MTU 16V4000Lx2x Operating Instructions Manual Download

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2 Product Summary

2.1 Engine overview

1 Throttle, A-side
2 Engine governor/engine

monitoring

3 Air 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 Starter
12 Flywheel

KS Driving end

20 | Product Summary | MS150121/00E 2015-07

TIM-ID: 0000062772 - 001

Summary of Contents for 16V4000Lx2x

Page 1: ...Operating Instructions Gas engine 16V4000Lx2x MS150121 00E ...

Page 2: ... without the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion microfilming and storage or processing in electronic systems including databases and online services All information in this publication was the latest information available at the time of going to print MTU Friedrichshafen GmbH reserves the right to change...

Page 3: ...g and stopping sequences 42 3 5 Engine Start 44 3 6 Operational checks 45 3 7 Emission values Check 46 3 8 Engine Shutdown 47 3 9 Emergency engine shutdown 48 3 10 After stopping the engine Engine remains ready for operation 50 3 11 After stopping the engine Putting the engine out of operation 51 4 Maintenance 4 1 50 hours check 52 4 2 Maintenance task reference table QL1 53 5 Troubleshooting 5 1 ...

Page 4: ...t 167 6 10 1 Mixture coolant level Check 167 6 10 2 Mixture coolant Change 168 6 10 3 Mixture coolant Draining 169 6 10 4 Mixture coolant Filling 170 6 11 Wiring General for Engine Gearbox Unit 171 6 11 1 Engine cabling Check 171 6 11 2 Sensors Overview 172 6 11 3 Sensors Removal 176 6 11 4 Sensor Installation 178 7 Appendix A 7 1 Abbreviations 179 7 2 MTU Onsite Energy contact person service part...

Page 5: ...e with the Spare Parts Catalog MTU contact Service partner In the original as delivered configuration or in a configuration 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 With maintenance work performed in accordance with the Maintenance Schedule throughout the useful li...

Page 6: ...ation authorities The manufacturer does not accept any liability for violations of the emission reg ulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product Replacing components with emission labels Emission labels are attached to all MTU engines These must remain on the engine throughout its op erational life Engines used exclusively in lan...

Page 7: ...l must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical personnel from the areas mechanical engineering plant construction and electrical engi neering The operator must define the responsibilities of the personnel involved in operation maintenance re pai...

Page 8: ...y instruments as well as the monitoring signaling and alarm systems are working properly Smoking is prohibited in the area of the product Safety regulations during operation The operator must be familiar with the controls and displays The operator must be familiar with the consequences of any operations performed During operation the display instruments and monitoring units must be permanently obs...

Page 9: ...Observe the warning information applicable to the devices MS150121 00E 2015 07 Safety 9 TIM ID 0000040533 010 ...

Page 10: ...o gas shutoff valves a pressure regulating device The gas train must be fitted with an automatic leak check The gas shutoff valves 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 The plant designer must ensure that the gas train is positioned directly i...

Page 11: ...ne mounts damping elements couplings and V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy pinions Wear a respirator mask filter class P3 Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing...

Page 12: ...cable straps Welding work Welding operations on the product or mounted units are not permitted Cover the product when welding in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the vicinity of the pr...

Page 13: ...hat cabling cannot be dam aged during operation by Contact with sharp edges Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to secure cables Always use connector pliers to tighten union nuts on connectors Subject the device as well as the product to a functional testing on completion of all repair work In particular check the fu...

Page 14: ...has been trained and authorized for this task All work on gas carrying components must only be resourced to authorized specialized companies Shut off the gas supply to the product and aivate the emergency stop at the engine interface switchgear cabinet MIS or by turning the key switch if fitted Close the manual shutoff valve for the gas supply The coolant pumps must keep running on for a longer pe...

Page 15: ... with its handling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating danger are drowned Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB A Environmental protection and disposal Dispose of used fluids lubricants and filters in accordance with local regulations Within the EU batteries can be returned free of...

Page 16: ...test in accordance with the specifications Painting Observe the relevant safety data sheet for all materials When carrying out painting work outside the spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely af fected There must be no naked flames in the vicinity No smoking Observe fire prevention regulatio...

Page 17: ...an 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 even small quantities of hy drogen sulfide or ammonium may be lethal Caution Danger of suffocation Due to the lack of oxygen the absorption of methane can occasionally lead to increased breathing fr...

Page 18: ...emedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This manual with all safety instructions and safety notices must be issued to all personnel involved in operation maintenance repair or transportation 2 The higher level warning notice is used if several ...

Page 19: ...eight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking de vice for the crankshaft Prior to transporting the engine genset system it is imperative to install the transport locks for the engine mounts Secure the engine genset system such as to preclude tipping during transport Secure the engine system genset as to preclude slipping and t...

Page 20: ...r 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 Starter 12 Flywheel KS Driving end 20 Product Summary MS150121 00E 2015 07 TIM ID 0000062772 001 ...

Page 21: ...3 Connection engine cool ant inlet 14 Engine oil heat exchanger 15 Connection engine cool ant outlet KGS Free end Engine model designation Key to engine model designation16V4000L32FNER 16 Number of cylinders V Cylinder arrangement V engine 4000 Series L Application L Gas engine 3 Load profile 2 Design index F Additional feature F 50 Hertz N Natural Gas ER Epsilon reduced Table 2 Engine model desig...

Page 22: ... 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 letter Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also starts wit...

Page 23: ...significant Item Dimensions Length A approx 3372 mm Width B approx 1789 mm Height C approx 2156 mm Crankshaft center to oil pan D approx 636 mm Crankshaft center to engine mount E approx 280 5 mm Table 3 Main engine dimensions MS150121 00E 2015 07 Product Summary 23 TIM ID 0000062773 001 ...

Page 24: ...2 4 Firing order Firing order Number of cylinders Firing order 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 24 Product Summary MS150121 00E 2015 07 TIM ID 0000062774 001 ...

Page 25: ...ble 4 Reference conditions Power related data power ratings are net brake power to ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 1600 Mean effective pressure pme continuous power ISO 3046 bar 16 8 Table 5 Power related data power ratings are net brake power to ISO 3046 General conditions for max power Number of cylind...

Page 26: ...uit referenced to max power without HT heat extraction Number of cylinders 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 Coolant temperature at engine connection inlet from cooling equipment w o antifreeze A C 78 Coolant temperature after engine alarm R C 95 Coolant temperature after engine shutdown L C 98 Coolant temperature to enable load applicati...

Page 27: ... after oil heat exchanger to R C 90 Lube oil operating temperature after oil heat exchanger warning R C 93 Lube oil operating temperature after oil heat exchanger engine shutdown L C 97 Lube oil pressure after oil filter bar 5 5 Lube oil pressure after oil filter warning bar 4 5 Lube oil pressure after oil filter shutdown L bar 4 Table 11 Lube oil system referenced to max power without HT heat ext...

Page 28: ... engine side without cooling equipment R Liters 270 Mixture coolant engine side without cooling system R Liters 22 Total engine oil capacity for initial filling standard oil system R Liters See techni cal data sheet Oil change capacity max standard oil system R Liters See techni cal data sheet Table 15 Capacities Weights main dimensions Number of cylinders 16 Dry engine weight basic configuration ...

Page 29: ...oise unsilenced DL sound power level LW ISO 6798 R dB A 119 Genset surface noise with attenuated intake noise filter DL sound power level LW ISO 8528 10 R dB A 122 Table 18 Acoustics MS150121 00E 2015 07 Product Summary 29 TIM ID 0000062775 001 ...

Page 30: ...tings are net brake power to ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 1760 Mean effective pressure pme continuous power ISO 3046 bar 18 5 Table 20 Power related data power ratings are net brake power to ISO 3046 General conditions for max power Number of cylinders 16 Relative air humidity A 60 Intake air temperat...

Page 31: ...perature at engine connection inlet from cooling equipment w o antifreeze A C 78 Coolant temperature after engine alarm R C 95 Coolant temperature after engine shutdown L C 98 Coolant temperature to enable load application min L C 40 Coolant antifreeze content max L 50 Coolant pump Volumetric flow L m h 80 Filling pressure in cooling system cold R bar 0 5 Pressure in cooling system max L bar 6 0 P...

Page 32: ... oil filter bar 5 5 Lube oil pressure after oil filter warning bar 4 5 Lube oil pressure after oil filter shutdown L bar 4 0 Table 26 Lube oil system referenced to max power without HT heat extraction Fuel system Number of cylinders 16 Gas temperature before engine min L C See MTU Fluids and Lubricants Specifica tions Gas temperature before engine max L C See MTU Fluids and Lubricants Specifica ti...

Page 33: ...hout cooling system R Liters 22 Total engine oil capacity for initial filling standard oil system R Liters See techni cal data sheet Oil change capacity max standard oil system R Liters See techni cal data sheet Table 30 Capacities Weights main dimensions Number of cylinders 16 Dry engine weight basic configuration engine R kg 8000 Heaviest component to be lifted during extended component maintena...

Page 34: ...oise unsilenced DL sound power level LW ISO 6798 R dB A 119 Genset surface noise with attenuated intake noise filter DL sound power level LW ISO 8528 10 R dB A 122 Table 33 Acoustics 34 Product Summary MS150121 00E 2015 07 TIM ID 0000062776 001 ...

Page 35: ...ontrol 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 compre...

Page 36: ...layed for the cylinder concerned The power is reduced if this does not lead to improvement Gas control valve TecJet52 Controls the required amount of gas Mixture throttles P Series Mixture throttles in the mixture lines which are controlled by the Engine Control Unit 36 Product Summary MS150121 00E 2015 07 TIM ID 0000043155 002 ...

Page 37: ...ics 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 Initiation of power reduction engine stop or emergency engine stop configurable Diagnostic function via CAN interface Default CAN1 connection for dialog unit provided Software structure One data record for ...

Page 38: ...toring Unit EMU 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 38 Product Summary MS150121 00E 2015 07 TIM ID 0000040818 002 ...

Page 39: ...load Recommended maximum run time at this load Recommended minimum run time in subsequent operation at load 50 0 to 30 30 minutes 120 minutes 30 to 50 120 minutes 120 minutes 50 to 100 No restriction No restriction Table 34 Runtimes at partial load A minimum operating time of 2 hours per start is recommended to counteract increased engine loading resulting from temperature changes cold start to en...

Page 40: ... 133 Valve gear Standstill 6 months Lubricate valve gear Page 151 Lube oil system Check engine oil level Page 157 Check oil level in oil storage tank Page 157 Coolant circuit Standstill 1 year Change engine coolant Page 162 Change mixture coolant Page 168 Coolant circuit Check engine coolant level Page 161 Check mixture coolant level Page 167 Engine cabling Check plug connections Page 171 Gas supp...

Page 41: ...d starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 157 Coolant circuit Check engine coolant level Page 161 Check mixture coolant level Page 167 Engine management system Check for fault messages MS150121 00E 2015 07 Operation 41 TIM ID 0000010660 002 ...

Page 42: ...on 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 when a start command is activated with the engine at standstill 1 Setting start counter 2 Priming optional 3 Checking gas supply solenoid valves for leaks 4 Activating starter 5 Waiting for starting s...

Page 43: ...owing 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 running down to standstill 7 Resetting start counter 8 Awaiting start request Oil refill sequence 1 Waiting for engine running 2 Engine running for a minimum programmed time period 3 Oil refilling enable...

Page 44: ...G 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 opening time of 15 seconds respectively After a max of 5 unsuccessful start attempts the fuel supply must be locked Before at tempting to start the engine again allow time for sufficient inertization of...

Page 45: ...ne room for smell of gas Page 134 ECU Check for fault messages if fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Operation log if available Document operating parameters This is especially useful for fault localization and fast remedial action Engine under load engine at rated speed Visually inspect engine plant ...

Page 46: ... 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 leaking exhaust pipework immediately Emission values Check 1 Insert exhaust probe 1 in the exhaust gas flow of the exhaust pipe bellows 3 at tur bocharger 4 2 Carry out measurement ans read off meas ured value for N...

Page 47: ...and mechanical stresses Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Shutting down engine u Shut down engine in accordance with stopping sequence specifications Page 42 MS150121 00E 2015 07 Operation 47 TIM ID 0000042720 001 ...

Page 48: ...in emergency situations Emergency engine shutdown Item Action Gas shut off solenoids Two contacts are provided for electrical connection Close gas shut off sole noids Engine is stopped Ignition ignition system In the case of an external EMERGENCY STOP the ignition remains on until the engine has run down to a standstill in order to safely burn off uncombust ed fuel air mixture The ignition is only...

Page 49: ...again following an emergency engine stop Suitable exhaust gas ventilation equipment must be provided in the facility to ensure that the exhaust gas system downstream of the engine is safely purged A contact is provided to request the ventilation system in the scavenging phase Note Gas train The gas control system must be equipped with an SAV safety shut off valve when using gas control systems wit...

Page 50: ...ngine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC 50 Operation MS150121 00E 2015 07 TIM ID 0000002329 003 ...

Page 51: ...s 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 seal the en gine s air and exhaust sides If the engine is to remain out of service for more than 1 month carry out preservation MTU Preservation and Represerva tion Specifications A001070 The corrosi...

Page 52: ...ylinder heads after component mainte nance 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 operating hours is not necessary Qualifi cation Interval Item Maintenance tasks Task h a QL1 Valve gear Check valve clearance Page 149 Table 38 50 hours check 52 Maintenance MS150121 00E 2015 07 TIM ID...

Page 53: ... W1005 Replace air filter Page 155 W1008 Replace engine oil filter when changing engine oil or when the time limit years is reached at the latest Page 160 W1046 Replace filter or filter element Page 135 W1089 Check gas lines for leaks repair if required Page 154 W1091 Check ignition timing adjust as necessary Page 145 W1341 Check emission values adjust if necessary Page 46 W1382 X Replace coolant ...

Page 54: ...imit 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 keys AKR Anti Knock Control GET Important information about fault messages from the engine governor engine monitoring Fault messages from the engine governor are represented in the fault code list Page...

Page 55: ...the 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 MS150121 00E 2015 07 Troubleshooting 55 TIM ID 0000027852 002 ...

Page 56: ...ion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emissi...

Page 57: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112307 HI T Exhaust A7 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emis...

Page 58: ...action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112312 HI T Exhaust B2 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emi...

Page 59: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112317 HI T Exhaust B7 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emis...

Page 60: ...use Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112402 LO T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check...

Page 61: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112407 LO T Exhaust A7 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug...

Page 62: ...tive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112412 LO T Exhaust B2 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plu...

Page 63: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112417 LO T Exhaust B7 Yellow alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug...

Page 64: ...ividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112502 HIHI T Exhaust A2 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission value...

Page 65: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112507 HIHI T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emiss...

Page 66: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112512 HIHI T Exhaust B2 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emiss...

Page 67: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112517 HIHI T Exhaust B7 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emiss...

Page 68: ...se Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112602 LOLO T Exhaust A2 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check s...

Page 69: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112607 LOLO T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug ...

Page 70: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112612 LOLO T Exhaust B2 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug ...

Page 71: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 145 4 Check valve drive 112617 LOLO T Exhaust B7 Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug ...

Page 72: ...sion values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112702 HIHI T Exhaust A2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112703 HIHI T Exhaust A3 abs Red alarm Initiated by EMU Ca...

Page 73: ...ition timing Page 145 3 Check valve drive exhaust valves do not close 112708 HIHI T Exhaust A8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112709 HIHI T Exhaust A9 abs Red alarm Initiated by EMU Cause Corrective action I...

Page 74: ...ition timing Page 145 3 Check valve drive exhaust valves do not close 112714 HIHI T Exhaust B4 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112715 HIHI T Exhaust B5 abs Red alarm Initiated by EMU Cause Corrective action I...

Page 75: ...as temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 145 3 Check valve drive exhaust valves do not close 1...

Page 76: ...rective action Transmission combined alarm At least one further transmission alarm is present u Rectify cause of alarm 1 4510 187 Combined Error Red alarm Initiated by antiknock control Cause Corrective action Combined alarm for details refer to the source alarm u Combined alarm for details refer to the source alarm 1 4510 188 Internal Error Red alarm Initiated by antiknock control Cause Correctiv...

Page 77: ... cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 195 Knock Sensor Error A4 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 196 Knock Sensor Error A5 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knoc...

Page 78: ... cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 201 Knock Sensor Error A10 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 202 Knock Sensor Error B1 Red alarm Initiated by antiknock control Cause Corrective action No signal from this kno...

Page 79: ... cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 207 Knock Sensor Error B6 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 208 Knock Sensor Error B7 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knoc...

Page 80: ...tance and cabling replace if necessary 1 4520 233 Error Missing Reset Signal Red alarm Initiated by IC922 Cause Corrective action Reset signal missing u Check sensor sensor distance and cabling replace if necessary 1 4520 234 Error Missing Camshaft Signal Red alarm Initiated by IC922 Cause Corrective action No camshaft signal u Check sensor sensor distance and cabling replace if necessary 1 4520 2...

Page 81: ...22 Cause Corrective action No global ignition timing and power level received CAN bus connection is faulty u Check cabling and setting 1 4520 241 Individual Timing out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified individual ignition timing is beyond the valid range u Adjust value 1 4520 242 Selftest Shutdown Yellow alarm Initiated by IC922 Cause Corrective action Self...

Page 82: ...ary Channel 4 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 249 Open Primary Channel 5 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 250 Open Primary Channel 6 Yellow alarm Initiated b...

Page 83: ...y Channel 11 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 256 Open Primary Channel 12 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 257 Open Primary Channel 13 Yellow alarm Initiated ...

Page 84: ...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 264 Open Primary Channel 19 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 265 Open Primary Channel 20 Yellow alarm Initiated by IC922 Ca...

Page 85: ...ardware not ready for operation u Restart ignition 1 4520 274 SCR Fault Even Red alarm Initiated by IC922 Cause Corrective action Hardware not ready for operation u Restart ignition 1 4520 275 Odd Energy Level out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified energy level is beyond the valid range u Adjust value 1 4520 276 Even Energy Level out of Range Yellow alarm In...

Page 86: ...correct u Check setting 1 4530 011 PWM Input Low Duty Cycle Error Yellow alarm Initiated by F Series Cause Corrective action F Series setting is not correct u Check setting 1 4530 012 Analog Input High Error Yellow alarm Initiated by F Series Cause Corrective action F Series setting is not correct u Check setting 1 4530 013 Analog Input Low Error Yellow alarm Initiated by F Series Cause Corrective...

Page 87: ...ation u Restart F Series 1 4530 018 Position Error Red alarm Initiated by F Series Cause Corrective action Position demand and feedback do not match 1 Check mechanical system 2 Restart F Series 1 4530 019 Run Enable not active Yellow alarm Initiated by F Series Cause Corrective action F Series setting is not correct u Check setting 1 4530 020 Spring Check Failed Yellow alarm Initiated by F Series ...

Page 88: ...rm Initiated by TecJet Cause Corrective action No gas flow detected 1 Check inlet and outlet 2 Check gas pressure gas quality gas filter 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 4540 013 High Elec Temp Red alarm Initiated by TecJet Cause Correctiv...

Page 89: ... 018 Coil Current Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 019 Position 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 action Hardware not ready for operation u Restart TecJet ...

Page 90: ...ady for operation u Restart TecJet 1 4540 025 Position Fail Low Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 026 Analog Input Low Error Red alarm Initiated by TecJet Cause 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 se...

Page 91: ...GP Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Configured limit value was not attained u Check position direction of TecJet 1 4540 033 Battery Volt High Error Red alarm Initiated by TecJet Cause 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 Correct...

Page 92: ...ecJet Shutdown Red alarm Initiated by TecJet Cause Corrective action TecJet combined alarm At least one further TecJet alarm is present u Rectify cause of alarm 1 4540 041 TecJet Internal Fault Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 042 Keyswitch State Red alarm Initiated by TecJet Cause Corrective action Keyswitch cabling mis...

Page 93: ...start TecJet 1 4540 047 Reading Parameters Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 048 SPI ADC Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 049 Sense 5V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart T...

Page 94: ...bling 1 4540 054 Exception Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 055 Factory CAL Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 056 PWM Duty Cycle High Error Red alarm Initiated by TecJet Cause Corrective action TecJet setting is not correct u Check s...

Page 95: ...m Initiated by ProAct A Bank Cause Corrective action Hardware not ready for operation u Restart ProAct 1 4550 036 A Temperature derating active Yellow alarm Initiated by ProAct A Bank Cause Corrective action The internal temperature is higher than the limit 1 Check room temperature Restart ProAct 2 Restart ProAct 1 4550 037 A Temperature above 120 C Red alarm Initiated by ProAct A Bank Cause Corre...

Page 96: ...N Position Demand Failed Red alarm Initiated by ProAct A Bank Cause Corrective action Position demand not received or received too late u Check cabling and setting 1 4550 043 A CAN Fault CAN Bus Off CAN Ad Red alarm Initiated by ProAct A Bank Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 044 A CAN Stop Command Yellow alarm Initiated by ProAct A Bank Cause Cor...

Page 97: ...rm Initiated by ProAct B Bank Cause Corrective action Hardware not ready for operation u Restart ProAct 1 4550 136 B Temperature derating active Yellow alarm Initiated by ProAct B Bank Cause Corrective action The internal temperature is higher than the limit 1 Check room temperature Restart ProAct 2 Restart ProAct 1 4550 137 B Temperature above 120 C Red alarm Initiated by ProAct B Bank Cause Corr...

Page 98: ...e action ProAct setting is not correct u Check setting 1 4550 142 B CAN Position Demand Failed Red alarm Initiated by ProAct B Bank Cause Corrective action Position demand 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 B Bank Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 14...

Page 99: ...il system oil heat exchanger 2 Replace oil filter Page 160 3 Take oil sample and analyze Page 159 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas temperature A side after turbine too high limit value 1 Incorrect ignition timing mixture too lean or too rich damage to turbine 1 Check exhaust turbocharger 2 Check ignition timing Page 145 3 Check mix...

Page 100: ...charger 2 Check ignition timing Page 145 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 filter too high limit value 1 1 Replace oil filter Page 160 2 If this fault message occurs again after unexpectedly short filter runtime check oil filter for deposits change oil if required Page 158 02...

Page 101: ...ine 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 input 036 HI ETC2 Overspeed Yellow alarm Associated parameter 2 3013 931 Cause Corrective action Speed of 1st secondary turbocharger too high limit value 1 u Turbocharger speed sensor is not fitted ...

Page 102: ...o high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 157 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Corrective action Intake air temperature too high limit value 1 u Check ventilation system 054 HIHI T Intake Air Yellow alarm Associated parameter 2 0123 932 Cause Corrective action Intake air temperature too...

Page 103: ...Check oil separator condition replace as necessary Page 135 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restrictor valve in crankcase breather is closed too far air filter is defective oil separator is clogged piston rings are seized other damage to crank drive 1 Check crank drive Bar engine Page 133...

Page 104: ...lly open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 155 Check exhaust back pressure Check differential pressure over mixture cooler Check emissions and injection timing Page 145 Check oil separator efficiency oil in compressor intake elbow clean compressor as necessary Check valve clearance Page 149 Che...

Page 105: ...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 coolant pressure 3 Check heating elements 4 Check cabling 095 AL Prelubrication Fault Red alarm Start terminated Associated parameter 2 1090 920 Cause Corrective action Oil priming fault 1 Check oil pr...

Page 106: ... 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 cabling 122 HI T ECU Yellow alarm Associated parameter 2 0132 921 Cause Corrective action Electronics temperature too high limit value 1 u Provide improved cooling for ECU Reduce room temperature che...

Page 107: ...AN 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 Red alarm Associated parameter 2 0500 684 Cause Corrective action A programming error occurred when attempting to copy a received PU data module into the Flash module u Contact Service configuration f...

Page 108: ... 0500 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 stations and cabling 190 AL EMU Parameter Not Supported Red alarm Associated parameter 2 0500 690 Cause Corrective action EMU parameters are not supported u Contact Service configuration fault 201 SD T Coolant Red a...

Page 109: ...ause 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 SD P Lube Oil Red alarm Engine shutdown Associated parameter 1 8004 563 Cause Corrective action Engine oil pressure sensor after filter defective short circuit or wire break u Check sensor and cabling...

Page 110: ...rective 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 Oil Red alarm Associated parameter 1 8004 585 Cause Corrective action Engine oil pressure sensors defective short circuit or wire break u Check sensor and cabling before filter B5 3 and after filter B...

Page 111: ...as 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 circuit or wire break u Turbocharger speed sensor is not fitted at present 233 SD ETC Speed 2 Yellow alarm Associated parameter 1 3011 129 Cause Corrective action Speed sensor of secondary turbocharger ...

Page 112: ...2 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 parameter 2 8006 640 Cause Corrective action Short circuit or wire break at transistor output plant side 3 TOP 3 Activation of gas supply solenoid valve No 1 faulty u Check cabling 384 AL Wiring TOP 4...

Page 113: ...ssociated 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 alarm Engine shutdown Associated parameter 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 b...

Page 114: ...rameter 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 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 high limit va...

Page 115: ...ixture 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 volumetric flow too low cooling system 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 para...

Page 116: ...3 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 short circuit or wire break u Check sensor and cabling replace as necessary Fault is rectified following engine restart 472 AL Stop SD Red alarm Engine shutdown Associated parameter 2 8006 593 Cause Co...

Page 117: ...it 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 Corrective action Mixture pressure sensor on B side defective short circuit or wire break u Check sensor and cabling B79 22 replace as necessary Fault is rectified following engine restart 498 SD P ...

Page 118: ...r 2 0182 932 Cause Corrective action Mixture pressure on B side too high limit value 2 1 Check emissions 2 Check ignition timing Page 145 3 Check exhaust back pressure 4 Check valve clearance Page 149 5 Check throttle 6 Check mixture coolant system 513 SD P Coolant Diff Red alarm Associated parameter 1 8004 610 Cause Corrective action Coolant differential pressure sensor defective short circuit or...

Page 119: ...ted 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 rectified following engine restart 536 AL Wiring PWM_CM1 Red alarm Associated parameter 1 1041 921 Cause Corrective action Cable break or short circuit on channel PWM_CM1 u Check ignition cabling 552 ...

Page 120: ...pply 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 1090 126 Cause Corrective action Speed drop Alarm is activated if engine speed drops during starting sequence u Check gas train 559 AL mixture throttle A fault Red alarm Engine shutdown Associated p...

Page 121: ...s over air filter on A side is too high u Replace air filter Page 155 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure loss over air filter on A side is too high u Replace air filter Page 155 567 AL L1 P Intake Air after Filter B Yellow alarm Associated parameter 2 0187 921 Cause Corrective action Pressure loss over air filter on B...

Page 122: ... emissions 2 Check ignition timing Page 145 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 932 Cause Corrective action The cylinder set to maximum retarded timing due to knocking has violated the second limit value Power reduction is initiated 1 Check emissions 2 Check ignition tim...

Page 123: ...bling 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 value u Check gas quality if feasible 618 LOLO Current Heat Value of Fuel Yellow alarm Associated parameter 2 1210 007 Cause Corrective action Fuel calorific value has undershot the second limit value ...

Page 124: ...d 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 Value Yellow alarm Associated parameter 2 3050 026 Cause Corrective action NOx emissions have exceeded the first limit value 1 Check gas quality if feasible 2 Check NOx sensor 3 Check emissions 624 HI...

Page 125: ...Cause Corrective action Engine power sensor defect analog input 2 1 Generator eff power not correctly transmitted 2 Generator eff power can also be transmitted via CAN bus as an option 3 Check configuration of plant control system 646 Al Knock Intensity Red alarm Associated parameter 2 1200 934 Cause Corrective action Knock intensity exceeded extreme knocking detected 1 Check gas quality if feasib...

Page 126: ...on for knock control faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU knock control 4 Check settings with device specific dialog software XD10 653 AL IC92x Comm Lost Red alarm Associated parameter 1 4520 996 Cause Corrective action CAN bus communication for ignition system faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU knock control 4 Check set...

Page 127: ...alog software XD50 1 657 AL ProActB Comm Lost Red alarm Associated parameter 1 4550 196 Cause Corrective action CAN bus communication for throttle B faulty 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU throttle B 4 Check settings with device specific dialog software XD50 2 658 AL NOxA Comm Lost Red alarm Associated parameter 1 4560 096 Cause Corrective action CAN bus communic...

Page 128: ...ellow alarm Associated parameter 1 4520 993 Cause Corrective action An internal combined alarm in the ignition system was detected u An exact fault designation is transmitted via CAN bus to the genset control system 667 AL FSeries Yellow Yellow alarm Associated parameter 1 4530 993 Cause Corrective action An internal combined alarm in the bypass flap was detected u An exact fault designation is tr...

Page 129: ...ault designation is transmitted via CAN bus to the genset control system 672 AL NOxB Yellow Yellow alarm Associated parameter 1 4560 193 Cause Corrective action An internal combined alarm at NOx sensor B was detected u An exact fault designation is transmitted via CAN bus to the genset control system 675 AL GET Red Red alarm Associated parameter 1 4510 991 Cause Corrective action An internal combi...

Page 130: ...act 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 combined alarm in throttle B was detected u An exact fault designation is transmitted via CAN bus to the genset control system 681 AL NOxA Red Red alarm Associated parameter 1 4560 091 Cause Corrective action An internal comb...

Page 131: ...l Yellow alarm Associated parameter 1 1480 301 Cause Corrective action No oil replenishment within a programmable time u Check oil replenishment system 689 HI Oil Refill Yellow alarm Associated parameter 1 1480 303 Cause Corrective action Engine oil was refilled too often within a certain time interval u Check engine oil level Page 157 Check oil supply 691 HI Lube Oil Level Refill Yellow alarm Ass...

Page 132: ...n Limit value 2 exceeded u Check gas supply 842 AL Fuel Throttle Pos L1 Yellow alarm Associated parameter 2 8006 038 Cause Corrective action TecJet throttle position has exceeded limit value 1 u Check gas supply 848 AL Rel Humidity L1 Yellow alarm Associated parameter 2 8006 039 Cause Corrective action Calculated air humidity has exceeded limit value 1 u Check air humidity 891 AL Scavenging Active...

Page 133: ...body 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 barring gear 2 in ring gear 3 and install on flywheel housing 3 Apply ratchet 1 to barring gear 2 4 Rotate crankshaft in direction of engine ro tation Apart from compression resistance there should be no...

Page 134: ... smoke Checking machine room for smell of gas 1 Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit 2 If smell of gas is detected or the gas detection and alarm unit is triggered Avoid naked flames Avoid sparks Do not use electrical appliances including switches connectors sockets telephone bell Do not smoke Close main gas shut off device Open window...

Page 135: ...oil 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 WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Oil separator Filter replace ment 1 Release clamp 2 on...

Page 136: ...lescence filter 5 must be installed in the correct position in the housing 10 Place coalescence filter 5 in housing en suring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12 Screw on washer 2 with new locknut 1 and tighten to specified tightening torque with torque wrench Name Size Type Lubricant Value Standard Locknut Tightening torque 15 Nm 13 Fit housing cover 1 14 F...

Page 137: ...ment Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 138 2 Install new spark plug Page 139 MS150121 00E 2015 07 Task Description 137 TIM ID 0000004224 002 ...

Page 138: ...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 rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Removing spark plug 1 Remove spark plug connector 1 Page 142 2 Unscrew spark plug a few turn...

Page 139: ...C 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 and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Installing spark plug 1 Clean and dry the mating surfaces ...

Page 140: ... 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 Nm 7 Install spark plug connector 1 Page 143 140 Task Description MS150121 00E 2015 07 TIM ID 0000043425 004 ...

Page 141: ...rial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 142 2 Install spark plug connector Page 143 MS150121 00E 2015 07 Task Description 141 TIM ID 0000035897 004 ...

Page 142: ...aring 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 cov er 7 turning them back approx one revo lution 2 Turn flange 6 counterclockwise out of un ion 4 3 Pull protective cap 2 up and back to gain access to threaded connection of the igni tion lead underneath 4 L...

Page 143: ...e s low er sealing ring and replace with a new seal ing ring 2 Remove any dust and impurities from the ignition line connector s Teflon body on the outside and inside on the spark plug side 3 Check the spark plug isolator sealing ring for damage If damaged install a new spark plug isolator sealing ring Page 144 4 Insert the ignition line connector 5 into the spark plug duct press down the igni tio...

Page 144: ... pull out sealing ring 2 3 Fold together new sealing ring 2 4 Insert sealing ring 2 into the bore in Tef lon sleeve 1 with the article number fac ing downwards 5 Carefully press sealing ring 1 into the groove until it is flush with the bore in Tef lon sleeve 2 144 Task Description MS150121 00E 2015 07 TIM ID 0000043226 006 ...

Page 145: ...NING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note The service tool Diasys and a dongle with access rights 1A or higher is required to determine the ignition setpoint 1 Stop engine Page 47 2 Install stroboscope clamp on cylinder A1 ignition cable 3 Start engine Page 44 4 Using the stroboscope check ign...

Page 146: ... Qty Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 138 2 Remove cylinder head covers Page 152 3 Remove sleeves arrow 4 Install barring device Page 133 5 Rotate crankshaft with barring device in en gine direction of rotation until marking OT and pointer are aligned 146 Task Description MS150121 00E 2015 07 TIM ID 0000043220 002 ...

Page 147: ... 3 Release 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 specified value for a new cylinder head 93 8 mm Admissible wear 3 mm If the measured value is 96 8 mm re place the relevant cylinder head ahead of schedule 5 Install valve bridge 6 Adjust valve clearan...

Page 148: ...3 Install sleeves arrow 4 Install cylinder head covers Page 153 5 Install spark plugs with new sealing rings Page 139 148 Task Description MS150121 00E 2015 07 TIM ID 0000043220 002 ...

Page 149: ... 133 3 Rotate crankshaft with barring device in en gine direction of rotation until marking OT and pointer are aligned Diagram for 16V engines two crankshaft positions Position Cylinder 1 2 3 4 5 6 7 8 9 10 16V Firing TDC in cylinder A1 Bank A I X X I X I I I X Bank B I I X X I X X Overlap TDC in cylinder A1 Bank A I X I X X I X Bank B X X I X I I X I I I Inlet Valve clearance adjustment of inlet ...

Page 150: ...the specified value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release locknut 1 2 Insert feeler gauge 3 between valve bridge and rocker arm 3 Using angular screw driver set adjusting screw 2 so that the specified valve clear ance is provided 4 Feeler gauge 3 must just pass through the gap 5 Tighten locknut 1 with torque wrench to the specified tightening torque holding the ...

Page 151: ...ols Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 152 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install cylinder head covers Page 153 MS150121 00E 2015 07 Task Description 151 TIM ID 0000043352 001 ...

Page 152: ...g disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 142 3 Remove screws 2 4 Remove cylinder head cover with gasket from cylinder head 152 Task Description MS150121 00E 2015 07 TIM ID 0000042136 002 ...

Page 153: ...mponents 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 head 4 Insert screws 2 in cylinder head cover and tighten them Note The locking plate must be removed from the cylinder head cover 5 Install spark plug connector Page 143 MS150121 00E 2015 07 Task Descrip...

Page 154: ...rt 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 thermal gloves Avoid unprotected contact with hot surfaces Gas supply Checking gas lines for leaks 1 Coat all connections of the gas supply line with soap solution or spray with leakage detection spray fr...

Page 155: ...ilter made of fleece option Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the corresponding fault message appears Replacing air filter 1 Remove air filter Page 156 2 Install new air filter Page 156 MS150121 00E 2015 07 Task Description 155 TIM ID 0000013394 002 ...

Page 156: ...talla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from connecting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air filter 3 with clamp 2 onto intake housing 1 5 Tighten clamp 2 156 Task Description MS150121 00E 2015 07 TIM ID 0000044568 002 ...

Page 157: ...o 2 cm The cause of this may be that oil e g from the oil filter and oil heat exchanger flows back into the oil pan 3 The oil level must reach the mark 2 or ex ceed the mark 1 by up to 2 cm Note Topping up oil manually is not required The oil level check is only intended to confirm that the automatic oil replenishment fea ture works properly 4 Insert oil dipstick into guide tube up to the stop Oil...

Page 158: ...r 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 shutoff valve s in extraction line from engine and waste oil tank 2 Extract all oil from oil pan using the electric pump 3 Close shutoff valve s Filling with new engine oil 1 Determine engine oil change volume for 100 kW cyl...

Page 159: ...ask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine oil Sample extraction 1 Connect sampling hose genset manufac turer s scope of delivery t...

Page 160: ...ves 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 sources Do not smoke Replacing engine oil filter 1 Unscrew oil filter with oil filter wrench 2 Clean the sealing face on the adapter 3 Check condition of the new sealing ring and coat it with oil 4 Sc...

Page 161: ...NG Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Checking engine coolant level 1 Read off system filling pressure for 100 kW cylinder Page 25 or for 110 kW cylinder Page 30 at pressure gauge 2 If required top up with treated engine coolant Page 165 MS150121 00E 2015 07 Task Description 161 TIM ID 00000...

Page 162: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 163 2 Fill with engine coolant Page 165 162 Task Description MS150121 00E 2015 07 TIM ID 0000000036 031 ...

Page 163: ...e Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch off preheater if installed Engine coolant Draining 1 Open drain valves and drain coolant at the following points At the crankcase free end left and right side MS150121 00E 2015 07 Task Description 163 ...

Page 164: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 164 Task Description MS150121 00E 2015 07 TIM ID 0000006751 002 ...

Page 165: ...oves 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 engine coolant 1 Fill prepared coolant with pressure pump until system filling pressure for 100 kW cylinder Page 25 or for 110 kW cylinder Page 30 has been reached 2 Vent engine coolant circuit at vent line 3 Start the ...

Page 166: ... 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 163 2 Release union nuts 1 and 3 3 Remove coolant vent line 2 4 Install new coolant vent line 2 5 Fill with engine coolant Page 165 166 Task Description MS150121 00E 2015 07 TIM ID 0000029143 003 ...

Page 167: ...is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Checking mixture coolant level 1 Read off system filling pressure for 100 kW cylinder Page 25 or for 110 kW cylinder Page 30 at pressure gauge 2 If required top up with treated engine coolant Page 170 MS150121 00E 2015 07 Task Description 167 TIM ID 0000063516 001 ...

Page 168: ...al tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 169 2 Fill with fresh mixture coolant Page 170 168 Task Description MS150121 00E 2015 07 TIM ID 0000007027 004 ...

Page 169: ... 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 drain point in coolant line to mixture coolant cooler and drain coolant MS150121 00E 2015 07 Task Description 169 TIM ID 0000042774 001 ...

Page 170: ... 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 engine coolant 1 Fill prepared coolant with pressure pump until system filling pressure for 100 kW cylinder Page 25 or for 110 kW cylinder Page 30 has been reached 2 Vent mixture coolant circuit via plant 3 Start the...

Page 171: ... closed and 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 housings Contacts Plug connectors Cables and terminals Plug in contacts Result If cable conductors are damaged contact Service Note Close connectors that are not plugged in with the protect...

Page 172: ... pressure after filter 3 B16 1 Coolant pressure after engine 4 B4 X Exhaust temperature downstream of cylinder 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 41 Sensors B side The knocking sensors B80 XX are arranged on the crankcase right and left below the cylinder heads 172 Task Description MS150121 00E 2015 07 TIM ID 0000043933 004 ...

Page 173: ...n oxide NOx concentration in the exhaust gas 2 B79 23 Mixture pressure before throttle 3 B75 Crankshaft speed reset ignition system 4 B13 3 Crankshaft speed ignition Table 42 Sensors on engine driving end MS150121 00E 2015 07 Task Description 173 TIM ID 0000043933 004 ...

Page 174: ...d optional 2 B79 21 Mixture pressure A side 3 B50 Crankcase pressure 4 B5 3 Engine oil pressure before filter 5 B7 Engine oil temperature 6 B5 1 Engine oil pressure after filter Table 43 Sensors A side 174 Task Description MS150121 00E 2015 07 TIM ID 0000043933 004 ...

Page 175: ...charger 3 B6 3 Coolant temperature before engine 4 B1 2 Camshaft speed for ignition system 5 B1 3 Camshaft speed for antiknock control 6 B1 1 Camshaft speed for engine governor 7 B24 Lube oil level 8 B16 3 Coolant pressure before engine Table 44 Sensors on engine free end MS150121 00E 2015 07 Task Description 175 TIM ID 0000043933 004 ...

Page 176: ...e clothing 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 scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal glov...

Page 177: ...ing general information Arrangement and position of sensor Page 172 2 Unfasten electrical connector 2 and re move 3 Unscrew electronics box 1 at the eyelets 4 Remove sensor via nut 3 MS150121 00E 2015 07 Task Description 177 TIM ID 0000054588 003 ...

Page 178: ...re assembly Note Do not wipe off the thread grease from the manufacturer If necessary coat thread with high temperature anti corrosion thread grease Too much grease can con taminate the sensor during operation Dis assemble and assemble sensor a maximum of two times 2 Manually screw sensor into bore 3 Tighten nut 3 with torque wrench to specified tightening torque Name Size Type Lubricant Value Sta...

Page 179: ...aximum 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 international cod ing for the power specification of combustion engines ISO International Organization for Standardi zation International umbrella organization for all na tional standardization institutes KG...

Page 180: ...motive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische Anleitung zur Reinhaltung der Luft General administrative instruction for federal emission control law in Germany TD Transmitter Deviation Alarm Sensor comparison fault UT Bottom Dead Center WZK Too...

Page 181: ...r during 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 http www mtuonsiteenergy com haendlersuche index de html Your contact at Headquarters support oeg mtu online com Spare Parts Service Quick easy and correct identification of the spare part require...

Page 182: ...ear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 133 Feeler gauge Part No Y20098771 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 149 Gas detection and alarm unit not stocked by MTU Part No Qty Used in 6 1 2 Machine room Check for smell of gas Page 134 182 Appendix B MS150121 00E 2015 07 DCL ID 0000038659 001 ...

Page 183: ...ty Used in 1 6 8 1 Engine oil filter Replacement Page 160 Ratchet adapter Part No F30027340 Qty Used in 1 6 11 3 Sensors Removal Page 176 Qty Used in 1 6 11 4 Sensor Installation Page 178 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Engine Barring manually Page 133 MS150121 00E 2015 07 Appendix B 183 DCL ID 0000038659 001 ...

Page 184: ... 6 4 2 Valve clearance Check and adjustment Page 149 Special wrench 20 8 mm Part No F30452574 Qty Used in 1 6 3 2 Spark plug Removal Page 138 Qty Used in 1 6 3 3 Spark plug Installation Page 139 Stroboscope Not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 145 184 Appendix B MS150121 00E 2015 07 DCL ID 0000038659 001 ...

Page 185: ...Page 139 Qty Used in 1 6 3 6 Spark plug connector Installation Page 143 Qty Used in 1 6 11 4 Sensor Installation Page 178 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 149 MS150121 00E 2015 07 Appendix B 185 DCL ID 0000038659 001 ...

Page 186: ...ta 16V4000 L32FNER Fuel optimized TA Luft 100 kW cylinder 25 Engine data 16V4000L32FNER Fuel optimized TA Luft 110 kW cylinder 30 Engine driving end Definition 22 Engine free end Definition 22 Engine layout 20 Engine oil Change 158 Sample extraction and analysis 159 Engine oil filter Replacement 160 Engine oil level Check 157 Engine sides Designation 22 F Fault messages Engine Control Unit 99 Gens...

Page 187: ...ons 5 Maintenance work 11 Operation 8 Organizational requirements 7 Personnel requirements 7 Repair work 11 Startup 8 Safety requirements Maintenance work special instructions for applica tions with gaseous fuel 14 Operation special instructions for applications with gaseous fuel 10 Repair work special instructions for applications with gaseous fuel 14 Safety notices standards 18 Startup special i...

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MTU 16V4000Lx2x, Operating Instructions Manual

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