MTU 8V4000L62FB Operating Instructions Manual
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MTU 8V4000L62FB Operating Instructions Manual

MTU 8V4000L62FB Operating Instructions Manual

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Operating Instructions

Gas engine
8 V 4000 Lx2 xx
MS150097/01E

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Summary of Contents for MTU 8V4000L62FB

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 8 V 4000 Lx2 xx MS150097/01E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 3.10 After stopping the engine – Engine remains ready for operation 1.1 Important provisions for all products 3.11 After stopping the engine – Putting the 1.2 Transport engine out of operation 1.3 Personnel and organizational requirements 1.4 Safety regulations for startup and operation 4 Maintenance 1.5 Safety regulations for startup and operation,...
  • Page 4 7 Appendix A 6.9.4 Engine coolant ‒ Filling 6.9.5 Vent line of engine coolant circuit – 7.1 Abbreviations Replacement 7.2 MTU Onsite Energy contacts / service 6.10 Low-Temperature Circuit partners 6.10.1 Mixture coolant level ‒ Check 6.10.2 Mixture coolant – Change 8 Appendix B 6.10.3 Mixture coolant –...

  • 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: 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 7: Personnel And Organizational Requirements

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

  • Page 8: Safety Regulations For Startup And Operation

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

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

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

  • Page 10: Safety Regulations For Maintenance And Repair Work

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

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

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

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

    The latest version can be found on the website on the "Technical Info" 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

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

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

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

  • Page 17: Standards For Safety Notices In The Text

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

  • Page 18: Product Summary

    2 Product Summary 2.1 Engine layout 1 Engine governor/engine 5 Engine lifting equipment 9 Engine mounting bracket, monitoring 6 Capacitor discharge igni- driving end 2 Air filter/air inlet tion system 10 Starter 3 Mixture cooler 7 Engine mounting bracket, 11 Flywheel 4 Exhaust turbocharger free end KS Driving end...
  • Page 19 1 Crankcase breather, oil 7 Spark plug 13 Connection: engine cool- separator 8 Cylinder head cover ant inlet 2 Exhaust gas outlet connec- 9 Cylinder head 14 Engine oil heat exchanger tion 10 Engine oil sampling port 15 Connection: engine cool- 3 Gas control valve 11 Engine oil filter ant outlet...

  • Page 20: Engine Side And Cylinder Designations

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

  • Page 21: Main Engine Dimensions

    2.3 Main engine dimensions Main engine dimensions Length (A) approx. 2185.4 mm Width (B) approx. 1751.3 mm Height (C) approx. 2140.2 mm Crankshaft center to oil pan (D) approx. 625 mm Crankshaft center to engine mount (E) approx. 280.5 mm Heat shield, A side to crankshaft center (F) approx.

  • Page 22: Firing Order

    2.4 Firing order Firing order A1-A3-A4-A2-B3-B4-B2-B1 22 | Product Summary | MS150097/01E 2013-10...

  • Page 23: Technical Data

    2.5 Technical Data 2.5.1 8V 4000 L62FB engine data, fuel-optimized (TA-Luft) Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value r Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 24 Number of cylinders Gas type: Biogas Methane number, min. Table 6: General conditions (for maximum power) Consumption Number of cylinders Lube oil consumption after 1000 h run time g/kWh Table 7: Consumption Model related data (basic design) Number of cylinders Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders...

  • Page 25: Fuel System

    Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooling equipment (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler (at nominal flow rate 8.56) Table 10: Coolant system (LT circuit) Lube oil system Number of cylinders...

  • Page 26: Exhaust Emissions

    Number of cylinders Starting-attempt duration, max. Number of teeth on starter ring gear Table 14: Starter (electric) Capacities Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Liters Mixture coolant, engine side (without cooling system) Liters Total engine oil capacity at initial filling (standard oil system) Liters Oil change quantity, max.

  • Page 27: Monitoring, Control And Regulation Equipment

    2.6 Monitoring, Control and Regulation Equipment 2.6.1 Gas engine phase 3 system – Overview Overview 1 Unit system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 NOx sensor (option) 10 Gas dosing unit 3 System 7 Compressor bypass 11 Throttles 4 Engine governor 8 Ignition...
  • Page 28 Ignition system (IC922) • Adjusts ignition timing for cylinders Anti-knock control (AKR) • Controls monitored cylinders re. knock characteristics. If knocking is found, the ignition timing is re- tarded on the cylinder in question. If this does not result in an improvement, the power is reduced. Gas control valve (TecJet110) •...

  • Page 29: Purpose Of The Units

    2.6.2 Purpose of the units Engine governor ADEC (ECU 7) Central control and monitoring unit for the engine • Communication with other devices and higher-level systems via CAN bus • Control of throttles (mixture and gas) • Registration and analysis of engine operating states •...
  • Page 30 Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring 30 | Product Summary | MS150097/01E 2013-10...

  • Page 31: Operation

    3 Operation 3.1 Runtimes at partial load Gas engines were designed and optimized for continuous operation at 100 % load. The following restrictions apply to ensure maximum operational availability of the engine plant and to reduce maintenance to a minimum: Power, referenced to nominal Recommended maximum run- Recommended minimum run-...

  • Page 32: 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 engine into operation after extended out-of-service-periods (>3 months) Item Measure Engine Depreserve (→...

  • Page 33: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    3.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑Engine shut down and starting disabled. Putting into operation Item Measure Lube oil system Check oil level in oil storage tank (→ Page 150). Coolant circuit Check engine coolant level (→ Page 154); Check mixture coolant level (→...

  • Page 34: Control, Starting And Stopping Sequences

    3.4 Control, starting and stopping sequences NOTICE Risk of engine damage due to incorrect action. Risk of severe damage to property! • Ensure engine is ready for operation before starting. See engine documentation. Starting and stopping sequences The start sequence is software-controlled and depends on the place of start command input. To ensure that no mixture is in the engine when ignition is switched on or off, which is a specific re- quirement for gas engines, special procedures for engine start / stop are specified.
  • Page 35 Emergency stop sequence If an emergency stop command is activated, the following steps are carried out automatically: 1. Closing gas supply solenoid valves and mixture throttles 2. Mixture throttles close 3. Coasting down engine to standstill for a maximum coasting period 4.

  • Page 36: Engine - Start

    3.5 Engine – Start Preconditions ☑Generator not connected to network. ☑Start interlock not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 37: Operational Checks

    3.6 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! •...

  • Page 38: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas detection and alarm unit (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 39: Engine - Shutdown

    3.8 Engine – Shutdown Preconditions ☑Generator is not connected to network. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses. Overheating of and, therefore, damage to components is possible! • Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant levels are indicated.

  • Page 40: Emergency Stop

    3.9 Emergency stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Item Measure Gas shut-off valves with con- Two contacts are available for connection to the electrical system. trol solenoids Gas shut-off valves with control solenoids close.

  • Page 41: 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) MS150097/01E 2013-10 | Operation | 41...

  • Page 42: After Stopping The Engine - Putting The Engine Out Of Operation

    If the engine is to remain out of service for more than 1 week, seal the en- tems gine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Preservation and Represerva- tion Specifications A001070/..). Starting system Disconnect electric starter from power supply.

  • Page 43: Maintenance

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

  • Page 44: Maintenance Task Reference Table [Ql1]

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

  • Page 45: Troubleshooting

    OEM (see documentation of the genset man- ufacturer). A prerequisite for performing the measures to rectify faults is corresponding qualification/training at MTU. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful. Recommended action in case of alarm...
  • Page 46 Red alarm: Caution, the engine is running at its limits. Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled. 46 | Troubleshooting | MS150097/01E 2013-10...

  • Page 47: Fault Messages On Genset Control System Log

    5.2 Fault messages on genset control system log 112222 – HI T-Exhaust Mean Yellow alarm. Initiated by EMU. Cause Corrective action Weighted average of all 1. Check emission values. individual exhaust gas 2. Check ignition timing (→ Page 137). temperatures is too high. 3.
  • Page 48 112304 – HI T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 49 112309 – HI T-Exhaust A9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 50 112314 – HI T-Exhaust B4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 51 112319 – HI T-Exhaust B9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 52 112404 – LO T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 53 112409 – LO T-Exhaust A9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 54 112414 – LO T-Exhaust B4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 55 112419 – LO T-Exhaust B9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 56 112504 – HIHI T-Exhaust A4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 57 112509 – HIHI T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 58 112514 – HIHI T-Exhaust B4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 59 112519 – HIHI T-Exhaust B9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 60 112604 – LOLO T-Exhaust A4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 61 112609 – LOLO T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 62 112614 – LOLO T-Exhaust B4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 63 112619 – LOLO T-Exhaust B9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too high in comparison with 3. Check ignition timing (→ Page 137). weighted average.
  • Page 64 112705 – HIHI T-Exhaust A5 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high. 3. Check valve drive (exhaust valves do not close). 112706 –...
  • Page 65 112711 – HIHI T-Exhaust B1 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high. 3. Check valve drive (exhaust valves do not close). 112712 –...
  • Page 66 112717 – HIHI T-Exhaust B7 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 137). too high. 3. Check valve drive (exhaust valves do not close). 112718 –...
  • Page 67 113601 – AL Gas Valve 1 feedback Red alarm. Initiated by SAM. Cause Corrective action u Check valve 1 and cabling. Feedback signal from valve 1 does not correspond with setpoint signal. 113902 – SS Local Initiated Emerg. Stop Red alarm. Initiated by SAM. Cause Corrective action Emergency stop detected.
  • Page 68 1.4540.013 – High Elec Temp Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.014 – Elec Temp Fail High Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 69 1.4540.020 – Elec Temp Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.021 – FGT Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Gas temperature before TecJet u Check TecJet and configuration. is below the preset limit value.
  • Page 70 1.4540.027 – Analog Input High Error Red alarm. Initiated by TecJet. Cause Corrective action u Check setting. TecJet setting is not correct. 1.4540.028 – PWM Duty Cycle Low Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting.
  • Page 71 1.4540.033 – Battery Volt High Error Red alarm. Initiated by TecJet. Cause Corrective action Supply voltage has reached 1. Check supply voltage. maximum limit value. 2. Check cabling. 1.4540.034 – FGT High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet.
  • Page 72 1.4540.041 – TecJet Internal Fault Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.042 – Keyswitch State Red alarm. Initiated by TecJet. Cause Corrective action Keyswitch cabling missing. u Check cabling. 1.4520.232 – Error Missing Ring Gear Signal Red alarm.
  • Page 73 1.4520.237 – OverSpeed Shutdown Red alarm. Initiated by IC922. Cause Corrective action u Restart ignition. Genset has exceeded admissible speed. 1.4520.238 – E2PROM Checksum Error Red alarm. Initiated by IC922. Cause Corrective action Hardware not ready for u Restart ignition. operation.
  • Page 74 1.4520.245 – Open Primary, Channel 1 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.246 – Open Primary, Channel 2 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 75 1.4520.252 – Open Primary, Channel 8 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.253 – Open Primary, Channel 9 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 76 1.4520.259 – Open Primary, Channel 15 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.260 – Open Primary, Channel 16 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 77 1.4520.271 – Warning Missing Reset Signal Yellow alarm. Initiated by IC922. Cause Corrective action u Sensor B 75, check sensor, sensor distance and cabling, Reset signal from crankshaft is missing. replace as necessary. 1.4520.272 – Warn. Missing Camshaft Signal Yellow alarm. Initiated by IC922. Cause Corrective action Missing camshaft signal for...
  • Page 78 1.4510.187 – Combined Error Red alarm. Initiated by anti-knock control. Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm (for details, refer to the source alarm). 1.4510.188 – Internal Error Red alarm. Initiated by anti-knock control. Cause Corrective action Hardware not ready for...
  • Page 79 1.4510.195 – Knock Sensor Error A4 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.196 – Knock Sensor Error A5 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 80 1.4510.201 – Knock Sensor Error A10 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.202 – Knock Sensor Error B1 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 81 1.4510.207 – Knock Sensor Error B6 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.208 – Knock Sensor Error B7 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 82 1.4530.008 – Alarm Yellow alarm. Initiated by F-series. Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm (for details, refer to the source alarm). 1.4530.009 – Derating Active Yellow alarm. Initiated by F-series. Cause Corrective action Combined alarm (for details, u Combined alarm (for details, refer to the source alarm).
  • Page 83 1.4530.015 – Input Supply Voltage Low Error Yellow alarm. Initiated by F-series. Cause Corrective action Supply voltage has reached 1. Check supply voltage. minimum limit value. 2. Check cabling. 1.4530.016 – Electronics Temperature High Error Red alarm. Initiated by F-series. Cause Corrective action Hardware not ready for...
  • Page 84 1.4530.022 – CAN Fault Red alarm. Initiated by F-series. Cause Corrective action u Check cabling and setting. CAN bus connection faulty. 1.4550.031 – A - Internal Fault Red alarm. Initiated by ProAct A-Bank. Cause Corrective action Hardware not ready for u Restart ProAct.
  • Page 85 1.4550.037 – A - Temperature above 120 °C Red alarm. Initiated by ProAct A-Bank. Cause Corrective action The internal temperature is 1. Check temperature in room. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.038 – A - Loss of Position Demand Red alarm.
  • Page 86 1.4550.044 – A - CAN Stop Command Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting. "Stop" specification received via CAN bus 1.4550.131 – B - Internal Fault Red alarm. Initiated by ProAct A-Bank. Cause Corrective action Hardware not ready for u Restart ProAct.
  • Page 87 1.4550.137 – A - Temperature above 120 °C Red alarm. Initiated by ProAct A-Bank. Cause Corrective action The internal temperature is 1. Check temperature in room. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.138 – B - Loss of Position Demand Red alarm.
  • Page 88 1.4550.144 – B - CAN Stop Command Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting. "Stop" specification received via CAN bus 88 | Troubleshooting | MS150097/01E 2013-10...

  • Page 89: Engine Governor - Fault Messages

    5.3 Engine governor – Fault messages 015 – LO P-Lube oil Yellow alarm. Associated parameter 2.0100.921 Cause Corrective action Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger. value 1). No oil in engine, engine 2. Replace oil filter (→ Page 153). speed too low, oil lines, oil heat 3.
  • Page 90 021 – HI T-Exhaust B Yellow alarm. Associated parameter 2.0127.931 Cause Corrective action Exhaust gas temperature (B 1. Check exhaust turbocharger. side) after turbine too high (limit 2. Check ignition timing (→ Page 137). value 1). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4.
  • Page 91 030 – SS Engine Overspeed Red alarm. Engine shutdown. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. 1. Check governor. This usually fault message 2. Check throttle closing position. usually follows other fault messages. Check of governor, throttle closing position 031 –...
  • Page 92 051 – HI T-Lube Oil Yellow alarm. Associated parameter 2.0125.931 Cause Corrective action Engine oil temperature after oil 1. Check engine coolant circuit. heat exchanger too high (limit 2. Check oil heat exchanger. value 1). Oil heat exchanger 3. Check oil level (→ Page 150). contaminated, coolant temperature too high.
  • Page 93 058 – SS P-Coolant Red alarm. Engine shutdown. Associated parameter 2.0101.922 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure after engine too low (limit value 2). Insufficient volume flow, static pressure too low. 063 – HI P-Crankcase Yellow alarm.
  • Page 94 068 – SS T-Coolant Red alarm. Engine shutdown. Associated parameter 2.0120.932 Cause Corrective action u Check engine coolant circuit. Coolant temperature after engine too high (limit value 2). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit. 089 –...
  • Page 95 092 – SS Starter Speed Not Reached Red alarm. Start terminated. Associated parameter 2.1090.923 Cause Corrective action u Check starter system. Minimum speed for flushing process and ignition release was not attained. 093 – SS T-Preheat Red alarm. Engine shutdown. Associated parameter 2.1090.922 Cause Corrective action...
  • Page 96 118 – LO ECU Power Supply Voltage Yellow alarm. Associated parameter 2.0140.921 Cause Corrective action Supply voltage too low (limit 1. Check supply voltage. value 1) 2. Check cabling. 119 – LOLO ECU Power Supply Voltage Red alarm. Associated parameter 2.0140.922 Cause Corrective action Supply voltage too low (limit...
  • Page 97 176 – AL LifeData not available Red alarm. Associated parameter 2.4000.004 Cause Corrective action u Contact Service. (Configuration fault) No (suitable) LifeData backup system available following timeout expiry after ECU reset. Backup system has no LifeData feature or CAN bus to backup system is disrupted.
  • Page 98 183 – AL CAN No PU Data Red alarm. Associated parameter 2.0500.683 Cause Corrective action u Contact Service. (Configuration fault) The selected CAN mode initializes communication by means of the PU data module. However, the necessary PU data module is not present or is invalid.
  • Page 99 189 – AL CAN2 Error Passive Yellow alarm. Associated parameter 2.0500.689 Cause Corrective action u Check operation of bus users and cabling. CAN controller 2 has indicated a warning. Some reasons are, for example, no corresponding node, minor malfunctions or temporary bus overload.
  • Page 100 207 – SD T-Exhaust B Yellow alarm. Associated parameter 1.8004.577 Cause Corrective action u Check sensor and cabling (B4.22), replace if necessary. Fault is Exhaust temperature sensor on B side defective, short circuit or rectified following engine restart. wire break. 211 –...
  • Page 101 219 – SD T-Intake Air Yellow alarm. Associated parameter 1.8004.573 Cause Corrective action u Check sensor and cabling (B49.2), replace as necessary. Fault Intake air temperature sensor defective, short circuit or wire is rectified when engine is restarted. break. 221 – SD P-Diff Lube Oil Red alarm.
  • Page 102 232 – SD ETC Speed 1 Yellow alarm. Associated parameter 1.3011.128 Cause Corrective action u Turbocharger speed sensor is not fitted at present. Speed sensor of primary turbocharger defective, short circuit or wire break. 233 – SD ETC Speed 2 Yellow alarm.
  • Page 103 382 – AL Wiring TOP 2 Red alarm. Associated parameter 2.8006.639 Cause Corrective action u Check cabling. Short circuit or wire break on transistor output, plant-side 2 (TOP 2). Activation of red combined alarm faulty. 383 – AL Wiring TOP 3 Red alarm.
  • Page 104 423 – LO P-Coolant Diff. Red alarm. Engine shutdown. Associated parameter 2.0180.921 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant differential pressure too low (limit value 1). Insufficient volume flow. 429 – HI P-Coolant Red alarm. Engine shutdown. Associated parameter 2.0101.931 Cause Corrective action...
  • Page 105 435 – SS T-Coolant Before Engine Red alarm. Engine shutdown. Associated parameter 2.0173.932 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant temperature before engine too high (limit value 2). Engine coolant pump failure, flow too low, air in engine cooling system.
  • Page 106 452 – HIHI T-Charge Mix Red alarm. Engine shutdown. Associated parameter 2.0169.932 Cause Corrective action Mixture temperature too high 1. Check mixture cooling circuit. (limit value 2). Mixture coolant 2. Check mixture cooler for dirt. pump failure, volumetric flow too low, cooling system inlet temperature too high, mixture cooler clogged.
  • Page 107 459 – SD P-Coolant b. Engine Red alarm. Associated parameter 1.8004.627 Cause Corrective action u Check sensor and cabling (B16.3), replace if necessary. Fault is Coolant pressure sensor before engine defective, short circuit or rectified following engine restart. wire break. 470 –...
  • Page 108 479 – AL Comb. Alarm Red (Plant) 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. 496 – SD P-Charge Mix A Red alarm. Engine shutdown. Associated parameter 1.8004.628 Cause Corrective action...
  • Page 109 511 – HIHI P-Charge Mix A Red alarm. Engine shutdown. Associated parameter 2.0181.932 Cause Corrective action Mixture pressure on A side too 1. Check emissions. high (limit value 2). 2. Check ignition timing (→ Page 137). 3. Check exhaust back pressure. 4.
  • Page 110 520 – SD P-Intake Air after Filter A Yellow alarm. Associated parameter 1.0186.900 Cause Corrective action u Check sensor and cabling (B81.1), replace if necessary. Fault is Intake air pressure sensor after filter on A side defective, short rectified following engine restart. circuit or wire break.
  • Page 111 543 – AL Multiple FDH Slaves Yellow alarm. Associated parameter 2.0555.005 Cause Corrective action u Contact Service. (Configuration fault) There is more than one device activated as backup medium for FDH. 544 – AL Configuration Changed Yellow alarm. Associated parameter 2.0555.003 Cause Corrective action u Contact Service.
  • Page 112 556 – AL GasValve Fault Red alarm. Associated parameter 2.1090.124 Cause Corrective action Gas supply solenoid valve faulty. 1. Check gas train. Alarm is active if there are 2. Check cabling. problems with the gas supply solenoid valves. Either the gas supply solenoid valves are faulty, the timeout period is set too short, or communication is...
  • Page 113 565 – AL L1 P-Intake Air after Filter A Yellow alarm. Associated parameter 2.0186.921 Cause Corrective action u Replace air filter (→ Page 148). Pressure loss over air filter on A side is too high. 566 – AL L2 P-Intake Air after Filter A Yellow alarm.
  • Page 114 570 – L1 Al CAN Max. Retarded Timing Yellow alarm. Associated parameter 2.1200.931 Cause Corrective action The cylinder set to maximum 1. Check emissions. retarded timing due to knocking 2. Check ignition timing (→ Page 137). has violated the first limit value. 3.
  • Page 115 618 – LOLO Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.007 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has undershot the second limit value 619 – HI Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.008 Cause Corrective action...
  • Page 116 623 – HI NOx Value Yellow alarm. Associated parameter 2.3050.026 Cause Corrective action NOx emissions have exceeded 1. Check gas quality if feasible. the first limit value 2. Check NOx sensor. 3. Check emissions. 624 – HIHI NOx Value Yellow alarm. Associated parameter 2.3050.027 Cause Corrective action...
  • Page 117 646 – Al Knock Intensity Red alarm Associated parameter 2.1200.934 Cause Corrective action Knock intensity exceeded 1. Check gas quality if feasible (methane number). (extreme knocking detected) 2. Check emissions. 3. Check combustion chamber. 649 – Al Req Angle Throttle A Red alarm Associated parameter 2.1200.935 Cause...
  • Page 118 653 – AL IC92x Comm Lost Red alarm Associated parameter 1.4520.996 Cause Corrective action CAN bus communication for 1. Check cabling. ignition system faulty 2. Check power supply. 3. Carry out restart of ECU, EMU & knock control. 4. Check settings with device-specific dialog software (in device). 654 –...
  • Page 119 658 – AL NOxA Comm Lost Red alarm Associated parameter 1.4560.096 Cause Corrective action CAN bus communication for 1. Check cabling. NOx sensor A faulty 2. Check power supply. 3. Carry out restart of ECU and EMU. 4. Replace sensor. 659 –...
  • Page 120 665 – AL GET Yellow Yellow alarm Associated parameter 1.4510.993 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm in knock control was detected genset control system 666 – AL IC92x Yellow Yellow alarm Associated parameter 1.4520.993 Cause...
  • Page 121 671 – AL NOxA Yellow Yellow alarm Associated parameter 1.4560.093 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm at NOx sensor A was detected genset control system 672 – AL NOxB Yellow Yellow alarm Associated parameter 1.4560.193 Cause...
  • Page 122 677 – AL FSeries Red Red alarm Associated parameter 1.4530.991 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm in the bypass flap was detected genset control system 678 – AL TecJet Red Red alarm Associated parameter 1,4540.991 Cause...
  • Page 123 683 – AL PhyA Red Red alarm Associated parameter 1.4570.091 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm at step motor A was detected genset control system 684 – AL PhyB Red Red alarm Associated parameter 1.4570.191 Cause...
  • Page 124 691 – HI Lube Oil Level Refill. Yellow alarm Associated parameter 1.1480.311 Cause Corrective action u Check engine oil level. Check oil supply. Engine oil was refilled too often within a certain time interval. 694 – SD T-Gas Yellow alarm Associated parameter 1.8004.123 Cause Corrective action...

  • Page 125: Task Description

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

  • Page 126: Checking Machine Room For Smell Of Gas

    6.1.2 Checking machine room 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 127: Crankcase Breather

    6.2 Crankcase Breather 6.2.1 Oil separator – Filter replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter element (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) O-ring (→...
  • Page 128 Remove locknut (1). Remove filter cover (3) with washer (2). Carefully lift out fine filter (6). Carefully lift out coalescence filter (5). Clean sealing faces and inside of housing. Check condition of gaskets on new fine fil- ter and new coalescence filter. Note: The fine filter (6) must be installed in the correct position in the housing.

  • Page 129: Ignition System

    6.3 Ignition System 6.3.1 Spark plug – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug (→ Spare Parts Catalog) Replacing spark plug Remove spark plug (→ Page 130). Install new spark plug (→ Page 131). MS150097/01E 2013-10 | Task Description | 129...

  • Page 130: Spark Plug - Removal

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

  • Page 131: Spark Plug - Installation

    6.3.3 Spark plug – Installation Preconditions ☑Engine is stopped and starting disabled. ☑Open protective packing of new spark plug only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Special wrench, 20.8 mm F30452574 Assembly compound (Molycote P 37)
  • Page 132 Note: Make sure that the color code of the spark plugs is identical. Screw spark plug into cylinder head (1). Note: The temperature of spark plug and cylinder head (1) must be the same prior to tightening. Tighten spark plug to specified tightening torque using a torque wrench. Name Size Type...

  • Page 133: Spark Plug Connector - Replacement

    6.3.4 Spark plug connector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug connector (→ Spare Parts Catalog) Replacing spark plug connector Remove spark plug connector (→ Page 134). Install spark plug connector (→ Page 135). MS150097/01E 2013-10 | Task Description | 133...

  • Page 134: Spark Plug Connector - Removal

    6.3.5 Spark plug connector ‒ Removal Preconditions ☑Engine is stopped and starting disabled. ☑Open protective packing of new spark plug connector only immediately prior to installation. DANGER Live components, flash-over. Risk of serious injury - danger to life! • Always wear electrical gloves (class 4 minimum) when touching the ignition cable in operation. WARNING Component is hot.

  • Page 135: Spark Plug Connector - Installation

    6.3.6 Spark plug connector – Installation Preconditions ☑Engine is stopped and starting disabled. ☑Open protective packing of new spark plug connector only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Spark plug connector with ignition line (→...
  • Page 136 Fit protective cap (2) and check for correct seating. 136 | Task Description | MS150097/01E 2013-10...

  • Page 137: Ignition System - Ignition Timing Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Stroboscope (not stocked by MTU) DANGER Live components, flash-over. Risk of serious injury - danger to life! • Always wear electrical gloves (class 4 minimum) when touching the ignition cable in operation.

  • Page 138: Valve Drive

    6.4 Valve Drive 6.4.1 Valve gear – Lubrication Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear Remove cylinder head covers (→ Page 145). Fill oil chambers of rocker arms and adjust- ing screws with oil.

  • Page 139: Valve Clearance - Check And Adjustment

    6.4.2 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Engine coolant temperature is max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Angular screw driver F30452765 Torque wrench, 60-320 Nm F30452768...

  • Page 140: Adjusting Valve Clearance

    Diagram for 8V engines, two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...
  • Page 141 Final steps Remove barring device (→ Page 125). Install cylinder head cover (→ Page 146). MS150097/01E 2013-10 | Task Description | 141...

  • Page 142: Valve Depth - Measurement

    6.4.3 Valve depth – Measurement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sliding depth gauge, 200 mm Y20000918 Preparatory steps Remove spark plugs (→ Page 130). Remove cylinder head covers (→ Page 145). Remove sleeves (arrow).
  • Page 143 Measuring valve depth Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. Measure valve depth for each valve in two crankshaft positions (firing TDC and overlap TDC for cylinder A1) according to the diagram.
  • Page 144 Install sleeves (arrow). Install cylinder head covers (→ Page 146). Install spark plugs with new sealing rings (→ Page 131). 144 | Task Description | MS150097/01E 2013-10...

  • Page 145: Cylinder Head Cover - Removal

    6.4.4 Cylinder head cover – Removal Preconditions ☑Engine is stopped and starting disabled. Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 134). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 146: Cylinder Head Cover - Installation

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

  • Page 147: Gas System

    6.5 Gas System 6.5.1 Gas supply - Checking gas lines for leaks Preconditions ☑Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Leak identification spray Soap suds WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! •...

  • Page 148: Air Filter

    6.6 Air Filter 6.6.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Prefilter made of fleece (option) (→ Spare Parts Catalog) Note: Air filter condition is monitored by a sensor. Replace air filter and/or (optional) fleece prefilter when the corresponding fault message appears.

  • Page 149: Air Filter - Removal And Installation

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

  • Page 150: Lube Oil System, Lube Oil Circuit

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

  • Page 151: 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 152: 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 153: Oil Filtration / Cooling

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

  • Page 154: 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 155: 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 156). Fill with engine coolant (→ Page 158). MS150097/01E 2013-10 | Task Description | 155...

  • Page 156: Engine Coolant – Draining

    6.9.3 Engine coolant – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 157 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS150097/01E 2013-10 | Task Description | 157...

  • Page 158: 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 159: Vent Line Of Engine Coolant Circuit Replacement

    6.9.5 Vent line of engine coolant circuit – Replacement Preconditions ☑Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Replacing coolant vent line Drain engine coolant (→...

  • Page 160: 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 161: 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 162). Fill with fresh mixture coolant (→ Page 163). MS150097/01E 2013-10 | Task Description | 161...

  • Page 162: Mixture Coolant – Draining

    6.10.3 Mixture coolant – Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Draining mixture coolant Provide a suitable receptacle to catch the coolant.

  • Page 163: 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 164: Wiring (General) For Engine/Gearbox/Unit

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

  • Page 165: Sensors ‒ Overview

    6.11.2 Sensors ‒ Overview Item Name Monitoring of B49.2 Intake air temperature B81.2 Intake air pressure after filter B4.X Exhaust temperature downstream of cylinder B16.1 Coolant pressure after engine B79.22 Mixture pressure B side Mixture temperature Table 22: Sensors on B side ‒ Overview The knocking sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads.
  • Page 166 Item Name Monitoring of B13.2 Crankshaft speed ignition B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system Table 23: Sensors on engine driving end - Overview 166 | Task Description | MS150097/01E 2013-10...
  • Page 167 Item Name Monitoring of B79.21 Mixture pressure A side Crankcase pressure B5.1 Engine oil pressure after filter Engine oil temperature B5.3 Engine oil pressure before filter B4.21 Exhaust bulk temperature after turbocharger Table 24: Sensors on A side ‒ Overview MS150097/01E 2013-10 | Task Description | 167...
  • Page 168 Item Name Monitoring of B16.3 Coolant pressure before engine B1.3 Camshaft speed for antiknock control B1.2 Camshaft speed for ignition system B1.1 Camshaft speed for engine governor Engine oil level B6.3 Coolant temperature before engine B6.1 Coolant temperature after engine Table 25: Sensors on engine free end - Overview 168 | Task Description | MS150097/01E 2013-10...

  • Page 169: Abbreviations

    Abgasturbolader Exhaust turbocharger (ETC) Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Pub- lication No. A01061/.. Controller Area Network Data bus system, bus standard Circuit Deutsches Institut für Normung e. V. At the same time identifier of German stand-...
  • Page 170 Abbreviation Meaning Explanation Original Equipment Manufacturer ORFS O-Ring Face Seal Oberer Totpunkt Top dead center (TDC) Panel Control panel Peripheral Interface Module Pulse Width Modulation Modulated signal Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sicherheitsabsperrventil Safety shut-off valve Sicherheitsabbalseventil...

  • Page 171: 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 172: Special Tools

    8 Appendix B 8.1 Special Tools Angular screw driver Part No.: F30452765 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 139) Barring gear Part No.: F6555766 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 125) Feeler gage Part No.: Y20098771...
  • Page 173 Filter wrench Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 153) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 3.7 Emission values ‒ Check (→ Page 38) Qty.: Used in: 6.1.2 Checking machine room for smell of gas...
  • Page 174 Used in: 6.3.2 Spark plug – Removal (→ Page 130) Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 131) Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 6.3.7 Ignition system – Ignition timing check (→ Page 137) Torque wrench, 10-60 Nm Part No.:...
  • Page 175 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 139) MS150097/01E 2013-10 | Appendix B | 175...

  • Page 176: Index

     89 – Replacement  148 – Genset control system log  47 – Key  45 Firing order 22 Contacts  – MTU Onsite Energy  171 Control  Gas engine phase 3 system  – Starting sequence  34 – Overview  27 – Stopping sequence  34 Gas supply ...
  • Page 177  17 – Startup  8 – Startup, special instructions for applications with gas- eous fuel  9 Sensors  – Overview  165 Service partners  – MTU Onsite Energy  171 Spark plug  – Installation  131 – Removal  130 – Replacement  129 Spark plug connector ...

Table of Contents