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MTU 12V4000L62FB, Operating Instructions Manual

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MTU 12V4000L62FB Operating Instructions Manual Download Page 4

8.4.3 Valve gear – Lubrication

161

8.4.4 Cylinder head cover ‒ Removal

162

8.4.5 Cylinder head cover ‒ Installation

163

8.5 Exhaust Turbocharger

164

8.5.1 Exhaust turbocharger – Cleaning

164

8.6 Gas System

174

8.6.1 Gas supply - Checking gas lines for leaks

174

8.7 Air Filter

175

8.7.1 Air filter – Replacement

175

8.7.2 Air filter – Removal and installation

176

8.8 Starting System

177

8.8.1 Starter – Replacement

177

8.8.2 Starter – Removal

178

8.8.3 Starter – Installation

179

8.9 Lube Oil System, Lube Oil Circuit

181

8.9.1 Engine oil level – Check

181

8.9.2 Engine oil – Change

182

8.9.3 Engine oil – Sample extraction and analysis

183

8.10 Oil Filtration / Cooling

184

8.10.1 Engine oil filter – Replacement

184

8.11 Coolant Circuit, General, High-Temperature

Circuit

185

8.11.1 Engine coolant – Level check

185

8.11.2 Engine coolant – Change

186

8.11.3 Engine coolant – Draining

187

8.11.4 Engine coolant ‒ Filling

189

8.11.5 Coolant vent line (engine coolant circuit) –

Replacement

190

8.12 Low-Temperature Circuit

191

8.12.1 Mixture coolant level ‒ Check

191

8.12.2 Mixture coolant – Change

192

8.12.3 Mixture coolant – Draining

193

8.12.4 Mixture coolant ‒ Filling

194

8.13 Wiring (General) for Engine/Gearbox/Unit

195

8.13.1 Engine cabling – Check

195

9 Appendix A

9.1 Abbreviations

196

9.2 MTU Onsite Energy contact person / service

partner

198

10 Appendix B

10.1 Special Tools

199

10.2 Index

205

4 | Table of Contents | MS150098/03E 2018-04

DCL-ID: 0000010330 - 005

Summary of Contents for 12V4000L62FB

Page 1: ...Operating Instructions Gas engine 12V4000L62FB 16V4000L62FB MS150098 03E...

Page 2: ...whether 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 p...

Page 3: ...ne Main dimensions 47 5 Operation 5 1 Runtimes at partial load 48 5 2 Putting the engine into operation after extended out of service periods 3 months 49 5 3 Putting the engine into operation after sc...

Page 4: ...sis 183 8 10 Oil Filtration Cooling 184 8 10 1 Engine oil filter Replacement 184 8 11 Coolant Circuit General High Temperature Circuit 185 8 11 1 Engine coolant Level check 185 8 11 2 Engine coolant C...

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

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: ...ator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediately after putting the pro...

Page 10: ...ds and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrical...

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: ...fitted Lock circuit breakers Before starting work on CaPoS if used Switch off the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the Ultr...

Page 14: ...ines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when wor...

Page 15: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 16: ...rly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in...

Page 17: ...shall be performed by specially trained qualified and author ized personnel only Ensure adequate possibly increased ventilation before opening the gas system Shut down the gas supply to the product b...

Page 18: ...fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wear protective gloves when handling compo...

Page 19: ...vided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smoking Observe...

Page 20: ...one 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 that the atmosphere is no longer haza...

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: ...gine 6 Always raise lower the engine slowly The lifting ropes or chains must not butt against the engine or its com ponents during the lifting procedure Readjust lifting gear as necessary 7 For specia...

Page 23: ...ear personal protective equipment e g protective helmet safety shoes 1 Max permissible diagonal pull 10 2 Center of gravity Taking note of the engine center of gravity Refer to the installation arrang...

Page 24: ...nstalled If the generator is al ready mounted on the engine ensure that the transport locking device of the generator is removed 3 Prior to every engine transport reinstall the transport locking devic...

Page 25: ...ousing 5 Tighten screw 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M10 Tightening torque Engine oil 30 Nm 3 Nm 6 Fit locknut 2 of screw 1 on plate 6 and secure Remov...

Page 26: ...nated in 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...

Page 27: ...unit 3 Air filter air inlet 4 Mixture cooler 5 Exhaust turbocharger 6 Engine lifting eye 7 Capacitor discharge ignition system 8 Engine mounting bracket free end 9 Oil pan 10 Engine mounting bracket...

Page 28: ...nnec tion 14 Engine oil heat exchanger 15 Engine coolant outlet con nection KGS Free end Engine model designation Key to the engine model designation12 16V4000L62FB 12 16 Number of cylinders V Cylinde...

Page 29: ...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 Ev...

Page 30: ...ion timing is retarded on the cylinder in question If this does not result in an improvement the power is reduced Gas control valve TecJet110 Controls the required amount of gas Mixture throttles P Se...

Page 31: ...ensive I O features Plant side 14 inputs 7 outputs 2 serial interfaces Engine side 39 inputs 28 outputs 1 serial interface Engine and plant related parameter settings in Flash memory In the event of i...

Page 32: ...8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 32 Monitoring Control and Regulation Equipment MS150098 03E 201...

Page 33: ...re after filter B side 3 B16 1 Coolant pressure after engine 4 B4 X Exhaust temperature after cylinder 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 3 Sensors on B side The knocking...

Page 34: ...toring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset 3 B13 2 Crankshaft speed ignition system Table 4 Sensors on driving end 34 Monitoring Control and Regulation Equipment...

Page 35: ...pressure A side 2 B50 Crankcase pressure 3 B5 1 Engine oil pressure after filter 4 B7 Engine oil temperature 5 B5 3 Engine oil pressure before filter Table 5 Sensors on A side MS150098 03E 2018 04 Mon...

Page 36: ...B1 3 Camshaft speed knock module 4 B1 2 Camshaft speed ignition system 5 B1 1 Camshaft speed engine governor 6 B24 Engine oil level 7 B6 3 Coolant temperature before engine 8 B6 1 Coolant temperature...

Page 37: ...g Overview Engine wiring harness W2 Illustrations show 8V Figures also apply similarly to 12V and 16V 1 Engine wiring harness W2 MS150098 03E 2018 04 Monitoring Control and Regulation Equipment 37 TIM...

Page 38: ...t installed B49 2 Intake air temperature B50 Crankcase pressure B73 Mixture temperature B79 21 Intake air pressure A side B79 22 Intake air pressure B side B79 23 Intake mixture pressure B81 2 Intake...

Page 39: ...knock sensors Designation Pin assignment Engine wiring harness W2 B80AX Knock sensors A side X2 Knock module adaptation B80BX Knock sensors B side Table 8 Engine wiring harness W2 MS150098 03E 2018 0...

Page 40: ...Ignition rail 1 Ignition coil 2 Screw 3 Washer 4 Ignition rail 40 Monitoring Control and Regulation Equipment MS150098 03E 2018 04 TIM ID 0000040024 002...

Page 41: ...ess VM001 for starter connecting cable W020 for ignition coil 1 Wiring harness for starter 2 Connecting cable for igni tion coil MS150098 03E 2018 04 Monitoring Control and Regulation Equipment 41 TIM...

Page 42: ...ble 9 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 powe...

Page 43: ...13 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 90 Coolant temperature...

Page 44: ...r 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 Table 16 Lube oil system Fuel system Number of cylinders 12 16 Gas temperat...

Page 45: ...basic configuration engine R kg 5850 7750 Heaviest component to be lifted during extended component maintenance QL3 R kg 415 440 Table 21 Weights main dimensions Exhaust emissions Number of cylinders...

Page 46: ...ng order Firing order Number of cylinders Firing order 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 46 Technical Data MS150098 03E 2018 04 TIM ID 0000002...

Page 47: ...mm Width B 12V approx 1751 mm Width B 16V approx 1797 mm Height C 12V approx 2193 mm Height C 16V approx 2203 mm Crankshaft center to oil pan D 12 16 V approx 636 mm Crankshaft center to engine mount...

Page 48: ...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 49: ...e 161 Lube oil system Check engine oil level Page 181 Check oil level in oil storage tank Page 181 Coolant circuit Standstill 1 year Change engine coolant Page 186 Change mixture coolant Page 192 Cool...

Page 50: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 181 Coolant circuit Check engine coolant level Page 185 Check mixture coolant level Page...

Page 51: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Page 52: ...gas A 24V digital output is pro vided to activate such systems Start sequence If a start command is activated with the engine being at standstill the following steps are carried out auto matically 1...

Page 53: ...activation request for external ventilation is sent via the 24V digital output 1 Activation request for external ventilation via contact 2 Activating starter 3 Waiting for starting speed 4 Purging eng...

Page 54: ...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 3 engine starting attempts are permitted at a max fuel supply open...

Page 55: ...n sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Operational checks Item Measure Machine room Check machine room for s...

Page 56: ...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 57: ...1 at the measuring point 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 th...

Page 58: ...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 59: ...tdown Item Measure Gas shut off valves with con trol solenoids Two contacts are available for connection to the electrical system Gas shut off valves with control solenoids close Engine will be shut d...

Page 60: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC 60 Operation MS150098 03E 201...

Page 61: ...ne room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Power supply to engine con trol system Switch off Gas supply The gas shut off valves with control solenoid...

Page 62: ...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 63: ...ILTRATION COOLING Replace oil filter at each oil change or when the time limit years is reached at the latest Page 184 WM00510 CRANKCASE BREATHER Check crankcase pressure control and adjust as necessa...

Page 64: ...ilure on the default field bus PB Pushbutton Status indication due to activation of certain control keys AKR Anti Knock Control GET Important information about fault messages from the Engine Control U...

Page 65: ...Procedure following an automatic safety shutdown Page 51 MS150098 03E 2018 04 Troubleshooting 65 TIM ID 0000027852 003...

Page 66: ...k ignition timing Page 154 3 Check valve gear exhaust valves do not close 112301 HI T Exhaust A1 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too h...

Page 67: ...ition timing Page 154 3 Check valve gear exhaust valves do not close 112307 HI T Exhaust A7 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high i...

Page 68: ...nition timing Page 154 3 Check valve gear exhaust valves do not close 112313 HI T Exhaust B3 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high...

Page 69: ...ck ignition timing Page 154 3 Check valve gear exhaust valves do not close 112319 HI T Exhaust B9 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too...

Page 70: ...orrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check igniter 2 Check emission values 3 Check ignition timing Page 154 4 Check valve gear 11...

Page 71: ...orrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check igniter 2 Check emission values 3 Check ignition timing Page 154 4 Check valve gear 11...

Page 72: ...orrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check igniter 2 Check emission values 3 Check ignition timing Page 154 4 Check valve gear 11...

Page 73: ...alues 3 Check ignition timing Page 154 4 Check valve gear 112420 LO T Exhaust B10 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparis...

Page 74: ...ition timing Page 154 3 Check valve gear 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 75: ...nition timing Page 154 3 Check valve gear 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 76: ...ition timing Page 154 3 Check valve gear 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 77: ...orrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values 3 Check ignition timing Page 154 4 Check valve gear 112...

Page 78: ...orrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values 3 Check ignition timing Page 154 4 Check valve gear 112...

Page 79: ...orrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values 3 Check ignition timing Page 154 4 Check valve gear 112...

Page 80: ...orrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values 3 Check ignition timing Page 154 4 Check valve gear 112...

Page 81: ...ition timing Page 154 3 Check valve gear exhaust valves do not close 112704 HIHI T Exhaust A4 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too hig...

Page 82: ...ition timing Page 154 3 Check valve gear exhaust valves do not close 112710 HIHI T Exhaust A10 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too hi...

Page 83: ...ition timing Page 154 3 Check valve gear exhaust valves do not close 112716 HIHI T Exhaust B6 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too hig...

Page 84: ...Cause Corrective action Summary alarm for details refer to the source alarm u Summary alarm for details refer to the source alarm 113200 Communication Lost ECU Red alarm Initiated by SAM Cause Correct...

Page 85: ...ilter gas line for obstruction 3 Check engine for overloading 1 4540 012 Valve Position Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1...

Page 86: ...ition Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 020 Elec Temp Fail Low Red alarm Initiated by TecJet Cause Corrective act...

Page 87: ...Corrective action TecJet setting is not correct u Check setting 1 4540 027 Analog Input High Error Red alarm Initiated by TecJet Cause Corrective action TecJet setting is not correct u Check setting...

Page 88: ...Corrective action Supply voltage has reached maximum limit value 1 Check supply voltage 2 Check cabling 1 4540 034 FGT High Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware n...

Page 89: ...larm Initiated by TecJet Cause Corrective action Keyswitch cabling missing u Check cabling 1 4520 232 Error Missing Ring Gear Signal Red alarm Initiated by IC922 Cause Corrective action Crankshaft sig...

Page 90: ...ated by IC922 Cause Corrective action Hardware not ready for operation u Restart ignition 1 4520 239 Global Timing out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified global...

Page 91: ...2 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 247 Open Primary Channel 3 Yellow alarm Ini...

Page 92: ...Channel 9 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 254 Open Primary Channel 10 Yellow...

Page 93: ...y Channel 16 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 262 Open Primary Channel 17 Yello...

Page 94: ...nsor B 75 sensor gap and cabling replace as necessary 1 4520 272 Warn Missing Camshaft Signal Yellow alarm Initiated by IC922 Cause Corrective action Missing camshaft signal for ignition system u Chec...

Page 95: ...itiated by anti knock control Cause Corrective action Hardware not ready for operation u Restart knock module 1 4510 189 Error Camshaft Red alarm Initiated by anti knock control Cause Corrective actio...

Page 96: ...d alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 198 Knock Sensor Er...

Page 97: ...d alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 205 Knock Sensor Er...

Page 98: ...amage replace as necessary 1 4510 211 Knock Sensor Error B10 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightenin...

Page 99: ...ct u Check setting 1 4530 014 Input Supply Voltage High Error Yellow alarm Initiated by F Series Cause Corrective action Supply voltage has reached maximum limit value 1 Check supply voltage 2 Check c...

Page 100: ...t ready for operation u Restart F Series 1 4530 022 CAN Fault Red alarm Initiated by F Series Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 031 A Internal Fault...

Page 101: ...mperature above 120 C Red alarm Initiated by ProAct of cylinder bank A Cause Corrective action The internal temperature is higher than the limit 1 Check room temperature Restart ProAct 2 Restart ProAc...

Page 102: ...1 4550 044 A CAN Stop Command Yellow alarm Initiated by ProAct of cylinder bank A Cause Corrective action Stop demand received via CAN bus u Check setting 1 4550 131 B Internal Fault Red alarm Initia...

Page 103: ...emperature above 120 C Red alarm Initiated by ProAct of cylinder bank A Cause Corrective action The internal temperature is higher than the limit 1 Check room temperature Restart ProAct 2 Restart ProA...

Page 104: ...n Position specification not received or received too late u Check cabling and setting 1 4550 143 B CAN Fault CAN Bus Off CAN Ad Red alarm Initiated by ProAct of cylinder bank A Cause Corrective actio...

Page 105: ...184 3 Take oil sample and analyze Page 183 016 SS P Lube Oil Red alarm engine shutdown Associated parameter 2 0100 922 Cause Corrective action Engine oil pressure too low limit value 2 No oil in engin...

Page 106: ...ust turbocharger 2 Check ignition timing Page 154 3 Check mixture setting 4 Check igniters 022 SS T Exhaust B Yellow alarm Associated parameter 2 0127 932 Cause Corrective action Exhaust gas temperatu...

Page 107: ...rottle closing position 031 HI ETC1 Overspeed Yellow alarm Associated parameter 2 3011 931 Cause Corrective action Speed of primary turbocharger too high limit value 1 u Turbocharger speed sensor is n...

Page 108: ...oil level Page 181 052 SS T Lube Oil Red alarm engine shutdown Associated parameter 2 0125 932 Cause Corrective action Engine oil temperature after oil heat exchanger too high limit value 2 Oil heat e...

Page 109: ...1 Check crank drive Bar engine Page 141 Endoscope combustion chambers from bottom dead center to top dead center 2 Check air filter for contamination replace if contamination is visible Page 175 3 Ch...

Page 110: ...set in parameter 2 2500 027 Engine stall speed limit without an engine stop having taken place The engine is shut down for safety reasons 1 In mains parallel operation Check mains for frequency drop C...

Page 111: ...1090 923 Cause Corrective action Minimum speed for flushing process and ignition release was not attained u Check starter system 093 SS T Preheat Red alarm engine shutdown Associated parameter 2 1090...

Page 112: ...rective action Supply voltage too low limit value 1 1 Check supply voltage 2 Check cabling 119 LOLO ECU Power Supply Voltage Red alarm Associated parameter 2 0140 922 Cause Corrective action Supply vo...

Page 113: ...Incomplete Red alarm Associated parameter 2 4000 006 Cause Corrective action The fault is generated if a CRC is faulty specified for each module during the restoration data upload into ADEC or if the...

Page 114: ...d alarm Associated parameter 2 0500 684 Cause Corrective action A program error occurred while trying to copy a received PU data module to the flash module u Contact Service Configuration fault 186 AL...

Page 115: ...d alarm Associated parameter 2 0500 690 Cause Corrective action EMU parameters are not supported u Contact Service Configuration fault 201 SD T Coolant Red alarm engine shutdown Associated parameter 1...

Page 116: ...arameter 1 8004 563 Cause Corrective action Engine oil pressure sensor after filter faulty short circuit or wire break u Check sensor and cabling B5 1 replace as necessary Error cleared after restarti...

Page 117: ...ressure sensors faulty short circuit or wire break u Check sensor and cabling before filter B5 3 and after filter B5 1 replace as necessary Error cleared after restarting the engine 227 SD P Lube Oil...

Page 118: ...t present 233 SD Charger 2 Speed Yellow alarm Associated parameter 1 3011 129 Cause Corrective action Speed sensor of secondary turbocharger faulty short circuit or wire break u Turbocharger speed sen...

Page 119: ...eter 2 8006 640 Cause Corrective action Short circuit or wire break at transistor output 3 plant side TOP 3 Activation of gas supply solenoid valve No 1 faulty u Check cabling 384 AL Wiring TOP 4 Red...

Page 120: ...ter 2 0101 931 Cause Corrective action Coolant pressure after engine too high limit value 3 u Check engine coolant circuit pressure and flow 430 LO P Coolant before Engine Yellow alarm Associated para...

Page 121: ...engine coolant circuit pressure and flow 443 HI P Charge Mix Diff Yellow alarm Associated parameter 2 0183 931 Cause Corrective action Difference in mixture pressures sensed on A and B side is too hi...

Page 122: ...em inlet temperature too high mixture cooler clogged 1 Check mixture cooling circuit 2 Check mixture cooler for dirt 453 LO T Charge Mix Yellow alarm Associated parameter 2 0169 921 Cause Corrective a...

Page 123: ...ty short circuit or wire break u Check sensor and cabling replace as necessary Error cleared after restarting the engine 472 AL Stop SD Red alarm engine shutdown Associated parameter 2 8006 593 Cause...

Page 124: ...D P Charge Mix B Red alarm engine shutdown Associated parameter 1 8004 629 Cause Corrective action Mixture pressure sensor on B side faulty short circuit or wire break u Check sensor and cabling B79 2...

Page 125: ...re coolant system 513 SD P Coolant Diff Red alarm Associated parameter 1 8004 610 Cause Corrective action Coolant differential pressure sensor faulty short circuit or wire break u Check sensors and ca...

Page 126: ...after restarting the engine 531 AL Wiring PWM_CM1 Red alarm Associated parameter 1 1044 900 Cause Corrective action Wire break or short circuit on channel PWM_CM1 u Check cabling to TecJet throttle re...

Page 127: ...118 Cause Corrective action Gas train test was not successful Alarm is activated if the gas train does not report OK within a specified time out period Either the gas train leak test was not successf...

Page 128: ...arameter 1 1450 010 Cause Corrective action A problem related to mixture restrictor flap on A side occurred Possible causes Mixture restrictor flap faulty no power supply to restrictor flap cabling of...

Page 129: ...r filter Page 175 568 AL L2 P Intake Air after Filter B Yellow alarm Associated parameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Pa...

Page 130: ...Retarded Timing Red alarm engine shutdown Associated parameter 2 1200 933 Cause Corrective action The cylinder set to maximum retarded timing due to knocking has violated the third limit value 1 Chec...

Page 131: ...Cause Corrective action Fuel calorific value has undershot the second limit value u Check gas quality if feasible 621 LO Nox Value Yellow alarm Associated parameter 2 3050 024 Cause Corrective action...

Page 132: ...part of standard scope of supply 634 SD T0 Ambient Air HDT2800 none Associated parameter 1 0700 089 Cause Corrective action Air moisture sensor defect u Sensor is not currently part of standard scope...

Page 133: ...936 Cause Corrective action Opening angle of throttles B exceeded 1 Check charge pressure reserve 2 Intake air temperature outside TVU data 3 Check compressor for contamination 4 Reduce power 651 AL P...

Page 134: ...tion for gas control valve faulty alternatively a step motor with gas mixer can be installed 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU and gas control valve 4 Check settings...

Page 135: ...er supply 3 Carry out restart of ECU EMU and restrictor flap B 4 Check settings with device specific dialog software XD11 1 661 AL PhytronB Comm Lost Red alarm Associated parameter 1 4570 196 Cause Co...

Page 136: ...designation 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 cont...

Page 137: ...lt designation is transmitted via CAN bus to the genset control system 674 AL PhyB Yellow Yellow alarm Associated parameter 1 4570 193 Cause Corrective action An internal summary alarm at step motor B...

Page 138: ...ct fault designation is transmitted via CAN bus to the genset control system 680 AL ProActB Red Red alarm Associated parameter 1 4550 191 Cause Corrective action An internal summary alarm in throttle...

Page 139: ...ne oil filling level detected 1 Check engine oil level Page 181 2 Check replenishment system 3 Top up oil 686 AL Lube Oil Max Red alarm Associated parameter 1 1480 309 Cause Corrective action Maximum...

Page 140: ...ction Gas temperature sensor faulty short circuit or wire break 1 Not installed in all engine versions optional 2 Check sensor and cabling B38 replace as necessary 719 AL T Gas L1 Yellow alarm Associa...

Page 141: ...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 142: ...nal safety equipment Do not smoke Checking machine room for smell of gas 1 Check machine room to localize gas supply leaks using gas detection and alarm unit 2 If the gas detection and alarm unit resp...

Page 143: ...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 144: ...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 145: ...ts Designation Use Part No Qty Open end wrench 36 mm F30454308 15 1 Checking and adjusting pres sure 1 Check crankcase pressure and adjust as nec essary 2 Turn restrictor 1 for adjustment by 90 Power...

Page 146: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 147 2 Install new spark plug Page 148 146 Ignition Syste...

Page 147: ...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 148: ...gine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressuriz...

Page 149: ...wrench to tighten spark plug to specified tightening torque Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molycote P 37 50 5 Nm 9 Fit spark plug conn...

Page 150: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 151 2 Install spark plug connector Page 152 150 I...

Page 151: ...otected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at peop...

Page 152: ...ine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurize...

Page 153: ...6 Fit protective cap 2 and check for correct seating MS150098 03E 2018 04 Ignition System 153 TIM ID 0000043642 002...

Page 154: ...nning 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 155: ...Use Part No Qty Feeler gage Y20098771 1 Offset screwdriver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Plug in open end wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head...

Page 156: ...s in firing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance adjustment with cold engine Inlet valves long rocker arm 0 3 mm Exhaust valves sho...

Page 157: ...knut 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 oil 9...

Page 158: ...y Sliding depth gage 200 mm Y20000918 1 Preparatory steps 1 Remove igniters Page 147 2 Remove cylinder head covers Page 162 3 Remove sleeves arrowed 4 Install barring tool Page 141 5 Rotate crankshaft...

Page 159: ...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 160: ...3 Install sleeves arrowed 4 Install cylinder head covers Page 163 5 Install igniters with new sealing rings Page 148 160 Valve Drive MS150098 03E 2018 04 TIM ID 0000043220 003...

Page 161: ...tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 162 2 Fill oil chambers of rocker arms and adjusting screws with oil 3 Insta...

Page 162: ...ing disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 151 3 Remove screws 2 4 Remove cylinder head cover with gasket fr...

Page 163: ...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 164: ...mponents surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING...

Page 165: ...are installed so that they are never under tension or strain Ensure correct installation position of components NOTICE Contamination of components Damage to component Observe manufacturer s instructio...

Page 166: ...e segments 3 are used on 12 V en gines while 16V engines feature one flange 3 12 Take off exhaust elbow 2 with flange 3 and gasket 4 13 Release screw connections 4 from bel lows 3 in exhaust system do...

Page 167: ...oil penetrates the compressor hous ing the cause can be found in the oil separa tor 3 Axially remove compressor housing 1 from bearing housing 3 4 Remove O ring 5 Unscrew screws 1 with locating washer...

Page 168: ...sealing faces 2 Clean compressor wheel turbine wheel nozzle ring compressor housing turbine housing and diffuser with cleaner 3 Clean diffuser if necessary with wire brush 4 Thoroughly clean securing...

Page 169: ...cant Value Standard Screw Tightening torque Assembly compound Molykote P 37 45 Nm 5 Nm b Screw connections on 16V Name Size Type Lubricant Value Standard Screw Tightening torque Assembly compound Moly...

Page 170: ...s on 12V Name Size Type Lubricant Value Standard Screw Tightening torque Assembly compound Molykote P 37 70 Nm 5 Nm b Screw connections on 16V Name Size Type Lubricant Value Standard Screw Tightening...

Page 171: ...ening torque Assembly compound Ultra Therm MTU Assembly compound Molykote P 37 30 Nm 5 Nm 4 Coat studs 5 on exhaust turbocharger with assembly compound Molykote P 37 Note Flange segments 3 are used on...

Page 172: ...ing a torque wrench Name Size Type Lubricant Value Standard Union nut M10 Tightening torque 35 Nm 5 Nm 12 Remove covers Note Use new O ring 6 13 Coat O ring 6 with assembly compound Kluthe Hakuform 30...

Page 173: ...nt line 2 22 Screw on nut 1 and tighten 23 Use torque wrench to tighten clamp 3 to specified tightening torque Name Size Type Lubricant Value Standard Clamp Tightening torque 8 Nm 1 Nm 24 Fill with en...

Page 174: ...of 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...

Page 175: ...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 176: ...er Removal and installa tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from con necting flange 1 of intake housing 3 Check connecting flange 1 of intake hous ing for obstruction 4 Use suitabl...

Page 177: ...lacement Special tools Material Spare parts Designation Use Part No Qty Starter Spare Parts Catalog Replacing starter 1 Remove starter Page 178 2 Install new starter Page 179 MS150098 03E 2018 04 Star...

Page 178: ...f crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes Disconnecting starter 1 Prior to disconnecting mark all cables with writable adhesive tape 1 Terminal 50 Control...

Page 179: ...is switched off before starting work Secure against unintentional switching on WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs Use appropriate...

Page 180: ...e Type Lubricant Value Standard Nut M5x0 8 Tightening torque 2 5 Nm 0 5 Nm 3 Screw nuts 2 3 4 5 onto terminals 30 30 b 45 31 and tighten to specified torque using a torque wrench Name Size Type Lubric...

Page 181: ...y 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 mar...

Page 182: ...y mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke...

Page 183: ...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 184: ...k 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...

Page 185: ...NING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant Level check 1 Read off system filling...

Page 186: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 187 2 Fill with engine coolant Page 189 186 Coolant Circuit General High Temperature Circuit...

Page 187: ...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...

Page 188: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 188 Coolant Circuit General High Temperature Circuit MS150098 03E 2018 04 TIM ID 0000006751 002...

Page 189: ...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 Engine coolant Filling 1 Fill w...

Page 190: ...scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Coolant vent line Replacement 1 Drain engine coolant Page 187 2 Release union nuts 1 and 3 3 Remove coolant ve...

Page 191: ...NING Coolant 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 fillin...

Page 192: ...ools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 193 2 Fill with fresh mixture coolant Page 194 192 Low Temperature Circuit MS1...

Page 193: ...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 194: ...lothing 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 Engine coolant Fi...

Page 195: ...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 196: ...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 197: ...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 198: ...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 199: ...No F6555766 Qty Used in 1 8 1 1 Engine Barring manually Page 141 Crossbeam Part No T80092210 Qty Used in 1 2 1 Transport Page 22 Crossbeam Part No T80092360 Qty Used in 1 2 1 Transport Page 22 MS15009...

Page 200: ...Page 56 Gas detection and alarm unit not stocked by MTU Part No Qty Used in 8 1 2 Checking machine room for smell of gas Page 142 Offset screwdriver Part No F30452765 Qty Used in 1 8 4 1 Valve clearan...

Page 201: ...0029815 Qty Used in 1 8 4 1 Valve clearance Check and adjustment Page 155 Ratchet adapter Part No F30027340 Qty Used in 1 2 3 Crankshaft transport locking device Page 24 Qty Used in 1 8 8 3 Starter In...

Page 202: ...Part No F30006212 Qty Used in 1 8 1 1 Engine Barring manually Page 141 Screwdriver bit Part No F30378921 Qty Used in 1 8 8 3 Starter Installation Page 179 Sliding depth gage 200 mm Part No Y20000918 Q...

Page 203: ...1 8 3 2 Spark plug Removal Page 147 Qty Used in 1 8 3 3 Spark plug Installation Page 148 Stroboscope not stocked by MTU Part No Qty Used in 8 3 7 Ignition system Ignition timing check Page 154 Torque...

Page 204: ...300 800 Nm Part No F30047798 Qty Used in 1 8 5 1 Exhaust turbocharger Cleaning Page 164 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 2 3 Crankshaft transport locking device Page 24 Qty Used...

Page 205: ...Removal 24 Cylinder Designation 26 Cylinder head cover Installation 163 Removal 162 E Emergency shutdown Engine 59 Emission values Check 56 Engine After stopping Putting out of operation 61 Barring m...

Page 206: ...l protection specific information for gas eous fuel supply applications 20 Fire prevention 18 Fire prevention specific information for dual fuel ap plications 20 Fire prevention specific information f...

Page 207: ...eplacement 177 Starting sequence Control 52 Stopping sequence Control 52 T Transport Description 22 Lifting specifications 23 V Valve clearance Adjustment 155 Check 155 Valve gear Lubrication 161 Valv...

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