MTU 12V4000L62FB Operating Instructions Manual
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MTU 12V4000L62FB Operating Instructions Manual

MTU 12V4000L62FB Operating Instructions Manual

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Operating Instructions
Gas engine
12V4000L62FB
16V4000L62FB
MS150098/03E

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Summary of Contents for MTU 12V4000L62FB

  • Page 1 Operating Instructions Gas engine 12V4000L62FB 16V4000L62FB MS150098/03E...
  • 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 5 Operation 1.1 Important provisions for all products 5.1 Runtimes at partial load 1.2 Correct use of all products 5.2 Putting the engine into operation after 1.3 Personnel and organizational requirements extended out-of-service periods (>3 months) 1.4 Initial start-up and operation –...
  • 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. MS150098/03E 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 | MS150098/03E 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 Illustrations are also applicable to 16 V. 1 Throttle, B side 6 Engine lifting eye 11 Starter 2 Engine governor/engine 7 Capacitor discharge ignition 12 Flywheel monitoring unit system KS Driving end 3 Air filter/air inlet 8 Engine mounting bracket, 4 Mixture cooler free end...
  • Page 28 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 neck 15 Engine coolant outlet con- 4 Gas inlet connection 11 Engine oil filter...

  • Page 29: Monitoring, Control And Regulation Equipment

    3.3 Monitoring, Control and Regulation Equipment 3.3.1 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 30 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 31: Purpose Of The Units

    3.3.2 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 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 | MS150098/03E 2018-04...

  • Page 33: Sensors - Overview

    3.3.3 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 34 Sensors on driving end Pos. Designation Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset B13.2 Crankshaft speed, ignition system Table 4: Sensors on driving end 34 | Monitoring, Control and Regulation Equipment | MS150098/03E 2018-04...
  • Page 35 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 5: Sensors on A side MS150098/03E 2018-04 | Monitoring, Control and Regulation Equipment | 35...
  • Page 36 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 6: Sensors on free end...

  • Page 37: Engine Wiring - Overview

    3.3.4 Engine wiring – Overview Engine wiring harness W2 Illustrations show 8V. Figures also apply similarly to 12V and 16V. 1 Engine wiring harness W2 MS150098/03E 2018-04 | Monitoring, Control and Regulation Equipment | 37...
  • Page 38 Designation Pin assignment Engine wiring harness B1.1 Camshaft speed for ECU7 B1.2 Camshaft speed for ignition module B1.3 Camshaft speed for knock module B4AX Individual exhaust gas temperature A-side B4BX Individual exhaust gas temperature B-side B4.21 Combined exhaust temperature, A side B5.1 Lube oil pressure after filter B5.3...
  • Page 39 Wiring harness W080 for knock sensors 1 Engine wiring harness W080 for knock sensors Designation Pin assignment Engine wiring harness B80AX Knock sensors, A-side Knock module adaptation B80BX Knock sensors, B-side Table 8: Engine wiring harness W2 MS150098/03E 2018-04 | Monitoring, Control and Regulation Equipment | 39...
  • Page 40 Ignition rail 1 Ignition coil 3 Washer 2 Screw 4 Ignition rail 40 | Monitoring, Control and Regulation Equipment | MS150098/03E 2018-04...
  • Page 41 Engine wiring harness VM001 for starter, connecting cable W020 for ignition coil 1 Wiring harness for starter 2 Connecting cable for igni- tion coil MS150098/03E 2018-04 | Monitoring, Control and Regulation Equipment | 41...

  • Page 42: Technical Data

    4 Technical Data 4.1 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 43 Number of cylinders Gas type: Biogas Methane number, min. Table 11: General conditions (for max. power) Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh Table 12: 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 44 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 15: Coolant system (LT circuit) Lube oil system Number of cylinders...
  • Page 45 Number of cylinders Starting-attempt duration, max. Number of teeth on starter ring gear Table 19: 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 46: Firing Order

    4.2 Firing order Firing order Number of cylinders Firing order A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 46 | Technical Data | MS150098/03E 2018-04...

  • Page 47: Engine - Main Dimensions

    4.3 Engine – Main dimensions Engine – Main dimensions Item 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 48: 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: Power range [kW Recommended max.

  • Page 49: 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 50: 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 181). Coolant circuit Check engine coolant level (→ Page 185); Check mixture coolant level (→...

  • Page 51: 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 52: 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 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 53 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 54: 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 55: 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 Gaseous fuels are combustible/explosive.

  • Page 56: 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 57 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 58: 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 59: Engine - Emergency Shutdown

    5.10 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 60: 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) 60 | Operation | MS150098/03E 2018-04...

  • Page 61: 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 62: 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 63: 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 64: 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 65 Procedure following an automatic safety shutdown (→ Page 51) MS150098/03E 2018-04 | Troubleshooting | 65...

  • Page 66: 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 51) 112222 –...
  • Page 67 112304 – HI T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high in comparison 2. Check ignition timing (→ Page 154). with weighted average. 3. Check valve gear (exhaust valves do not close). 112305 –...
  • Page 68 112310 – HI T-Exhaust A10 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high in comparison 2. Check ignition timing (→ Page 154). with weighted average. 3. Check valve gear (exhaust valves do not close). 112311 –...
  • Page 69 112316 – HI T-Exhaust B6 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high in comparison 2. Check ignition timing (→ Page 154). with weighted average. 3. Check valve gear (exhaust valves do not close). 112317 –...
  • Page 70 112402 – LO T-Exhaust A2 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too high in comparison 2. Check emission values. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 71 112407 – LO T-Exhaust A7 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too high in comparison 2. Check emission values. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 72 112412 – LO T-Exhaust B2 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too high in comparison 2. Check emission values. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 73 112417 – LO T-Exhaust B7 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too high in comparison 2. Check emission values. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 74 112503 – HIHI T-Exhaust A3 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high in comparison 2. Check ignition timing (→ Page 154). with weighted average. 3. Check valve gear (exhaust valves do not close). 112504 –...
  • Page 75 112509 – HIHI T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high in comparison 2. Check ignition timing (→ Page 154). with weighted average. 3. Check valve gear (exhaust valves do not close). 112510 –...
  • Page 76 112515 – HIHI T-Exhaust B5 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high in comparison 2. Check ignition timing (→ Page 154). with weighted average. 3. Check valve gear (exhaust valves do not close). 112516 –...
  • Page 77 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. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 78 112606 – LOLO T-Exhaust A6 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. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 79 112611 – LOLO T-Exhaust B1 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. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 80 112616 – LOLO T-Exhaust B6 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. with weighted average. 3. Check ignition timing (→ Page 154). 4.
  • Page 81 112701 – HIHI T-Exhaust A1 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 154). 3. Check valve gear (exhaust valves do not close). 112702 –...
  • Page 82 112707 – HIHI T-Exhaust A7 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 154). 3. Check valve gear (exhaust valves do not close). 112708 –...
  • Page 83 112713 – HIHI T-Exhaust B3 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 154). 3. Check valve gear (exhaust valves do not close). 112714 –...
  • Page 84 112719 – HIHI T-Exhaust B9 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 154). 3. Check valve gear (exhaust valves do not close). 112720 –...
  • Page 85 1.4540.009 – Zero Pressure Detected Yellow alarm. Initiated by TecJet. Cause Corrective action u Check gas pressure. No gas pressure/gas flow detected. 1.4540.010 – Zero Flow Detected Yellow alarm. Initiated by TecJet. Cause Corrective action No gas pressure/gas flow u Check gas pressure. detected.
  • Page 86 1.4540.016 – Delta P Fail High Red alarm. Initiated by TecJet. Cause Corrective action Differential pressure at TecJet too 1. Check gas pressure. high. 2. Check TecJet for dirt. 1.4540.017 – FGP Fail High Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for operation.
  • Page 87 1.4540.023 – FGP Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet and configuration. Gas pressure before TecJet is below the preset limit value. 1.4540.024 – Coil Current Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for operation.
  • Page 88 1.4540.030 – FGT Low Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.031 – Delta P Low Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation.
  • Page 89 1.4540.038 – CAN Flow Demand Failed Red alarm. Initiated by TecJet. Cause Corrective action u Check setting. TecJet setting is not correct. 1.4540.040 – TecJet Shutdown Red alarm. Initiated by TecJet. Cause Corrective action u Rectify cause of alarm. TecJet combined alarm. At least one further TecJet alarm is present.
  • Page 90 1.4520.235 – Error Number of Teeth Red alarm. Initiated by IC922. Cause Corrective action Incorrect number of teeth on 1. Check timing wheel. timing wheel detected. 2. Check settings. 1.4520.236 – Unknown Engine Appl. Code Red alarm. Initiated by IC922. Cause Corrective action Ignition setting is not correct.
  • Page 91 1.4520.242 – Selftest Shutdown Yellow alarm. Initiated by IC922. Cause Corrective action u Restart ignition. Self-test is active with the engine rotating. 1.4520.243 – Open Primary Rate Exceeded Red alarm. Initiated by IC922. Cause Corrective action Admissible summation of 1. Check associated cabling. discharge faults is reached.
  • Page 92 1.4520.250 – Open Primary, Channel 6 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.251 – Open Primary, Channel 7 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 93 1.4520.257 – Open Primary, Channel 13 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.258 – Open Primary, Channel 14 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 94 1.4520.265 – Open Primary, Channel 20 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.270 – Warn. Missing Ring Gear Signal Yellow alarm. Initiated by IC922. Cause Corrective action Crankshaft speed signal 182 teeth...
  • Page 95 1.4520.276 – Even Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adjust value. Specified energy level is beyond the valid range. 1.4510.186 – Error Status Red alarm. Initiated by anti-knock control. Cause Corrective action Transmission combined alarm.
  • Page 96 1.4510.194 – Knock Sensor Error A3 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. 1.4510.195 – Knock Sensor Error A4 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor.
  • Page 97 1.4510.201 – Knock Sensor Error A10 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. 1.4510.202 – Knock Sensor Error B1 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor.
  • Page 98 1.4510.208 – Knock Sensor Error B7 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor. 1. Check cabling. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.209 – Knock Sensor Error B8 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock sensor.
  • Page 99 1.4530.010 – PWM Input High Duty Cycle Error Yellow alarm. Initiated by F-Series. Cause Corrective action u Check setting. F-Series setting is not correct. 1.4530.011 – PWM Input Low Duty Cycle Error Yellow alarm. Initiated by F-Series. Cause Corrective action u Check setting.
  • Page 100 1.4530.018 – Position Error Red alarm. Initiated by F-Series. Cause Corrective action Position demand and feedback do 1. Check mechanical system. not match 2. Restart F-Series. 1.4530.019 – Run Enable not active Yellow alarm. Initiated by F-Series. Cause Corrective action F-Series setting is not correct.
  • Page 101 1.4550.034 – A - Position Error Red alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action u Check mechanical system. Restart ProAct. Position demand and feedback do not match 1.4550.035 – A - Temperature Sensor Fault Red alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action Hardware not ready for operation.
  • Page 102 1.4550.041 – A - PWM Position Demand Failed Yellow alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action u Check setting. ProAct setting is not correct. 1.4550.042 – A - CAN Position Demand Failed Red alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action u Check cabling and setting.
  • Page 103 1.4550.134 – B - Position Error Red alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action Position demand and feedback do 1. Check mechanical system. not match 2. Restart ProAct. 1.4550.135 – B - Temperature Sensor Fault Red alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action Hardware not ready for operation.
  • Page 104 1.4550.141 – B - PWM Position Demand Failed Yellow alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action u Check setting. ProAct setting is not correct. 1.4550.142 – B - CAN Position Demand Failed Red alarm. Initiated by ProAct of cylinder bank A. Cause Corrective action u Check cabling and setting.

  • Page 105: 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 51) 015 –...
  • Page 106 020 – 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 154). 2). Incorrect ignition timing, 3. Check mixture setting. mixture too lean or too rich, 4.
  • Page 107 026 – 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 184). (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 108 037 – SS ETC2 Overspeed Red alarm. engine shutdown. Associated parameter 2.3013.912 Cause Corrective action u Turbocharger speed sensor is not fitted at present. Check ECU Speed of 1st secondary turbocharger too high (limit value setting for this input. 051 – HI T-Lube Oil Yellow alarm.
  • Page 109 057 – 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 110 067 – HI T-Coolant Yellow alarm. 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. 068 – SS T-Coolant Red alarm.
  • Page 111 090 – SS Idle Speed Not Reached Red alarm. Start is terminated. Associated parameter 2.1090.925 Cause Corrective action Idling speed not attained 1. Check ignition. 2. Check gas supply. 3. Check mixture setting. 091 – SS Release Speed Not Reached Red alarm.
  • Page 112 095 – 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 113 122 – HI T-ECU Yellow alarm. Associated parameter 2.0132.921 Cause Corrective action u Ensure better cooling of the ECU. Reduce room temperature, Temperature of electronics too high (limit value 1). check air flow to ADEC. 176 – AL LifeData not available Red alarm.
  • Page 114 182 – AL CAN Wrong Parameters Red alarm. Associated parameter 2.0500.682 Cause Corrective action u Contact Service. (Configuration fault) Wrong parameter value entered in data record. 183 – AL CAN No PU-Data Red alarm. Associated parameter 2.0500.683 Cause Corrective action A CAN mode has been selected u Contact Service.
  • Page 115 188 – AL CAN2 Bus Off Yellow alarm. Associated parameter 2.0500.688 Cause Corrective action u Check operation of nodes and cabling. CAN controller 2 is in “Bus-Off” status. Automatic switching to CAN bus 1. Bus nodes (ECU, SAM or EMU) faulty. 189 –...
  • Page 116 206 – SD T-Exhaust A Yellow alarm. Associated parameter 1.8004.576 Cause Corrective action u Check sensor and cabling (B4.21), replace as necessary. Error Exhaust temperature sensor on A side faulty, short circuit or wire cleared after restarting the engine. break. 207 –...
  • Page 117 216 – SD T-Lube Oil Red alarm. engine shutdown. Associated parameter 1.8004.575 Cause Corrective action u Check sensor and cabling (B7), replace as necessary. Error cleared Engine oil temperature sensor after oil heat exchanger faulty, after restarting the engine. short circuit or wire break. 219 –...
  • Page 118 231 – SD Camshaft Speed Red alarm. engine shutdown. Associated parameter 1.8004.499 Cause Corrective action u Check sensor and cabling (B1.1), replace as necessary. Error Camshaft sensor faulty, short circuit or wire break. cleared after restarting the engine. 232 – SD Charger 1 Speed Yellow alarm.
  • Page 119 381 – AL Wiring TOP 1 Yellow alarm. Associated parameter 2.8006.638 Cause Corrective action u Check cabling. Short circuit or wire break at transistor output 1 plant side (TOP 1). Activation of yellow summary alarm faulty. 382 – AL Wiring TOP 2 Red alarm.
  • Page 120 419 – SD T-Coolant before Engine Red alarm. Associated parameter 1.8004.604 Cause Corrective action u Check sensor and cabling (B6.3), replace as necessary. Coolant temperature sensor at engine inlet faulty, short circuit or wire break. 423 – LO P-Coolant Diff Red alarm.
  • Page 121 434 – HI T-Coolant before Engine Yellow alarm. Associated parameter 2.0173.931 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant temperature before engine too high (limit value 1). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit.
  • Page 122 451 – HI T-Charge Mix Yellow alarm. Associated parameter 2.0169.931 Cause Corrective action Mixture temperature is too high 1. Check mixture cooling circuit. (limit value 1). Mixture coolant 2. Check mixture cooler for dirt. pump failure, volumetric flow too low, cooling system inlet temperature too high, mixture cooler clogged.
  • Page 123 458 – LOLO T-Intake Air Red alarm. engine shutdown. Associated parameter 2.0123.922 Cause Corrective action u Check ventilation system. Intake air temperature is too low (limit value 4). 459 – SD P-Coolant b.Engine Red alarm. Associated parameter 1.8004.627 Cause Corrective action Coolant pressure sensor before u Check sensor and cabling (B16.3), replace as necessary.
  • Page 124 478 – AL Comb. Alarm Yel (Plant) Yellow alarm. Associated parameter 2.8006.001 Cause Corrective action u Summary alarm (for details, refer to the source alarm). Summary alarm YELLOW from system. 479 – AL Comb. Alarm Red (Plant) Red alarm. engine shutdown. Associated parameter 2.8006.002 Cause Corrective action...
  • Page 125 511 – 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 154). 3. Check exhaust back pressure. 4.
  • Page 126 520 – 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 as necessary. Error Intake air pressure sensor after filter on A side faulty, short circuit cleared after restarting the engine. or wire break.
  • Page 127 543 – 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 128 556 – AL GasValve Fault Red alarm. Associated parameter 2.1090.124 Cause Corrective action Gas supply solenoid valve faulty. 1. Check gas train. Alarm is activated when problems 2. Check cabling. with the gas supply solenoid valves occur. Either the gas supply solenoid valves are faulty, the time-out period is set too short, or communication is faulty.
  • Page 129 565 – AL L1 P-Intake Air after Filter A Yellow alarm. Associated parameter 2.0186.921 Cause Corrective action u Replace air filter (→ Page 175). Pressure loss over air filter on A side is too high. 566 – AL L2 P-Intake Air after Filter A Yellow alarm.
  • Page 130 570 – L1 AI 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 154). has violated the first limit value. 3.
  • Page 131 618 – LOLO Actual Value Hu 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 Actual Value Hu Yellow alarm. Associated parameter 2.1210.008 Cause Corrective action Fuel calorific value has exceeded...
  • Page 132 623 – 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 133 646 – 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 134 653 – 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 and knock control. 4. Check settings using device-specific dialog software (in device). 654 –...
  • Page 135 658 – 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. Restart ECU, EMU. 4. Replace sensor. 659 – AL NOxB Comm Lost Red alarm Associated parameter 1.4560.196 Cause...
  • Page 136 665 – AL GET Yellow Yellow alarm Associated parameter 1.4510.993 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in knock control was detected control system 666 – AL IC92x Yellow Yellow alarm Associated parameter 1.4520.993 Cause...
  • Page 137 671 – AL NOxA Yellow Yellow alarm Associated parameter 1.4560.093 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm at NOx sensor A was detected control system 672 – AL NOxB Yellow Yellow alarm Associated parameter 1.4560.193 Cause...
  • Page 138 677 – 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 summary alarm in the bypass flap was detected control system 678 – AL TecJet Red Red alarm Associated parameter 1.4540.991 Cause...
  • Page 139 683 – 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 summary alarm at step motor A was detected control system 684 – AL PhyB Red Red alarm Associated parameter 1.4570.191 Cause...
  • Page 140 691 – 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 141: 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 142: 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 143: 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 144 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 145: Crankcase Breather - Pressure Control Check And Adjustment

    8.2.2 Crankcase breather – Pressure control check and adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Open-end wrench, 36 mm F30454308/15 Checking and adjusting pres- sure Check crankcase pressure and adjust as nec- essary.

  • Page 146: 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 147). Install new spark plug (→ Page 148). 146 | Ignition System | MS150098/03E 2018-04...

  • Page 147: 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 DANGER Live components, flash-over.

  • Page 148: 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 149 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 150: 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 151). Install spark plug connector (→ Page 152). 150 | Ignition System | MS150098/03E 2018-04...

  • Page 151: 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. DANGER Live components, flash-over. Risk of serious injury - danger to life! •...

  • Page 152: 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 cable (→...
  • Page 153 Fit protective cap (2) and check for correct seating. MS150098/03E 2018-04 | Ignition System | 153...

  • Page 154: 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 155: 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 156 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 157 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 158: 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 147). Remove cylinder head covers (→ Page 162). Remove sleeves (arrowed).
  • Page 159 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 160 Install sleeves (arrowed). Install cylinder head covers (→ Page 163). Install igniters with new sealing rings (→ Page 148). 160 | Valve Drive | MS150098/03E 2018-04...

  • Page 161: 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 162). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 162: 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 151). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 163: 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 164: 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 165 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 166 Open screw connections (1, 2, 4) and loosen V-band clamp (5). Rake off intake elbow (7) with and O-ring (6) and gasket (3). Seal openings with suitable covers. Remove temperature sensor (1). Loosen nuts (6) on stud (5). Note: Flange segments (3) are used on 12 V en- gines, while 16V engines feature one flange (3).
  • Page 167 Disassembling exhaust turbo- charger Mark position of compressor housing relative to bearing housing (3). Remove screws from compressor hous- ing (1). Note: The O-ring on the insert wall is not 100% leak- tight. If oil penetrates the compressor hous- ing, the cause can be found in the oil separa- tor.
  • Page 168 Remove nozzle ring (1) from turbine housing. Cleaning exhaust turbocharger 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. Clean compressor wheel, turbine wheel, nozzle ring, compressor housing, turbine housing and diffuser with cleaner.
  • Page 169 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. a) Screw connections on 12V Name Size Type Lubricant Value/Standard Screw Tightening torque (Assembly compound 45 Nm +5 Nm (Molykote P 37)) b) Screw connections on 16V...
  • Page 170 Size Type Lubricant Value/Standard Screw Tightening torque (Assembly compound 105 Nm +5 Nm (Ultra-Therm MTU)) Final steps Install new gaskets between bellows (1) and compressor housing and between bellows (3) and turbine housing. 170 | Exhaust Turbocharger | MS150098/03E 2018-04...
  • Page 171 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). Note: Flange segments (3) are used on 12 V en- gines, while 16V engines feature one flange (3).
  • Page 172 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 screw adapter (2) by hand. Tighten screw adapter (2) to specified torque using a torque wrench. Name Size Type...
  • Page 173 Lubricant Value/Standard V-band clamp Tightening torque (Assembly compound 60 Nm +5 Nm (Ultra-Therm MTU)) (Assembly compound (Molykote P 37)) Remove covers. Install and align vent line (2). Screw on nut (1) and tighten. Use torque wrench to tighten clamp (3) to specified tightening torque.

  • Page 174: 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 175: 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 176: 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 177: 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 178). Install new starter (→ Page 179). MS150098/03E 2018-04 | Starting System | 177...

  • Page 178: 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 179: 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 180 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 181: 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 182: 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 183: 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 184: 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 185: 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 186: 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 187). Fill with engine coolant (→ Page 189). 186 | Coolant Circuit, General, High-Temperature Circuit | MS150098/03E 2018-04...

  • Page 187: 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 188 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. 188 | Coolant Circuit, General, High-Temperature Circuit | MS150098/03E 2018-04...

  • Page 189: 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 190: 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 191: 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 192: 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 193). Fill with fresh mixture coolant (→ Page 194). 192 | Low-Temperature Circuit | MS150098/03E 2018-04...

  • Page 193: 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 194: 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 195: 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 196: 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 197 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 198: 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 199: Special Tools

    10 Appendix B 10.1 Special Tools Barring gear Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 141) Crossbeam Part No.: T80092210 Qty.: Used in: 2.1 Transport (→ Page 22) Crossbeam Part No.: T80092360 Qty.: Used in: 2.1 Transport (→...
  • Page 200 Y20098771 Qty.: Used in: 8.4.1 Valve clearance – Check and adjustment (→ Page 155) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 5.8 Emission values – Check (→ Page 56) Gas detection and alarm unit (not stocked by MTU) Part No.:...
  • Page 201 Open-end wrench, 36 mm Part No.: F30454308/15 Qty.: Used in: 8.2.2 Crankcase breather – Pressure control check and adjustment (→ Page 145) Plug-in open-end wrench, 24 mm Part No.: F30029815 Qty.: Used in: 8.4.1 Valve clearance – Check and adjustment (→...
  • Page 202 Ratchet bit Part No.: F30027341 Qty.: Used in: 8.5.1 Exhaust turbocharger – Cleaning (→ Page 164) Ratchet head with extension Part No.: F30006212 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 141) Screwdriver bit Part No.: F30378921 Qty.: Used in: 8.8.3 Starter –...
  • Page 203 Used in: 8.3.2 Spark plug – Removal (→ Page 147) Qty.: Used in: 8.3.3 Spark plug – Installation (→ Page 148) Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 8.3.7 Ignition system – Ignition timing check (→ Page 154) Torque wrench 1.0–5.0 Nm...
  • Page 204 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 24) Qty.: Used in: 8.3.3 Spark plug – Installation (→ Page 148) Qty.: Used in: 8.3.6 Spark plug connector – Installation (→ Page 152) Qty.: Used in: 8.5.1 Exhaust turbocharger –...

  • Page 205: Index

    Engine oil filter  Compressor wheel  – Replacement  184 – Cleaning  164 Engine oil level  Contact person  – Check  181 – MTU Onsite Energy  198 Engine sides  Control  – Designation  26 – Starting sequence  52 Engine wiring  – Stopping sequence  52 –...
  • Page 206 – Startup, specific information for gaseous fuel supply applications  11 Safety requirements  – Warning notices, standards  21 Sensors  – Overview  33 Service partner  – MTU Onsite Energy  198 Spark plug  – Installation  148 – Removal  147 – Replacement  146 206 | Index | MS150098/03E 2018-04...
  • Page 207 Spark plug connector  – Installation  152 – Removal  151 – Replacement  150 Starter  – Electric   – Installation  179 – Removal  178 – Replacement  177 Starting sequence  – Control  52 Stopping sequence  – Control  52 Transport  – Description  22 – Lifting specifications  23 Valve clearance ...

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