MTU 12V4000L32F Operating Instructions Manual Download Page 179

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Install sleeves (arrowed).

Install cylinder head covers (→ Page 184).

Install igniters with new sealing rings
(→ Page 169).

MS150104/03E 2017-09

| Valve Drive | 179

TIM-ID: 0000043220 - 003

Summary of Contents for 12V4000L32F

Page 1: ...Operating Instructions Gas engine 12V4000L32F 16V4000L32F MS150104 03E...

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: ...n after extended out of service periods 3 months 41 4 3 Putting the engine into operation after scheduled out of service period 42 4 4 Control starting and stopping sequences 43 4 5 Engine Start 45 4...

Page 4: ...4 Engine coolant Filling 196 7 9 5 Vent line of engine coolant circuit Replacement 197 7 10 Low Temperature Circuit 198 7 10 1 Mixture coolant level Check 198 7 10 2 Mixture coolant Change 199 7 10 3...

Page 5: ...purpose are approved by the manufacturer Noncompliance with these specifications will invalidate the design type approval or certification issued by the emissions regulation authorities The manufactu...

Page 6: ...ollowing when replacing components with emission labels The relevant emission labels must be affixed to the spare part Emission labels shall not be transferred from the replaced part to the spare part...

Page 7: ...ons contained in this manual in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair The...

Page 8: ...instructed and qualified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering The...

Page 9: ...g Protect battery terminals generator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return...

Page 10: ...iately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrically live Follow the appl...

Page 11: ...stem with one path assigned to each of the gas shutoff valves The gas train shall feature minimum pressure monitoring Additional equipment may be necessary in the gas train e g maximum pressure monito...

Page 12: ...as trains feature the following components in the direction of flow plant manufacturer user scope of sup ply a manual shutoff valve a gas filter Gas trains feature the following components in the dire...

Page 13: ...ltraCap modules using the appropriate discharger Short circuit the UltraCap modules with a suitable wire jumper Close the main valve on the compressed air system and vent the compressed air line when...

Page 14: ...t touch elastomeric seals e g Viton sealing rings with your bare hands if they have a carbonized or resinous appearance Elastomer components e g engine mounts damping elements couplings and V belts mu...

Page 15: ...lic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working with batteries Observe the safety instructions of the manufacture...

Page 16: ...e proof Shock proof Wrapped in antistatic foil as necessary Working with laser equipment Work with laser devices shall be carried out by trained and qualified personnel only Follow the safety in struc...

Page 17: ...d personnel 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...

Page 18: ...at staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wear protective gloves when handling compo nents and wear additional personal protective...

Page 19: ...ded with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected There must be no naked flames in the vicinity No smoking Obser...

Page 20: ...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 21: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in...

Page 22: ...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 23: ...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 24: ...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 25: ...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 26: ...prox 2869 mm Length A for 16V approx 3367 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 27: ...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 MS150104 03E 2017 09 Product Summary 27 TIM ID 00000...

Page 28: ...ce condition Power 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 10 5 10 5 Continuous power as per I...

Page 29: ...system HT circuit referenced to max power without HT heat recovery Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant tempe...

Page 30: ...exchanger 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 5 0 5 0 Lube oil pressure after oil filter shutdown L bar 4 5 4 5 Table 11...

Page 31: ...in dimensions Number of 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 Weig...

Page 32: ...t brake power as per 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 c...

Page 33: ...ecovery 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...

Page 34: ...exchanger 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 5 0 5 0 Lube oil pressure after oil filter shutdown L bar 4 5 4 5 Table 26...

Page 35: ...ain dimensions Number of 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 Wei...

Page 36: ...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 37: ...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 38: ...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 39: ...8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring MS150104 03E 2017 09 Monitoring Control and Regulation Equipmen...

Page 40: ...ech cylinder max 5 hours without interruption max 25 hours per year 120 minutes 35 to 100 kWmech cylinder No restriction No restriction Engine operation below a load of 5 kWmech cylinder is to be redu...

Page 41: ...163 Valve gear Standstill 6 months Lubricate valve gear Page 182 Lube oil system Check engine oil level Page 188 Check oil level in oil storage tank Page 188 Coolant circuit Standstill 1 year Change e...

Page 42: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 188 Coolant circuit Check engine coolant level Page 192 Check mixture coolant level Page...

Page 43: ...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 44: ...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 45: ...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 46: ...achine room for smell of gas Page 164 ECU Check for fault messages If fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressur...

Page 47: ...the engine is running Risk of damage to hearing Wear ear protectors WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventil...

Page 48: ...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 49: ...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 50: ...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 51: ...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 52: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC 52 Operation MS150104 03E 201...

Page 53: ...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 54: ...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 55: ...age 191 W1089 Check gas lines for leaks seal if required Page 185 W1091 Check ignition timing adjust as necessary Page 176 W1207 Check valve clearance and adjust if necessary IMPORTANT First adjustmen...

Page 56: ...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 57: ...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 MS150104 03E 2017 09 Troubleshooting 57 TIM ID...

Page 58: ...ck ignition timing Page 176 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too...

Page 59: ...eck ignition timing Page 176 3 Check valve drive exhaust valves do not close 112308 HI T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is to...

Page 60: ...tion timing Page 176 3 Check valve drive exhaust valves do not close 112314 HI T Exhaust B4 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high i...

Page 61: ...is cylinder is too high in comparison with weighted average 1 Check emission values Page 47 2 Check ignition timing Page 176 3 Check valve drive exhaust valves do not close 112320 HI T Exhaust B10 Yel...

Page 62: ...on the ignition rail ignition coil for thermal and mechanical damage 112404 LO T Exhaust A4 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in...

Page 63: ...on the ignition rail ignition coil for thermal and mechanical damage 112408 LO T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in...

Page 64: ...on the ignition rail ignition coil for thermal and mechanical damage 112412 LO T Exhaust B2 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low i...

Page 65: ...on the ignition rail ignition coil for thermal and mechanical damage 112416 LO T Exhaust B6 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in...

Page 66: ...rm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 47 3 Check ignition tim...

Page 67: ...tion timing Page 176 3 Check valve drive exhaust valves do not close 112506 HIHI T Exhaust A6 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in...

Page 68: ...ition timing Page 176 3 Check valve drive exhaust valves do not close 112512 HIHI T Exhaust B2 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high i...

Page 69: ...tion timing Page 176 3 Check valve drive exhaust valves do not close 112518 HIHI T Exhaust B8 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in...

Page 70: ...on the ignition rail ignition coil for thermal and mechanical damage 112603 LOLO T Exhaust A3 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in...

Page 71: ...on the ignition rail ignition coil for thermal and mechanical damage 112607 LOLO T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in...

Page 72: ...ring on the ignition rail ignition coil for thermal and mechanical damage 112611 LOLO T Exhaust B1 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too lo...

Page 73: ...on the ignition rail ignition coil for thermal and mechanical damage 112615 LOLO T Exhaust B5 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in...

Page 74: ...use Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 47 3 Check ignition timing Page 176 4 Check v...

Page 75: ...tion timing Page 176 3 Check valve drive exhaust valves do not close 112705 HIHI T Exhaust A5 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too hig...

Page 76: ...ition timing Page 176 3 Check valve drive exhaust valves do not close 112711 HIHI T Exhaust B1 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too hi...

Page 77: ...tion timing Page 176 3 Check valve drive exhaust valves do not close 112717 HIHI T Exhaust B7 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too hig...

Page 78: ...1 Check ECU supply voltage 2 Check CAN connecting line 113601 AL Gas Valve 1 feedback Red alarm Initiated by EMU Cause Corrective action Summary alarm gas solenoid valve 1 feedback does not correspon...

Page 79: ...ummary alarm for details refer to the source alarm u Rectify cause of alarm 1 4510 188 Internal Error Red alarm Initiated by anti knock control Cause Corrective action Hardware not ready for operation...

Page 80: ...Check sensor tightening torque damage replace as necessary Page 203 1 4510 196 Knock Sensor Error A5 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 81: ...2 Check sensor tightening torque damage replace as necessary Page 203 1 4510 202 Knock Sensor Error B1 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock senso...

Page 82: ...Check sensor tightening torque damage replace as necessary Page 203 1 4510 208 Knock Sensor Error B7 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 83: ...replace as necessary Page 203 Page 202 1 4520 234 Error Missing Camshaft Signal Red alarm Initiated by IC922 Cause Corrective action Missing camshaft signal for ignition system u Check sensor B1 2 che...

Page 84: ...Timing out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified individual ignition timing is beyond the valid range 1 Adapt value in ECU parameter record 2 Check settings at ig...

Page 85: ...annel 5 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 202 2 Check ignition coils 1 4520 250 Open Primary Channel 6 Ye...

Page 86: ...nnel 12 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 202 2 Check ignition coils 1 4520 257 Open Primary Channel 13 Y...

Page 87: ...IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 202 2 Check ignition coils 1 4520 265 Open Primary Channel 20 Yellow alarm Initiated by IC922 Cau...

Page 88: ...20 275 Odd Energy Level out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified energy level is beyond the valid range u Adapt value in ECU parameter record 1 4520 276 Even Ener...

Page 89: ...Initiated by MIC5 Cause Corrective action The ignitions system settings are invalid 1 Check ignition system settings in the engine governor 2 Restart ignition control unit 1 4520 524 MIC5 Stat W inval...

Page 90: ...ensor B1 2 Page 202 2 Check sensor B1 2 Page 203 3 Restart ignition control unit 4 Replace ignition control unit 1 4520 530 MIC5 Stat Global timing limited Yellow alarm Initiated by MIC5 Cause Correct...

Page 91: ...rm Initiated by MIC5 Cause Corrective action The high voltage power supply unit is faulty 1 Restart ignition control unit 2 Replace ignition control unit 1 4520 546 MIC5 E1 Failure temperature sensor...

Page 92: ...ecord settings and timing wheel Replace sensor as necessary Page 203 Page 202 2 Restart ignition control unit 1 4520 552 MIC5 E1 Tr1 no signal detected Yellow alarm Initiated by MIC5 Cause Corrective...

Page 93: ...ve action Unexpected signal from pulse sensor 1 B1 2 detected u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 203 Page 202 1 4520 559 MIC5 E1 T...

Page 94: ...Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 4 in ignition sequence 1 Check cabling to ignition coil Page 202 2 Check ignition coil 1 4520 574 MIC5 IP...

Page 95: ...ed alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 11 in ignition sequence 1 Check cabling to ignition coil Page 202 2 Check ignition coil 1 4520 581 MIC5 IPE...

Page 96: ...Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 18 in ignition sequence 1 Check cabling to ignition coil Page 202 2 Check ignition coil 1 4520 588 MIC5 IP...

Page 97: ...Red alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 5 in ignition sequence 1 Check cabling to ignition coil Page 202 2 Check ignition coil 1 4520 595 MIC5...

Page 98: ...ed alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 12 in ignition sequence 1 Check cabling to ignition coil Page 202 2 Check ignition coil 1 4520 602 MIC5...

Page 99: ...alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 19 in ignition sequence 1 Check cabling to ignition coil Page 202 2 Check ignition coil 1 4520 609 MIC5 IP...

Page 100: ...llow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 6 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 616 MIC...

Page 101: ...llow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 13 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 623 MI...

Page 102: ...ow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 20 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 630 MIC5...

Page 103: ...w alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 7 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 637 MIC...

Page 104: ...ce 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 643 MIC5 ISE Secon Short Circuit Cyl 14 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary ci...

Page 105: ...2 Check ignition coil 1 4520 649 MIC5 ISE Secon Short Circuit Cyl 20 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 20 in ignition sequence 1 Che...

Page 106: ...se Corrective action Unable to detect index mark of pulse sensor 2 B75 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 203 Page 202 1 4520 664...

Page 107: ...Initiated by MIC5 Cause Corrective action Unable to synchronize with signal from pulse sensor 3 B13 2 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessar...

Page 108: ...tive action Expected signal from pulse sensor 3 B13 2 is missing u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 203 Page 202 1 4520 678 MIC5 E...

Page 109: ...e 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 3 Rest...

Page 110: ...mpressor 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 temp...

Page 111: ...1 4530 022 CAN Fault Red alarm Initiated by compressor bypass Cause Corrective action CAN bus connection faulty 1 Check cabling Page 202 2 Check compressor bypass flap settings 1 4540 009 Zero Pressur...

Page 112: ...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 113: ...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 114: ...ached minimum limit value 1 Check supply voltage 2 Check cabling Page 202 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Gas temperature before TecJet is below th...

Page 115: ...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 116: ...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 117: ...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 118: ...A Cause Corrective action Throttle setting is not correct u Check throttle setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by throttle of cylinder bank A Cause Corrective action...

Page 119: ...Check cabling Page 202 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by throttle of cylinder bank A Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550...

Page 120: ...iated by throttle of cylinder bank B Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by throttle of cyl...

Page 121: ...Check cabling Page 202 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by throttle of cylinder bank B Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550...

Page 122: ...n CAN bus connection faulty 1 Check cabling Page 202 2 Check throttle settings 1 4550 144 B CAN Stop Command Yellow alarm Initiated by throttle of cylinder bank B Cause Corrective action Stop input si...

Page 123: ...system oil heat exchanger 2 Replace oil filter Page 191 3 Take oil sample and analyze Page 190 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas temp...

Page 124: ...harger 2 Check ignition timing Page 176 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 125: ...eed of turbocharger 1 too high limit value 2 1 Check intake air temperature 2 Check emissions Page 47 3 If the sensor is not obstructed check the conditions for activating this monitoring feature in t...

Page 126: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 188 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...

Page 127: ...separator condition replace as necessary Page 165 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restri...

Page 128: ...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 186 Check exhaust back pressure Check d...

Page 129: ...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 130: ...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 202 122 HI T ECU Yellow...

Page 131: ...n selected that initiates communications with the 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...

Page 132: ...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 133: ...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 203 Page 202 Error cleared after restarting the engin...

Page 134: ...ction Intake air temperature sensor faulty short circuit or wire break u Check sensor and cabling B49 1 B90 replace as necessary Page 203 Page 202 Error cleared after restarting the engine 221 SD P Di...

Page 135: ...hort circuit or wire break 1 Check sensor and cabling B44 1 replace as necessary Page 203 Page 202 Error cleared after restarting the engine 2 If the sensor is not obstructed check the conditions for...

Page 136: ...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 202 383 A...

Page 137: ...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 138: ...n 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 139: ...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...

Page 140: ...uit or wire break u Check sensor and cabling B16 3 replace as necessary Page 203 Page 202 Error cleared after restarting the engine 470 SD T ECU Red alarm Associated parameter 1 8004 587 Cause Correct...

Page 141: ...Check sensor and cabling B79 21 replace as necessary Page 203 Page 202 Error cleared after restarting the engine 497 SD P Charge Mix B Red alarm Engine shutdown Associated parameter 1 8004 629 Cause...

Page 142: ...80 5 Check restrictor 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 143: ...ssociated 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 2...

Page 144: ...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 145: ...ps 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 setting at...

Page 146: ...action Pressure loss over air filter on A side is too high u Replace air filter Page 186 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pres...

Page 147: ...7 2 Check ignition timing Page 176 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...

Page 148: ...alarm Associated parameter 1 1041 924 Cause Corrective action Wire break or short circuit on channel PWM_CM4 u Check setting at engine governor 596 AL Develop PR Set Red alarm Associated parameter 1...

Page 149: ...ause Corrective action Wire break or short circuit on channel PWM_CM6 u Check setting at engine governor 609 AL Wiring PWM_CM7 Red alarm Associated parameter 1 1041 927 Cause Corrective action Wire br...

Page 150: ...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 151: ...sions Page 47 624 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 sen...

Page 152: ...detected 1 Check gas quality if feasible methane number 2 Check emissions Page 47 3 Check combustion chamber 649 Al Req Angle Throttle A Yellow alarm Power reduction Associated parameter 2 1200 935 C...

Page 153: ...Check cabling Page 202 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 154: ...0 2 658 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 202 2 Check power supply 3 Restart ECU 4...

Page 155: ...ation 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 val...

Page 156: ...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 157: ...s 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 al...

Page 158: ...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 159: ...Await 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 summar...

Page 160: ...is in Bus Off status Bus nodes ignition knock module restrictor flaps or gas mixture malfunctioning u Check operation of bus users and cabling 975 AL CAN3 Error Passive Yellow alarm Associated paramet...

Page 161: ...A and B are too far apart limit value 1 1 Check emissions Page 47 2 Check NOx sensors Page 203 3 Check ignition points Page 176 1014 HIHI Delta NOx A B Red alarm Associated parameter 2 3050 121 Cause...

Page 162: ...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 163: ...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 164: ...o 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 detect...

Page 165: ...ces which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid cont...

Page 166: ...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 167: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 168 2 Install new spark plug Page 169 MS150104 03E 2017...

Page 168: ...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 169: ...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 170: ...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 171: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 172 2 Install spark plug connector Page 174 MS150...

Page 172: ...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 173: ...ning and check 1 Remove spark plug connector Page 172 2 Remove spark plug isolator sealing ring Page 174 3 Check spark plug connector 1 and ignition line 2 visually for kinks pinching points and britt...

Page 174: ...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 175: ...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 176: ...ning Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note Service tool DiaSys and a 1A level dongle or higher as well as the Woodward IC900 series service tool for...

Page 177: ...rt No Qty Sliding depth gage 200 mm Y20000918 1 Preparatory steps 1 Remove igniters Page 168 2 Remove cylinder head covers Page 183 3 Remove sleeves arrowed 4 Install barring tool Page 163 5 Rotate cr...

Page 178: ...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 179: ...3 Install sleeves arrowed 4 Install cylinder head covers Page 184 5 Install igniters with new sealing rings Page 169 MS150104 03E 2017 09 Valve Drive 179 TIM ID 0000043220 003...

Page 180: ...3 2 Install barring device Page 163 3 Rotate crankshaft with barring device in en gine direction of rotation until marking OT and pointer are aligned Diagram for 12 16 V engines Two crankshaft positio...

Page 181: ...learances 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 deviation from...

Page 182: ...tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 183 2 Fill oil chambers of rocker arms and adjusting screws with oil 3 Insta...

Page 183: ...ing disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 172 3 Remove screws 2 4 Remove cylinder head cover with gasket fr...

Page 184: ...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 185: ...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 186: ...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 187: ...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 188: ...ay 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 ex ceed the ma...

Page 189: ...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 engine oil 1 O...

Page 190: ...ve 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 ign...

Page 191: ...Wear protective clothing protective 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 o...

Page 192: ...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 28 o...

Page 193: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 194 2 Fill with engine coolant Page 196 MS150104 03E 2017 09 Coolant Circuit General High Tem...

Page 194: ...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 195: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points MS150104 03E 2017 09 Coolant Circuit General High Temperature Circuit 195 TIM ID 0000006751 002...

Page 196: ...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 197: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 194 2 Release union nuts 1 and 3 3 Remove coolant vent l...

Page 198: ...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 199: ...ools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 200 2 Fill with fresh mixture coolant Page 201 MS150104 03E 2017 09 Low Temper...

Page 200: ...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 201: ...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 202: ...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 203: ...sure 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 40 Sensors B side The knock sensors B...

Page 204: ...centration in the exhaust gas option 2 B79 23 Mixture pressure before restrictor flap 3 B75 Crankshaft speed reset ignition system 4 B13 2 Crankshaft speed ignition Table 41 Sensors Engine driving end...

Page 205: ...ption 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 42 Sensors A side MS1...

Page 206: ...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 207: ...before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Coolant is hot and under pressure Risk of injury and s...

Page 208: ...eral information Arrangement and position of sensor Page 203 2 Loosen and disconnect connector 2 3 Unscrew electronics box 1 at the eyelets 4 Remove sensor via nut 3 208 Wiring General for Engine Gear...

Page 209: ...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 210: ...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 211: ...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 212: ...er 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...

Page 213: ...Used in 1 7 1 1 Engine Barring manually Page 163 Feeler gauge Part No Y20098771 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 180 Gas detection and alarm unit not stocked by MTU Part...

Page 214: ...er Part No F30027340 Qty Used in 1 7 11 4 Sensors Installation Page 209 Ratchet bit Part No F30027340 Qty Used in 1 7 11 3 Sensors Removal Page 207 Ratchet head with extension Part No F30006212 Qty Us...

Page 215: ...4 2 Valve clearance Check and adjustment Page 180 Special wrench 20 8 mm Part No F30452574 Qty Used in 1 7 3 2 Spark plug Removal Page 168 Qty Used in 1 7 3 3 Spark plug Installation Page 169 Strobosc...

Page 216: ...e 169 Qty Used in 1 7 3 7 Spark plug connector Installation Page 174 Qty Used in 1 7 11 4 Sensors Installation Page 209 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 4 2 Valve clearance Ch...

Page 217: ...000L32 Emissions optimized 1 2 TA Luft 32 Engine data 12V4000L32F Fuel optimized TA Luft 28 Engine data 16V4000L32 Emissions optimized 1 2 TA Luft 32 Engine data 16V4000L32F Fuel optimized TA Luft 28...

Page 218: ...ntion specific information for gaseous fuel supply applications 20 Fluids and lubricants 18 Fluids and lubricants specific information for dual fuel applications 20 Fluids and lubricants specific info...

Page 219: ...oval 172 Replacement 171 Starting sequence 43 Stopping sequence 43 T transport 22 V Valve clearance Adjustment 180 Check 180 Valve gear Lubrication 182 Valve protrusion Measurement 177 Vent line of en...

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MTU 12V4000L32F, Operating Instructions Manual

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