MTU 12V 4000 L64 Operating Instructions Manual
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MTU 12V 4000 L64 Operating Instructions Manual

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Operating Instructions
Gas engine
12V 4000 L64
16V 4000 L64
MS15027/04E

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Questions and answers

Md Rashedul islam
April 23, 2025

Al p charge mix mean elect. Engine power alarm solve

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1 comments:
Mr. Anderson
May 11, 2025

The "Al P-Charge Mix" alarm indicates a difference in mixture pressures between sides A and B that is too high. This can lead to a red alarm and engine shutdown. The causes may include malfunctioning restrictor flaps, leakage in mixture lines, or faulty sensors and cabling.

This answer is automatically generated

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Md Rashedul islam
April 23, 2025

ECU 9 control daigham

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Summary of Contents for MTU 12V 4000 L64

  • Page 1 Operating Instructions Gas engine 12V 4000 L64 16V 4000 L64 MS15027/04E...
  • 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

    Table of Contents 1 Safety 4.2 Putting the engine into operation after extended out-of-service periods (>3 months) 1.1 Important provisions for all products 4.3 Putting the engine into operation after 1.2 Correct use of all products scheduled out-of-service-period 1.3 Personnel and organizational requirements 4.4 Control, starting and stopping sequences 1.4 Safety regulations for initial start-up and 4.5 Engine –...
  • Page 4 7.7.3 Engine oil – Sample extraction and analysis 8 Appendix A 7.8 Oil Filtration / Cooling 7.8.1 Engine oil filter – Replacement 8.1 Abbreviations 8.2 MTU Onsite Energy contact person / service 7.9 Coolant Circuit, General, High-Temperature partner Circuit 7.9.1 Engine coolant – Level check 7.9.2 Engine coolant –...

  • Page 5: Safety

    (→ Page 6). 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. Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies.

  • Page 6: Correct Use Of All Products

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

  • Page 7: Personnel And Organizational Requirements

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

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

    1.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 9 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. Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times.

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

    1.5 Safety regulations for startup and operation, specific information for gaseous fuel or dual fuel supply applications General safety regulations 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 11 • 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 12: Safety Regulations For Assembly, Maintenance, And Repair Work

    1.6 Safety regulations for assembly, maintenance, and repair work 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 for oil vapors, fluids and lubricants, risk of burning).
  • Page 13 Never use the product as a climbing aid. 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.
  • Page 14 Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. • Separate the electrical ground of electronic equipment from the ground of the unit. No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld- ing is in progress.
  • Page 15 Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines. Always use connector pliers to tighten union nuts on connectors. Subject the device as well as the product to functional testing on completion of all repair work. The emergen- cy stop function must be tested in particular.

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

    1.7 Safety regulations for assembly, maintenance and repair 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 17: Fire Prevention And Environmental Protection, Fluids And Lubricants, Indirect Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only use fluids and lubricants which have been approved by the manufacture and are specified in the Fluids and Lubricants Specifications.
  • Page 18 → SVHC acc. 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. • Wear goggles when blowing off workpieces or blowing away chips.

  • Page 19: Fire Prevention And Environmental

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

  • Page 20: Standards For 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 21: Transport

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

  • Page 22: Product Summary

    3 Product Summary 3.1 Engine overview 1 Engine Control Unit / En- 5 Engine lifting equipment 9 Engine mounting bracket, gine Monitoring Unit 6 Capacitor ignition system driving end 2 Throttle 7 Engine mounting bracket - 10 Flywheel 3 Mixture cooler free end 11 Air filter/air inlet 4 Exhaust turbocharger...
  • Page 23 1 Crankcase breather, oil sep- 6 Spark plug 11 Oil level switch arator 7 Cylinder head cover 12 Connection: engine coolant 2 Exhaust outlet 8 Cylinder head inlet 3 Gas control valve 9 Oil filter 13 Engine oil heat exchanger 4 Gas inlet connection 10 Engine oil sampling connec- 14 Connection: engine coolant...

  • Page 24: Engine Side And Cylinder Designations

    3.2 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

  • Page 25: Main Engine Dimensions

    3.3 Main engine dimensions Main engine dimensions Item Dimensions Length 12 V (A) Approx. 2868 mm Length 16 V (A) Approx. 3372 mm Width 12 V (B) Approx. 1742 mm Width 16 V (B) Approx. 1789 mm Height 12 V (C) Approx.

  • Page 26: Firing Order

    3.4 Firing order Firing order Number of cylinders Firing order 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 26 | Product Summary | MS15027/04E 2017-08...

  • Page 27: Technical Data

    3.5 Technical Data 3.5.1 12V4000L64, 16V4000L64 engine data, fuel-optimized (TA-Luft) Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 28 Number of cylinders Gas type: natural gas Methane number, min. Table 6: General conditions (for maximum power) Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh 0.15 0.15 Table 7: Consumption Model-related data (basic design) Number of cylinders Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders...
  • Page 29 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) Table 10: Coolant system (LT circuit) Lube oil system Number of cylinders...
  • Page 30 Number of cylinders Starter, current consumption, max. (standard design) 2500 2 x 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 14: Starter (electric) Capacities Number of cylinders Engine coolant capacity, 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)

  • Page 31: 12V4000L64, 16V4000L64 Engine Data, Emissions Optimized (1/2 Ta-Luft)

    3.5.2 12V4000L64, 16V4000L64 engine data, emissions optimized (1/2 TA-Luft) Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 32 Number of cylinders Gas type: natural gas Methane number, min. Table 21: General conditions (for maximum power) Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh 0.15 0.15 Table 22: Consumption Model-related data (basic design) Number of cylinders Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders...
  • Page 33 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) Table 25: Coolant system (LT circuit) Lube oil system Number of cylinders...
  • Page 34 Number of cylinders Starter, current consumption, max. (standard design) 2500 2 x 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 29: Starter (electric) Capacities Number of cylinders Engine coolant capacity, engine side (w/o cooling equipment) Liters Engine coolant, mixture coolant side (w/o cooling equipment) Liters Total engine oil capacity for initial filling (standard oil system)

  • Page 35: Monitoring, Control And Regulation Equipment

    3.6 Monitoring, Control and Regulation Equipment 3.6.1 Gas engine system – Overview Overview 1 Unit system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 Humidity sensor 10 Ignition 3 System 7 Throttles 11 Compressor bypass 4 Engine Control Unit 8 Gas control unit 12 NOx sensor (optional) Closed-/open-loop control / monitoring...
  • Page 36 Anti-Knock Regulation AKR • Controls monitored cylinders in regard of knock characteristics. If knocking is detected, the ignition tim- ing is retarded on the cylinder in question. If this does not result in an improvement, the power is reduced. Gas control valve TecJet52 / TecJet85 •...

  • Page 37: Purpose Of The Units

    3.6.2 Purpose of the units ECU 9 engine governor Central control and monitoring unit for the engine • Communication with other devices and higher-level systems via CAN bus • Control of throttles (mixture and gas) • Registration and analysis of engine operating states •...
  • Page 38 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring 38 | Monitoring, Control and Regulation Equipment | MS15027/04E 2017-08...

  • Page 39: Operation

    4 Operation 4.1 Runtimes at partial load Gas engines were designed and optimized for continuous operation at 100% load. The following restrictions apply to ensure maximum operational availability of the engine plant and to reduce maintenance to a minimum: Mechanical cylinder output Recommended maximum run- Recommended minimum run- time...

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

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

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

    4.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine shut down and starting disabled. Putting into operation Item Measure Lube oil system Check oil level in oil storage tank (→ Page 190). Coolant circuit Check engine coolant level (→ Page 194); Check mixture coolant level (→...

  • Page 42: Control, Starting And Stopping Sequences

    4.4 Control, starting and stopping sequences NOTICE Risk of engine damage due to incorrect action. Risk of severe damage to property! • Ensure engine is ready for operation before starting. See engine documentation. Starting and stopping sequences The starting sequence is software-controlled and depends on the place of start command input. To ensure that no mixture is in the engine when ignition is switched on or off, which is a specific requirement for gas engines, special procedures for engine start / stop are specified.
  • Page 43 Emergency stopping sequence If an emergency stop command is activated, the following steps are carried out automatically: 1. Closing gas supply solenoid valves 2. Closing mixture throttles 3. Engine running down to standstill 4. Deactivating ignition 5. Requesting external ventilation by contact Restarting after emergency stop A scavenging phase and a request for external ventilation by contact ensue following a start request after emergency shutdown.

  • Page 44: Engine - Start

    4.5 Engine – Start Preconditions ☑ Generator is not connected to network. ☑ Start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 45: Operational Checks

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

  • Page 46: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas 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 47 Checking emission values Note: Open the exhaust gas test section and in- stall/remove measuring equipment only when the engine is at standstill. Apply the exhaust probe (1) at the measuring point (2). Start engine. Approach the measuring point until a stable operating state has been reached.

  • Page 48: Engine - Shutdown

    4.8 Engine – Shutdown Preconditions ☑ Generator is not connected to network. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 49: Engine - Emergency Shutdown

    4.9 Engine – Emergency shutdown WARNING Escaping residual gas may create an explosive atmosphere in case of emergency stop. Explosion hazard! • Ensure that any escaping residual gas is routed out by means of appropriate facility ventilation and use of an SBV (safety blow-off valve) to prevent any risk of explosive atmosphere. •...
  • Page 50 Remedy the cause, re-enable starting Item Measure Engine control system Determine cause for emergency stop and take remedial action; if the fault cannot be corrected, contact Service. Fault acknowledgment is possible in engine stop mode only . Automatic se- lection and remote start immediately following an emergency engine stop is not admissible.

  • Page 51: After Stopping The Engine - Engine Remains Ready For Operation

    4.10 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator controller Select operating mode, e.g. MANUAL, AUTOMATIC. (manufacturer-specific) MS15027/04E 2017-08 | Operation | 51...

  • Page 52: After Stopping The Engine - Putting The Engine Out Of Operation

    If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Preservation and Represerva- tion Specifications A001070/..). The corrosion-inhibiting effect of the engine coolant may be used as an alter- native in case of out-of-service periods lasting for more than 1 month, by run- ning the engine for at least 2 hours at rated power once a month.

  • Page 53: Maintenance

    5 Maintenance 5.1 50-hours check 50-hours check One-time operations to be carried out after a test run or after the first 10 to 50 operating hours of the cylin- der head (with a new engine, after installation of new cylinder heads, after component maintenance or ex- tended component maintenance).

  • Page 54: Maintenance Task Reference Table [Ql1]

    5.2 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a standalone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 55: Troubleshooting

    OEM (see documentation of the genset manufacturer). A prerequisite for performing the measures to rectify faults is corresponding qualification/training at MTU. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
  • Page 56 Caution, the engine is running at its limits. Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled. 56 | Troubleshooting | MS15027/04E 2017-08...

  • Page 57: Fault Messages In Genset Control System Log

    6.2 Fault messages in genset control system log 112222 – HI T-Exhaust Mean Yellow alarm. Initiated by EMU. Cause Corrective action Weighted average of all individual 1. Check emission values (→ Page 46). exhaust gas temperatures is too 2. Check ignition timing (→ Page 178). high.
  • Page 58 112304 – HI T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 59 112309 – HI T-Exhaust A9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 60 112314 – HI T-Exhaust B4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 61 112319 – HI T-Exhaust B9 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 62 112404 – LO T-Exhaust A4 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 63 112408 – LO T-Exhaust A8 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 64 112412 – LO T-Exhaust B2 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 65 112416 – LO T-Exhaust B6 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 66 112420 – LO T-Exhaust B10 Yellow alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 67 112505 – HIHI T-Exhaust A5 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 68 112510 – HIHI T-Exhaust A10 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 69 112515 – HIHI T-Exhaust B5 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 70 112520 – HIHI T-Exhaust B10 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high in comparison with weighted 3.
  • Page 71 112605 – LOLO T-Exhaust A5 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 72 112609 – LOLO T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 73 112613 – LOLO T-Exhaust B3 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 74 112617 – LOLO T-Exhaust B7 Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check igniter. temperature of this cylinder is too 2. Check emission values (→ Page 46). low in comparison with weighted 3. Check ignition timing (→ Page 178). average.
  • Page 75 112702 – HIHI T-Exhaust A2 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high. 3. Check valve drive (exhaust valves do not close). 112703 –...
  • Page 76 112708 – HIHI T-Exhaust A8 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high. 3. Check valve drive (exhaust valves do not close). 112709 –...
  • Page 77 112714 – HIHI T-Exhaust B4 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high. 3. Check valve drive (exhaust valves do not close). 112715 –...
  • Page 78 112720 – HIHI T-Exhaust B10 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values (→ Page 46). temperature of this cylinder is too 2. Check ignition timing (→ Page 178). high. 3. Check valve drive (exhaust valves do not close). 112923 –...
  • Page 79 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 restrictor flap closing position. system reported overspeed.
  • Page 80 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 204). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 205). 1.4510.194 – Knock Sensor Error A3 Red alarm.
  • Page 81 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 204). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 205). 1.4510.200 – Knock Sensor Error A9 Red alarm.
  • Page 82 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 204). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 205). 1.4510.206 – Knock Sensor Error B5 Red alarm.
  • Page 83 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 204). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 205). 1.4520.232 – Error Missing Ring Gear Signal Red alarm.
  • Page 84 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 85 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 204). 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 86 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 204). 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 87 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 204). 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 88 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 205) (→ Page 204). 1.4520.273 – SCR Fault Odd Red alarm.
  • Page 89 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 90 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 91 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 92 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 governor. the admissible value. 2. Check ignition coils. 3. Check igniters. 4.
  • Page 93 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 205) (→ Page 204) 1.4520.556 –...
  • Page 94 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 204). cylinder 1 in ignition sequence. 2. Check ignition coil. 1.4520.571 – MIC5 IPE Primary Open Cylinder 2 Red alarm.
  • Page 95 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 204). cylinder 8 in ignition sequence. 2. Check ignition coil. 1.4520.578 – MIC5 IPE Primary Open Cylinder 9 Red alarm.
  • Page 96 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 204). cylinder 15 in ignition sequence. 2. Check ignition coil. 1.4520.585 – MIC5 IPE Primary Open Cylinder 16 Red alarm.
  • Page 97 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 204). cylinder 2 in ignition sequence. 2. Check ignition coil. 1.4520.592 –...
  • Page 98 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 204). cylinder 9 in ignition sequence. 2. Check ignition coil. 1.4520.599 –...
  • Page 99 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 204). cylinder 16 in ignition sequence. 2. Check ignition coil. 1.4520.606 –...
  • Page 100 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 101 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 102 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 103 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 104 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 105 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 106 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 205) (→ Page 204) 1.4520.661 –...
  • Page 107 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 108 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 205) (→ Page 204) 1.4520.675 –...
  • Page 109 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 110 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 111 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 112 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 113 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 114 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 115 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 204). 1.4540.034 – FGT High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Gas temperature before TecJet is...
  • Page 116 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 117 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 118 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 119 1.4550.036 – A - Temperature derating active Yellow alarm. Initiated by restrictor flap A-Bank. Cause Corrective action Internal temperature above 100 1. Check room temperature and ventilation. ºC. Adjustment rate is reduced. 2. Restart restrictor flap. 1.4550.037 – A - Temperature above 120 °C Red alarm.
  • Page 120 1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by restrictor flap A-Bank. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 204). 2. Check restrictor flap settings. 1.4550.044 – A - CAN Stop Command Yellow alarm.
  • Page 121 1.4550.136 – B - Temperature derating active Yellow alarm. Initiated by restrictor flap B-Bank. Cause Corrective action Internal temperature above 100 1. Check room temperature and ventilation. ºC. Adjustment rate is reduced. 2. Restart restrictor flap. 1.4550.137 – B - Temperature above 120 °C Red alarm.
  • Page 122 1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by restrictor flap B-Bank. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 204). 2. Check restrictor flap settings. 1.4550.144 – B - CAN Stop Command Yellow alarm.

  • Page 123: Engine Governor - Fault Messages

    6.3 Engine governor – Fault messages 015 – LO P-Lube Oil Yellow alarm. Associated parameter 2.0100.921 Cause Corrective action Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger. value 1). No oil in engine, engine 2. Replace oil filter (→ Page 193). speed too low, oil lines, oil heat 3.
  • Page 124 021 – HI T-Exhaust B Yellow alarm. Associated parameter 2.0127.931 Cause Corrective action Exhaust gas temperature (B side) 1. Check exhaust turbocharger. after turbine too high (limit value 2. Check ignition timing (→ Page 178). 1). Incorrect ignition timing, 3. Check mixture setting. mixture too lean or too rich, 4.
  • Page 125 030 – SS Engine Speed Red alarm. Engine shutdown. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. This 1. Check speed governor. usually fault message usually 2. Check restrictor flap closing position. follows other fault messages. Check speed governor, restrictor flap closing position.
  • Page 126 051 – HI T-Lube Oil Yellow alarm. Associated parameter 2.0125.931 Cause Corrective action Engine oil temperature after oil 1. Check engine coolant circuit. heat exchanger too high (limit 2. Check oil heat exchanger. value 1). Oil heat exchanger 3. Check oil level (→ Page 190). contaminated, coolant temperature too high.
  • Page 127 058 – SS P-Coolant Red alarm. Engine shutdown. Associated parameter 2.0101.922 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure after engine too low (limit value 2). Insufficient volume flow, static pressure too low. 063 – HI P-Crankcase Yellow alarm.
  • Page 128 068 – SS T-Coolant Red alarm. Engine shutdown. Associated parameter 2.0120.932 Cause Corrective action u Check engine coolant circuit. Coolant temperature after engine too high (limit value 2). Engine coolant pump failure, volumetric flow too low, air in engine coolant circuit.
  • Page 129 092 – SS No Starter Speed Red alarm. Start is terminated. Associated parameter 2.1090.923 Cause Corrective action u Check starter system. Minimum speed for flushing process and ignition release was not attained. 093 – SS T-Preheat Red alarm. Engine shutdown. Associated parameter 2.1090.922 Cause Corrective action...
  • Page 130 118 – LO ECU Supply Voltage Yellow alarm. Associated parameter 2.0140.921 Cause Corrective action Supply voltage too low (limit value 1. Check supply voltage. 2. Check cabling (→ Page 204). 119 – LOLO ECU Supply Voltage Red alarm. Associated parameter 2.0140.922 Cause Corrective action Supply voltage too low (limit value...
  • Page 131 181 – AL CAN2 Node Lost Red alarm. Engine shutdown. Associated parameter 2.0500.681 Cause Corrective action u Check operation of bus users and cabling. Buses (CAN bus 1 and Bus node (EMU) lost on CAN bus CAN bus 2) are redundant. 182 –...
  • Page 132 187 – AL CAN1 Error Passive Yellow alarm. Associated parameter 2.0500.687 Cause Corrective action u Check operation of bus users and cabling. CAN controller 1 signaled a warning. Possible causes may be, e.g. missing node, minor faults or temporary bus overload. 188 –...
  • Page 133 204 – SD Level Lube Oil Red alarm. Engine shutdown. Associated parameter 1.8004.602 Cause Corrective action u Check sensor and cabling (B24), replace as necessary Engine oil level sensor faulty, short circuit or wire break. (→ Page 205) (→ Page 204). Error cleared after restarting the engine.
  • Page 134 214 – SD P-Crankcase Red alarm. Associated parameter 1.8004.568 Cause Corrective action u Check sensor and cabling (B50), replace as necessary Crankcase pressure sensor faulty, short circuit or wire break. (→ Page 205) (→ Page 204). Error cleared after restarting the engine.
  • Page 135 229 – AL Stop Camshaft Sensor Defect Red alarm. Engine shutdown. Associated parameter 1.8004.562 Cause Corrective action u Check sensor and cabling (B1.1), replace as necessary Engine stop due to camshaft sensor failure. (→ Page 205) (→ Page 204). Error cleared after restarting the engine.
  • Page 136 266 – SD Speed Demand Red alarm. Associated parameter 2.8006.586 Cause Corrective action Speed setting signal can no longer 1. Check engine governor setting (default setting is speed demand via be transmitted from plant. CAN bus). 2. Check signal and cabling between plant and ECU. 381 –...
  • Page 137 418 – SD T-Intake Air B Yellow alarm. Associated parameter 1.8004.603 Cause Corrective action u Check sensor and cabling (B49.2), replace as necessary Intake air temperature sensor faulty, short circuit or wire break. (→ Page 205) (→ Page 204). 419 – SD T-Coolant b.Engine Red alarm.
  • Page 138 431 – SS P-Coolant Before Engine Red alarm. Engine shutdown. Associated parameter 2.0168.922 Cause Corrective action u Check engine coolant circuit (pressure and flow). Coolant pressure before engine too low (limit value 2). Insufficient volume flow, static pressure too low. 434 –...
  • Page 139 447 – HIHI P-Charge Mix Diff. Red alarm. Engine shutdown. Associated parameter 2.0183.932 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 2).
  • Page 140 457 – LO T-Intake Air Yellow alarm. Associated parameter 2.0123.921 Cause Corrective action u Check ventilation system. Intake air temperature is too low (limit value 3). 458 – LOLO T-Intake Air Red alarm. Engine shutdown. Associated parameter 2.0123.922 Cause Corrective action Intake air temperature is too low u Check ventilation system.
  • Page 141 478 – AL Combined Alarm Yellow (System) Yellow alarm. Associated parameter 2.8006.001 Cause Corrective action u Summary alarm (for details, refer to the source alarm). Summary alarm YELLOW from system. 479 – AL Combined Alarm Red (System) Red alarm. Engine shutdown. Associated parameter 2.8006.002 Cause Corrective action...
  • Page 142 499 – SD T-Charge Mix Red alarm. Associated parameter 1.8004.632 Cause Corrective action u Check sensor and cabling (B73), replace as necessary Mixture temperature sensor faulty, short circuit or wire break. (→ Page 205) (→ Page 204). Error cleared after restarting the engine.
  • Page 143 515 – AL Starter Not Engaged Yellow alarm. Associated parameter 2.1090.926 Cause Corrective action Starter not engaged. ECU does 1. Check starter. not detect engine speed during 2. Check cabling (→ Page 204). starting sequence. 3. Check speed sensor B1.1 if speed is not indicated although engine is turning (→...
  • Page 144 535 – LOLO Power Difference Red alarm. Engine shutdown. Associated parameter 2.1005.921 Cause Corrective action Set and actual power deviate 1. Check converter. excessively from each other. 2. Check fuel settings. 3. Check emissions (→ Page 46). 536 – AL Wiring PWM_CM1 Red alarm.
  • Page 145 556 – AL GasValve Fault Red alarm. Associated parameter 2.1090.124 Cause Corrective action Gas supply solenoid valve faulty. 1. Check gas train. Alarm is active if there are 2. Check cabling (→ Page 204). problems with the gas supply solenoid valves. Either the gas supply solenoid valves are faulty, the timeout period is set too short, or communication is faulty.
  • Page 146 560 – AL mixture throttle B fault Red alarm. Engine shutdown. Associated parameter 1.1450.013 Cause Corrective action u Check mixture restrictor flap on B side and cabling. Replace A problem related to mixture restrictor flap on B side occurred. mixture restrictor flap on B side as necessary. Possible causes: Mixture restrictor flap faulty, no power supply to restrictor flap, cabling of...
  • Page 147 569 – AL SAM Missing Data Fault Red alarm. Associated parameter 2.1090.128 Cause Corrective action u Check the cabling/connectors of the devices connected to EMU This alarm is activated if the ECU does not receive some messages and ECU bus. Replace devices as necessary. to be transmitted from EMU.
  • Page 148 581 – AL Wiring PWM_CM3 Red alarm. Associated parameter 1.1041.923 Cause Corrective action u Check setting at engine governor. Wire break or short circuit on channel PWM_CM3. 583 – AL GLS closed Red alarm. Engine shutdown. Associated parameter 2.0451.115 Cause Corrective action Generator load switch does not 1.
  • Page 149 604 – AL Hut Changespeed max. Yellow alarm. Associated parameter 2.1210.910 Cause Corrective action u Check gas system. Excessively rapid change in gas quality. 606 – AL Double Nodes Lost CAN 1 + 2 Yellow alarm. Associated parameter 2.0500.691 Cause Corrective action Bus node (EMU) lost on CAN bus u Check operation of bus nodes and cabling (→...
  • Page 150 617 – LO Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.006 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has undershot the first limit value. 618 – LOLO Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.007 Cause Corrective action...
  • Page 151 622 – LOLO NOx Value Yellow alarm. Associated parameter 2.3050.025 Cause Corrective action NOx emissions have undershot 1. Check gas quality if feasible. the second limit value. 2. Check gas pressure. 3. Check NOx sensor (→ Page 205). 4. Check emissions (→ Page 46). 623 –...
  • Page 152 628 – AL Wiring PWM_CM10 Red alarm. Associated parameter 1.1041.930 Cause Corrective action u Check setting at engine governor. Wire break or short circuit on channel PWM_CM10. 642 – SD Electr. Motor Power AI2 Yellow alarm. Associated parameter 2.8006.040 Cause Corrective action Engine power sensor defect 1.
  • Page 153 651 – AL Preheating Error Yellow alarm. Associated parameter 1.1480.101 Cause Corrective action Engine preheating faulty. 1. Low coolant. 2. Missing differential pressure in coolant system. 3. Coolant pump does not start, is faulty. 652 – AL GET Comm Lost Red alarm.
  • Page 154 656 – AL ProActA Comm Lost Red alarm. Associated parameter 1.4550.096 Cause Corrective action CAN bus communication for 1. Check cabling (→ Page 204). restrictor flap A faulty. 2. Check power supply. 3. Carry out restart of ECU, EMU and restrictor flap A. 4.
  • Page 155 665 – AL GET Yellow Yellow alarm. Associated parameter 1.4510.993 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in knock control was detected. control system. 666 – AL IC92x Yellow Yellow alarm.
  • Page 156 671 – AL NOxA Yellow Yellow alarm. Associated parameter 1.4560.093 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm at NOx sensor A was detected. control system. 672 – AL NOxB Yellow Yellow alarm.
  • Page 157 679 – AL ProActA Red Red alarm. Associated parameter 1.4550.091 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the genset An internal summary alarm in restrictor flap A was detected. control system. 680 – AL ProActB Red Red alarm.
  • Page 158 688 – LO Oil Refill Yellow alarm. Associated parameter 1.1480.301 Cause Corrective action u Check oil replenishment system. No oil replenishment within a programmable time. 689 – HI Oil Refill Yellow alarm. Associated parameter 1.1480.303 Cause Corrective action Engine oil was refilled too often u Check engine oil level (→...
  • Page 159 842 – AL Fuel Throttle Pos. L1 Yellow alarm. Power reduction. Associated parameter 2.8006.038 Cause Corrective action u Check gas supply. TecJet restrictor flap position has exceeded limit value 1. 848 – AL Rel. Humidity L1 Yellow alarm. Power reduction. Associated parameter 2.8006.039 Cause Corrective action...
  • Page 160 948 – AL ESI activated Red alarm. Associated parameter 2.8006.044 Cause Corrective action Emergency stop input has been 1. Rectify fault at source. activated. 2. Check cabling (→ Page 204). 972 – AL MIC5 Signature difference Red alarm. Associated parameter 1.4520.969 Cause Corrective action The ignition system has not...
  • Page 161 977 – AL CAN4 Error Passive Yellow alarm. Associated parameter 2.0500.695 Cause Corrective action u None CAN controller 4 has indicated a warning. 1012 – AL MIC5 parameter download active Yellow alarm. Associated parameter 1.4520.966 Cause Corrective action Parameter download from the u Wait until parameter downloading has been completed.
  • Page 162 1030 – LO P-Crank Case Yellow alarm. Associated parameter 2.0106.935 Cause Corrective action Crankcase pressure too low (limit 1. Check air filter for damage, replace if damage is visible . value 1). Restrictor valve in 2. Check setting of blow-by restrictor valve. crankcase breather too widely open, faulty air filter.

  • Page 163: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring gear F6555766 Ratchet head with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 164: Machine Room - Check For Smell Of Gas

    7.1.2 Machine room – Check for smell of gas Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas detection and alarm unit (not stocked by MTU) WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources.

  • Page 165: Engine - Test Run

    7.1.3 Engine – Test run 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 166: Crankcase Breather

    7.2 Crankcase Breather 7.2.1 Oil separator – Filter replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter element (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) O-ring (→...
  • Page 167 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 168: Crankcase Breather - Pressure Control Check And Adjustment

    7.2.2 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 a/f F30454308/15 Checking and adjusting pres- sure Check crankcase pressure and adjust if nec- essary.

  • Page 169: Ignition System

    7.3 Ignition System 7.3.1 Spark plug – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug (→ Spare Parts Catalog) Replacing spark plug Remove spark plug (→ Page 170). Install new spark plug (→ Page 171). MS15027/04E 2017-08 | Ignition System | 169...

  • Page 170: Spark Plug - Removal

    7.3.2 Spark plug – Removal Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Special wrench, 20.8 mm F30452574 WARNING Hot components/surfaces.

  • Page 171: Spark Plug - Installation

    7.3.3 Spark plug – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Special wrench, 20.8 mm F30452574...
  • Page 172 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 173: Spark Plug Connector - Replacement

    7.3.4 Spark plug connector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Spark plug connector (→ Spare Parts Catalog) Replacing spark plug connector Remove spark plug connector (→ Page 174). Install spark plug connector (→ Page 176). MS15027/04E 2017-08 | Ignition System | 173...

  • Page 174: Spark Plug Connector - Removal

    7.3.5 Spark plug connector – Removal Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug connector only immediately prior to installation. WARNING Hot components/surfaces. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. •...

  • Page 175: Spark Plug Connector - Cleaning And Check

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

  • Page 176: Spark Plug Connector - Installation

    7.3.7 Spark plug connector – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Open protective packing of new spark plug connector only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Spark plug connector with ignition line (→...
  • Page 177 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 178: Ignition System - Ignition Timing Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Stroboscope (not stocked by MTU) DANGER Live components, flash-over. Risk of serious injury - danger to life! • Always wear electrical gloves (class 4 minimum) when touching the ignition cable in operation.

  • Page 179: Valve Drive

    7.4 Valve Drive 7.4.1 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sliding depth gage, 200 mm Y20000918 Preparatory steps Remove igniters (→ Page 170). Remove cylinder head covers (→...
  • Page 180 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 181 Install sleeves (arrowed). Install cylinder head covers (→ Page 186). Install igniters with new sealing rings (→ Page 171). MS15027/04E 2017-08 | Valve Drive | 181...

  • Page 182: Valve Gear - Lubrication

    7.4.2 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear Remove cylinder head covers (→ Page 185). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 183: Valve Clearance - Check And Adjustment

    7.4.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Angular screw driver F30452765...
  • Page 184 Position Cylinder 16 V Firing TDC in cylinder A1 Bank A – X I – – X I – I – – – Bank B I – I – – – – X – – – X – X Overlap TDC in cylinder A1 Bank A –...

  • Page 185: Cylinder Head Cover - Removal

    7.4.4 Cylinder head cover ‒ Removal Preconditions ☑ Engine is stopped and starting disabled. Cylinder head cover ‒ Removal Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 174). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 186: Cylinder Head Cover - Installation

    7.4.5 Cylinder head cover ‒ Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) NOTICE Contamination of components. Damage to component! • Observe manufacturer's instructions. • Check components for special cleanliness. Cylinder head cover ‒ Installa- tion Clean mounting surface.
  • Page 187 7.5 Gas System 7.5.1 Gas supply - Checking gas lines for leaks Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Leak identification spray Soap suds WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! •...
  • Page 188 7.6 Air Filter 7.6.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Prefilter made of fleece (option) (→ Spare Parts Catalog) Note: Air filter condition is monitored by a sensor. Replace air filter and/or (optional) fleece prefilter when the cor- responding fault message appears.
  • Page 189 7.6.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installa- tion Loosen clamp (2). Remove air filter (3) and clamp (2) from con- necting flange (1) of intake housing. Clean connecting flange (1) of the intake housing and check for obstructions.
  • Page 190 7.7 Lube Oil System, Lube Oil Circuit 7.7.1 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 191 7.7.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Oil is hot.
  • Page 192 7.7.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine.
  • Page 193 7.8 Oil Filtration / Cooling 7.8.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Oil is hot.
  • Page 194 7.9 Coolant Circuit, General, High-Temperature Circuit 7.9.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 195 7.9.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 196). Fill with engine coolant (→ Page 198). MS15027/04E 2017-08 | Coolant Circuit, General, High-Temperature Circuit | 195...
  • Page 196 7.9.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 197 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS15027/04E 2017-08 | Coolant Circuit, General, High-Temperature Circuit | 197...
  • Page 198 7.9.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 199 7.9.5 Vent line of engine coolant circuit – Replacement Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Replacing coolant vent line Drain engine coolant (→...
  • Page 200 7.10 Low-Temperature Circuit 7.10.1 Mixture coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 201 7.10.2 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 202). Fill with fresh mixture coolant (→ Page 203). MS15027/04E 2017-08 | Low-Temperature Circuit | 201...
  • Page 202 7.10.3 Mixture coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Draining mixture coolant Provide a suitable receptacle to catch the coolant.
  • Page 203 7.10.4 Mixture coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant WARNING Coolant is hot and under pressure.
  • Page 204 7.11 Wiring (General) for Engine/Gearbox/Unit 7.11.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
  • Page 205 7.11.2 Sensors – Overview Sensors – B-side Illustration also applicable to 16V engines. Item Designation Monitoring of Humidity sensor B81.2 Intake air pressure after filter B16.1 Coolant pressure after engine B4.X Exhaust temperature after cylinder B79.22 Mixture pressure B side Mixture temperature Table 41: Sensors –...
  • Page 206 Sensors – Driving end Item Designation Monitoring of Nitrogen oxide (NOx) concentration in exhaust gas B79.23 Mixture pressure before throttle Crankshaft speed, reset, ignition system B13.2 Crankshaft speed, ignition Table 42: Sensors – Engine driving end 206 | Wiring (General) for Engine/Gearbox/Unit | MS15027/04E 2017-08...
  • Page 207 Sensors – A-side Item Designation Monitoring of B44.1 (optional) Turbocharger speed sensor B5.1 Engine oil pressure after filter Engine oil temperature B5.3 Engine oil pressure before filter Crankcase pressure B79.21 Mixture pressure A side Table 43: Sensors – A-side MS15027/04E 2017-08 | Wiring (General) for Engine/Gearbox/Unit | 207...
  • Page 208 Sensors – Free end Item Designation Monitoring of B6.1 Coolant temperature after engine B4.21 Collective exhaust gas temperature 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 for ignition system B6.3 Coolant temperature before engine Table 44: Sensors –...
  • Page 209 American National Standards Institute Association of American standardization organ- izations Exhaust turbocharger Series Betriebsstoffvorschrift MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Circuit Deutsches Institut für Normung e. V. At the same time identifier of German stand- ards (DIN = “Deutsche Industrie-Norm”)
  • Page 210 Abbreviation Meaning Explanation ORFS O-Ring Face Seal O-ring seal Top Dead Center Panel Control panel Peripheral Interface Module Peripheral interface module Pulse Width Modulation Modulated signal Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sicherheitsabsperrventil Sicherheitsabbalseventil Sensor Defect...
  • Page 211 Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For our locally available support, go to MTU's Internet site: • http://www.mtuonsiteenergy.com/haendlersuche/index.de.html 24-h Hotline...
  • Page 212 Part No.: Y20098771 Qty.: Used in: 7.4.3 Valve clearance – Check and adjustment (→ Page 183) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 4.7 Emission values – Check (→ Page 46) Qty.: Used in: 7.1.2 Machine room –...
  • Page 213 Oil filter wrench Part No.: F30379104 Qty.: Used in: 7.8.1 Engine oil filter – Replacement (→ Page 193) Open-end wrench 36 a/f Part No.: F30454308/15 Qty.: Used in: 7.2.2 Crankcase breather – Pressure control check and adjustment (→ Page 168) Ratchet head with extension Part No.: F30006212...
  • Page 214 Used in: 7.3.2 Spark plug – Removal (→ Page 170) Qty.: Used in: 7.3.3 Spark plug – Installation (→ Page 171) Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 7.3.8 Ignition system – Ignition timing check (→ Page 178) Torque wrench, 10–60 Nm...
  • Page 215 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 7.4.3 Valve clearance – Check and adjustment (→ Page 183) MS15027/04E 2017-08 | Special Tools | 215...
  • Page 216 – Check   – Engine governor  123 – On engine  204 – Genset control system log  57 Contact person  – Key  55 – MTU Onsite Energy  211 Firing order 26 Control 42 Coolant  – Change  195 Gas supply  Crankcase breather  – Checking gas lines for leaks  187...
  • Page 217 – Startup, specific information for dual fuel supply appli- cations  10 – Startup, specific information for gaseous fuel supply applications  10 Safety requirements  – Warning notices, standards  20 Sensors  – Overview  205 Service partner  – MTU Onsite Energy  211 MS15027/04E 2017-08 | Index | 217...
  • Page 218 Spark plug  – Installation  171 – Removal  170 – Replacement  169 Spark plug connector  – Check  175 – Cleaning  175 – Installation  176 – Removal  174 – Replacement  173 Starting sequence 42 Stopping sequence 42 System  – Gas engine   – Overview  35 transport 21 Valve clearance ...

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