MTU 12 V 4000 Lx2 xx Operating Instructions Manual Download Page 1

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Operating Instructions

Gas engine

8 V 4000 Lx2 xx

MS150114/01E

Summary of Contents for 12 V 4000 Lx2 xx

Page 1: ...Operating Instructions Gas engine 8 V 4000 Lx2 xx MS150114 01E ...

Page 2: ...ithout the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion microfilming and storage or processing in electronic systems including databases and online services All information in this publication was the latest information available at the time of going to print MTU Friedrichshafen GmbH reserves the right to change d...

Page 3: ...ng sequences 39 3 5 Engine Start 41 3 6 Operational checks 42 3 7 Emission values Check 43 3 8 Engine Shutdown 44 3 9 Emergency engine shutdown 45 3 10 After stopping the engine Engine remains ready for operation 47 3 11 After stopping the engine Putting the engine out of operation 48 4 Maintenance 4 1 50 hours check 49 4 2 Maintenance task reference table QL1 50 5 Troubleshooting 5 1 Fault messag...

Page 4: ...t Replacement 162 6 10 Low Temperature Circuit 163 6 10 1 Mixture coolant Level check 163 6 10 2 Mixture coolant Change 164 6 10 3 Mixture coolant Draining 165 6 10 4 Mixture coolant Filling 166 6 11 Wiring General for Engine Gearbox Unit 167 6 11 1 Engine cabling Check 167 6 11 2 Sensors Overview 168 7 Appendix A 7 1 Abbreviations 172 7 2 MTU Onsite Energy contact person service partner 174 8 App...

Page 5: ...e with the Spare Parts Catalog MTU contact Service partner In the original as delivered configuration or in a configuration approved by the manufacturer in writ ing including engine control parameters In compliance with all safety regulations and in adherence with all warning notices in this manual With maintenance work performed in accordance with the Maintenance Schedule throughout the useful li...

Page 6: ...ation authorities The manufacturer does not accept any liability for violations of the emission reg ulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product Replacing components with emission labels Emission labels are attached to all MTU engines These must remain on the engine throughout its op erational life Engines used exclusively in lan...

Page 7: ... around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation maintenance re pair an...

Page 8: ...eight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking de vice for the crankshaft Prior to transporting the engine genset system it is imperative to install the transport locks for the engine mounts Secure the engine genset system such as to preclude tipping during transport Secure the engine system genset as to preclude slipping and t...

Page 9: ...struments as well as the monitoring signaling and alarm systems are working properly Safety requirements for operation The operator must be familiar with the controls and displays The operator must be familiar with the consequences of any operations performed During operation the display instruments and monitoring units must be permanently observed with re gard to present operating status violatio...

Page 10: ...ng device The gas train must be fitted with an automatic leak check The gas shutoff valves are activated via two different paths from the control system whereby one gas shutoff valve respectively is activated via one of the paths Gas trains must be monitored to detect minimum pressure The plant designer must ensure that the gas train is positioned directly in front of the engine yet a max imum of ...

Page 11: ...ounts damping elements couplings and V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy pinions Wear a respirator mask filter class P3 Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing ins...

Page 12: ...the power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on Risk of explosion or fire due to oil vapors and highly flammable process materials Do not use product as ground terminal Never position the welding po...

Page 13: ... Always use connector pliers to tighten union nuts on connectors Subject the device as well as the product to a functional testing on completion of all repair work In particular check the function of the engine emergency stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack age faulty electronic components or assemblies properly before di...

Page 14: ...that has been trained and authorized for this task Have all work on gas bearing components carried out by authorized specialized companies Shut off the gas supply to the product and activate the emergency stop at the interface switchgear cab inet or by turning the key switch if applicable Close the manual shutoff valve for the gas supply The coolant pumps must keep running on for a longer period i...

Page 15: ... lubricants and filters in accordance with local regulations Within the EU batteries can be returned free of charge to the manufacturer where they will be properly recycled Fluids and lubricants auxiliary materials The Fluids and Lubricants Specifications will be amended or supplemented as necessary Prior to opera tion make sure that the latest version is used The latest version can be found on th...

Page 16: ...e spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely af fected There must be no naked flames in the vicinity No smoking Observe fire prevention regulations Always wear a mask providing protection against paint and solvent vapors Liquid nitrogen Observe the relevant safety data sheet for all materials Wo...

Page 17: ...an be life threatening depending on concentration Some gases can no longer be detected by sense of smell in higher concentrations Caution Risk of poisoning due to hazardous byproducts The absorption of even small quantities of hy drogen sulfide or ammonium may be lethal Caution Danger of suffocation Due to the lack of oxygen the absorption of methane can occasionally lead to increased breathing fr...

Page 18: ...emedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This manual with all safety instructions and safety notices must be issued to all personnel involved in operation maintenance repair or transportation 2 The higher level warning notice is used if several ...

Page 19: ...r inlet 3 Mixture cooler 4 Exhaust turbocharger 5 Engine lifting eye 6 Capacitor discharge igni tion system 7 Engine mounting bracket free end 8 Oil pan 9 Engine mounting bracket driving end 10 Starter 11 Flywheel KS Driving end MS150114 01E 2015 03 Product Summary 19 TIM ID 0000045275 002 ...

Page 20: ...et con nection 14 Engine oil heat exchanger 15 Engine coolant outlet con nection KGS Free end Engine model designation Key to the engine model designation 8 V 4000 L32 FB 8 Number of cylinders V Cylinder arrangement V engine 4000 Series L Application L Gas engine 3 Load profile 2 Design index F Additional feature F 50 Hertz B Additional feature B Biogases from fermentation processes Table 2 Engine...

Page 21: ... 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 letter Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also starts wit...

Page 22: ...ons Length A Approx 2484 mm Width B Approx 1743 mm Height C Approx 2154 mm Crankshaft center to oil pan D Approx 625 mm Crankshaft center to engine mount E Approx 280 5 mm Table 3 Engine Main dimensions 22 Product Summary MS150114 01E 2015 03 TIM ID 0000045276 002 ...

Page 23: ...2 4 Firing order Firing order Number of cylinders Firing order 8 V A1 A3 A4 A2 B3 B4 B2 B1 MS150114 01E 2015 03 Product Summary 23 TIM ID 0000002807 003 ...

Page 24: ...e 4 Reference conditions Power related data power ratings are net brake power to ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 800 Mean effective pressure pme continuous power ISO 3046 bar 16 8 Table 5 Power related data power ratings are net brake power to ISO 3046 General conditions for max power Number of cylinders ...

Page 25: ...elated data basic design Coolant system HT circuit Number of cylinders 8 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 Coolant temperature at engine connection inlet from cooling system w o antifreeze A C 78 Coolant temperature after engine warning R C 95 Coolant temperature after engine shutdown L C 98 Coolant temperature to enable load application min...

Page 26: ... oil filter bar 5 0 Lube oil pressure after oil filter warning R bar 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 Table 11 Lube oil system Fuel system Number of cylinders 8 Gas temperature before engine min L C 10 Gas temperature before engine max L C 50 Gas flow pressure before gas flow control valve min L mbar 30 Gas flow pressure before gas flow control valve max L mbar 120 Table 1...

Page 27: ... cylinders 8 Engine dry weight basic configuration engine R kg 4400 Heaviest component to be lifted during extended component maintenance QL3 R kg 280 Table 16 Weights main dimensions Exhaust emissions Number of cylinders 8 Exhaust emission before catalytic converter at 100 DL nitric oxides NOx in dry exhaust gas 5 O2 G mg m3 n 500 Exhaust emission before catalytic converter at 100 DL nitric oxide...

Page 28: ...r ratings are net brake power to ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 800 Mean effective pressure pme continuous power ISO 3046 bar 16 8 Table 20 Power related data power ratings are net brake power to ISO 3046 General conditions for max power Number of cylinders 8 Relative air humidity A 60 Intake air tempera...

Page 29: ...freeze A C 90 Coolant temperature at engine connection inlet from cooling system w o antifreeze A C 78 Coolant temperature after engine warning R C 95 Coolant temperature after engine shutdown L C 98 Coolant temperature to enable load application min L C 40 Coolant antifreeze content max L 50 Coolant pump Volumetric flow L m h 32 Filling pressure in cooling system cold R bar 0 5 Pressure in coolin...

Page 30: ...ber of cylinders 8 Gas temperature before engine min L C 10 Gas temperature before engine max L C 50 Gas flow pressure before gas flow control valve min L mbar 30 Gas flow pressure before gas flow control valve max L mbar 120 Table 27 Fuel system General operating data Number of cylinders 8 Cold start capability Air temperature w o starting aid with preheating case C R C 15 Site condition for case...

Page 31: ...e lifted during extended component maintenance QL3 R kg 280 Table 31 Weights main dimensions Exhaust emissions Number of cylinders 8 Exhaust emission before catalytic converter at 100 DL nitric oxides NOx in dry exhaust gas 5 O2 G mg m3 n 500 Exhaust emission before catalytic converter at 100 DL nitric oxides NOx in dry exhaust gas A ppm 188 Table 32 Exhaust emissions Acoustics Number of cylinders...

Page 32: ...ing Engine Control Unit ECU 9 Controls engine starting stopping and 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 Monitors second gas solenoid in gas train to engine Compressor bypass F series Controls throttle reserve prevents compressor surges Ig...

Page 33: ...ayed 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 Mixture throttles in the mixture lines which are controlled by the Engine Control Unit MS150114 01E 2015 03 Product Summary 33 TIM ID 0000044676 001 ...

Page 34: ...ics Integral status fault display Fault memory Extensive I O features Engine and genset related parameter settings in flash memory In the event of inadmissible states and limit value violations Initiation of power reduction engine stop or emergency engine stop configurable Diagnostic function via CAN interface Default CAN1 connection for dialog unit provided Software structure One data record for ...

Page 35: ...toring Unit EMU 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring MS150114 01E 2015 03 Product Summary 35 TIM ID 0000040818 002 ...

Page 36: ...load Recommended maximum run time at this load Recommended minimum run time in subsequent operation at load 50 0 to 30 30 minutes 120 minutes 30 to 50 120 minutes 120 minutes 50 to 100 No restriction No restriction Table 34 Runtimes at partial load A minimum operating time of 2 hours per start is recommended to counteract increased engine loading resulting from temperature changes cold start to en...

Page 37: ...ge 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 Coolant circuit Check engine coolant level Page 157 Check mixture coolant level Page 163 Engine cabling Check plug in connections Page 167 Gas supply The gas shut off valves with control solenoids are no...

Page 38: ...d 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 163 Engine management system Check for fault messages 38 Operation MS150114 01E 2015 03 TIM ID 0000010660 002 ...

Page 39: ...on gas pipework up to gas control valve and exhaust gas system after turbine A contact is designated to initiate such safety measures Starting sequence The following steps are performed automatically when a start command is activated with the engine at standstill 1 Setting start counter 2 Priming optional 3 Checking gas supply solenoid valves for leaks 4 Activating starter 5 Waiting for starting s...

Page 40: ...owing a start request after emergency shutdown 1 Requesting external ventilation by contact 2 Activating starter 3 Waiting for starting speed 4 Scavenging the engine 5 Disengaging starter 6 Engine running down to standstill 7 Resetting start counter 8 Awaiting start request Oil refill sequence 1 Waiting for engine running 2 Engine running for a minimum programmed time period 3 Oil refilling enable...

Page 41: ...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 WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Starting engine u Start engine in accordance with starting sequence specifications Page 39 MS150114 01E 2015 03 Operation 41 TIM ID 0000042719 001 ...

Page 42: ...ne room for smell of gas Page 130 ECU Check for fault messages if fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Operation log if available Document operating parameters This is especially useful for fault localization and fast remedial action Engine under load engine at rated speed Visually inspect engine plant ...

Page 43: ...k of injury and burning Wear protective clothing gloves and goggles safety mask WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well ventilated Repair leaking exhaust pipework immediately Emission values Check 1 Insert exhaust probe 1 in the exhaust gas flow of the exhaust pipe bellows 3 at tur bocharger 4 2 Carry out measurement ans read off meas ured ...

Page 44: ...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 Shutting down engine u Shut down engine in accordance with stopping sequence specifications Page 39 44 Operation MS150114 01E 2015 03 TIM ID 0000042720 001 ...

Page 45: ...in emergency situations Emergency engine shutdown Item Action Gas shut off solenoids Two contacts are provided for electrical connection Close gas shut off sole noids Engine is stopped Ignition ignition system In the case of an external EMERGENCY STOP the ignition remains on until the engine has run down to a standstill in order to safely burn off uncombust ed fuel air mixture The ignition is only...

Page 46: ...again following an emergency engine stop Suitable exhaust gas ventilation equipment must be provided in the facility to ensure that the exhaust gas system downstream of the engine is safely purged A contact is provided to request the ventilation system in the scavenging phase Note Gas train The gas control system must be equipped with an SAV safety shut off valve when using gas control systems wit...

Page 47: ...ngine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC MS150114 01E 2015 03 Operation 47 TIM ID 0000002329 003 ...

Page 48: ...s below 40 C Operating voltage for engine management Switch off Gas supply Close manual gas shutoff valve Air intake and exhaust sys tems If the engine is to remain out of service for more than 1 week seal the en gine s air and exhaust sides 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 corrosi...

Page 49: ...ylinder heads after component mainte nance or extended component maintenance When installing a cylinder head with run in mating faces e g after piston replacement a repeated check after the first 50 operating hours is not necessary Qualifi cation Interval Item Maintenance tasks Task h a QL1 Valve gear Check valve clearance Page 145 Table 38 50 hours check MS150114 01E 2015 03 Maintenance 49 TIM ID...

Page 50: ... adjust if necessary Page 145 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 leaks repair if required Page 150 W1091 Check ignition timing adjust if required Page 141 W1341 Check emission values adjust if required Page 43 W1382 Replace vent line of engine coolant circu...

Page 51: ...imit value 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 AKR Anti Knock Control GET Important information about fault messages from the engine governor engine monitoring Fault messages from the engine governor are represented in the fault code list Page...

Page 52: ...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 52 Troubleshooting MS150114 01E 2015 03 TIM ID 0000027852 002 ...

Page 53: ...on values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112303 HI T Exhaust A3 Yellow alarm Ini...

Page 54: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112308 HI T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112309 HI T Exhaust A9 Yellow alarm Initiated by EMU Cause C...

Page 55: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112314 HI T Exhaust B4 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112315 HI T Exhaust B5 Yellow alarm Initiated by EMU Cause C...

Page 56: ...Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112320 HI T Exhaust B10 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112401 LO T Exhaust A1 Yellow alarm Initiated by E...

Page 57: ...orrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112406 LO T Exhaust A6 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emissio...

Page 58: ...orrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112411 LO T Exhaust B1 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emissio...

Page 59: ...orrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112416 LO T Exhaust B6 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emissio...

Page 60: ...alues 3 Check ignition timing Page 141 4 Check valve drive 112501 HIHI T Exhaust A1 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112502 HIHI T Exhaust A2 Red alarm Initiated by EMU Cause Corrective act...

Page 61: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112507 HIHI T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112508 HIHI T Exhaust A8 Red alarm Initiated by EMU Cause Cor...

Page 62: ...nition timing Page 141 3 Check valve drive exhaust valves do not close 112513 HIHI T Exhaust B3 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112514 HIHI T Exhaust B4 Red alarm Initiated by EMU Cause Co...

Page 63: ...k ignition timing Page 141 3 Check valve drive exhaust valves do not close 112519 HIHI T Exhaust B9 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112520 HIHI T Exhaust B10 Red alarm Initiated by EMU Cau...

Page 64: ...orrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112605 LOLO T Exhaust A5 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission v...

Page 65: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112610 LOLO T Exhaust A10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission v...

Page 66: ...orrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112615 LOLO T Exhaust B5 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission v...

Page 67: ...ug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112701 HIHI T Exhaust A1 abs Red alarm Initiated by EMU Caus...

Page 68: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112707 HIHI T Exhaust A7 abs Red alarm Initiated by EMU Cause Corrective action I...

Page 69: ...nition timing Page 141 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112713 HIHI T Exhaust B3 abs Red alarm Initiated by EMU Cause Corrective action ...

Page 70: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112719 HIHI T Exhaust B9 abs Red alarm Initiated by EMU Cause Corrective action I...

Page 71: ... cabling 113902 SS Local Initiated Emerg Stop Red alarm Initiated by SAM Cause Corrective action Emergency stop detected Emergency stop was released manually button or ignition system reported overspeed 1 Clear emergency stop 2 Check governor 3 Check throttle closing position 1 4510 186 Error Status Red alarm Initiated by anti knock control Cause Corrective action GET combined alarm At least one o...

Page 72: ...ng torque damage replace as necessary 1 4510 193 Knock Sensor Error A2 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 194 Knock Sensor Error A3 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Che...

Page 73: ... cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 199 Knock Sensor Error A8 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 200 Knock Sensor Error A9 Red alarm Initiated by anti knock control Cause Corrective action No signal from this kn...

Page 74: ... cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 205 Knock Sensor Error B4 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 206 Knock Sensor Error B5 Red alarm Initiated by anti knock control Cause Corrective action No signal from this kn...

Page 75: ...om this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 211 Knock Sensor Error B10 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4520 232 Error Missing Ring Gear Signal Red alarm Initiated by IC922 Cause Corrective acti...

Page 76: ...7 OverSpeed 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 Corrective action Hardware not ready for operation u Restart ignition 1 4520 239 Global Timing out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified global ignition timing is be...

Page 77: ... 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 Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 247 Open Primary Channel 3 Yellow alarm Initiated by IC922 Cause...

Page 78: ...ry 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 alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 254 Open Primary Channel 10 Yellow alarm Initiated b...

Page 79: ...ry 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 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 262 Open Primary Channel 17 Yellow alarm Initiated...

Page 80: ...ace 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 cabling replace as necessary 1 4520 272 Warn Missing Camshaft Signal Yellow alarm Initiated by IC922 Cause Corrective action Missing camshaft signal for ignition system u Sensor B 1 2 check sensor sen...

Page 81: ...y F series Cause Corrective action Combined alarm for details refer to the source alarm u Combined alarm for details refer to the source alarm 1 4530 009 Derating Active Yellow alarm Initiated by F series Cause Corrective action Combined alarm for details refer to the source alarm u Combined alarm for details refer to the source alarm 1 4530 010 PWM Input High Duty Cycle Error Yellow alarm Initiat...

Page 82: ... Error Yellow alarm Initiated by F series Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4530 016 Electronics Temperature High Error Red alarm Initiated by F series Cause Corrective action Hardware not ready for operation u Restart F series 1 4530 017 Electronics Temperature Low Error Red alarm Initiated by F series Cause Corrective ...

Page 83: ...ries Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4540 009 Zero Pressure Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow detected u Check gas 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 R...

Page 84: ...GT Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 016 Delta P Fail High Red alarm Initiated by TecJet Cause Corrective action Differential pressure at TecJet too high 1 Check gas pressure 2 Check TecJet for dirt 1 4540 017 FGP Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u ...

Page 85: ...022 Delta P Fail Low Red alarm Initiated by TecJet Cause Corrective action Delta p via TecJet below set limit value u Check TecJet and configuration 1 4540 023 FGP Fail Low Red alarm Initiated by TecJet Cause Corrective action Gas pressure before TecJet is below the preset limit value u Check TecJet and configuration 1 4540 024 Coil Current Fail Low Red alarm Initiated by TecJet Cause Corrective a...

Page 86: ...r Red alarm Initiated by TecJet Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 031 Delta P Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u...

Page 87: ...rt TecJet 1 4540 036 FGP High Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 037 Watchdog Reset Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 038 CAN Flow Demand Failed Red alarm Initiated by TecJet Cause Corrective action TecJet setting is not correct u Chec...

Page 88: ...0 044 Parameter Version Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 045 Main EEP Read Fail Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 046 Main EEP Write Fail Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJ...

Page 89: ...51 Sense 12V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 052 ADC Test Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 053 CAN Timing Changed Yellow alarm Initiated by TecJet Cause Corrective action Change of CAN baud rate detected 1 Check settings 2 Check ca...

Page 90: ...Act A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action Supply voltage has reached maximum or minimum limit value 1 Check supply voltage 2 Check cabling 1 4550 034 A Position Error Red alarm Initiated by ProAct A Bank Cause Corrective action Position specification and feed...

Page 91: ...ing or is outside the range 1 Check setting 2 Check cabling 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 040 A Analog Position Demand Failed Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 041 A PWM Position Demand Failed Yellow...

Page 92: ... Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action Supply voltage has reached maximum or minimum limit value 1 Check supply voltage 2 Check cabling 1 4550 134 B Position Error Red alarm Initiated by ProAct B Bank Cause Corrective action Position speci...

Page 93: ...ing or is outside the range 1 Check setting 2 Check cabling 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 140 B Analog Position Demand Failed Yellow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 141 B PWM Position Demand Failed Yellow...

Page 94: ...e Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 144 B CAN Stop Command Yellow alarm Initiated by ProAct B Bank Cause Corrective action Stop input signal received via CAN bus u Check setting 94 Troubleshooting MS150114 01E 2015 03 TIM ID 0000038611 002 ...

Page 95: ... oil system oil heat exchanger 2 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 too high limit value 1 Incorrect ignition timing mixture too lean or too rich damage to turbine 1 Check exhaust turbocharger 2 Check ignition timing Page 141 3 Check m...

Page 96: ...ocharger 2 Check ignition timing Page 141 3 Check mixture setting 4 Check spark plugs 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective action Pressure loss via oil filter too high limit value 1 1 Replace oil filter Page 156 2 If this fault message occurs again after unexpectedly short filter runtime check oil filter for deposits change oil if required Page 154 0...

Page 97: ...ine 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 this input 036 HI ETC2 Overspeed Yellow alarm Associated parameter 2 3013 931 Cause Corrective action Speed of 1st secondary turbocharger too high limit value 1 u Turbocharger speed sensor is not fitted ...

Page 98: ...o 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 Corrective action Intake air temperature too high limit value 1 u Check ventilation system 054 HIHI T Intake Air Yellow alarm Associated parameter 2 0123 932 Cause Corrective action Intake air temperature too...

Page 99: ... Check oil separator condition replace as necessary Page 131 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restrictor valve in crankcase breather is closed too far air filter is defective oil separator is clogged piston rings are seized other damage to crank drive 1 Check crank drive Bar engine Page 12...

Page 100: ...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 pressure over mixture cooler Check emissions and injection timing Page 141 Check oil separator efficiency oil in compressor intake elbow clean compressor as necessary Check valve clearance Page 145 Che...

Page 101: ...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 differential coolant pressure 3 Check heating elements 4 Check cabling 095 AL Prelubrication Fault Red alarm Start terminated Associated parameter 2 1090 920 Cause Corrective action Oil priming fault 1 Check oil pr...

Page 102: ...k supply voltage 2 Check cabling 121 HIHI ECU Power Supply Voltage Red alarm Associated parameter 2 0140 932 Cause Corrective action Supply voltage too high limit value 2 1 Check supply voltage 2 Check cabling 122 HI T ECU Yellow alarm Associated parameter 2 0132 921 Cause Corrective action Electronics temperature too high limit value 1 u Provide improved cooling for ECU Reduce room temperature ch...

Page 103: ...AN mode initializes communication by means of the PU data module However the necessary PU data module is not present or is invalid u Contact Service configuration fault 184 AL CAN PU Data Flash Error Red alarm Associated parameter 2 0500 684 Cause Corrective action A programming error occurred when attempting to copy a received PU data module into the Flash module u Contact Service configuration f...

Page 104: ...0500 689 Cause Corrective action CAN controller 2 has indicated a warning Possible causes may be e g missing node minor malfunctions or temporary bus overload u Check operation of bus nodes and cabling 190 AL EMU Parameter Not Supported Red alarm Associated parameter 2 0500 690 Cause Corrective action EMU parameters are not supported u Contact Service configuration fault 201 SD T Coolant Red alarm...

Page 105: ...ause Corrective action Exhaust temperature sensor on B side defective short circuit or wire break u Check sensor and cabling B4 22 replace as necessary Fault is rectified following engine restart 211 SD P Lube Oil Red alarm Engine shutdown Associated parameter 1 8004 563 Cause Corrective action Engine oil pressure sensor after filter defective short circuit or wire break u Check sensor and cabling...

Page 106: ...rective action Intake air temperature sensor defective short circuit or wire break u Check sensor and cabling B49 2 replace as necessary Fault is rectified when engine is restarted 221 SD P Diff Lube Oil Red alarm Associated parameter 1 8004 585 Cause Corrective action Engine oil pressure sensors defective short circuit or wire break u Check sensor and cabling before filter B5 3 and after filter B...

Page 107: ...as necessary Fault is rectified following engine restart 232 SD ETC Speed 1 Yellow alarm Associated parameter 1 3011 128 Cause Corrective action Speed sensor of primary turbocharger defective short circuit or wire break u Turbocharger speed sensor is not fitted at present 233 SD ETC Speed 2 Yellow alarm Associated parameter 1 3011 129 Cause Corrective action Speed sensor of secondary turbocharger ...

Page 108: ...2 8006 639 Cause Corrective action Short circuit or wire break at transistor output plant side 2 TOP 2 Activation of red combined alarm faulty u Check cabling 383 AL Wiring TOP 3 Red alarm Associated parameter 2 8006 640 Cause Corrective action Short circuit or wire break at transistor output plant side 3 TOP 3 Activation of gas supply solenoid valve No 1 faulty u Check cabling 384 AL Wiring TOP 4...

Page 109: ...ssociated parameter 2 0180 921 Cause Corrective action Coolant differential pressure too low limit value 1 Insufficient volume flow u Check engine coolant circuit pressure and flow 429 HI P Coolant Red alarm Engine shutdown Associated parameter 2 0101 931 Cause Corrective action Coolant pressure after engine too high limit value 3 u Check engine coolant circuit pressure and flow 430 LO P Coolant b...

Page 110: ...rameter 2 0173 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure volumetric flow too low air in engine coolant circuit u Check engine coolant circuit pressure and flow 443 HI P Charge Mix Diff Yellow alarm Associated parameter 2 0183 931 Cause Corrective action Difference in mixture pressures sensed on A and B side is too high limit va...

Page 111: ...ixture cooler for dirt 452 HIHI T Charge Mix Red alarm Engine shutdown Associated parameter 2 0169 932 Cause Corrective action Mixture temperature too high limit value 2 Mixture coolant pump failure volumetric flow too low cooling system inlet temperature too high mixture cooler clogged 1 Check mixture cooling circuit 2 Check mixture cooler for dirt 453 LO T Charge Mix Yellow alarm Associated para...

Page 112: ...3 replace as necessary Fault is rectified following engine restart 470 SD T ECU Red alarm Associated parameter 1 8004 587 Cause Corrective action Temperature sensor for Engine Control Unit defective short circuit or wire break u Check sensor and cabling replace as necessary Fault is rectified following engine restart 472 AL Stop SD Red alarm Engine shutdown Associated parameter 2 8006 593 Cause Co...

Page 113: ...it or wire break u Check sensor and cabling B79 21 replace as necessary Fault is rectified following engine restart 497 SD P Charge Mix B Red alarm Engine shutdown Associated parameter 1 8004 629 Cause Corrective action Mixture pressure sensor on B side defective short circuit or wire break u Check sensor and cabling B79 22 replace as necessary Fault is rectified following engine restart 498 SD P ...

Page 114: ...r 2 0182 932 Cause Corrective action Mixture pressure on B side too high limit value 2 1 Check emissions 2 Check ignition timing Page 141 3 Check exhaust back pressure 4 Check valve clearance Page 145 5 Check throttle 6 Check mixture coolant system 513 SD P Coolant Diff Red alarm Associated parameter 1 8004 610 Cause Corrective action Coolant differential pressure sensor defective short circuit or...

Page 115: ...ted parameter 1 0187 900 Cause Corrective action Intake air pressure sensor after filter on B side defective short circuit or wire break u Check sensor and cabling B81 2 replace as necessary Fault is rectified following engine restart 536 AL Wiring PWM_CM1 Red alarm Associated parameter 1 1041 921 Cause Corrective action Cable break or short circuit on channel PWM_CM1 u Check ignition cabling 552 ...

Page 116: ...pply solenoid valves are faulty the timeout period is set too short or communication is faulty 1 Check gas train 2 Check cabling 557 AL speed drop fault Red alarm Engine shutdown Associated parameter 2 1090 126 Cause Corrective action Speed drop Alarm is activated if engine speed drops during starting sequence u Check gas train 559 AL mixture throttle A fault Red alarm Engine shutdown Associated p...

Page 117: ...s over air filter on A side is too high u Replace air filter Page 151 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure loss over air filter on A side is too high u Replace air filter Page 151 567 AL L1 P Intake Air after Filter B Yellow alarm Associated parameter 2 0187 921 Cause Corrective action Pressure loss over air filter on B...

Page 118: ... emissions 2 Check ignition timing Page 141 3 Check combustion chamber 4 Check gas quality if feasible methane number 571 L2 Al CAN Max Retarded Timing Yellow alarm Power reduction Associated parameter 2 1200 932 Cause Corrective action The cylinder set to maximum retarded timing due to knocking has violated the second limit value Power reduction is initiated 1 Check emissions 2 Check ignition tim...

Page 119: ...bling to NOx sensors and air humidity sensor 617 LO Current Heat Value of Fuel Yellow alarm Associated parameter 2 1210 006 Cause Corrective action Fuel calorific value has undershot the first limit value u Check gas quality if feasible 618 LOLO Current Heat Value of Fuel Yellow alarm Associated parameter 2 1210 007 Cause Corrective action Fuel calorific value has undershot the second limit value ...

Page 120: ...d parameter 2 3050 025 Cause Corrective action NOx emissions have undershot the second limit value 1 Check gas quality if feasible 2 Check gas pressure 3 Check NOx sensor 4 Check emissions 623 HI NOx Value Yellow alarm Associated parameter 2 3050 026 Cause Corrective action NOx emissions have exceeded the first limit value 1 Check gas quality if feasible 2 Check NOx sensor 3 Check emissions 624 HI...

Page 121: ...arm Associated parameter 2 1200 935 Cause Corrective action Opening angle of throttles A exceeded 1 Check charge air pressure reserve 2 Intake air temperature outside TVU data 3 Check compressor for contamination 4 Reduce power 650 Al Req Angle Throttle B Red alarm Associated parameter 2 1200 936 Cause Corrective action Opening angle of throttles B exceeded 1 Check charge air pressure reserve 2 In...

Page 122: ...mmunication for bypass flap faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU bypass flap 4 Check settings with device specific dialog software XD50 3 655 AL TecJet Comm Lost Red alarm Associated parameter 1 4540 996 Cause Corrective action CAN bus communication for gas control valve faulty alternatively a stepper motor with gas mixer can be installed 1 Check cabling 2 Che...

Page 123: ...0 196 Cause Corrective action CAN bus communication for NOx sensor B faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU and EMU 4 Replace sensor 664 AL Oil Refill Error Red alarm Associated parameter 1 1480 305 Cause Corrective action Combined alarm for automatic oil replenishment faulty u After initiation of the alarms HI Oil Refill and HI Lube Oil Level refill a programmable ...

Page 124: ... exact fault designation is transmitted via CAN bus to the genset control system 669 AL ProActA Yellow Yellow alarm Associated parameter 1 4550 093 Cause Corrective action An internal combined alarm in throttle A was detected u An exact fault designation is transmitted via CAN bus to the genset control system 670 AL ProActB Yellow Yellow alarm Associated parameter 1 4550 193 Cause Corrective actio...

Page 125: ...designation is transmitted via CAN bus to the genset control system 677 AL FSeries Red Red alarm Associated parameter 1 4530 991 Cause Corrective action An internal combined alarm in the bypass flap was detected u An exact fault designation is transmitted via CAN bus to the genset control system 678 AL TecJet Red Red alarm Associated parameter 1 4540 991 Cause Corrective action An internal combine...

Page 126: ...arm at NOx sensor B was detected u An exact fault designation is transmitted via CAN bus to the genset control system 685 AL Lube Oil Min Red alarm Associated parameter 1 1480 307 Cause Corrective action Minimum engine 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 a...

Page 127: ...ause Corrective action 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 Associated parameter 2 8006 034 Cause Corrective action Limit value 1 exceeded u Check gas supply 720 AL T Gas L2 Yellow alarm Associated parameter 2 8006 035 Cause Corrective action Limi...

Page 128: ...e 2 Check cabling 974 AL CAN3 Bus Off Yellow alarm Associated parameter 2 0500 692 Cause Corrective action CAN controller 3 is in Bus Off status Bus nodes ignition anti knock module throttles or gas mixer are faulty u Check operation of bus nodes and cabling 975 AL CAN3 Error Passive Yellow alarm Associated parameter 2 0500 693 Cause Corrective action CAN controller 3 has indicated a warning Bus n...

Page 129: ...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 Barring engine manually 1 Remove guard plate 2 Engage barring gear 2 in ring gear 3 and install on flywheel housing 3 Apply ratchet 1 to barring gear 2 4 Rotate crankshaft in direction of engine ro tation Apart from compression resistance there should be no...

Page 130: ...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 responds Avoid naked flames Avoid sparks Do not use electrical appliances including switches connectors sockets telephone bell Do not smoke Close the magnetic gas shutoff valves Open windows and doors Warn re...

Page 131: ...oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask 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 Do not smoke Oil separator Filter replace ment 1 Release clamp 2 on...

Page 132: ...lescence filter 5 must be installed in the correct position in the housing 10 Place coalescence filter 5 in housing en suring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12 Screw on washer 2 with new locknut 1 and tighten to specified tightening torque with torque wrench Name Size Type Lubricant Value Standard Locknut Tightening torque 15 Nm 13 Fit housing cover 1 14 F...

Page 133: ...ment Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 134 2 Install new spark plug Page 135 MS150114 01E 2015 03 Task Description 133 TIM ID 0000004224 002 ...

Page 134: ...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 rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Removing spark plug 1 Remove spark plug connector 1 Page 138 2 Unscrew spark plug a few turn...

Page 135: ...C before beginning work Wear suitable 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 rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Installing spark plug 1 Clean and dry the mating surfaces ...

Page 136: ... prior to tightening 6 Tighten spark plug to specified torque using a torque wrench Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molykote P 37 50 5 Nm 7 Install spark plug connector 1 Page 139 136 Task Description MS150114 01E 2015 03 TIM ID 0000043425 004 ...

Page 137: ...rial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 138 2 Install spark plug connector Page 139 MS150114 01E 2015 03 Task Description 137 TIM ID 0000035897 004 ...

Page 138: ...aring risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Removing spark plug connector 1 Loosen screws 4 on cylinder head cov er 7 turning them back approx one revo lution 2 Turn flange 6 counterclockwise out of un ion 4 3 Pull protective cap 2 up and back to gain access to threaded connection of the igni tion lead underneath 4 L...

Page 139: ...e s low er sealing ring and replace with a new seal ing ring 2 Remove any dust and impurities from the ignition line connector s Teflon body on the outside and inside on the spark plug side 3 Check the spark plug isolator sealing ring for damage If damaged install a new spark plug isolator sealing ring Page 140 4 Insert the ignition line connector 5 into the spark plug duct press down the igni tio...

Page 140: ... pull out sealing ring 2 3 Fold together new sealing ring 2 4 Insert sealing ring 2 into the bore in Tef lon sleeve 1 with the article number fac ing downwards 5 Carefully press sealing ring 1 into the groove until it is flush with the bore in Tef lon sleeve 2 140 Task Description MS150114 01E 2015 03 TIM ID 0000043226 006 ...

Page 141: ...NING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note The service tool Diasys and a dongle with access rights 1A or higher is required to determine the ignition setpoint 1 Stop engine Page 44 2 Install stroboscope clamp on cylinder A1 ignition cable 3 Start engine Page 41 4 Using the stroboscope check ign...

Page 142: ... Qty Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 134 2 Remove cylinder head covers Page 148 3 Remove sleeves arrow 4 Install barring device Page 129 5 Rotate crankshaft with barring device in en gine direction of rotation until marking OT and pointer are aligned 142 Task Description MS150114 01E 2015 03 TIM ID 0000043220 002 ...

Page 143: ... 3 Release adjusting screw 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 depth gauge see figure The specified value for a new cylinder head 93 8 mm Admissible wear 3 mm If the measured value is 96 8 mm re place the relevant cylinder head ahead of schedule 5 Install valve bridge 6 Adjust valve clearan...

Page 144: ...3 Install sleeves arrow 4 Install cylinder head covers Page 149 5 Install spark plugs with new sealing rings Page 135 144 Task Description MS150114 01E 2015 03 TIM ID 0000043220 002 ...

Page 145: ...ve cylinder head cover Page 148 2 Install barring device Page 129 3 Rotate crankshaft with barring tool in en gine direction of rotation until TDC marking and pointer are aligned Diagram for 8 V engines Two crankshaft positions Position Cylinder 1 2 3 4 5 6 7 8 9 10 8 V Firing TDC in cylinder A1 Bank A I X X I X X Bank B I X I I Overlap TDC in cylinder A1 Bank A I I Bank B X I X X I Inlet Adjustme...

Page 146: ...rom the set value exceeds 0 1 mm adjust valve clearance Valve clearance Adjustment 1 Release locknut 1 2 Insert feeler gauge 3 between valve bridge and rocker arm 3 Use angular screw driver to set adjusting screw 2 so that specified valve clearance is provided 4 Feeler gauge 3 must just pass through the gap 5 Use torque wrench to tighten locknut 1 to specified tightening torque holding the adjusti...

Page 147: ...ols 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 adjust ing screws with oil 3 Install cylinder head covers Page 149 MS150114 01E 2015 03 Task Description 147 TIM ID 0000043352 001 ...

Page 148: ...g disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 138 3 Remove screws 2 4 Remove cylinder head cover with gasket from cylinder head 148 Task Description MS150114 01E 2015 03 TIM ID 0000042136 002 ...

Page 149: ...mponents 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 head 4 Insert screws 2 in cylinder head cover and tighten them Note The locking plate must be removed from the cylinder head cover 5 Install spark plug connector Page 139 MS150114 01E 2015 03 Task Descrip...

Page 150: ...f 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 all connections of the gas supply line with soap solution or spray with leakage detection spray from a distance of 30 to 50 cm Leaks are indicated by the formation of bubbles or foam 2 Replace leaking ...

Page 151: ...ilter 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 Replacing air filter 1 Remove air filter Page 152 2 Install new air filter Page 152 MS150114 01E 2015 03 Task Description 151 TIM ID 0000013394 002 ...

Page 152: ...talla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from connecting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air filter 3 with clamp 2 onto intake housing 1 5 Tighten clamp 2 152 Task Description MS150114 01E 2015 03 TIM ID 0000044568 002 ...

Page 153: ...o 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 ex ceed the mark 1 by up to 2 cm Note Topping up oil manually is not required The oil level check is only intended to confirm that the automatic oil replenishment fea ture works properly 4 Insert oil dipstick into guide tube up to the stop Oil...

Page 154: ... vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Engine oil extraction 1 Open shut off valve s in extraction line from engine and waste oil tank 2 Extract all oil from oil pan using the electric pump 3 Close shut off valve s Filling with new engine oil 1 Determine oil change quantity fuel optimiz...

Page 155: ...ask 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 Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine oil Sample extraction 1 Connect sampling hose genset manufac turer s scope of delivery t...

Page 156: ...loves and goggles safety mask 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 Do not smoke Replacing engine oil filter 1 Remove oil filter using filter wrench 2 Clean sealing surface of connecting piece 3 Check condition of new oil filter sealing ring and coat it with...

Page 157: ...ARNING 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 pressure fuel optimized Page 24 or for tropical applications Page 28 at pressure gauge 2 Top up with treated coolant as necessary Page 161 MS150114 01E 2015 03 Task Description 157 TIM ID 000004467...

Page 158: ...ge Special tools 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 Task Description MS150114 01E 2015 03 TIM ID 0000000036 031 ...

Page 159: ...e Risk of injury 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 installed Engine coolant Draining 1 Open drain valves and drain coolant at the following points At the crankcase free end left and right side MS150114 01E 2015 03 Task Description 159 ...

Page 160: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 160 Task Description MS150114 01E 2015 03 TIM ID 0000006751 002 ...

Page 161: ...oves 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 Filling with coolant 1 Fill with treated coolant using a pressure pump until the system filling pressure fuel optimized Page 24 or for tropical applications Page 28 has been reached 2 Vent engine coolant circuit at vent line 3 ...

Page 162: ... of injury and scalding 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 line 2 4 Install new coolant vent line 2 5 Fill with engine coolant Page 161 162 Task Description MS150114 01E 2015 03 TIM ID 0000029143 003 ...

Page 163: ...ant 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 filling pressure fuel optimized Page 24 or for tropical applications Page 28 at pressure gauge 2 Top up with treated coolant as necessary Page 166 MS150114 01E 2015 03 Task Description 163 TIM ID 0000045193 001 ...

Page 164: ...al tools 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 Task Description MS150114 01E 2015 03 TIM ID 0000007027 004 ...

Page 165: ... injury 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 drain point in coolant line to mixture coolant cooler and drain coolant MS150114 01E 2015 03 Task Description 165 TIM ID 0000042774 001 ...

Page 166: ...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 Filling with coolant 1 Fill with treated coolant using a pressure pump until the system filling pressure fuel optimized Page 24 or for tropical applications Page 28 has been reached 2 Vent mixture coolant circuit via system 3...

Page 167: ... closed and 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 housings Contacts Plug connectors Cables and terminals Plug in contacts Result If cable conductors are damaged contact Service Note Close connectors that are not plugged in with the protect...

Page 168: ...r 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 40 Sensors on right engine side The knocking sensors B80 XX are located on the crankcase right and left below the cylinder heads 168 Task Description MS150114 01E 2015 03 TIM ID 0000045279 002 ...

Page 169: ... B88 Nitric oxide values in exhaust gas NOx 2 B75 Crankshaft speed reset 3 B13 3 Crankshaft speed ignition system 4 B79 23 Mixture pressure before throttle Table 41 Sensors on driving end MS150114 01E 2015 03 Task Description 169 TIM ID 0000045279 002 ...

Page 170: ...ide 2 B50 Crankcase pressure 3 B5 3 Engine oil pressure before filter 4 B7 Engine oil temperature 5 B5 1 Engine oil pressure after filter 6 B44 1 Turbocharger speed optional Table 42 Sensors on left engine side 170 Task Description MS150114 01E 2015 03 TIM ID 0000045279 002 ...

Page 171: ...engine 3 B1 3 Camshaft speed knock module 4 B1 2 Camshaft speed ignition system 5 B1 1 Camshaft speed engine control system 6 B24 Engine oil level 7 B6 3 Coolant temperature before engine 8 B6 1 Coolant temperature after engine Table 43 Sensors on free end MS150114 01E 2015 03 Task Description 171 TIM ID 0000045279 002 ...

Page 172: ...aximum 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 international cod ing for the power specification of combustion engines ISO International Organization for Standardi zation International umbrella organization for all na tional standardization institutes KG...

Page 173: ...motive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische Anleitung zur Reinhaltung der Luft General administrative instruction for federal emission control law in Germany TD Transmitter Deviation Alarm Sensor comparison fault UT Bottom Dead Center WZK Too...

Page 174: ...r during operation for preventive maintenance corrective work in case of malfunction or changed oper ating conditions or for spare parts supply For our locally available support go to MTU s Internet site http www mtuonsiteenergy com haendlersuche index de html Your contact at Headquarters support oeg mtu online com Spare Parts Service Quick easy and correct identification of the spare part require...

Page 175: ...4 2 Valve clearance Check and adjustment Page 145 Barring gear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 129 Feeler gauge Part No Y20098771 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 145 MS150114 01E 2015 03 Appendix B 175 DCL ID 0000029666 002 ...

Page 176: ... 3 7 Emission values Check Page 43 Qty Used in 6 1 2 Checking machine room for smell of gas Page 130 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Engine Barring manually Page 129 Sliding depth gauge 200 mm Part No Y20000918 Qty Used in 1 6 4 1 Valve projection Measurement Page 142 176 Appendix B MS150114 01E 2015 03 DCL ID 0000029666 002 ...

Page 177: ...al Page 134 Qty Used in 1 6 3 3 Spark plug Installation Page 135 Stroboscope Not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 141 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 6 3 3 Spark plug Installation Page 135 Qty Used in 1 6 3 6 Spark plug connector Installation Page 139 MS150114 01E 2015 03 Appendix B 177 DCL ID 0000029666 002 ...

Page 178: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 145 178 Appendix B MS150114 01E 2015 03 DCL ID 0000029666 002 ...

Page 179: ...ine cabling Check 167 Engine coolant Change 158 Draining 159 Filling 161 Level check 157 Engine driving end Definition 21 Engine free end Definition 21 Engine oil Chgange 154 Sample extraction and analysis 155 Engine oil filter Replacement 156 Engine oil level Check 153 Engine sides Designation 21 F Fault messages Engine governor 95 Key 51 Protocol to genset control system 53 Firing order 23 G Gas...

Page 180: ...ons 5 Maintenance work 11 Operation 9 Organizational requirements 7 Personnel requirements 7 Repair work 11 Startup 9 Safety requirements Maintenance work special instructions for applica tions with gaseous fuel 14 Operation special instructions for applications with gaseous fuel 10 Repair work special instructions for applications with gaseous fuel 14 Safety notices standards 18 Startup special i...

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MTU 12 V 4000 Lx2 xx, Operating Instructions Manual

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