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MTU 20V4000L32FB Operating Instructions Manual

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Operating Instructions
Gas engine
20V4000L32FB
MS150116/04E

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Summary of Contents for MTU 20V4000L32FB

  • Page 1 Operating Instructions Gas engine 20V4000L32FB MS150116/04E...
  • 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

    8.3.1 Spark plug – Replacement 8.3.2 Spark plug – Removal 4 Technical Data 8.3.3 Spark plug – Installation 4.1 20V4000L32FB engine data, fuel-optimized 8.3.4 Spark plug connector – Replacement 8.3.5 Spark plug connector – Removal (TA-Luft) 8.3.6 Spark plug connector – Installation 4.2 20V4000L32FB engine data, tropical...
  • Page 4 9 Appendix A 8.9 Lube Oil System, Lube Oil Circuit 9.1 Abbreviations 8.9.1 Engine oil level – Check 9.2 MTU Onsite Energy contact person / service 8.9.2 Engine oil – Change partner 8.9.3 Engine oil – Sample extraction and analysis 8.10 Oil Filtration / Cooling...

  • Page 5: Safety

    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. MS150116/04E 2018-04 | Safety | 5...
  • Page 6 Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies. Please note the following when replacing components with emission labels: • The relevant emission labels must be affixed to the spare part. • Emission labels shall not be transferred from the replaced part to the spare part. •...

  • Page 7: 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 8: 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 9: Initial Start-Up And Operation - Safety Regulations

    1.4 Initial start-up and operation – Safety regulations 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 10 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.

  • Page 11: 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 Important information The fuel supplied to the gas engine is exclusively fuel gas. The fuel supply for dual fuel application is diesel with different shares of fuel gas. Requirement for the user: Check the gas train every time the product is started.
  • Page 12 • a manual shutoff valve • a gas filter Gas trains feature the following components in the direction of flow (MTU scope of supply): • two gas shutoff valves (automatic) • a pressure regulating device • a manual shutoff valve...

  • Page 13: Assembly, Maintenance, And Repair Work - Safety Regulations

    1.6 Assembly, maintenance, and repair work – Safety regulations Safety regulations for work prior to assembly, maintenance, and repair Have assembly, 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 from oil vapors, fluids and lubricants, risk of burning).
  • Page 14 When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing. Removing, installing and cleanliness Pay particular attention to cleanliness at all times. Completely wipe up escaped fluids and lubricants due to the risk of slipping.
  • Page 15 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
  • Page 16 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.

  • Page 17: Safety Regulations For Assembly, Maintenance And Servicing Work, Specific Information For Gaseous Fuel And Dual Fuel Supply Or Applications

    1.7 Safety regulations for assembly, maintenance and servicing work, specific information for gaseous fuel and dual fuel supply or applications Safety regulations for work prior to assembly, maintenance, and repair 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 18: Fire And Environmental Protection, Fluids And Lubricants

    Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
  • Page 19 Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products 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.

  • Page 20: 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 21: Standards For Warning Notices In The Text And Highlighted Information

    1.10 Standards for warning notices in the text and highlighted information 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 22: Transport

    Make sure that consistency and load-bearing capacity of ground or support surface is adequate. Never set engine down on oil pan unless expressively authorized to do so by MTU on a case-to-case basis. 22 | Transport | MS150116/04E 2018-04...

  • Page 23: Lifting Specifications

    2.2 Lifting specifications DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. • Never stand beneath a suspended load and keep a safe distance. • Wear personal protective equipment (e.g. protective helmet, safety shoes). 1 Max. permissible diagonal 2 Center of gravity pull: 10°...

  • Page 24: Crankshaft Transport Locking Device

    2.3 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Ratchet adapter F30027340 Engine oil Transport locking device Note: The locking device on both ends protects the crankshaft bearings from shocks and vibration damage during engine transport.
  • Page 25 Screw locknut (2) onto screw (1) up to the end of the thread. The long end of holder (3) must face downwards. Push holder (3) through the plate openings (6). Note: The holder (3) must lock the flywheel only, not the ring gear. Install screw (1) into the bore of holder (3) until the holder (3) is locked in position.

  • Page 26: General Information

    3 General Information 3.1 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)

  • Page 27: Engine - Overview

    3.2 Engine – Overview 1 Air filter/air inlet 6 Capacitor discharge ignition 11 Throttle 2 Mixture cooler system 12 Flywheel 3 Exhaust turbocharger, left- 7 Engine mounting bracket, 13 Engine governor/engine hand side free end monitoring 4 Exhaust turbocharger, right- 8 Oil pan KS Driving end hand side...
  • Page 28 1 Crankcase breather, oil sep- 6 Throttle 11 Engine oil filter arator 7 Spark plug 12 Oil level switch 2 Exhaust outlet 8 Cylinder head cover 13 Engine oil heat exchanger 3 Gas control valve 9 Cylinder head KGS Free end 4 Gas inlet connection 10 Engine oil sampling port 5 Ignition coil...

  • Page 29: Monitoring, Control And Regulation Equipment

    3.3 Monitoring, Control and Regulation Equipment 3.3.1 Gas engine phase 4 system – Overview General overview 1 Unit system 5 Engine Monitoring Unit 9 Ignition 2 Engine system 6 Throttle flaps 10 Compressor bypass 3 System 7 Gas dosing unit 11 NOx sensor (optional) 4 Engine Control Unit 8 Knock module...
  • Page 30 Anti-knock regulation 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 31: Purpose Of The Units

    3.3.2 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 32 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring 32 | Monitoring, Control and Regulation Equipment | MS150116/04E 2018-04...

  • Page 33: Sensors - Overview

    3.3.3 Sensors – Overview Item Description Monitors B49.2 Intake air temperature B side B81.2 Intake air pressure after filter B side B44.2 Turbocharger speed, B side B16.1 Coolant pressure after engine B4.XX Exhaust gas temperature after cylinder XX B79.22 Mixture pressure, B side Mixture temperature Table 3: Sensors on B side The knock sensors (B80.XX) are mounted on the right and left sides of the crankcase below the mixture...
  • Page 34 Item Description Monitors B79.23 Mixture pressure before throttle Crankshaft speed, ignition system reset B13.2 Crankshaft speed, ignition Table 4: Sensors on driving end 34 | Monitoring, Control and Regulation Equipment | MS150116/04E 2018-04...
  • Page 35 Item Description Monitors B44.1 Turbocharger speed, A side B81.1 Intake air pressure after filter A side B49.1 Intake air temperature A side B79.21 Mixture pressure, A side Crankcase pressure B5.3 Engine oil pressure before filter Engine oil temperature B5.1 Engine oil pressure after filter Table 5: Sensors on A side MS150116/04E 2018-04 | Monitoring, Control and Regulation Equipment | 35...
  • Page 36 Item Description Monitors B88.X Nitrogen oxide in exhaust gas (NOx) B4.21 Exhaust bulk temperature after turbocharger, A side B16.3 Coolant pressure before engine B1.3 Camshaft speed for anti-knock control B1.1 Camshaft speed for engine governor Engine oil level B1.2 Camshaft speed ignition system B6.3 Coolant temperature before engine B6.1...

  • Page 37: Technical Data

    4 Technical Data 4.1 20V4000L32FB engine data, fuel-optimized (TA-Luft) Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
  • Page 38 Number of cylinders Gas type: Biogas Methane number, min. Table 9: Site conditions (for max. power) Consumption Number of cylinders Lube oil consumption after 1000 h run time g/kWh Table 10: 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 configuration: V angle...
  • Page 39 Number of cylinders Thermostat: Starts to open °C Thermostat: Opening stops (thermostat fully open and bypass closed) °C Table 12: Coolant system (HT circuit) Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooling equipment) (w/o antifreeze) Coolant antifreeze content, max.
  • Page 40 General operating data Number of cylinders Cold start capability: Air temperature (w/o starting aid, with preheating) - °C (case C) Site condition (for case C): Engine coolant temperature °C Minimum idling speed 1500 Limit speed for overspeed alarm/emergency shutdown 1900 Table 17: General operating data Starting (electric) Number of cylinders...
  • Page 41 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise (filter) - DL (sound power dB(A) level LW, ISO 8528-10) Table 22: Acoustics MS150116/04E 2018-04 | Technical Data | 41...

  • Page 42: 20V4000L32Fb Engine Data, Tropical Application (Ta-Luft)

    4.2 20V4000L32FB engine data, tropical application (TA-Luft) Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
  • Page 43 Consumption Number of cylinders Lube oil consumption after 1000 h run time g/kWh Table 26: 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 configuration: V angle Degrees (°) Bore...
  • Page 44 Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooling equipment) (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over LT mixture cooler (at nominal flow rate 8.56) Table 29: Coolant system (LT circuit) Coolant system (MT circuit) Number of cylinders...
  • Page 45 General operating data Number of cylinders Cold start capability: Air temperature (w/o starting aid, with preheating) - °C (case C) Site condition (for case C): Engine coolant temperature °C Minimum idling speed 1500 Limit speed for overspeed alarm/emergency shutdown 1900 Table 33: General operating data Starting (electric) Number of cylinders...
  • Page 46 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise (filter) - DL (sound power dB(A) level LW, ISO 8528-10) Table 37: Acoustics 46 | Technical Data | MS150116/04E 2018-04...

  • Page 47: Firing Order

    4.3 Firing order Firing order Number of cylin- Firing order ders A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS150116/04E 2018-04 | Technical Data | 47...

  • Page 48: Engine - Main Dimensions

    4.4 Engine – Main dimensions Engine – Main dimensions Item Dimensions Length (A) for 20V approx. 3896 mm Width (B) for 20V approx. 1584 mm Height (C) for 20V approx. 2293 mm Crankshaft center to approx. 636 mm oil pan (D) Crankshaft center to approx.

  • Page 49: Operation

    5 Operation 5.1 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: Mechanical cylinder output Recommended maximum run- Recommended minimum run-...

  • Page 50: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    5.2 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 51: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    5.3 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 213). Coolant circuit Check engine coolant level (→ Page 217); Check mixture coolant level (→...

  • Page 52: Re-Starting The Engine Following An Automatic Safety Shutdown

    5.4 Re-starting the engine following an automatic safety shutdown NOTICE Re-starting the engine following an automatic safety shutdown. Risk of severe engine damage! • Before starting the engine, make sure the root cause of the safety shutdown was eliminated. • If the root cause cannot be identified or eliminated, contact Service. Note: •...

  • Page 53: Control, Starting And Stopping Sequences

    5.5 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 54 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 55: Engine - Start

    5.6 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 56: Operational Checks

    5.7 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 57: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas detection and alarm unit (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 58 Emission values – Check 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. Start engine. Approach the measuring point until a stable operating state has been reached.

  • Page 59: Engine - Shutdown

    5.9 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 60: Engine - Emergency Shutdown

    5.10 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 61 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 62: After Stopping The Engine - Engine Remains Ready For Operation

    5.11 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) 62 | Operation | MS150116/04E 2018-04...

  • Page 63: 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 64: Maintenance

    6 Maintenance 6.1 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 65: Maintenance Task Reference Table [Ql1]

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

  • Page 66: Troubleshooting

    OEM (see documentation of the genset manufacturer). Appropriate MTU qualifications/training are a requirement for performing troubleshooting activities. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
  • Page 67 Procedure following an automatic safety shutdown (→ Page 52) MS150116/04E 2018-04 | Troubleshooting | 67...

  • Page 68: Fault Messages In Genset Control System Log

    7.2 Fault messages in genset control system log Possible engine responses to yellow alarm: Warning, power limitation/reduction, speed limitation, engine stop Possible engine responses to red alarm: Engine stop, power limitation/reduction, speed limitation, warning Procedure following an automatic safety shutdown (→ Page 52) 112222 –...
  • Page 69 112304 – HI T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high in comparison 2. Check ignition timing (→ Page 186). with weighted average. 3.
  • Page 70 112310 – HI T-Exhaust A10 Yellow alarm. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high in comparison 2. Check ignition timing (→ Page 186). with weighted average. 3. Check valve drive (exhaust valves do not close). 112311 –...
  • Page 71 112316 – HI T-Exhaust B6 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high in comparison 2. Check ignition timing (→ Page 186). with weighted average. 3.
  • Page 72 112402 – LO T-Exhaust A2 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 73 112406 – LO T-Exhaust A6 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 74 112410 – LO T-Exhaust A10 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 75 112414 – LO T-Exhaust B4 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 76 112418 – LO T-Exhaust B8 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 77 112503 – HIHI T-Exhaust A3 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high in comparison 2. Check ignition timing (→ Page 186). with weighted average. 3.
  • Page 78 112509 – HIHI T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high in comparison 2. Check ignition timing (→ Page 186). with weighted average. 3.
  • Page 79 112515 – HIHI T-Exhaust B5 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high in comparison 2. Check ignition timing (→ Page 186). with weighted average. 3.
  • Page 80 112601 – LOLO T-Exhaust A1 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 81 112605 – LOLO T-Exhaust A5 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 82 112609 – LOLO T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 83 112613 – LOLO T-Exhaust B3 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 84 112617 – LOLO T-Exhaust B7 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 57). with weighted average. 3. Check ignition timing (→ Page 186). 4.
  • Page 85 112702 – HIHI T-Exhaust A2 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high. 2. Check ignition timing (→ Page 186). 3. Check valve drive (exhaust valves do not close). 112703 –...
  • Page 86 112708 – HIHI T-Exhaust A8 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high. 2. Check ignition timing (→ Page 186). 3. Check valve drive (exhaust valves do not close). 112709 –...
  • Page 87 112714 – HIHI T-Exhaust B4 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high. 2. Check ignition timing (→ Page 186). 3. Check valve drive (exhaust valves do not close). 112715 –...
  • Page 88 112720 – HIHI T-Exhaust B10 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 57). cylinder is too high. 2. Check ignition timing (→ Page 186). 3. Check valve drive (exhaust valves do not close). 112923 –...
  • Page 89 113902 – SS Local Initiated Emerg. Stop Red alarm. Initiated by EMU. Cause Corrective action Emergency stop detected. 1. Clear emergency stop. Emergency stop was released 2. Check speed governor. manually (button), or ignition 3. Check throttle closing position. system reported overspeed. 1.4510.186 –...
  • Page 90 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 (→ Page 227). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 33). 1.4510.194 – Knock Sensor Error A3 Red alarm.
  • Page 91 1.4510.199 – Knock Sensor Error A8 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling (→ Page 227). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 33). 1.4510.200 – Knock Sensor Error A9 Red alarm.
  • Page 92 1.4510.205 – Knock Sensor Error B4 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling (→ Page 227). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 33). 1.4510.206 – Knock Sensor Error B5 Red alarm.
  • Page 93 1.4510.211 – Knock Sensor Error B10 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling (→ Page 227). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 33). 1.4520.232 – Error Missing Ring Gear Signal Red alarm.
  • Page 94 1.4520.238 – E2PROM Checksum Error Red alarm. Initiated by IC922. Cause Corrective action Hardware not ready for operation. 1. Restart ignition. 2. Replace ignition. 1.4520.239 – Global Timing out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified global ignition timing is 1.
  • Page 95 1.4520.246 – Open Primary, Channel 2 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil (→ Page 227). discharged. 2. Check ignition coils. 1.4520.247 – Open Primary, Channel 3 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 96 1.4520.253 – Open Primary, Channel 9 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil (→ Page 227). discharged. 2. Check ignition coils. 1.4520.254 – Open Primary, Channel 10 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 97 1.4520.260 – Open Primary, Channel 16 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil (→ Page 227). discharged. 2. Check ignition coils. 1.4520.262 – Open Primary, Channel 17 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 98 1.4520.272 – Warn. Missing Camshaft Signal Yellow alarm. Initiated by IC922. Cause Corrective action u Sensor B 1.2, check sensor, sensor gap and cabling, replace as Missing camshaft signal for ignition system. necessary (→ Page 33) (→ Page 227). 1.4520.273 – SCR Fault Odd Red alarm.
  • Page 99 1.4520.520 – MIC5 Stat W: temperat. limit reached Yellow alarm. Initiated by MIC5. Cause Corrective action u Ensure that the genset room is adequately ventilated. The device temperature is too high. 1.4520.521 – MIC5 Stat W: pow output lim reached Yellow alarm.
  • Page 100 1.4520.527 – MIC5 Stat Analogue voltage sig fail Red alarm. Initiated by MIC5. Cause Corrective action u Check settings in ignitions control unit. Failure of the voltage signal to adjust the ignition point. 1.4520.528 – MIC5 Stat Aux inp supply volt. fail Red alarm.
  • Page 101 1.4520.542 – MIC5 E1 Speed sig during selftest Red alarm. Initiated by MIC5. Cause Corrective action u Restart ignition control unit. Pulse sensor signals were detected during the self-test. 1.4520.543 – MIC5 E1 Shutdown due to alarm Red alarm. Initiated by MIC5. Cause Corrective action Shutdown due to alarm.
  • Page 102 1.4520.549 – MIC5 E1 Power output limit reached Red alarm. Initiated by MIC5. Cause Corrective action The power output has exceeded 1. Check ignition system settings in the Engine Control Unit. the admissible value. 2. Check ignition coils. 3. Check igniters. 4.
  • Page 103 1.4520.555 – MIC5 E1 Tr1 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 1 (B1.2). wheel. Replace sensor as necessary. (→ Page 33) (→ Page 227) 1.4520.556 –...
  • Page 104 1.4520.570 – MIC5 IPE Primary Open Cylinder 1 Red alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 227). cylinder 1 in ignition sequence. 2. Check ignition coil. 1.4520.571 – MIC5 IPE Primary Open Cylinder 2 Red alarm.
  • Page 105 1.4520.577 – MIC5 IPE Primary Open Cylinder 8 Red alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 227). cylinder 8 in ignition sequence. 2. Check ignition coil. 1.4520.578 – MIC5 IPE Primary Open Cylinder 9 Red alarm.
  • Page 106 1.4520.584 – MIC5 IPE Primary Open Cylinder 15 Red alarm. Initiated by MIC5. Cause Corrective action Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 227). cylinder 15 in ignition sequence. 2. Check ignition coil. 1.4520.585 – MIC5 IPE Primary Open Cylinder 16 Red alarm.
  • Page 107 1.4520.591 – MIC5 IPE Prim Short Circuit Cyl 2 Red alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 227). cylinder 2 in ignition sequence. 2. Check ignition coil. 1.4520.592 –...
  • Page 108 1.4520.598 – MIC5 IPE Prim Short Circuit Cyl 9 Red alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 227). cylinder 9 in ignition sequence. 2. Check ignition coil. 1.4520.599 –...
  • Page 109 1.4520.605 – MIC5 IPE Prim Short Circuit Cyl 16 Red alarm. Initiated by MIC5. Cause Corrective action Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 227). cylinder 16 in ignition sequence. 2. Check ignition coil. 1.4520.606 –...
  • Page 110 1.4520.612 – MIC5 ISE Secondary Open Cylinder 3 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit of 1. Check ignition lead, connector and igniter. cylinder 3 in ignition sequence. 2. Check ignition coil. 1.4520.613 – MIC5 ISE Secondary Open Cylinder 4 Yellow alarm.
  • Page 111 1.4520.619 – MIC5 ISE Secondary Open Cylinder 10 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit of 1. Check ignition lead, connector and igniter. cylinder 10 in ignition sequence. 2. Check ignition coil. 1.4520.620 – MIC5 ISE Secondary Open Cylinder 11 Yellow alarm.
  • Page 112 1.4520.626 – MIC5 ISE Secondary Open Cylinder 17 Yellow alarm. Initiated by MIC5. Cause Corrective action Disruption in secondary circuit of 1. Check ignition lead, connector and igniter. cylinder 17 in ignition sequence. 2. Check ignition coil. 1.4520.627 – MIC5 ISE Secondary Open Cylinder 18 Yellow alarm.
  • Page 113 1.4520.633 – MIC5 ISE Secon Short Circuit Cyl 4 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition lead, connector and igniter. of cylinder 4 in ignition sequence. 2. Check ignition coil. 1.4520.634 – MIC5 ISE Secon Short Circuit Cyl 5 Yellow alarm.
  • Page 114 1.4520.640 – MIC5 ISE Secon Short Circuit Cyl 11 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition lead, connector and igniter. of cylinder 11 in ignition 2. Check ignition coil. sequence. 1.4520.641 – MIC5 ISE Secon Short Circuit Cyl 12 Yellow alarm.
  • Page 115 1.4520.646 – MIC5 ISE Secon Short Circuit Cyl 17 Yellow alarm. Initiated by MIC5. Cause Corrective action Short circuit in secondary circuit 1. Check ignition lead, connector and igniter. of cylinder 17 in ignition 2. Check ignition coil. sequence. 1.4520.647 – MIC5 ISE Secon Short Circuit Cyl 18 Yellow alarm.
  • Page 116 1.4520.660 – MIC5 E2 Tr2 no signal detected Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing No signal from pulse sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 33) (→ Page 227) 1.4520.661 –...
  • Page 117 1.4520.667 – MIC5 E2 Tr2 index mark not 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 2 (B75) in operation. wheel.
  • Page 118 1.4520.674 – MIC5 E2 Tr3 wrong polarity Yellow alarm. Initiated by MIC5. Cause Corrective action u Check sensor, sensor gap, cabling, data record settings and timing Pulse sensor 3 (B13.2) has wrong polarity. wheel. Replace sensor as necessary. (→ Page 33) (→ Page 227) 1.4520.675 –...
  • Page 119 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 120 1.4530.013 – Analog Input Low Error Yellow alarm. Initiated by compressor bypass. Cause Corrective action u Check compressor bypass flap 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...
  • Page 121 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 122 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 123 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 124 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 125 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 227). 1.4540.034 – FGT High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Gas temperature before TecJet is...
  • Page 126 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 127 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 128 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 129 1.4550.036 – A - Temperature derating active Yellow alarm. Initiated by throttle of cylinder bank A. Cause Corrective action Internal temperature above 100 1. Check room temperature and ventilation. ºC. Adjustment rate is reduced. 2. Restart throttle. 1.4550.037 – A - Temperature above 120 °C Red alarm.
  • Page 130 1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by throttle of cylinder bank A. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 227). 2. Check throttle settings. 1.4550.044 – A - CAN Stop Command Yellow alarm.
  • Page 131 1.4550.136 – B - Temperature derating active Yellow alarm. Initiated by throttle of cylinder bank B. Cause Corrective action Internal temperature above 100 1. Check room temperature and ventilation. ºC. Adjustment rate is reduced. 2. Restart throttle. 1.4550.137 – B - Temperature above 120 °C Red alarm.
  • Page 132 1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by throttle of cylinder bank B. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 227). 2. Check throttle settings. 1.4550.144 – B - CAN Stop Command Yellow alarm.

  • Page 133: Engine Control Unit - Fault Messages

    7.3 Engine Control Unit – Fault messages Possible engine responses to yellow alarm: Warning, power limitation/reduction, speed limitation, engine stop Possible engine responses to red alarm: Engine stop, power limitation/reduction, speed limitation, warning Procedure following an automatic safety shutdown (→ Page 52) 015 –...
  • Page 134 020 – SS T-Exhaust A Yellow alarm. Associated parameter 2.0126.932 Cause Corrective action Exhaust gas temperature (A side) 1. Check exhaust turbocharger. after turbine too high (limit value 2. Check ignition timing (→ Page 186). 2). Incorrect ignition timing, 3. Check mixture setting. mixture too lean or too rich, 4.
  • Page 135 026 – SS P-Diff-Lube Oil Red alarm. Engine shutdown. Associated parameter 2.0154.932 Cause Corrective action Pressure loss via oil filter too high 1. Replace oil filter (→ Page 216). (limit value 2). 2. If this fault message occurs again after unexpectedly short filter runtime, check oil filter for deposits, change oil as necessary (→...
  • Page 136 037 – SS ETC2 Overspeed Red alarm. Engine shutdown. Associated parameter 2.3013.912 Cause Corrective action Speed of turbocharger 2 too high 1. Check intake air temperature. (limit value 2). 2. Check emissions (→ Page 57). 3. If the sensor is not obstructed, check the conditions for activating this monitoring feature in the ECU parameter record.
  • Page 137 057 – LO P-Coolant Yellow alarm. Associated parameter 2.0101.921 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure after engine too low (limit value 1). Insufficient volume flow, static pressure too low. 058 – SS P-Coolant Red alarm.
  • Page 138 067 – HI T-Coolant Yellow alarm. Power reduction. Associated parameter 2.0120.931 Cause Corrective action u Check engine coolant circuit. Coolant temperature after engine too high (limit value 1). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit.
  • Page 139 090 – SS Idle Speed Not Reached Red alarm. Start is terminated. Associated parameter 2.1090.925 Cause Corrective action Idle speed not reached. 1. Check ignition. 2. Check gas supply. 3. Check mixture setting. 091 – SS Release Speed Not Reached Yellow alarm.
  • Page 140 095 – AL Prelubrication Fault Red alarm. Start is terminated. Associated parameter 2.1090.920 Cause Corrective action Oil priming fault. 1. Check oil pressure, oil temperature, oil level. 2. Check oil priming pump. 104 – AL Eng Hours Counter Defect Yellow alarm. Associated parameter 1.8004.623 Cause Corrective action...
  • Page 141 122 – HI T-ECU Yellow alarm. Associated parameter 2.0132.921 Cause Corrective action Temperature of electronics too 1. Provide improved cooling for ECU. Reduce room temperature, high (limit value 1). check air flow to ECU. 2. Compare device temperature with temperature gauge in DiaSys®. 180 –...
  • Page 142 184 – AL CAN PU-Data Flash Error Red alarm. Associated parameter 2.0500.684 Cause Corrective action u Contact Service (configuration error). A program error occurred while trying to copy a received PU data module to the flash module. 186 – AL CAN1 Bus Off Yellow alarm.
  • Page 143 190 – AL EMU Parameter Not Supported Red alarm. Associated parameter 2.0500.690 Cause Corrective action u Contact Service (configuration error). EMU parameters are not supported . 201 – SD T-Coolant Red alarm. Engine shutdown. Associated parameter 1.8004.570 Cause Corrective action Coolant temperature sensor at u Check sensor and cabling (B6.1), replace as necessary (→...
  • Page 144 211 – SD P-Lube Oil Red alarm. Engine shutdown. Associated parameter 1.8004.563 Cause Corrective action u Check sensor and cabling (B5.1), replace as necessary (→ Page 33) Engine oil pressure sensor after filter faulty, short circuit or wire (→ Page 227). Error cleared after restarting the engine. break.
  • Page 145 221 – SD P-Diff Lube Oil Red alarm. Associated parameter 1.8004.585 Cause Corrective action u Check sensor and cabling before filter (B5.3) and after filter (B5.1), Engine oil pressure sensors faulty, short circuit or wire break. replace as necessary (→ Page 33) (→ Page 227). Error cleared after restarting the engine.
  • Page 146 233 – SD Charger 2 Speed Red alarm. Associated parameter 1.3011.129 Cause Corrective action Speed sensor of turbocharger 2 1. Check sensor and wiring (B44.2), replace as necessary (→ Page 33) faulty, short circuit or wire break. (→ Page 227). Error cleared after restarting the engine. 2.
  • Page 147 383 – AL Wiring TOP 3 Red alarm. Associated parameter 2.8006.640 Cause Corrective action u Check cabling (→ Page 227). Short circuit or wire break at transistor output 3 plant side (TOP 3). Activation of gas supply solenoid valve No.1 faulty. 384 –...
  • Page 148 429 – HI P-Coolant Red alarm. Engine shutdown. Associated parameter 2.0101.931 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure after engine too high (limit value 3). 430 – LO P-Coolant Before Engine Yellow alarm. Associated parameter 2.0168.921 Cause Corrective action Coolant pressure before engine...
  • Page 149 443 – HI P-Charge Mix Diff. Yellow alarm. Associated parameter 2.0183.931 Cause Corrective action Difference in mixture pressures 1. Check restrictor flaps for varying positions and malfunction. sensed on A and B side is too high 2. Check mixture lines for leakage. (limit value 1).
  • Page 150 452 – 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 151 459 – SD P-Coolant b.Engine Red alarm. Associated parameter 1.8004.627 Cause Corrective action u Check sensor and wiring (B16.3), replace as necessary (→ Page 33) Coolant pressure sensor before engine faulty, short circuit or wire (→ Page 227). Error cleared after restarting the engine. break.
  • Page 152 496 – SD P-Charge Mix A Red alarm. Engine shutdown. Associated parameter 1.8004.628 Cause Corrective action u Check sensor and cabling (B79.21), replace as necessary Mixture pressure sensor on A side faulty, short circuit or wire break. (→ Page 33) (→ Page 227). Error cleared after restarting the engine. 497 –...
  • Page 153 512 – HIHI P-Charge Mix B Red alarm. Engine shutdown. Associated parameter 2.0182.932 Cause Corrective action Mixture pressure on B side too 1. Check emissions (→ Page 57). high (limit value 2). 2. Check ignition timing (→ Page 186). 3. Check exhaust back pressure. 4.
  • Page 154 522 – SD P-Intake Air after Filter B Yellow alarm. Associated parameter 1.0187.900 Cause Corrective action u Check sensor and wiring (B81.2), replace as necessary (→ Page 33) Intake air pressure sensor after filter on B side faulty, short circuit (→...
  • Page 155 554 – AL Ignition Fault Red alarm. Associated parameter 2.1090.122 Cause Corrective action Ignition failure. Alarm is activated 1. Check ignition system. if the feedback signal from 2. Check ignition system speed sensors (→ Page 33). ignition system is not received 3.
  • Page 156 559 – AL mixture throttle A fault Red alarm. Engine shutdown. Associated parameter 1.1450.010 Cause Corrective action u Check mixture restrictor flap on A side and cabling. Replace A problem related to mixture restrictor flap on A side occurred. mixture restrictor flap on A side as necessary. Possible causes: Mixture restrictor flap faulty, no power supply to restrictor flap, cabling of...
  • Page 157 568 – AL L2 P-Intake Air after Filter B Yellow alarm. Associated parameter 2.0187.931 Cause Corrective action u Replace air filter (→ Page 207). Pressure loss over air filter on B side is too high. 569 – AL SAM Missing Data Fault Red alarm.
  • Page 158 572 – L3 Al CAN Max. Retarded Timing Red alarm. Engine shutdown. Associated parameter 2.1200.933 Cause Corrective action Due to detected knocking, the 1. Check emissions (→ Page 57). cylinder set to maximum retarded 2. Check ignition timing (→ Page 186). timing has violated the limit value.
  • Page 159 597 – AL Wiring PWM_CM5 Red alarm. Associated parameter 1.1041.925 Cause Corrective action u Check setting at Engine Control Unit. Wire break or short circuit on channel PWM_CM5. 603 – SD Air Humidity Yellow alarm. Associated parameter 1.0165.900 Cause Corrective action Air humidity sensor faulty.
  • Page 160 615 – AL EIL Protection Red alarm. Associated parameter 2.0610.951 Cause Corrective action u Check EIL. Response to faulty or manipulated EIL. 616 – AL EIL Error Red alarm. Associated parameter 1.0610.952 Cause Corrective action Faulty or manipulated EIL. u Check EIL. 617 –...
  • Page 161 621 – LO NOx Value Yellow alarm. Associated parameter 2.3050.024 Cause Corrective action NOx emissions have undershot 1. Check gas quality if feasible. the first limit value. 2. Check gas pressure. 3. Check NOx sensor (→ Page 33). 4. Check emissions (→ Page 57). 622 –...
  • Page 162 627 – AL Wiring PWM_CM9 Red alarm. Associated parameter 1.1041.929 Cause Corrective action u Check setting at Engine Control Unit. Wire break or short circuit on channel PWM_CM9. 628 – AL Wiring PWM_CM10 Red alarm. Associated parameter 1.1041.930 Cause Corrective action Wire break or short circuit on u Check setting at Engine Control Unit.
  • Page 163 650 – Al Req Angle Throttle B Yellow alarm. Power reduction. Associated parameter 2.1200.936 Cause Corrective action Opening angle of restrictor flaps B 1. Check charge-air pressure reserve. exceeded. 2. Intake air temperature not as per TVU data. 3. Check exhaust system for leakage. 4.
  • Page 164 655 – AL TecJet Comm Lost Red alarm. Associated parameter 1.4540.996 Cause Corrective action CAN bus communication for gas 1. Check cabling (→ Page 227). control valve faulty (alternatively, 2. Check power supply. a stepper motor with gas mixer 3. Carry out restart of ECU, EMU and gas control valve. can be installed).
  • Page 165 664 – AL Oil Refill Error Red alarm. Associated parameter 1.1480.305 Cause Corrective action u After initiation of the alarms “HI Oil Refill” and Summary alarm for automatic oil replenishment. “HI Lube Oil Level refill” a programmable timeout period starts. The engine is stopped when this time expires.
  • Page 166 670 – AL ProActB Yellow Yellow alarm. Associated parameter 1.4550.193 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in restrictor flap B was detected. control system. 671 – AL NOxA Yellow Yellow alarm.
  • Page 167 678 – AL TecJet Red Red alarm. Associated parameter 1.4540.991 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in the gas control valve was detected. control system. 679 – AL ProActA Red Red alarm.
  • Page 168 686 – AL Lube Oil Max Red alarm. Associated parameter 1.1480.309 Cause Corrective action Maximum engine oil filling level 1. Check engine oil level (→ Page 213). detected. 2. Check replenishment system. 3. Drain oil. 688 – LO Oil Refill Yellow alarm.
  • Page 169 832 – AL EIL Different Engine Number Yellow alarm. Associated parameter 1.0610.953 Cause Corrective action Engine number in EIL differs from 1. Check the engine number in the ECU. Check that the ECU engine number in ECU. Two parameter record matches this engine. further attempts at engine 2.
  • Page 170 933 – AL MIC5 Red Red alarm. Associated parameter 1.4520.936 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in the ignition system was detected. control system. 934 – AL MIC5 Comm Lost Red alarm.
  • Page 171 975 – AL CAN3 Error Passive Yellow alarm. Associated parameter 2.0500.693 Cause Corrective action u Check operation of bus users and cabling. CAN controller 3 has indicated a warning. Bus nodes (ignition, knock module, restrictor flaps or gas mixture) malfunctioning. 976 –...
  • Page 172 1014 – HIHI Delta NOx (A-B) Red alarm. Associated parameter 2.3050.121 Cause Corrective action NOx values measured for banks A 1. Check emissions (→ Page 57). and B are too far apart (limit value 2. Check NOx sensors (→ Page 33). 3.

  • Page 173: Task Description

    8 Task Description 8.1 Engine 8.1.1 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 174: Checking Machine Room For Smell Of Gas

    8.1.2 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 175: Crankcase Breather

    8.2 Crankcase Breather 8.2.1 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 176 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 177: Crankcase Breather - Pressure Control Check And Adjustment

    8.2.2 Crankcase breather – Pressure control check and adjustment Preconditions ☑ Engine is stopped and starting disabled. Pressure control – Check and adjustment Check crankcase pressure, adjust if required. To adjust pressure control, turn ball valve (1). Performance at engine setting Setting value 100 % -10 mbar ±2 mbar...

  • Page 178: Ignition System

    8.3 Ignition System 8.3.1 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 179). Install new spark plug (→ Page 180). 178 | Ignition System | MS150116/04E 2018-04...

  • Page 179: Spark Plug - Removal

    8.3.2 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 180: Spark Plug - Installation

    8.3.3 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 181 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 182: Spark Plug Connector - Replacement

    8.3.4 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 183). Install spark plug connector (→ Page 184). 182 | Ignition System | MS150116/04E 2018-04...

  • Page 183: Spark Plug Connector - Removal

    8.3.5 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 184: Spark Plug Connector - Installation

    8.3.6 Spark plug connector – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug connector only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Spark plug connector with ignition line (→...
  • Page 185 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 186: Ignition System - Ignition Timing Check

    ☑ Engine-generator set is disconnected from the mains. Special tools, Material, Spare parts Designation / Use Part No. Qty. Stroboscope (not stocked by MTU) DANGER Live components, arcing due to flash-over. Risk of serious injury – danger to life! • Do not touch live components during operation.

  • Page 187: Valve Drive

    8.4 Valve Drive 8.4.1 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 188 Position Cylin- Overlap TDC in cylinder Bank A – – I – – X I – – X I – – – – X Bank B – X I – – X – – I – – – – X I –...

  • Page 189: Valve Protrusion - Measurement

    8.4.2 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 179). Remove cylinder head covers (→ Page 193). Remove sleeves (arrowed).
  • Page 190 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 191 Install sleeves (arrowed). Install cylinder head covers (→ Page 194). Install igniters with new sealing rings (→ Page 180). MS150116/04E 2018-04 | Valve Drive | 191...

  • Page 192: Valve Gear – Lubrication

    8.4.3 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 193). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 193: Cylinder Head Cover ‒ Removal

    8.4.4 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 183). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 194: Cylinder Head Cover ‒ Installation

    8.4.5 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 195: Exhaust Turbocharger

    F30027340 Ratchet bit F30027341 Cleaner (Snow-White 11-0) X00054118 Engine oil Assembly compound (Kluthe Hakuform 30-15) X00067260 Assembly compound (Ultra-Therm MTU) 50547 Assembly compound (Molykote P 37) 50564 O-rings (→ Spare Parts Catalog) Gaskets (→ Spare Parts Catalog) (→ Spare Parts Catalog) WARNING Hot components/surfaces.
  • Page 196 WARNING Spring/circlip/tensioning roller preload. Risk of injury! • Only use specified tool and equipment. NOTICE Inappropriate cleaning tool. Risk of damage to component! • Observe manufacturer's instructions. • Use appropriate cleaning tool. NOTICE Incorrect installation of components and lines. Damage to component! •...
  • Page 197 Loosen screws (3). Take off bellows (4, 5) with gaskets (2) from intake housing (1). Seal openings with suitable covers. Loosen V-band clamp (1). Remove intake neck (3) from compressor housing. Remove O-ring (2) from intake housing (3). Remove temperature sensor (1). Loosen nuts (6) on stud (5).
  • Page 198 Release screw connections (4) from bel- lows (3) in exhaust system downstream of cylinder head. Release screw connections (2) on bellows (1) in mixture line upstream of mixture cooler. Seal openings with suitable covers. Disassembling exhaust turbo- charger Mark position of compressor housing relative to bearing housing (3).
  • Page 199 Remove nuts (3) on turbine housing (1). Axially remove turbine housing (1) from bear- ing housing (2). Remove nozzle ring (1) from turbine housing. Exhaust turbocharger – Cleaning Note: Do not use scrapers or other tools which could damage the functional and sealing surfaces. Remove all deposits from functional areas and sealing faces.
  • Page 200 Exhaust turbocharger – Assem- Insert nozzle ring (1) in turbine housing. Position turbine housing (1) axially and install on bearing housing (2). Tighten screw connections (3) on turbine housing (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw...
  • Page 201 Position diffuser axially in compressor hous- ing ensuring position is correct. Unscrew screws (1) with locating washers. Coat O-ring with assembly compound (Kluthe Hakuform 30-15). Place O-ring in wall. Install compressor housing (1) on bearing housing (3). Tighten screw connections (2) on compressor housing (1) to specified tightening torque. Name Size Type...
  • Page 202 Lubricant Value/Standard Screw connection Tightening torque (Assembly compound 30 Nm +5 Nm (Ultra-Therm MTU)) (Assembly compound (Molykote P 37)) Coat studs (5) on exhaust turbocharger with assembly compound (Molykote P 37). Position exhaust elbow (2) with flange seg- ments (3) and new gasket (4) on exhaust tur- bocharger.
  • Page 203 Observe the following general information: • The sensors are identical with regard to their design and electrical functions. In- stallation is identical. • Arrangement and position of sensors (→ Page 33). Screw in union (2) by hand. Tighten union (2) to specified torque using a torque wrench. Name Size Type...
  • Page 204 Size Type Lubricant Value/Standard V-band clamp Tightening torque (Assembly compound 60 Nm +5 Nm (Ultra-Therm MTU)) (Assembly compound (Molykote P 37)) Remove covers. Note: Use new gaskets (2). Install bellows (4, 5) between intake housing (1) and gas mixer. Tighten screw connections (3) on bellows (4, 5) to specified torque using a torque wrench.
  • Page 205 Remove covers. Install and align vent lines (2). Screw on nuts (3) and tighten. Tighten clamps (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Clamp Tightening torque 8 Nm +1 Nm Fill with engine coolant (→ Page 221). Install insulation.

  • Page 206: Gas System

    8.6 Gas System 8.6.1 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 207: Air Filter

    8.7 Air Filter 8.7.1 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 208: Air Filter – Removal And Installation

    8.7.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 WARNING Hot components/surfaces. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. •...

  • Page 209: Starting System

    8.8 Starting System 8.8.1 Starter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Starter (→ Spare Parts Catalog) Replacing starter Remove starter (→ Page 210). Install new starter (→ Page 211). MS150116/04E 2018-04 | Starting System | 209...

  • Page 210: Starter – Removal

    8.8.2 Starter – Removal Preconditions ☑ Engine is stopped and starting disabled. DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! • Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! WARNING Heavy part, risk of falling or overturning due to lack of stability.

  • Page 211: Starter – Installation

    8.8.3 Starter – Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Screwdriver bit F30378921 Socket screwdriver, 14 mm F30378499 Torque wrench 1.0–5.0 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Lubricating grease (Molykote Longtherm 2 Plus NLGI 2) X00057299 DANGER Electric voltage supply for operation.
  • Page 212 Connecting starter Connect cables to starter as marked. Screw nut (1) onto terminal 50 and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard M5x0.8 Tightening torque 2.5 Nm ±0.5 Nm Screw nuts (2), (3), (4), (5) onto terminals 30, 30 b, 45, 31 and tighten to specified torque using a torque wrench.

  • Page 213: Lube Oil System, Lube Oil Circuit

    8.9 Lube Oil System, Lube Oil Circuit 8.9.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Oil is hot. Oil can contain residue/substances which are harmful to health. Risk of injury and poisoning! • Allow the product to cool to below 50 °C before beginning work. •...

  • Page 214: Engine Oil – Change

    8.9.2 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 Oil is hot.

  • Page 215: Engine Oil – Sample Extraction And Analysis

    8.9.3 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 216: Oil Filtration / Cooling

    8.10 Oil Filtration / Cooling 8.10.1 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 Oil is hot.

  • Page 217: Circuit

    8.11 Coolant Circuit, General, High-Temperature Circuit 8.11.1 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 218: Engine Coolant – Change

    8.11.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 219). Fill with engine coolant (→ Page 221). 218 | Coolant Circuit, General, High-Temperature Circuit | MS150116/04E 2018-04...

  • Page 219: Engine Coolant – Draining

    8.11.3 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 220 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 220 | Coolant Circuit, General, High-Temperature Circuit | MS150116/04E 2018-04...

  • Page 221: Engine Coolant – Filling

    8.11.4 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 222: Coolant Vent Line (Engine Coolant Circuit Replacement

    8.11.5 Coolant vent line (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. Coolant vent line –...

  • Page 223: Low-Temperature Circuit

    8.12 Low-Temperature Circuit 8.12.1 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 224: Mixture Coolant – Change

    8.12.2 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 225). Fill with fresh mixture coolant (→ Page 226). 224 | Low-Temperature Circuit | MS150116/04E 2018-04...

  • Page 225: Mixture Coolant – Draining

    8.12.3 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 226: Mixture Coolant – Filling

    8.12.4 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 227: Wiring (General) For Engine/Gearbox/Unit

    8.13 Wiring (General) for Engine/Gearbox/Unit 8.13.1 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 228: 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 229 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 230: 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 231: Special Tools

    10 Appendix B 10.1 Special Tools Angular screw driver Part No.: F30452765 Qty.: Used in: 8.4.1 Valve clearance – Check and adjustment (→ Page 187) Barring gear Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 173) Crossbeam Part No.: T80092210...
  • Page 232 Y20098771 Qty.: Used in: 8.4.1 Valve clearance – Check and adjustment (→ Page 187) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 5.8 Emission values – Check (→ Page 57) Gas detection and alarm unit (not stocked by MTU) Part No.:...
  • Page 233 Ratchet adapter Part No.: F30027340 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 24) Qty.: Used in: 8.8.3 Starter – Installation (→ Page 211) Ratchet bit Part No.: F30027340 Qty.: Used in: 8.5.1 Exhaust turbocharger – Cleaning (→ Page 195) Ratchet bit Part No.: F30027341...
  • Page 234 Screwdriver bit Part No.: F30378921 Qty.: Used in: 8.8.3 Starter – Installation (→ Page 211) Sliding depth gage, 200 mm Part No.: Y20000918 Qty.: Used in: 8.4.2 Valve protrusion – Measurement (→ Page 189) Socket screwdriver, 14 mm Part No.: F30378499 Qty.: Used in:...
  • Page 235 Used in: 8.3.2 Spark plug – Removal (→ Page 179) Qty.: Used in: 8.3.3 Spark plug – Installation (→ Page 180) Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 8.3.7 Ignition system – Ignition timing check (→ Page 186) Torque wrench 1.0–5.0 Nm...
  • Page 236 Torque wrench, 300–800 Nm Part No.: F30047798 Qty.: Used in: 8.5.1 Exhaust turbocharger – Cleaning (→ Page 195) Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 24) Qty.: Used in: 8.4.1 Valve clearance – Check and adjustment (→...

  • Page 237: Index

    10.2 Index Numerics Engine  – After stopping   20V4000L32FB engine data  – Putting out of operation  63 – Fuel-optimized (TA-Luft)  37 – Barring manually  173 – Tropical application (TA-Luft)  42 – Emergency shutdown  60 50-hours check 64 – Main dimensions  48 –...
  • Page 238 – Startup, specific information for gaseous fuel supply applications  11 Safety requirements  – Warning notices, standards  21 Sensors  – Overview  33 Service partner  – MTU Onsite Energy  230 Spark plug  – Installation  180 – Removal  179 – Replacement  178 238 | Index | MS150116/04E 2018-04...
  • Page 239 Spark plug connector  – Installation  184 – Removal  183 – Replacement  182 Starter  – Electric   – Installation  211 – Removal  210 – Replacement  209 Starting sequence 53 Stopping sequence 53 Transport  – Description  22 – Lifting specifications  23 Valve clearance  – Adjustment  187 –...

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