MTU 20V4000Lx2x Operating Instructions Manual
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MTU 20V4000Lx2x Operating Instructions Manual

MTU 20V4000Lx2x Operating Instructions Manual

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Operating Instructions

Gas engine
20V4000Lx2x
MS150122/00E

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  • Page 1: Operating Instructions

    Operating Instructions Gas engine 20V4000Lx2x MS150122/00E...
  • 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 Transport 3.11 After stopping the engine – Putting the 1.4 Safety regulations for startup and operation engine out of operation 1.5 Safety requirements for startup and...
  • Page 4 6.9.3 Engine coolant – Draining 6.9.4 Engine coolant – Filling 7.1 Abbreviations 6.10 Low-Temperature Circuit 7.2 MTU Onsite Energy contact person / service 6.10.1 Mixture coolant level – Check partner 6.10.2 Mixture coolant level – Check 6.10.3 Mixture coolant – Change 8 Appendix B 6.10.4 Mixture coolant –...

  • Page 5: Safety

    Nameplate, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi- cations.
  • Page 6 The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Replacing components with emission labels Emission labels are attached to all MTU engines. These must remain on the engine throughout its operational life.

  • 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 transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, and transport personnel at all times.

  • Page 8: Transport

    Setting the engine down after transport • Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. • Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

  • Page 9: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications 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 10: Safety Requirements For Startup And Operation, Special Instructions For Applications With Gaseous Fuel

    1.5 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

    1.6 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 12 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. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components.
  • Page 13 Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow electrolyte to come into contact with skin or clothing. Wear protective clothing, goggles and protective gloves. Do not place tools on the battery.

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

    1.7 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

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

  • Page 18: Standards For Safety Notices In The Text

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

  • Page 19: Product Summary

    2 Product Summary 2.1 Engine overview 1 Air filter/air inlet 6 Capacitor discharge ignition 11 Throttle 2 Mixture cooler system 12 Flywheel 3 Exhaust turbocharger, left- 7 Engine mounting bracket, 13 Engine governor/engine hand side free end monitoring 4 Exhaust turbocharger, right- 8 Oil pan KS Driving end hand side...
  • Page 20 1 Crankcase breather, oil sep- 6 Throttle 11 Engine oil filter arator 7 Spark plug 12 Oil level switch 2 Exhaust outlet 8 Cylinder head cover 13 Engine oil heat exchanger 3 Gas control valve 9 Cylinder head KGS Free end 4 Gas inlet connection 10 Engine oil sampling port 5 Ignition coil...

  • Page 21: 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 22: Engine - Main Dimensions

    2.3 Engine – Main dimensions Engine – Main dimensions Dimensions Item Length (A) for 20V approx. 3894 mm Width (B) for 20V approx. 1584 mm Height (C) for 20V approx. 2240 mm Crankshaft center to oil pan (D) approx. 636 mm Crankshaft center to engine mount (E) approx.

  • Page 23: Firing Order

    2.4 Firing order Firing order Firing order Number of cylin- ders A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS150122/00E 2015-07 | Product Summary | 23...

  • Page 24: Technical Data

    2.5 Technical Data 2.5.1 20V4000L32FNER engine data, optimized fuel consumption (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 25 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 26 Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooling equipment) (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over LT mixture cooler (at nominal flow rate 8.56) Table 10: Coolant system (LT circuit) Lube-oil system Number of cylinders...
  • Page 27 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 28 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 28 | Product Summary | MS150122/00E 2015-07...

  • Page 29: 20V4000L32Fner Engine Data, Optimized Fuel Consumption (Ta-Luft), 110 Kw/Cylinder

    2.5.2 20V4000L32FNER engine data, optimized fuel consumption (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 30 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...
  • Page 31 Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooling equipment) (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over LT mixture cooler (at nominal flow rate 8.56) Table 25: Coolant system (LT circuit) Lube-oil system Number of cylinders...
  • Page 32 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 28: General operating data Starting (electric) Number of cylinders...
  • Page 33 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 32: Acoustics MS150122/00E 2015-07 | Product Summary | 33...

  • Page 34: 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 35 Anti-knock control AKR • Controls monitored cylinders with regard to knock characteristics. If knocking is detected, ignition is de- layed 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 36: 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 37 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring MS150122/00E 2015-07 | Product Summary | 37...

  • Page 38: 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 39: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

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

  • Page 40: 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 155). Coolant circuit Check engine coolant level (→ Page 159); Check mixture coolant level (→...

  • Page 41: 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 requirement for gas engines, special procedures for engine start / stop are specified.
  • Page 42 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 43: 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 engine's danger zone.

  • Page 44: 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 45: Emission Values - Check

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

  • Page 46: Engine - Shutdown

    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 stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 47: 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 48 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 49: 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) MS150122/00E 2015-07 | Operation | 49...

  • Page 50: 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 51: 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 cylin- der head (with a new engine, after installation of new cylinder heads, after component maintenance or ex- tended component maintenance).

  • Page 52: 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 Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 53: Troubleshooting

    OEM (see documentation of the genset manufacturer). 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.
  • Page 54 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. 54 | Troubleshooting | MS150122/00E 2015-07...

  • Page 55: 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 individual 1. Check emission values. exhaust gas temperatures is too 2. Check ignition timing (→ Page 143). high.
  • Page 56 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 57 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 58 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 59 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 60 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 61 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 62 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 63 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 64 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 65 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 66 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 67 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 too 2. Check ignition timing (→ Page 143). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 68 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 69 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 70 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 71 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 too 2. Check emission values. low in comparison with weighted 3. Check ignition timing (→ Page 143). average.
  • Page 72 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 too 2. Check ignition timing (→ Page 143). high. 3. Check valve drive (exhaust valves do not close). 112706 –...
  • Page 73 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 too 2. Check ignition timing (→ Page 143). high. 3. Check valve drive (exhaust valves do not close). 112712 –...
  • Page 74 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 too 2. Check ignition timing (→ Page 143). high. 3. Check valve drive (exhaust valves do not close). 112718 –...
  • Page 75 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 76 1.4510.192 – Knock Sensor Error A1 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling. 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 sensor.
  • Page 77 1.4510.199 – Knock Sensor Error A8 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.200 – Knock Sensor Error A9 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock sensor.
  • Page 78 1.4510.206 – Knock Sensor Error B5 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.207 – Knock Sensor Error B6 Red alarm. Initiated by antiknock control. Cause Corrective action No signal from this knock sensor.
  • Page 79 1.4520.233 – Error Missing Reset Signal Red alarm. Initiated by IC922. Cause Corrective action u Check sensor, sensor distance and cabling; replace if necessary. Reset signal missing. 1.4520.234 – Error Missing Camshaft Signal Red alarm. Initiated by IC922. Cause Corrective action u Check sensor, sensor distance and cabling;...
  • Page 80 1.4520.240 – Unknown Timing or Energy Level Red alarm. Initiated by IC922. Cause Corrective action u Check cabling and setting. No global ignition timing and power level received, CAN bus connection is faulty. 1.4520.241 – Individual Timing out of Range Yellow alarm.
  • Page 81 1.4520.248 – Open Primary, Channel 4 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.249 – Open Primary, Channel 5 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 82 1.4520.255 – Open Primary, Channel 11 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.256 – Open Primary, Channel 12 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 83 1.4520.263 – Open Primary, Channel 18 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.264 – Open Primary, Channel 19 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 84 1.4520.274 – SCR Fault Even Red alarm. Initiated by IC922. Cause Corrective action u Restart ignition. Hardware not ready for operation. 1.4520.275 – Odd Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adjust value. Specified energy level is beyond the valid range.
  • Page 85 1.4530.011 – PWM Input Low Duty Cycle Error Yellow alarm. Initiated by F-Series. Cause Corrective action u Check setting. F-Series setting is not correct. 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.
  • Page 86 1.4530.018 – Position Error Red alarm. Initiated by F-Series. Cause Corrective action Position demand and feedback do 1. Check mechanical system. not match 2. Restart F-Series. 1.4530.019 – Run Enable not active Yellow alarm. Initiated by F-Series. Cause Corrective action F-Series setting is not correct.
  • Page 87 1.4540.011 – Flow Not Reached Red alarm. Initiated by TecJet. Cause Corrective action No gas flow detected. 1. Check inlet and outlet. 2. Check gas pressure, gas quality, gas filter, gas line for obstruction. 3. Check engine for overloading. 1.4540.012 – Valve Position Error Red alarm.
  • Page 88 1.4540.018 – Coil Current Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 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 –...
  • Page 89 1.4540.025 – Position Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 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 –...
  • Page 90 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 operation.
  • Page 91 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 u Check cabling. Keyswitch cabling missing. 1.4540.043 – Parameter Error Red alarm.
  • Page 92 1.4540.049 – Sense 5V Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.050 – Sense -9V Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.051 –...
  • Page 93 1.4550.031 – A - Internal Fault Red alarm. Initiated by ProAct A-Bank. Cause Corrective action u Restart ProAct. Hardware not ready for operation. 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.
  • Page 94 1.4550.038 – A - Loss of Position Demand Red alarm. Initiated by ProAct A-Bank. Cause Corrective action Position demand is missing or out 1. Check setting. of range 2. Check cabling. 1.4550.039 – A - Demand Tracking Fault Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action ProAct setting is not correct.
  • Page 95 1.4550.131 – B - Internal Fault Red alarm. Initiated by ProAct B-Bank. Cause Corrective action u Restart ProAct. Hardware not ready for operation. 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.
  • Page 96 1.4550.138 – B - Loss of Position Demand Red alarm. Initiated by ProAct B-Bank. Cause Corrective action Position demand is missing or out 1. Check setting. of range 2. Check cabling. 1.4550.139 – B - Demand Tracking Fault Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action ProAct setting is not correct.

  • Page 97: 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 98 021 – HI T-Exhaust B Yellow alarm. Associated parameter 2.0127.931 Cause Corrective action Exhaust gas temperature (B side) 1. Check exhaust turbocharger. after turbine too high (limit value 2. Check ignition timing (→ Page 143). 1). Incorrect ignition timing, 3. Check mixture setting. mixture too lean or too rich, 4.
  • Page 99 030 – SS Engine Overspeed Red alarm. Engine shutdown. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. This 1. Check governor. usually fault message usually 2. Check throttle closing position. follows other fault messages. Check governor, throttle closing position.
  • Page 100 051 – 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 155). contaminated, coolant temperature too high.
  • Page 101 058 – 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 102 068 – 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.
  • Page 103 092 – 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 104 118 – LO ECU Power Supply Voltage Yellow alarm. Associated parameter 2.0140.921 Cause Corrective action Supply voltage too low (limit value 1. Check supply voltage. 2. Check cabling. 119 – LOLO ECU Power Supply Voltage Red alarm. Associated parameter 2.0140.922 Cause Corrective action Supply voltage too low (limit value...
  • Page 105 181 – 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 106 187 – 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 107 204 – 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 108 214 – 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 109 229 – 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 110 266 – 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 111 418 – 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 112 431 – 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 113 447 – 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 high 2. Check mixture lines for leakage. (limit value 2).
  • Page 114 457 – 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 115 478 – 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 116 499 – 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 117 517 – 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 is Mixture pressure sensor before throttle defective, short circuit or rectified following engine restart. wire break. 520 –...
  • Page 118 554 – AL Ignition Fault Red alarm. Associated parameter 2.1090.122 Cause Corrective action Ignition failure. Alarm is activated 1. Check ignition system. if the feedback signal from 2. Check cabling. 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...
  • Page 119 560 – 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 120 569 – 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 SAM This alarm is activated if the ECU does not receive some messages and ECU bus. Replace devices as necessary. to be transmitted from SAM.
  • Page 121 583 – 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 122 621 – LO NOx Value Yellow alarm. Associated parameter 2.3050.024 Cause Corrective action NOx emissions have undershot 1. Check gas quality if feasible. the first limit value. 2. Check gas pressure. 3. Check NOx sensor. 4. Check emissions. 622 – LOLO NOx Value Yellow alarm.
  • Page 123 634 – SD T0-Ambient Air (HDT2800) none Associated parameter 1.0700.089 Cause Corrective action u Sensor currently not in standard scope of delivery. Air humidity sensor defect. 635 – SD Air humidity (HDT2800) none Associated parameter 1.0700.091 Cause Corrective action u Sensor currently not in standard scope of delivery. Air humidity sensor defect.
  • Page 124 650 – 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 125 655 – 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 (alternatively, 2. Check power supply. a stepper motor with gas mixer 3. Carry out restart of ECU, EMU & gas control valve. can be installed).
  • Page 126 664 – 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 127 670 – AL ProActB Yellow Yellow alarm. Associated parameter 1.4550.193 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal combined alarm in throttle B was detected. control system. 671 – AL NOxA Yellow Yellow alarm.
  • Page 128 678 – AL TecJet Red Red alarm. Associated parameter 1.4540.991 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal combined alarm in the gas control valve was detected. control system. 679 – AL ProActA Red Red alarm.
  • Page 129 686 – AL Lube Oil Max Red alarm. Associated parameter 1.1480.309 Cause Corrective action Maximum engine oil filling level 1. Check engine oil level (→ Page 155). detected. 2. Check replenishment system. 3. Drain oil. 688 – LO Oil Refill Yellow alarm.
  • Page 130 720 – AL T-Gas L2 Yellow alarm. Associated parameter 2.8006.035 Cause Corrective action u Check gas supply. Limit value 2 exceeded. 842 – AL Fuel Throttle Pos. L1 Yellow alarm. Associated parameter 2.8006.038 Cause Corrective action u Check gas supply. TecJet throttle position has exceeded limit value 1.

  • Page 131: 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 132: 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 133: 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 134 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 filter and new coalescence filter. Note: The fine filter (6) must be installed in the cor- rect position in the housing.

  • Page 135: 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 136). Install new spark plug (→ Page 137). MS150122/00E 2015-07 | Task Description | 135...

  • Page 136: 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 137: 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...
  • Page 138 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 139: 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 140). Install spark plug connector (→ Page 141). MS150122/00E 2015-07 | Task Description | 139...

  • Page 140: 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 141: 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 142 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 Teflon sleeve (1) with the article number facing downwards.

  • Page 143: 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 144: 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 136). Remove cylinder head covers (→...
  • Page 145 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 cylinder A1) according to the diagram.
  • Page 146 Install sleeves (arrow). Install cylinder head covers (→ Page 151). Install spark plugs with new sealing rings (→ Page 137). 146 | Task Description | MS150122/00E 2015-07...

  • Page 147: 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 150). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 148: 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...
  • Page 149 Position Cylin- Overlap TDC in cylinder Bank A – – I – – X I – – X I – – – – X Bank B – X I – – X – – I – – – – X I –...

  • Page 150: 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 140). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 151: 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 152: 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 153: 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 cor- responding fault message appears.

  • Page 154: 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 con- necting flange (1) of intake housing. Clean connecting flange (1) of the intake housing and check for obstructions.

  • Page 155: 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 156: 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 157: 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 158: 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 159: 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! •...

  • Page 160: 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 161). Fill with engine coolant (→ Page 163). 160 | Task Description | MS150122/00E 2015-07...

  • Page 161: 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 162 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 162 | Task Description | MS150122/00E 2015-07...

  • Page 163: 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 164: 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 165: Mixture Coolant Level – Check

    6.10.2 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 166: Mixture Coolant – Change

    6.10.3 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 167). Fill with fresh mixture coolant (→ Page 168). 166 | Task Description | MS150122/00E 2015-07...

  • Page 167: Mixture Coolant – Draining

    6.10.4 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 168: Mixture Coolant – Filling

    6.10.5 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 169: 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 170: Sensors – Overview

    6.11.2 Sensors – Overview Sensors on B-side, 20V Item Name Monitoring of B49.2 Intake air temperature, B side B81.2 Intake air pressure after filter, B side B44.2 Turbocharger speed, B side B16.1 Coolant pressure after engine B4.XX Exhaust gas temperature after cylinder XX B79.22 Mixture pressure, B side Mixture temperature...
  • Page 171 Sensors on driving end, 20V Item Name Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.3 Crankshaft speed ignition Table 41: Sensors – Engine, driving end, 20V MS150122/00E 2015-07 | Task Description | 171...
  • Page 172 Sensors on A-side, 20V Item Name Monitoring of B4.21 Exhaust bulk temperature after exhaust turbocharg- B81.1 Intake air pressure after filter, A side B49.1 Intake air temperature, A side 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...
  • Page 173 Sensors on free end, 20V Item Name Monitoring of B88.X Nitrogen oxide (NOx) concentration in exhaust gas B4.21 Exhaust bulk temperature after exhaust turbocharg- er, A side B16.3 Coolant pressure before engine B1.3 Camshaft speed for anti-knock control B1.1 Camshaft speed for engine governor Engine oil level B1.2 Camshaft speed ignition system...

  • Page 174: 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 175 Removing NOx sensor (B88) Observe the following general information: • Arrangement and position of sensor (→ Page 170). Unfasten electrical connector (2) and re- move. Unscrew electronics box (1) at the eyelets. Remove sensor via nut (3). MS150122/00E 2015-07 | Task Description | 175...

  • Page 176: 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 177: 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 178 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 179: 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...

  • Page 180: Special Tools

    Y20098771 Qty.: Used in: 6.4.3 Valve clearance – Check and adjustment (→ Page 148) 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 132)
  • Page 181 Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 3.7 Emission values – Check (→ Page 45) Oil filter wrench Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 158) Ratchet adapter Part No.:...
  • Page 182 Used in: 6.3.2 Spark plug – Removal (→ Page 136) Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 137) Stroboscope (Not stocked by MTU) Part No.: Qty.: Used in: 6.3.7 Ignition system – Ignition timing check (→ Page 143)
  • Page 183 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 137) Qty.: Used in: 6.3.6 Spark plug connector – Installation (→ Page 141) Qty.: Used in: 6.11.4 Sensor – Installation (→ Page 176) Torque wrench, 60–320 Nm Part No.: F30452768...

  • Page 184: Index

    Cabling  – Check   Gas engine phase 3 system  – On engine  169 – Overview  34 Contact person  Gas supply  – MTU Onsite Energy  179 – Check   Control 41 – Gas lines for leaks  152 Coolant  – Change  160 Cylinder ...
  • Page 185 – Startup, special instructions for applications with gas- eous fuel  10 Sensors  – Installation  176 – Overview  170 – Removal  174 Service partner  – MTU Onsite Energy  179 Spark plug  – Installation  137 – Removal  136 – Replacement  135 Spark plug connector  – Installation  141...

Table of Contents