MTU 20V4000L32FNER Operating Instructions Manual
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MTU 20V4000L32FNER Operating Instructions Manual

MTU 20V4000L32FNER Operating Instructions Manual

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Operating Instructions
Gas engine
20V4000L32FNER
MS150122/02E

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Summary of Contents for MTU 20V4000L32FNER

  • Page 1 Operating Instructions Gas engine 20V4000L32FNER MS150122/02E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    3.4 Firing order 7.3.4 Spark plug connector – Replacement 3.5 Technical Data 7.3.5 Spark plug connector – Removal 3.5.1 20V4000L32FNER engine data, fuel-optimized 7.3.6 Spark plug connector – Cleaning and check (TA-Luft), 100 kW/cylinder 7.3.7 Spark plug connector – Installation 3.5.2 20V4000L32FNER engine data, fuel-optimized...
  • Page 4 7.9.1 Engine coolant – Level check 7.9.2 Engine coolant – Change 8.1 Abbreviations 7.9.3 Engine coolant – Draining 8.2 MTU Onsite Energy contact person / service 7.9.4 Engine coolant – Filling partner 7.9.5 Vent line of engine coolant circuit –...

  • Page 5: Safety

    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. MS150122/02E 2017-09 | 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 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 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 for oil vapors, fluids and lubricants, risk of burning).
  • Page 14 Removing, installing and cleanliness Pay particular attention to cleanliness at all times. Take special care when removing ventilation or plug screws from the product. Ensure that O-rings are not installed in a slanted/twisted condition. Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
  • Page 15 No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld- ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri- cants.
  • Page 16 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. The functional check of the emergency stop, during which the voltage supply of the ECU is switched off, must only be carried out when the product is cold. Store spare parts properly prior to replacement, i.e.

  • Page 17: 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 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

    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 23: Product Summary

    3 Product Summary 3.1 Engine overview 1 Air filter/air inlet 6 Capacitor discharge ignition 11 Throttle 2 Mixture cooler system 12 Flywheel 3 Exhaust turbocharger, left- 7 Engine mounting bracket, 13 Engine governor/engine hand side free end monitoring 4 Exhaust turbocharger, right- 8 Oil pan KS Driving end hand side...
  • Page 24 9 Cylinder head KGS Free end 4 Gas inlet connection 10 Engine oil sampling port 5 Ignition coil Engine model designation Explanation of engine model designation 20V4000L32FNER Number of cylinders Cylinder arrangement: V engine 4000 Series Application: L = Gas engine...

  • Page 25: 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 26: Engine - Main Dimensions

    3.3 Engine – Main dimensions Engine – Main dimensions Item Dimensions Length (A) for 20V approx. 3894 mm Width (B) for 20V approx. 1584 mm Height (C) for 20V approx. 2240 mm Crankshaft center to oil pan (D) approx. 636 mm Crankshaft center to engine mount (E) approx.

  • Page 27: Firing Order

    3.4 Firing order Firing order Number of cylin- Firing order ders A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS150122/02E 2017-09 | Product Summary | 27...

  • Page 28: Technical Data

    3.5 Technical Data 3.5.1 20V4000L32FNER engine data, fuel-optimized (TA-Luft), 100 kW/cylinder Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
  • Page 29 Consumption Lube-oil consumption after 1000 h runtime g/kWh Table 7: Consumption Model-related data (basic design) Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders Cylinder configuration: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 4.77 Total displacement...
  • Page 30 Pressure in cooling system, max. Pressure loss over LT mixture cooler (at nominal flow rate 8.56) Table 10: Coolant system (LT circuit) Lube oil system Lube oil operating temperature after oil heat exchanger, from °C Lube oil operating temperature after oil heat exchanger, to °C Lube oil operating temperature after oil heat exchanger, warning °C...
  • Page 31 Starter (electric) Starter, rated power (standard design) 2 x 9 Starter, rated voltage (standard design) Starter, current consumption, max. (standard design) 2 x 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 14: Starter (electric) Capacities Engine coolant, engine side (w/o cooling equipment) Liters Engine coolant, mixture cooler side (w/o cooling equipment) Liters...

  • Page 32: 20V4000L32Fner Engine Data, Fuel-Optimized (Ta-Luft), 110 Kw/Cylinder

    3.5.2 20V4000L32FNER engine data, fuel-optimized (TA-Luft), 110 kW/cylinder Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
  • Page 33 Consumption Lube-oil consumption after 1000 h runtime g/kWh Table 22: Consumption Model-related data (basic design) Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders Cylinder configuration: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 4.77 Total displacement...
  • Page 34 Pressure in cooling system, max. Pressure loss over LT mixture cooler (at nominal flow rate 8.56) Table 25: Coolant system (LT circuit) Lube oil system Lube oil operating temperature after oil heat exchanger, from °C Lube oil operating temperature after oil heat exchanger, to °C Lube oil operating temperature after oil heat exchanger, warning °C...
  • Page 35 Starter (electric) Starter, rated power (standard design) 2 x 9 Starter, rated voltage (standard design) Starter, current consumption, max. (standard design) 2 x 2500 Starting-attempt duration, max. Number of teeth on starter ring gear Table 29: Starter (electric) Capacities Engine coolant, engine side (w/o cooling equipment) Liters Engine coolant, mixture cooler side (w/o cooling equipment) Liters...

  • Page 36: Monitoring, Control And Regulation Equipment

    3.6 Monitoring, Control and Regulation Equipment 3.6.1 Gas engine phase 4 system – Overview General overview 1 Unit system 5 Engine monitoring 9 Knock module 2 Engine system 6 Empty 10 Ignition 3 System 7 Throttles 11 Compressor bypass 4 Engine governor 8 Gas dosing unit 12 NOx sensor (optional) Governing/control/monitoring...
  • Page 37 Anti-knock control AKR • Controls monitored cylinders re. knock characteristics. If knocking is found, the ignition timing is retarded on the cylinder in question. If this does not result in an improvement, the power is reduced. Gas control valve TecJet52 •...

  • Page 38: 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 39 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring MS150122/02E 2017-09 | Monitoring, Control and Regulation Equipment | 39...

  • Page 40: 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 and to reduce main- tenance tasks to a minimum: Mechanical cylinder output Recommended maximum run- Recommended minimum run-...

  • Page 41: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

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

  • Page 42: 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 188). Coolant circuit Check engine coolant level (→ Page 192); Check mixture coolant level (→...

  • Page 43: 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 44 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 45: 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 46: 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 47: 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 48 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 49: 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 50: 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 51 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 52: 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) 52 | Operation | MS150122/02E 2017-09...

  • Page 53: 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 54: 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 55: 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 56: 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 57 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. MS150122/02E 2017-09 | Troubleshooting | 57...

  • Page 58: 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 cylinder 1. Check emission values (→ Page 47). exhaust gas temperatures is too 2. Check ignition timing (→ Page 176). high.
  • Page 59 112305 – HI T-Exhaust A5 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high in comparison 2. Check ignition timing (→ Page 176). with weighted average. 3.
  • Page 60 112311 – HI T-Exhaust B1 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high in comparison 2. Check ignition timing (→ Page 176). with weighted average. 3.
  • Page 61 112317 – HI T-Exhaust B7 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high in comparison 2. Check ignition timing (→ Page 176). with weighted average. 3.
  • Page 62 112402 – LO T-Exhaust A2 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 63 112406 – LO T-Exhaust A6 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 64 112410 – LO T-Exhaust A10 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 65 112414 – LO T-Exhaust B4 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 66 112418 – LO T-Exhaust B8 Yellow alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 67 112503 – HIHI T-Exhaust A3 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high in comparison 2. Check ignition timing (→ Page 176). with weighted average. 3.
  • Page 68 112509 – HIHI T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high in comparison 2. Check ignition timing (→ Page 176). with weighted average. 3.
  • Page 69 112515 – HIHI T-Exhaust B5 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high in comparison 2. Check ignition timing (→ Page 176). with weighted average. 3.
  • Page 70 112601 – LOLO T-Exhaust A1 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 71 112605 – LOLO T-Exhaust A5 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 72 112609 – LOLO T-Exhaust A9 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 73 112613 – LOLO T-Exhaust B3 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 74 112617 – LOLO T-Exhaust B7 Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check igniter. cylinder is too low in comparison 2. Check emission values (→ Page 47). with weighted average. 3. Check ignition timing (→ Page 176). 4.
  • Page 75 112702 – HIHI T-Exhaust A2 (abs) Red alarm. Initiated by EMU. Cause Corrective action Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high. 2. Check ignition timing (→ Page 176). 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 Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high. 2. Check ignition timing (→ Page 176). 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 Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high. 2. Check ignition timing (→ Page 176). 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 Exhaust gas temperature of this 1. Check emission values (→ Page 47). cylinder is too high. 2. Check ignition timing (→ Page 176). 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 throttle closing position. system reported overspeed. 1.4510.186 –...
  • 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 203). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 204). 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 203). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 204). 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 203). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 204). 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 203). 2. Check sensor (tightening torque, damage), replace as necessary (→ Page 204). 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 203). 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 203). 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 203). 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 204) (→ Page 203). 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 204) (→ Page 203) 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 203). 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 203). 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 203). 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 203). 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 203). 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 203). 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 204) (→ Page 203) 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 204) (→ Page 203) 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 203). 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 throttle of cylinder bank A. Cause Corrective action Internal temperature above 100 1. Check room temperature and ventilation. ºC. Adjustment rate is reduced. 2. Restart throttle. 1.4550.037 – A - Temperature above 120 °C Red alarm.
  • Page 120 1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by throttle of cylinder bank A. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 203). 2. Check throttle settings. 1.4550.044 – A - CAN Stop Command Yellow alarm.
  • Page 121 1.4550.136 – B - Temperature derating active Yellow alarm. Initiated by throttle of cylinder bank B. Cause Corrective action Internal temperature above 100 1. Check room temperature and ventilation. ºC. Adjustment rate is reduced. 2. Restart throttle. 1.4550.137 – B - Temperature above 120 °C Red alarm.
  • Page 122 1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by throttle of cylinder bank B. Cause Corrective action CAN bus connection faulty. 1. Check cabling (→ Page 203). 2. Check throttle 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 191). 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 176). 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 188). 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 203). 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 204) (→ Page 203). 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 204) (→ Page 203). 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 204) (→ Page 203). 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 204) (→ Page 203). 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 204) (→ Page 203). 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 203). 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 47). 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 203). 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 204). 4. Check emissions (→ Page 47). 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 203). 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 203). 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: 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 166 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 167: 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 168). Install new spark plug (→ Page 169). MS150122/02E 2017-09 | Ignition System | 167...

  • Page 168: 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 169: 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 170 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 171: 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 172). Install spark plug connector (→ Page 174). MS150122/02E 2017-09 | Ignition System | 171...

  • Page 172: 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 173: 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 174: 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 175 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 176: 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 177: 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 168). Remove cylinder head covers (→...
  • Page 178 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 179 Install sleeves (arrowed). Install cylinder head covers (→ Page 184). Install igniters with new sealing rings (→ Page 169). MS150122/02E 2017-09 | Valve Drive | 179...

  • Page 180: 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 183). Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 181: 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 182 Position Cylin- Overlap TDC in cylinder Bank A – – I – – X I – – X I – – – – X Bank B – X I – – X – – I – – – – X I –...

  • Page 183: 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 172). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 184: 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 185: Gas System

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

  • Page 186: Air Filter

    7.6 Air Filter 7.6.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Prefilter made of fleece (option) (→ Spare Parts Catalog) Note: Air filter condition is monitored by a sensor. Replace air filter and/or (optional) fleece prefilter when the cor- responding fault message appears.
  • Page 187 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 188 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 189 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 190 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 191 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 192 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 193 7.9.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 194). Fill with engine coolant (→ Page 196). MS150122/02E 2017-09 | Coolant Circuit, General, High-Temperature Circuit | 193...
  • Page 194 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 195 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS150122/02E 2017-09 | Coolant Circuit, General, High-Temperature Circuit | 195...
  • Page 196 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 197 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 198 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 199 7.10.2 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 200 7.10.3 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 201). Fill with fresh mixture coolant (→ Page 202). 200 | Low-Temperature Circuit | MS150122/02E 2017-09...
  • Page 201 7.10.4 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 202 7.10.5 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 203 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 204 7.11.2 Sensors – Overview Sensors on B-side, 20V Item Designation Monitoring of B49.2 Intake air temperature, B-side B81.2 Intake air pressure after filter, B-side B44.2 Exhaust turbocharger speed, B side B16.1 Coolant pressure after engine B4.XX Exhaust gas temperature after cylinder XX B79.22 Mixture pressure, B-side Mixture temperature...
  • Page 205 Sensors on driving end, 20V Item Designation Monitoring of B79.23 Mixture pressure before restrictor flap Crankshaft speed, reset ignition system B13.2 Crankshaft speed ignition Table 40: Sensors – Engine, driving end, 20V MS150122/02E 2017-09 | Wiring (General) for Engine/Gearbox/Unit | 205...
  • Page 206 Sensors on A-side, 20V Item Designation Monitoring of B44.1 Exhaust turbocharger speed, A side B49.1 Intake air pressure after filter, A-side B81.1 Intake air temperature, A-side B79.21 Mixture pressure, A-side Crankcase pressure B5.3 Engine oil pressure before filter Engine oil temperature B5.1 Engine oil pressure after filter Table 41: Sensors on A-side, 20V...
  • Page 207 Sensors on free end, 20V Item Designation Monitoring of B88.X Nitrogen oxide (NOx) concentration in the exhaust gas (option) B4.21 Exhaust gas bulk temperature after exhaust turbo- charger, A-side B16.3 Coolant pressure before engine B1.3 Camshaft speed for anti-knock control B1.1 Camshaft speed for engine governor Engine oil level...
  • Page 208 7.11.3 Sensors – Removal Preconditions ☑ Preparatory steps have been completed. ☑ Engine is stopped and starting disabled. ☑ Provide containers for catching any fluids that escape. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ratchet bit F30027340 WARNING Fuels are combustible and explosive.
  • Page 209 Removing NOx sensor (B88) Observe the following general information: • Arrangement and position of sensor (→ Page 204). Loosen and disconnect connector (2). Unscrew electronics box (1) at the eyelets. Remove sensor via nut (3). MS150122/02E 2017-09 | Wiring (General) for Engine/Gearbox/Unit | 209...
  • Page 210 7.11.4 Sensors – Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Kluthe Hakuform 30-15) X00067260 O-ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→...
  • Page 211 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 212 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 213 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 214 Part No.: Y20098771 Qty.: Used in: 7.4.3 Valve clearance – Check and adjustment (→ Page 181) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 4.7 Emission values – Check (→ Page 47) Qty.: Used in: 7.1.2 Machine room –...
  • Page 215 Oil filter wrench Part No.: F30379104 Qty.: Used in: 7.8.1 Engine oil filter – Replacement (→ Page 191) Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.11.4 Sensors – Installation (→ Page 210) Ratchet bit Part No.: F30027340 Qty.: Used in: 7.11.3 Sensors –...
  • Page 216 Used in: 7.3.2 Spark plug – Removal (→ Page 168) Qty.: Used in: 7.3.3 Spark plug – Installation (→ Page 169) Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 7.3.8 Ignition system – Ignition timing check (→ Page 176)
  • Page 217 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 7.3.3 Spark plug – Installation (→ Page 169) Qty.: Used in: 7.3.7 Spark plug connector – Installation (→ Page 174) Qty.: Used in: 7.11.4 Sensors – Installation (→ Page 210) Torque wrench, 60–320 Nm Part No.: F30452768...
  • Page 218 9.2 Index Numerics Engine driving end  – Definition  25 20V4000L32FNER engine data  Engine free end  – Fuel-optimized (TA-Luft)   – Definition  25 – 100 kW/cylinder  28 Engine oil  – 110 kW/cylinder  32 – Change  189 50-hours check 54 – Sample extraction and analysis  190...
  • Page 219 – Startup, specific information for gaseous fuel supply applications  11 Safety requirements  – Warning notices, standards  21 Sensors  – Installation  210 – Overview  204 – Removal  208 Service partner  – MTU Onsite Energy  213 MS150122/02E 2017-09 | Index | 219...
  • Page 220 Spark plug  – Installation  169 – Removal  168 – Replacement  167 Spark plug connector  – Check  173 – Cleaning  173 – Installation  174 – Removal  172 – Replacement  171 Starting sequence 43 Stopping sequence 43 transport 22 Valve clearance  – Adjustment  181 – Check  181 Valve gear ...

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