MTU 8V4000Lx4 Operating Instructions Manual
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MTU 8V4000Lx4 Operating Instructions Manual

MTU 8V4000Lx4 Operating Instructions Manual

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Operating Instructions

Gas engine
8V4000Lx4
MS15026/00E

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Summary of Contents for MTU 8V4000Lx4

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 8V4000Lx4 MS15026/00E...
  • 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

    Table of Contents 1 Safety 3.8 Engine – Shutdown 3.9 Emergency engine shutdown 1.1 Important provisions for all products 3.10 After stopping the engine – Engine remains 1.2 Personnel and organizational requirements ready for operation 1.3 Safety regulations for startup and operation 3.11 After stopping the engine –...
  • Page 4 6.9.2 Engine coolant – Change 7 Appendix A 6.9.3 Engine coolant – Draining 7.1 Abbreviations 6.9.4 Engine coolant – Filling 7.2 MTU Onsite Energy contact person / service 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 –...

  • 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

    1.2 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair or 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

    1.3 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica- tions before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 9 Observe the warning information applicable to the devices. MS15026/00E 2015-05 | Safety | 9...

  • Page 10: Safety Requirements For Startup And Operation, Special Instructions For Applications With Gaseous Fuel

    1.4 Safety requirements for startup and operation, special instructions for applications with gaseous fuel Safety requirements for startup Whenever the product is started, always ensure that: • The operator has fulfilled the requirement to: Check the gas train. • The temperature in the area of the product must not fall below 5 °C at any point. Gas system, requirements Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device.

  • Page 11: Safety Regulations For Maintenance And Repair Work

    1.5 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 (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 12 Always seal connections with caps or covers if a line is removed or opened. Fit new seals when re-installing lines. Never bend lines and avoid damaging lines, particularly the fuel lines. Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed ina slanted/twisted condition.
  • Page 13 For a hydraulic installation/removal device 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 on. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries.

  • Page 14: Safety Requirements For Maintenance And Repair Work, Special Instructions For Applications With Gaseous Fuel

    1.6 Safety requirements for maintenance and repair work, special instructions for applications with gaseous fuel Safety requirements before commencing 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 15: 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 16: Compressed Air

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

  • Page 17: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials, Special Instructions For Applications With Gaseous Fuel

    1.8 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 18: Standards For Safety Notices In The Text

    1.9 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 19: 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 20: Product Summary

    2 Product Summary 2.1 Engine – Overview 1 Crankcase breather, oil 7 Spark plug 13 Engine coolant inlet con- separator 8 Cylinder head cover nection 2 Exhaust outlet 9 Cylinder head 14 Engine oil heat exchanger 3 Gas control valve 10 Engine oil sampling port 15 Engine coolant outlet con- 4 Gas inlet connection...
  • Page 21 Engine overview, driving end 1 Engine governor/engine 5 Engine lifting equipment 9 Engine mounting bracket, monitoring unit 6 Capacitor ignition system driving end 2 Air filter/air inlet 7 Engine mounting bracket, 10 Starter 3 Mixture cooler free end 11 Flywheel 4 Exhaust turbocharger 8 Oil pan KS Driving end...

  • Page 22: Engine Side And Cylinder Designations

    2.2 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

  • Page 23: Engine - Main Dimensions

    2.3 Engine – Main dimensions Main engine dimensions Dimensions Item Length (A) approx. 2484 mm Width (B) approx. 1742 mm Height (C) approx. 2135 mm Crankshaft center to oil pan (D) approx. 625 mm Crankshaft center to engine mount (E) approx.

  • Page 24: Firing Order

    2.4 Firing order Firing order Number of cylinders Firing order A1-A3-A4-A2-B3-B4-B2-B1 24 | Product Summary | MS15026/00E 2015-05...

  • Page 25: Technical Data

    2.5 Technical Data 2.5.1 8V4000L64 engine data, fuel-optimized (TA-Luft) Explanation: DL Reference value: Continuous power BL Reference 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 26 Number of cylinders Gas type: natural gas Methane number, min. Table 6: General conditions (for max. power) Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh 0.15 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 27 Number of cylinders Thermostat: Starts to open °C Thermostat: Opening stops (thermostat fully open and bypass closed) °C Table 9: Coolant system (HT circuit) Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooler system (w/o antifreeze) Coolant antifreeze content, max.
  • Page 28 Starting (electric) Number of cylinders Rated starter power (standard design) Rated starter voltage (standard design) Starter current consumption, max. (standard design) 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 14: Starting (electric) Capacities Number of cylinders Engine coolant capacity, engine side (without cooler system) Liters Mixture coolant, engine side (without cooler system)

  • Page 29: 8V4000L64 Engine Data, Emissions Optimized (1/2 Ta-Luft)

    2.5.2 8V4000L64 engine data, emissions optimized (1/2 TA-Luft) Explanation: DL Reference value: Continuous power BL Reference 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 30 Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh 0.15 Table 22: 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 Cylinder arrangement: V angle Degrees (°) Bore...
  • Page 31 Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooler system (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 25: Coolant system (LT circuit) Lube oil system Number of cylinders...
  • Page 32 Number of cylinders Starter current consumption, max. (standard design) 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 29: Starting (electric) Capacities Number of cylinders Engine coolant capacity, engine side (without cooler system) Liters Mixture coolant, engine side (without cooler system) Liters Total engine oil capacity for initial filling (standard oil system) Liters...

  • Page 33: Monitoring, Control And Regulation Equipment

    2.6 Monitoring, Control and Regulation Equipment 2.6.1 Gas engine system – Overview Overview 1 Unit system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 Humidity sensor 10 Ignition 3 System 7 Throttles 11 Compressor bypass 4 Engine Control Unit 8 Gas control unit 12 NOx sensor (optional) Closed-/open-loop control / monitoring...
  • Page 34 Anti-Knock Regulation AKR • Controls monitored cylinders in regard of knock characteristics. If knocking is detected, the ignition timing is retarded on the cylinder in question. If this does not result in an improvement, the power is reduced. Gas control valve TecJet52 / TecJet85 •...

  • Page 35: Purpose Of The Units

    2.6.2 Purpose of the units ECU 9 engine governor 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 36 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring 36 | Product Summary | MS15026/00E 2015-05...

  • Page 37: 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: Recommended minimum run- Power, referenced to nominal Recommended maximum run- time...

  • Page 38: 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 39: 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 175). Coolant circuit Check engine coolant level (→ Page 179); Check mixture coolant level (→...

  • Page 40: 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 starting 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 41 Emergency stopping sequence If an emergency stop command is activated, the following steps are carried out automatically: 1. Closing gas supply solenoid valves 2. Closing mixture throttles 3. Engine running down to standstill 4. Deactivating ignition 5. Requesting external ventilation by contact Restarting after emergency stop A scavenging phase and a request for external ventilation by contact ensue following a start request after emergency shutdown.

  • Page 42: 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 43: 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 High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 44: 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 45: 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 46: Emergency Engine Shutdown

    3.9 Emergency engine shutdown WARNING Escaping residual gas may create an explosive atmosphere in case of emergency stop. Explosion hazard! • Ensure that any escaping residual gas is routed out by means of appropriate facility ventilation and use of an SBV (safety blow-off valve) to prevent any risk of explosive atmosphere. •...
  • Page 47 Remedy the cause, re-enable starting Item Action Engine Control System Determine cause of emergency stop and take remedial action; contact Serv- ice if the fault cannot be corrected. Fault acknowledgment is possible in engine stop mode only . Automatic se- lection and remote start immediately following an emergency engine stop is not admissible.

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

    3.10 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator controller Select operating mode, e.g. MANUAL, AUTOMATIC. (manufacturer-specific) 48 | Operation | MS15026/00E 2015-05...

  • Page 49: After Stopping The Engine - Putting The Engine Out Of Operation

    If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Preservation and Represerva- tion Specifications A001070/..). The corrosion-inhibiting effect of the engine coolant may be used as an alter- native in case of out-of-service periods lasting for more than 1 month, by run- ning the engine for at least 2 hours at rated power once a month.

  • Page 50: Maintenance

    4 Maintenance 4.1 50-hours check 50-hours check One-time operations to be carried out after a test run or after the first 10 to 50 operating hours of the cylinder head (with a new engine, after installation of new cylinder heads, after component mainte- nance or extended component maintenance).

  • Page 51: Maintenance Schedule Reference Table [Ql1]

    4.2 Maintenance schedule 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 52: 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 53 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. MS15026/00E 2015-05 | Troubleshooting | 53...

  • Page 54: Fault Messages In Log For Genset Controller

    5.2 Fault messages in log for genset controller 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 163). temperatures is too high. 3.
  • Page 55 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 56 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 57 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 58 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 59 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 60 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 61 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 62 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 63 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 64 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 65 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 66 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 163). too high in comparison with 3. Check valve gear (exhaust valves do not close). weighted average.
  • Page 67 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 68 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 69 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 70 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 low in comparison with 3. Check ignition timing (→ Page 163). weighted average.
  • Page 71 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 163). too high. 3. Check valve gear (exhaust valves do not close). 112706 –...
  • Page 72 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 163). too high. 3. Check valve gear (exhaust valves do not close). 112712 –...
  • Page 73 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 163). too high. 3. Check valve gear (exhaust valves do not close). 112718 –...
  • Page 74 113601 – AL Gas Valve 1 feedback Red alarm. Initiated by EMU. 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 EMU. Cause Corrective action Emergency stop detected.
  • Page 75 1.4510.192 – Knock Sensor Error A1 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. 1.4510.193 – Knock Sensor Error A2 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock...
  • Page 76 1.4510.198 – Knock Sensor Error A7 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. 1.4510.199 – Knock Sensor Error A8 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock...
  • Page 77 1.4510.204 – Knock Sensor Error B3 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. 1.4510.205 – Knock Sensor Error B4 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock...
  • Page 78 1.4510.210 – Knock Sensor Error B9 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. 1.4510.211 – Knock Sensor Error B10 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock...
  • Page 79 1.4520.523 – MIC5 Stat W: invalid configuration Yellow alarm. Initiated by MIC5. Cause Corrective action u Check settings. Restart ignition control unit. The ignition system settings are invalid. 1.4520.524 – MIC5 Stat W: invalid trigger config Yellow alarm. Initiated by MIC5. Cause Corrective action The ignition system settings are...
  • Page 80 1.4520.530 – MIC5 Stat Global timing limited Yellow alarm. Initiated by MIC5. Cause Corrective action u Check settings. The global timing is outside of the valid range. 1.4520.540 – MIC5 E1 General fault Red alarm. Initiated by MIC5. Cause Corrective action A general fault occurred.
  • Page 81 1.4520.546 – MIC5 E1 Failure temperature sensor Red alarm. Initiated by MIC5. Cause Corrective action u Restart ignition control unit. The temperature sensor is defective. 1.4520.547 – MIC5 E1 Failure current sensor Red alarm. Initiated by MIC5. Cause Corrective action The current sensor is defective.
  • Page 82 1.4520.553 – MIC5 E1 Tr1 polarity detection fail Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record Polarity of trigger 1 (B1.2) could not be detected. and timing wheel. Replace sensor if required. 1.4520.554 –...
  • Page 83 1.4520.560 – MIC5 E1 Tr1 index too early / faulty 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 detected too early or and timing wheel.
  • Page 84 1.4520.575 – MIC5 IPE Primary Open Cylinder 6 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil. cylinder 6 in firing order. 2. Check ignition coil. 1.4520.576 – MIC5 IPE Primary Open Cylinder 7 Yellow alarm.
  • Page 85 1.4520.582 – MIC5 IPE Primary Open Cylinder 13 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil. cylinder 13 in firing order. 2. Check ignition coil. 1.4520.583 – MIC5 IPE Primary Open Cylinder 14 Yellow alarm.
  • Page 86 1.4520.589 – MIC5 IPE Primary Open Cylinder 20 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil. cylinder 20 in firing order. 2. Check ignition coil. 1.4520.590 – MIC5 IPE Prim Short Circuit Cyl 1 Yellow alarm.
  • Page 87 1.4520.596 – MIC5 IPE Prim Short Circuit Cyl 7 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil. cylinder 7 in firing order. 2. Check ignition coil. 1.4520.597 – MIC5 IPE Prim Short Circuit Cyl 8 Yellow alarm.
  • Page 88 1.4520.603 – MIC5 IPE Prim Short Circuit Cyl 14 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil. cylinder 14 in firing order. 2. Check ignition coil. 1.4520.604 – MIC5 IPE Prim Short Circuit Cyl 15 Yellow alarm.
  • Page 89 1.4520.610 – MIC5 ISE Secondary Open Cylinder 1 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 1 in firing order. 2. Check ignition coil. 1.4520.611 –...
  • Page 90 1.4520.617 – MIC5 ISE Secondary Open Cylinder 8 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 8 in firing order. 2. Check ignition coil. 1.4520.618 –...
  • Page 91 1.4520.624 – MIC5 ISE Secondary Open Cylinder 15 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit 1. Check ignition line, spark plug connector and spark plug. of cylinder 15 in firing order. 2. Check ignition coil. 1.4520.625 –...
  • Page 92 1.4520.631 – MIC5 ISE Secon Short Circuit Cyl 2 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 2 in firing order. 2. Check ignition coil. 1.4520.632 –...
  • Page 93 1.4520.638 – MIC5 ISE Secon Short Circuit Cyl 9 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 9 in firing order. 2. Check ignition coil. 1.4520.639 –...
  • Page 94 1.4520.645 – MIC5 ISE Secon Short Circuit Cyl 16 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 16 in firing order. 2. Check ignition coil. 1.4520.646 –...
  • Page 95 1.4520.660 – MIC5 E2 Tr2 no signal detected Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record No signal from trigger 2 (B75). and timing wheel. Replace sensor if required. 1.4520.661 – MIC5 E2 Tr2 polarity detection fail Yellow alarm.
  • Page 96 1.4520.667 – MIC5 E2 Tr2 index mark not detected Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record The index mark of trigger 2 (B75) was not detected during and timing wheel. Replace sensor if required. operation.
  • Page 97 1.4520.673 – MIC5 E2 Tr3 polarity detection fail Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor clearance, cabling, settings in data record Polarity of trigger 3 (B13.2) could not be detected. and timing wheel. Replace sensor if required. 1.4520.674 –...
  • Page 98 1.4520.680 – MIC5 E2 Tr3 index too early / faulty 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 detected too early and timing wheel. Replace sensor if required. or was faulty.
  • Page 99 1.4530.012 – Analog Input High Error Yellow alarm. Initiated by F-Series. Cause Corrective action u Check setting. F-Series setting is not correct. 1.4530.013 – Analog Input Low Error Yellow alarm. Initiated by F-Series. Cause Corrective action F-Series setting is not correct. u Check setting.
  • Page 100 1.4530.019 – Run Enable not active Yellow alarm. Initiated by F-Series. Cause Corrective action u Check setting. F-Series setting is not correct. 1.4530.020 – Spring Check Failed Yellow alarm. Initiated by F-Series. Cause Corrective action F-Series setting is not correct. u Check setting.
  • Page 101 1.4540.012 – Valve Position Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.013 – High Elec Temp Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 102 1.4540.019 – Position Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.020 – Elec Temp Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 103 1.4540.026 – Analog Input Low Error Red alarm. Initiated by TecJet. Cause Corrective action u Check setting. TecJet setting is not correct. 1.4540.027 – Analog Input High Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting.
  • Page 104 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 105 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. 1.4540.043 – Parameter Error Red alarm.
  • Page 106 1.4540.048 – SPI ADC Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.049 – Sense 5V Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 107 1.4540.055 – Factory CAL Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.056 – PWM Duty Cycle High Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting.
  • Page 108 1.4550.036 – A - Temperature derating active Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action The internal temperature is 1. Check room temperature. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.037 – A - Temperature above 120 °C Red alarm.
  • Page 109 1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check cabling and setting. CAN bus connection faulty. 1.4550.044 – A - CAN Stop Command Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action “Stop”...
  • Page 110 1.4550.136 – B - Temperature derating active Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action The internal temperature is 1. Check room temperature. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.137 – B - Temperature above 120 °C Red alarm.
  • Page 111 1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by ProAct B-Bank. Cause Corrective action u 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”...

  • Page 112: Engine Control Unit - Fault Messages

    5.3 Engine Control Unit – 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.
  • Page 113 021 – 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 163). value 1). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4.
  • Page 114 031 – HI ETC1 Overspeed Yellow alarm. Associated parameter 2.3011.931 Cause Corrective action Speed of primary turbocharger 1. Check settings for this input in the ECU if no turbocharger too high (limit value 1). speed sensor is installed. 2. Check ignition timing and emission if a turbocharger speed sensor is installed.
  • Page 115 051 – 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 175). contaminated, coolant temperature is too high.
  • Page 116 058 – SS P-Coolant Red alarm. Engine stop. 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). Flow too low, static pressure too low. 063 – HI P-Crankcase Yellow alarm.
  • Page 117 068 – SS T-Coolant Red alarm. Engine stop. 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 118 092 – 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 stop. Associated parameter 2.1090.922 Cause Corrective action...
  • Page 119 118 – 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 120 181 – AL CAN2 Node Lost Yellow alarm. Associated parameter 2.0500.681 Cause Corrective action u Check operation of nodes and cabling. Buses (CAN bus 1 and Bus node (SAM or EMU) lost on CAN bus 2. CAN bus 2) are redundant. 182 –...
  • Page 121 187 – AL CAN1 Error Passive Yellow alarm. Associated parameter 2.0500.687 Cause Corrective action u Check operation of nodes and cabling. CAN controller 1 has indicated a warning. Bus nodes (ECU, SAM or EMU) are faulty. 188 – AL CAN2 Bus Off Yellow alarm.
  • Page 122 204 – SD Level Lube Oil Red alarm. Engine stop. Associated parameter 1.8004.602 Cause Corrective action u Check sensor and cabling (B24), replace as necessary. Fault is Engine oil level sensor defective, short circuit or wire break. rectified following engine restart. 206 –...
  • Page 123 214 – SD P-Crankcase Red alarm. Associated parameter 1.8004.568 Cause Corrective action u Check sensor and cabling (B50), replace as necessary. Fault is Crankcase pressure sensor defective, short circuit or wire rectified following engine restart. break. 216 – SD T-Lube Oil Red alarm.
  • Page 124 229 – AL Stop Camshaft Sensor Defect Red alarm. Engine stop. Associated parameter 1.8004.562 Cause Corrective action u Check sensor and cabling (B1.1), replace if necessary. Fault is Engine stop due to camshaft sensor fault (and a previous rectified following engine restart. crankshaft sensor fault in the same operating cycle).
  • Page 125 266 – SD Speed Demand Red alarm. Associated parameter 2.8006.586 Cause Corrective action u Check signal and cabling between plant and ADEC. Speed setting signal can no longer be transmitted from plant. 381 – AL Wiring TOP 1 Yellow alarm. Associated parameter 2.8006.638 Cause Corrective action...
  • Page 126 418 – SD T-Intake Air B Yellow alarm. Associated parameter 1.8004.603 Cause Corrective action u Check sensor and cabling (B49.2), replace if necessary. Intake air temperature sensor defective, short circuit or wire break. 419 – SD T-Coolant b.Engine Yellow alarm. Associated parameter 1.8004.604 Cause Corrective action...
  • Page 127 431 – SS P-Coolant before Engine Red alarm. Engine stop. Associated parameter 2.0168.922 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure before engine too low (limit value 2). Flow too low, static pressure too low. 434 –...
  • Page 128 447 – HIHI P-Charge Mix Diff. Red alarm. Engine stop. Associated parameter 2.0183.932 Cause Corrective action Difference in mixture pressures 1. Check throttles for varying positions and malfunction. sensed on A- and B-side is too 2. Check mixture lines for leakage. high (limit value 2).
  • Page 129 457 – LO T-Intake Air Yellow alarm. Associated parameter 2.0123.921 Cause Corrective action u Check ventilation system. Intake air temperature is too low (limit value 3). 458 – LOLO T-Intake Air Red alarm. Engine stop. Associated parameter 2.0123.922 Cause Corrective action Intake air temperature is too low u Check ventilation system.
  • Page 130 478 – AL Comb. Alarm Yel (Plant) Yellow alarm. Associated parameter 2.8006.001 Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm YELLOW from plant. 479 – AL Comb. Alarm Red (Plant) Red alarm. Engine stop. Associated parameter 2.8006.002 Cause Corrective action...
  • Page 131 499 – SD T-Charge Mix Red alarm. Associated parameter 1.8004.632 Cause Corrective action u Check sensor and cabling (B73), replace as necessary. Fault is Mixture temperature sensor defective, short circuit or wire rectified following engine restart. break. 511 – HIHI P-Charge Mix A Red alarm.
  • Page 132 517 – SD P-Charge Mix before Throttle Red alarm. Associated parameter 1.8004.631 Cause Corrective action u Check sensor and cabling (B79.23), replace if necessary. Fault Mixture pressure sensor before throttle defective, short circuit is rectified following engine restart. or wire break. 520 –...
  • Page 133 536 – AL Wiring PWM_CM1 Red alarm. Associated parameter 1.1041.921 Cause Corrective action u Check cabling to ignition. Cable break or short circuit on channel PWM_CM1. 552 – AL GasControlCheck Fault Red alarm. Associated parameter 2.1090.118 Cause Corrective action Gas train test was not 1.
  • Page 134 557 – AL speed drop fault Red alarm. Engine stop. Associated parameter 2.1090.126 Cause Corrective action u Check gas train. Speed drop. Alarm is activated if engine speed drops during starting sequence. 559 – AL mixture throttle A fault Red alarm. Engine stop. Associated parameter 1.1450.010 Cause Corrective action...
  • Page 135 567 – AL L1 P-Intake Air after Filter B Yellow alarm. Associated parameter 2.0187.921 Cause Corrective action u Replace air filter (→ Page 173). Pressure loss over air filter on B side is too high. 568 – AL L2 P-Intake Air after Filter B Yellow alarm.
  • Page 136 571 – L2 AI CAN Max Retarded Timing Yellow alarm. Power reduction. Associated parameter 2.1200.932 Cause Corrective action The cylinder set to maximum 1. Check emissions. retarded timing due to knocking 2. Check ignition timing (→ Page 163). has violated the second limit 3.
  • Page 137 609 – AL Wiring PWM_CM7 Red alarm. Associated parameter 1.1041.927 Cause Corrective action u Check cabling to the NOx sensors and to the air humidity Cable break or short circuit on channel PWM_CM7. sensor. 615 – AL EIL Protection Red alarm. Associated parameter 2.0610.951 Cause Corrective action...
  • Page 138 620 – HIHI Current net calorific value Yellow alarm. Associated parameter 2.1210.009 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has exceeded the second limit value. 621 – LO Nox Value Yellow alarm. Associated parameter 2.3050.024 Cause Corrective action NOx emissions have fallen below...
  • Page 139 633 – SD P-ambient air (HDT2800) Associated parameter 1.0700.087 Cause Corrective action u Sensor is not currently part of standard scope of supply. Air humidity sensor defect. 634 – SD T0-Ambient Air (HDT2800) Associated parameter 1.0700.089 Cause Corrective action Air humidity sensor defect. u Sensor is not currently part of standard scope of supply.
  • Page 140 650 – Al Req Angle Throttle B Yellow alarm. Associated parameter 2.1200.936 Cause Corrective action Throttle B 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. 651 –...
  • Page 141 655 – AL TecJet Comm Lost Red alarm. Associated parameter 1.4540.996 Cause Corrective action CAN bus communication to gas 1. Check cabling. control valve faulty (alternatively 2. Check power supply. a stepper motor with gas mixer 3. Restart ECU, EMU & gas control valve. can be installed).
  • Page 142 664 – AL Oil Refill Error Red alarm. Associated parameter 1.1480.305 Cause Corrective action u A programmable timeout period starts after signaling of the Automatic oil replenishment combined alarm faulty. alarms HI Oil Refill and HI Lube Oil Level refill. The engine is stopped when this time expires.
  • Page 143 669 – AL ProActA Yellow Yellow alarm. Associated parameter 1.4550.093 Cause Corrective action u Precise error name is transmitted to the genset controller via An internal combined alarm in throttle A was detected. CAN bus. 670 – AL ProActB Yellow Yellow alarm.
  • Page 144 677 – AL FSeries Red Red alarm. Associated parameter 1.4530.991 Cause Corrective action u Precise error name is transmitted to the genset controller via An internal combined alarm in the bypass valve was detected. CAN bus. 678 – AL TecJet Red Red alarm.
  • Page 145 685 – AL Lube Oil Min. Red alarm. Associated parameter 1.1480.307 Cause Corrective action Min. engine oil filling level 1. Check engine oil level (→ Page 175). detected. 2. Check replenishment system. 3. Top up oil. 686 – AL Lube Oil Max. Red alarm.
  • Page 146 694 – SD T-Gas Yellow alarm. Associated parameter 1.8004.123 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. 719 – AL T-Gas L1 Yellow alarm.
  • Page 147 891 – AL Purging active Yellow alarm. Associated parameter 2.1090.048 Cause Corrective action u None Engine was stopped with emergency stop or did not finish starting successfully on several occasions. 932 – AL MIC5 Yellow Yellow alarm. Associated parameter 1.4520.933 Cause Corrective action An internal combined alarm in...
  • Page 148 972 – AL MIC5 Signature difference Red alarm. Associated parameter 1.450.969 Cause Corrective action The ignition system has not 1. ECU restart taken on the configuration from 2. Check configuration in the ECU the Engine Control Unit. 974 – AL CAN3 Bus Off Yellow alarm.
  • Page 149 1012 – AL MIC5 Parameter Download Active Yellow alarm. Associated parameter 1.4520.966 Cause Corrective action u Wait until parameter downloading has been completed. Max. Parameter download from ECU to ignition system is active. time is approx. 2 min. 1013 – Hi Delta NOx (A-B) Yellow alarm.
  • Page 150 1031 – LOLO P-Crankcase Red alarm. Associated parameter 2.0106.936 Cause Corrective action 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.

  • Page 151: 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 152: 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 153: 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 154 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 155: 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 156). Install new spark plug (→ Page 157). MS15026/00E 2015-05 | Task Description | 155...

  • Page 156: 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 WARNING Hot components/surfaces.

  • Page 157: 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 (Molykote P 37)
  • Page 158 Screw spark plug into cylinder head. Note: The temperature of spark plug and cylinder head must be the same prior to tightening. 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))

  • Page 159: 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 160). Install spark plug connector (→ Page 161). MS15026/00E 2015-05 | Task Description | 159...

  • Page 160: 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. WARNING Hot components/surfaces. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. •...

  • Page 161: 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 162 Exchanging spark plug isolator sealing ring Insert screwdriver (3) between Teflon sleeve (1) and sealing ring (2). Pry out and pull out sealing ring (2). Fold together new sealing ring (2). Insert sealing ring (2) into the bore in Tef- lon sleeve (1) with the article number fac- ing downwards.

  • Page 163: 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 164: Valve Drive

    6.4 Valve Drive 6.4.1 Valve projection – 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 156). Remove cylinder head covers (→...
  • Page 165 Measuring valve projection 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 projection for each valve in two crankshaft positions (firing TDC and overlap TDC for cyl- inder A1) according to the diagram.
  • Page 166 Install sleeves (arrow). Install cylinder head covers (→ Page 171). Install spark plugs with new sealing rings (→ Page 157). 166 | Task Description | MS15026/00E 2015-05...

  • Page 167: Valve Gear - Lubrication

    6.4.2 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 170). Fill oil chambers of rocker arms and adjust- ing screws with oil.

  • Page 168: Valve Clearance - Check And Adjustment

    6.4.3 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 gauge Y20098771 Angular screw driver F30452765 Torque wrench, 60–320 Nm F30452768...
  • Page 169 Valve clearance at two crankshaft positions – Check Check TDC position of piston in cylinder A1: • If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC. • If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC. Check valve clearance adjustment with cold engine: •...

  • Page 170: Cylinder Head Cover - Removal

    6.4.4 Cylinder head cover ‒ Removal Preconditions ☑Engine is stopped and starting disabled. Cylinder head cover ‒ Removal Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 160). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 171: 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. Cylinder head cover ‒ Installa- tion Clean mounting surface.

  • Page 172: 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 173: 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 174: 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 175: 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 176: 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 177: 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 178: 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. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 179: 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 180: 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 181). Fill with engine coolant (→ Page 183). 180 | Task Description | MS15026/00E 2015-05...

  • Page 181: 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 182 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 182 | Task Description | MS15026/00E 2015-05...

  • Page 183: 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 184: 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 185: 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 186). Fill with fresh mixture coolant (→ Page 187). MS15026/00E 2015-05 | Task Description | 185...

  • Page 186: 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 187: 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 188: Wiring (General) For Engine/Gearbox/Unit

    6.11 Wiring (General) for Engine/Gearbox/Unit 6.11.1 Engine cabling – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.

  • Page 189: Sensors – Overview

    6.11.2 Sensors – Overview Sensors on B side Item Designation Monitoring of Intake temperature/humidity B81.2 Intake air pressure after filter B16.1 Coolant pressure after engine B4.X Exhaust temperature after cylinder B79.22 Mixture pressure B-side Mixture temperature Table 39: Sensors on right engine side The knocking sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads on the intake pipe.
  • Page 190 Sensors on driving end Item Designation Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.2 Crankshaft speed ignition system Table 40: Sensors on driving end 190 | Task Description | MS15026/00E 2015-05...
  • Page 191 Sensors on A side Item Designation Monitoring of B79.21 Mixture pressure A-side Crankcase pressure Engine oil temperature B5.3 Engine oil pressure before filter B5.1 Engine oil pressure after filter Table 41: Sensors on A side MS15026/00E 2015-05 | Task Description | 191...
  • Page 192 Sensors on free end Item Designation Monitoring of B4.21 Exhaust bulk temperature B16.3 Coolant pressure before engine B1.3 Camshaft speed knock module B1.1 Camshaft speed, engine governor B1.2 Camshaft speed, ignition system Engine oil level B6.3 Coolant temperature before engine B6.1 Coolant temperature after engine Table 42: Sensors on free end...

  • Page 193: Abbreviations

    American National Standards Institute Association of American standardization organ- izations Exhaust turbocharger Series Betriebsstoffvorschrift MTU Publication 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- ards (DIN = “Deutsche Industrie-Norm”)
  • Page 194 Explanation Abbreviation Meaning ORFS O-Ring Face Seal O-ring seal Top Dead Center Panel Control panel Peripheral Interface Module Peripheral interface module Pulse Width Modulation Modulated signal Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sicherheitsabsperrventil Sicherheitsabbalseventil Sensor Defect...

  • Page 195: 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 196: Special Tools

    Y20098771 Qty.: Used in: 6.4.3 Valve clearance – Check and adjustment (→ Page 168) 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 152)
  • Page 197 Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 3.7 Emission values – Check (→ Page 44) Oil filter wrench Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 178) Ratchet head with extension Part No.:...
  • Page 198 Used in: 6.3.2 Spark plug – Removal (→ Page 156) Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 157) Stroboscope (Not stocked by MTU) Part No.: Qty.: Used in: 6.3.7 Ignition system – Ignition timing check (→ Page 163) Torque wrench, 10-60 Nm Part No.:...
  • Page 199 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 6.4.3 Valve clearance – Check and adjustment (→ Page 168) MS15026/00E 2015-05 | Appendix B | 199...

  • Page 200: Index

    Cabling  – Log  54 – Check   – Key  52 – On engine  188 Firing order 24 Contact person  – MTU Onsite Energy  195 Control 40 Gas supply  Coolant  – Checking gas lines for leaks  172 – Change  180 Cylinder  – Designation  22...
  • Page 201 – Safety notices, standards  18 – Startup, special instructions for applications with gas- eous fuel  10 Sensors  – Overview  189 Service partner  – MTU Onsite Energy  195 Spark plug  – Installation  157 – Removal  156 – Replacement  155 MS15026/00E 2015-05 | Appendix B | 201...

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