MTU 12 V 4000 Lx4 Operating Instructions Manual Download Page 194

Page: 194 / 199

8 Appendix B

8.1 Special Tools

Angular screw driver

Part No.:

F30452765

Qty.:
Used in:

1
6.4.3 Valve clearance – Check and adjustment
(→ Page 165)

Barring gear

Part No.:

F6555766

Qty.:
Used in:

1
6.1.1 Engine – Barring manually (→ Page 147)

Feeler gage

Part No.:

Y20098771

Qty.:
Used in:

1
6.4.3 Valve clearance – Check and adjustment
(→ Page 165)

194 | Appendix B | MS15027/00E 2013-10

DCL-ID: 0000028920 - 002

Summary of Contents for 12 V 4000 Lx4

Page 1: ...Operating Instructions Gas engine 12 V 4000 Lx4 16 V 4000 Lx4 MS15027 00E...

Page 2: ...copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translatio...

Page 3: ...ting and stopping sequences 38 3 5 Engine Start 40 3 6 Operational checks 41 3 7 Emission values Check 42 3 8 Engine Shutdown 43 3 9 Emergency engine shutdown 44 3 10 After stopping the engine Engine...

Page 4: ...cuit 182 6 10 1 Mixture coolant level Check 182 6 10 2 Mixture coolant Change 183 6 10 3 Mixture coolant Draining 184 6 10 4 Mixture coolant Filling 185 6 11 Wiring General for Engine Gearbox Unit 186...

Page 5: ...onfiguration 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 In accordan...

Page 6: ...rk on or 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 Tra...

Page 7: ...th 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 violation of limit v...

Page 8: ...alves 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...

Page 9: ...e work Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device Observe the safety data sheet Saf...

Page 10: ...ct beforehand Hydraulic installation and removal Check satisfactory function and safe operating condition of tools jigs and fixtures to be used Use only the specified jigs and fixtures for hydraulic r...

Page 11: ...y stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched...

Page 12: ...f that has been trained and authorized for this task Have all work on gas carrying components carried out by authorized specialized companies Prior to starting maintenance work shut off the gas supply...

Page 13: ...product are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Non...

Page 14: ...ly line or before device or tool is to be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting...

Page 15: ...n 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...

Page 16: ...event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequ...

Page 17: ...for the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transpor...

Page 18: ...Mixture cooler 4 Exhaust turbocharger 5 Engine lifting equipment 6 Capacitor ignition system 7 Engine mounting bracket free end 8 Oil pan 9 Engine mounting bracket driving end 10 Flywheel 11 Air filte...

Page 19: ...ch 12 Connection engine cool ant inlet 13 Engine oil heat exchanger 14 Connection engine cool ant outlet KGS Free end Engine model designation Key to the engine model designation 12 16V 4000 L64 12 16...

Page 20: ...he left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at the driving end The numb...

Page 21: ...eight 12V C approx 2146 mm Height 16V C approx 2171 mm Crankshaft center to oil pan 12 V D approx 636 mm Crankshaft center to oil pan 16 V D approx 636 mm Crankshaft center to engine mount 12 V E appr...

Page 22: ...2 4 Ignition order Ignition order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 22 Product Summary MS15027 00E 2013 10 TIM ID 0000002806 001...

Page 23: ...er related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s not speci fied not speci fied Continuous power as p...

Page 24: ...ed not speci fied Standard housing connecting flange engine main PTO SAE 00 00 Table 8 Model related data basic design Coolant system HT circuit Number of cylinders 12 16 Coolant temperature at engine...

Page 25: ...g temperature after oil heat exchanger to r C 90 90 Lube oil operating temperature after oil heat exchanger warning r C 93 93 Lube oil operating temperature after oil heat exchanger engine shutdown L...

Page 26: ...stem r Liters 260 285 Oil change capacity max standard oil system r Liters 220 250 Table 15 Oil and coolant capacity Weights main dimensions Number of cylinders 12 16 Dry engine weight basic configura...

Page 27: ...046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s not speci fied not speci fied Continuous power as per ISO 3046 A kW 1560 2080 Mean effective pressure pme continu...

Page 28: ...ber of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature at engine connection inlet from cooling equipment w o antifreez...

Page 29: ...re after oil filter bar 5 4 5 5 Lube oil pressure after oil filter warning r bar 5 0 5 0 Lube oil pressure after oil filter shutdown L bar 4 5 4 5 Table 26 Lube oil system Fuel system Number of cylind...

Page 30: ...rs 12 16 Dry engine weight basic configuration engine r kg 6700 8300 Heaviest component to be lifted during extended component maintenance QL3 r kg 415 440 Table 31 Weights main dimensions Exhaust emi...

Page 31: ...opping 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 Un...

Page 32: ...the cylinder in question If this does not result in an improvement the power is reduced Gas control valve TecJet52 TecJet85 Controls the required amount of gas Mixture throttles P Series The mixture...

Page 33: ...cs 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 Initiat...

Page 34: ...oring Unit EMU 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 34 Product Summary MS15027 00E 2013 10 TIM ID 000...

Page 35: ...Power referenced to nominal 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 minu...

Page 36: ...e 164 Lube oil system Check engine oil level Page 173 Check oil level in oil storage tank Page 173 Coolant circuit Standstill 1 year Change engine coolant Page 178 Change mixture coolant Page 183 Cool...

Page 37: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 173 Coolant circuit Check engine coolant level Page 177 Check mixture coolant level Page...

Page 38: ...by means of suitable systems in the facility A contact is provided to activate such sys tems Starting sequence The following steps are performed automatically when a start command is activated with t...

Page 39: ...wing a start request after emergency shutdown 1 Requesting external ventilation by contact 2 Activating starter 3 Waiting for starting speed 4 Flushing the engine 5 Disengaging starter 6 Engine runnin...

Page 40: ...aught 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...

Page 41: ...e room for smell of gas Page 148 ECU Check for fault messages if fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Op...

Page 42: ...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 leak...

Page 43: ...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 in...

Page 44: ...order to safely burn off uncombust ed fuel air mixture The ignition is only switched off in case of an overspeed violation or an internal ignition fault Throttles The throttles are always closed in c...

Page 45: ...t be equipped with an SAV safety shut off valve when using gas control systems with inlet pressures in excess of 0 1 bar If the SAV is tripped by an EMERGENCY STOP it must be reset manually SAV trippi...

Page 46: ...e Engine remains ready for operation After stopping the engine Item Action Engine generator control manufacturer specific Select operating mode e g HAND MANUAL AUTO AUTOMATIC 46 Operation MS15027 00E...

Page 47: ...is be low 40 C Power supply to engine con trol system Switch off Gas supply Close gas shut off valve Air intake and exhaust sys tems If the engine is to remain out of service for more than 1 week sea...

Page 48: ...cylinder heads after component maintenance 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 o...

Page 49: ...W0527 Check engine oil level in storage tank Page 173 W1002 Check valve clearance adjust if required Page 165 W1005 Replace air filter Page 171 W1008 Replace engine oil filter when changing engine oi...

Page 50: ...mit 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 ke...

Page 51: ...he 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 MS15027 00E 2013 10 Troubleshooting 51 TIM...

Page 52: ...n Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 160 3 Check valve drive exhaust valves do not...

Page 53: ...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 160 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 160 3 Check valve drive exhaust valves do...

Page 55: ...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 160 3 Check valve drive exhaust valves do...

Page 56: ...e 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 160 4 Ch...

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 160 4 Check valve...

Page 58: ...ive 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 160 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 160 4 Check valve...

Page 60: ...dividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 160 3 Check valve drive exhaust valves do not clo...

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 160 3 Check valve drive exhaust valves do...

Page 62: ...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 160 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 160 3 Check valve drive exhaust valves do...

Page 64: ...se Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 160 4 Ch...

Page 65: ...ve action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 160 4 Check valve d...

Page 66: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 160 4 Check valve...

Page 67: ...ve action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 160 4 Check valve d...

Page 68: ...ion values 2 Check ignition timing Page 160 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 tempe...

Page 69: ...tion timing Page 160 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: ...ition timing Page 160 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 cylinde...

Page 71: ...s temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 160 3 Check valve drive exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated by...

Page 72: ...ective action Transmission combined alarm At least one further transmission alarm is present u Rectify cause of alarm 1 4510 187 Combined Error Red alarm Initiated by antiknock control Cause Correctiv...

Page 73: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 195 Knock Sensor Error A4 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knock sensor...

Page 74: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 201 Knock Sensor Error A10 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knock sensor...

Page 75: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 207 Knock Sensor Error B6 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knock sensor...

Page 76: ...m 1 4520 509 MIC5 Stat System error Red alarm Initiated by MIC5 Cause Corrective action A system error has occurred u Rectify cause of alarm 1 4520 520 MIC5 Stat W temperat limit reached Yellow alarm...

Page 77: ...tion control unit 1 4520 526 MIC5 Stat Analogue current sig fail Red alarm Initiated by MIC5 Cause Corrective action Failure of current signal for adjusting the ignition timing u Check settings 1 4520...

Page 78: ...d sig during selftest Red alarm Initiated by MIC5 Cause Corrective action Pickup signals were detected during self test u Restart ignition control unit 1 4520 543 MIC5 E1 Shutdown due to alarm Red ala...

Page 79: ...value u Check settings in data record ignition coils and spark plugs Restart ignition control unit 1 4520 550 MIC5 E1 Tr1 synchronization fault Yellow alarm Initiated by MIC5 Cause Corrective action S...

Page 80: ...Cause Corrective action The number of trigger 1 B1 2 events is not correct u Check sensor sensor spacing cabling settings in data record and timing wheel Replace sensor if required 1 4520 557 MIC5 E1...

Page 81: ...oil 2 Check ignition coil 1 4520 571 MIC5 IPE Primary Open Cylinder 2 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 2 in firing order 1 Check cabling...

Page 82: ...r 9 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 9 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 579 MIC5 IPE Primar...

Page 83: ...der 16 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 16 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 586 MIC5 IPE Pr...

Page 84: ...yl 3 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 3 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 593 MIC5 IPE Pr...

Page 85: ...10 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 10 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 600 MIC5 IPE Pri...

Page 86: ...yl 17 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 17 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 607 MIC5 IPE...

Page 87: ...alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 4 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 61...

Page 88: ...larm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 11 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 621...

Page 89: ...alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 18 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 6...

Page 90: ...alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 5 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520...

Page 91: ...larm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 12 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520...

Page 92: ...nitiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 19 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 649 MI...

Page 93: ...5 Cause Corrective action Index mark of trigger 2 B75 was not detected u Check sensor sensor spacing cabling settings in data record and timing wheel Replace sensor if required 1 4520 664 MIC5 E2 Tr2...

Page 94: ...ng u Check sensor sensor spacing cabling settings in data record and timing wheel Replace sensor if required 1 4520 670 MIC5 E2 Tr3 synchronization fault Yellow alarm Initiated by MIC5 Cause Correctiv...

Page 95: ...Cause Corrective action The number of trigger 3 B13 2 events is not correct u Check sensor sensor spacing cabling settings in data record and timing wheel Replace sensor if required 1 4520 677 MIC5 E...

Page 96: ...se Corrective action Hardware not ready for operation u Restart F Series 1 4530 008 Alarm Yellow alarm Initiated by F Series Cause Corrective action Combined alarm for details refer to the source alar...

Page 97: ...ltage Low 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...

Page 98: ...Series 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...

Page 99: ...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...

Page 100: ...22 Delta P Fail Low Red alarm Initiated by TecJet Cause Corrective action Delta p from TecJet below the set limit value u Check TecJet and configuration 1 4540 023 FGP Fail Low Red alarm Initiated by...

Page 101: ...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 TecJe...

Page 102: ...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...

Page 103: ...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 C...

Page 104: ...051 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 act...

Page 105: ...iated by ProAct A Bank Cause Corrective action ProAct setting is not correct u Check setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action Upp...

Page 106: ...ng or out of 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 not correct u Check setting 1 45...

Page 107: ...llow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is not correct u Check setting 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by ProAct B Bank Cause Correc...

Page 108: ...ng or out of 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 not correct u Check setting 1 45...

Page 109: ...use 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 command received via CAN...

Page 110: ...stem oil heat exchanger 2 Replace oil filter Page 176 3 Take oil sample and analyze Page 175 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas tempera...

Page 111: ...d parameter 2 0154 931 Cause Corrective action Pressure loss via oil filter too high limit value 1 1 Replace oil filter Page 176 2 If this fault occurs again after unexpectedly short filter runtime ch...

Page 112: ...ondary turbocharger too high limit value 1 u Turbocharger speed sensor is not fitted at present Check ECU setting for this input 037 SS ETC2 Overspeed Red alarm Engine stop Associated parameter 2 3013...

Page 113: ...system 054 HIHI T Intake Air Yellow alarm Associated parameter 2 0123 932 Cause Corrective action Intake air temperature too high limit value 2 1 Check ventilation system 2 Reduce power 057 LO P Coola...

Page 114: ...closed too much air filter is defective oil separator is clogged piston rings are seized other damage to crank drive 1 Check crank drive Crank engine Page 147 endoscope combustion chambers from BDC to...

Page 115: ...ction timing Page 160 Check oil separator efficiency oil in compressor intake elbow clean compressor if necessary Check valve clearance Page 165 Check gasket between mixture line and cylinder head for...

Page 116: ...rential 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 Che...

Page 117: ...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 Ensure better cooling of the ECU Reduce room temperat...

Page 118: ...Red alarm Associated parameter 2 0500 684 Cause Corrective action A program fault occurred while trying to copy a received application environment data module u Contact Service configuration fault 186...

Page 119: ...ed 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 Engine stop Associated parameter...

Page 120: ...eter 1 8004 563 Cause Corrective action Engine oil pressure sensor after filter defective short circuit or wire break u Check sensor and cabling B5 1 replace as necessary Fault is rectified following...

Page 121: ...ssure sensors defective short circuit or wire break u Check sensor and cabling before filter B5 3 and after filter B5 1 replace as necessary Fault is rectified following engine restart 227 SD P Lube O...

Page 122: ...fitted at present 233 SD Charger 2 Speed Yellow alarm Associated parameter 1 3011 129 Cause Corrective action Speed sensor of secondary turbocharger defective short circuit or wire break u Turbocharg...

Page 123: ...eter 2 8006 640 Cause Corrective action Short circuit or wire break on transistor output plant side 3 TOP 3 Activation of gas supply solenoid valve No 1 faulty u Check cabling 384 AL Wiring TOP 4 Red...

Page 124: ...ameter 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 before Engine Yellow alarm Associated p...

Page 125: ...Corrective action Difference in mixture pressures sensed on A and B side is too high limit value 1 1 Check throttles for varying positions and malfunction 2 Check mixture lines for leakage 3 Check sen...

Page 126: ...erature too high mixture cooler clogged 1 Check mixture cooling circuit 2 Check mixture cooler for dirt 453 LO T Charge Mix Yellow alarm Associated parameter 2 0169 921 Cause Corrective action Mixture...

Page 127: ...ne governor 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 stop Associated parameter...

Page 128: ...ture 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 Red ala...

Page 129: ...ff 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 B16 1 B16 3 replace if neces...

Page 130: ...eck sensor and cabling B81 2 replace if 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 sho...

Page 131: ...s supply solenoid valves are faulty the time out period is set too short or communication is faulty 1 Check gas train 2 Check cabling 557 AL speed drop fault Red alarm Engine stop Associated parameter...

Page 132: ...ver air filter on A side is too high u Replace air filter Page 171 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure loss over air fil...

Page 133: ...ck emissions 2 Check ignition timing Page 160 3 Check combustion chamber 4 Check gas quality if feasible methane number 571 L2 AI CAN Max Retarded Timing Yellow alarm Power reduction Associated parame...

Page 134: ...d parameter 2 1210 006 Cause Corrective action Fuel calorific value has fallen below the first limit value u Check gas quality if feasible 618 LOLO Current net calorific value Yellow alarm Associated...

Page 135: ...sions 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...

Page 136: ...enerator power not transmitted correctly 2 Effective generator power can be optionally transmitted by CAN bus 3 Check plant control application engineering 646 Al Knock Intensity Red alarm Associated...

Page 137: ...m Associated parameter 1 4510 996 Cause Corrective action CAN bus communication to knock control faulty 1 Check cabling 2 Check power supply 3 Restart ECU EMU knock control 4 Check settings using devi...

Page 138: ...specific dialog software XD50 1 657 AL ProActB Comm Lost Red alarm Associated parameter 1 4550 196 Cause Corrective action CAN bus communication to throttle B faulty 1 Check cabling 2 Check power supp...

Page 139: ...genset control via CAN bus 666 AL IC92x Yellow Yellow alarm Associated parameter 1 4520 993 Cause Corrective action An internal combined alarm in the ignition system was detected u Check data record 6...

Page 140: ...x sensor A was detected u Precise error name is sent to the genset control via CAN bus 672 AL NOxB Yellow Yellow alarm Associated parameter 1 4560 193 Cause Corrective action An internal combined alar...

Page 141: ...A was detected u Precise error name is sent to the genset control via CAN bus 680 AL ProActB Red Red alarm Associated parameter 1 4550 191 Cause Corrective action An internal combined alarm in throttl...

Page 142: ...ellow alarm Associated parameter 1 1480 301 Cause Corrective action No oil replenishment within a configurable time u Check oil replenishment system 689 HI Oil Refill Yellow alarm Associated parameter...

Page 143: ...action Limit value 2 exceeded u Check gas supply 842 AL FuelThrottlePosition L1 Yellow alarm Associated parameter 2 8006 038 Cause Corrective action Tecjet throttle position has exceeded limit value 1...

Page 144: ...4520 939 Cause Corrective action CAN bus communication to ignition system faulty 1 Check cabling 2 Check power supply 3 Restart ECU EMU knock control 4 Check settings using device specific dialog soft...

Page 145: ...692 Cause Corrective action CAN controller 3 is in Bus Off status Bus nodes ignition knock module throttles or gas mixer have faults u Check operation of nodes and cabling 975 AL CAN3 Error Passive Y...

Page 146: ...977 AL CAN4 Bus Off Yellow alarm Associated parameter 2 0500 695 Cause Corrective action CAN controller 4 has indicated a warning u None 146 Troubleshooting MS15027 00E 2013 10 TIM ID 0000044567 001...

Page 147: ...ody 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 barr...

Page 148: ...smoke Checking machine room for smell of gas 1 Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit 2 If smell of gas is detected or the gas detection a...

Page 149: ...il 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...

Page 150: ...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 1...

Page 151: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 152 2 Install new spark plug Page 153 MS15027 00E 2013 1...

Page 152: ...he ignition cable in operation WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing r...

Page 153: ...ways wear electrical gloves class 4 minimum when touching the ignition cable in operation WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of pre...

Page 154: ...to tightening 6 Tighten spark plug to specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molykote P 37...

Page 155: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 156 2 Install spark plug connector Page 157 MS150...

Page 156: ...amage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Spark plug connector Removal 1 Loosen screws 4 on cylinder head...

Page 157: ...ir jet at people Always wear safety goggles face mask and ear defenders Installing spark plug connector 1 If necessary remove the ignition line s low er sealing ring and replace with a new seal ing ri...

Page 158: ...tective cap 2 and check for correct seating Exchanging spark plug isolator sealing ring 1 Insert screwdriver 3 between Teflon sleeve 1 and sealing ring 2 2 Pry out and pull out sealing ring 2 3 Fold t...

Page 159: ...5 Carefully press sealing ring 1 into the groove until it is flush with the hole in Tef lon sleeve 2 MS15027 00E 2013 10 Task Description 159 TIM ID 0000043226 004...

Page 160: ...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 rig...

Page 161: ...y Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 152 2 Remove cylinder head covers Page 168 3 Remove sleeves arrow 4 Install barring device Page 147 5 Rotate cranks...

Page 162: ...ease 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 specifi...

Page 163: ...3 Install sleeves arrow 4 Install cylinder head covers Page 169 5 Install spark plugs with new sealing rings Page 153 MS15027 00E 2013 10 Task Description 163 TIM ID 0000043220 002...

Page 164: ...ls Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 168 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install...

Page 165: ...No Qty Feeler gage Y20098771 1 Angular screw driver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 168 2...

Page 166: ...n is in firing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 3 mm Exhaust valves short rocke...

Page 167: ...locknut 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 oi...

Page 168: ...disabled Removing cylinder head cover 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 156 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 169: ...omponents for special cleanliness Installing cylinder head cover 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...

Page 170: ...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 al...

Page 171: ...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 Repl...

Page 172: ...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 fi...

Page 173: ...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 Toppi...

Page 174: ...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 extra...

Page 175: ...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 WAR...

Page 176: ...oves 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...

Page 177: ...WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Checking engine coolant level 1 Read off fuel opt...

Page 178: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 179 2 Fill with engine coolant Page 181 178 Task Description MS15027 00E 2013...

Page 179: ...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 o...

Page 180: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 180 Task Description MS15027 00E 2013 10 TIM ID 0000006751 002...

Page 181: ...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 Fi...

Page 182: ...olant 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 press...

Page 183: ...al tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 184 2 Fill with fresh mixture coolant Page 185 MS15027 00E 2013 10 Task De...

Page 184: ...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...

Page 185: ...tive clothing 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 wit...

Page 186: ...swing freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Conta...

Page 187: ...ure after filter 4 B16 1 Coolant pressure after engine 5 B4 X Exhaust temperature after cylinder 6 B79 22 Mixture pressure B side 7 B73 Mixture temperature Table 38 Sensors right 20V The knock sensors...

Page 188: ...nitoring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset ignition system 3 B13 2 Crankshaft speed ignition Table 39 Sensors engine driving end 188 Task Description MS15027 00...

Page 189: ...e oil pressure after filter 2 B79 21 Mixture pressure A side 3 B50 Crankcase pressure 4 B5 3 Engine oil pressure before filter 5 B7 Engine oil temperature Table 40 Sensors left engine side MS15027 00E...

Page 190: ...B16 3 Coolant pressure before engine 4 B1 3 Camshaft speed for anti knock control 5 B1 1 Camshaft speed for engine governor 6 B24 Engine oil level 7 B1 2 Camshaft speed for ignition system 8 B6 3 Cool...

Page 191: ...andard ETK Ersatzteilkatalog Spare Parts Catalog SPC HI High Alarm Measured value exceeds 1st maxi mum limit value HIHI High High Alarm Measured value exceeds 2nd maxi mum limit value HT High Temperat...

Page 192: ...zation SAV Sicherheitsabsperrventil Safety shut off valve SBV Sicherheitsabbalseventil Safety discharge valve SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technis...

Page 193: ...ring 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...

Page 194: ...4 3 Valve clearance Check and adjustment Page 165 Barring gear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 147 Feeler gage Part No Y20098771 Qty Used in 1 6 4 3 Valve clearance C...

Page 195: ...or smell of gas Page 148 Gas measuring and warning device not stocked by MTU Part No Qty Used in 3 7 Emission values Check Page 42 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Eng...

Page 196: ...al Page 152 Qty Used in 1 6 3 3 Spark plug Installation Page 153 Stroboscope Not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 160 Torque wrench 10 60 Nm Part No...

Page 197: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 3 Valve clearance Check and adjustment Page 165 MS15027 00E 2013 10 Appendix B 197 DCL ID 0000028920 002...

Page 198: ...44 Main dimensions 21 Shutdown 43 Start 40 Wiring check 186 Engine coolant Change 178 Draining 179 Filling 181 Level check 177 Engine oil Change 174 Sample extraction and analysis 175 Engine oil filt...

Page 199: ...for applica tions with gaseous fuel 15 Important provisions 5 Maintenance work 9 Maintenance work special instructions for applica tions with gaseous fuel 12 Operation 7 Operation special instruction...

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Summary of Contents for 12 V 4000 Lx4

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MTU 12 V 4000 Lx4, Operating Instructions Manual, Page: 194 / 199

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Summary of Contents for 12 V 4000 Lx4

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