MTU 12 V 4000 L62FB Operating Instructions Manual Download Page 1

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Operating Instructions

Gas engine

12 V 4000 L62FB
16 V 4000 L62FB

MS150098/02E

Summary of Contents for 12 V 4000 L62FB

Page 1: ...Operating Instructions Gas engine 12 V 4000 L62FB 16 V 4000 L62FB MS150098 02E...

Page 2: ...whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and storage or p...

Page 3: ...ds 3 months 36 4 3 Putting the engine into operation after scheduled out of service period 37 4 4 Control starting and stopping sequences 38 4 5 Engine Start 40 4 6 Operational checks 41 4 7 Emission...

Page 4: ...59 7 9 4 Engine coolant Filling 161 7 9 5 Vent line of engine coolant circuit Replacement 162 7 10 Low Temperature Circuit 163 7 10 1 Mixture coolant level Check 163 7 10 2 Mixture coolant Change 164...

Page 5: ...the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex ch...

Page 6: ...regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops authorized by the man...

Page 7: ...se personnel must be instructed repeatedly Personnel requirements All work on the product must be carried out by trained instructed and qualified personnel only Training at the Training Center of the...

Page 8: ...that all connections have been correctly allocated e g polarity direction Immediately after putting the product into operation make sure that all control and display instruments as well as the signali...

Page 9: ...quipment is in operation certain components of these appliances are electrically live Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times...

Page 10: ...control system with one path assigned to each of the gas shut off valves The gas train shall feature minimum pressure monitoring Additional equipment may be necessary in the gas train e g maximum pres...

Page 11: ...f flow plant manufacturer user scope of sup ply a manual shut off valve a gas filter Gas trains feature the following components in the direction of flow MTU scope of supply two gas shut off valves au...

Page 12: ...mer components e g engine mounts damping elements couplings and V belts must not be painted Only install them after painting the engine or mask them prior to painting The following applies to starters...

Page 13: ...installed and that all tools and loose parts have been removed especially the barring tool Ensure that no unattached parts have been left in on the product e g including rags and cable straps Ensure...

Page 14: ...prior to working on assemblies ESD Work on electrostatically endangered components which could be damaged by electrostatic discharge ESD must always be carried out with appropriate equipment Appropri...

Page 15: ...easuring component dimensions Workpieces components and measuring equipment lie in the specified tolerance range at a reference tem perature of 20 C MS150098 02E 2016 11 Safety 15 TIM ID 0000040535 01...

Page 16: ...nnel only The gas supply shall be connected by trained qualified and authorized personnel only Work on the gas bearing parts of the product shall be performed by specially trained qualified and author...

Page 17: ...always available and that staff are familiar with their correct handling Noise Wear ear protectors in work areas with a sound pressure level in excess of 85 dB A Noise can lead to an increased risk of...

Page 18: ...stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not impaired Avoid open flames in the vicinity No smoking Observe fire p...

Page 19: ...emergency stop Cordon off danger zone Ensure sufficient ventilation Do not enter the hazard zone until it has been established via measurement of the gas concentration with a suitable gas detector tha...

Page 20: ...n NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with...

Page 21: ...en weight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking device for the crankshaft Prior to transporting the engine genset system it is...

Page 22: ...nitoring 3 Air filter air intake 4 Mixture cooler 5 Exhaust turbocharger 6 Engine lifting equipment 7 Capacitor discharge ignition system 8 Engine mounting bracket free end 9 Oil pan 10 Engine mountin...

Page 23: ...connec tion 14 Engine oil heat exchanger 15 Engine coolant outlet con nection KGS Free end Engine model designation Key to the engine model designation 12 16 V 4000 L62FB 12 16 Number of cylinders V...

Page 24: ...accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and lette...

Page 25: ...h B 12V approx 1751 mm Width B 16V approx 1797 mm Height C 12V approx 2193 mm Height C 16V approx 2203 mm Crankshaft center to oil pan D 12 16 V approx 636 mm Crankshaft center to engine mount E 12 16...

Page 26: ...g order Firing order Number of cylinders Firing order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 26 Product Summary MS150098 02E 2016 11 TIM ID 00000...

Page 27: ...Table 4 Reference conditions Power related data power ratings are net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous p...

Page 28: ...8 Model related data basic design Coolant system HT circuit Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature...

Page 29: ...r 5 0 5 0 Lube oil pressure after oil filter warning R bar 3 5 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 2 5 Table 11 Lube oil system Fuel system Number of cylinders 12 16 Gas temperat...

Page 30: ...basic configuration engine R kg 5850 7750 Heaviest component to be lifted during extended component maintenance QL3 R kg 415 440 Table 16 Weights main dimensions Exhaust emissions Number of cylinders...

Page 31: ...emergency stop Monitors engine operating parameters Controls throttles and sets gas mixture for requested speed power Monitors first gas solenoid in gas train to engine Engine Monitoring Unit EMU 8 Ev...

Page 32: ...ion timing is retarded on the cylinder in question If this does not result in an improvement the power is reduced Gas control valve TecJet110 Controls the required amount of gas Mixture throttles P Se...

Page 33: ...ensive I O features Plant side 14 inputs 7 outputs 2 serial interfaces Engine side 39 inputs 28 outputs 1 serial interface Engine and plant related parameter settings in Flash memory In the event of i...

Page 34: ...8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 34 Monitoring Control and Regulation Equipment MS150098 02E 201...

Page 35: ...d Recommended min time in subsequent op eration at load 50 kWmech cyl Emission compliance as specified in technical data 0 to 30 30 minutes 120 minutes No 30 to 50 120 minutes 120 minutes No 50 to ful...

Page 36: ...e 147 Lube oil system Check engine oil level Page 153 Check oil level in oil storage tank Page 153 Coolant circuit Standstill 1 year Change engine coolant Page 158 Change mixture coolant Page 164 Cool...

Page 37: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 153 Coolant circuit Check engine coolant level Page 157 Check mixture coolant level Page...

Page 38: ...gas A 24V digital output is pro vided to activate such systems Start sequence If a start command is activated with the engine being at standstill the following steps are carried out auto matically 1...

Page 39: ...activation request for external ventilation is sent via the 24V digital output 1 Activation request for external ventilation via contact 2 Activating starter 3 Waiting for starting speed 4 Purging eng...

Page 40: ...High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Starting the engine Note A max of 5 engine starting attempts are permitted at a max fuel supply open...

Page 41: ...n sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Operational checks Item Measure Machine room Check machine room for s...

Page 42: ...l of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well ventilated...

Page 43: ...1 at the measuring point 2 2 Start engine 3 Approach the measuring point until a stable operating state has been reached 4 Carry out measurement and read off meas ured value for NOx rel ppm 5 Compare...

Page 44: ...nd mechanical stress es 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 in...

Page 45: ...tdown Item Measure Gas shut off valves with con trol solenoids Two contacts are available for connection to the electrical system Gas shut off valves with control solenoids close Engine will be shut d...

Page 46: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC 46 Operation MS150098 02E 201...

Page 47: ...ne room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Power supply to engine con trol system Switch off Gas supply The gas shut off valves with control solenoid...

Page 48: ...linder heads after component maintenance or ex tended component maintenance When installing a cylinder head with run in mating faces e g after piston replacement a repeated check after the first 50 op...

Page 49: ...necessary Page 141 W1005 Replace air filter Page 151 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 156 W1089 Check gas lines for lea...

Page 50: ...alue has not been attained MG Message General message SE System Error Warning due to node failure on the default field bus PB Push Button Status indication due to activation of certain control keys AK...

Page 51: ...gine 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 MS150098 02E 2016 11 Troubleshooting 51 TIM ID...

Page 52: ...on Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do no...

Page 53: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do...

Page 54: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do...

Page 55: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do...

Page 56: ...Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Che...

Page 57: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Check valve...

Page 58: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Check valve...

Page 59: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Check valve...

Page 60: ...ividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do not clos...

Page 61: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do...

Page 62: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do...

Page 63: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do...

Page 64: ...Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Che...

Page 65: ...e action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Check valve d...

Page 66: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Check valve...

Page 67: ...e action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 140 4 Check valve d...

Page 68: ...sion values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do not close 112702 HIHI T Exhaust A2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temp...

Page 69: ...tion timing Page 140 3 Check valve drive exhaust valves do not close 112708 HIHI T Exhaust A8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 70: ...tion timing Page 140 3 Check valve drive exhaust valves do not close 112714 HIHI T Exhaust B4 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 71: ...s temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 140 3 Check valve drive exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated by...

Page 72: ...as pressure 1 4540 010 Zero Flow Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow detected u Check gas pressure 1 4540 011 Flow Not Reached Red alarm Initiate...

Page 73: ...ive action Hardware not ready for operation u Restart TecJet 1 4540 018 Coil Current Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1...

Page 74: ...m Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 026 Analog Input Low Error Red alarm Initiated by TecJet Cause Corrective action TecJet setting i...

Page 75: ...P Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Configured limit value was not attained u Check position direction of TecJet 1 4540 033 Battery Volt High Error Red alarm Initia...

Page 76: ...t alarm is pending u Rectify cause of alarm 1 4540 041 TecJet Internal Fault Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 042 Keyswitc...

Page 77: ...verSpeed Shutdown Red alarm Initiated by IC922 Cause Corrective action Genset has exceeded admissible speed u Restart ignition 1 4520 238 E2PROM Checksum Error Red alarm Initiated by IC922 Cause Corre...

Page 78: ...Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 246 Open Primary Channel 2 Yellow alarm Initia...

Page 79: ...y Channel 8 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 253 Open Primary Channel 9 Yellow...

Page 80: ...y Channel 15 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 260 Open Primary Channel 16 Yello...

Page 81: ...as necessary 1 4520 271 Warning Missing Reset Signal Yellow alarm Initiated by IC922 Cause Corrective action Reset signal from crankshaft is missing u Sensor B 75 check sensor sensor distance and cabl...

Page 82: ...rol Cause Corrective action Combined alarm for details refer to the source alarm u Combined alarm for details refer to the source alarm 1 4510 188 Internal Error Red alarm Initiated by anti knock cont...

Page 83: ...d alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 197 Knock Sensor Er...

Page 84: ...ed alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 204 Knock Sensor E...

Page 85: ...ace as necessary 1 4510 210 Knock Sensor Error B9 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque da...

Page 86: ...alog Input High Error Yellow alarm Initiated by F series Cause Corrective action F series setting is incorrect u Check setting 1 4530 013 Analog Input Low Error Yellow alarm Initiated by F series Caus...

Page 87: ...active Yellow alarm Initiated by F series Cause Corrective action F series setting is incorrect u Check setting 1 4530 020 Spring Check Failed Yellow alarm Initiated by F series Cause Corrective actio...

Page 88: ...larm Initiated by ProAct A Bank Cause Corrective action Hardware not ready for operation u Restart ProAct 1 4550 036 A Temperature derating active Yellow alarm Initiated by ProAct A Bank Cause Correct...

Page 89: ...on Position specification not received or received too late u Check cabling and setting 1 4550 043 A CAN Fault CAN Bus Off CAN Ad Red alarm Initiated by ProAct A Bank Cause Corrective action CAN bus c...

Page 90: ...ive Yellow alarm Initiated by ProAct A Bank Cause Corrective action The internal temperature is higher than the limit 1 Check temperature in room Restart ProAct 2 Restart ProAct 1 4550 137 A Temperatu...

Page 91: ...mand Failed Red alarm Initiated by ProAct A Bank Cause Corrective action Position specification not received or received too late u Check cabling and setting 1 4550 143 B CAN Fault CAN Bus Off CAN Ad...

Page 92: ...Replace oil filter Page 156 3 Take oil sample and analyze Page 155 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas temperature A side after turbine...

Page 93: ...bine 1 Check exhaust turbocharger 2 Check ignition timing Page 140 3 Check mixture setting 4 Check spark plugs 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective acti...

Page 94: ...gine shutdown Associated parameter 2 3012 932 Cause Corrective action Speed of primary turbocharger too high limit value 2 u Turbocharger speed sensor is not fitted at present Check ECU setting for th...

Page 95: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 153 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...

Page 96: ...Check oil separator condition replace if necessary Page 130 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value...

Page 97: ...lly open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 151 Check exhaust back pressure Check differential p...

Page 98: ...T Preheat Yellow alarm Associated parameter 2 1090 921 Cause Corrective action Preheating temperature too low limit value 1 Coolant temperature too low for engine start 1 Check preheating 2 Check diff...

Page 99: ...w alarm Associated parameter 2 0140 931 Cause Corrective action Supply voltage too high limit value 1 1 Check supply voltage 2 Check cabling 121 HIHI ECU Power Supply Voltage Red alarm Associated para...

Page 100: ...upload is incomplete u Power up ECU contact Service 180 AL CAN1 Node Lost Yellow alarm Associated parameter 2 0500 680 Cause Corrective action Bus node SAM or EMU lost on CAN bus 1 u Check operation o...

Page 101: ...s Off Yellow alarm Associated parameter 2 0500 686 Cause Corrective action CAN controller 1 is in Bus Off status Automatic switching to CAN bus 2 Bus users ECU SAM or EMU faulty u Check operation of n...

Page 102: ...emperature sensor at engine outlet defective short circuit or wire break u Check sensor and cabling B6 1 replace if necessary Fault is rectified following engine restart 204 SD Level Lube Oil Red alar...

Page 103: ...Cause Corrective action Coolant pressure sensor after engine defective short circuit or wire break u Check sensor and cabling B16 1 replace if necessary Fault is rectified following engine restart 21...

Page 104: ...rective action Engine oil pressure sensor before filter defective short circuit or wire break u Check sensor and cabling B5 3 replace as necessary Fault is rectified following engine restart 229 AL St...

Page 105: ...t 245 SD ECU Power Supply Voltage Red alarm Associated parameter 2 8006 589 Cause Corrective action Internal governor fault u Replace ADEC engine governor 266 SD Speed Setting Red alarm Associated par...

Page 106: ...er 2 8006 641 Cause Corrective action Short circuit or wire break on transistor output plant side 4 TOP 4 Activation of gas supply solenoid valve No 2 faulty u Check cabling 418 SD T Intake Air B Yell...

Page 107: ...ssure before engine too low limit value 1 Insufficient volume flow static pressure too low u Check engine coolant circuit pressure and flow 431 SS P Coolant Before Engine Red alarm Engine shutdown Ass...

Page 108: ...kage 3 Check sensors and cabling B79 22 B79 21 447 HIHI P Charge Mix Diff Red alarm Engine shutdown Associated parameter 2 0183 932 Cause Corrective action Difference in mixture pressures sensed on A...

Page 109: ...3 1 Check intake air temperature 2 Check mixture cooling circuit 454 SS Power Limitation Active Yellow alarm Associated parameter 2 7000 011 Cause Corrective action Power limitation activated u Rectif...

Page 110: ...r 2 8006 593 Cause Corrective action Engine stop since all shutdown channels have sensor faulty u Combined alarm for details refer to the source alarm 473 AL Cabling PWM_CM2 Red alarm Engine shutdown...

Page 111: ...on Mixture pressure sensor on B side defective short circuit or wire break u Check sensor and cabling B79 22 replace if necessary Fault is rectified following engine restart 498 SD P Charge Mix Diff R...

Page 112: ...nt system 513 SD P Coolant Diff Red alarm Associated parameter 1 8004 610 Cause Corrective action Coolant differential pressure sensor defective short circuit or wire break u Check sensors and cabling...

Page 113: ...ctified following engine restart 531 AL Wiring PWM_CM1 Red alarm Associated parameter 1 1044 900 Cause Corrective action Cable break or short circuit on channel PWM_CM1 u Check cabling to TecJet throt...

Page 114: ...118 Cause Corrective action Gas train test was not successful Alarm is activated if the gas train does not report OK within a specified time out period Either the gas train leak test was not successf...

Page 115: ...ngine shutdown Associated parameter 1 1450 010 Cause Corrective action A problem related to mixture throttle on A side occurred Possible causes Mixture throttle defective no power supply to throttle c...

Page 116: ...r filter Page 151 568 AL L2 P Intake Air after Filter B Yellow alarm Associated parameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Pa...

Page 117: ...Retarded Timing Red alarm Engine shutdown Associated parameter 2 1200 933 Cause Corrective action The cylinder set to maximum retarded timing due to knocking has violated the third limit value 1 Check...

Page 118: ...meter 2 1210 009 Cause Corrective action Fuel calorific value has undershot the second limit value u Check gas quality if feasible 621 LO NOx Value Yellow alarm Associated parameter 2 3050 024 Cause C...

Page 119: ...tly not in standard scope of delivery 634 SD T0 Ambient Air HDT2800 none Associated parameter 1 0700 089 Cause Corrective action Air moisture sensor defect u Sensor currently not in standard scope of...

Page 120: ...0 936 Cause Corrective action Opening angle of throttles B exceeded 1 Check charge air pressure reserve 2 Intake air temperature outside TVU data 3 Check compressor for contamination 4 Reduce power 65...

Page 121: ...communication for gas control valve faulty alternatively a step motor with gas mixer can be installed 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU gas control valve 4 Check sett...

Page 122: ...1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU throttle B 4 Check settings with device specific dialog software XD11 1 661 AL PhytronB Comm Lost Red alarm Associated parameter 1...

Page 123: ...designation is transmitted via CAN bus to the genset control system 668 AL TecJet Yellow Yellow alarm Associated parameter 1 4540 993 Cause Corrective action An internal combined alarm in the gas con...

Page 124: ...lt designation is transmitted via CAN bus to the genset control system 674 AL PhyB Yellow Yellow alarm Associated parameter 1 4570 193 Cause Corrective action An internal combined alarm at step motor...

Page 125: ...ct fault designation is transmitted via CAN bus to the genset control system 680 AL ProActB Red Red alarm Associated parameter 1 4550 191 Cause Corrective action An internal combined alarm in throttle...

Page 126: ...gine oil filling level detected 1 Check engine oil level Page 153 2 Check replenishment system 3 Fill oil 686 AL Lube Oil Max Red alarm Associated parameter 1 1480 309 Cause Corrective action Maximum...

Page 127: ...tion Gas temperature sensor defective short circuit or wire break 1 Not installed in all engine versions optional 2 Check sensor and cabling B38 replace as necessary 719 AL T Gas L1 Yellow alarm Assoc...

Page 128: ...ody being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the engine s danger zone Barring engine manually 1 Remove guard plate 2 Engage barri...

Page 129: ...nal safety equipment Do not smoke Checking machine room for smell of gas 1 Check machine room to localize gas supply leaks using gas detection and alarm unit 2 If the gas detection and alarm unit resp...

Page 130: ...ues which are harmful to health Risk of injury and poisoning Allow the engine to cool to below 50 C before beginning work Wear protective clothing protective gloves and safety glasses facial protectio...

Page 131: ...filter 5 must be installed in the correct position in the housing 10 Place coalescer filter 5 in housing ensuring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12 Screw on w...

Page 132: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 133 2 Install new spark plug Page 134 132 Ignition Syste...

Page 133: ...ble protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupt...

Page 134: ...gine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressuriz...

Page 135: ...wrench to tighten spark plug to specified tightening torque Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molycote P 37 50 5 Nm 9 Fit spark plug conn...

Page 136: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 137 2 Install spark plug connector Page 138 136 I...

Page 137: ...otected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at peop...

Page 138: ...ine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurize...

Page 139: ...6 Fit protective cap 2 and check for correct seating MS150098 02E 2016 11 Ignition System 139 TIM ID 0000043642 002...

Page 140: ...en the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition check Note The DiaSys service tool in conjunction with a dongle with access rights 1A or higher and the...

Page 141: ...Use Part No Qty Feeler gage Y20098771 1 Offset screwdriver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Plug in open end wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head...

Page 142: ...s in firing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance adjustment with cold engine Inlet valves long rocker arm 0 3 mm Exhaust valves sho...

Page 143: ...knut 1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 Tightening torque Engine oil 9...

Page 144: ...Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 133 2 Remove cylinder head covers Page 148 3 Remove sleeves arrow 4 Install barring tool Page 128 5 Rotate crankshaf...

Page 145: ...ew 1 and remove valve bridge Do not remove rocker arm 2 4 Measure distance between valve stem end and cylinder head top at the spark plug bore with sliding depth gauge see figure The specified value f...

Page 146: ...3 Install sleeves arrow 4 Install cylinder head covers Page 149 5 Install spark plugs with new sealing rings Page 134 146 Valve Drive MS150098 02E 2016 11 TIM ID 0000012015 004...

Page 147: ...tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 148 2 Fill oil chambers of rocker arms and adjusting screws with oil 3 Insta...

Page 148: ...ing disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 137 3 Remove screws 2 4 Remove cylinder head cover with gasket fr...

Page 149: ...omponents for special cleanliness Cylinder head cover Installa tion 1 Clean mounting surface 2 Check condition of gasket replace if dam aged 3 Position gasket and cylinder head cover 1 on cylinder hea...

Page 150: ...of fire and explosion Avoid open flames electrical sparks and ignition sources Carry gas warning unit part of the personal safety equipment Do not smoke Gas supply checking gas lines for leaks 1 Coat...

Page 151: ...efilter made of fleece option Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the cor responding fault message appears R...

Page 152: ...stalla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from con necting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air...

Page 153: ...e oil level may ex ceed the mark 1 by up to 2 cm The cause of this may be that oil e g from the oil filter and oil heat exchanger flows back into the oil pan 3 The oil level must reach the mark 2 or e...

Page 154: ...s facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources...

Page 155: ...ctive gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electri...

Page 156: ...protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion...

Page 157: ...ING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant Level check 1 Read off system filling...

Page 158: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 159 2 Fill with engine coolant Page 161 158 Coolant Circuit General High Temperature Circuit...

Page 159: ...and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch off preheater if i...

Page 160: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 160 Coolant Circuit General High Temperature Circuit MS150098 02E 2016 11 TIM ID 0000006751 002...

Page 161: ...and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Engine coolant Filling 1 Fill w...

Page 162: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 159 2 Release union nuts 1 and 3 3 Remove coolant vent l...

Page 163: ...NING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Mixture coolant level Check 1 Read off system fillin...

Page 164: ...ools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 165 2 Fill with fresh mixture coolant Page 166 164 Low Temperature Circuit MS1...

Page 165: ...ry and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining mixture coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve at dra...

Page 166: ...lothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Engine coolant Fi...

Page 167: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector h...

Page 168: ...sure after filter B side 3 B16 1 Coolant pressure after engine 4 B4 X Exhaust temperature after cylinder 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 23 Sensors on B side The knock...

Page 169: ...nitoring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset 3 B13 2 Crankshaft speed ignition system Table 24 Sensors on driving end MS150098 02E 2016 11 Wiring General for Engi...

Page 170: ...pressure A side 2 B50 Crankcase pressure 3 B5 1 Engine oil pressure after filter 4 B7 Engine oil temperature 5 B5 3 Engine oil pressure before filter Table 25 Sensors on A side 170 Wiring General for...

Page 171: ...3 B1 3 Camshaft speed knock module 4 B1 2 Camshaft speed ignition system 5 B1 1 Camshaft speed engine governor 6 B24 Engine oil level 7 B6 3 Coolant temperature before engine 8 B6 1 Coolant temperatur...

Page 172: ...ximum limit value HIHI High High Alarm Measured value exceeds 2nd maximum limit value HT High Temperature High temperature ICFN ISO Continuous Fuel stop brake power Fuel stop power acc to ISO internat...

Page 173: ...otive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische...

Page 174: ...r during operation for preventive maintenance corrective work in case of malfunction or changed operating condi tions or for spare parts supply For our locally available support go to MTU s Internet s...

Page 175: ...manually Page 128 Feeler gage Part No Y20098771 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 141 Gas detection and alarm unit not stocked by MTU Part No Qty Used in 7 1 2 Checking ma...

Page 176: ...765 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 141 Oil filter wrench Part No F30379104 Qty Used in 1 7 8 1 Engine oil filter Replacement Page 156 Plug in open end wrench 24 mm Part...

Page 177: ...n 1 7 4 2 Valve protrusion Measurement Page 144 Special wrench 20 8 mm Part No F30452574 Qty Used in 1 7 3 2 Spark plug Removal Page 133 Qty Used in 1 7 3 3 Spark plug Installation Page 134 Stroboscop...

Page 178: ...ark plug Installation Page 134 Qty Used in 1 7 3 6 Spark plug connector Installation Page 138 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 14...

Page 179: ...ion 47 Barring manually 128 Emergency shutdown 45 Layout 22 Main dimensions 25 Shutdown 44 Start 40 Engine cabling Check 167 Engine coolant Change 158 Draining 159 Filling 161 Level check 157 Engine d...

Page 180: ...ts 17 Fluids and lubricants specific information for dual fuel applications 19 Fluids and lubricants specific information for gaseous fuel supply applications 19 Important provisions 5 6 Indirect mate...

Page 181: ...quence Control 38 T transport 21 V Valve clearance Adjustment 141 Check 141 Valve gear Lubrication 147 Valve protrusion Measurement 144 Vent line of engine coolant circuit Replacement 162 MS150098 02E...

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MTU 12 V 4000 L62FB, Operating Instructions Manual

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Summary of Contents for 12 V 4000 L62FB

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