action Mixture temperature is too low 1. Check intake air temperature. (limit value 3). 2. Check mixture cooling circuit. 126 | Troubleshooting | MS150033/05E 2013-10...
  • Page 127 Red alarm. Associated parameter 1.8004.587 Cause Corrective action u Check sensor and cabling, replace as necessary. Fault is Temperature sensor for engine governor defective, short circuit rectified when engine is restarted. or wire break. MS150033/05E 2013-10 | Troubleshooting | 127...
  • Page 128 479 – AL Comb. Alarm Red (Plant) ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.8006.002 Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm RED from plant. 128 | Troubleshooting | MS150033/05E 2013-10...
  • Page 129 ZKP-Number: Red alarm. Associated parameter 1.8004.632 Cause Corrective action Mixture temperature sensor u Check sensor and cabling (B73), replace as necessary. Fault is defective, short circuit or wire rectified when engine is restarted. break. MS150033/05E 2013-10 | Troubleshooting | 129...
  • Page 130 515 – AL Starter Not Engaged ZKP-Number: Yellow alarm. Associated parameter 2.1090.926 Cause Corrective action ECU does not detect engine 1. Check starter. speed during starting sequence. 2. Check cabling. 3. Check speed sensor. 130 | Troubleshooting | MS150033/05E 2013-10...
  • Page 131 531 – AL Wiring PWM_CM1 ZKP-Number: Red alarm. Associated parameter 1.1044.900 Cause Corrective action Cable break or short circuit on u Check cabling to TecJet throttle, replace TecJet throttle if channel PWM_CM1. necessary. MS150033/05E 2013-10 | Troubleshooting | 131...
  • Page 132 544 – AL Configuration Changed ZKP-Number: Yellow alarm. Associated parameter 2.0555.003 Cause Corrective action u Contact Service (configuration fault). This alarm is activated when the system configuration was changed, e.g. because the ECU or SAM was exchanged. 132 | Troubleshooting | MS150033/05E 2013-10...
  • Page 133 Associated parameter 2.1090.124 Cause Corrective action u Check gas train and cabling. Gas supply solenoid valve faulty. Either the gas supply solenoid valves are faulty, the time-out period is set too short, or communication is faulty. MS150033/05E 2013-10 | Troubleshooting | 133...
  • Page 134 565 – AL L1 P-Intake Air after Filter A ZKP-Number: Yellow alarm. Associated parameter 2.0186.921 Cause Corrective action u Replace air filter (→ Page 160). Pressure loss over air filter on A side is too high. 134 | Troubleshooting | MS150033/05E 2013-10...
  • Page 135 SAM. Possible problem related to CAN bus, SAM does not work properly or a device connected to SAM does not work properly so that SAM cannot transmit the messages from this device successfully. MS150033/05E 2013-10 | Troubleshooting | 135...
  • Page 136 4. Check gas quality if feasible (methane number). 583 – AL GLS closed ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0451.005 Cause Corrective action u Check generator load switch. Generator load switch does not open when engine stops. Engine is motoring. 136 | Troubleshooting | MS150033/05E 2013-10...

  • Page 137: Task Description

    Apply ratchet (1) to barring gear (2). Rotate crankshaft in direction of engine ro- tation. Apart from compression resistance, there should be no abnormal resistance. Remove barring gear in reverse order. MS150033/05E 2013-10 | Task Description | 137...

  • Page 138: Machine Room - Check For Smell Of Gas

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

  • Page 139: Crankcase Breather

    • Avoid open flames, electric sparks and ignition sources. • Do not smoke. Oil separator – Filter replace- ment Release clamp (2) on both sides and re- move it. Remove housing cover (1). MS150033/05E 2013-10 | Task Description | 139...
  • Page 140 Value/Standard Locknut Tightening torque 15 Nm Fit housing cover (1). Fit clamp (2) neatly and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Clamp Tightening torque 5 Nm 140 | Task Description | MS150033/05E 2013-10...

  • Page 141: Ignition System

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug (→ Spare Parts Catalog) Replacing spark plug Remove spark plug (→ Page 142). Install new spark plug (→ Page 143). MS150033/05E 2013-10 | Task Description | 141...

  • Page 142: Spark Plug - Removal

    Remove spark plug connector (3) with igni- tion cable (2) from spark plug. Unscrew spark plug a few threads. Clean spark-plug recess with compressed air. Unscrew spark plug from cylinder head. Remove lower seal of ignition cable. 142 | Task Description | MS150033/05E 2013-10...

  • Page 143: Spark Plug - Installation

    Clean mating faces on spark plug, sealing ring and cylinder head. Apply thin coat of assembly compound to spark plug. Fit new sealing ring (2) on spark plug (1), positioning it correctly. MS150033/05E 2013-10 | Task Description | 143...
  • Page 144 (Molycote P 37)) Fit spark plug connector (3) with ignition cable (2) on spark plug. Install tab washer (4) with screws (5) on cylinder head cover (1). Install ignition cable on ignition coil. 144 | Task Description | MS150033/05E 2013-10...

  • Page 145: 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 146). Install spark plug connector (→ Page 147). MS150033/05E 2013-10 | Task Description | 145...

  • Page 146: Spark Plug Connector - Removal

    Remove screws (5) and tab washer (7) from cylinder head cover. Remove spark plug connector (6) with igni- tion cable (4) from spark plug. Remove sealing ring from Teflon sleeve of ignition line. 146 | Task Description | MS150033/05E 2013-10...

  • Page 147: Spark Plug Connector - Installation

    (4) on spark plug. Fit tab washer (7) on cylinder head cover. Install screw (2) with spring washer onto ignition coil (1). Name Size Type Lubricant Value/Standard Screw Tightening torque 10 Nm MS150033/05E 2013-10 | Task Description | 147...
  • Page 148 Push protective cap (3) onto ignition coil. 148 | Task Description | MS150033/05E 2013-10...

  • Page 149: Ignition System - Ignition Timing Check

    Reset position adjustment is carried out with the Diasys service tool. Check ignition timing. Disconnect stroboscope. Stop engine (→ Page 46). MS150033/05E 2013-10 | Task Description | 149...

  • Page 150: Valve Drive

    Remove cylinder head covers (→ Page 157). Remove sleeves (arrow). Install barring device (→ Page 137). Rotate crankshaft with barring device in en- gine direction of rotation until marking “OT” and pointer are aligned. 150 | Task Description | MS150033/05E 2013-10...
  • Page 151 . Install valve bridge. Adjust valve clearance (→ Page 153) Final steps Remove barring device (→ Page 137). Check condition of O-rings at the sleeves, replace if damaged. MS150033/05E 2013-10 | Task Description | 151...
  • Page 152 Install sleeves (arrow). Install cylinder head covers (→ Page 158). Install spark plugs with new sealing rings (→ Page 143). 152 | Task Description | MS150033/05E 2013-10...

  • Page 153: Valve Clearance - Check And Adjustment

    Preparatory steps Remove cylinder head cover (→ Page 157). Install barring gear (→ Page 137). Rotate crankshaft with barring gear in en- gine direction of rotation until marking “OT” and pointer are aligned. MS150033/05E 2013-10 | Task Description | 153...
  • Page 154 Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram. Use feeler gage to determine the distance between valve bridge and rocker arm. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance. 154 | Task Description | MS150033/05E 2013-10...

  • Page 155: Adjusting Valve Clearance

    90 Nm +9 Nm Replace or rectify adjusting screws and/or locknuts which do not move freely. Check valve clearance. Final steps Remove barring gear (→ Page 137). Install cylinder head cover (→ Page 158). MS150033/05E 2013-10 | Task Description | 155...

  • Page 156: Valve Gear - Lubrication

    Part No. Qty. Engine oil Lubricating valve gear Remove cylinder head covers (→ Page 157). Fill oil chambers of rocker arms and adjust- ing screws with oil. Install cylinder head covers (→ Page 158). 156 | Task Description | MS150033/05E 2013-10...

  • Page 157: Cylinder Head Cover - Removal

    Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 146). Remove screws (2). Remove cylinder head cover with gasket from cylinder head. MS150033/05E 2013-10 | Task Description | 157...

  • Page 158: Cylinder Head Cover - Installation

    Position gasket and cylinder head cover (1) on cylinder head. Insert screws (2) in cylinder head cover and tighten them. Note: The locking plate must be removed from the cylinder head cover. Install spark plug connector (→ Page 147). 158 | Task Description | MS150033/05E 2013-10...

  • Page 159: Gas System

    Coat all connections of the gas supply line with soap solution or spray with leakage detection spray from a distance of 30 to 50 cm. • Leaks are indicated by the formation of bubbles or foam. Replace leaking parts. MS150033/05E 2013-10 | Task Description | 159...

  • Page 160: Air Filter

    Air filter condition is monitored by a sensor. Replace air filter and/or (optional) fleece prefilter when the corresponding fault message appears. Replacing air filter Remove air filter (→ Page 161). Install new air filter (→ Page 161). 160 | Task Description | MS150033/05E 2013-10...

  • Page 161: Air Filter - Removal And Installation

    (1) of intake housing. Clean connecting flange (1) of the intake housing and check for obstructions. Place new air filter (3) with clamp (2) onto intake housing (1). Tighten clamp (2). MS150033/05E 2013-10 | Task Description | 161...

  • Page 162: Lube Oil System, Lube Oil Circuit

    Topping up oil manually is not required. The oil level check is only intended to confirm that the automat- ic oil replenishment feature works properly. Oil level must be between marks (1) and (2). Insert oil dipstick into guide tube up to the stop. 162 | Task Description | MS150033/05E 2013-10...

  • Page 163: Engine Oil - Change

    6.7.2 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 Hot oil.

  • Page 164: Engine Oil - Sample Extraction And Analysis

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

  • Page 165: Oil Filtration / Cooling

    Check condition of new oil filter sealing ring and coat it with oil. Screw on and tighten new oil filter by hand. Replace other oil filters in the same way. Check oil level (→ Page 162). MS150033/05E 2013-10 | Task Description | 165...

  • Page 166: Circuit

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

  • Page 167: Engine Coolant – Change

    6.9.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 168). Fill with engine coolant (→ Page 170). MS150033/05E 2013-10 | Task Description | 167...

  • Page 168: Engine Coolant – Draining

    Provide an appropriate container to drain the coolant into. Switch off preheater, if installed. Engine coolant – Draining Open drain valves and drain coolant at the following points: • At the crankcase free end, left and right side 168 | Task Description | MS150033/05E 2013-10...
  • Page 169 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS150033/05E 2013-10 | Task Description | 169...

  • Page 170: Engine Coolant – Filling

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

  • Page 171: Vent Line Of Engine Coolant Circuit Replacement

    Replacing coolant vent line Drain engine coolant (→ Page 168). Release union nuts (1) and (3). Remove coolant vent line (2). Install new coolant vent line (2). Fill with engine coolant (→ Page 170). MS150033/05E 2013-10 | Task Description | 171...

  • Page 172: Low-Temperature Circuit

    6.10 Low-Temperature Circuit 6.10.1 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 173: Mixture Coolant – Change

    6.10.2 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 174). Fill with fresh mixture coolant (→ Page 175). MS150033/05E 2013-10 | Task Description | 173...

  • Page 174: Mixture Coolant – Draining

    • Wear protective clothing, gloves, and goggles / safety mask. Draining mixture coolant Provide a suitable receptacle to catch the coolant. Open drain valve at drain point in coolant line to mixture coolant cooler and drain coolant. 174 | Task Description | MS150033/05E 2013-10...

  • Page 175: Mixture Coolant – Filling

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

  • Page 176: Wiring (General) For Engine/Gearbox/Unit

    Contact Service if cable conductors are damaged. Note: Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts using isopropyl alcohol. Ensure that all sensor connectors are securely engaged. 176 | Task Description | MS150033/05E 2013-10...

  • Page 177: Sensors – Overview

    Exhaust gas temperature after cylinder XX B79.22 Mixture pressure B-side Mixture temperature Table 39: Sensors on B side The knocking sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads. MS150033/05E 2013-10 | Task Description | 177...
  • Page 178 Sensors on driving end Item Designation Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.2 Crankshaft speed ignition Table 40: Sensors on driving end 178 | Task Description | MS150033/05E 2013-10...
  • Page 179 Monitoring of B79.21 Mixture pressure A-side Crankcase pressure B5.1 Engine oil pressure before filter Engine oil temperature B44.1 Turbocharger speed (optional) B5.1 Engine oil pressure after filter Table 41: Sensors on A side MS150033/05E 2013-10 | Task Description | 179...
  • Page 180 Camshaft speed knock module B1.2 Camshaft speed ignition system B1.1 Camshaft speed Engine Control Unit Engine oil level B6.3 Coolant temperature before engine B6.1 Coolant temperature after engine Table 42: Sensors on free end 180 | Task Description | MS150033/05E 2013-10...

  • Page 181: Abbreviations

    Low Low Alarm: Measured value lower than 2nd mini- mum limit value Low temperature Missing Data A measuring point does not provide data Message General message Motoren- und Turbinen-Union Onsite Energy MTU Onsite Energy MS150033/05E 2013-10 | Appendix A | 181...
  • Page 182 Technische Anleitung zur Reinhaltung General administrative instruction for federal der Luft emission control law in Germany Transmitter Deviation Alarm: Sensor comparison fault Unterer Totpunkt Bottom dead center (BDC) Werkzeugkatalog Tool Catalog (TC) Zündzeitpunkt Ignition timing 182 | Appendix A | MS150033/05E 2013-10...

  • Page 183: Mtu Onsite Energy Contacts / Service Partners

    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.htm 24h Hotline With our 24h hotline and the flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed oper- ating conditions, or for spare parts supply.

  • Page 184: Special Tools

    Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 165) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 6.1.2 Machine room – Check for smell of gas (→ Page 138)
  • Page 185 Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 3.7 Emission values – Check (→ Page 45) Offset screwdriver Part No.: F30452765 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 153) Plug-in open-end wrench, 24 mm Part No.:...
  • Page 186 (→ Page 149) Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 143) Qty.: Used in: 6.3.6 Spark plug connector – Installation (→ Page 147) 186 | Appendix B | MS150033/05E 2013-10...
  • Page 187 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 153) MS150033/05E 2013-10 | Appendix B | 187...

  • Page 188: Index

    – Start  43 – Service partners  183 – Wiring check  176 Engine coolant  – Change  167 Oil separator  – Draining  168 – Filter replacement  139 – Filling  170 Operational checks 44 – Level check  166 188 | Appendix B | MS150033/05E 2013-10...
  • Page 189 – Fault messages   – On the display  52 SAM – Fault messages 56 Sensors  – Overview  177 Service partners  – MTU Onsite Energy  183 Spark plug  – Installation  143 – Removal  142 – Replacement  141 MS150033/05E 2013-10 | Appendix B | 189...

Table of Contents