MTU 12V4000L32FB Operating Instructions Manual Download Page 33

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2.6 Monitoring, Control and Regulation Equipment

2.6.1 Gas engine phase 3 system – Overview

General overview

1 Plant system
2 Engine system
3 Plant
4 Engine Control Unit

5 Engine Monitoring Unit
6 Throttles
7 Gas dosing unit
8 Knock module

9 Ignition

10 Compressor bypass
11 NOx sensor (optional)

Governing/control/monitoring

Engine Control Unit ECU-9

• Controls engine starting, stopping and emergency stop
• Monitors engine operating parameters
• Controls throttles and sets gas mixture for requested speed/power
• Monitors first gas solenoid in gas train to engine

Engine Monitoring Unit EMU 8

• Monitors second gas solenoid in gas train to engine

Compressor bypass (F series)

• Controls throttle reserve, prevents compressor surges

Ignition system IC922

• Adjusts ignition timing for cylinders

MS150115/00E 2013-10

| Product Summary | 33

TIM-ID: 0000044676 - 001

Summary of Contents for 12V4000L32FB

Page 1: ...Operating Instructions Gas engine 12 V 4000 Lx2 xx 16 V 4000 Lx2 xx MS150115 00E...

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

Page 3: ...tarting and stopping sequences 40 3 5 Engine Start 42 3 6 Operational checks 43 3 7 Emission values Check 44 3 8 Engine Shutdown 45 3 9 Emergency engine shutdown 46 3 10 After stopping the engine Engi...

Page 4: ...uit Replacement 165 6 10 Low Temperature Circuit 166 6 10 1 Mixture coolant Level check 166 6 10 2 Mixture coolant Change 167 6 10 3 Mixture coolant Draining 168 6 10 4 Mixture coolant Filling 169 6 1...

Page 5: ...nfiguration approved by the manufacturer in writ ing including engine control parameters In compliance with all safety regulations and in adherence with all warning notices in this manual In accordanc...

Page 6: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

Page 7: ...or the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transport...

Page 8: ...th the consequences of any operations performed During operation the display instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit v...

Page 9: ...lves are activated via two different paths from the control system whereby one gas shutoff valve respectively is activated via one of the paths Gas trains must be monitored to detect minimum pressure...

Page 10: ...work Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device Observe the safety data sheet Safe...

Page 11: ...ct beforehand Hydraulic installation and removal Check satisfactory function and safe operating condition of tools jigs and fixtures to be used Use only the specified jigs and fixtures for hydraulic r...

Page 12: ...stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched f...

Page 13: ...that has been trained and authorized for this task Have all work on gas carrying components carried out by authorized specialized companies Prior to starting maintenance work shut off the gas supply...

Page 14: ...roduct are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Nonc...

Page 15: ...y line or before device or tool is to be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting...

Page 16: ...n be life threatening depending on concentration Some gases can no longer be detected by sense of smell in higher concentrations Caution Risk of poisoning due to hazardous byproducts The absorption of...

Page 17: ...event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequ...

Page 18: ...r air inlet 4 Mixture cooler 5 Exhaust turbocharger 6 Engine lifting equipment 7 Capacitor discharge igni tion system 8 Engine mounting bracket free end 9 Oil pan 10 Engine mounting bracket driving en...

Page 19: ...inlet 14 Engine oil heat exchanger 15 Connection engine cool ant outlet KGS Free end Engine model designation Key to the engine model designations 12 16V 4000 L32 FB 12 16 Number of cylinders V Cylin...

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

Page 21: ...prox 3372 mm Width B for 12V approx 1743 mm Width B for 16V approx 1789 mm Height C for 12V approx 2156 mm Height C for 16V approx 2175 mm Crankshaft center to oil pan D approx 636 mm Crankshaft cente...

Page 22: ...2 4 Ignition order Ignition order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 22 Product Summary MS150115 00E 2013 10 TIM ID 0000002806 001...

Page 23: ...4 Reference conditions Power related data power ratings are net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power a...

Page 24: ...Model related data basic design Coolant system HT circuit Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 88 Coolant temperature a...

Page 25: ...cooler at nominal flow rate 8 56 bar 3 4 Table 11 Coolant system MT circuit Lube oil system Number of cylinders 12 16 Lube oil operating temperature after oil heat exchanger from R C 82 82 Lube oil o...

Page 26: ...2 16 Engine coolant capacity engine side without cooling equipment R Liters 200 255 Mixture coolant engine side without cooling system R Liters 20 25 Total engine oil capacity for initial filling stan...

Page 27: ...unsilenced DL sound power level LW ISO 6798 R dB A 119 119 Genset surface noise with attenuated intake noise filter DL sound power level LW ISO 8528 10 R dB A 118 117 Table 19 Acoustics MS150115 00E...

Page 28: ...ings 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 ISO 3046 A kW 1200 1600 Mean effective pressur...

Page 29: ...t 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 anti...

Page 30: ...cooler at nominal flow rate 8 56 bar 2 9 Table 27 Coolant system MT circuit Lube oil system Number of cylinders 12 16 Lube oil operating temperature after oil heat exchanger from R C 82 82 Lube oil o...

Page 31: ...16 Engine coolant capacity engine side without cooling equipment R Liters 200 255 Mixture coolant engine side without cooling system R Liters 20 25 Total engine oil capacity for initial filling stand...

Page 32: ...unsilenced DL sound power level LW ISO 6798 R dB A 119 119 Genset surface noise with attenuated intake noise filter DL sound power level LW ISO 8528 10 R dB A 118 117 Table 35 Acoustics 32 Product Su...

Page 33: ...ng Engine Control Unit ECU 9 Controls engine starting stopping and emergency stop Monitors engine operating parameters Controls throttles and sets gas mixture for requested speed power Monitors first...

Page 34: ...yed for the cylinder concerned The power is reduced if this does not lead to improvement Gas control valve TecJet110 Controls the required amount of gas Mixture throttles P Series Mixture throttles in...

Page 35: ...cs Integral status fault display Fault memory Extensive I O features Engine and genset related parameter settings in flash memory In the event of inadmissible states and limit value violations Initiat...

Page 36: ...oring Unit EMU 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 36 Product Summary MS150115 00E 2013 10 TIM ID 00...

Page 37: ...oad Recommended maximum run time at this load Recommended minimum run time in subsequent operation at load 50 0 to 30 30 minutes 120 minutes 30 to 50 120 minutes 120 minutes 50 to 100 No restriction N...

Page 38: ...e 150 Lube oil system Check engine oil level Page 156 Check oil level in oil storage tank Page 156 Coolant circuit Standstill 1 year Change engine coolant Page 161 Change mixture coolant Page 167 Cool...

Page 39: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 156 Coolant circuit Check engine coolant level Page 160 Check mixture coolant level Page...

Page 40: ...by means of suitable systems in the facility A contact is provided to activate such sys tems Starting sequence The following steps are performed automatically when a start command is activated with t...

Page 41: ...ing a start request after emergency shutdown 1 Requesting external ventilation by contact 2 Activating starter 3 Waiting for starting speed 4 Flushing the engine 5 Disengaging starter 6 Engine running...

Page 42: ...aught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of...

Page 43: ...e room for smell of gas Page 131 ECU Check for fault messages if fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Op...

Page 44: ...of injury and burning Wear protective clothing gloves and goggles safety mask WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well ventilated Repair leaki...

Page 45: ...nd mechanical stresses Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are ind...

Page 46: ...order to safely burn off uncombust ed fuel air mixture The ignition is only switched off in case of an overspeed violation or an internal ignition fault Throttles The throttles are always closed in ca...

Page 47: ...t be equipped with an SAV safety shut off valve when using gas control systems with inlet pressures in excess of 0 1 bar If the SAV is tripped by an EMERGENCY STOP it must be reset manually SAV trippi...

Page 48: ...Engine remains ready for operation After stopping the engine Item Action Engine generator control manufacturer specific Select operating mode e g HAND MANUAL AUTO AUTOMATIC 48 Operation MS150115 00E...

Page 49: ...is be low 40 C Power supply to engine con trol system Switch off Gas supply Close gas shut off valve Air intake and exhaust sys tems If the engine is to remain out of service for more than 1 week sea...

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

Page 51: ...adjust if necessary Page 147 W1005 Replace air filter Page 154 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 159 W1089 Check gas lin...

Page 52: ...mit value has not been attained MG Message General message SE System Error Warning due to node failure on the default field bus PB Push Button Status indication due to activation of certain control ke...

Page 53: ...he engine is running at its limits Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled MS150115 00E 2013 10 Troubleshooting 53 TI...

Page 54: ...n values 2 Check ignition timing Page 143 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this c...

Page 55: ...tion timing Page 143 3 Check valve drive exhaust valves do not close 112308 HI T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 56: ...tion timing Page 143 3 Check valve drive exhaust valves do not close 112314 HI T Exhaust B4 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 57: ...heck ignition timing Page 143 3 Check valve drive exhaust valves do not close 112320 HI T Exhaust B10 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is...

Page 58: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 143 4 Check valve drive...

Page 59: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 143 4 Check valve drive...

Page 60: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 143 4 Check valve drive...

Page 61: ...lues 3 Check ignition timing Page 143 4 Check valve drive 112501 HIHI T Exhaust A1 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared w...

Page 62: ...tion timing Page 143 3 Check valve drive exhaust valves do not close 112507 HIHI T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as...

Page 63: ...ition timing Page 143 3 Check valve drive exhaust valves do not close 112513 HIHI T Exhaust B3 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 64: ...ignition timing Page 143 3 Check valve drive exhaust valves do not close 112519 HIHI T Exhaust B9 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hi...

Page 65: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 143 4 Check valve drive 1...

Page 66: ...rective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 143 4 Check valve drive 11...

Page 67: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 143 4 Check valve drive 1...

Page 68: ...g 2 Check emission values 3 Check ignition timing Page 143 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is...

Page 69: ...tion timing Page 143 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 70: ...ition timing Page 143 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinde...

Page 71: ...tion timing Page 143 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 72: ...cabling 113902 SS Local Initiated Emerg Stop Red alarm Initiated by SAM Cause Corrective action Emergency stop detected Emergency stop was released manually button or ignition system reported overspee...

Page 73: ...g torque damage replace as necessary 1 4510 193 Knock Sensor Error A2 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor...

Page 74: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 199 Knock Sensor Error A8 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 75: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 205 Knock Sensor Error B4 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 76: ...m this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 211 Knock Sensor Error B10 Red alarm Initiated by anti knock control Cause Corrective action No...

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

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

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

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

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

Page 82: ...F series Cause Corrective action Combined alarm for details refer to the source alarm u Combined alarm for details refer to the source alarm 1 4530 009 Derating Active Yellow alarm Initiated by F ser...

Page 83: ...Error Yellow alarm Initiated by F series Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4530 016 Electronics Temperature High Error Red...

Page 84: ...ies Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4540 009 Zero Pressure Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow de...

Page 85: ...T Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 016 Delta P Fail High Red alarm Initiated by TecJet Cause Corrective action D...

Page 86: ...22 Delta P Fail Low Red alarm Initiated by TecJet Cause Corrective action Delta p via TecJet below set limit value u Check TecJet and configuration 1 4540 023 FGP Fail Low Red alarm Initiated by TecJe...

Page 87: ...Red alarm Initiated by TecJet Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJe...

Page 88: ...t TecJet 1 4540 036 FGP High Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 037 Watchdog Reset Red alarm Initiated by TecJet...

Page 89: ...044 Parameter Version Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 045 Main EEP Read Fail Red alarm Initiated by TecJet Cause C...

Page 90: ...1 Sense 12V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 052 ADC Test Error Red alarm Initiated by TecJet Cause Corrective actio...

Page 91: ...ct A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action Supply voltage has...

Page 92: ...ng or is outside the range 1 Check setting 2 Check cabling 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is incorrect u Check settin...

Page 93: ...Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action S...

Page 94: ...ng or is outside the range 1 Check setting 2 Check cabling 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check settin...

Page 95: ...Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 144 B CAN Stop Command Yellow alarm Initiated by ProAct B Bank Cause Corrective action Stop input signal received via CA...

Page 96: ...oil system oil heat exchanger 2 Replace oil filter Page 159 3 Take oil sample and analyze Page 158 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas t...

Page 97: ...charger 2 Check ignition timing Page 143 3 Check mixture setting 4 Check spark plugs 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective action Pressure loss via oil f...

Page 98: ...ne shutdown Associated parameter 2 3012 932 Cause Corrective action Speed of primary turbocharger too high limit value 2 u Turbocharger speed sensor is not fitted at present Check ECU setting for this...

Page 99: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 156 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...

Page 100: ...heck oil separator condition replace as necessary Page 132 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value...

Page 101: ...ly open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 154 Check exhaust back pressure Check differential pr...

Page 102: ...ellow 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 co...

Page 103: ...supply voltage 2 Check cabling 121 HIHI ECU Power Supply Voltage Red alarm Associated parameter 2 0140 932 Cause Corrective action Supply voltage too high limit value 2 1 Check supply voltage 2 Check...

Page 104: ...N mode initializes communication by means of the PU data module However the necessary PU data module is not present or is invalid u Contact Service configuration fault 184 AL CAN PU Data Flash Error R...

Page 105: ...500 689 Cause Corrective action CAN controller 2 has indicated a warning Possible causes may be e g missing node minor malfunctions or temporary bus overload u Check operation of bus nodes and cabling...

Page 106: ...use Corrective action Exhaust temperature sensor on B side defective short circuit or wire break u Check sensor and cabling B4 22 replace as necessary Fault is rectified following engine restart 211 S...

Page 107: ...ective action Intake air temperature sensor defective short circuit or wire break u Check sensor and cabling B49 2 replace as necessary Fault is rectified when engine is restarted 221 SD P Diff Lube O...

Page 108: ...s necessary Fault is rectified following engine restart 232 SD ETC Speed 1 Yellow alarm Associated parameter 1 3011 128 Cause Corrective action Speed sensor of primary turbocharger defective short cir...

Page 109: ...8006 639 Cause Corrective action Short circuit or wire break at transistor output plant side 2 TOP 2 Activation of red combined alarm faulty u Check cabling 383 AL Wiring TOP 3 Red alarm Associated p...

Page 110: ...sociated parameter 2 0180 921 Cause Corrective action Coolant differential pressure too low limit value 1 Insufficient volume flow u Check engine coolant circuit pressure and flow 429 HI P Coolant Red...

Page 111: ...ameter 2 0173 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure volumetric flow too low air in engine coolant circuit u Check engine cool...

Page 112: ...xture cooler for dirt 452 HIHI T Charge Mix Red alarm Engine shutdown Associated parameter 2 0169 932 Cause Corrective action Mixture temperature too high limit value 2 Mixture coolant pump failure vo...

Page 113: ...replace as necessary Fault is rectified following engine restart 470 SD T ECU Red alarm Associated parameter 1 8004 587 Cause Corrective action Temperature sensor for Engine Control Unit defective sh...

Page 114: ...t or wire break u Check sensor and cabling B79 21 replace as necessary Fault is rectified following engine restart 497 SD P Charge Mix B Red alarm Engine shutdown Associated parameter 1 8004 629 Cause...

Page 115: ...2 0182 932 Cause Corrective action Mixture pressure on B side too high limit value 2 1 Check emissions 2 Check ignition timing Page 143 3 Check exhaust back pressure 4 Check valve clearance Page 147...

Page 116: ...ed parameter 1 0187 900 Cause Corrective action Intake air pressure sensor after filter on B side defective short circuit or wire break u Check sensor and cabling B81 2 replace as necessary Fault is r...

Page 117: ...ply solenoid valves are faulty the timeout period is set too short or communication is faulty 1 Check gas train 2 Check cabling 557 AL speed drop fault Red alarm Engine shutdown Associated parameter 2...

Page 118: ...over air filter on A side is too high u Replace air filter Page 154 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure loss over air f...

Page 119: ...emissions 2 Check ignition timing Page 143 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...

Page 120: ...ling to NOx sensors and air humidity sensor 617 LO Current Heat Value of Fuel Yellow alarm Associated parameter 2 1210 006 Cause Corrective action Fuel calorific value has undershot the first limit va...

Page 121: ...parameter 2 3050 025 Cause Corrective action NOx emissions have undershot the second limit value 1 Check gas quality if feasible 2 Check gas pressure 3 Check NOx sensor 4 Check emissions 623 HI NOx V...

Page 122: ...rm Associated parameter 2 1200 935 Cause Corrective action Opening angle of throttles A exceeded 1 Check charge air pressure reserve 2 Intake air temperature outside TVU data 3 Check compressor for co...

Page 123: ...munication for bypass flap faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU bypass flap 4 Check settings with device specific dialog software XD50 3 655 AL TecJet Comm Lost R...

Page 124: ...196 Cause Corrective action CAN bus communication for NOx sensor B faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU and EMU 4 Replace sensor 664 AL Oil Refill Error Red alarm As...

Page 125: ...exact fault designation is transmitted via CAN bus to the genset control system 669 AL ProActA Yellow Yellow alarm Associated parameter 1 4550 093 Cause Corrective action An internal combined alarm in...

Page 126: ...esignation is transmitted via CAN bus to the genset control system 677 AL FSeries Red Red alarm Associated parameter 1 4530 991 Cause Corrective action An internal combined alarm in the bypass flap wa...

Page 127: ...rm at NOx sensor B was detected u An exact fault designation is transmitted via CAN bus to the genset control system 685 AL Lube Oil Min Red alarm Associated parameter 1 1480 307 Cause Corrective acti...

Page 128: ...use Corrective action Gas temperature sensor defective short circuit or wire break 1 Not installed in all engine versions optional 2 Check sensor and cabling B38 replace as necessary 719 AL T Gas L1 Y...

Page 129: ...2 Check cabling 974 AL CAN3 Bus Off Yellow alarm Associated parameter 2 0500 692 Cause Corrective action CAN controller 3 is in Bus Off status Bus nodes ignition anti knock module throttles or gas mi...

Page 130: ...ody being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Barring engine manually 1 Remove guard plate 2 Engage barr...

Page 131: ...afety equipment Do not smoke Checking machine room for smell of gas 1 Check machine room to localize gas supply leaks using gas detection and alarm unit 2 If the gas detection and alarm unit responds...

Page 132: ...il Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor...

Page 133: ...escence filter 5 must be installed in the correct position in the housing 10 Place coalescence filter 5 in housing en suring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12...

Page 134: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 135 2 Install new spark plug Page 136 134 Task Descripti...

Page 135: ...he ignition cable in operation WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing r...

Page 136: ...ways wear electrical gloves class 4 minimum when touching the ignition cable in operation WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of pre...

Page 137: ...to tightening 6 Tighten spark plug to specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molykote P 37...

Page 138: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 139 2 Install spark plug connector Page 140 138 T...

Page 139: ...mage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Spark plug connector Removal 1 Loosen screws 4 on cylinder head...

Page 140: ...r jet at people Always wear safety goggles face mask and ear defenders Installing spark plug connector 1 If necessary remove the ignition line s low er sealing ring and replace with a new seal ing rin...

Page 141: ...tective cap 2 and check for correct seating Exchanging spark plug isolator sealing ring 1 Insert screwdriver 3 between Teflon sleeve 1 and sealing ring 2 2 Pry out and pull out sealing ring 2 3 Fold t...

Page 142: ...5 Carefully press sealing ring 1 into the groove until it is flush with the hole in Tef lon sleeve 2 142 Task Description MS150115 00E 2013 10 TIM ID 0000043226 004...

Page 143: ...ING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note The service tool Diasys and a dongle with access righ...

Page 144: ...Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 135 2 Remove cylinder head covers Page 151 3 Remove sleeves arrow 4 Install barring device Page 130 5 Rotate cranksh...

Page 145: ...ase adjusting screw 1 and remove valve bridge Do not remove rocker arm 2 4 Measure distance between valve stem end and cylinder head top at the spark plug bore with depth gauge see figure The specifie...

Page 146: ...3 Install sleeves arrow 4 Install cylinder head covers Page 152 5 Install spark plugs with new sealing rings Page 136 146 Task Description MS150115 00E 2013 10 TIM ID 0000043220 002...

Page 147: ...No Qty Feeler gage Y20098771 1 Angular screw driver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 151 2...

Page 148: ...is in firing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 3 mm Exhaust valves short rocker...

Page 149: ...locknut 1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 Tightening torque Engine oi...

Page 150: ...ls Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 151 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install...

Page 151: ...disabled Removing cylinder head cover 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 139 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 152: ...mponents for special cleanliness Installing cylinder head cover 1 Clean mounting surface 2 Check condition of gasket replace if dam aged 3 Position gasket and cylinder head cover 1 on cylinder head 4...

Page 153: ...fire and explosion Avoid open flames electrical sparks and ignition sources Carry gas warning unit part of the personal safety equipment Do not smoke Gas supply checking gas lines for leaks 1 Coat al...

Page 154: ...lter made of fleece option Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the corresponding fault message appears Repla...

Page 155: ...alla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from connecting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air fil...

Page 156: ...2 cm The cause of this may be that oil e g from the oil filter and oil heat exchanger flows back into the oil pan 3 The oil level must reach the mark 2 or ex ceed the mark 1 by up to 2 cm Note Toppin...

Page 157: ...vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Engine oil extraction 1 Open shut off valve s in...

Page 158: ...sk Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke WARN...

Page 159: ...oves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition...

Page 160: ...RNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant Level check 1 Read off system fillin...

Page 161: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 162 2 Fill with engine coolant Page 164 MS150115 00E 2013 10 Task Description...

Page 162: ...Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch of...

Page 163: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points MS150115 00E 2013 10 Task Description 163 TIM ID 0000006751 002...

Page 164: ...ves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with coolant 1 Fill...

Page 165: ...of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 162 2 Release union nuts 1 and 3 3 Remov...

Page 166: ...nt 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 167: ...l tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 168 2 Fill with fresh mixture coolant Page 169 MS150115 00E 2013 10 Task De...

Page 168: ...injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining mixture coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve at...

Page 169: ...loves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with coolant 1 Fil...

Page 170: ...swing freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Conta...

Page 171: ...ke air 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 on B side The k...

Page 172: ...tion Monitoring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset ignition system 3 B13 3 Crankshaft speed ignition Table 42 Sensors on engine driving end 172 Task Description...

Page 173: ...ure A side 2 B50 Crankcase pressure 3 B5 3 Engine oil pressure before filter 4 B7 Engine oil temperature 5 B5 1 Engine oil pressure after filter 6 B44 1 Turbocharger speed optional Table 43 Sensors on...

Page 174: ...ore engine 3 B1 2 Camshaft speed for engine governor 4 B1 3 Camshaft speed for anti knock control 5 B1 1 Camshaft speed for engine governor 6 B24 Lube oil level 7 B16 3 Coolant pressure before engine...

Page 175: ...andard ETK Ersatzteilkatalog Spare Parts Catalog SPC HI High Alarm Measured value exceeds 1st maxi mum limit value HIHI High High Alarm Measured value exceeds 2nd maxi mum limit value HT High Temperat...

Page 176: ...zation SAV Sicherheitsabsperrventil Safety shut off valve SBV Sicherheitsabbalseventil Safety discharge valve SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technis...

Page 177: ...ring operation for preventive maintenance corrective work in case of malfunction or changed oper ating conditions or for spare parts supply For our locally available support go to MTU s Internet site...

Page 178: ...4 2 Valve clearance Check and adjustment Page 147 Barring gear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 130 Feeler gage Part No Y20098771 Qty Used in 1 6 4 2 Valve clearance C...

Page 179: ...n 3 7 Emission values Check Page 44 Qty Used in 6 1 2 Checking machine room for smell of gas Page 131 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Engine Barring manually Page 130...

Page 180: ...al Page 135 Qty Used in 1 6 3 3 Spark plug Installation Page 136 Stroboscope Not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 143 Torque wrench 10 60 Nm Part No...

Page 181: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 147 MS150115 00E 2013 10 Appendix B 181 DCL ID 0000029696 001...

Page 182: ...Main dimensions 21 Shutdown 45 Start 42 Wiring check 170 Engine coolant Change 161 Draining 162 Filling 164 Level check 160 Engine layout 18 Engine oil Chgange 157 Sample extraction and analysis 158...

Page 183: ...eous fuel 16 Important provisions 5 Maintenance work 10 Maintenance work special instructions for applica tions with gaseous fuel 13 Operation 8 Operation special instructions for applications with ga...

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MTU 12V4000L32FB, Operating Instructions Manual

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