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MTU 8V4000L63 Operating Instructions Manual

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Operating Instructions

Gas engine
8 V 4000 Lx3
MS150057/02E

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Summary of Contents for MTU 8V4000L63

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 8 V 4000 Lx3 MS150057/02E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 3.7 Emission values – Check 3.8 Engine – Shutdown 1.1 Important provisions for all products 3.9 Emergency stop 1.2 Personnel and organizational requirements 3.10 After stopping the engine – Engine remains 1.3 Transport ready for operation 1.4 Safety regulations for startup and operation 3.11 After stopping the engine –...
  • Page 4 7 Appendix A 6.9.3 Engine coolant – Draining 6.9.4 Engine coolant – Filling 7.1 Abbreviations 6.9.5 Vent line of engine coolant circuit – 7.2 MTU Onsite Energy contacts / service Replacement partners 6.10 Low-Temperature Circuit 6.10.1 Mixture coolant level – Check 8 Appendix B 6.10.2 Mixture coolant –...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 7: Transport

    Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis.

  • Page 8: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.

  • Page 9: Safety Regulations For Startup And Operation, Special Instructions For Applications With Gaseous Fuel

    1.5 Safety regulations for startup and operation, special instructions for applications with gaseous fuel Gas system Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device. This must be designed by the plant designer according to site conditions. The connection to the gas supply network is made by the plant designer in accordance with regulations of the DVGW (DVGW490, G490/I).

  • Page 10: Safety Regulations For Maintenance And Repair Work

    1.6 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 11 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths and cable ties). Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
  • Page 12 Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work.

  • Page 13: Safety Regulations For Maintenance And Repair Work, Special Instructions For Applications With Gaseous Fuel

    1.7 Safety regulations for maintenance and repair work, special instructions for applications with gaseous fuel Safety regulations prior to maintenance and repair work Installation and connection of the gas supply must only be carried out by a specialized company with staff that has been trained and authorized for this task.

  • Page 14: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product.

  • Page 15: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 16: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials, Special Instructions For Applications With Gaseous Fuel

    1.9 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials, special instructions for applications with gaseous fuel Natural gas Observe the safety data sheet. Caution: Highly flammable gas, forms an explosive mixture with air/oxygen. Caution: Weak narcotic gas, risk of suffocation at very high concentration. All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during operation.

  • Page 17: Standards For Safety Notices In The Text

    1.10 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 18: Product Summary

    2 Product Summary 2.1 Engine layout 1 Engine governor/engine 5 Engine lifting eye 9 Engine mounting bracket, monitoring 6 Capacitor ignition system driving end 2 Air filter/air inlet 7 Engine mounting bracket, 10 Starter 3 Mixture cooler free end 11 Flywheel 4 Exhaust turbocharger 8 Oil pan KS Driving end...
  • Page 19 1 Crankcase breather, oil 7 Spark plug 13 Engine coolant inlet con- separator 8 Cylinder head cover nection 2 Exhaust gas outlet connec- 9 Cylinder head 14 Engine oil heat exchanger tion 10 Engine oil sampling con- 15 Engine coolant outlet con- 3 Gas control valve nection nection...

  • Page 20: Engine Side And Cylinder Designations

    2.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B"...

  • Page 21: Engine - Main Dimensions

    2.3 Engine ‒ Main dimensions Engine ‒ Main dimensions Length (A) approx. 2166 mm Width (B) approx. 1751 mm Height (C) approx. 2103 mm Crankshaft center to oil pan (D) approx. 625 mm Crankshaft center to engine mount (E) approx. 280.5 mm Table 3: Main dimensions MS150057/02E 2013-10 | Product Summary | 21...

  • Page 22: Firing Order

    2.4 Firing order Firing order A1-A3-A4-A2-B3-B4-B2-B1 22 | Product Summary | MS150057/02E 2013-10...

  • Page 23: Technical Data

    2.5 Technical Data 2.5.1 8V 4000 L63 engine data, fuel-optimized (TA-Luft) Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 24 Number of cylinders Gas type: natural gas Methane number, min. Table 6: General conditions (for max. power) Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh Table 7: Consumption Model-related data (basic design) Number of cylinders Operating method: Four-stroke cycle, Otto engine, single-acting Combustion method: Mixture charging, spark ignition Number of cylinders Cylinder arrangement: V angle...

  • Page 25: Fuel System

    Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: inlet from °C cooling equipment (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler (at nominal flow rate 8.56) Table 10: Coolant system (LT circuit) Lube oil system Number of cylinders...
  • Page 26 Number of cylinders Starter current consumption, max. (standard design) Starting-attempt duration, max. Number of teeth on starter ring gear Table 14: Starting (electric) Capacities Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Liters Mixture coolant, engine side (without cooling system) Liters Total engine oil capacity for initial filling (standard oil system) Liters...

  • Page 27: 4000 L63 Engine Data, Emissions-Optimized (1/2 Ta-Luft)

    2.5.2 8V 4000 L63 engine data, emissions-optimized (1/2 TA-Luft) Explanation: DL Reference value: Continuous power BL Reference value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 28 Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh 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 Cylinder arrangement: V angle Degrees (°) Bore...
  • Page 29 Number of cylinders Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler (at nominal flow rate 8.56) Table 25: Coolant system (LT circuit) Lube oil system Number of cylinders Lube oil operating temperature after oil heat exchanger, from °C Lube oil operating temperature after oil heat exchanger, to °C...
  • Page 30 Capacities Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Liters Mixture coolant, engine side (without cooling system) Liters Total engine oil capacity for initial filling (standard oil system) Liters Oil change capacity, max. (standard oil system) Liters Table 30: Capacities Weights / main dimensions Number of cylinders...

  • Page 31: Monitoring, Control And Regulation Equipment

    2.6 Monitoring, Control and Regulation Equipment 2.6.1 Gas engine phase 3 system – Overview Overview 1 Unit system 5 Engine Monitoring Unit 9 Knock module 2 Engine system 6 NOx sensor 10 Gas dosing unit 3 System 7 Compressor bypass 11 Throttles 4 Engine governor 8 Ignition...
  • Page 32 Compressor bypass (F-series) • Controls throttle reserve, blocks compressor pumps Ignition system IC922 • Adjusts ignition timing for cylinders Anti-knock control AKR • Controls monitored cylinders with regard to 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.

  • Page 33: Control Cabinet Mis - Overview

    2.6.2 Control cabinet MIS – Overview Phase 3 gas engine control cabinet MIS – Overview A Control cabinet door, ex- 2 Automatic cutout 6A 5 Automatic cutout 32A ternal side 3 Relay 6 Automatic cutout 16A B Mounting plate 4 Terminal block 7 Emergency stop (key 1 SAM switch)

  • Page 34: Purpose Of The Units

    2.6.3 Purpose of the units Engine governor ADEC (ECU 7) 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) • Acquisition and evaluation of engine operating states •...
  • Page 35 Service and Automation Module SAM 1 Module cassette, slots for 4 Control keys for Mini Dia- 7 Connector with spring de- additional I/O PIM cards sign 2 Compact Flash Memory 5 Diagnostic lamp card 6 Interface for dialog unit 3 Display for fault code and Mini Dialog SAM functions •...
  • Page 36 Customer interface • 24 binary outputs • 3 PWM outputs • 8 display outputs • 28 channel binary input • 10 analog inputs (e.g. PT100, 4–20 mA, 0-10 V, etc.) • 4 frequency inputs • 1 dialog interface • Extendable with MCS 5 PIM I/O cards CANOpen and SAE-J1939 interface For CANOpen and J1939 interface, a type CCB2 printed circuit board (1) is inserted in slot 3 of the SAM unit.
  • Page 37 Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring MS150057/02E 2013-10 | Product Summary | 37...

  • Page 38: Operation

    3 Operation 3.1 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: Power, referenced to nominal Recommended maximum run- Recommended minimum run-...

  • Page 39: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    3.2 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 Action Engine Depreserve (→...

  • Page 40: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    3.3 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 162). Coolant circuit Check engine coolant level (→ Page 166); Check mixture coolant level (→...

  • Page 41: Control, Starting And Stopping Sequences

    3.4 Control, starting and stopping sequences NOTICE Risk of engine damage due to incorrect action. Risk of severe damage to property! • Ensure engine is ready for operation before starting. See engine documentation. Starting and stopping sequences The start sequence is software-controlled and depends on the place of start command input. To ensure that no mixture is in the engine when ignition is switched on or off, which is a specific re- quirement for gas engines, special procedures for engine start / stop are specified.
  • Page 42 Emergency stop sequence If an emergency stop command is activated, the following steps are carried out automatically: 1. Closing gas supply solenoid valves and mixture throttles 2. Mixture throttles close 3. Coasting down engine to standstill for a maximum coasting period 4.

  • Page 43: Engine - Start

    3.5 Engine – Start Preconditions ☑Generator not connected to network. ☑Start interlock 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 en- gine's danger zone.

  • Page 44: Operational Checks

    3.6 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! •...

  • Page 45: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas measuring and warning device (not stocked by MTU) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 46: Engine - Shutdown

    3.8 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 stresses. Overheating of and, therefore, damage to components is possible! • Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant levels are indicated.

  • Page 47: Emergency Stop

    3.9 Emergency stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Item Measure Emergency stop pushbutton Press pushbutton. • Engine will be shut down. Safety measures Item Measure...

  • Page 48: After Stopping The Engine - Engine Remains Ready For Operation

    3.10 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator control Select operating mode, e.g. HAND, MANUAL, AUTO, AUTOMATIC. (manufacturer-specific) 48 | Operation | MS150057/02E 2013-10...

  • Page 49: 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 50: Maintenance

    4 Maintenance 4.1 50-hours check 50-hours check One-time operations to be carried out after the first 50 operating hours of the cylinder head (with a new engine, after installation of new cylinder heads, after component maintenance or extended component maintenance). When installing a cylinder head with run-in mating faces (e.g.

  • Page 51: Maintenance Task Reference Table [Ql1]

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

  • Page 52: Troubleshooting

    5 Troubleshooting 5.1 Fault indication on SAM display Explanation of the abbreviations used The following abbreviations are used in the texts for the fault messages: Abbreviation Meaning DL <number> Default Lost: The device with designation <number> has lost its connec- tion to the default CAN bus.
  • Page 53 Fault messages from the SAM are represented in the fault code list (→ Page 56). A prerequisite for performing the measures to rectify faults is a corresponding qualification/training at MTU. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
  • Page 54 OEM (see documentation of the genset man- ufacturer). A prerequisite for performing the measures to rectify faults is a corresponding qualification/training at MTU. Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful. Recommended action in case of alarm...
  • Page 55 SE no. Error message text I/O-Module Slot5 Defect I/O-Module Slot6 Defect I/O-Module Slot7 Defect I/O-Module Slot8 Defect Download Server Collision not projected node Device specific error not projected node Device specific error Table 38: SE (System Error) alarms MS150057/02E 2013-10 | Troubleshooting | 55...

  • Page 56: Sam - Fault Messages

    5.2 SAM – Fault messages 112222 – HI T-Exhaust Mean Yellow alarm. Initiated by EMU. Cause Corrective action The average value of all 1. Check emission values. individual cylinder exhaust 2. Check ignition timing (→ Page 149). temperatures is too high. 3.
  • Page 57 112305 – HI T-Exhaust A5 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 112306 –...
  • Page 58 112311 – HI T-Exhaust B1 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 112312 –...
  • Page 59 112317 – HI T-Exhaust B7 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 112318 –...
  • Page 60 112403 – LO T-Exhaust A3 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 61 112408 – LO T-Exhaust A8 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 62 112413 – LO T-Exhaust B3 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 63 112418 – LO T-Exhaust B8 Yellow alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 64 112504 – HIHI T-Exhaust A4 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 112505 –...
  • Page 65 112510 – HIHI T-Exhaust A10 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 112511 –...
  • Page 66 112516 – HIHI T-Exhaust B6 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high as compared 2. Check ignition timing (→ Page 149). with the average value. 3. Check valve drive (exhaust valves do not close). 112517 –...
  • Page 67 112602 – LOLO T-Exhaust A2 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 68 112607 – LOLO T-Exhaust A7 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 69 112612 – LOLO T-Exhaust B2 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 70 112617 – LOLO T-Exhaust B7 Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check spark plug. cylinder is too low as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 149). 4.
  • Page 71 112703 – HIHI T-Exhaust A3 (abs) Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 149). 3. Check valve drive (exhaust valves do not close). 112704 –...
  • Page 72 112709 – HIHI T-Exhaust A9 (abs) Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 149). 3. Check valve drive (exhaust valves do not close). 112710 –...
  • Page 73 112715 – HIHI T-Exhaust B5 (abs) Red alarm. Initiated by EMU. Cause Corrective action The exhaust temperature of this 1. Check emission values. cylinder is too high. 2. Check ignition timing (→ Page 149). 3. Check valve drive (exhaust valves do not close). 112716 –...
  • Page 74 112923 – MD/SD T-Exhaust Red alarm. Initiated by EMU. Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined alarm (for details, refer to the source alarm). 150176 – Lube Oil Min Red alarm. Initiated by SAM. Cause Corrective action Minimum engine oil level...
  • Page 75 150204 – Comm. Lost Mixer (TecJet) Red alarm. Initiated by SAM. Cause Corrective action No communication with mixer 1. Check supply voltage. (TecJet) CAN. 2. Check connecting line. 150352 – SS Release Circuit Breaker Red alarm. Initiated by SAM. Cause Corrective action Circuit breaker release u Check circuit breakers.
  • Page 76 150402 – LO Oil Refill Yellow alarm. Initiated by SAM. Cause Corrective action u Check oil replenishment system. No oil replenishment within a configurable time. 150403 – AL Oil Refill Error Red alarm. Initiated by SAM. Cause Corrective action After initiation of the alarms 1.
  • Page 77 151021 – Warning Hold Position Yellow alarm. Initiated by TecJet. Cause Corrective action u Deactivate setting or interrupt serial communication. Hold position is activated. 151022 – Zero Pressure Detected Yellow alarm. Initiated by TecJet. Cause Corrective action No gas pressure/gas flow u Check gas pressure.
  • Page 78 151029 – FGT Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 151030 – Delta P Fail High Red alarm. Initiated by TecJet. Cause Corrective action Excessive differential pressure 1. Check gas pressure. over TecJet detected.
  • Page 79 151038 – Delta P Fail Low Red alarm. Initiated by TecJet. Cause Corrective action u Check TecJet and configuration. Differential pressure at TecJet is below the preset limit value. 151039 – FGP Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Gas pressure before TecJet is u Check TecJet and configuration.
  • Page 80 151051 – PWM Duty Cycle High Error Red alarm. Initiated by TecJet. Cause Corrective action PWM signal is beyond the valid 1. Check cabling. range. 2. Check frequency. 3. Check signal. 151052 – Battery Volt Low Error Red alarm. Initiated by TecJet. Cause Corrective action Supply voltage has reached...
  • Page 81 151058 – Delta P High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 151059 – FGP High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet.
  • Page 82 152011 – Error Missing Ring Gear Signal Red alarm. Initiated by IC922. Cause Corrective action u Check sensor B13.2, check sensor clearance and cabling, Crankshaft signal for ignition speed 182 teeth missing. replace if necessary. Restart of ignition system required to restart the engine.
  • Page 83 152019 – Global Timing out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adjust value. Specified global ignition timing is beyond the valid range. 152020 – Unknown Timing or Energy Level Red alarm. Initiated by IC922. Cause Corrective action No global ignition timing and u Check cabling and setting.
  • Page 84 152028 – Open Primary, Channel 3 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. 152029 – Open Primary, Channel 4 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 85 152035 – Open Primary, Channel 10 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. 152036 – Open Primary, Channel 11 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 86 152042 – Open Primary, Channel 17 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coil. 152043 – Open Primary, Channel 18 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 87 152054 – SCR Fault Odd Red alarm. Initiated by IC922. Cause Corrective action u Restart ignition system. Hardware not ready for operation. 152055 – SCR Fault Even Red alarm. Initiated by IC922. Cause Corrective action Hardware not ready for u Restart ignition system. operation.
  • Page 88 153104 – Error Camshaft Red alarm. Initiated by antiknock control. Cause Corrective action No signal from camshaft sensor 1. Check cabling. for antiknock control. 2. Check sensor B1.3, replace as necessary. 153111 – Knock Sensor Error A1 Red alarm. Initiated by antiknock control. Cause Corrective action No signal received from this...
  • Page 89 153116 – Knock Sensor Error A6 Red alarm. Initiated by antiknock control. Cause Corrective action No signal received from this 1. Check cabling. knock sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 153117 – Knock Sensor Error A7 Red alarm.
  • Page 90 153122 – Knock Sensor Error B2 Red alarm. Initiated by antiknock control. Cause Corrective action No signal received from this 1. Check cabling. knock sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 153123 – Knock Sensor Error B3 Red alarm.
  • Page 91 153128 – Knock Sensor Error B8 Red alarm. Initiated by antiknock control. Cause Corrective action No signal received from this 1. Check cabling. knock sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 153129 – Knock Sensor Error B9 Red alarm.
  • Page 92 153224 – HI Knock Integrator A4 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 93 153229 – HI Knock Integrator A9 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 94 153234 – HI Knock Integrator B4 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 95 153239 – HI Knock Integrator B9 Yellow alarm. Initiated by SAM. Cause Corrective action Readjustment of ignition timing 1. Check emission values. beyond a limit value because 2. Check ignition timing (→ Page 149). knocking was detected in this 3. Check combustion chamber. cylinder.
  • Page 96 153244 – HIHI Knock Integrator A4 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153245 –...
  • Page 97 153249 – HIHI Knock Integrator A9 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153250 –...
  • Page 98 153254 – HIHI Knock Integrator B4 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153255 –...
  • Page 99 153259 – HIHI Knock Integrator B9 Red alarm. Initiated by SAM. Cause Corrective action Emergency stop due to knocking 1. Check emission values. detected in this cylinder. 2. Check ignition timing (→ Page 149). 3. Check combustion chamber. 4. Check gas quality if feasible (methane number). 153260 –...
  • Page 100 153265 – HI Misfire Integrator A5 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153266 – HI Misfire Integrator A6 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 101 153272 – HI Misfire Integrator B2 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153273 – HI Misfire Integrator B3 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 102 153279 – HI Misfire Integrator B9 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153280 – HI Misfire Integrator B10 Yellow alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 103 153286 – HIHI Misfire Integrator A6 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153287 – HIHI Misfire Integrator A7 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 104 153293 – HIHI Misfire Integrator B3 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). 153294 – HIHI Misfire Integrator B4 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this...
  • Page 105 153300 – HIHI Misfire Integrator B10 Red alarm. Initiated by SAM. Cause Corrective action Misfiring was detected in this 1. Check emission values. cylinder. 2. Check spark plug (energy level ignition system). MS150057/02E 2013-10 | Troubleshooting | 105...

  • Page 106: Engine Governor - Fault Messages

    5.3 Engine governor – Fault messages 015 – LO P-Lube Oil ZKP-Number: 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). Lack of engine oil, 2. Replace oil filter (→ Page 165). engine speed too low, oil lines, 3.
  • Page 107 020 – SS T-Exhaust A ZKP-Number: Yellow alarm. Associated parameter 2.0126.932 Cause Corrective action Exhaust gas temperature (A 1. Check exhaust turbocharger. side) after turbine too high (limit 2. Check ignition timing (→ Page 149). value 2). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4.
  • Page 108 026 – HI P-Diff-Lube Oil ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0154.932 Cause Corrective action Pressure loss via oil filter too 1. Replace oil filter (→ Page 165). high (limit value 2). 2. If this fault message occurs again after unexpectedly short filter runtime, check oil filter for deposits, change oil if required (→...
  • Page 109 036 – HI ETC2 Overspeed ZKP-Number: Yellow alarm. Associated parameter 2.3013.931 Cause Corrective action u Turbocharger speed sensor is not fitted at present. Check ECU Speed of 1st secondary turbocharger too high (limit setting for this input. value 1). 037 – SS ETC2 Overspeed ZKP-Number: Red alarm.
  • Page 110 053 – HI T-Intake Air ZKP-Number: Yellow alarm. Associated parameter 2.0123.931 Cause Corrective action u Check ventilation system. Intake air temperature too high (limit value 1). 054 – HIHI T-Intake Air ZKP-Number: Yellow alarm. Associated parameter 2.0123.932 Cause Corrective action Intake air temperature too high 1.
  • Page 111 063 – HI P-Crank Case ZKP-Number: Yellow alarm. Associated parameter 2.0106.931 Cause Corrective action Crankcase pressure too high 1. Check crank drive: (limit value 1). Restrictor valve in • Crank engine (→ Page 137). crankcase breather is closed too • Endoscope combustion chambers from bottom dead center much, air filter is defective, oil to top dead center.
  • Page 112 068 – SS T-Coolant ZKP-Number: 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. 089 –...
  • Page 113 091 – SS Release Speed Not Reached ZKP-Number: Red alarm. Start terminated. Associated parameter 2.1090.924 Cause Corrective action The speed (starter DISENGAGE) 1. Check ignition. was not attained, ignition not 2. Check gas supply. working or no gas available. 3. Check mixture setting. 092 –...
  • Page 114 095 – AL Prelubrication Fault ZKP-Number: Red alarm. Start terminated. Associated parameter 2.1090.920 Cause Corrective action Oil priming fault. 1. Check oil pressure, oil temperature, oil level. 2. Check oil priming pump. 104 – AL Eng Hours Counter Defect ZKP-Number: Yellow alarm.
  • Page 115 121 – HIHI ECU Supply Voltage ZKP-Number: Red alarm. Associated parameter 2.0140.932 Cause Corrective action Supply voltage too high (limit 1. Check supply voltage. value 2). 2. Check cabling. 122 – HI T-ECU ZKP-Number: Yellow alarm. Associated parameter 2.0132.921 Cause Corrective action u Improve cooling of governor.
  • Page 116 180 – AL CAN1 Node Lost ZKP-Number: Yellow alarm. Associated parameter 2.0500.680 Cause Corrective action u Check operation of nodes and cabling. Busses (CAN bus 1 and Bus node (SAM or EMU) lost on CAN bus 1. CAN bus 2) are redundant. 181 –...
  • Page 117 184 – AL CAN PU-Data Flash Error ZKP-Number: Red alarm. Associated parameter 2.0500.684 Cause Corrective action u Contact Service (configuration fault). A programming error occurred when attempting to copy a received PU data module into the Flash module. 186 – AL CAN1 Bus Off ZKP-Number: Yellow alarm.
  • Page 118 189 – AL CAN2 Error Passive ZKP-Number: Yellow alarm. Associated parameter 2.0500.689 Cause Corrective action u Check operation of nodes (ECU, SAM or EMU) and cabling. CAN controller 2 has signaled a warning. The cause may be e.g. missing listening nodes, minor malfunctions or temporary bus overload.
  • Page 119 206 – SD T-Exhaust A ZKP-Number: Yellow alarm. Associated parameter 1.8004.576 Cause Corrective action u Check sensor and cabling (B4.21), replace if necessary. Fault is Exhaust temperature sensor on A side defective, short circuit or rectified when engine is restarted. wire break.
  • Page 120 214 – SD P-Crank Case ZKP-Number: Red alarm. Associated parameter 1.8004.568 Cause Corrective action u Check sensor and cabling (B50), replace as necessary. Fault is Crankcase pressure sensor defective, short circuit or wire rectified when engine is restarted. break. 216 – SD T-Lube Oil ZKP-Number: Red alarm.
  • Page 121 227 – SD P- Lube Oil before Filter ZKP-Number: Yellow alarm. Associated parameter 1.8004.620 Cause Corrective action u Check sensor and cabling (B5.3), replace as necessary. Fault is Engine oil pressure sensor before filter defective, short rectified when engine is restarted. circuit or wire break.
  • Page 122 233 – SD Charger 2 Speed ZKP-Number: Yellow alarm. Associated parameter 1.3011.129 Cause Corrective action u Turbocharger speed sensor is not fitted at present. Speed sensor of secondary turbocharger defective, short circuit or wire break. 245 – SD ECU Power Supply Voltage ZKP-Number: Red alarm.
  • Page 123 382 – AL Wiring TOP 2 ZKP-Number: Red alarm. Associated parameter 2.8006.639 Cause Corrective action u Check cabling. Short circuit or wire break on transistor output, plant-side 2 (TOP 2). Activation of red combined alarm faulty. 383 – AL Wiring TOP 3 ZKP-Number: Red alarm.
  • Page 124 419 – SD T-Coolant b. Engine ZKP-Number: Red alarm. Associated parameter 1.8004.604 Cause Corrective action u Check sensor and cabling (B6.3), replace if necessary. Coolant temperature sensor at engine inlet defective, short circuit or wire break. 423 – LO P-Coolant Diff. ZKP-Number: Red alarm.
  • Page 125 431 – SS P-Coolant before Engine ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0168.922 Cause Corrective action u Check engine coolant circuit (pressure and volumetric flow). Coolant pressure before engine too low (limit value 2). Volumetric flow too low, static pressure too low.
  • Page 126 447 – HIHI P-Charge Mix Diff. ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0183.932 Cause Corrective action Difference in mixture pressures 1. Check throttles for varying positions and malfunction. sensed on A and B side is too 2. Check mixture lines for leakage. high (limit value 2).
  • Page 127 454 – SS Power Reduction Active ZKP-Number: Yellow alarm. Associated parameter 2.7000.011 Cause Corrective action u Rectify limit value violation of the source alarm (e.g. reduce Power reduction activated. intake air temperature). 457 – LO T-Intake Air ZKP-Number: Yellow alarm. Associated parameter 2.0123.921 Cause Corrective action...
  • Page 128 472 – AL Stop SD ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.8006.593 Cause Corrective action u Combined alarm (for details, refer to the source alarm). Engine stop, since all shutdown channels detect “sensor defect". 473 – AL Wiring PWM_CM2 ZKP-Number: Red alarm.
  • Page 129 496 – SD P-Charge Mix A ZKP-Number: Red alarm. Engine shutdown. Associated parameter 1.8004.628 Cause Corrective action u Check sensor and cabling (B79.21), replace if necessary. Fault Mixture pressure sensor on A side defective, short circuit or is rectified when engine is restarted. wire break.
  • Page 130 511 – HIHI P-Charge Mix A ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.0181.932 Cause Corrective action Mixture pressure on A side too 1. Check emissions. high (limit value 2). 2. Check ignition timing (→ Page 149). 3. Check exhaust back pressure. 4.
  • Page 131 517 – SD P-Charge Mix before Throttle ZKP-Number: Red alarm. Associated parameter 1.8004.631 Cause Corrective action u Check sensor and cabling (B79.23), replace if necessary. Fault Mixture pressure sensor before throttle defective, short circuit is rectified when engine is restarted. or wire break.
  • Page 132 532 – AL Wiring PWM1 ZKP-Number: Red alarm. Associated parameter 1.1046.900 Cause Corrective action u Check wiring to mixture throttle on A side, replace mixture Wire break or short circuit on channel PWM1. throttle on A side if necessary. 533 – AL Wiring PWM2 ZKP-Number: Red alarm.
  • Page 133 552 – AL GasControlCheck Fault ZKP-Number: Red alarm. Associated parameter 2.1090.118 Cause Corrective action Gas train test was not 1. Check gas train. successful. Alarm is activated if 2. Check cabling. the gas train does not report OK within a specified time-out period.
  • Page 134 557 – AL speed drop fault ZKP-Number: Red alarm. Engine shutdown. Associated parameter 2.1090.126 Cause Corrective action u Check gas train. Speed drop. Alarm is activated if engine speed drops during starting sequence. 559 – AL mixture throttle A fault ZKP-Number: Red alarm.
  • Page 135 566 – AL L2 P-Intake Air after Filter A ZKP-Number: Yellow alarm. Associated parameter 2.0186.931 Cause Corrective action u Replace air filter (→ Page 160). Pressure loss over air filter on A side is too high. 567 – AL L1 P-Intake Air after Filter B ZKP-Number: Yellow alarm.
  • Page 136 570 – L1 AI CAN Max Retarded Timing ZKP-Number: Yellow alarm. Associated parameter 2.1200.931 Cause Corrective action The cylinder set to maximum 1. Check emissions. retarded timing due to knocking 2. Check ignition timing (→ Page 149). has violated the first limit value. 3.

  • Page 137: Task Description

    6 Task Description 6.1 Engine 6.1.1 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 138: Machine Room - Check For Smell Of Gas

    6.1.2 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 139: Crankcase Breather

    6.2 Crankcase Breather 6.2.1 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 140 Remove locknut (1). Remove filter cover (3) with washer (2). Carefully lift out fine filter (6). Carefully lift out coalescence filter (5). Clean sealing faces and inside of housing. Check condition of gaskets on new fine fil- ter and new coalescence filter. Note: The fine filter (6) must be installed in the correct position in the housing.

  • Page 141: Ignition System

    6.3 Ignition System 6.3.1 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 142). Install new spark plug (→ Page 143). MS150057/02E 2013-10 | Task Description | 141...

  • Page 142: Spark Plug - Removal

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

  • Page 143: Spark Plug - Installation

    6.3.3 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 Assembly compound (Molycote P 37)
  • Page 144 Note: Make sure that the color code of the spark plugs is identical. Screw spark plug into cylinder head (1). Note: The temperature of spark plug and cylinder head (1) must be the same prior to tightening. Tighten spark plug to specified tightening torque using a torque wrench. Name Size Type...

  • Page 145: Spark Plug Connector - Replacement

    6.3.4 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 146). Install spark plug connector (→ Page 147). MS150057/02E 2013-10 | Task Description | 145...

  • Page 146: Spark Plug Connector - Removal

    6.3.5 Spark plug connector – Removal Preconditions ☑Engine is stopped and starting disabled. ☑Open protective packing of new spark plug connector only immediately prior to installation. DANGER Live components, flash-over. Risk of serious injury - danger to life! • Always wear electrical gloves (class 4 minimum) when touching the ignition cable in operation. WARNING Component is hot.

  • Page 147: Spark Plug Connector - Installation

    6.3.6 Spark plug connector – Installation Preconditions ☑Engine is stopped and starting disabled. ☑Open protective packing of new spark plug connector only immediately prior to installation. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Spark plug connector with ignition line (→...
  • Page 148 Push protective cap (3) onto ignition coil. 148 | Task Description | MS150057/02E 2013-10...

  • Page 149: 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 150: Valve Drive

    6.4 Valve Drive 6.4.1 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Engine coolant temperature is max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Angular screw driver F30452765...

  • Page 151: Adjusting Valve Clearance

    Diagram for 8V engines, two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...
  • Page 152 Final steps Remove barring device (→ Page 137). Install cylinder head cover (→ Page 158). 152 | Task Description | MS150057/02E 2013-10...

  • Page 153: Valve Projection - Measurement

    6.4.2 Valve projection – Measurement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sliding depth gauge, 200 mm Y20000918 Preparatory steps Remove spark plugs (→ Page 142). Remove cylinder head covers (→ Page 157). Remove sleeves (arrow).
  • Page 154 Measuring valve projection Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. Measure valve projection for each valve in two crankshaft positions (firing TDC and overlap TDC for cyl- inder A1) according to the diagram.
  • Page 155 Install sleeves (arrow). Install cylinder head covers (→ Page 158). Install spark plugs with new sealing rings (→ Page 143). MS150057/02E 2013-10 | Task Description | 155...

  • Page 156: Valve Gear - Lubrication

    6.4.3 Valve gear – Lubrication Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear Remove cylinder head covers (→ Page 157). Fill oil chambers of rocker arms and adjust- ing screws with oil.

  • Page 157: Cylinder Head Cover - Removal

    6.4.4 Cylinder head cover – Removal Preconditions ☑Engine is stopped and starting disabled. Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal. Remove spark plug connector (→ Page 146). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 158: Cylinder Head Cover - Installation

    6.4.5 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. Installing cylinder head cover Clean mounting surface.

  • Page 159: Gas System

    6.5 Gas System 6.5.1 Gas supply – Checking gas lines for leaks Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Leakage detection spray Soap solution WARNING Natural gas is combustible. Risk of fire and explosion! •...

  • Page 160: Air Filter

    6.6 Air Filter 6.6.1 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 corresponding fault message appears.

  • Page 161: Air Filter - Removal And Installation

    6.6.2 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 connecting flange (1) of intake housing. Clean connecting flange (1) of the intake housing and check for obstructions.

  • Page 162: Lube Oil System, Lube Oil Circuit

    6.7 Lube Oil System, Lube Oil Circuit 6.7.1 Engine oil – Level check Preconditions ☑Engine is stopped and starting disabled. WARNING Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. •...

  • Page 163: Engine Oil - Change

    6.7.2 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 Hot oil.

  • Page 164: Engine Oil - Sample Extraction And Analysis

    6.7.3 Engine oil – Sample extraction and analysis Preconditions ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone.

  • Page 165: Oil Filtration / Cooling

    6.8 Oil Filtration / Cooling 6.8.1 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 Hot oil.

  • Page 166: Circuit

    6.9 Coolant Circuit, General, High-Temperature Circuit 6.9.1 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! • Let the engine cool down.

  • Page 167: Engine Coolant – Change

    6.9.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 168). Fill with engine coolant (→ Page 170). MS150057/02E 2013-10 | Task Description | 167...

  • Page 168: Engine Coolant – Draining

    6.9.3 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 169 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS150057/02E 2013-10 | Task Description | 169...

  • Page 170: Engine Coolant – Filling

    6.9.4 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 171: Vent Line Of Engine Coolant Circuit Replacement

    6.9.5 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 172: Low-Temperature Circuit

    6.10 Low-Temperature Circuit 6.10.1 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 173: Mixture Coolant – Change

    6.10.2 Mixture coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Mixture coolant Mixture coolant – Change Drain mixture coolant (→ Page 174). Fill with fresh mixture coolant (→ Page 175). MS150057/02E 2013-10 | Task Description | 173...

  • Page 174: Mixture Coolant – Draining

    6.10.3 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 175: Mixture Coolant – Filling

    6.10.4 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 176: Wiring (General) For Engine/Gearbox/Unit

    6.11 Wiring (General) for Engine/Gearbox/Unit 6.11.1 Engine wiring – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Checking engine wiring Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 177: Sensors ‒ Overview

    6.11.2 Sensors ‒ Overview Sensors on B side Item Name Monitoring of B49.2 Intake air temperature B81.2 Intake air pressure after filter B16.1 Coolant pressure after engine B4.XX Exhaust gas temperature after cylinder XX B79.22 Mixture pressure B side Mixture temperature Table 39: Sensors on B side ‒...
  • Page 178 Sensors on driving end Item Name Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.2 Crankshaft speed ignition Table 40: Sensors on engine driving end ‒ Overview 178 | Task Description | MS150057/02E 2013-10...
  • Page 179 Sensors on A side Item Name Monitoring of B4.21 Exhaust bulk temperature after turbocharger Engine oil temperature B5.1 Engine oil pressure after filter B5.3 Engine oil pressure before filter Crankcase pressure B79.21 Mixture pressure A side Table 41: Sensors on A side ‒ Overview MS150057/02E 2013-10 | Task Description | 179...
  • Page 180 Sensors on free end Item Name Monitoring of B16.3 Coolant pressure before engine B1.3 Camshaft speed for antiknock control B1.1 Camshaft speed for engine governor Engine oil level B1.2 Camshaft speed for ignition system B6.3 Coolant temperature before engine B6.1 Coolant temperature after engine Table 42: Sensors on engine free end ‒...

  • Page 181: Abbreviations

    Abgasturbolader Exhaust turbocharger (ETC) Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Pub- lication 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-...
  • Page 182 Abbreviation Meaning Explanation Original Equipment Manufacturer ORFS O-Ring Face Seal Oberer Totpunkt Top dead center (TDC) Panel Control panel Peripheral Interface Module Pulse Width Modulation Modulated signal Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sicherheitsabsperrventil Safety shut-off valve Sicherheitsabbalseventil...

  • Page 183: Mtu Onsite Energy Contacts / Service Partners

    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.htm 24h Hotline With our 24h hotline and the flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed oper- ating conditions, or for spare parts supply.

  • Page 184: Special Tools

    Y20098771 Qty.: Used in: 6.4.1 Valve clearance – Check and adjustment (→ Page 150) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 6.1.2 Machine room – Check for smell of gas (→ Page 138)
  • Page 185 Gas measuring and warning device (not stocked by MTU) Part No.: Qty.: Used in: 3.7 Emission values – Check (→ Page 45) Oil filter wrench Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 165) Ratchet head with extension Part No.:...
  • Page 186 Used in: 6.3.2 Spark plug – Removal (→ Page 142) Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 143) Stroboscope (not stocked by MTU) Part No.: Qty.: Used in: 6.3.7 Ignition system – Ignition timing check (→ Page 149) Torque wrench, 10-60 Nm Part No.:...
  • Page 187 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 6.4.1 Valve clearance – Check and adjustment (→ Page 150) MS150057/02E 2013-10 | Appendix B | 187...

  • Page 188: Index

     161 – Replacement  160 Fault messages  – SAM   – On the display  52 Contacts  Firing order 22 – MTU Onsite Energy  183 Control  – Starting sequence  41 Gas engine system  – Stopping sequence  41 – Overview  31 Control cabinet MIS –...
  • Page 189 – Fault messages   – On the display  52 SAM – Fault messages 56 Sensors  – Overview  177 Service partners  – MTU Onsite Energy  183 Spark plug  – Installation  143 – Removal  142 – Replacement  141 MS150057/02E 2013-10 | Appendix B | 189...

Table of Contents