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MTU 12V 4000 L32 F, Operating Instructions Manual

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MTU 12V 4000 L32 F Operating Instructions Manual Download Page 182

7.4.4 Cylinder head cover ‒ Removal

Preconditions

☑

Engine is stopped and starting disabled.

Cylinder head cover ‒ Removal

1.

Clean very dirty cylinder head covers (1) prior
to removal.

2.

Remove spark plug connector (→ Page 171).

3.

Remove screws (2).

4.

Remove cylinder head cover with gasket from
cylinder head.

182 | Valve Drive | MS150104/02E 2016-11

TIM-ID: 0000042136 - 002

Summary of Contents for 12V 4000 L32 F

Page 1: ...Operating Instructions Gas engine 12V 4000 L32 F 16V 4000 L32 F MS150104 02E...

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

Page 3: ...on after extended out of service periods 3 months 40 4 3 Putting the engine into operation after scheduled out of service period 41 4 4 Control starting and stopping sequences 42 4 5 Engine Start 44 4...

Page 4: ...4 Engine coolant Filling 195 7 9 5 Vent line of engine coolant circuit Replacement 196 7 10 Low Temperature Circuit 197 7 10 1 Mixture coolant level Check 197 7 10 2 Mixture coolant Change 198 7 10 3...

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

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

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

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

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

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

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

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

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

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

Page 15: ...easuring component dimensions Workpieces components and measuring equipment lie in the specified tolerance range at a reference tem perature of 20 C MS150104 02E 2016 11 Safety 15 TIM ID 0000040535 01...

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

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

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

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

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

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

Page 22: ...filter air inlet 4 Mixture cooler 5 Exhaust turbocharger 6 Engine lifting equipment 7 Capacitor ignition system 8 Engine mounting bracket free end 9 Oil pan 10 Engine mounting bracket driving end 11 S...

Page 23: ...l switch 13 Connection engine coolant inlet 14 Engine oil heat exchanger 15 Connection engine coolant outlet KGS Free end Engine model designation Key to the engine model designations 12 16 V 4000 L32...

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

Page 25: ...prox 2868 mm Length A for 16V approx 3372 mm Width B for 12V approx 1743 mm Width B for 16V approx 1789 mm Height C for 12V approx 2146 mm Height C for 16V approx 2156 mm Crankshaft center to oil pan...

Page 26: ...g order Firing order Number of cylinders Firing order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 26 Product Summary MS150104 02E 2016 11 TIM ID 00000...

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

Page 28: ...circuit referenced to max power without HT heat extraction Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature a...

Page 29: ...xchanger engine shutdown L C 97 97 Lube oil pressure after oil filter bar 5 0 5 0 Lube oil pressure after oil filter warning R bar 3 5 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 2 5 Tab...

Page 30: ...cylinders 12 16 Dry engine weight basic configuration engine R kg 6500 8000 Heaviest component to be lifted during extended component maintenance QL3 R kg 450 450 Table 16 Weights main dimensions Exha...

Page 31: ...net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046 A kW 1200 1600 Mean effective pressure pme co...

Page 32: ...Number 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 antifr...

Page 33: ...xchanger engine shutdown L C 97 97 Lube oil pressure after oil filter bar 5 0 5 0 Lube oil pressure after oil filter warning R bar 3 5 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 2 5 Tab...

Page 34: ...cylinders 12 16 Dry engine weight basic configuration engine R kg 6500 8000 Heaviest component to be lifted during extended component maintenance QL3 R kg 450 450 Table 31 Weights main dimensions Exh...

Page 35: ...rols 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 engi...

Page 36: ...r in question If this does not result in an improvement the power is reduced Gas control valve TecJet52 Controls the required amount of gas Mixture throttles P Series The mixture throttles in the mixt...

Page 37: ...atus 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 r...

Page 38: ...8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 38 Monitoring Control and Regulation Equipment MS150104 02E 201...

Page 39: ...d Recommended min time in subsequent op eration at load 50 kWmech cyl Emission compliance as specified in technical data 0 to 30 30 minutes 120 minutes No 30 to 50 120 minutes 120 minutes No 50 to ful...

Page 40: ...162 Valve gear Standstill 6 months Lubricate valve gear Page 181 Lube oil system Check engine oil level Page 187 Check oil level in oil storage tank Page 187 Coolant circuit Standstill 1 year Change e...

Page 41: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 187 Coolant circuit Check engine coolant level Page 191 Check mixture coolant level Page...

Page 42: ...n 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 w...

Page 43: ...wing 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 runn...

Page 44: ...High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Starting the engine Note A max of 5 engine starting attempts are permitted at a max fuel supply open...

Page 45: ...achine room for smell of gas Page 163 ECU Check for fault messages If fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressur...

Page 46: ...l of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well ventilated...

Page 47: ...1 at the measuring point 2 2 Start engine 3 Approach the measuring point until a stable operating state has been reached 4 Carry out measurement and read off meas ured value for NOx rel ppm 5 Compare...

Page 48: ...nd mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are in...

Page 49: ...in emergency situations Emergency engine shutdown Item Measure Gas shut off solenoids Two contacts are provided for electrical connection Close gas shut off sole noids engine stop Ignition ignition sy...

Page 50: ...ain following an emergency engine stop Suitable exhaust gas ventilation equipment shall be provided in the facility to ensure that the exhaust gas system downstream of the engine is safely purged A co...

Page 51: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC MS150104 02E 2016 11 Operatio...

Page 52: ...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...

Page 53: ...linder heads after component maintenance or ex tended component maintenance When installing a cylinder head with run in mating faces e g after piston replacement a repeated check after the first 50 op...

Page 54: ...age 190 W1089 Check gas lines for leaks seal if required Page 184 W1091 Check ignition timing adjust as necessary Page 175 W1207 Check valve clearance and adjust if necessary IMPORTANT First adjustmen...

Page 55: ...lue 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...

Page 56: ...gine is running at its limits Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled 56 Troubleshooting MS150104 02E 2016 11 TIM ID...

Page 57: ...ndividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves d...

Page 58: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...

Page 59: ...n Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valve...

Page 60: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...

Page 61: ...se Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175...

Page 62: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valv...

Page 63: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valv...

Page 64: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valv...

Page 65: ...exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves do not clos...

Page 66: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...

Page 67: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...

Page 68: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...

Page 69: ...se Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175...

Page 70: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valve...

Page 71: ...tive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check...

Page 72: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valve...

Page 73: ...Page 46 2 Check ignition timing Page 175 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 temperat...

Page 74: ...tion timing Page 175 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 75: ...tion timing Page 175 3 Check valve drive exhaust valves do not close 112714 HIHI T Exhaust B4 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 76: ...perature of this cylinder is too high 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated...

Page 77: ...back does not correspond with setpoint signal u Check valve 1 113902 SS Local Initiated Emerg Stop Red alarm Initiated by EMU Cause Corrective action Emergency stop detected Emergency stop was release...

Page 78: ...damage replace as necessary Page 202 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 Page 201 2 Che...

Page 79: ...Check sensor tightening torque damage replace as necessary Page 202 1 4510 199 Knock Sensor Error A8 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 80: ...Check sensor tightening torque damage replace as necessary Page 202 1 4510 205 Knock Sensor Error B4 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 81: ...Check sensor tightening torque damage replace as necessary Page 202 1 4510 211 Knock Sensor Error B10 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock senso...

Page 82: ...em 1 4520 237 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 IC...

Page 83: ...imary Channel 1 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 201 2 Check ignition coils 1 4520 246 Open Primary Chan...

Page 84: ...nnel 8 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 201 2 Check ignition coils 1 4520 253 Open Primary Channel 9 Yel...

Page 85: ...annel 15 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 201 2 Check ignition coils 1 4520 260 Open Primary Channel 16...

Page 86: ...Reset Signal Yellow alarm Initiated by IC922 Cause Corrective action Reset signal from crankshaft is missing u Sensor B 75 check sensor sensor gap and cabling replace as necessary Page 202 Page 201 1...

Page 87: ...use Corrective action A system error has occurred 1 Rectify cause of alarm 2 Restart ignition control unit 1 4520 520 MIC5 Stat W temperat limit reached Yellow alarm Initiated by MIC5 Cause Corrective...

Page 88: ...valid 1 Check ignition system settings in the Engine Control Unit 2 Restart ignition control unit 1 4520 526 MIC5 Stat Analogue current sig fail Red alarm Initiated by MIC5 Cause Corrective action Fai...

Page 89: ...urred 1 Check Engine Control Unit settings 2 Check cabling Page 201 3 Restart ignition control unit 4 Replace ignition control unit 1 4520 541 MIC5 E1 Overspeed Red alarm Initiated by MIC5 Cause Corre...

Page 90: ...Replace ignition control unit 1 4520 547 MIC5 E1 Failure current sensor Red alarm Initiated by MIC5 Cause Corrective action The current sensor is faulty 1 Restart ignition control unit 2 Replace ignit...

Page 91: ...low alarm Initiated by MIC5 Cause Corrective action Unable to detect polarity of pulse sensor 1 B1 2 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary...

Page 92: ...early faulty Yellow alarm Initiated by MIC5 Cause Corrective action Index mark of pulse sensor 1 B1 2 detected too early or faulty u Check sensor sensor gap cabling data record settings and timing whe...

Page 93: ...Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 6 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 576 MIC5 IP...

Page 94: ...Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 13 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 583 MIC5 I...

Page 95: ...d alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 20 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 590 MIC5 IPE...

Page 96: ...ed alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 7 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 597 MIC5 I...

Page 97: ...Red alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 14 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 604 MIC5...

Page 98: ...alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 1 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 611 MIC5 IS...

Page 99: ...ow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 8 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 618 MIC5...

Page 100: ...llow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 15 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 625 MI...

Page 101: ...w alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 2 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 632 MIC...

Page 102: ...1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 638 MIC5 ISE Secon Short Circuit Cyl 9 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circu...

Page 103: ...ce 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 644 MIC5 ISE Secon Short Circuit Cyl 15 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary ci...

Page 104: ...ck ignition coil 1 4520 658 MIC5 E2 Tr2 synchronisation fault Yellow alarm Initiated by MIC5 Cause Corrective action Unable to synchronize with signal from pulse sensor 2 B75 u Check sensor sensor gap...

Page 105: ...Cause Corrective action Incorrect number of events from pulse sensor 2 B75 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 202 Page 201 1 4520...

Page 106: ...arm Initiated by MIC5 Cause Corrective action Pulse sensor 3 B13 2 has tripped an operational error 1 Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary...

Page 107: ...iming wheel Replace sensor as necessary Page 202 Page 201 1 4520 678 MIC5 E2 Tr3 signal faulty Yellow alarm Initiated by MIC5 Cause Corrective action Unexpected signal from pulse sensor 3 B13 2 detect...

Page 108: ...g Active Yellow alarm Initiated by compressor bypass Cause Corrective action Internal temperature too high Adjustment rate is reduced 1 Check room temperature and ventilation 2 Check mechanical system...

Page 109: ...pressor bypass Cause Corrective action Temperature of the electronics above 140 C or internal temperature sensor faulty 1 Check room temperature and ventilation 2 Compare device temperature with tempe...

Page 110: ...1 4530 022 CAN Fault Red alarm Initiated by compressor bypass Cause Corrective action CAN bus connection faulty 1 Check cabling Page 201 2 Check compressor bypass flap settings 1 4540 009 Zero Pressur...

Page 111: ...1 4540 015 FGT Fail High Red alarm Initiated by TecJet Cause Corrective action Internal gas temperature sensor faulty 1 Restart TecJet 2 Replace TecJet 1 4540 016 Delta P Fail High Red alarm Initiated...

Page 112: ...Low Red alarm Initiated by TecJet Cause Corrective action Internal differential gas pressure sensor faulty 1 Restart TecJet 2 Replace TecJet 1 4540 023 FGP Fail Low Red alarm Initiated by TecJet Cause...

Page 113: ...ached minimum limit value 1 Check supply voltage 2 Check cabling Page 201 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Gas temperature before TecJet is below th...

Page 114: ...ngs 2 Check gas pressure 1 4540 036 FGP High Limit Error Red alarm Initiated by TecJet Cause Corrective action Gas pressure before TecJet is above the preset limit value 1 Check TecJet settings 2 Chec...

Page 115: ...Jet 1 4540 044 Parameter Version Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation 1 Restart TecJet 2 Replace TecJet 1 4540 045 Main EEP Read Fail Red alarm...

Page 116: ...12V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation 1 Restart TecJet 2 Replace TecJet 1 4540 052 ADC Test Error Red alarm Initiated by TecJet Cause Correct...

Page 117: ...Cause Corrective action Throttle flap setting is not correct u Check throttle flap setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by throttle flap A Bank Cause Corrective actio...

Page 118: ...bling Page 201 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by throttle flap A Bank Cause Corrective action Throttle flap setting is not correct u Check throttle flap settings 1 4550 040...

Page 119: ...tiated by throttle flap B Bank Cause Corrective action Throttle flap setting is not correct u Check throttle flap settings 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by throttle fl...

Page 120: ...bling Page 201 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by throttle flap B Bank Cause Corrective action Throttle flap setting is not correct u Check throttle flap settings 1 4550 140...

Page 121: ...bus connection faulty 1 Check cabling Page 201 2 Check throttle flap settings 1 4550 144 B CAN Stop Command Yellow alarm Initiated by throttle flap B Bank Cause Corrective action Stop input signal re...

Page 122: ...il system oil heat exchanger 2 Replace oil filter Page 190 3 Take oil sample and analyze Page 189 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas te...

Page 123: ...harger 2 Check ignition timing Page 175 3 Check mixture setting 4 Check igniters 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective action Pressure loss via oil filte...

Page 124: ...d of turbocharger 1 too high limit value 2 1 Check intake air temperature 2 Check emissions Page 46 3 If the sensor is not obstructed check the conditions for activating this monitoring feature in the...

Page 125: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 187 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...

Page 126: ...separator condition replace as necessary Page 164 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restri...

Page 127: ...tle flaps are fully open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 185 Check exhaust back pressure Chec...

Page 128: ...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...

Page 129: ...121 HIHI ECU 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 Page 201 122 HI T ECU Yellow...

Page 130: ...een selected that initiates communications with help of the PU data module However the necessary PU data module is not present or is invalid u Contact Service configuration error 184 AL CAN PU Data Fl...

Page 131: ...parameter 2 0500 689 Cause Corrective action CAN controller 2 has signaled a warning Possible causes may be e g missing node minor faults or temporary bus overload u Check operation of bus users and c...

Page 132: ...rrective action Exhaust temperature sensor on B side faulty short circuit or wire break u Check sensor and cabling B4 22 replace as necessary Page 202 Page 201 Error cleared after restarting the engin...

Page 133: ...ction Intake air temperature sensor faulty short circuit or wire break u Check sensor and cabling B49 1 B90 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 221 SD P Di...

Page 134: ...circuit or wire break 1 Check sensor and cabling B44 1 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 2 If the sensor is not obstructed check the conditions for acti...

Page 135: ...d alarm Associated parameter 2 8006 639 Cause Corrective action Short circuit or line break at transistor output 2 system side TOP 2 Activation of red summary alarm faulty u Check cabling Page 201 383...

Page 136: ...shutdown Associated 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...

Page 137: ...wn Associated parameter 2 0173 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure flow too low air in engine cooling system u Check engine...

Page 138: ...2 Check mixture 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...

Page 139: ...e break u Check sensor and cabling B16 3 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 470 SD T ECU Red alarm Associated parameter 1 8004 587 Cause Corrective action...

Page 140: ...Check sensor and cabling B79 21 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 497 SD P Charge Mix B Red alarm Engine shutdown Associated parameter 1 8004 629 Cause...

Page 141: ...179 5 Check throttle flap 6 Check mixture coolant system 512 HIHI P Charge Mix B Red alarm Engine shutdown Associated parameter 2 0182 932 Cause Corrective action Mixture pressure on B side too high...

Page 142: ...sociated parameter 1 0186 900 Cause Corrective action Intake air pressure sensor after filter on A side faulty short circuit or wire break u Check sensor and cabling B81 1 replace as necessary Page 20...

Page 143: ...is activated if the gas train does not report OK within a specified time out period Either the gas train leak test was not successful the time out period is set too short or communication is faulty 1...

Page 144: ...eed drops during starting sequence u Check gas train 558 AL Wiring PWM_CM2 Red alarm Associated parameter 1 1041 922 Cause Corrective action Wire break or short circuit on channel PWM_CM2 u Check sett...

Page 145: ...n Pressure loss over air filter on A side is too high u Replace air filter Page 185 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure...

Page 146: ...ge 46 2 Check ignition timing Page 175 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 1...

Page 147: ...larm Associated parameter 1 1041 924 Cause Corrective action Wire break or short circuit on channel PWM_CM4 u Check setting at Engine Control Unit 596 AL Develop PR Set Red alarm Associated parameter...

Page 148: ...se Corrective action Wire break or short circuit on channel PWM_CM6 u Check setting at Engine Control Unit 609 AL Wiring PWM_CM7 Red alarm Associated parameter 1 1041 927 Cause Corrective action Wire...

Page 149: ...ated parameter 2 1210 008 Cause Corrective action Fuel calorific value has exceeded the first limit value u Check gas quality if feasible 620 HIHI Current Heat Value of Fuel Yellow alarm Associated pa...

Page 150: ...ons Page 46 624 HIHI NOx Value Yellow alarm Associated parameter 2 3050 027 Cause Corrective action NOx emissions have exceeded the second limit value 1 Check gas quality if feasible 2 Check NOx senso...

Page 151: ...Knock intensity exceeded extreme knocking detected 1 Check gas quality if feasible methane number 2 Check emissions Page 46 3 Check combustion chamber 649 Al Req Angle Throttle A Yellow alarm Power r...

Page 152: ...Check cabling Page 201 2 Check power supply 3 Restart ECU EMU and ignition system 4 Check settings with device specific dialog software 654 AL FSeries Comm Lost Red alarm Associated parameter 1 4530 9...

Page 153: ...658 AL NOxA Comm Lost Red alarm Associated parameter 1 4560 096 Cause Corrective action CAN bus communication for NOx sensor A faulty 1 Check cabling Page 201 2 Check power supply 3 Restart ECU 4 Repl...

Page 154: ...gnation is transmitted via CAN bus to the genset control system 668 AL TecJet Yellow Yellow alarm Associated parameter 1 4540 993 Cause Corrective action An internal summary alarm in the gas control v...

Page 155: ...ation is transmitted via CAN bus to the genset control system 676 AL IC92x Red Red alarm Associated parameter 1 4520 991 Cause Corrective action An internal summary alarm in the ignition system was de...

Page 156: ...detected u An exact fault designation is transmitted via CAN bus to the genset control system 682 AL NOxB Red Red alarm Associated parameter 1 4560 191 Cause Corrective action An internal summary alar...

Page 157: ...ck engine oil level Check oil supply 719 AL T Gas L1 Yellow alarm Associated parameter 2 8006 034 Cause Corrective action 1st lower limit value violated u Check gas supply 720 AL T Gas L2 Red alarm As...

Page 158: ...wait end of scavenging phase 2 Check engine speed A speed of at least 80 rpm must be reached 932 AL MIC5 Yellow Yellow alarm Associated parameter 1 4520 933 Cause Corrective action An internal summary...

Page 159: ...ller 3 is in Bus Off status Bus nodes ignition knock module throttle flaps or gas mixture malfunctioning u Check operation of bus users and cabling 975 AL CAN3 Error Passive Yellow alarm Associated pa...

Page 160: ...A and B are two far apart limit value 1 1 Check emissions Page 46 2 Check NOx sensors Page 202 3 Check ignition points Page 175 1014 HIHI Delta NOx A B Red alarm Associated parameter 2 3050 121 Cause...

Page 161: ...amage is visible 2 Check setting of blow by restrictor valve 1031 LOLO P Crank Case Red alarm Engine shutdown Associated parameter 2 0106 936 Cause Corrective action Crankcase pressure too low limit v...

Page 162: ...ody being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the engine s danger zone Barring engine manually 1 Remove guard plate 2 Engage barri...

Page 163: ...not 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 detecti...

Page 164: ...ues which are harmful to health Risk of injury and poisoning Allow the engine to cool to below 50 C before beginning work Wear protective clothing protective gloves and safety glasses facial protectio...

Page 165: ...filter 5 must be installed in the correct position in the housing 10 Place coalescer filter 5 in housing ensuring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12 Screw on w...

Page 166: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 167 2 Install new spark plug Page 168 166 Ignition Syste...

Page 167: ...ble protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupt...

Page 168: ...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 a...

Page 169: ...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...

Page 170: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 171 2 Install spark plug connector Page 173 170 I...

Page 171: ...earing 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 cover 7...

Page 172: ...ning and check 1 Remove spark plug connector Page 171 2 Remove spark plug isolator sealing ring Page 173 3 Check spark plug connector 1 and ignition line 2 visually for kinks pinching points and britt...

Page 173: ...ne s lower sealing ring and replace with a new sealing ring 2 Remove any dust and impurities from the ig nition line connector s Teflon body on the outside and inside on the spark plug side 3 Check th...

Page 174: ...d pull out sealing ring 2 3 Fold together new sealing ring 2 4 Insert sealing ring 2 into the bore in Teflon sleeve 1 with the article number facing downwards 5 Carefully press sealing ring 1 into the...

Page 175: ...of damage to hearing Wear ear protectors Checking ignition timing Note Service tool DiaSys and a 1A level dongle or higher or the Woodward IC900 series service tool for Woodward ignition systems only...

Page 176: ...rt No Qty Sliding depth gage 200 mm Y20000918 1 Preparatory steps 1 Remove igniters Page 167 2 Remove cylinder head covers Page 182 3 Remove sleeves arrowed 4 Install barring tool Page 162 5 Rotate cr...

Page 177: ...se 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 igniter bore with depth gage see figure The specified val...

Page 178: ...3 Install sleeves arrowed 4 Install cylinder head covers Page 183 5 Install igniters with new sealing rings Page 168 178 Valve Drive MS150104 02E 2016 11 TIM ID 0000043220 003...

Page 179: ...82 2 Install barring device Page 162 3 Rotate crankshaft with barring tool in engine direction of rotation until marking OT and pointer are aligned Diagram for 12 16 V engines Two crankshaft positions...

Page 180: ...valve clearances in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviatio...

Page 181: ...tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 182 2 Fill oil chambers of rocker arms and adjusting screws with oil 3 Insta...

Page 182: ...ing disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 171 3 Remove screws 2 4 Remove cylinder head cover with gasket fr...

Page 183: ...omponents for special cleanliness Cylinder head cover Installa tion 1 Clean mounting surface 2 Check condition of gasket replace if dam aged 3 Position gasket and cylinder head cover 1 on cylinder hea...

Page 184: ...part of the personal safety equipment Do not smoke WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment th...

Page 185: ...efilter made of fleece option Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the cor responding fault message appears R...

Page 186: ...stalla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from con necting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air...

Page 187: ...e oil level may ex ceed the mark 1 by up to 2 cm The cause of this may be that oil e g from the oil filter and oil heat exchanger flows back into the oil pan 3 The oil level must reach the mark 2 or e...

Page 188: ...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 Extracting en...

Page 189: ...ctive gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electri...

Page 190: ...protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion...

Page 191: ...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 optimized Page 27 o...

Page 192: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 193 2 Fill with engine coolant Page 195 192 Coolant Circuit General High Temperature Circuit...

Page 193: ...and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch off preheater if i...

Page 194: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 194 Coolant Circuit General High Temperature Circuit MS150104 02E 2016 11 TIM ID 0000006751 002...

Page 195: ...es 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...

Page 196: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 193 2 Release union nuts 1 and 3 3 Remove coolant vent l...

Page 197: ...t 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...

Page 198: ...ools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 199 2 Fill with fresh mixture coolant Page 200 198 Low Temperature Circuit MS1...

Page 199: ...ry and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining mixture coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve at dra...

Page 200: ...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 with coo...

Page 201: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector h...

Page 202: ...r pressure after filter 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 41 Sensors B side The knock sen...

Page 203: ...concentration in the exhaust gas 2 B79 23 Mixture pressure before restrictor flap 3 B75 Crankshaft speed reset ignition system 4 B13 3 Crankshaft speed ignition Table 42 Sensors Engine driving end MS1...

Page 204: ...al 2 B79 21 Mixture pressure A side 3 B50 Crankcase pressure 4 B5 3 Engine oil pressure before filter 5 B7 Engine oil temperature 6 B5 1 Engine oil pressure after filter Table 43 Sensors A side 204 Wi...

Page 205: ...bocharg er 3 B6 3 Coolant temperature before engine 4 B1 2 Camshaft speed for ignition system 5 B1 3 Camshaft speed for AKR 6 B1 1 Camshaft speed for engine governor 7 B24 Lube oil level 8 B16 3 Coola...

Page 206: ...g work Wear protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Coolant is hot and under pressure Risk of injury and scal...

Page 207: ...eral information Arrangement and position of sensor Page 202 2 Loosen and disconnect connector 2 3 Unscrew electronics box 1 at the eyelets 4 Remove sensor via nut 3 MS150104 02E 2016 11 Wiring Genera...

Page 208: ...re assembly Note Do not wipe off thread grease of manufactur er If necessary coat thread with high tem perature anti corrosion thread grease Too much grease can contaminate the sensor during operation...

Page 209: ...ximum limit value HIHI High High Alarm Measured value exceeds 2nd maximum limit value HT High Temperature High temperature ICFN ISO Continuous Fuel stop brake power Fuel stop power acc to ISO internat...

Page 210: ...otive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische...

Page 211: ...r during operation for preventive maintenance corrective work in case of malfunction or changed operating condi tions or for spare parts supply For our locally available support go to MTU s Internet s...

Page 212: ...2 Valve clearance Check and adjustment Page 179 Barring gear Part No F6555766 Qty Used in 1 7 1 1 Engine Barring manually Page 162 Feeler gauge Part No Y20098771 Qty Used in 1 7 4 2 Valve clearance C...

Page 213: ...stocked by MTU Part No Qty Used in 4 7 Emission values Check Page 46 Oil filter wrench Part No F30379104 Qty Used in 1 7 8 1 Engine oil filter Replacement Page 190 Ratchet adapter Part No F30027340 Qt...

Page 214: ...1 7 4 1 Valve protrusion Measurement Page 176 Socket wrench 24 mm Part No F30029815 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 179 Special wrench 20 8 mm Part No F30452574 Qty Used...

Page 215: ...2769 Qty Used in 1 7 3 3 Spark plug Installation Page 168 Qty Used in 1 7 3 7 Spark plug connector Installation Page 173 Qty Used in 1 7 11 4 Sensors Installation Page 208 Torque wrench 60 320 Nm Part...

Page 216: ...32 Emission optimized 1 2 TA Luft 31 Engine data 12 V 4000 L32F Fuel optimized TA Luft 27 Engine data 16 V 4000 L32 Emission optimized 1 2 TA Luft 31 Engine data 16 V 4000 L32F Fuel optiimized TA Luft...

Page 217: ...information for dual fuel applications 19 Fluids and lubricants specific information for gaseous fuel supply applications 19 Important provisions 5 6 Indirect materials 17 Initial start up 8 Maintena...

Page 218: ...acement 170 Starting sequence 42 Stopping sequence 42 T transport 21 V Valve clearance Adjustment 179 Check 179 Valve gear Lubrication 181 Valve protrusion Measurement 176 Vent line of engine coolant...

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