MTU MS15027/02E Operating Instuctions
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MTU MS15027/02E Operating Instuctions

MTU MS15027/02E Operating Instuctions

12 v 4000 lx4; 16 v 4000 lx4
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Operating Instructions

Gas engine
12 V 4000 Lx4
16 V 4000 Lx4
MS15027/02E

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Summary of Contents for MTU MS15027/02E

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 12 V 4000 Lx4 16 V 4000 Lx4 MS15027/02E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    3.4 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 6.8 Oil Filtration / Cooling 3.7 Emission values – Check MS15027/02E 2015-04 | Table of Contents | 3...
  • Page 4 6.10 Low-Temperature Circuit partner 6.10.1 Mixture coolant level – Check 6.10.2 Mixture coolant – Change 8 Appendix B 6.10.3 Mixture coolant – Draining 6.10.4 Mixture coolant – Filling 8.1 Special Tools 8.2 Index 4 | Table of Contents | MS15027/02E 2015-04...

  • 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 Replacing components with emission labels Emission labels are attached to all MTU engines. These must remain on the engine throughout its op- erational life. Engines used exclusively in land-based, military applications other than by US government agencies are excepted from this proviso.

  • Page 7: Personnel And Organizational Requirements

    Wear proper protective clothing for all work. When working, always wear the necessary personal protective equipment (e.g. safety footwear, ear pro- tectors, protective gloves, goggles, breathing protection). Observe the information on personal protec- tive equipment in the respective activity description. MS15027/02E 2015-04 | Safety | 7...

  • 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 | MS15027/02E 2015-04...

  • Page 9: Safety Requirements 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. MS15027/02E 2015-04 | Safety | 9...

  • Page 10: Safety Regulations For Maintenance And Repair Work

    (e.g. components carrying oil, fuel, or air). Always seal connections with caps or covers if a line is removed or opened. Fit new seals when re-installing lines. Avoid damaging lines, particularly the fuel lines. 10 | Safety | MS15027/02E 2015-04...
  • Page 11 For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed. MS15027/02E 2015-04 | Safety | 11...
  • Page 12 – which have a maximum output of 5 mW – which are arranged such as to prevent the beam from harming eyesight. Measuring component deviations Workpieces, components and measuring equipment are within specified tolerances at a reference tem- perature of 20 °C. 12 | Safety | MS15027/02E 2015-04...

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

    (if applicable). Close the manual shutoff valve for the gas supply. The coolant pumps must keep running-on for a longer period in the case of scheduled shutdowns. MS15027/02E 2015-04 | Safety | 13...

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

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials.

  • Page 15: Compressed Air

    • After contact with skin, rinse affected parts of the body with plenty of water. • Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi- ble. MS15027/02E 2015-04 | 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 | MS15027/02E 2015-04...

  • Page 17: Standards For Safety Notices In The Text

    The higher level warning notice is used if several hazards apply at the same time. Warnings related to personal injury shall be considered to include a warning of potential damage. MS15027/02E 2015-04 | Safety | 17...

  • Page 18: Transport

    Transport • Lift the engine/genset/system only with the lifting eyes provided. • Only use transport and lifting devices approved by MTU. • The engine/genset/system must only be transported in installation position. • Max. permissible diagonal pull 10°.

  • Page 19: Product Summary

    6 Capacitor ignition system driving end 2 Throttle 7 Engine mounting bracket - 10 Flywheel 3 Mixture cooler free end 11 Air filter/air inlet 4 Exhaust turbocharger 8 Oil pan KS Driving end MS15027/02E 2015-04 | Product Summary | 19...
  • Page 20 Key to the engine model designation 12/16 V 4000 L64 12/16 Number of cylinders Cylinder arrangement: V engine 4000 Series Application: L = Gas engine Load profile Design index Table 2: Key to the engine model designation 20 | Product Summary | MS15027/02E 2015-04...

  • Page 21: Engine Side And Cylinder Designations

    (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4). The numbering of other engine components also starts with 1 at driving end (4). MS15027/02E 2015-04 | Product Summary | 21...

  • Page 22: Main Engine Dimensions

    Approx. 636 mm oil pan 16 V (D) Crankshaft center to Approx. 280.5 mm engine mount 12 V (E) Crankshaft center to Approx. 280.5 mm engine mount 16 V (E) Table 3: Main engine dimensions 22 | Product Summary | MS15027/02E 2015-04...

  • Page 23: Firing Order

    2.4 Firing order Firing order Number of cylinders Firing 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 MS15027/02E 2015-04 | Product Summary | 23...

  • Page 24: 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, min. mbar 24 | Product Summary | MS15027/02E 2015-04...
  • Page 25 Coolant outlet temperature for 100% load °C Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Filling pressure in cooling system (cold) Pressure in cooling system, max. Pressure loss over engine (at nominal flow rate 7.27) MS15027/02E 2015-04 | Product Summary | 25...
  • Page 26 Table 12: Fuel system General operating data Number of cylinders Cold start capability: Air temperature (w/o starting aid, with pre- °C heating) - (case C) General condition (to case C): Engine coolant temperature °C 26 | Product Summary | MS15027/02E 2015-04...
  • Page 27 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 MS15027/02E 2015-04 | Product Summary | 27...

  • Page 28: 4000 L64, 16V 4000 L64 Engine Data, Emissions-Optimized (1/2 "Ta-Luft")

    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, min. mbar Exhaust back pressure, max. mbar 28 | Product Summary | MS15027/02E 2015-04...
  • Page 29 Coolant outlet temperature for 100% load °C Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Filling pressure in cooling system (cold) Pressure in cooling system, max. Pressure loss over engine (at nominal flow rate 7.27) MS15027/02E 2015-04 | Product Summary | 29...
  • Page 30 Table 27: Fuel system General operating data Number of cylinders Cold start capability: Air temperature (w/o starting aid, with pre- °C heating) - (case C) General condition (to case C): Engine coolant temperature °C 30 | Product Summary | MS15027/02E 2015-04...
  • Page 31 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 MS15027/02E 2015-04 | Product Summary | 31...

  • Page 32: Monitoring, Control And Regulation Equipment

    • Evaluation unit for PT 1000 temperature sensor to determine and monitor exhaust temperatures of individual cylinders • Monitors second gas solenoid in gas train to engine Compressor bypass (F-Series) • Controls throttle reserve, prevents compressor pumping Ignition system MIC5 • Adjusts ignition timing for cylinders 32 | Product Summary | MS15027/02E 2015-04...
  • Page 33 Gas control valve TecJet52 / TecJet85 • Controls the required amount of gas Mixture throttles (P-Series) • The mixture throttles in the mixture lines which are controlled by the Engine Control Unit MS15027/02E 2015-04 | 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 | MS15027/02E 2015-04...
  • Page 35 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring MS15027/02E 2015-04 | Product Summary | 35...

  • Page 36: Operation

    120 minutes 50% to 100% No restriction No restriction To reduce increased engine load due to temperature change (cold start to engine at operating tempera- ture), a minimum runtime of 5h per start is recommended. 36 | Operation | MS15027/02E 2015-04...

  • Page 37: 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 38: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    Lube oil system Check oil level in oil storage tank (→ Page 174). Coolant circuit Check engine coolant level (→ Page 178); Check mixture coolant level (→ Page 183) Engine management system Check for fault messages. 38 | Operation | MS15027/02E 2015-04...

  • Page 39: Control, Starting And Stopping Sequences

    The following steps are performed automatically when a stop command is activated: 1. Closing gas supply solenoid valves 2. Opening mixture throttles, scavenging residual gas 3. Engine running down to standstill 4. Deactivating ignition 5. Closing mixture throttles MS15027/02E 2015-04 | Operation | 39...
  • Page 40 2. Engine running for a minimum (programmed) time period 3. Oil refilling enabled 4. When oil refill request is received 5. Refilling oil (automatically) 6. When oil refill request is canceled 7. Stopping oil refilling (automatically) 40 | Operation | MS15027/02E 2015-04...

  • Page 41: 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 39). MS15027/02E 2015-04 | Operation | 41...

  • Page 42: Operational Checks

    • This is especially useful for fault localization and fast remedial action. Engine under load, Visually inspect engine/plant and all pipework for leaks, rectify any leaks engine at rated speed with the engine stopped; check for abnormal running noises and vibration. 42 | Operation | MS15027/02E 2015-04...

  • Page 43: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas measuring and warning device (not stocked by MTU) WARNING Exhaust gases are hot and pressurized. Risk of injury and burning! • Wear protective clothing, gloves, and goggles / safety mask.

  • Page 44: 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 39). 44 | Operation | MS15027/02E 2015-04...

  • Page 45: Emergency Engine Shutdown

    Room ventilation, facility Residual gas may escape from the fuel line in case of EMERGENCY STOP. ventilation • A contact is provided to request room and facility ventilation. Table 34: Emergency engine shutdown MS15027/02E 2015-04 | Operation | 45...
  • Page 46 0.1 bar. If the SAV is tripped by an EMERGENCY STOP it must be reset manually. SAV tripping is not indicated by the engine. Table 35: Remedy the cause, re-enable starting 46 | Operation | MS15027/02E 2015-04...

  • Page 47: 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 controller Select operating mode, e.g. MANUAL, AUTOMATIC. (manufacturer-specific) MS15027/02E 2015-04 | Operation | 47...

  • Page 48: 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 49: 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 Maintenance tasks Task cation Valve gear Check valve clearance (→ Page 167) Table 37: 50-hours check MS15027/02E 2015-04 | Maintenance | 49...

  • Page 50: Maintenance Schedule Reference Table [Ql1]

    (→ Page 154) W1341 Check emission values, adjust if required. (→ Page 43) W1688 Replace spark plug connector. (→ Page 158) W1689 Measure valve clearance. (→ Page 163) Table 38: Maintenance task reference table [QL1] 50 | Maintenance | MS15027/02E 2015-04...

  • Page 51: Troubleshooting

    Recommended action in case of alarm Yellow alarm: The engine can still be operated providing that automatic engine shutdown to protect the engine has not been configured or is not tripped. Contact Service immediately/start fault rectification. MS15027/02E 2015-04 | Troubleshooting | 51...
  • Page 52 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. 52 | Troubleshooting | MS15027/02E 2015-04...

  • Page 53: Fault Messages In Log For Genset Controller

    Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. MS15027/02E 2015-04 | Troubleshooting | 53...
  • Page 54 Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. 54 | Troubleshooting | MS15027/02E 2015-04...
  • Page 55 Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. MS15027/02E 2015-04 | Troubleshooting | 55...
  • Page 56 Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. 56 | Troubleshooting | MS15027/02E 2015-04...
  • Page 57 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. MS15027/02E 2015-04 | Troubleshooting | 57...
  • Page 58 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. 58 | Troubleshooting | MS15027/02E 2015-04...
  • Page 59 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. MS15027/02E 2015-04 | Troubleshooting | 59...
  • Page 60 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. 60 | Troubleshooting | MS15027/02E 2015-04...
  • Page 61 Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. MS15027/02E 2015-04 | Troubleshooting | 61...
  • Page 62 Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. 62 | Troubleshooting | MS15027/02E 2015-04...
  • Page 63 Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. MS15027/02E 2015-04 | Troubleshooting | 63...
  • Page 64 Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 162). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average. 64 | Troubleshooting | MS15027/02E 2015-04...
  • Page 65 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. MS15027/02E 2015-04 | Troubleshooting | 65...
  • Page 66 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. 66 | Troubleshooting | MS15027/02E 2015-04...
  • Page 67 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. MS15027/02E 2015-04 | Troubleshooting | 67...
  • Page 68 Individual exhaust gas 1. Check spark plug. temperature of this cylinder is 2. Check emission values. too low in comparison with 3. Check ignition timing (→ Page 162). weighted average. 4. Check valve gear. 68 | Troubleshooting | MS15027/02E 2015-04...
  • Page 69 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 162). too high. 3. Check valve gear (exhaust valves do not close). MS15027/02E 2015-04 | Troubleshooting | 69...
  • Page 70 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 162). too high. 3. Check valve gear (exhaust valves do not close). 70 | Troubleshooting | MS15027/02E 2015-04...
  • Page 71 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 162). too high. 3. Check valve gear (exhaust valves do not close). MS15027/02E 2015-04 | Troubleshooting | 71...
  • Page 72 Combined alarm (for details, refer to the source alarm). refer to the source alarm). 113200 – Communication Lost ECU Red alarm. Initiated by EMU. Cause Corrective action No communication with ECU 1. Check supply voltage. CAN. 2. Check connecting line. 72 | Troubleshooting | MS15027/02E 2015-04...
  • Page 73 Restart knock module. operation. 1.4510.189 – Error Camshaft Red alarm. Initiated by antiknock control. Cause Corrective action u Check cabling. Check sensor B 1.3, replace if required. No signal from camshaft sensor for antiknock control. MS15027/02E 2015-04 | Troubleshooting | 73...
  • Page 74 1.4510.197 – Knock Sensor Error A6 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 74 | Troubleshooting | MS15027/02E 2015-04...
  • Page 75 1.4510.203 – Knock Sensor Error B2 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. MS15027/02E 2015-04 | Troubleshooting | 75...
  • Page 76 1.4510.209 – Knock Sensor Error B8 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 76 | Troubleshooting | MS15027/02E 2015-04...
  • Page 77 The power output is too high. 1.4520.522 – MIC5 Stat W: invalid coil data Yellow alarm. Initiated by MIC5. Cause Corrective action u Check settings. Restart ignition control unit. The ignition system settings are invalid. MS15027/02E 2015-04 | Troubleshooting | 77...
  • Page 78 Check settings. voltage failure. 1.4520.529 – MIC5 Stat Trigger supply volt. fail Red alarm. Initiated by MIC5. Cause Corrective action Trigger auxiliary supply voltage 1. Check wiring to sensor B1.2. failure. 2. Check settings. 78 | Troubleshooting | MS15027/02E 2015-04...
  • Page 79 Restart ignition control unit. were unreadable or are incorrect. 1.4520.545 – MIC5 E1 Fail hi-voltage pow supply Red alarm. Initiated by MIC5. Cause Corrective action The high-voltage power supply is u Restart ignition control unit. defective. MS15027/02E 2015-04 | Troubleshooting | 79...
  • Page 80 1.4520.552 – MIC5 E1 Tr1 no signal detected Yellow alarm. Initiated by MIC5. Cause Corrective action No signal from trigger 1 (B1.2). u Check sensor, sensor clearance, cabling, settings in data record and timing wheel. Replace sensor if required. 80 | Troubleshooting | MS15027/02E 2015-04...
  • Page 81 Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record The index mark of trigger 1 (B1.2) was not detected during and timing wheel. Replace sensor if required. operation. MS15027/02E 2015-04 | Troubleshooting | 81...
  • Page 82 1.4520.574 – MIC5 IPE Primary Open Cylinder 5 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil. cylinder 5 in firing order. 2. Check ignition coil. 82 | Troubleshooting | MS15027/02E 2015-04...
  • Page 83 1.4520.581 – MIC5 IPE Primary Open Cylinder 12 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil. cylinder 12 in firing order. 2. Check ignition coil. MS15027/02E 2015-04 | Troubleshooting | 83...
  • Page 84 1.4520.588 – MIC5 IPE Primary Open Cylinder 19 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil. cylinder 19 in firing order. 2. Check ignition coil. 84 | Troubleshooting | MS15027/02E 2015-04...
  • Page 85 1.4520.595 – MIC5 IPE Prim Short Circuit Cyl 6 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil. cylinder 6 in firing order. 2. Check ignition coil. MS15027/02E 2015-04 | Troubleshooting | 85...
  • Page 86 1.4520.602 – MIC5 IPE Prim Short Circuit Cyl 13 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil. cylinder 13 in firing order. 2. Check ignition coil. 86 | Troubleshooting | MS15027/02E 2015-04...
  • Page 87 1.4520.609 – MIC5 IPE Prim Short Circuit Cyl 20 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil. cylinder 20 in firing order. 2. Check ignition coil. MS15027/02E 2015-04 | Troubleshooting | 87...
  • Page 88 1.4520.616 – MIC5 ISE Secondary Open Cylinder 7 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 7 in firing order. 2. Check ignition coil. 88 | Troubleshooting | MS15027/02E 2015-04...
  • Page 89 1.4520.623 – MIC5 ISE Secondary Open Cylinder 14 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 14 in firing order. 2. Check ignition coil. MS15027/02E 2015-04 | Troubleshooting | 89...
  • Page 90 1.4520.630 – MIC5 ISE Secon Short Circuit Cyl 1 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 1 in firing order. 2. Check ignition coil. 90 | Troubleshooting | MS15027/02E 2015-04...
  • Page 91 1.4520.637 – MIC5 ISE Secon Short Circuit Cyl 8 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 8 in firing order. 2. Check ignition coil. MS15027/02E 2015-04 | Troubleshooting | 91...
  • Page 92 1.4520.644 – MIC5 ISE Secon Short Circuit Cyl 15 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 15 in firing order. 2. Check ignition coil. 92 | Troubleshooting | MS15027/02E 2015-04...
  • Page 93 1.4520.659 – MIC5 E2 Tr2 operational error Red alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record Trigger 2 (B75) has triggered operational error. and timing wheel. Replace sensor if required. MS15027/02E 2015-04 | Troubleshooting | 93...
  • Page 94 Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record An unexpected signal from trigger 2 (B75) was detected. and timing wheel. Replace sensor if required. 94 | Troubleshooting | MS15027/02E 2015-04...
  • Page 95 1.4520.672 – MIC5 E2 Tr3 no signal detected Yellow alarm. Initiated by MIC5. Cause Corrective action No signal from trigger 3 (B13.2). u Check sensor, sensor clearance, cabling, settings in data record and timing wheel. Replace sensor if required. MS15027/02E 2015-04 | Troubleshooting | 95...
  • Page 96 Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record The index mark of trigger 3 (B13.2) was not detected during and timing wheel. Replace sensor if required. operation. 96 | Troubleshooting | MS15027/02E 2015-04...
  • Page 97 Corrective action F-Series setting is not correct. u Check setting. 1.4530.011 – PWM Input Low Duty Cycle Error Yellow alarm. Initiated by F-Series. Cause Corrective action F-Series setting is not correct. u Check setting. MS15027/02E 2015-04 | Troubleshooting | 97...
  • Page 98 Restart F-Series. Hardware not ready for operation. 1.4530.018 – Position Error Red alarm. Initiated by F-Series. Cause Corrective action Position demand and feedback 1. Check mechanical system. do not match 2. Restart F-Series. 98 | Troubleshooting | MS15027/02E 2015-04...
  • Page 99 Red alarm. Initiated by TecJet. Cause Corrective action No gas flow detected. 1. Check inlet and outlet. 2. Check gas pressure, gas quality, gas filter, gas line for obstruction. 3. Check engine for overloading. MS15027/02E 2015-04 | Troubleshooting | 99...
  • Page 100 Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 1.4540.018 – Coil Current Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 100 | Troubleshooting | MS15027/02E 2015-04...
  • Page 101 Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 1.4540.025 – Position Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. MS15027/02E 2015-04 | Troubleshooting | 101...
  • Page 102 Hardware not ready for u Restart TecJet. operation. 1.4540.032 – FGP Low Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Check position direction of TecJet. Configured limit value was not attained. 102 | Troubleshooting | MS15027/02E 2015-04...
  • Page 103 TecJet setting is not correct. u Check setting. 1.4540.040 – TecJet Shutdown Red alarm. Initiated by TecJet. Cause Corrective action TecJet combined alarm. At least u Rectify cause of alarm. one further TecJet alarm is present. MS15027/02E 2015-04 | Troubleshooting | 103...
  • Page 104 Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.047 – Reading Parameters Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation. 104 | Troubleshooting | MS15027/02E 2015-04...
  • Page 105 Cause Corrective action CAN baud rate change detected. 1. Check settings. 2. Check cabling. 1.4540.054 – Exception Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. MS15027/02E 2015-04 | Troubleshooting | 105...
  • Page 106 Check mechanical system. Restart ProAct. Position demand and feedback do not match 1.4550.035 – A - Temperature Sensor Fault Red alarm. Initiated by ProAct A-Bank. Cause Corrective action Hardware not ready for u Restart ProAct. operation. 106 | Troubleshooting | MS15027/02E 2015-04...
  • Page 107 ProAct setting is not correct. 1.4550.042 – A - CAN Position Demand Failed Red alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check cabling and setting. Position demand not received or received too late MS15027/02E 2015-04 | Troubleshooting | 107...
  • Page 108 1. Check mechanical system. do not match 2. Restart ProAct. 1.4550.135 – B - Temperature Sensor Fault Red alarm. Initiated by ProAct B-Bank. Cause Corrective action Hardware not ready for u Restart ProAct. operation. 108 | Troubleshooting | MS15027/02E 2015-04...
  • Page 109 ProAct setting is not correct. 1.4550.142 – B - CAN Position Demand Failed Red alarm. Initiated by ProAct B-Bank. Cause Corrective action u Check cabling and setting. Position demand not received or received too late MS15027/02E 2015-04 | Troubleshooting | 109...
  • Page 110 Check cabling and setting. CAN bus connection faulty. 1.4550.144 – B - CAN Stop Command Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action “Stop” command received via u Check setting. CAN bus 110 | Troubleshooting | MS15027/02E 2015-04...

  • Page 111: Engine Control Unit - Fault Messages

    (limit 2. Check ignition timing (→ Page 162). value 2). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4. Check spark plugs. rich, damage to turbine. MS15027/02E 2015-04 | Troubleshooting | 111...
  • Page 112 Red alarm. Engine stop. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. 1. Check governor. This fault message usually 2. Check throttle closing position. follows other fault messages. Check governor, throttle closing position. 112 | Troubleshooting | MS15027/02E 2015-04...
  • Page 113 1. Check settings for this input in the ECU if no turbocharger turbocharger too high (limit speed sensor is installed. value 2). 2. Check ignition timing and emission if a turbocharger speed sensor is installed. MS15027/02E 2015-04 | Troubleshooting | 113...
  • Page 114 057 – LO P-Coolant Yellow alarm. Associated parameter 2.0101.921 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure after engine too low (limit value 1). Flow too low, static pressure too low. 114 | Troubleshooting | MS15027/02E 2015-04...
  • Page 115 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. MS15027/02E 2015-04 | Troubleshooting | 115...
  • Page 116 Red alarm. Associated parameter 2.1090.924 Cause Corrective action Gas temperature sensor 1. Not available in all engine versions (optional). defective, short circuit or wire 2. Check sensor and cabling (B38), replace as necessary. break. 116 | Troubleshooting | MS15027/02E 2015-04...
  • Page 117 2. Check oil priming pump. 104 – AL Eng Hours Counter Defect Yellow alarm. Associated parameter 1.8004.623 Cause Corrective action u Replace Engine Control Unit. Engine hours counter defective. Internal Engine Control Unit fault. MS15027/02E 2015-04 | Troubleshooting | 117...
  • Page 118 Red alarm. Associated parameter 2.0500.680 Cause Corrective action Bus node (SAM or EMU) lost on u Check operation of nodes and cabling. Buses (CAN bus 1 and CAN bus 1. CAN bus 2) are redundant. 118 | Troubleshooting | MS15027/02E 2015-04...
  • Page 119 Yellow alarm. Associated parameter 2.0500.686 Cause Corrective action CAN controller 1 is in “Bus-Off” u Check operation of nodes and cabling. status. Automatic switching to CAN bus 2. Bus nodes (ECU, SAM or EMU) faulty. MS15027/02E 2015-04 | Troubleshooting | 119...
  • Page 120 Red alarm. Engine stop. Associated parameter 1.8004.570 Cause Corrective action Coolant temperature sensor at u Check sensor and cabling (B6.1), replace if necessary. Fault is engine outlet defective, short rectified following engine restart. circuit or wire break. 120 | Troubleshooting | MS15027/02E 2015-04...
  • Page 121 Red alarm. Associated parameter 1.8004.564 Cause Corrective action u Check sensor and cabling (B16.1), replace if necessary. Fault is Coolant pressure sensor after engine defective, short circuit or rectified following engine restart. wire break. MS15027/02E 2015-04 | Troubleshooting | 121...
  • Page 122 Yellow alarm. Associated parameter 1.8004.620 Cause Corrective action u Check sensor and cabling (B5.3), replace as necessary. Fault is Engine oil pressure sensor before filter defective, short rectified following engine restart. circuit or wire break. 122 | Troubleshooting | MS15027/02E 2015-04...
  • Page 123 Speed sensor of secondary turbocharger defective, short circuit or wire break. 245 – SD ECU Power Supply Voltage Red alarm. Associated parameter 2.8006.589 Cause Corrective action Internal Engine Control Unit u Replace ADEC Engine Control Unit. fault. MS15027/02E 2015-04 | Troubleshooting | 123...
  • Page 124 384 – AL Wiring TOP 4 Red alarm. Associated parameter 2.8006.641 Cause Corrective action Short circuit or wire break on u Check cabling. transistor output, plant-side 4 (TOP 4). Activation of gas supply solenoid valve No.2 faulty. 124 | Troubleshooting | MS15027/02E 2015-04...
  • Page 125 430 – LO P-Coolant before Engine Yellow alarm. Associated parameter 2.0168.921 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure before engine too low (limit value 1). Flow too low, static pressure too low. MS15027/02E 2015-04 | Troubleshooting | 125...
  • Page 126 445 – SD P-Ambient Air Yellow alarm. Associated parameter 1.8004.580 Cause Corrective action u Check sensor and cabling, replace as necessary. Fault is Ambient air pressure sensor on ECU defective. rectified following engine restart. 126 | Troubleshooting | MS15027/02E 2015-04...
  • Page 127 2. Check mixture cooling circuit. 454 – SS Power Reduction Active Yellow alarm. Associated parameter 2.7000.011 Cause Corrective action Power reduction activated. u Rectify limit value violation of the source alarm (e.g. reduce intake air temperature). MS15027/02E 2015-04 | Troubleshooting | 127...
  • Page 128 Combined alarm (for details, refer to the source alarm). Engine stops because “Sensor faulty” present at channels. 476 – AL Crash Rec.Init Fault Red alarm. Associated parameter 1.8010.007 Cause Corrective action Initialization error of crash u Contact Service. recorder. 128 | Troubleshooting | MS15027/02E 2015-04...
  • Page 129 Associated parameter 1.8004.630 Cause Corrective action Mixture differential pressure u Check sensors and cabling (B79.21, B79.22), replace if sensor on A- or B-side defective, necessary. Fault is rectified following engine restart. short circuit or wire break. MS15027/02E 2015-04 | Troubleshooting | 129...
  • Page 130 Fault is rectified following engine restart. wire break. 515 – AL Starter Not Engaged Yellow alarm. Associated parameter 2.1090.926 Cause Corrective action u Check starter and cabling. Starter not engaged. 130 | Troubleshooting | MS15027/02E 2015-04...
  • Page 131 3. Check emissions. 535 – LOLO Power Difference Red alarm. Associated parameter 2.1005.921 Cause Corrective action Set and actual power deviate 1. Check converter. excessively from one another. 2. Check fuel settings. 3. Check emissions. MS15027/02E 2015-04 | Troubleshooting | 131...
  • Page 132 Alarm is activated when 2. Check cabling. problems with the gas supply solenoid valves occur. Either the gas supply solenoid valves are faulty, the time-out period is set too short, or communication is faulty. 132 | Troubleshooting | MS15027/02E 2015-04...
  • Page 133 566 – AL L2 P-Intake Air after Filter A Yellow alarm. Associated parameter 2.0186.931 Cause Corrective action Pressure loss over air filter on A u Replace air filter (→ Page 172). side is too high. MS15027/02E 2015-04 | Troubleshooting | 133...
  • Page 134 The cylinder set to maximum 1. Check emissions. retarded timing due to knocking 2. Check ignition timing (→ Page 162). has violated the first limit value. 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 134 | Troubleshooting | MS15027/02E 2015-04...
  • Page 135 Check sensor and cabling, replace as necessary. Air humidity sensor defect. Short circuit or wire break 604 – AL Hut Changespeed max. Yellow alarm. Associated parameter 2.1210.910 Cause Corrective action Gas qualities change too u Check gas system. quickly. MS15027/02E 2015-04 | Troubleshooting | 135...
  • Page 136 619 – HI Current net calorific value Yellow alarm. Associated parameter 2.1210.008 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has exceeded the first limit value. 136 | Troubleshooting | MS15027/02E 2015-04...
  • Page 137 624 – HIHI Nox value Yellow alarm. Associated parameter 2.3050.027 Cause Corrective action NOx emissions have exceeded 1. Check gas quality if feasible. the second limit value. 2. Check NOx sensor. 3. Check emissions. MS15027/02E 2015-04 | Troubleshooting | 137...
  • Page 138 Yellow alarm. Associated parameter 2.1200.935 Cause Corrective action Throttle A opening angle 1. Check charge pressure reserve. exceeded. 2. Intake air temperature not as per TVU data. 3. Check compressor for contamination. 4. Reduce power. 138 | Troubleshooting | MS15027/02E 2015-04...
  • Page 139 Associated parameter 1.4530.996 Cause Corrective action CAN bus communication to 1. Check cabling. bypass valve faulty. 2. Check power supply. 3. Restart ECU, EMU & bypass valve. 4. Check settings using device-specific dialog software (XD50.3). MS15027/02E 2015-04 | Troubleshooting | 139...
  • Page 140 659 – AL NOxB Comm Lost Yellow alarm. Associated parameter 1.4560.196 Cause Corrective action CAN bus communication to NOx 1. Check cabling. sensor B faulty. 2. Check power supply. 3. Restart ECU, EMU. 4. Replace sensor. 140 | Troubleshooting | MS15027/02E 2015-04...
  • Page 141 668 – AL TecJet Yellow Yellow alarm. Associated parameter 1.4540.993 Cause Corrective action u Precise error name is transmitted to the genset controller via An internal combined alarm in the gas control valve was CAN bus. detected. MS15027/02E 2015-04 | Troubleshooting | 141...
  • Page 142 CAN bus. 676 – AL IC92x Red Red alarm. Associated parameter 1.4520.991 Cause Corrective action An internal combined alarm in u Check data record. the ignition system was detected. 142 | Troubleshooting | MS15027/02E 2015-04...
  • Page 143 682 – AL NOxB Red Red alarm. Associated parameter 1.4560.191 Cause Corrective action u Precise error name is transmitted to the genset controller via An internal combined alarm on NOx sensor B was detected. CAN bus. MS15027/02E 2015-04 | Troubleshooting | 143...
  • Page 144 691 – HI Lube oil level top-up. 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. 144 | Troubleshooting | MS15027/02E 2015-04...
  • Page 145 Check gas supply. exceeded limit value 1. 848 – AL Rel. air humidity L1 Yellow alarm. Associated parameter 2.8006.039 Cause Corrective action u Check air humidity. Calculated air humidity has exceeded limit value 1. MS15027/02E 2015-04 | Troubleshooting | 145...
  • Page 146 4. Check settings using device-specific dialog software (in device). 948 – AL ESI activated Red alarm. Associated parameter 2.8006.044 Cause Corrective action Emergency stop input is 1. Rectify the fault causing the alarm. activated. 2. Check cabling. 146 | Troubleshooting | MS15027/02E 2015-04...
  • Page 147 Bus nodes (ignition, knock module, throttles or gas mixer) have faults. 977 – AL CAN4 Bus Off Yellow alarm. Associated parameter 2.0500.695 Cause Corrective action CAN controller 4 has indicated a u None warning. MS15027/02E 2015-04 | Troubleshooting | 147...
  • Page 148 Crankcase pressure too low 1. Check air filter for damage, replace if visibly damaged. (limit value 1). Restrictor valve in 2. Check setting of BlowBy restrictor valve. crankcase breather too widely open, faulty air filter. 148 | Troubleshooting | MS15027/02E 2015-04...
  • Page 149 Crankcase pressure too low 1. Check air filter for damage, replace if visibly damaged. (limit value 2). Restrictor valve in 2. Check setting of BlowBy restrictor valve. crankcase breather too widely open, faulty air filter. MS15027/02E 2015-04 | Troubleshooting | 149...

  • Page 150: 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. 150 | Task Description | MS15027/02E 2015-04...

  • Page 151: 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 152: 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). 152 | Task Description | MS15027/02E 2015-04...
  • Page 153 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 MS15027/02E 2015-04 | Task Description | 153...

  • Page 154: Ignition System

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug (→ Spare Parts Catalog) Replacing spark plug Remove spark plug (→ Page 155). Install new spark plug (→ Page 156). 154 | Task Description | MS15027/02E 2015-04...

  • Page 155: Spark Plug - Removal

    Remove spark plug connector (1) (→ Page 159). Unscrew spark plug a few turns. Clean spark plug bore with compressed air. Unscrew spark plug from cylinder head and remove from spark plug bore. MS15027/02E 2015-04 | Task Description | 155...

  • Page 156: Spark Plug - Installation

    Fit new sealing ring (2) on spark plug (1) with the flat side facing the insulator. Check satisfactory condition of spark plug connector and ignition cable, replace parts if damaged. Apply thin coat of assembly compound to spark plug thread. 156 | Task Description | MS15027/02E 2015-04...
  • Page 157 Tighten spark plug to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Spark plug M18 x 1.5 Tightening torque (Assembly compound 50 +5 Nm (Molykote P 37)) Install spark plug connector (1) (→ Page 160). MS15027/02E 2015-04 | Task Description | 157...

  • Page 158: 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 159). Install spark plug connector (→ Page 160). 158 | Task Description | MS15027/02E 2015-04...

  • Page 159: Spark Plug Connector - Removal

    Loosen threaded connection of the ignition lead on ignition coil (1) and disconnect igni- tion cable (3). Grip ignition lead connector (5) by flange (6) and disconnect from spark plug before fully extracting it from spark plug bore. MS15027/02E 2015-04 | Task Description | 159...

  • Page 160: Spark Plug Connector - Installation

    Fasten the ring eyelet of the ignition line (3) to the ignition coil (1) with the bolt and spring washer. Name Size Type Lubricant Value/Standard Screw Tightening torque 10 Nm Fit the protective cap (2) and check for correct seating. 160 | Task Description | MS15027/02E 2015-04...
  • Page 161 Insert sealing ring (2) into the bore in Tef- lon sleeve (1) with the article number fac- ing downwards. Carefully press sealing ring (1) into the groove until it is flush with the bore in Tef- lon sleeve (2). MS15027/02E 2015-04 | Task Description | 161...

  • Page 162: Ignition System - Ignition Timing Check

    The reset position is corrected in the engine governor with the Diasys service tool. Check ignition timing. Disconnect stroboscope. Stop engine (→ Page 44). 162 | Task Description | MS15027/02E 2015-04...

  • Page 163: Valve Drive

    Remove cylinder head covers (→ Page 169). Remove sleeves (arrow). Install barring device (→ Page 150). Rotate crankshaft with barring device in en- gine direction of rotation until marking “OT” and pointer are aligned. MS15027/02E 2015-04 | Task Description | 163...
  • Page 164 Install valve bridge. Adjust valve clearance (→ Page 167). Final steps Remove barring device (→ Page 150). Check condition of O-rings at the sleeves, replace if damaged. 164 | Task Description | MS15027/02E 2015-04...
  • Page 165 Install sleeves (arrow). Install cylinder head covers (→ Page 170). Install spark plugs with new sealing rings (→ Page 156). MS15027/02E 2015-04 | Task Description | 165...

  • Page 166: Valve Gear - Lubrication

    Part No. Qty. Engine oil Lubricating valve gear Remove cylinder head covers (→ Page 169). Fill oil chambers of rocker arms and adjust- ing screws with oil. Install cylinder head covers (→ Page 170). 166 | Task Description | MS15027/02E 2015-04...

  • Page 167: Valve Clearance - Check And Adjustment

    – – – X I – – X Inlet: Valve clearance adjustment of inlet valve is permitted Exhaust: Valve clearance adjustment of exhaust valve is permitted Valve clearance adjustment is not permitted – MS15027/02E 2015-04 | Task Description | 167...

  • Page 168: 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 device (→ Page 150). Install cylinder head cover (→ Page 170). 168 | Task Description | MS15027/02E 2015-04...

  • Page 169: Cylinder Head Cover - Removal

    Cylinder head cover ‒ Removal Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 159). Remove screws (2). Remove cylinder head cover with gasket from cylinder head. MS15027/02E 2015-04 | Task Description | 169...

  • Page 170: 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 160). 170 | Task Description | MS15027/02E 2015-04...

  • Page 171: 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. MS15027/02E 2015-04 | Task Description | 171...

  • Page 172: 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 173). Install new air filter (→ Page 173). 172 | Task Description | MS15027/02E 2015-04...

  • Page 173: 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). MS15027/02E 2015-04 | Task Description | 173...

  • Page 174: 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. 174 | Task Description | MS15027/02E 2015-04...

  • Page 175: 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 176: 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 177: 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 174). MS15027/02E 2015-04 | Task Description | 177...

  • Page 178: 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 179: 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 180). Fill with engine coolant (→ Page 182). MS15027/02E 2015-04 | Task Description | 179...

  • Page 180: 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 180 | Task Description | MS15027/02E 2015-04...
  • Page 181 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS15027/02E 2015-04 | Task Description | 181...

  • Page 182: 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 183: 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 184: 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 185). Fill with fresh mixture coolant (→ Page 186). 184 | Task Description | MS15027/02E 2015-04...

  • Page 185: 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. MS15027/02E 2015-04 | Task Description | 185...

  • Page 186: 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 187: Wiring (General) For Engine/Gearbox/Unit

    Close connectors that are not plugged in with the protective cap supplied. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts. Ensure that all connecting plugs of the sensors are correctly engaged. MS15027/02E 2015-04 | Task Description | 187...

  • Page 188: Sensors – Overview

    B4.X Exhaust temperature after cylinder B79.22 Mixture pressure B side Mixture temperature Table 40: Sensors – B-side The knock sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads. 188 | Task Description | MS15027/02E 2015-04...
  • Page 189 Sensors – driving end Item Name Monitoring of Nitrogen oxide (NOx) concentration in exhaust gas B79.23 Mixture pressure before throttle Crankshaft speed, reset, ignition system B13.2 Crankshaft speed, ignition Table 41: Sensors – engine driving end MS15027/02E 2015-04 | Task Description | 189...
  • Page 190 Monitoring of B44.1 (optional) Turbocharger speed sensor B5.1 Engine oil pressure after filter Engine oil temperature B5.3 Engine oil pressure before filter Crankcase pressure B79.21 Mixture pressure A side Table 42: Sensors – A-side 190 | Task Description | MS15027/02E 2015-04...
  • Page 191 B1.3 Camshaft speed for anti-knock control B1.1 Camshaft speed for engine governor Engine oil level B1.2 Camshaft speed for ignition system B6.3 Coolant temperature before engine Table 43: Sensors – engine free end MS15027/02E 2015-04 | Task Description | 191...

  • Page 192: Abbreviations

    Low Low Alarm: Measured value lower than 2nd mini- mum limit value Missing Data A measuring point does not provide data. Message General message Niedertemperatur Onsite Energy MTU Onsite Energy Original Equipment Manufacturer 192 | Appendix A | MS15027/02E 2015-04...
  • Page 193 Safety System Safety system alarm TA-Luft Technische Anleitung zur Reinhaltung General administrative instruction for federal der Luft emission control law in Germany Transmitter Deviation Alarm: Sensor comparison fault Bottom Dead Center Tool Catalog Zündzeitpunkt MS15027/02E 2015-04 | Appendix A | 193...

  • Page 194: Partner

    Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For our locally available support, go to MTU's Internet site: • http://www.mtuonsiteenergy.com/haendlersuche/index.de.html 24-h Hotline With our 24-h 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 195: Special Tools

    Barring gear Part No.: F6555766 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 150) Feeler gauge Part No.: Y20098771 Qty.: Used in: 6.4.3 Valve clearance – Check and adjustment (→ Page 167) MS15027/02E 2015-04 | Appendix B | 195...
  • Page 196 Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 177) 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 151) Gas measuring and warning device (not stocked by MTU) Part No.:...
  • Page 197 (→ Page 162) Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 156) Qty.: Used in: 6.3.6 Spark plug connector – Installation (→ Page 160) MS15027/02E 2015-04 | Appendix B | 197...
  • Page 198 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 6.4.3 Valve clearance – Check and adjustment (→ Page 167) 198 | Appendix B | MS15027/02E 2015-04...

  • Page 199: Index

    – Contact person  194 – Shutdown  44 – Service partner  194 – Start  41 Engine cabling  – Check  187 Oil separator  Engine Control Unit  – Filter replacement  152 – Fault messages  111 Operational checks  42 MS15027/02E 2015-04 | Appendix B | 199...
  • Page 200 – Startup, special instructions for applications with gas- eous fuel  9 Sensors  – Overview  188 Service partner  – MTU Onsite Energy  194 Spark plug  – Installation  156 – Removal  155 – Replacement  154 200 | Appendix B | MS15027/02E 2015-04...

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