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MTU 20 V 4000 Lx4, Operating Instuctions

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MTU 20 V 4000 Lx4 Operating Instuctions Download Page 170

6.4.5 Cylinder head cover ‒ Installation

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Gasket

(→ Spare Parts Catalog)

NOTICE

Contamination of components.

Damage to component!

• Observe manufacturer's instructions.
• Check components 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 160).

170 | Task Description | MS15027/02E 2015-04

TIM-ID: 0000042137 - 002

Summary of Contents for 20 V 4000 Lx4

Page 1: ...Operating Instructions Gas engine 12 V 4000 Lx4 16 V 4000 Lx4 MS15027 02E...

Page 2: ...whether in whole or in part without the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion microfilming and storage or p...

Page 3: ...topping sequences 39 3 5 Engine Start 41 3 6 Operational checks 42 3 7 Emission values Check 43 3 8 Engine Shutdown 44 3 9 Emergency engine shutdown 45 3 10 After stopping the engine Engine remains re...

Page 4: ...t 183 6 10 1 Mixture coolant level Check 183 6 10 2 Mixture coolant Change 184 6 10 3 Mixture coolant Draining 185 6 10 4 Mixture coolant Filling 186 6 11 Wiring General for Engine Gearbox Unit 187 6...

Page 5: ...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...

Page 6: ...tion 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...

Page 7: ...around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Cen...

Page 8: ...truments as well as the monitoring signaling and alarm systems are working properly Safety requirements for operation The operator must be familiar with the controls and displays The operator must be...

Page 9: ...ng 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 a...

Page 10: ...ounts 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 st...

Page 11: ...he 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 v...

Page 12: ...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 function of t...

Page 13: ...that has been trained and authorized for this task Have all work on gas bearing components carried out by authorized specialized companies Shut off the gas supply to the product and activate the emerg...

Page 14: ...lubricants and filters in accordance with local regulations Within the EU batteries can be returned free of charge to the manufacturer where they will be properly recycled Fluids and lubricants auxili...

Page 15: ...e 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 vici...

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

Page 17: ...medial 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...

Page 18: ...ight 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 imp...

Page 19: ...le 3 Mixture cooler 4 Exhaust turbocharger 5 Engine lifting equipment 6 Capacitor ignition system 7 Engine mounting bracket free end 8 Oil pan 9 Engine mounting bracket driving end 10 Flywheel 11 Air...

Page 20: ...ch 12 Connection engine cool ant inlet 13 Engine oil heat exchanger 14 Connection engine cool ant outlet KGS Free end Engine model designation Key to the engine model designation 12 16 V 4000 L64 12 1...

Page 21: ...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 lett...

Page 22: ...1789 mm Height 12 V C Approx 2146 mm Height 16 V C Approx 2171 mm Crankshaft center to oil pan 12 V D Approx 636 mm Crankshaft center to oil pan 16 V D Approx 636 mm Crankshaft center to engine mount...

Page 23: ...g order Firing order Number of cylinders Firing order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 MS15027 02E 2015 04 Product Summary 23 TIM ID 000000...

Page 24: ...tions Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046...

Page 25: ...4 1 Standard housing connecting flange engine main PTO SAE 00 00 Table 8 Model related data basic design Coolant system HT circuit Number of cylinders 12 16 Coolant temperature at engine connection ou...

Page 26: ...ting temperature after oil heat exchanger to R C 90 90 Lube oil operating temperature after oil heat exchanger warning R C 93 93 Lube oil operating temperature after oil heat exchanger shutdown L C 97...

Page 27: ...system R Liters 320 365 Oil change capacity max standard oil system R Liters 280 330 Table 15 Oil and coolant capacity Weights main dimensions Number of cylinders 12 16 Dry engine weight basic configu...

Page 28: ...er ratings are net brake power as per ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046 A kW 1560 2080 Mean effecti...

Page 29: ...g connecting flange engine main PTO SAE 00 00 Table 23 Model related data basic design Coolant system HT circuit Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling eq...

Page 30: ...ating temperature after oil heat exchanger to R C 90 90 Lube oil operating temperature after oil heat exchanger warning R C 93 93 Lube oil operating temperature after oil heat exchanger shutdown L C 9...

Page 31: ...system R Liters 320 365 Oil change capacity max standard oil system R Liters 280 330 Table 30 Oil and coolant capacity Weights main dimensions Number of cylinders 12 16 Dry engine weight basic config...

Page 32: ...g 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 Monitorin...

Page 33: ...d on the cylinder in question If this does not result in an improvement the power is reduced Gas control valve TecJet52 TecJet85 Controls the required amount of gas Mixture throttles P Series The mixt...

Page 34: ...cs Integral status fault display Fault memory Extensive I O features Engine and genset related parameter settings in flash memory In the event of inadmissible states and limit value violations Initiat...

Page 35: ...oring Unit EMU 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring MS15027 02E 2015 04 Product Summary 35 TIM ID 000...

Page 36: ...Power referenced to nominal 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 minu...

Page 37: ...e 166 Lube oil system Check engine oil level Page 174 Check oil level in oil storage tank Page 174 Coolant circuit Standstill 1 year Change engine coolant Page 179 Change mixture coolant Page 184 Cool...

Page 38: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 174 Coolant circuit Check engine coolant level Page 178 Check mixture coolant level Page...

Page 39: ...n gas pipework up to gas control valve and exhaust gas system after turbine A contact is designated to initiate such safety measures Starting sequence The following steps are performed automatically w...

Page 40: ...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 run...

Page 41: ...aught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of...

Page 42: ...e room for smell of gas Page 151 ECU Check for fault messages if fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Op...

Page 43: ...e is running Risk of damage to hearing Wear ear protectors Checking emission values Note Open the exhaust gas measuring line and install the measuring instrument only when the engine is at standstill...

Page 44: ...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 in...

Page 45: ...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 igniti...

Page 46: ...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 c...

Page 47: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC MS15027 02E 2015 04 Operation...

Page 48: ...below 40 C Operating voltage for engine management Switch off Gas supply Close manual gas shutoff valve Air intake and exhaust sys tems If the engine is to remain out of service for more than 1 week...

Page 49: ...linder 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 op...

Page 50: ...W0527 Check engine oil level in storage tank Page 174 W1002 Check valve clearance adjust if required Page 167 W1005 Replace air filter Page 172 W1008 Replace engine oil filter when changing engine oi...

Page 51: ...mit value has not been attained MG Message General message SE System Error Warning due to node failure on the default field bus PB Push Button Status indication due to activation of certain control ke...

Page 52: ...he engine is running at its limits Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled 52 Troubleshooting MS15027 02E 2015 04 TIM...

Page 53: ...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 162 3 Check valve gear exhaust valves do no...

Page 54: ...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 162 3 Check valve gear exhaust valves do...

Page 55: ...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 162 3 Check valve gear exhaust valves do...

Page 56: ...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 162 3 Check valve gear exhaust valves do...

Page 57: ...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 162 4 C...

Page 58: ...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 162 4 Check valve...

Page 59: ...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 162 4 Check valve...

Page 60: ...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 162 4 Check valve...

Page 61: ...ividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 162 3 Check valve gear exhaust valves do not close...

Page 62: ...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 162 3 Check valve gear exhaust valves do...

Page 63: ...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 162 3 Check valve gear exhaust valves do...

Page 64: ...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 162 3 Check valve gear exhaust valves do...

Page 65: ...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 162 4 Ch...

Page 66: ...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 162 4 Check valve...

Page 67: ...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 162 4 Check valve...

Page 68: ...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 162 4 Check valve...

Page 69: ...sion values 2 Check ignition timing Page 162 3 Check valve gear exhaust valves do not close 112702 HIHI T Exhaust A2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas tempe...

Page 70: ...ition timing Page 162 3 Check valve gear exhaust valves do not close 112708 HIHI T Exhaust A8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 71: ...nition timing Page 162 3 Check valve gear 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 cylinde...

Page 72: ...s temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 162 3 Check valve gear exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated by...

Page 73: ...ective 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 Correctiv...

Page 74: ...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...

Page 75: ...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...

Page 76: ...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...

Page 77: ...m 1 4520 509 MIC5 Stat System error Red alarm Initiated by MIC5 Cause Corrective action A system error has occurred u Rectify cause of alarm 1 4520 520 MIC5 Stat W temperat limit reached Yellow alarm...

Page 78: ...it 1 4520 526 MIC5 Stat Analogue current sig fail Red alarm Initiated by MIC5 Cause Corrective action Failure of current signal for adjusting the ignition timing u Check settings 1 4520 527 MIC5 Stat...

Page 79: ...d sig during selftest Red alarm Initiated by MIC5 Cause Corrective action Pickup signals were detected during self test u Restart ignition control unit 1 4520 543 MIC5 E1 Shutdown due to alarm Red ala...

Page 80: ...ue u Check settings in data record ignition coils and spark plugs Restart ignition control unit 1 4520 550 MIC5 E1 Tr1 synchronization fault Yellow alarm Initiated by MIC5 Cause Corrective action Sync...

Page 81: ...Cause Corrective action The number of trigger 1 B1 2 events is not correct u Check sensor sensor clearance cabling settings in data record and timing wheel Replace sensor if required 1 4520 557 MIC5 E...

Page 82: ...coil 2 Check ignition coil 1 4520 571 MIC5 IPE Primary Open Cylinder 2 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 2 in firing order 1 Check cabli...

Page 83: ...r 9 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 9 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 579 MIC5 IPE Primar...

Page 84: ...der 16 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 16 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 586 MIC5 IPE Pr...

Page 85: ...yl 3 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 3 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 593 MIC5 IPE Pr...

Page 86: ...10 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 10 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 600 MIC5 IPE Pri...

Page 87: ...yl 17 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 17 in firing order 1 Check cabling to ignition coil 2 Check ignition coil 1 4520 607 MIC5 IPE...

Page 88: ...alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 4 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 61...

Page 89: ...larm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 11 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 621...

Page 90: ...alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 18 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 6...

Page 91: ...alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 5 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520...

Page 92: ...larm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 12 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520...

Page 93: ...tiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 19 in firing order 1 Check ignition line spark plug connector and spark plug 2 Check ignition coil 1 4520 649 MIC5...

Page 94: ...Cause Corrective action Index mark of trigger 2 B75 was not detected u Check sensor sensor clearance cabling settings in data record and timing wheel Replace sensor if required 1 4520 664 MIC5 E2 Tr2...

Page 95: ...u Check sensor sensor clearance cabling settings in data record and timing wheel Replace sensor if required 1 4520 670 MIC5 E2 Tr3 synchronization fault Yellow alarm Initiated by MIC5 Cause Correctiv...

Page 96: ...Cause Corrective action The number of trigger 3 B13 2 events is not correct u Check sensor sensor clearance cabling settings in data record and timing wheel Replace sensor if required 1 4520 677 MIC5...

Page 97: ...ause Corrective action Hardware not ready for operation u Restart F Series 1 4530 008 Alarm Yellow alarm Initiated by F Series Cause Corrective action Combined alarm for details refer to the source al...

Page 98: ...ltage Low Error Yellow alarm Initiated by F Series Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4530 016 Electronics Temperature High...

Page 99: ...Series Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4540 009 Zero Pressure Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow...

Page 100: ...T Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 016 Delta P Fail High Red alarm Initiated by TecJet Cause Corrective action D...

Page 101: ...Delta P Fail Low Red alarm Initiated by TecJet Cause Corrective action Delta p from TecJet below the set limit value u Check TecJet and configuration 1 4540 023 FGP Fail Low Red alarm Initiated by Tec...

Page 102: ...Red alarm Initiated by TecJet Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJe...

Page 103: ...TecJet 1 4540 036 FGP High Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 037 Watchdog Reset Red alarm Initiated by TecJet...

Page 104: ...044 Parameter Version Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 045 Main EEP Read Fail Red alarm Initiated by TecJet Cause C...

Page 105: ...051 Sense 12V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 052 ADC Test Error Red alarm Initiated by TecJet Cause Corrective act...

Page 106: ...iated by ProAct A Bank Cause Corrective action ProAct setting is not correct u Check setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action Upp...

Page 107: ...ng or out of range 1 Check setting 2 Check cabling 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is not correct u Check setting 1 45...

Page 108: ...llow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is not correct u Check setting 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by ProAct B Bank Cause Correc...

Page 109: ...ng or out of range 1 Check setting 2 Check cabling 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is not correct u Check setting 1 45...

Page 110: ...use Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 144 B CAN Stop Command Yellow alarm Initiated by ProAct B Bank Cause Corrective action Stop command received via CAN...

Page 111: ...l system oil heat exchanger 2 Replace oil filter Page 177 3 Take oil sample and analyze Page 176 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas tem...

Page 112: ...parameter 2 0154 931 Cause Corrective action Pressure loss via oil filter too high limit value 1 1 Replace oil filter Page 177 2 If this fault occurs again after unexpectedly short filter runtime che...

Page 113: ...iming and emission if a turbocharger speed sensor is installed 036 HI ETC2 Overspeed Yellow alarm Associated parameter 2 3013 931 Cause Corrective action Speed of 1st secondary turbocharger too high l...

Page 114: ...is too high Insufficient oil volume flow rate 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 174 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cau...

Page 115: ...alve 4 Check oil separator condition replace if necessary Page 152 064 SS P Crankcase Red alarm Engine stop Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit va...

Page 116: ...ck if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 172 Check exhaust back pressure Check differential pressure over...

Page 117: ...llow 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 coo...

Page 118: ...Check 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...

Page 119: ...itializes communication by means of the application environment data module However the necessary PU data module is not present or is invalid u Contact Service configuration fault 184 AL CAN PU Data F...

Page 120: ...89 Cause Corrective action CAN controller 2 has indicated a warning Some reasons are for example no corresponding node minor malfunctions or temporary bus overload u Check operation of nodes and cabli...

Page 121: ...ause Corrective action Exhaust temperature sensor on B side defective short circuit or wire break u Check sensor and cabling B4 22 replace if necessary Fault is rectified following engine restart 211...

Page 122: ...ctive action Intake air temperature sensor defective short circuit or wire break u Check sensor and cabling B49 2 replace if necessary Fault is rectified following engine restart 221 SD P Diff Lube Oi...

Page 123: ...cessary Fault is rectified following engine restart 232 SD Charger 1 Speed Red alarm Associated parameter 1 3011 128 Cause Corrective action Speed sensor of primary turbocharger defective short circui...

Page 124: ...2 8006 639 Cause Corrective action Short circuit or wire break on transistor output plant side 2 TOP 2 Activation of red combined alarm faulty u Check cabling 383 AL Wiring TOP 3 Red alarm Associated...

Page 125: ...ine stop Associated parameter 2 0180 921 Cause Corrective action Coolant differential pressure too low limit value 1 Flow too low u Check engine coolant circuit pressure and flow 429 HI P Coolant Red...

Page 126: ...73 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure flow too low air in engine cooling system u Check engine coolant circuit pressure an...

Page 127: ...ure cooler for dirt 452 HIHI T Charge Mix Red alarm Engine stop Associated parameter 2 0169 932 Cause Corrective action Mixture temperature too high limit value 2 Mixture coolant pump failure volumetr...

Page 128: ...6 3 replace if 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...

Page 129: ...or wire break u Check sensor and cabling B79 21 replace if necessary Fault is rectified following engine restart 497 SD P Charge Mix B Red alarm Engine stop Associated parameter 1 8004 629 Cause Corre...

Page 130: ...arge Mix B Red alarm Engine stop Associated parameter 2 0182 932 Cause Corrective action Mixture pressure on B side too high limit value 2 1 Check emissions 2 Check ignition timing Page 162 3 Check ex...

Page 131: ...522 SD P Intake Air after Filter B Yellow alarm Associated parameter 1 0187 900 Cause Corrective action Intake air pressure sensor after filter on B side defective short circuit or wire break u Check...

Page 132: ...t Red alarm Associated parameter 2 1090 122 Cause Corrective action Ignition failure Alarm is activated if the feedback signal from ignition system is not received within a specified time out period E...

Page 133: ...le B fault Red alarm Engine stop Associated parameter 1 1450 013 Cause Corrective action A problem related to mixture throttle on B side occurred Possible causes Mixture throttle defective no power su...

Page 134: ...eive some messages to be transmitted from SAM Possible problem related to CAN bus SAM does not work properly or a device connected to SAM does not work properly so that SAM cannot transmit the message...

Page 135: ...ng Page 162 3 Check combustion chamber 4 Check gas quality if feasible methane number 583 AL GLS closed Red alarm Engine stop Associated parameter 2 0451 005 Cause Corrective action Generator load swi...

Page 136: ...eck EIL 617 LO Current net calorific value Yellow alarm Associated parameter 2 1210 006 Cause Corrective action Fuel calorific value has fallen below the first limit value u Check gas quality if feasi...

Page 137: ...d parameter 2 3050 025 Cause Corrective action NOx emissions have fallen below the second limit value 1 Check gas quality if feasible 2 Check gas pressure 3 Check NOx sensor 4 Check emissions 623 HI N...

Page 138: ...ause Corrective action Motor power sensor defect analog input 2 1 Effective generator power not transmitted correctly 2 Effective generator power can be optionally transmitted by CAN bus 3 Check plant...

Page 139: ...arm Associated parameter 1 4510 996 Cause Corrective action CAN bus communication to knock control faulty 1 Check cabling 2 Check power supply 3 Restart ECU EMU knock control 4 Check settings using de...

Page 140: ...cific dialog software XD50 1 657 AL ProActB Comm Lost Red alarm Associated parameter 1 4550 196 Cause Corrective action CAN bus communication to throttle B faulty 1 Check cabling 2 Check power supply...

Page 141: ...ntroller via CAN bus 666 AL IC92x Yellow Yellow alarm Associated parameter 1 4520 993 Cause Corrective action An internal combined alarm in the ignition system was detected u Check data record 667 AL...

Page 142: ...sor A was detected u Precise error name is transmitted to the genset controller via CAN bus 672 AL NOxB Yellow Yellow alarm Associated parameter 1 4560 193 Cause Corrective action An internal combined...

Page 143: ...cted u Precise error name is transmitted to the genset controller via CAN bus 680 AL ProActB Red Red alarm Associated parameter 1 4550 191 Cause Corrective action An internal combined alarm in throttl...

Page 144: ...ellow 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...

Page 145: ...ive action Limit value 2 exceeded u Check gas supply 832 AL EIL Different Engine Number Yellow alarm Associated parameter 1 0610 953 Cause Corrective action Engine number in EIL differs from engine nu...

Page 146: ...20 936 Cause Corrective action An internal combined alarm in the ignition system was detected u Precise error name is transmitted to the genset controller via CAN bus 934 AL MIC5 Comm Lost Red alarm A...

Page 147: ...CAN3 Error Passive Yellow alarm Associated parameter 2 0500 693 Cause Corrective action CAN controller 3 has indicated a warning Bus nodes ignition knock module throttles or gas mixer have faults u C...

Page 148: ...n NOx values measured for bank A and B deviate excessively from one another limit value 2 1 Check emissions 2 Check NOx sensors 3 Check ignition timing 1017 HI HI Delta p5 for NOx A B Yellow alarm Ass...

Page 149: ...ction Crankcase pressure too low limit value 2 Restrictor valve in crankcase breather too widely open faulty air filter 1 Check air filter for damage replace if visibly damaged 2 Check setting of Blow...

Page 150: ...ody being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Barring engine manually 1 Remove guard plate 2 Engage barr...

Page 151: ...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 a...

Page 152: ...il Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor...

Page 153: ...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 1...

Page 154: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 155 2 Install new spark plug Page 156 154 Task Descripti...

Page 155: ...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 156: ...before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes a...

Page 157: ...prior to tightening 6 Tighten spark plug to specified torque using a torque wrench Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molykote P 37 50 5...

Page 158: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 159 2 Install spark plug connector Page 160 158 T...

Page 159: ...ring 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 t...

Page 160: ...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 th...

Page 161: ...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 th...

Page 162: ...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 rig...

Page 163: ...Qty Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 155 2 Remove cylinder head covers Page 169 3 Remove sleeves arrow 4 Install barring device Page 150 5 Rotate cran...

Page 164: ...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 sp...

Page 165: ...3 Install sleeves arrow 4 Install cylinder head covers Page 170 5 Install spark plugs with new sealing rings Page 156 MS15027 02E 2015 04 Task Description 165 TIM ID 0000043220 002...

Page 166: ...ls Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 169 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install...

Page 167: ...2 Install barring device Page 150 3 Rotate crankshaft with barring tool in en gine direction of rotation until marking OT and pointer are aligned Diagram for 12 16 V engines Two crankshaft positions...

Page 168: ...lve clearances in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation...

Page 169: ...g disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 159 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 170: ...ponents 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...

Page 171: ...fire and explosion Avoid open flames electrical sparks and ignition sources Carry gas warning unit part of the personal safety equipment Do not smoke Gas supply checking gas lines for leaks 1 Coat al...

Page 172: ...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 Repl...

Page 173: ...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 fi...

Page 174: ...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 Toppi...

Page 175: ...WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Engine oil extraction 1 Open shut off valve s in extra...

Page 176: ...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 WAR...

Page 177: ...oves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition...

Page 178: ...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 Checking engine coolant level 1 Read off fuel opt...

Page 179: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 180 2 Fill with engine coolant Page 182 MS15027 02E 2015 04 Task Description...

Page 180: ...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 o...

Page 181: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points MS15027 02E 2015 04 Task Description 181 TIM ID 0000006751 002...

Page 182: ...gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with coolant 1 Fi...

Page 183: ...olant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Mixture coolant level Check 1 Read off system filling press...

Page 184: ...al tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 185 2 Fill with fresh mixture coolant Page 186 184 Task Description MS1502...

Page 185: ...injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining mixture coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve at...

Page 186: ...tive clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling wit...

Page 187: ...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...

Page 188: ...ressure after filter 3 B16 1 Coolant pressure after engine 4 B4 X Exhaust temperature after cylinder 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 40 Sensors B side The knock sensor...

Page 189: ...oxide NOx concentration in exhaust gas 2 B79 23 Mixture pressure before throttle 3 B75 Crankshaft speed reset ignition system 4 B13 2 Crankshaft speed ignition Table 41 Sensors engine driving end MS15...

Page 190: ...speed sensor 2 B5 1 Engine oil pressure after filter 3 B7 Engine oil temperature 4 B5 3 Engine oil pressure before filter 5 B50 Crankcase pressure 6 B79 21 Mixture pressure A side Table 42 Sensors A...

Page 191: ...B16 3 Coolant pressure before engine 4 B1 3 Camshaft speed for anti knock control 5 B1 1 Camshaft speed for engine governor 6 B24 Engine oil level 7 B1 2 Camshaft speed for ignition system 8 B6 3 Cool...

Page 192: ...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 193: ...motive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technisch...

Page 194: ...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 s...

Page 195: ...4 3 Valve clearance Check and adjustment Page 167 Barring gear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 150 Feeler gauge Part No Y20098771 Qty Used in 1 6 4 3 Valve clearance...

Page 196: ...smell of gas Page 151 Gas measuring and warning device not stocked by MTU Part No Qty Used in 3 7 Emission values Check Page 43 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Engin...

Page 197: ...l Page 155 Qty Used in 1 6 3 3 Spark plug Installation Page 156 Stroboscope Not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 162 Torque wrench 10 60 Nm Part No F...

Page 198: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 3 Valve clearance Check and adjustment Page 167 198 Appendix B MS15027 02E 2015 04 DCL ID 0000028920 004...

Page 199: ...manually 150 Emergency shutdown 45 Main dimensions 22 Shutdown 44 Start 41 Engine cabling Check 187 Engine Control Unit Fault messages 111 Engine coolant Change 179 Draining 180 Filling 182 Level che...

Page 200: ...ons with gaseous fuel 16 Important provisions 5 Maintenance work 10 Operation 8 Organizational requirements 7 Personnel requirements 7 Repair work 10 Startup 8 Safety requirements Maintenance work spe...

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