MTU 12V 4000 L32 F Operating Instructions Manual
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MTU 12V 4000 L32 F Operating Instructions Manual

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Operating Instructions

Gas engine
12V 4000 L32 F
16V 4000 L32 F
MS150104/02E

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Summary of Contents for MTU 12V 4000 L32 F

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 12V 4000 L32 F 16V 4000 L32 F MS150104/02E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 4.3 Putting the engine into operation after scheduled out-of-service-period 1.1 Important provisions for all products 4.4 Control, starting and stopping sequences 1.2 Correct use of all products 4.5 Engine – Start 1.3 Personnel and organizational requirements 4.6 Operational checks 1.4 Safety regulations for initial start-up and 4.7 Emission values –...
  • Page 4 7.9.1 Engine coolant – Level check 7.9.2 Engine coolant – Change 8.1 Abbreviations 7.9.3 Engine coolant – Draining 8.2 MTU Onsite Energy contact person / service 7.9.4 Engine coolant – Filling partner 7.9.5 Vent line of engine coolant circuit –...

  • Page 5: Safety

    The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life.

  • Page 6: Correct Use Of All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...

  • Page 7: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 8: Safety Regulations For Initial Start-Up And Operation

    1.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up 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 9 Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live. Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times. MS150104/02E 2016-11 | Safety | 9...

  • Page 10: Safety Regulations For Startup And Operation, Specific Information For Gaseous Fuel Or Dual Fuel Supply Applications

    1.5 Safety regulations for startup and operation, specific information for gaseous fuel or dual fuel supply applications General safety regulations Requirement for the user: Check the gas train every time the product is started. During operation, the surface temperature of the gas-bearing parts must not fall below 5 °C anywhere within the vicinity of the product.
  • Page 11 • a manual shut-off valve • a gas filter Gas trains feature the following components in the direction of flow (MTU scope of supply): • two gas shut-off valves (automatic) • a pressure regulating device • a manual shut-off valve...

  • Page 12: Safety Regulations For Maintenance And Repair Work

    1.6 Safety regulations for maintenance and repair work Safety regulations when preparing to perform 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 13 Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g. components carrying oil, fuel, or air). Always seal connections with caps or covers if a line is removed or opened. Fit new seals when re-installing lines. Never bend lines and avoid damaging lines, particularly the fuel lines.
  • Page 14 Before starting work, pay attention to the following: • Vent the installation/removal device, the pumps and the pipework at the relevant designated points. • For hydraulic installation, screw on the tool with the piston retracted. • For hydraulic removal, screw on the tool with the piston extended. For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft end until correct sealing is established.
  • Page 15 Measuring component dimensions Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem- perature of 20 °C. MS150104/02E 2016-11 | Safety | 15...

  • Page 16: Safety Regulations For Maintenance And Servicing Work, Specific Information For Gaseous Fuel And Dual Fuel Supply Or Applications

    1.7 Safety regulations for maintenance and servicing work, specific information for gaseous fuel and dual fuel supply or applications Safety regulations for work prior to maintenance and servicing Assembly work shall be performed by specially trained/qualified and authorized personnel only. The gas supply shall be connected by trained/qualified and authorized personnel only.

  • Page 17: Fire Prevention And Environmental Protection, Fluids And Lubricants, Indirect Materials

    Indirect materials, fluids and lubricants may be hazardous or contain toxic substances. Observe the informa- tion provided in the safety data sheet for the product when using indirect materials and other chemical sub- stances. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Used oil Used oil contains harmful combustion residue.

  • Page 18: Compressed Air

    Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion. • Wear goggles when blowing off components or blowing away chips. • Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass) for drying purposes or to check for leaks risks bursting them.

  • Page 19: Fire Prevention And Environmental

    1.9 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials, specific information for gaseous fuel supply in gaseous-fuel or dual-fuel applications General notes on gas Observe the information contained in the safety data sheet of the gas used. Consult with gas supplier/utility. The gas used must comply with the (→...

  • Page 20: 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 21: 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 22: Product Summary

    3 Product Summary 3.1 Engine layout 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 23 1 Crankcase breather, oil sep- 7 Spark plug 13 Connection: engine coolant arator 8 Cylinder head cover inlet 2 Exhaust gas outlet connec- 9 Cylinder head 14 Engine oil heat exchanger tion 10 Engine oil sampling connec- 15 Connection: engine coolant 3 Gas control valve tion outlet...

  • Page 24: Engine Side And Cylinder Designations

    3.2 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 25: Engine - Main Dimensions

    3.3 Engine – Main dimensions Engine – Main dimensions Deviations from illustrations are insignificant. Also valid for 16V engines. Item Dimensions Length (A) for 12V approx. 2868 mm Length (A) for 16V approx. 3372 mm Width (B) for 12V approx. 1743 mm Width (B) for 16V approx.

  • Page 26: Firing Order

    3.4 Firing order Firing order Number of cylinders Firing order 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 26 | Product Summary | MS150104/02E 2016-11...

  • Page 27: Technical Data

    3.5 Technical Data 3.5.1 12 V 4000 L32F, 16 V 4000 L32F engine data, fuel optimized (TA-Luft) Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 28 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 29 Coolant system (LT circuit, referenced to max. power without HT heat extraction) Number of cylinders Coolant temperature before mixture cooler (at engine connection: °C inlet from cooling equipment (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric fllow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler (at nominal flow rate 8.56) Table 10: Coolant system (LT circuit, referenced to max.
  • Page 30 Number of cylinders Starter, current consumption, max. (standard design) 2500 2 x 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 14: Starting (electric) Capacities Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Liters Mixture coolant, engine side (without cooling system) Liters Total engine oil capacity for initial filling (standard oil system)

  • Page 31: 4000 L32F, 16 V 4000 L32F Engine Data, Emission Optimized (1/2 Ta-Luft)

    3.5.2 12 V 4000 L32F, 16 V 4000 L32F engine data, emission optimized (1/2 TA-Luft) Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 32 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 33 Coolant system (LT circuit, referenced to max. power without HT heat extraction) Number of cylinders Coolant temperature before mixture cooler (at engine connection: °C inlet from cooling equipment (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric fllow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler (at nominal flow rate 8.56) Table 25: Coolant system (LT circuit, referenced to max.
  • Page 34 Number of cylinders Starter, current consumption, max. (standard design) 2500 2 x 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 29: Starting (electric) Capacities Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Liters Mixture coolant, engine side (without cooling system) Liters Total engine oil capacity for initial filling (standard oil system)

  • Page 35: Monitoring, Control And Regulation Equipment

    3.6 Monitoring, Control and Regulation Equipment 3.6.1 Gas engine phase 4 system – Overview General overview 1 Unit system 5 Engine monitoring 9 Knock module 2 Engine system 6 Empty 10 Ignition 3 System 7 Throttles 11 Compressor bypass 4 Engine governor 8 Gas dosing unit 12 NOx sensor (optional) Governing/control/monitoring...
  • Page 36 Anti-knock control AKR • Controls monitored cylinders re. knock characteristics. If knocking is found, the ignition timing is retarded on the cylinder in question. If this does not result in an improvement, the power is reduced. Gas control valve TecJet52 •...

  • Page 37: Purpose Of The Units

    3.6.2 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 | Monitoring, Control and Regulation Equipment | MS150104/02E 2016-11...

  • Page 39: Operation

    4 Operation 4.1 Runtimes at partial load Gas engines are designed and optimized for continuous operation at 100 % load. The following restrictions apply to ensure maximum operational availability of the engine plant and to reduce maintenance to a minimum: Power range [kW Recommended max.

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

    4.2 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 41: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.3 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 187). Coolant circuit Check engine coolant level (→ Page 191); Check mixture coolant level (→...

  • Page 42: Control, Starting And Stopping Sequences

    4.4 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 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

    4.5 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 45: Operational Checks

    4.6 Operational checks DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 46: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas measuring and warning device (not stocked by MTU) WARNING Engine operation at high load/speed when measuring emissions. Risk of injury! • Conduct measuring in a room which offers safe protection from the engine if at all possible. If this is not feasible, keep the greatest possible distance away when measuring, e.g.
  • Page 47 Checking emission values Note: Open the exhaust gas test section and in- stall/remove measuring equipment only when the engine is at standstill. Apply the exhaust probe (1) at the measuring point (2). Start engine. Approach the measuring point until a stable operating state has been reached.

  • Page 48: Engine - Shutdown

    4.8 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 49: Engine - Emergency Shutdown

    4.9 Engine – Emergency 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 50 Remedy the cause, re-enable starting Item Measure Engine control system Determine cause for emergency stop and take remedial action; if the fault cannot be corrected, contact Service. 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 51: After Stopping The Engine - Engine Remains Ready For Operation

    4.10 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) MS150104/02E 2016-11 | Operation | 51...

  • Page 52: 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 53: Maintenance

    5 Maintenance 5.1 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 54: Maintenance Task Reference Table [Ql1]

    5.2 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 standalone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 55: 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 56 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. 56 | Troubleshooting | MS150104/02E 2016-11...

  • Page 57: Fault Messages In Genset Control System Log

    6.2 Fault messages in genset control system log 112222 – HI T-Exhaust Mean Yellow alarm. Initiated by EMU. Cause Corrective action Weighted average of all individual 1. Check emission values (→ Page 46). exhaust gas temperatures is too 2. Check ignition timing (→ Page 175). high.
  • Page 58 112304 – HI T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 59 112309 – HI T-Exhaust A9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 60 112314 – HI T-Exhaust B4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 61 112319 – HI T-Exhaust B9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 62 112404 – LO T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 63 112409 – LO T-Exhaust A9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 64 112414 – LO T-Exhaust B4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 65 112419 – LO T-Exhaust B9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 66 112504 – HIHI T-Exhaust A4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 67 112509 – HIHI T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 68 112514 – HIHI T-Exhaust B4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 69 112519 – HIHI T-Exhaust B9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high in comparison with weighted 3.
  • Page 70 112604 – LOLO T-Exhaust A4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 71 112609 – LOLO T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 72 112614 – LOLO T-Exhaust B4 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 73 112619 – LOLO T-Exhaust B9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 175). average.
  • Page 74 112705 – HIHI T-Exhaust A5 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high. 3. Check valve drive (exhaust valves do not close). 112706 –...
  • Page 75 112711 – HIHI T-Exhaust B1 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high. 3. Check valve drive (exhaust valves do not close). 112712 –...
  • Page 76 112717 – HIHI T-Exhaust B7 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 175). high. 3. Check valve drive (exhaust valves do not close). 112718 –...
  • Page 77 113601 – AL Gas Valve 1 feedback Red alarm. Initiated by EMU. Cause Corrective action Summary alarm, gas solenoid 1. Check valve 1 and cabling (→ Page 201). valve 1 feedback does not 2. Rectify cause of alarm. correspond with setpoint signal. 113602 –...
  • Page 78 1.4510.188 – Internal Error Red alarm. Initiated by anti-knock control. Cause Corrective action Hardware not ready for operation. 1. Restart knock module. 2. Replace knock module. 1.4510.189 – Error Camshaft Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from camshaft sensor 1.
  • Page 79 1.4510.196 – Knock Sensor Error A5 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling (→ Page 201). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 202). 1.4510.197 – Knock Sensor Error A6 Red alarm.
  • Page 80 1.4510.202 – Knock Sensor Error B1 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling (→ Page 201). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 202). 1.4510.203 – Knock Sensor Error B2 Red alarm.
  • Page 81 1.4510.208 – Knock Sensor Error B7 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling (→ Page 201). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 202). 1.4510.209 – Knock Sensor Error B8 Red alarm.
  • Page 82 1.4520.234 – Error Missing Camshaft Signal Red alarm. Initiated by IC922. Cause Corrective action u Check sensor B1.2, check sensor clearance and cabling, replace as Missing camshaft signal for ignition system. necessary (→ Page 202) (→ Page 201). 1.4520.235 – Error Number of Teeth Red alarm.
  • Page 83 1.4520.241 – Individual Timing out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified individual ignition timing 1. Adapt value in ECU parameter record. is beyond the valid range. 2. Check settings at ignition system. 1.4520.242 – Selftest Shutdown Yellow alarm.
  • Page 84 1.4520.249 – Open Primary, Channel 5 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil (→ Page 201). discharged. 2. Check ignition coils. 1.4520.250 – Open Primary, Channel 6 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 85 1.4520.256 – Open Primary, Channel 12 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil (→ Page 201). discharged. 2. Check ignition coils. 1.4520.257 – Open Primary, Channel 13 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 86 1.4520.264 – Open Primary, Channel 19 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil (→ Page 201). discharged. 2. Check ignition coils. 1.4520.265 – Open Primary, Channel 20 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 87 1.4520.275 – Odd Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adapt value in ECU parameter record. Specified energy level is beyond the valid range. 1.4520.276 – Even Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified energy level is beyond...
  • Page 88 1.4520.523 – MIC5 Stat W: invalid configuration Yellow alarm. Initiated by MIC5. Cause Corrective action The ignitions system settings are 1. Check ignition system settings in the Engine Control Unit. invalid. 2. Restart ignition control unit. 1.4520.524 – MIC5 Stat W: invalid trigger config Yellow alarm.
  • Page 89 1.4520.529 – MIC5 Stat Trigger supply volt. fail Red alarm. Initiated by MIC5. Cause Corrective action Malfunction in the auxiliary supply 1. Check cabling to sensor B1.2 (→ Page 201). voltage for the pulse sensor. 2. Check sensor B1.2 (→ Page 202). 3.
  • Page 90 1.4520.544 – MIC5 E1 Id of output board failed Red alarm. Initiated by MIC5. Cause Corrective action The characteristic data of the 1. Restart ignition control unit. output board is illegible or 2. Replace ignition control unit. corrupt. 1.4520.545 – MIC5 E1 Fail hi-voltage pow supply Red alarm.
  • Page 91 1.4520.550 – MIC5 E1 Tr1 synchronisation fault Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing Unable to synchronize with signal from pulse sensor 1 (B1.2). wheel. Replace sensor as necessary. (→ Page 202) (→ Page 201) 1.4520.551 –...
  • Page 92 1.4520.557 – MIC5 E1 Tr1 signal missing Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing Expected signal from pulse sensor 1 (B1.2) is missing. wheel. Replace sensor as necessary. (→ Page 202) (→ Page 201) 1.4520.558 –...
  • Page 93 1.4520.572 – MIC5 IPE Primary Open Cylinder 3 Red alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 201). cylinder 3 in ignition sequence. 2. Check ignition coil. 1.4520.573 – MIC5 IPE Primary Open Cylinder 4 Red alarm.
  • Page 94 1.4520.579 – MIC5 IPE Primary Open Cylinder 10 Red alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 201). cylinder 10 in ignition sequence. 2. Check ignition coil. 1.4520.580 – MIC5 IPE Primary Open Cylinder 11 Red alarm.
  • Page 95 1.4520.586 – MIC5 IPE Primary Open Cylinder 17 Red alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 201). cylinder 17 in ignition sequence. 2. Check ignition coil. 1.4520.587 – MIC5 IPE Primary Open Cylinder 18 Red alarm.
  • Page 96 1.4520.593 – MIC5 IPE Prim Short Circuit Cyl 4 Red alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 201). cylinder 4 in ignition sequence. 2. Check ignition coil. 1.4520.594 –...
  • Page 97 1.4520.600 – MIC5 IPE Prim Short Circuit Cyl 11 Red alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 201). cylinder 11 in ignition sequence. 2. Check ignition coil. 1.4520.601 –...
  • Page 98 1.4520.607 – MIC5 IPE Prim Short Circuit Cyl 18 Red alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 201). cylinder 18 in ignition sequence. 2. Check ignition coil. 1.4520.608 –...
  • Page 99 1.4520.614 – MIC5 ISE Secondary Open Cylinder 5 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit of 1. Check ignition lead, connector and igniter. cylinder 5 in ignition sequence. 2. Check ignition coil. 1.4520.615 – MIC5 ISE Secondary Open Cylinder 6 Yellow alarm.
  • Page 100 1.4520.621 – MIC5 ISE Secondary Open Cylinder 12 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit of 1. Check ignition lead, connector and igniter. cylinder 12 in ignition sequence. 2. Check ignition coil. 1.4520.622 – MIC5 ISE Secondary Open Cylinder 13 Yellow alarm.
  • Page 101 1.4520.628 – MIC5 ISE Secondary Open Cylinder 19 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit of 1. Check ignition lead, connector and igniter. cylinder 19 in ignition sequence. 2. Check ignition coil. 1.4520.629 – MIC5 ISE Secondary Open Cylinder 20 Yellow alarm.
  • Page 102 1.4520.635 – MIC5 ISE Secon Short Circuit Cyl 6 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition lead, connector and igniter. of cylinder 6 in ignition sequence. 2. Check ignition coil. 1.4520.636 – MIC5 ISE Secon Short Circuit Cyl 7 Yellow alarm.
  • Page 103 1.4520.641 – MIC5 ISE Secon Short Circuit Cyl 12 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition lead, connector and igniter. of cylinder 12 in ignition 2. Check ignition coil. sequence. 1.4520.642 – MIC5 ISE Secon Short Circuit Cyl 13 Yellow alarm.
  • Page 104 1.4520.647 – MIC5 ISE Secon Short Circuit Cyl 18 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition lead, connector and igniter. of cylinder 18 in ignition 2. Check ignition coil. sequence. 1.4520.648 – MIC5 ISE Secon Short Circuit Cyl 19 Yellow alarm.
  • Page 105 1.4520.661 – MIC5 E2 Tr2 polarity detection fail Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing Unable to detect polarity of pulse sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 202) (→ Page 201) 1.4520.662 –...
  • Page 106 1.4520.668 – MIC5 E2 Tr2 index to early / faulty Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing Index mark of pulse sensor 2 (B75) detected too early or faulty. wheel.
  • Page 107 1.4520.675 – MIC5 E2 Tr3 no index mark detected Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing Unable to detect index mark of pulse sensor 3 (B13.2). wheel. Replace sensor as necessary. (→ Page 202) (→ Page 201) 1.4520.676 –...
  • Page 108 1.4520.681 – MIC5 E2 Tr3 index to late / missing Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing Index mark of pulse sensor 3 (B13.2) detected too late or wheel.
  • Page 109 1.4530.013 – Analog Input Low Error Yellow alarm. Initiated by compressor bypass. Cause Corrective action u Check compressor bypass setting. Compressor bypass setting is not correct. 1.4530.014 – Input Supply Voltage High Error Yellow alarm. Initiated by compressor bypass. Cause Corrective action Supply voltage has reached 1.
  • Page 110 1.4530.019 – Run Enable not active Yellow alarm. Initiated by compressor bypass. Cause Corrective action u Check compressor bypass flap settings. Compressor bypass setting is not correct. 1.4530.020 – Spring Check Failed Yellow alarm. Initiated by compressor bypass. Cause Corrective action Compressor bypass setting is not u Check compressor bypass flap settings.
  • Page 111 1.4540.012 – Valve Position Error Red alarm. Initiated by TecJet. Cause Corrective action Unable to set the requested flap 1. Restart TecJet. control. 2. Check mechanical system. 3. Replace TecJet. 1.4540.013 – High Elec Temp Red alarm. Initiated by TecJet. Cause Corrective action Ambient temperature too high.
  • Page 112 1.4540.019 – Position Fail High Red alarm. Initiated by TecJet. Cause Corrective action Internal position sensor faulty. 1. Restart TecJet. 2. Replace TecJet. 1.4540.020 – Elec Temp Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Internal temperature sensor 1.
  • Page 113 1.4540.026 – Analog Input Low Error Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet setting. TecJet setting is not correct. 1.4540.027 – Analog Input High Error Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet setting. TecJet setting is not correct.
  • Page 114 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 (→ Page 201). 1.4540.034 – FGT High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Gas temperature before TecJet is...
  • Page 115 1.4540.041 – TecJet Internal Fault Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for operation. 1. Restart TecJet. 2. Replace TecJet. 1.4540.042 – Keyswitch State Red alarm. Initiated by TecJet. Cause Corrective action Secondary alarm following 1. Rectify cause of alarm. emergency engine stop.
  • Page 116 1.4540.048 – SPI ADC Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for operation. 1. Restart TecJet. 2. Replace TecJet. 1.4540.049 – Sense 5V Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for operation. 1.
  • Page 117 1.4540.055 – Factory CAL Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for operation. 1. Restart TecJet. 2. Replace TecJet. 1.4540.056 – PWM Duty Cycle High Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check TecJet setting.
  • Page 118 1.4550.036 – A - Temperature derating active Yellow alarm. Initiated by throttle flap A-Bank. Cause Corrective action Internal temperature above 1. Check room temperature and ventilation. 100ºC. Adjustment rate is 2. Restart throttle flap. reduced. 1.4550.037 – A - Temperature above 120 °C Red alarm.
  • Page 119 1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by throttle flap A-Bank. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 201). 2. Check throttle flap settings. 1.4550.044 – A - CAN Stop Command Yellow alarm.
  • Page 120 1.4550.136 – B - Temperature derating active Yellow alarm. Initiated by throttle flap B-Bank. Cause Corrective action Internal temperature above 1. Check room temperature and ventilation. 100ºC. Adjustment rate is 2. Restart throttle flap. reduced. 1.4550.137 – B - Temperature above 120°C Red alarm.
  • Page 121 1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by throttle flap B-Bank. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 201). 2. Check throttle flap settings. 1.4550.144 – B - CAN Stop Command Yellow alarm.

  • Page 122: Engine Control Unit - Fault Messages

    6.3 Engine Control Unit – Fault messages 015 – LO P-Lube Oil Yellow alarm. Associated parameter 2.0100.921 Cause Corrective action Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger. value 1). No oil in engine, engine 2.
  • Page 123 021 – 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 175). 1). Incorrect ignition timing, 3. Check mixture setting. mixture too lean or too rich, 4.
  • Page 124 030 – SS Engine Speed Red alarm. Engine shutdown. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. This 1. Check speed governor. usually fault message usually 2. Check throttle flap closing position. follows other fault messages. Check speed governor, throttle flap closing position.
  • Page 125 051 – 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 187). contaminated, coolant temperature too high.
  • Page 126 058 – 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 127 068 – 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 128 092 – SS No Starter Speed Red alarm. start is 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 129 118 – LO ECU 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 (→ Page 201). 119 – LOLO ECU Supply Voltage Red alarm. Associated parameter 2.0140.922 Cause Corrective action Supply voltage too low (limit value...
  • Page 130 181 – AL CAN2 Node Lost Red alarm. Engine shutdown. Associated parameter 2.0500.681 Cause Corrective action u Check operation of bus users and cabling. Buses (CAN bus 1 and Bus node (EMU) lost on CAN bus CAN bus 2) are redundant. 182 –...
  • Page 131 187 – AL CAN1 Error Passive Yellow alarm. Associated parameter 2.0500.687 Cause Corrective action u Check operation of bus users and cabling. CAN controller 1 signaled a warning. Possible causes may be, e.g. missing node, minor faults or temporary bus overload. 188 –...
  • Page 132 204 – 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 Engine oil level sensor faulty, short circuit or wire break. (→ Page 202) (→ Page 201). Error cleared after restarting the engine.
  • Page 133 214 – SD P-Crankcase Red alarm. Associated parameter 1.8004.568 Cause Corrective action u Check sensor and cabling (B50), replace as necessary Crankcase pressure sensor faulty, short circuit or wire break. (→ Page 202) (→ Page 201). Error cleared after restarting the engine.
  • Page 134 229 – 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 Engine stop due to camshaft sensor failure. (→ Page 202) (→ Page 201). Error cleared after restarting the engine.
  • Page 135 266 – SD Speed Demand Red alarm. Associated parameter 2.8006.586 Cause Corrective action Speed setting signal can no longer 1. Check Engine Control Unit setting (default setting is speed demand be transmitted from plant. via CAN bus). 2. Check signal and cabling between plant and ECU. 381 –...
  • Page 136 418 – 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 faulty, short circuit or wire break. (→ Page 202) (→ Page 201). 419 – SD T-Coolant b.Engine Red alarm.
  • Page 137 431 – 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 138 447 – HIHI P-Charge Mix Diff. Red alarm. Engine shutdown. Associated parameter 2.0183.932 Cause Corrective action Difference in mixture pressures 1. Check throttle flaps for varying positions and malfunction. sensed on A and B side is too high 2. Check mixture lines for leakage. (limit value 2).
  • Page 139 457 – 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 140 478 – AL Combined Alarm Yellow (System) Yellow alarm. Associated parameter 2.8006.001 Cause Corrective action u Summary alarm (for details, refer to the source alarm). Summary alarm YELLOW from system. 479 – AL Combined Alarm Red (System) Red alarm. Engine shutdown. Associated parameter 2.8006.002 Cause Corrective action...
  • Page 141 499 – SD T-Charge Mix Red alarm. Associated parameter 1.8004.632 Cause Corrective action u Check sensor and cabling (B73), replace as necessary Mixture temperature sensor faulty, short circuit or wire break. (→ Page 202) (→ Page 201). Error cleared after restarting the engine.
  • Page 142 515 – AL Starter Not Engaged Yellow alarm. Associated parameter 2.1090.926 Cause Corrective action Starter not engaged. ECU does 1. Check starter. not detect engine speed during 2. Check cabling (→ Page 201). starting sequence. 3. Check speed sensor B1.1 if speed is not indicated although engine is turning (→...
  • Page 143 535 – LOLO Power Difference Red alarm. Engine shutdown. Associated parameter 2.1005.921 Cause Corrective action Set and actual power deviate 1. Check converter. excessively from each other. 2. Check fuel settings. 3. Check emissions (→ Page 46). 536 – AL Wiring PWM_CM1 Red alarm.
  • Page 144 556 – AL GasValve Fault Red alarm. Associated parameter 2.1090.124 Cause Corrective action Gas supply solenoid valve faulty. 1. Check gas train. Alarm is active if there are 2. Check cabling (→ Page 201). problems with the gas supply solenoid valves. Either the gas supply solenoid valves are faulty, the timeout period is set too short, or communication is faulty.
  • Page 145 560 – AL mixture throttle B fault Red alarm. Engine shutdown. Associated parameter 1.1450.013 Cause Corrective action u Check mixture throttle flap on B side and cabling. Replace mixture A problem related to mixture throttle flap on B side occurred. throttle flap on B side as necessary.
  • Page 146 569 – 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 EMU This alarm is activated if the ECU does not receive some messages and ECU bus. Replace devices as necessary. to be transmitted from EMU.
  • Page 147 581 – AL Wiring PWM_CM3 Red alarm. Associated parameter 1.1041.923 Cause Corrective action u Check setting at Engine Control Unit. Wire break or short circuit on channel PWM_CM3. 583 – AL GLS closed Red alarm. Engine shutdown. Associated parameter 2.0451.115 Cause Corrective action Generator load switch does not...
  • Page 148 604 – AL Hut Changespeed max. Yellow alarm. Associated parameter 2.1210.910 Cause Corrective action u Check gas system. Excessively rapid change in gas quality. 606 – AL Double Nodes Lost CAN 1 + 2 Yellow alarm. Associated parameter 2.0500.691 Cause Corrective action Bus node (EMU) lost on CAN bus u Check operation of bus nodes and cabling (→...
  • Page 149 617 – LO Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.006 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has undershot the first limit value. 618 – LOLO Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.007 Cause Corrective action...
  • Page 150 622 – LOLO NOx Value Yellow alarm. Associated parameter 2.3050.025 Cause Corrective action NOx emissions have undershot 1. Check gas quality if feasible. the second limit value. 2. Check gas pressure. 3. Check NOx sensor (→ Page 202). 4. Check emissions (→ Page 46). 623 –...
  • Page 151 628 – AL Wiring PWM_CM10 Red alarm. Associated parameter 1.1041.930 Cause Corrective action u Check setting at Engine Control Unit. Wire break or short circuit on channel PWM_CM10. 642 – SD Electr. Motor Power AI2 Yellow alarm. Associated parameter 2.8006.040 Cause Corrective action Engine power sensor defect...
  • Page 152 651 – AL Preheating Error Yellow alarm. Associated parameter 1.1480.101 Cause Corrective action Engine preheating faulty. 1. Low coolant. 2. Missing differential pressure in coolant system. 3. Coolant pump does not start, is faulty. 652 – AL GET Comm Lost Red alarm.
  • Page 153 656 – AL ProActA Comm Lost Red alarm. Associated parameter 1.4550.096 Cause Corrective action CAN bus communication for 1. Check cabling (→ Page 201). throttle flap A faulty. 2. Check power supply. 3. Carry out restart of ECU, EMU and throttle flap A. 4.
  • Page 154 665 – AL GET Yellow Yellow alarm. Associated parameter 1.4510.993 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in knock control was detected. control system. 666 – AL IC92x Yellow Yellow alarm.
  • Page 155 671 – AL NOxA Yellow Yellow alarm. Associated parameter 1.4560.093 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm at NOx sensor A was detected. control system. 672 – AL NOxB Yellow Yellow alarm.
  • Page 156 679 – AL ProActA Red Red alarm. Associated parameter 1.4550.091 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in throttle flap A was detected. control system. 680 – AL ProActB Red Red alarm.
  • Page 157 688 – LO Oil Refill Yellow alarm. Associated parameter 1.1480.301 Cause Corrective action u Check oil replenishment system. No oil replenishment within a programmable time. 689 – HI Oil Refill Yellow alarm. Associated parameter 1.1480.303 Cause Corrective action Engine oil was refilled too often u Check engine oil level (→...
  • Page 158 842 – AL Fuel Throttle Pos. L1 Yellow alarm. Power reduction. Associated parameter 2.8006.038 Cause Corrective action u Check gas supply. TecJet throttle flap position has exceeded limit value 1. 848 – AL Rel. Humidity L1 Yellow alarm. Power reduction. Associated parameter 2.8006.039 Cause Corrective action...
  • Page 159 948 – AL ESI activated Red alarm. Associated parameter 2.8006.044 Cause Corrective action Emergency stop input has been 1. Rectify fault at source. activated. 2. Check cabling (→ Page 201). 972 – AL MIC5 Signature difference Red alarm. Associated parameter 1.4520.969 Cause Corrective action The ignition system has not...
  • Page 160 977 – AL CAN4 Error Passive Yellow alarm. Associated parameter 2.0500.695 Cause Corrective action u None CAN controller 4 has indicated a warning. 1012 – AL MIC5 parameter download active Yellow alarm. Associated parameter 1.4520.966 Cause Corrective action Parameter download from the u Wait until parameter downloading has been completed.
  • Page 161 1030 – LO P-Crank Case Yellow alarm. Associated parameter 2.0106.935 Cause Corrective action Crankcase pressure too low (limit 1. Check air filter for damage, replace if damage is visible . value 1). Restrictor valve in 2. Check setting of blow-by restrictor valve. crankcase breather is open too wide, air filter is faulty.

  • Page 162: Task Description

    7 Task Description 7.1 Engine 7.1.1 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 163: Machine Room - Check For Smell Of Gas

    7.1.2 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 164: Crankcase Breather

    7.2 Crankcase Breather 7.2.1 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 165 Remove locknut (1). Remove filter cover (3) with washer (2). Carefully lift out fine filter (6). Carefully lift out coalescer filter (5). Clean sealing faces and inside of housing. Check condition of gaskets on new fine filter and new coalescer filter. Note: The fine filter (6) must be installed in the cor- rect position in the housing.

  • Page 166: Ignition System

    7.3 Ignition System 7.3.1 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 167). Install new spark plug (→ Page 168). 166 | Ignition System | MS150104/02E 2016-11...

  • Page 167: Spark Plug - Removal

    7.3.2 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 168: Spark Plug - Installation

    7.3.3 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 169 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 170: Spark Plug Connector - Replacement

    7.3.4 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 171). Install spark plug connector (→ Page 173). 170 | Ignition System | MS150104/02E 2016-11...

  • Page 171: Spark Plug Connector - Removal

    7.3.5 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 172: Spark Plug Connector - Cleaning And Check

    7.3.6 Spark plug connector – Cleaning and check Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug connector with ignition cable (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Hot components/surfaces. Risk of burns! •...

  • Page 173: Spark Plug Connector - Installation

    7.3.7 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 174 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 175: 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 176: Valve Drive

    7.4 Valve Drive 7.4.1 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sliding depth gage, 200 mm Y20000918 Preparatory steps Remove igniters (→ Page 167). Remove cylinder head covers (→...
  • Page 177 Measuring valve protrusion Check TDC position of piston in cylinder A1: • The piston is at firing TDC when the rocker arms on cylinder A1 are unloaded. • The piston is at overlap TDC when the rocker arms on cylinder A1 are loaded. Measure protrusion at each valve in two crankshaft positions (firing TDC and overlap TDC) according to the diagram.
  • Page 178 Install sleeves (arrowed). Install cylinder head covers (→ Page 183). Install igniters with new sealing rings (→ Page 168). 178 | Valve Drive | MS150104/02E 2016-11...

  • Page 179: Valve Clearance - Check And Adjustment

    7.4.2 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...

  • Page 180: Adjusting Valve Clearance

    Position Cylinder 16 V Firing TDC in cylinder A1 Bank A – X I – – X I – I – – – Bank B I – I – – – – X – – – X – X Overlap TDC in cylinder A1 Bank A –...

  • Page 181: Valve Gear - Lubrication

    7.4.3 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 182). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 182: Cylinder Head Cover - Removal

    7.4.4 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 171). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 183: Cylinder Head Cover - Installation

    7.4.5 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 184: Gas System

    7.5 Gas System 7.5.1 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 185: Air Filter

    7.6 Air Filter 7.6.1 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 186: Air Filter – Removal And Installation

    7.6.2 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 187: Lube Oil System, Lube Oil Circuit

    7.7 Lube Oil System, Lube Oil Circuit 7.7.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Engine oil is hot. Engine oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! •...

  • Page 188: Engine Oil – Change

    7.7.2 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 Engine oil is hot.

  • Page 189: Engine Oil – Sample Extraction And Analysis

    7.7.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine.

  • Page 190: Oil Filtration / Cooling

    7.8 Oil Filtration / Cooling 7.8.1 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 Engine oil is hot.

  • Page 191: Circuit

    7.9 Coolant Circuit, General, High-Temperature Circuit 7.9.1 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 192: Engine Coolant – Change

    7.9.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 193). Fill with engine coolant (→ Page 195). 192 | Coolant Circuit, General, High-Temperature Circuit | MS150104/02E 2016-11...

  • Page 193: Engine Coolant – Draining

    7.9.3 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 194 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 194 | Coolant Circuit, General, High-Temperature Circuit | MS150104/02E 2016-11...

  • Page 195: Engine Coolant – Filling

    7.9.4 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 196: Vent Line Of Engine Coolant Circuit Replacement

    7.9.5 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 197: Low-Temperature Circuit

    7.10 Low-Temperature Circuit 7.10.1 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 198: Mixture Coolant – Change

    7.10.2 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 199). Fill with fresh mixture coolant (→ Page 200). 198 | Low-Temperature Circuit | MS150104/02E 2016-11...

  • Page 199: Mixture Coolant – Draining

    7.10.3 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 200: Mixture Coolant – Filling

    7.10.4 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 201: Wiring (General) For Engine/Gearbox/Unit

    7.11 Wiring (General) for Engine/Gearbox/Unit 7.11.1 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 202: Sensors – Overview

    7.11.2 Sensors – Overview Sensors – B-side Illustrations are also applicable to 12V engines. Item Description Monitoring of B49.2 Intake air temperature B81.2 Intake air pressure after filter B16.1 Coolant pressure after engine B4.X Exhaust temperature after cylinder B79.22 Mixture pressure B-side Mixture temperature Table 41: Sensors –...
  • Page 203 Sensors – Engine driving end Item Description Monitoring of Nitrogen oxide (NOx) concentration in the exhaust B79.23 Mixture pressure before restrictor flap Crankshaft speed, reset ignition system B13.3 Crankshaft speed ignition Table 42: Sensors – Engine driving end MS150104/02E 2016-11 | Wiring (General) for Engine/Gearbox/Unit | 203...
  • Page 204 Sensors – A-side Item Description 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 204 | Wiring (General) for Engine/Gearbox/Unit | MS150104/02E 2016-11...
  • Page 205 Sensors – Engine free end Item Description Monitoring of B6.1 Coolant temperature after engine B4.21 Exhaust bulk temperature after exhaust turbocharg- B6.3 Coolant temperature before engine B1.2 Camshaft speed for ignition system B1.3 Camshaft speed for AKR B1.1 Camshaft speed for engine governor Lube oil level B16.3 Coolant pressure before engine...

  • Page 206: Sensors – Removal

    7.11.3 Sensors – Removal Preconditions ☑ Preparatory steps have been carried out. ☑ 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 207 Removing NOx sensor (B88) Observe the following general information: • Arrangement and position of sensor (→ Page 202). Loosen and disconnect connector (2). Unscrew electronics box (1) at the eyelets. Remove sensor via nut (3). MS150104/02E 2016-11 | Wiring (General) for Engine/Gearbox/Unit | 207...

  • Page 208: Sensors – Installation

    7.11.4 Sensors – 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 209: 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 210 Abbreviation Meaning Explanation 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 211: 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 212: Special Tools

    9 Appendix B 9.1 Special Tools Angular screw driver Part No.: F30452765 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 179) Barring gear Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 162) Feeler gauge Part No.: Y20098771...
  • Page 213 Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 7.1.2 Machine room – Check for smell of gas (→ Page 163) Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 4.7 Emission values –...
  • Page 214 Ratchet head with extension Part No.: F30006212 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 162) Sliding depth gage, 200 mm Part No.: Y20000918 Qty.: Used in: 7.4.1 Valve protrusion – Measurement (→ Page 176) Socket wrench, 24 mm Part No.: F30029815 Qty.:...
  • Page 215 Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 7.3.8 Ignition system – Ignition timing check (→ Page 175) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 7.3.3 Spark plug – Installation (→ Page 168) Qty.: Used in: 7.3.7 Spark plug connector –...

  • Page 216: Index

     187 Engine sides  Cabling  – Designation  24 – Check   – On engine  201 Contact person  Fault messages  – MTU Onsite Energy  211 – Engine Control Unit  122 Control 42 – Genset control system log  57 Coolant  – Key  55 – Change  192...
  • Page 217 Safety requirements  – Safety notices, standards  20 Sensors  – Installation  208 – Overview  202 – Removal  206 Service partner  – MTU Onsite Energy  211 Spark plug  – Installation  168 – Removal  167 – Replacement  166 MS150104/02E 2016-11 | Index | 217...
  • Page 218 Spark plug connector  – Check  172 – Cleaning  172 – Installation  173 – Removal  171 – Replacement  170 Starting sequence 42 Stopping sequence 42 transport 21 Valve clearance  – Adjustment  179 – Check  179 Valve gear  – Lubrication  181 Valve protrusion  – Measurement  176 Vent line of engine coolant circuit ...

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