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MTU 12V4000L32FB Operating Instructions Manual

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Operating Instructions

Gas engine
12 V 4000 Lx2 xx
16 V 4000 Lx2 xx
MS150115/00E

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Summary of Contents for MTU 12V4000L32FB

  • Page 1: Operating Instructions

    Operating Instructions Gas engine 12 V 4000 Lx2 xx 16 V 4000 Lx2 xx MS150115/00E...
  • 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 3.8 Engine – Shutdown 3.9 Emergency engine shutdown 1.1 Important provisions for all products 3.10 After stopping the engine – Engine remains 1.2 Personnel and organizational requirements ready for operation 1.3 Transport 3.11 After stopping the engine – Putting the 1.4 Safety regulations for startup and operation engine out of operation 1.5 Safety regulations for startup and operation,...
  • 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 Throttle, A side 6 Engine lifting equipment 11 Starter 2 Engine governor/engine 7 Capacitor discharge igni- 12 Flywheel monitoring tion system KS Driving end 3 Air filter/air inlet 8 Engine mounting bracket, 4 Mixture cooler free end 5 Exhaust turbocharger 9 Oil pan...
  • Page 19 1 Crankcase breather, oil 7 Spark plug 13 Connection: engine cool- separator 8 Cylinder head cover ant inlet 2 Exhaust outlet 9 Cylinder head 14 Engine oil heat exchanger 3 Gas control valve 10 Engine oil sampling con- 15 Connection: engine cool- 4 Gas inlet connection nection ant outlet...

  • 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: Main Engine Dimensions

    2.3 Main engine dimensions Main engine dimensions Also valid for 12V engines. Length (A) for 12V approx. 2858 mm Length (A) for 16V approx. 3372 mm Width (B) for 12V approx. 1743 mm Width (B) for 16V approx. 1789 mm Height (C) for 12V approx.

  • Page 22: Ignition Order

    2.4 Ignition order Ignition order 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 22 | Product Summary | MS150115/00E 2013-10...

  • Page 23: Technical Data

    2.5 Technical Data 2.5.1 12 V 4000 L32FB, 16 V 4000 L32FB 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: Biogas 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: °C inlet from cooling equipment (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler (at nominal flow rate 8.56) Table 10: Coolant system (LT circuit) Coolant system (MT circuit) Number of cylinders...

  • Page 26: Exhaust Emissions

    General operating data Number of cylinders Cold start capability: Air temperature (w/o starting aid, with pre- °C heating) - (case C) Site condition (for case C): Engine coolant temperature °C Minimum idling speed 1500 1500 Limit speed for overspeed alarm/emergency shutdown 1900 1900 Table 14: General operating data...
  • Page 27 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise filter) - DL dB(A) (sound power level LW, ISO 8528-10) Table 19: Acoustics MS150115/00E 2013-10 | Product Summary | 27...

  • Page 28: 4000 L32Fb, 16 V 4000 L32Fb Engine Data, Tropical Applications (Ta-Luft)

    2.5.2 12 V 4000 L32FB, 16 V 4000 L32FB engine data, tropical applications (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 29 Consumption Number of cylinders Lube oil consumption after 1000 h runtime g/kWh Table 23: 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 30 Coolant system (LT circuit) Number of cylinders Coolant temperature before mixture cooler (at engine connection: °C inlet from cooling equipment (w/o antifreeze) Coolant antifreeze content, max. Coolant pump: Volumetric flow m³/h Pressure in cooling system, max. Pressure loss over mixture cooler (at nominal flow rate 8.56) Table 26: Coolant system (LT circuit) Coolant system (MT circuit) Number of cylinders...
  • Page 31 General operating data Number of cylinders Cold start capability: Air temperature (w/o starting aid, with pre- °C heating) - (case C) Site condition (for case C): Engine coolant temperature °C Minimum idling speed 1500 1500 Limit speed for overspeed alarm/emergency shutdown 1900 1900 Table 30: General operating data...
  • Page 32 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) dB(A) Genset surface noise with attenuated intake noise filter) - DL dB(A) (sound power level LW, ISO 8528-10) Table 35: Acoustics 32 | Product Summary | MS150115/00E 2013-10...

  • Page 33: Monitoring, Control And Regulation Equipment

    2.6 Monitoring, Control and Regulation Equipment 2.6.1 Gas engine phase 3 system – Overview General overview 1 Plant system 5 Engine Monitoring Unit 9 Ignition 2 Engine system 6 Throttles 10 Compressor bypass 3 Plant 7 Gas dosing unit 11 NOx sensor (optional) 4 Engine Control Unit 8 Knock module Governing/control/monitoring...
  • Page 34 Anti-knock control AKR • Controls monitored cylinders with regard to knock characteristics. If knocking is detected, ignition is delayed for the cylinder concerned. The power is reduced if this does not lead to improvement. Gas control valve TecJet110 • Controls the required amount of gas Mixture throttles (P Series) •...

  • Page 35: Purpose Of The Units

    2.6.2 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 36 Engine Monitoring Unit EMU 8 EMU = Engine Monitoring Unit Monitoring unit for the engine • Acquisition and processing of cylinder exhaust temperatures Self-monitoring 36 | Product Summary | MS150115/00E 2013-10...

  • Page 37: 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 38: 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 engine into operation after extended out-of-service-periods (>3 months) Item Measure Engine Depreserve (→...

  • Page 39: 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 156). Coolant circuit Check engine coolant level (→ Page 160); Check mixture coolant level (→...

  • Page 40: 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 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 re- quirement for gas engines, special procedures for engine start / stop are specified.
  • Page 41 Emergency stop 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 42: 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 43: 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 High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 44: Emission Values - Check

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Gas detection and alarm unit (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 45: 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 46: Emergency Engine Shutdown

    3.9 Emergency engine 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 47 Item Action • A contact is provided to request the ventilation system in the scaveng- ing phase. • The gas control system must be equipped with an SAV (safety shut-off Note: Gas train valve) when using gas control systems with inlet pressures in excess of 0.1 bar.

  • 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 | MS150115/00E 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

    OEM (see documentation of the genset man- ufacturer). 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. Recommended action in case of alarm...
  • Page 53 Red alarm: 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. MS150115/00E 2013-10 | Troubleshooting | 53...

  • Page 54: Fault Messages In Communication Protocol To Genset Control System

    5.2 Fault messages in communication protocol to genset control system 112222 – HI T-Exhaust Mean Yellow alarm. Initiated by EMU. Cause Corrective action Weighted average of all 1. Check emission values. individual exhaust gas 2. Check ignition timing (→ Page 143). temperatures is too high.
  • Page 55 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 143). with the average value. 3. Check valve drive (exhaust valves do not close). 112306 –...
  • Page 56 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 143). with the average value. 3. Check valve drive (exhaust valves do not close). 112312 –...
  • Page 57 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 143). with the average value. 3. Check valve drive (exhaust valves do not close). 112318 –...
  • Page 58 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 high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 143). 4.
  • Page 59 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 high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 143). 4.
  • Page 60 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 high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 143). 4.
  • Page 61 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 high as compared 2. Check emission values. with the average value. 3. Check ignition timing (→ Page 143). 4.
  • Page 62 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 143). with the average value. 3. Check valve drive (exhaust valves do not close). 112505 –...
  • Page 63 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 143). with the average value. 3. Check valve drive (exhaust valves do not close). 112511 –...
  • Page 64 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 143). with the average value. 3. Check valve drive (exhaust valves do not close). 112517 –...
  • Page 65 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 143). 4.
  • Page 66 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 143). 4.
  • Page 67 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 143). 4.
  • Page 68 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 143). 4.
  • Page 69 112703 – HIHI T-Exhaust A3 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing(→ Page 143). too high. 3. Check valve drive (exhaust valves do not close). 112704 –...
  • Page 70 112709 – HIHI T-Exhaust A9 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 143). too high. 3. Check valve drive (exhaust valves do not close). 112710 –...
  • Page 71 112715 – HIHI T-Exhaust B5 (abs) Red alarm. Initiated by EMU. Cause Corrective action Individual exhaust gas 1. Check emission values. temperature of this cylinder is 2. Check ignition timing (→ Page 143). too high. 3. Check valve drive (exhaust valves do not close). 112716 –...
  • Page 72 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). 113200 – Communication Lost ECU Red alarm. Initiated by SAM. Cause Corrective action No communication with ECU...
  • Page 73 1.4510.188 – Internal Error Red alarm. Initiated by anti-knock control. Cause Corrective action u Restart knock module. Hardware not ready for operation. 1.4510.189 – Error Camshaft Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from camshaft sensor u Check cabling.
  • Page 74 1.4510.196 – Knock Sensor Error A5 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.197 – Knock Sensor Error A6 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 75 1.4510.202 – Knock Sensor Error B1 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.203 – Knock Sensor Error B2 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 76 1.4510.208 – Knock Sensor Error B7 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock 1. Check cabling. sensor. 2. Check sensor (tightening torque, damage), replace as necessary. 1.4510.209 – Knock Sensor Error B8 Red alarm. Initiated by anti-knock control. Cause Corrective action No signal from this knock...
  • Page 77 1.4520.234 – Error Missing Camshaft Signal Red alarm. Initiated by IC922. Cause Corrective action u Check sensor, sensor distance and cabling, replace as No camshaft signal. necessary. 1.4520.235 – Error Number of Teeth Red alarm. Initiated by IC922. Cause Corrective action Incorrect number of teeth on 1.
  • Page 78 1.4520.241 – Individual Timing out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adjust value. Specified individual ignition timing is beyond the valid range. 1.4520.242 – Selftest Shutdown Yellow alarm. Initiated by IC922. Cause Corrective action Self-test is active with the u Restart ignition.
  • Page 79 1.4520.249 – Open Primary, Channel 5 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.250 – Open Primary, Channel 6 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 80 1.4520.256 – Open Primary, Channel 12 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.257 – Open Primary, Channel 13 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 81 1.4520.264 – Open Primary, Channel 19 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not 1. Check cabling to ignition coil. discharged. 2. Check ignition coils. 1.4520.265 – Open Primary, Channel 20 Yellow alarm. Initiated by IC922. Cause Corrective action Ignition energy was not...
  • Page 82 1.4520.275 – Odd Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action u Adjust value. Specified energy level is beyond the valid range. 1.4520.276 – Even Energy Level out of Range Yellow alarm. Initiated by IC922. Cause Corrective action Specified energy level is beyond...
  • Page 83 1.4530.012 – Analog Input High Error Yellow alarm. Initiated by F-series. Cause Corrective action u Check setting. F-series setting is incorrect. 1.4530.013 – Analog Input Low Error Yellow alarm. Initiated by F-series. Cause Corrective action F-series setting is incorrect. u Check setting. 1.4530.014 –...
  • Page 84 1.4530.019 – Run Enable not active Yellow alarm. Initiated by F-series. Cause Corrective action u Check setting. F-series setting is incorrect. 1.4530.020 – Spring Check Failed Yellow alarm. Initiated by F-series. Cause Corrective action F-series setting is incorrect. u Check setting. 1.4530.021 –...
  • Page 85 1.4540.012 – Valve Position Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.013 – High Elec Temp Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 86 1.4540.019 – Position Fail High Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.020 – Elec Temp Fail Low Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 87 1.4540.026 – Analog Input Low Error Red alarm. Initiated by TecJet. Cause Corrective action u Check setting. TecJet setting is not correct. 1.4540.027 – Analog Input High Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting.
  • Page 88 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. 1.4540.034 – FGT High Limit Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet.
  • Page 89 1.4540.041 – TecJet Internal Fault Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.042 – Keyswitch State Red alarm. Initiated by TecJet. Cause Corrective action Keyswitch cabling missing. u Check cabling. 1.4540.043 – Parameter Error Red alarm.
  • Page 90 1.4540.048 – SPI ADC Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.049 – Sense 5V Error Red alarm. Initiated by TecJet. Cause Corrective action Hardware not ready for u Restart TecJet. operation.
  • Page 91 1.4540.055 – Factory CAL Error Red alarm. Initiated by TecJet. Cause Corrective action u Restart TecJet. Hardware not ready for operation. 1.4540.056 – PWM Duty Cycle High Error Red alarm. Initiated by TecJet. Cause Corrective action TecJet setting is not correct. u Check setting.
  • Page 92 1.4550.036 – A - Temperature derating active Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action The internal temperature is 1. Check temperature in room. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.037 – A - Temperature above 120 °C Red alarm.
  • Page 93 1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by ProAct A-Bank. Cause Corrective action u Check cabling and setting. CAN bus connection faulty. 1.4550.044 – A - CAN Stop Command Yellow alarm. Initiated by ProAct A-Bank. Cause Corrective action “Stop”...
  • Page 94 1.4550.136 – B - Temperature derating active Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action The internal temperature is 1. Check temperature in room. Restart ProAct. higher than the limit. 2. Restart ProAct. 1.4550.137 – A - Temperature above 120 °C Red alarm.
  • Page 95 1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad) Red alarm. Initiated by ProAct B-Bank. Cause Corrective action u Check cabling and setting. CAN bus connection faulty. 1.4550.144 – B - CAN Stop Command Yellow alarm. Initiated by ProAct B-Bank. Cause Corrective action “Stop”...

  • Page 96: Fault Messages Of The Engine Governor

    5.3 Fault messages of the engine governor 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.
  • Page 97 021 – HI T-Exhaust B Yellow alarm. Associated parameter 2.0127.931 Cause Corrective action Exhaust gas temperature (B 1. Check exhaust turbocharger. side) after turbine too high (limit 2. Check ignition timing (→ Page 143). value 1). Incorrect ignition 3. Check mixture setting. timing, mixture too lean or too 4.
  • Page 98 030 – SS Engine Overspeed Red alarm. Engine shutdown. Associated parameter 2.2510.932 Cause Corrective action Overspeed detected by ECU. 1. Check governor. This usually fault message 2. Check throttle closing position. usually follows other fault messages. Check governor, throttle closing position. 031 –...
  • Page 99 051 – 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 156). contaminated, coolant temperature too high.
  • Page 100 058 – 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 101 068 – 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. 089 –...
  • Page 102 092 – SS Starter Speed Not Reached Red alarm. Start 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 103 118 – LO ECU Power Supply Voltage Yellow alarm. Associated parameter 2.0140.921 Cause Corrective action Supply voltage too low (limit 1. Check supply voltage. value 1). 2. Check cabling. 119 – LOLO ECU Power Supply Voltage Red alarm. Associated parameter 2.0140.922 Cause Corrective action Supply voltage too low (limit...
  • Page 104 181 – AL CAN2 Node Lost Yellow alarm. Associated parameter 2.0500.681 Cause Corrective action u Check operation of bus nodes and cabling. Buses (CAN bus 1 Bus node (SAM or EMU) lost on CAN bus 2. and CAN bus 2) are redundant. 182 –...
  • Page 105 187 – AL CAN1 Error Passive Yellow alarm. Associated parameter 2.0500.687 Cause Corrective action u Check operation of bus nodes and cabling. CAN controller 1 has indicated a warning. Bus users (ECU, SAM or EMU) are faulty. 188 – AL CAN2 Bus Off Yellow alarm.
  • Page 106 204 – 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. Fault is Engine oil level sensor defective, short circuit or wire break. rectified following engine restart. 206 –...
  • Page 107 214 – SD P-Crankcase 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 following engine restart. break. 216 – SD T-Lube Oil Red alarm.
  • Page 108 229 – 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. Fault is Engine stop due to camshaft sensor fault (and a previous rectified following engine restart. crankshaft sensor fault in the same operating cycle).
  • Page 109 266 – SD Speed Demand Red alarm. Associated parameter 2.8006.586 Cause Corrective action u Check signal and cabling between plant and ADEC. Speed setting signal can no longer be transmitted from plant. 381 – AL Wiring TOP 1 Yellow alarm. Associated parameter 2.8006.638 Cause Corrective action...
  • Page 110 418 – 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 defective, short circuit or wire break. 419 – SD T-Coolant before Engine Red alarm. Associated parameter 1.8004.604 Cause Corrective action...
  • Page 111 431 – 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 112 447 – HIHI P-Charge Mix Diff. 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 113 457 – 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 114 478 – AL Comb. Alarm Yel (Plant) Yellow alarm. Associated parameter 2.8006.001 Cause Corrective action u Combined alarm (for details, refer to the source alarm). Combined YELLOW alarm from plant. 479 – AL Comb. Alarm Red (Plant) Red alarm. Engine shutdown. Associated parameter 2.8006.002 Cause Corrective action...
  • Page 115 499 – SD T-Charge Mix Red alarm. Associated parameter 1.8004.632 Cause Corrective action u Check sensor and cabling (B73), replace as necessary. Fault is Mixture temperature sensor defective, short circuit or wire rectified following engine restart. break. 511 – HIHI P-Charge Mix A Red alarm.
  • Page 116 517 – SD P-Charge Mix before Throttle Red alarm. Associated parameter 1.8004.631 Cause Corrective action u Check sensor and cabling (B79.23), replace as necessary. Fault Mixture pressure sensor before throttle defective, short circuit is rectified following engine restart. or wire break. 520 –...
  • Page 117 554 – AL Ignition Fault Red alarm. Associated parameter 2.1090.122 Cause Corrective action Ignition failure. Alarm is 1. Check ignition system. activated if the feedback signal 2. Check cabling. from ignition system is not received within a specified time- out period. Either the ignition could not be activated, the timeout period is set too short, or communication is faulty.
  • Page 118 560 – Mixture throttle B Red alarm. Engine shutdown. Associated parameter 1.1450.013 Cause Corrective action u Check mixture throttle on B side and cabling. Replace mixture A problem related to mixture throttle on B side occurred. throttle on B side as necessary. Possible causes: Mixture throttle defective, no power supply to throttle, cabling of feedback...
  • Page 119 569 – 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 This alarm is activated if the ECU does not receive some SAM and ECU bus. Replace devices as necessary. messages to be transmitted from SAM.
  • Page 120 583 – AL GLS closed Red alarm. Engine shutdown. Associated parameter 2.0451.115 Cause Corrective action Generator load switch does not 1. Check generator load switch. open when engine stops. Engine 2. Manually disconnect generator switch. is motoring. 3. Open any existing mains circuit breaker. 4.
  • Page 121 620 – HIHI Current Heat Value of Fuel Yellow alarm. Associated parameter 2.1210.009 Cause Corrective action u Check gas quality if feasible. Fuel calorific value has undershot the second limit value. 621 – LO NOx Value Yellow alarm. Associated parameter 2.3050.024 Cause Corrective action NOx emissions have undershot...
  • Page 122 642 – SD Electr. Motor Power AI2 Yellow alarm. Associated parameter 2.8006.040 Cause Corrective action Engine power sensor defect 1. Generator eff. power not correctly transmitted. (analog input 2). 2. Generator eff. power can also be transmitted via CAN bus as an option.
  • Page 123 652 – AL GET Comm Lost Red alarm. Associated parameter 1.4510.996 Cause Corrective action CAN bus communication for 1. Check cabling. knock control faulty. 2. Check power supply. 3. Carry out restart of ECU, EMU & knock control. 4. Check settings with device-specific dialog software (XD10). 653 –...
  • Page 124 657 – AL ProActB Comm Lost Red alarm. Associated parameter 1.4550.196 Cause Corrective action CAN bus communication for 1. Check cabling. throttle B faulty. 2. Check power supply. 3. Carry out restart of ECU, EMU & throttle B. 4. Check settings with device-specific dialog software (XD50.2). 658 –...
  • Page 125 666 – AL IC92x Yellow Yellow alarm. Associated parameter 1.4520.993 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm in the ignition system was genset control system. detected. 667 – AL FSeries Yellow Yellow alarm.
  • Page 126 672 – AL NOxB Yellow Yellow alarm. Associated parameter 1.4560.193 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm at NOx sensor B was detected. genset control system. 675 – AL GET Red Red alarm.
  • Page 127 680 – AL ProActB Red Red alarm. Associated parameter 1.4550.191 Cause Corrective action u An exact fault designation is transmitted via CAN bus to the An internal combined alarm in throttle B was detected. genset control system. 681 – AL NOxA Red Red alarm.
  • Page 128 689 – HI Oil Refill Yellow alarm. Associated parameter 1.1480.303 Cause Corrective action u Check engine oil level (→ Page 156). Check oil supply. Engine oil was refilled too often within a certain time interval. 691 – HI Lube Oil Level Refill. Yellow alarm.
  • Page 129 891 – AL Scavenging Active Yellow alarm. Associated parameter 2.1090.048 Cause Corrective action u None. Engine was shut down by emergency stop and has failed to successfully complete the starting sequence several times. 948 – AL ESI active Red alarm. Associated parameter 2.8006.044 Cause Corrective action...

  • Page 130: 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 131: Checking Machine Room For Smell Of Gas

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

  • Page 132: 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 133 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 134: 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 135). Install new spark plug (→ Page 136). 134 | Task Description | MS150115/00E 2013-10...

  • Page 135: Spark Plug - Removal

    6.3.2 Spark plug – Removal Preconditions ☑Engine is stopped and starting disabled. ☑Open protective packing of new spark plug just 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 136: Spark Plug - Installation

    6.3.3 Spark plug – Installation Preconditions ☑Engine is stopped and starting disabled. ☑Open protective packing of new spark plug just 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 (Molykote P 37)
  • Page 137 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 tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Spark plug M18 x 1.5 Tightening torque (Assembly compound 50 +5 Nm...

  • Page 138: 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 139). Install spark plug connector (→ Page 140). 138 | Task Description | MS150115/00E 2013-10...

  • Page 139: 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 140: Spark Plug Connector - Installing

    6.3.6 Spark plug connector – Installing 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 141 Fasten the ring eyelet of the ignition line (3) to the ignition coil (1) with the bolt and spring washer. Name Size Type Lubricant Value/Standard Bolt Tightening torque 10 Nm Fit the protective cap (2) and check for correct seating. Exchanging spark plug isolator sealing ring Insert screwdriver (3) between Teflon...
  • Page 142 Carefully press sealing ring (1) into the groove until it is flush with the hole in Tef- lon sleeve (2). 142 | Task Description | MS150115/00E 2013-10...

  • Page 143: 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 144: Valve Drive

    6.4 Valve Drive 6.4.1 Valve depth – 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 135). Remove cylinder head covers (→...
  • Page 145 Measuring valve depth 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 depth for each valve in two crankshaft positions (firing TDC and overlap TDC for cylinder A1) according to the diagram.
  • Page 146 Install sleeves (arrow). Install cylinder head covers (→ Page 152). Install spark plugs with new sealing rings (→ Page 136). 146 | Task Description | MS150115/00E 2013-10...

  • Page 147: Valve Clearance - Check And Adjustment

    6.4.2 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 Torque wrench, 60-320 Nm F30452768...
  • Page 148 Diagram for 12V engines – Two crankshaft positions Diagram for 16V engines – Two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...

  • Page 149: Adjust Valve Clearance

    Adjust valve clearance Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Using angular screw driver, set adjusting screw (2) so that the specified valve clear- ance is provided. Feeler gauge (3) must just pass through the gap.

  • Page 150: 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 151). Fill oil chambers of rocker arms and adjust- ing screws with oil.

  • Page 151: 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 139). Remove screws (2). Remove cylinder head cover with gasket from cylinder head.

  • Page 152: 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 153: Gas System

    6.5 Gas System 6.5.1 Gas supply - Checking gas lines for leaks Preconditions ☑Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Leak identification spray Soap suds WARNING Gaseous fuels are combustible/explosive. Risk of fire and explosion! •...

  • Page 154: 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 155: 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 156: 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 157: 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 158: 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 159: 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. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 160: 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 161: 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 162). Fill with engine coolant (→ Page 164). MS150115/00E 2013-10 | Task Description | 161...

  • Page 162: 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 163 Draining of residual coolant: • At coolant distribution housing. Close all open drain points. MS150115/00E 2013-10 | Task Description | 163...

  • Page 164: 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 165: 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 166: 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 167: 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 168). Fill with fresh mixture coolant (→ Page 169). MS150115/00E 2013-10 | Task Description | 167...

  • Page 168: 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 169: 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 170: 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 171: Sensors – Overview

    6.11.2 Sensors – Overview Sensors on B side Illustrations are also applicable to 12V. Item Designation Monitoring of B49.2 Intake air temperature B81.2 Intake air pressure after filter B16.1 Coolant pressure after engine B4.X Exhaust temperature after cylinder B79.22 Mixture pressure B-side Mixture temperature Table 41: Sensors on B side The knocking sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads.
  • Page 172 Sensors on engine driving end Item Designation Monitoring of B79.23 Mixture pressure before throttle Crankshaft speed, reset ignition system B13.3 Crankshaft speed ignition Table 42: Sensors on engine driving end 172 | Task Description | MS150115/00E 2013-10...
  • Page 173 Sensors on A side Item Designation Monitoring of 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 B44.1 Turbocharger speed (optional) Table 43: Sensors on A side MS150115/00E 2013-10 | Task Description | 173...
  • Page 174 Sensors on engine free end Item Designation Monitoring of B4.21 Exhaust bulk temperature after turbocharger B6.3 Coolant temperature before engine B1.2 Camshaft speed for engine governor B1.3 Camshaft speed for anti-knock control B1.1 Camshaft speed for engine governor Lube oil level B16.3 Coolant pressure before engine B6.1...

  • Page 175: 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 176 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 177: 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 178: Special Tools

    8 Appendix B 8.1 Special Tools Angular screw driver Part No.: F30452765 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 147) Barring gear Part No.: F6555766 Qty.: Used in: 6.1.1 Engine – Barring manually (→ Page 130) Feeler gage Part No.: Y20098771...
  • Page 179 Filter wrench Part No.: F30379104 Qty.: Used in: 6.8.1 Engine oil filter – Replacement (→ Page 159) Gas detection and alarm unit (not stocked by MTU) Part No.: Qty.: Used in: 3.7 Emission values – Check (→ Page 44) Qty.: Used in: 6.1.2 Checking machine room for smell of gas...
  • Page 180 Used in: 6.3.2 Spark plug – Removal (→ Page 135) Qty.: Used in: 6.3.3 Spark plug – Installation (→ Page 136) Stroboscope (Not stocked by MTU) Part No.: Qty.: Used in: 6.3.7 Ignition system – Ignition timing check (→ Page 143) Torque wrench, 10-60 Nm Part No.:...
  • Page 181 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page 147) MS150115/00E 2013-10 | Appendix B | 181...

  • Page 182: Index

    – Removal  155 – Replacement  154 Gas engine system  – Overview  33 Gas supply  Contacts  – Checking gas lines for leaks  153 – MTU Onsite Energy  177 Control, starting and stopping sequences 40 Coolant  Ignition order 22 – Change  161 Ignition system  Cylinder ...
  • Page 183  17 – Startup  8 – Startup, special instructions for applications with gas- eous fuel  9 Sensors  – Overview  171 Service partners  – MTU Onsite Energy  177 Spark plug  – Installation  136 – Removal  135 – Replacement  134 Spark plug connector ...

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