MTU 12 V 4000 L62FB Operating Instructions Manual
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MTU 12 V 4000 L62FB Operating Instructions Manual

MTU 12 V 4000 L62FB Operating Instructions Manual

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Operating Instructions

Gas engine
12 V 4000 L62FB
16 V 4000 L62FB
MS150098/02E

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Summary of Contents for MTU 12 V 4000 L62FB

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 12 V 4000 L62FB 16 V 4000 L62FB MS150098/02E...
  • 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 8 Appendix A 7.9.1 Engine coolant – Level check 8.1 Abbreviations 7.9.2 Engine coolant – Change 8.2 MTU Onsite Energy contact person / service 7.9.3 Engine coolant – Draining partner 7.9.4 Engine coolant ‒ Filling 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. MS150098/02E 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. MS150098/02E 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 Illustrations are also applicable to 16V. 1 Throttle, B side 6 Engine lifting equipment 11 Starter 2 Engine governor/engine 7 Capacitor discharge ignition 12 Flywheel monitoring system KS Driving end 3 Air filter/air intake 8 Engine mounting bracket, 4 Mixture cooler free end...
  • Page 23 1 Crankcase breather, oil sep- 7 Spark plug 13 Engine coolant inlet connec- arator 8 Cylinder head cover tion 2 Gas outlet connection 9 Cylinder head 14 Engine oil heat exchanger 3 Gas control valve 10 Engine oil sampling connec- 15 Engine coolant outlet con- 4 Gas inlet connection tion...

  • 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 Length (A) 12V approx. 2825.5 mm Length (A) 16V approx. 3348 mm Width (B) 12V approx. 1751 mm Width (B) 16V approx. 1797 mm Height (C) 12V approx. 2193 mm Height (C) 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 | MS150098/02E 2016-11...

  • Page 27: Technical Data

    3.5 Technical Data 3.5.1 12V 4000 L62FB, 16V 4000 L62FB engine data, fuel-optimized (TA-Luft) Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Reference value L Limit value up to which the engine can be operated without changes, e.g. to the power setting. N Non-defined value - Not applicable X Applicable...
  • Page 28 Number of cylinders Gas type: Biogas 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: Fuel System

    Coolant system (LT circuit) 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 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 30: Exhaust Emissions

    Number of cylinders Starting-attempt duration, max. Number of teeth on starter ring gear Table 14: Starter (electric) Capacities Number of cylinders Engine coolant, engine side (w/o cooling equipment) Liters Engine coolant, mixture cooler side (w/o cooling equipment) Liters Total engine oil capacity for initial filling (standard oil system) Liters Oil change capacity, max.

  • Page 31: Monitoring, Control And Regulation Equipment

    3.6 Monitoring, Control and Regulation Equipment 3.6.1 Gas engine phase 3 system – Overview Overview 1 Unit system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 NOx sensor (option) 10 Gas dosing unit 3 System 7 Compressor bypass 11 Throttles 4 Engine governor 8 Ignition...
  • Page 32 Ignition system (IC922) • Adjusts ignition timing for cylinders 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 (TecJet110) •...

  • Page 33: Purpose Of The Units

    3.6.2 Purpose of the units Engine governor ADEC (ECU 7) Central control and monitoring unit for the engine • Communication with other units and higher-level systems via CAN bus • Control of throttles (mixture and gas) • Acquisition and evaluation of engine operating states •...
  • Page 34 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring 34 | Monitoring, Control and Regulation Equipment | MS150098/02E 2016-11...

  • Page 35: 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 36: 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 engine into operation after extended out-of-service-periods (>3 months) Item...

  • Page 37: 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 153). Coolant circuit Check engine coolant level (→ Page 157); Check mixture coolant level (→...

  • Page 38: 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 start 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 39 Emergency stop sequence If an emergency stop command is activated, the following steps are carried out automatically: 1. Closing gas supply solenoid valves and mixture throttles 2. Mixture throttles close 3. Coasting down engine to standstill for a maximum coasting period 4.

  • Page 40: 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 41: 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 Gaseous fuels are combustible/explosive.

  • Page 42: 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 43 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 44: 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 45: Engine - Emergency Shutdown

    4.9 Engine – Emergency shutdown NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Engine – Emergency shutdown Item Measure Gas shut-off valves with con- Two contacts are available for connection to the electrical system.

  • Page 46: 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) 46 | Operation | MS150098/02E 2016-11...

  • Page 47: After Stopping The Engine - Putting The Engine Out Of Operation

    If the engine is to remain out of service for more than 1 week, seal the en- tems gine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Preservation and Represerva- tion Specifications A001070/..). Starting system Disconnect electric starter from power supply.

  • Page 48: 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 49: 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 50: 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 51 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. MS150098/02E 2016-11 | Troubleshooting | 51...

  • Page 52: Fault Messages On Genset Control System Log

    6.2 Fault messages on 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. exhaust gas temperatures is too 2. Check ignition timing (→ Page 140). high.
  • Page 53 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 54 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 55 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 56 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 57 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 58 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 59 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 60 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 61 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 62 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 63 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 64 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 140). high in comparison with weighted 3. Check valve drive (exhaust valves do not close). average.
  • Page 65 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 66 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 67 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 68 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. high in comparison with weighted 3. Check ignition timing (→ Page 140). average.
  • Page 69 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 140). high. 3. Check valve drive (exhaust valves do not close). 112706 –...
  • Page 70 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 140). high. 3. Check valve drive (exhaust valves do not close). 112712 –...
  • Page 71 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 140). high. 3. Check valve drive (exhaust valves do not close). 112718 –...
  • Page 72 113601 – AL Gas Valve 1 feedback Red alarm. Initiated by SAM. 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 SAM. Cause Corrective action Emergency stop detected.
  • Page 73 1.4540.014 – Elec Temp Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.015 – FGT Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.016 –...
  • Page 74 1.4540.022 – Delta P Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet and configuration. Delta-p via TecJet below set limit value. 1.4540.023 – FGP Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Gas pressure before TecJet is u Check TecJet and configuration.
  • Page 75 1.4540.029 – Battery Volt Low Error Red alarm. Initiated by TecJet. Cause Corrective action Supply voltage has reached 1. Check supply voltage. minimum limit value. 2. Check cabling. 1.4540.030 – FGT Low Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for operation.
  • Page 76 1.4540.036 – FGP High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.037 – Watchdog Reset Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.038 –...
  • Page 77 1.4520.234 – Error Missing Camshaft Signal Red alarm. Initiated by IC922. Cause Corrective action u Check sensor, sensor distance and cabling, replace as necessary. No camshaft signal. 1.4520.235 – Error Number of Teeth Red alarm. Initiated by IC922. Cause Corrective action Incorrect number of teeth on 1.
  • Page 78 1.4520.241 – Individual Timing out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adjust value. Specified individual ignition timing is beyond the valid range. 1.4520.242 – Selftest Shutdown Yellow alarm. Initiated by IC922. Cause Corrective action Self-test is active with the engine u Restart ignition.
  • Page 79 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. 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 80 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. 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 81 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. 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 82 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. 1.4520.276 – Even Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified energy level is beyond...
  • Page 83 1.4510.193 – Knock Sensor Error A2 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.194 – Knock Sensor Error A3 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor.
  • Page 84 1.4510.200 – Knock Sensor Error A9 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.201 – Knock Sensor Error A10 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor.
  • Page 85 1.4510.207 – Knock Sensor Error B6 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.208 – Knock Sensor Error B7 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor.
  • Page 86 1.4530.009 – Derating Active Yellow alarm. Initiated by F-series. Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm (for details, refer to the source alarm). 1.4530.010 – PWM Input High Duty Cycle Error Yellow alarm. Initiated by F-series. Cause Corrective action F-series setting is incorrect.
  • Page 87 1.4530.016 – Electronics Temperature High Error Red alarm. Initiated by F-series. Cause Corrective action u Restart F-series. Hardware not ready for operation. 1.4530.017 – Electronics Temperature Low Error Red alarm. Initiated by F-series. Cause Corrective action u Restart F-series. Hardware not ready for operation. 1.4530.018 –...
  • Page 88 1.4550.032 – A - Stop commanded (Run/Stop) Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting. ProAct setting is incorrect. 1.4550.033 – A - Input (Supply) Voltage Fault Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action Supply voltage has reached 1.
  • Page 89 1.4550.039 – A - Demand Tracking Fault Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting. ProAct setting is incorrect. 1.4550.040 – A - Analog Position Demand Failed Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting.
  • Page 90 1.4550.133 – B - Input (Supply) Voltage Fault Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action Supply voltage has reached 1. Check supply voltage. maximum or minimum limit value. 2. Check cabling. 1.4550.134 – B - Position Error Red alarm. Initiated by ProAct A-Bank. Cause Corrective action Position specification and...
  • Page 91 1.4550.140 – B - Analog Position Demand Failed Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting. ProAct setting is incorrect. 1.4550.141 – B - PWM Position Demand Failed Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check setting.

  • Page 92: Engine Governor - Fault Messages

    6.3 Engine governor – 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. Replace oil filter (→ Page 156). speed too low, oil lines, oil heat 3.
  • Page 93 021 – 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 140). 1). Incorrect ignition timing, 3. Check mixture setting. mixture too lean or too rich, 4.
  • Page 94 030 – 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 of governor, throttle closing position 031 –...
  • Page 95 051 – 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 153). contaminated, coolant temperature too high.
  • Page 96 058 – 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 97 068 – 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 98 092 – 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 99 118 – 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 100 176 – AL LifeData not available Red alarm. Associated parameter 2.4000.004 Cause Corrective action u Contact Service. (Configuration fault) No (suitable) LifeData backup system available following timeout expiry after ECU reset. Backup system has no LifeData feature or CAN bus to backup system is disrupted.
  • Page 101 183 – AL CAN No PU Data Red alarm. Associated parameter 2.0500.683 Cause Corrective action u Contact Service. (Configuration fault) The selected CAN mode initializes communication by means of the PU data module. However, the necessary PU data module is not present or is invalid.
  • Page 102 189 – AL CAN2 Error Passive Yellow alarm. Associated parameter 2.0500.689 Cause Corrective action u Check operation of bus users and cabling. CAN controller 2 has indicated a warning. Some reasons are, for example, no corresponding node, minor malfunctions or temporary bus overload.
  • Page 103 207 – SD T-Exhaust B Yellow alarm. Associated parameter 1.8004.577 Cause Corrective action u Check sensor and cabling (B4.22), replace if necessary. Fault is Exhaust temperature sensor on B side defective, short circuit or rectified following engine restart. wire break. 211 –...
  • Page 104 219 – SD T-Intake Air Yellow alarm. Associated parameter 1.8004.573 Cause Corrective action u Check sensor and cabling (B49.2), replace as necessary. Fault is Intake air temperature sensor defective, short circuit or wire rectified when engine is restarted. break. 221 – SD P-Diff Lube Oil Red alarm.
  • Page 105 232 – SD ETC Speed 1 Yellow alarm. Associated parameter 1.3011.128 Cause Corrective action u Turbocharger speed sensor is not fitted at present. Speed sensor of primary turbocharger defective, short circuit or wire break. 233 – SD ETC Speed 2 Yellow alarm.
  • Page 106 382 – AL Wiring TOP 2 Red alarm. Associated parameter 2.8006.639 Cause Corrective action u Check cabling. Short circuit or wire break on transistor output, plant-side 2 (TOP 2). Activation of red combined alarm faulty. 383 – AL Wiring TOP 3 Red alarm.
  • Page 107 423 – LO P-Coolant Diff. Red alarm. Engine shutdown. Associated parameter 2.0180.921 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant differential pressure too low (limit value 1). Insufficient volume flow. 429 – HI P-Coolant Red alarm. Engine shutdown. Associated parameter 2.0101.931 Cause Corrective action...
  • Page 108 435 – SS T-Coolant Before Engine Red alarm. Engine shutdown. Associated parameter 2.0173.932 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant temperature before engine too high (limit value 2). Engine coolant pump failure, flow too low, air in engine cooling system.
  • Page 109 452 – HIHI T-Charge Mix Red alarm. Engine shutdown. Associated parameter 2.0169.932 Cause Corrective action Mixture temperature too high 1. Check mixture cooling circuit. (limit value 2). Mixture coolant 2. Check mixture cooler for dirt. pump failure, volumetric flow too low, cooling system inlet temperature too high, mixture cooler clogged.
  • Page 110 459 – SD P-Coolant b. Engine Red alarm. Associated parameter 1.8004.627 Cause Corrective action u Check sensor and cabling (B16.3), replace if necessary. Fault is Coolant pressure sensor before engine defective, short circuit or rectified following engine restart. wire break. 470 –...
  • Page 111 479 – AL Comb. Alarm Red (Plant) Red alarm. Engine shutdown. Associated parameter 2.8006.002 Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm RED from plant. 496 – SD P-Charge Mix A Red alarm. Engine shutdown. Associated parameter 1.8004.628 Cause Corrective action...
  • Page 112 511 – HIHI P-Charge Mix A Red alarm. Engine shutdown. Associated parameter 2.0181.932 Cause Corrective action Mixture pressure on A side too 1. Check emissions. high (limit value 2). 2. Check ignition timing (→ Page 140). 3. Check exhaust back pressure. 4.
  • Page 113 520 – SD P-Intake Air after Filter A Yellow alarm. Associated parameter 1.0186.900 Cause Corrective action u Check sensor and cabling (B81.1), replace if necessary. Fault is Intake air pressure sensor after filter on A side defective, short rectified following engine restart. circuit or wire break.
  • Page 114 543 – AL Multiple FDH Slaves Yellow alarm. Associated parameter 2.0555.005 Cause Corrective action u Contact Service. (Configuration fault) There is more than one device activated as backup medium for FDH. 544 – AL Configuration Changed Yellow alarm. Associated parameter 2.0555.003 Cause Corrective action This fault becomes active in cases...
  • Page 115 556 – 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. 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 116 565 – AL L1 P-Intake Air after Filter A Yellow alarm. Associated parameter 2.0186.921 Cause Corrective action u Replace air filter (→ Page 151). Pressure loss over air filter on A side is too high. 566 – AL L2 P-Intake Air after Filter A Yellow alarm.
  • Page 117 570 – L1 Al CAN Max. Retarded Timing Yellow alarm. Associated parameter 2.1200.931 Cause Corrective action The cylinder set to maximum 1. Check emissions. retarded timing due to knocking 2. Check ignition timing (→ Page 140). has violated the first limit value. 3.
  • Page 118 618 – LOLO Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.007 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has undershot the second limit value 619 – HI Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.008 Cause Corrective action...
  • Page 119 623 – HI NOx Value Yellow alarm. Associated parameter 2.3050.026 Cause Corrective action NOx emissions have exceeded the 1. Check gas quality if feasible. first limit value 2. Check NOx sensor. 3. Check emissions. 624 – HIHI NOx Value Yellow alarm. Associated parameter 2.3050.027 Cause Corrective action...
  • Page 120 646 – Al Knock Intensity Red alarm Associated parameter 2.1200.934 Cause Corrective action Knock intensity exceeded 1. Check gas quality if feasible (methane number). (extreme knocking detected) 2. Check emissions. 3. Check combustion chamber. 649 – Al Req Angle Throttle A Red alarm Associated parameter 2.1200.935 Cause...
  • Page 121 653 – AL IC92x Comm Lost Red alarm Associated parameter 1.4520.996 Cause Corrective action CAN bus communication for 1. Check cabling. ignition system faulty 2. Check power supply. 3. Carry out restart of ECU, EMU & knock control. 4. Check settings with device-specific dialog software (in device). 654 –...
  • Page 122 658 – AL NOxA Comm Lost Red alarm Associated parameter 1.4560.096 Cause Corrective action CAN bus communication for NOx 1. Check cabling. sensor A faulty 2. Check power supply. 3. Carry out restart of ECU and EMU. 4. Replace sensor. 659 –...
  • Page 123 665 – 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 combined alarm in knock control was detected control system 666 – AL IC92x Yellow Yellow alarm Associated parameter 1.4520.993 Cause...
  • Page 124 671 – 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 combined alarm at NOx sensor A was detected control system 672 – AL NOxB Yellow Yellow alarm Associated parameter 1.4560.193 Cause...
  • Page 125 677 – AL FSeries Red Red alarm Associated parameter 1.4530.991 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal combined alarm in the bypass flap was detected control system 678 – AL TecJet Red Red alarm Associated parameter 1,4540.991 Cause...
  • Page 126 683 – AL PhyA Red Red alarm Associated parameter 1.4570.091 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal combined alarm at step motor A was detected control system 684 – AL PhyB Red Red alarm Associated parameter 1.4570.191 Cause...
  • Page 127 691 – HI Lube Oil Level Refill. Yellow alarm Associated parameter 1.1480.311 Cause Corrective action u Check engine oil level. Check oil supply. Engine oil was refilled too often within a certain time interval. 694 – SD T-Gas Yellow alarm Associated parameter 1.8004.123 Cause Corrective action...

  • Page 128: 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 129: Checking Machine Room For Smell Of Gas

    7.1.2 Checking machine room 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 130: 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 131 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 132: 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 133). Install new spark plug (→ Page 134). 132 | Ignition System | MS150098/02E 2016-11...

  • Page 133: 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 DANGER Live components, flash-over.

  • Page 134: 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 135 Note: Make sure that the color code of the spark plugs is identical. Screw spark plug into cylinder head (1). Note: The temperature of spark plug and cylinder head (1) must be the same prior to tightening. Use torque wrench to tighten spark plug to specified tightening torque. Name Size Type...

  • Page 136: 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 137). Install spark plug connector (→ Page 138). 136 | Ignition System | MS150098/02E 2016-11...

  • Page 137: 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. DANGER Live components, flash-over. Risk of serious injury - danger to life! •...

  • Page 138: Spark Plug Connector - Installation

    7.3.6 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 cable (→...
  • Page 139 Fit protective cap (2) and check for correct seating. MS150098/02E 2016-11 | Ignition System | 139...

  • Page 140: 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 141: Valve Drive

    7.4 Valve Drive 7.4.1 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.
  • Page 142 Diagram for 12V engines – Two crankshaft positions Diagram for 16V engines – Two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...

  • Page 143: Adjusting Valve Clearance

    Adjusting valve clearance Release locknut (1). Insert feeler gage between valve bridge and rocker arm. Using offset screwdriver, set adjusting screw (2) such that specified valve clearance is set. Feeler gage must just pass through the gap. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to prevent it from turning.

  • Page 144: Valve Protrusion - Measurement

    7.4.2 Valve protrusion – 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 133). Remove cylinder head covers (→ Page 148). Remove sleeves (arrow).
  • Page 145 Valve protrusion – Measurement 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 protrusion for each valve in two crankshaft positions (firing TDC and overlap TDC cylinder A1) according to the diagram.
  • Page 146 Install sleeves (arrow). Install cylinder head covers (→ Page 149). Install spark plugs with new sealing rings (→ Page 134). 146 | Valve Drive | MS150098/02E 2016-11...

  • Page 147: 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 148). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 148: 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 137). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 149: 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 150: Gas System

    7.5 Gas System 7.5.1 Gas supply - Checking gas lines for leaks Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Leak identification spray Soap suds WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! •...

  • Page 151: 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 152: 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 153: 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 154: 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 155: 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 156: 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 157: 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 158: 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 159). Fill with engine coolant (→ Page 161). 158 | Coolant Circuit, General, High-Temperature Circuit | MS150098/02E 2016-11...

  • Page 159: 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 160 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 160 | Coolant Circuit, General, High-Temperature Circuit | MS150098/02E 2016-11...

  • Page 161: 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 162: 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 163: 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 164: 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 165). Fill with fresh mixture coolant (→ Page 166). 164 | Low-Temperature Circuit | MS150098/02E 2016-11...

  • Page 165: 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 166: 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 167: 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 168: Sensors – Overview

    7.11.2 Sensors – Overview Sensors on B side Illustrations are also applicable to 12V. Pos. Designation Monitoring of B49.2 Intake air temperature B side B81.2 Intake air pressure after filter B side B16.1 Coolant pressure after engine B4.X Exhaust temperature after cylinder B79.22 Mixture pressure B side Mixture temperature...
  • Page 169 Sensors on driving end Pos. Designation Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset B13.2 Crankshaft speed, ignition system Table 24: Sensors on driving end MS150098/02E 2016-11 | Wiring (General) for Engine/Gearbox/Unit | 169...
  • Page 170 Sensors on A side Pos. Designation Monitoring of B79.21 Mixture pressure A side Crankcase pressure B5.1 Engine oil pressure after filter Engine oil temperature B5.3 Engine oil pressure before filter Table 25: Sensors on A side 170 | Wiring (General) for Engine/Gearbox/Unit | MS150098/02E 2016-11...
  • Page 171 Sensors on free end Pos. Designation Monitoring of B4.21 Exhaust bulk temperature A side B16.3 Coolant pressure before engine B1.3 Camshaft speed, knock module B1.2 Camshaft speed, ignition system B1.1 Camshaft speed, engine governor Engine oil level B6.3 Coolant temperature before engine B6.1 Coolant temperature after engine Table 26: Sensors on free end...

  • Page 172: 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 173 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 174: 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 175: Special Tools

    Part No.: Y20098771 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 141) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 7.1.2 Checking machine room for smell of gas (→ Page 129)
  • Page 176 Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 4.7 Emission values – Check (→ Page 42) Offset screwdriver Part No.: F30452765 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 141) Oil filter wrench Part No.:...
  • Page 177 Used in: 7.3.2 Spark plug – Removal (→ Page 133) Qty.: Used in: 7.3.3 Spark plug – Installation (→ Page 134) Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 7.3.7 Ignition system – Ignition timing check (→ Page 140)
  • Page 178 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 7.3.3 Spark plug – Installation (→ Page 134) Qty.: Used in: 7.3.6 Spark plug connector – Installation (→ Page 138) Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 7.4.1 Valve clearance –...

  • Page 179: Index

    – Check   – Genset control system log  52 – On engine  167 – Key  50 Contact person  Firing order 26 – MTU Onsite Energy  174 Control  – Starting sequence  38 Gas engine phase 3 system  – Stopping sequence  38 – Overview  31 Coolant ...
  • Page 180 – Startup, specific information for gaseous fuel supply applications  10 Safety requirements  – Safety notices, standards  20 Sensors  – Overview  168 Service partner  – MTU Onsite Energy  174 Spark plug  – Installation  134 – Removal  133 – Replacement  132 Spark plug connector ...
  • Page 181 Starting sequence  – Control  38 Stopping sequence  – Control  38 transport 21 Valve clearance  – Adjustment  141 – Check  141 Valve gear  – Lubrication  147 Valve protrusion  – Measurement  144 Vent line of engine coolant circuit  – Replacement  162 MS150098/02E 2016-11 | Index | 181...

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