MTU 16V4000Lx2x Operating Instructions Manual
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MTU 16V4000Lx2x Operating Instructions Manual

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Operating Instructions

Gas engine
16V4000Lx2x
MS150121/00E

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Summary of Contents for MTU 16V4000Lx2x

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 16V4000Lx2x MS150121/00E...
  • 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 6.9.4 Engine coolant – Filling 7 Appendix A 6.9.5 Vent line of engine coolant circuit – 7.1 Abbreviations Replacement 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. MS150121/00E 2015-07 | 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 Throttle, A-side 6 Engine lifting equipment 11 Starter 2 Engine governor/engine 7 Capacitor ignition system 12 Flywheel monitoring 8 Engine mounting bracket, KS Driving end 3 Air filter/air inlet free end 4 Mixture cooler 9 Oil pan 5 Exhaust turbocharger 10 Engine mounting bracket,...
  • Page 21 1 Crankcase breather, oil 7 Spark plug 13 Connection: engine cool- separator 8 Cylinder head cover ant inlet 2 Exhaust gas outlet connec- 9 Cylinder head 14 Engine oil heat exchanger tion 10 Engine oil sampling con- 15 Connection: engine cool- 3 Gas control valve nection ant outlet...

  • 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 Deviations from illustrations are insignificant. Dimensions Item Length (A) approx. 3372 mm Width (B) approx. 1789 mm Height (C) approx. 2156 mm Crankshaft center to oil pan (D) approx. 636 mm Crankshaft center to engine mount (E) approx.

  • Page 24: Firing Order

    2.4 Firing order Firing order Number of cylinders Firing order A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 24 | Product Summary | MS150121/00E 2015-07...

  • Page 25: Technical Data

    2.5 Technical Data 2.5.1 Engine data 16V4000L32FNER, fuel-optimized (TA-Luft), 100 kW/cylinder Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power 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 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 Cylinder arrangement: V-angle...
  • Page 27 Lube oil pressure after oil filter, shutdown Table 11: Lube oil system (referenced to max. power without HT heat extraction) Fuel system Number of cylinders Gas temperature before engine, min. °C See MTU Fluids and Lubricants Specifica- tions Gas temperature before engine, max.
  • Page 28 General operating data Number of cylinders Cold start capability: Air temperature (w/o starting aid, with preheating) - °C (case C) Site condition (to case C): Engine coolant temperature °C Minimum idling speed 1500 Limit speed for overspeed alarm/emergency shutdown 1900 Table 13: General operating data Starting (electric) Number of cylinders...
  • Page 29 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise filter) - DL (sound power dB(A) level LW, ISO 8528-10) Table 18: Acoustics MS150121/00E 2015-07 | Product Summary | 29...

  • Page 30: Engine Data 16V4000L32Fner, Fuel-Optimized (Ta-Luft), 110 Kw/Cylinder

    2.5.2 Engine data 16V4000L32FNER, fuel-optimized (TA-Luft), 110 kW/cylinder Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 31 Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh 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 Stroke...
  • Page 32 Lube oil pressure after oil filter, shutdown Table 26: Lube oil system (referenced to max. power without HT heat extraction) Fuel system Number of cylinders Gas temperature before engine, min. °C See MTU Fluids and Lubricants Specifica- tions Gas temperature before engine, max.
  • Page 33 Number of cylinders Minimum idling speed 1500 Limit speed for overspeed alarm/emergency shutdown 1900 Table 28: General operating data Starting (electric) Number of cylinders Rated starter power (standard design) 2 x 9 Rated starter voltage (standard design) Starter, current consumption, max. (standard design) 2 x 2500 Starting-attempt duration, max.
  • Page 34 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise filter) - DL (sound power dB(A) level LW, ISO 8528-10) Table 33: Acoustics 34 | Product Summary | MS150121/00E 2015-07...

  • Page 35: Monitoring, Control And Regulation Equipment

    2.6 Monitoring, Control and Regulation Equipment 2.6.1 Gas engine phase 3 system – Overview General overview 1 Plant system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 Humidity sensor (optional) 10 Ignition 3 Plant 7 Throttles 11 Compressor bypass 4 Engine Control Unit 8 Gas dosing unit 12 NOx sensor (optional)
  • Page 36 Anti-knock control AKR • Controls monitored cylinders with regard to knock characteristics. If knocking is detected, ignition is delayed for the cylinder concerned. The power is reduced if this does not lead to improvement. Gas control valve TecJet52 • Controls the required amount of gas Mixture throttles (P Series) •...

  • Page 37: 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 38 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring 38 | Product Summary | MS150121/00E 2015-07...

  • Page 39: 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-...

  • Page 40: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    3.2 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting the PowerPack into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...

  • Page 41: 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 157). Coolant circuit Check engine coolant level (→ Page 161); Check mixture coolant level (→...

  • Page 42: 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 43 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 44: Engine - Start

    3.5 Engine – Start Preconditions ☑Generator is not connected to network. ☑Start interlock is 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 45: 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 46: Emission Values - Check

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

  • Page 47: 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 48: 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 49 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 50: 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) 50 | Operation | MS150121/00E 2015-07...

  • Page 51: 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 52: 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 53: Maintenance Task Reference Table [Ql1]

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

  • Page 54: 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 55 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. MS150121/00E 2015-07 | Troubleshooting | 55...

  • Page 56: 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 145). temperatures is too high. 3.
  • Page 57 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 58 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 59 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 60 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 61 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 145). weighted average.
  • Page 62 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 145). weighted average.
  • Page 63 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 145). weighted average.
  • Page 64 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 145). weighted average.
  • Page 65 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 66 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 67 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 68 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 145). too high in comparison with 3. Check valve drive (exhaust valves do not close). weighted average.
  • Page 69 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 145). weighted average.
  • Page 70 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 145). weighted average.
  • Page 71 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 145). weighted average.
  • Page 72 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 145). weighted average.
  • Page 73 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 145). too high. 3. Check valve drive (exhaust valves do not close). 112706 –...
  • Page 74 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 145). too high. 3. Check valve drive (exhaust valves do not close). 112712 –...
  • Page 75 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 145). too high. 3. Check valve drive (exhaust valves do not close). 112718 –...
  • Page 76 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 77 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 78 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 79 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 80 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 81 1.4520.237 – OverSpeed Shutdown Red alarm. Initiated by IC922. Cause Corrective action u Restart ignition. Genset has exceeded admissible speed. 1.4520.238 – E2PROM Checksum Error Red alarm. Initiated by IC922. Cause Corrective action Hardware not ready for u Restart ignition. operation.
  • Page 82 1.4520.245 – Open Primary, Channel 1 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.246 – Open Primary, Channel 2 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 83 1.4520.252 – Open Primary, Channel 8 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.253 – Open Primary, Channel 9 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 84 1.4520.259 – Open Primary, Channel 15 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.260 – Open Primary, Channel 16 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 85 1.4520.271 – Warning Missing Reset Signal Yellow alarm. Initiated by IC922. Cause Corrective action u Check sensor B75, sensor distance and cabling; replace if Reset signal from crankshaft is missing. necessary. 1.4520.272 – Warn. Missing Camshaft Signal Yellow alarm. Initiated by IC922. Cause Corrective action Missing camshaft signal for...
  • Page 86 1.4530.008 – Alarm Yellow alarm. Initiated by F-Series. Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm (for details, refer to the source alarm). 1.4530.009 – Derating Active Yellow alarm. Initiated by F-Series. Cause Corrective action Combined alarm (for details, u Combined alarm (for details, refer to the source alarm).
  • Page 87 1.4530.015 – Input Supply Voltage Low Error Yellow alarm. Initiated by F-Series. Cause Corrective action Supply voltage has reached 1. Check supply voltage. minimum limit value. 2. Check cabling. 1.4530.016 – Electronics Temperature High Error Red alarm. Initiated by F-Series. Cause Corrective action Hardware not ready for...
  • Page 88 1.4530.022 – CAN Fault Red alarm. Initiated by F-Series. Cause Corrective action u Check cabling and setting. CAN bus connection faulty. 1.4540.009 – Zero Pressure Detected Yellow alarm. Initiated by TecJet. Cause Corrective action No gas pressure/gas flow u Check gas pressure. detected.
  • Page 89 1.4540.015 – FGT Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.016 – Delta P Fail High Red alarm. Initiated by TecJet. Cause Corrective action Differential pressure at TecJet 1. Check gas pressure. too high.
  • Page 90 1.4540.022 – Delta P Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet and configuration. Delta-p from TecJet below the set limit value. 1.4540.023 – FGP Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Gas pressure before TecJet is u Check TecJet and configuration.
  • Page 91 1.4540.029 – Battery Volt Low Error Red alarm. Initiated by TecJet. Cause Corrective action Supply voltage has reached 1. Check supply voltage. minimum limit value. 2. Check cabling. 1.4540.030 – FGT Low Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet.
  • Page 92 1.4540.036 – FGP High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.037 – Watchdog Reset Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 93 1.4540.044 – Parameter Version Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.045 – Main EEP Read Fail Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 94 1.4540.051 – Sense 12V Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.052 – ADC Test Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 95 1.4550.032 – A - Stop commanded (Run/Stop) Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting. ProAct setting is not correct. 1.4550.033 – A - Input (Supply) Voltage Fault Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action Upper or lower supply voltage 1.
  • Page 96 1.4550.039 – A - Demand Tracking Fault Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting. ProAct setting is not correct. 1.4550.040 – A - Analog Position Demand Failed Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action ProAct setting is not correct.
  • Page 97 1.4550.132 – B - Stop commanded (Run/Stop) Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action u Check setting. ProAct setting is not correct. 1.4550.133 – B - Input (Supply) Voltage Fault Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action Upper or lower supply voltage 1.
  • Page 98 1.4550.139 – B - Demand Tracking Fault Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action u Check setting. ProAct setting is not correct. 1.4550.140 – B - Analog Position Demand Failed Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action ProAct setting is not correct.

  • Page 99: Fault Messages - Engine Control Unit

    5.3 Fault messages – Engine Control Unit 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 100 021 – 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 145). value 1). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4.
  • Page 101 030 – SS Engine Overspeed Red alarm. Engine shutdown. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. 1. Check governor. This usually fault message 2. Check throttle closing position. usually follows other fault messages. Check governor, throttle closing position. 031 –...
  • Page 102 051 – 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 157). contaminated, coolant temperature too high.
  • Page 103 058 – SS P-Coolant Red alarm. Engine shutdown. Associated parameter 2.0101.922 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure after engine too low (limit value 2). Insufficient volume flow, static pressure too low. 063 – HI P-Crankcase Yellow alarm.
  • Page 104 068 – SS T-Coolant Red alarm. Engine shutdown. Associated parameter 2.0120.932 Cause Corrective action u Check engine coolant circuit. Coolant temperature after engine too high (limit value 2). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit. 089 –...
  • Page 105 092 – SS Starter Speed Not Reached Red alarm. Start terminated. Associated parameter 2.1090.923 Cause Corrective action u Check starter system. Minimum speed for flushing process and ignition release was not attained. 093 – SS T-Preheat Red alarm. Engine shutdown. Associated parameter 2.1090.922 Cause Corrective action...
  • Page 106 118 – 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 107 181 – AL CAN2 Node Lost Yellow alarm. Associated parameter 2.0500.681 Cause Corrective action u Check operation of bus stations and cabling. Buses (CAN bus 1 Bus node (SAM or EMU) lost on CAN bus 2. and CAN bus 2) are redundant. 182 –...
  • Page 108 187 – AL CAN1 Error Passive Yellow alarm. Associated parameter 2.0500.687 Cause Corrective action u Check operation of bus stations and cabling. CAN controller 1 has indicated a warning. Bus users (ECU, SAM or EMU) are faulty. 188 – AL CAN2 Bus Off Yellow alarm.
  • Page 109 204 – SD Level Lube Oil Red alarm. Engine shutdown. Associated parameter 1.8004.602 Cause Corrective action u Check sensor and cabling (B24), replace as necessary. Fault is Engine oil level sensor defective, short circuit or wire break. rectified following engine restart. 206 –...
  • Page 110 214 – 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 111 229 – AL Stop Camshaft Sensor Defect Red alarm. Engine shutdown. Associated parameter 1.8004.562 Cause Corrective action u Check sensor and cabling (B1.1), replace as 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 112 266 – 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 113 418 – SD T-Intake Air B Yellow alarm. Associated parameter 1.8004.603 Cause Corrective action u Check sensor and cabling (B49.2), replace as necessary. Intake air temperature sensor defective, short circuit or wire break. 419 – SD T-Coolant before Engine Red alarm. Associated parameter 1.8004.604 Cause Corrective action...
  • Page 114 431 – SS P-Coolant before Engine Red alarm. Engine shutdown. 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). Insufficient volume flow, static pressure too low. 434 –...
  • Page 115 447 – HIHI P-Charge Mix Diff. Red alarm. Engine shutdown. 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 116 457 – 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 shutdown. Associated parameter 2.0123.922 Cause Corrective action Intake air temperature is too low u Check ventilation system.
  • Page 117 478 – 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 YELLOW alarm from plant. 479 – AL Comb. Alarm Red (Plant) Red alarm. Engine shutdown. Associated parameter 2.8006.002 Cause Corrective action...
  • Page 118 499 – 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 119 517 – SD P-Charge Mix before Throttle Red alarm. Associated parameter 1.8004.631 Cause Corrective action u Check sensor and cabling (B79.23), replace as necessary. Fault Mixture pressure sensor before throttle defective, short circuit is rectified following engine restart. or wire break. 520 –...
  • Page 120 554 – AL Ignition Fault Red alarm. Associated parameter 2.1090.122 Cause Corrective action Ignition failure. Alarm is 1. Check ignition system. activated if the feedback signal 2. Check cabling. from ignition system is not received within a specified time- out period. Either the ignition could not be activated, the timeout period is set too short, or communication is faulty.
  • Page 121 560 – Mixture throttle B Red alarm. Engine shutdown. Associated parameter 1.1450.013 Cause Corrective action u Check mixture throttle on B side and cabling. Replace mixture A problem related to mixture throttle on B side occurred. throttle on B side as necessary. Possible causes: Mixture throttle defective, no power supply to throttle, cabling of feedback...
  • Page 122 569 – AL SAM Missing Data Fault Red alarm. Associated parameter 2.1090.128 Cause Corrective action u Check the cabling/connectors of the devices connected to This alarm is activated if the ECU does not receive some SAM and ECU bus. Replace devices as necessary. messages to be transmitted from SAM.
  • Page 123 583 – AL GLS closed Red alarm. Engine shutdown. Associated parameter 2.0451.115 Cause Corrective action Generator load switch does not 1. Check generator load switch. open when engine stops. Engine 2. Manually disconnect generator switch. is motoring. 3. Open any existing mains circuit breaker. 4.
  • Page 124 620 – HIHI Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.009 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has undershot the second limit value. 621 – LO NOx Value Yellow alarm. Associated parameter 2.3050.024 Cause Corrective action NOx emissions have undershot...
  • Page 125 633 – SD P-Ambient Air (HDT2800) none Associated parameter 1.0700.087 Cause Corrective action u Sensor currently not in standard scope of delivery. Air humidity sensor defect. 634 – SD T0-Ambient Air (HDT2800) none Associated parameter 1.0700.089 Cause Corrective action Air humidity sensor defect. u Sensor currently not in standard scope of delivery.
  • Page 126 650 – Al Req Angle Throttle B Red alarm. Associated parameter 2.1200.936 Cause Corrective action Opening angle of throttles B 1. Check charge-air pressure reserve. exceeded. 2. Intake air temperature outside TVU data. 3. Check compressor for contamination. 4. Reduce power. 651 –...
  • Page 127 655 – AL TecJet Comm Lost Red alarm. Associated parameter 1.4540.996 Cause Corrective action CAN bus communication for gas 1. Check cabling. control valve faulty 2. Check power supply. (alternatively, a stepper motor 3. Carry out restart of ECU, EMU & gas control valve. with gas mixer can be installed).
  • Page 128 664 – AL Oil Refill Error Red alarm. Associated parameter 1.1480.305 Cause Corrective action u After initiation of the alarms “HI Oil Refill” and Combined alarm for automatic oil replenishment faulty. “HI Lube Oil Level refill” a programmable timeout period starts. The engine is stopped when this time expires.
  • Page 129 669 – AL ProActA Yellow Yellow alarm. Associated parameter 1.4550.093 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm in throttle A was detected. genset control system. 670 – AL ProActB Yellow Yellow alarm.
  • Page 130 677 – AL FSeries Red Red alarm. Associated parameter 1.4530.991 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm in the bypass flap was detected. genset control system. 678 – AL TecJet Red Red alarm.
  • Page 131 685 – AL Lube Oil Min Red alarm. Associated parameter 1.1480.307 Cause Corrective action Minimum engine oil filling level 1. Check engine oil level (→ Page 157). detected. 2. Check replenishment system. 3. Fill oil. 686 – AL Lube Oil Max Red alarm.
  • Page 132 694 – SD T-Gas Yellow alarm. Associated parameter 1.8004.123 Cause Corrective action Gas temperature sensor 1. Not installed 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 133: 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 134: 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 135: 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 136 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 137: 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 138). Install new spark plug (→ Page 139). MS150121/00E 2015-07 | Task Description | 137...

  • Page 138: 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 139: 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 140 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 141: 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 142). Install spark plug connector (→ Page 143). MS150121/00E 2015-07 | Task Description | 141...

  • Page 142: 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 143: 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 144 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 145: 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 146: 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 138). Remove cylinder head covers (→...
  • Page 147 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 148 Install sleeves (arrow). Install cylinder head covers (→ Page 153). Install spark plugs with new sealing rings (→ Page 139). 148 | Task Description | MS150121/00E 2015-07...

  • Page 149: Valve Clearance - Check And Adjustment

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

  • Page 150: Adjusting Valve Clearance

    Checking valve clearance at two crankshaft positions 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 151: Valve Gear - Lubrication

    6.4.3 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 152). Fill oil chambers of rocker arms and adjust- ing screws with oil.

  • Page 152: 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 142). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 153: 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 154: Gas System

    6.5 Gas System 6.5.1 Gas supply - Checking gas lines for leaks Preconditions ☑Engine is stopped 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 155: 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 156: 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 157: 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 158: 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 159: 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 160: 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 161: 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 162: 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 163). Fill with engine coolant (→ Page 165). 162 | Task Description | MS150121/00E 2015-07...

  • Page 163: 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 164 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 164 | Task Description | MS150121/00E 2015-07...

  • Page 165: 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 166: Vent Line Of Engine Coolant Circuit Replacement

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

  • Page 167: 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 168: 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 169). Fill with fresh mixture coolant (→ Page 170). 168 | Task Description | MS150121/00E 2015-07...

  • Page 169: 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 170: 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 171: 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 172: Sensors – Overview

    6.11.2 Sensors – Overview Sensors – B side Illustrations are also applicable to 12 V. Item Name Monitoring of B49.2 Intake air temperature B81.2 Intake air pressure after filter B16.1 Coolant pressure after engine B4.X Exhaust temperature downstream of cylinder B79.22 Mixture pressure B side Mixture temperature...
  • Page 173 Sensors on engine driving end Item Name Monitoring of Nitrogen oxide (NOx) concentration in the exhaust B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.3 Crankshaft speed ignition Table 42: Sensors on engine driving end MS150121/00E 2015-07 | Task Description | 173...
  • Page 174 Sensors – A side Item Name Monitoring of B44.1 Turbocharger speed (optional) B79.21 Mixture pressure A side Crankcase pressure B5.3 Engine oil pressure before filter Engine oil temperature B5.1 Engine oil pressure after filter Table 43: Sensors – A side 174 | Task Description | MS150121/00E 2015-07...
  • Page 175 Sensors on engine free end Item Name Monitoring of B6.1 Coolant temperature after engine B4.21 Exhaust bulk temperature after turbocharger B6.3 Coolant temperature before engine B1.2 Camshaft speed for ignition system B1.3 Camshaft speed for antiknock control B1.1 Camshaft speed for engine governor Lube oil level B16.3 Coolant pressure before engine...

  • Page 176: Sensors – Removal

    6.11.3 Sensors – Removal Preconditions ☑Preparatory steps completed. ☑Provide containers for catching any fluids that escape. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ratchet adapter F30027340 WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 177 Removing NOx sensor (B88) Observe the following general information: • Arrangement and position of sensor (→ Page 172). Unfasten electrical connector (2) and re- move. Unscrew electronics box (1) at the eyelets. Remove sensor via nut (3). MS150121/00E 2015-07 | Task Description | 177...

  • Page 178: Sensor – Installation

    6.11.4 Sensor – Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Kluthe Hakuform 30-15) X00067260 O-ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→...

  • Page 179: 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 180 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 181: 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 182: Special Tools

    Y20098771 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 149) 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 134)
  • Page 183 Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 3.7 Emission values – Check (→ Page 46) Oil filter wrench Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 160) Ratchet adapter Part No.:...
  • Page 184 Used in: 6.3.2 Spark plug – Removal (→ Page 138) Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 139) Stroboscope (Not stocked by MTU) Part No.: Qty.: Used in: 6.3.7 Ignition system – Ignition timing check (→ Page 145)
  • Page 185 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 139) Qty.: Used in: 6.3.6 Spark plug connector – Installation (→ Page 143) Qty.: Used in: 6.11.4 Sensor – Installation (→ Page 178) Torque wrench, 60–320 Nm Part No.: F30452768...

  • Page 186: Index

     99 – Check   – Genset controller   – On engine  171 – Log  56 Contact person  – Key  54 – MTU Onsite Energy  181 Firing order 24 Control 42 Coolant  – Change  162 Gas engine phase 3 system  Cylinder  – Overview  35...
  • Page 187 – Startup, special instructions for applications with gas- eous fuel  10 Sensors  – Installation  178 – Overview  172 – Removal  176 Service partner  – MTU Onsite Energy  181 Spark plug  – Installation  139 – Removal  138 – Replacement  137 MS150121/00E 2015-07 | Appendix B | 187...

Table of Contents