MTU 8 V 4000 Lx3 x Operating Instructions Manual Download Page 32

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2.6 Monitoring, Control and Regulation Equipment

2.6.1 Gas engine phase 3 system – Overview

General overview

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

5 Engine Monitoring Unit
6 Humidity sensor (optional)
7 Throttles
8 Gas dosing unit

9 Knock module

10 Ignition
11 Compressor bypass
12 NOx sensor (optional)

Governing/control/monitoring

Engine Control Unit ECU-9

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

Engine Monitoring Unit EMU 8

• Monitors second gas solenoid in gas train to engine

Compressor bypass (F series)

• Controls throttle reserve, prevents compressor surges

Ignition system IC922

• Adjusts ignition timing for cylinders

32 | Product Summary | MS150103/01E 2015-03

TIM-ID: 0000043155 - 002

Summary of Contents for 8 V 4000 Lx3 x

Page 1: ...Operating Instructions Gas engine 8V 4000 Lx2 x MS150103 01E...

Page 2: ...hout 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...

Page 3: ...ing 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 ready...

Page 4: ...perature Circuit 163 6 10 1 Mixture coolant level Check 163 6 10 2 Mixture coolant Change 164 6 10 3 Mixture coolant Draining 165 6 10 4 Mixture coolant Filling 166 6 11 Wiring General for Engine Gear...

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: ...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 9: ...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 10: ...g 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 ac...

Page 11: ...unts 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 sta...

Page 12: ...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 13: ...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 14: ...hat 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 emerge...

Page 15: ...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 16: ...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 vicin...

Page 17: ...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 18: ...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 19: ...let 3 Mixture cooler 4 Exhaust turbocharger 5 Engine lifting equipment 6 Capacitor discharge igni tion system 7 Engine mounting bracket free end 8 Oil pan 9 Engine mounting bracket driving end 10 Star...

Page 20: ...el switch 13 Engine coolant inlet con nection 14 Engine oil heat exchanger 15 Engine coolant outlet con nection KGS Free end Engine model designation Key to the engine model designation 8 V 4000 L32 F...

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 lette...

Page 22: ...ns Length A Approx 2484 mm Width B approx 1743 mm Height C approx 2135 mm Crankshaft center to oil pan D approx 625 mm Crankshaft center to engine mount E approx 280 5 mm Table 3 Engine Main dimension...

Page 23: ...2 4 Firing order Firing order Number of cylinders Firing order 8 V A1 A3 A4 A2 B3 B4 B2 B1 MS150103 01E 2015 03 Product Summary 23 TIM ID 0000002807 003...

Page 24: ...conditions Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 800...

Page 25: ...related data basic design Coolant system HT circuit Number of cylinders 8 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 Coolant temperature at engine conn...

Page 26: ...e after oil filter bar 5 0 Lube oil pressure after oil filter alarm R bar 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 Table 11 Lube oil system Fuel system Number of cylinders 8 Gas tempe...

Page 27: ...ber of cylinders 8 Dry engine weight basic configuration engine R kg 5100 Heaviest component to be lifted during extended component maintenance QL3 R kg 280 Table 16 Weights main dimensions Exhaust em...

Page 28: ...brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 800 Mean effective pressure pme continuous power ISO 3...

Page 29: ...eze 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 Co...

Page 30: ...Number of cylinders 8 Gas temperature before engine min L C 10 Gas temperature before engine max L C 50 Gas flow pressure before gas control valve min L mbar 80 Gas flow pressure before gas control va...

Page 31: ...t to be lifted during extended component maintenance QL3 R kg 280 Table 31 Weights main dimensions Exhaust emissions Number of cylinders 8 Exhaust emission before catalytic converter 100 DL nitric oxi...

Page 32: ...ntrol 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 M...

Page 33: ...ayed 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...

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 MS150103 01E 2015 03 Product Summary 35 TIM ID 00...

Page 36: ...oad Recommended maximum run time at this load Recommended minimum run time in subsequent operation at load 50 0 to 30 30 minutes 120 minutes 30 to 50 120 minutes 120 minutes 50 to 100 No restriction N...

Page 37: ...129 Valve gear Standstill 6 months Lubricate valve gear Page 147 Lube oil system Check engine oil level Page 153 Check oil level in oil storage tank Page 153 Coolant circuit Standstill 1 year Change e...

Page 38: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 153 Coolant circuit Check engine coolant level Page 157 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: ...wing a start request after emergency shutdown 1 Requesting external ventilation by contact 2 Activating starter 3 Waiting for starting speed 4 Scavenging the engine 5 Disengaging starter 6 Engine runn...

Page 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 130 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: ...of injury and burning Wear protective clothing gloves and goggles safety mask WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well ventilated Repair leaki...

Page 44: ...nd mechanical stresses Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are ind...

Page 45: ...n 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 ignitio...

Page 46: ...gain 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 co...

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 MS150103 01E 2015 03 Operatio...

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: ...W1005 Replace air filter Page 151 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 156 W1046 Replace filter or filter element Page 131...

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 MS150103 01E 2015 03 TI...

Page 53: ...n values 2 Check ignition timing Page 141 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this c...

Page 54: ...tion timing Page 141 3 Check valve drive exhaust valves do not close 112308 HI T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 55: ...tion timing Page 141 3 Check valve drive exhaust valves do not close 112314 HI T Exhaust B4 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 56: ...heck ignition timing Page 141 3 Check valve drive exhaust valves do not close 112320 HI T Exhaust B10 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is...

Page 57: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive...

Page 58: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive...

Page 59: ...rrective action The exhaust temperature of this cylinder is too high as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive...

Page 60: ...lues 3 Check ignition timing Page 141 4 Check valve drive 112501 HIHI T Exhaust A1 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared w...

Page 61: ...tion timing Page 141 3 Check valve drive exhaust valves do not close 112507 HIHI T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as...

Page 62: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112513 HIHI T Exhaust B3 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Page 63: ...ignition timing Page 141 3 Check valve drive exhaust valves do not close 112519 HIHI T Exhaust B9 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hi...

Page 64: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 1...

Page 65: ...rective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 11...

Page 66: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 1...

Page 67: ...g 2 Check emission values 3 Check ignition timing Page 141 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is...

Page 68: ...tion timing Page 141 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 69: ...ition timing Page 141 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinde...

Page 70: ...tion timing Page 141 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...

Page 71: ...cabling 113902 SS Local Initiated Emerg Stop Red alarm Initiated by SAM Cause Corrective action Emergency stop detected Emergency stop was released manually button or ignition system reported overspee...

Page 72: ...g torque damage replace as necessary 1 4510 193 Knock Sensor Error A2 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor...

Page 73: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 199 Knock Sensor Error A8 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 74: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 205 Knock Sensor Error B4 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 75: ...m this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 211 Knock Sensor Error B10 Red alarm Initiated by anti knock control Cause Corrective action No...

Page 76: ...OverSpeed Shutdown Red alarm Initiated by IC922 Cause Corrective action Genset has exceeded admissible speed u Restart ignition 1 4520 238 E2PROM Checksum Error Red alarm Initiated by IC922 Cause Cor...

Page 77: ...Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 246 Open Primary Channel 2 Yellow alarm Initia...

Page 78: ...y Channel 8 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 253 Open Primary Channel 9 Yellow...

Page 79: ...y Channel 15 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coils 1 4520 260 Open Primary Channel 16 Yello...

Page 80: ...ce as necessary 1 4520 271 Warning Missing Reset Signal Yellow alarm Initiated by IC922 Cause Corrective action Reset signal from crankshaft is missing u Sensor B 75 check sensor sensor distance and c...

Page 81: ...F series Cause Corrective action Combined alarm for details refer to the source alarm u Combined alarm for details refer to the source alarm 1 4530 009 Derating Active Yellow alarm Initiated by F ser...

Page 82: ...Error Yellow alarm Initiated by F series Cause Corrective action Supply voltage has reached minimum limit value 1 Check supply voltage 2 Check cabling 1 4530 016 Electronics Temperature High Error Red...

Page 83: ...ies Cause Corrective action CAN bus connection faulty u Check cabling and setting 1 4540 009 Zero Pressure Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow de...

Page 84: ...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 85: ...22 Delta P Fail Low Red alarm Initiated by TecJet Cause Corrective action Delta p via TecJet below set limit value u Check TecJet and configuration 1 4540 023 FGP Fail Low Red alarm Initiated by TecJe...

Page 86: ...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 87: ...t TecJet 1 4540 036 FGP High Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 037 Watchdog Reset Red alarm Initiated by TecJet...

Page 88: ...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 89: ...1 Sense 12V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 052 ADC Test Error Red alarm Initiated by TecJet Cause Corrective actio...

Page 90: ...ct A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action Supply voltage has...

Page 91: ...ng or is outside the range 1 Check setting 2 Check cabling 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is incorrect u Check settin...

Page 92: ...Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action S...

Page 93: ...ng or is outside the range 1 Check setting 2 Check cabling 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by ProAct B Bank Cause Corrective action ProAct setting is incorrect u Check settin...

Page 94: ...Corrective action CAN bus connection faulty u Check cabling and setting 1 4550 144 B CAN Stop Command Yellow alarm Initiated by ProAct B Bank Cause Corrective action Stop input signal received via CA...

Page 95: ...l system oil heat exchanger 2 Replace oil filter Page 156 3 Take oil sample and analyze Page 155 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas tem...

Page 96: ...charger 2 Check ignition timing Page 141 3 Check mixture setting 4 Check spark plugs 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective action Pressure loss via oil f...

Page 97: ...ne shutdown Associated parameter 2 3012 932 Cause Corrective action Speed of primary turbocharger too high limit value 2 u Turbocharger speed sensor is not fitted at present Check ECU setting for this...

Page 98: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 153 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...

Page 99: ...Check oil separator condition replace as necessary Page 131 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value...

Page 100: ...ly open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 151 Check exhaust back pressure Check differential pr...

Page 101: ...ellow alarm Associated parameter 2 1090 921 Cause Corrective action Preheating temperature too low limit value 1 Coolant temperature too low for engine start 1 Check preheating 2 Check differential co...

Page 102: ...supply voltage 2 Check cabling 121 HIHI ECU Power Supply Voltage Red alarm Associated parameter 2 0140 932 Cause Corrective action Supply voltage too high limit value 2 1 Check supply voltage 2 Check...

Page 103: ...N mode initializes communication by means of the PU data module However the necessary PU data module is not present or is invalid u Contact Service configuration fault 184 AL CAN PU Data Flash Error R...

Page 104: ...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 cab...

Page 105: ...use Corrective action Exhaust temperature sensor on B side defective short circuit or wire break u Check sensor and cabling B4 22 replace as necessary Fault is rectified following engine restart 211 S...

Page 106: ...ective action Intake air temperature sensor defective short circuit or wire break u Check sensor and cabling B49 2 replace as necessary Fault is rectified when engine is restarted 221 SD P Diff Lube O...

Page 107: ...s necessary Fault is rectified following engine restart 232 SD ETC Speed 1 Yellow alarm Associated parameter 1 3011 128 Cause Corrective action Speed sensor of primary turbocharger defective short cir...

Page 108: ...8006 639 Cause Corrective action Short circuit or wire break at transistor output plant side 2 TOP 2 Activation of red combined alarm faulty u Check cabling 383 AL Wiring TOP 3 Red alarm Associated p...

Page 109: ...sociated parameter 2 0180 921 Cause Corrective action Coolant differential pressure too low limit value 1 Insufficient volume flow u Check engine coolant circuit pressure and flow 429 HI P Coolant Red...

Page 110: ...ameter 2 0173 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure volumetric flow too low air in engine coolant circuit u Check engine cool...

Page 111: ...xture cooler for dirt 452 HIHI T Charge Mix Red alarm Engine shutdown Associated parameter 2 0169 932 Cause Corrective action Mixture temperature too high limit value 2 Mixture coolant pump failure vo...

Page 112: ...replace as necessary Fault is rectified following engine restart 470 SD T ECU Red alarm Associated parameter 1 8004 587 Cause Corrective action Temperature sensor for Engine Control Unit defective sh...

Page 113: ...t or wire break u Check sensor and cabling B79 21 replace as necessary Fault is rectified following engine restart 497 SD P Charge Mix B Red alarm Engine shutdown Associated parameter 1 8004 629 Cause...

Page 114: ...2 0182 932 Cause Corrective action Mixture pressure on B side too high limit value 2 1 Check emissions 2 Check ignition timing Page 141 3 Check exhaust back pressure 4 Check valve clearance Page 145...

Page 115: ...ed parameter 1 0187 900 Cause Corrective action Intake air pressure sensor after filter on B side defective short circuit or wire break u Check sensor and cabling B81 2 replace as necessary Fault is r...

Page 116: ...ply solenoid valves are faulty the timeout period is set too short or communication is faulty 1 Check gas train 2 Check cabling 557 AL speed drop fault Red alarm Engine shutdown Associated parameter 2...

Page 117: ...over air filter on A side is too high u Replace air filter Page 151 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure loss over air f...

Page 118: ...emissions 2 Check ignition timing Page 141 3 Check combustion chamber 4 Check gas quality if feasible methane number 571 L2 Al CAN Max Retarded Timing Yellow alarm Power reduction Associated parameter...

Page 119: ...ling to NOx sensors and air humidity sensor 617 LO Current Heat Value of Fuel Yellow alarm Associated parameter 2 1210 006 Cause Corrective action Fuel calorific value has undershot the first limit va...

Page 120: ...parameter 2 3050 025 Cause Corrective action NOx emissions have undershot the second limit value 1 Check gas quality if feasible 2 Check gas pressure 3 Check NOx sensor 4 Check emissions 623 HI NOx V...

Page 121: ...ause 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 configur...

Page 122: ...n 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...

Page 123: ...log 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...

Page 124: ...llow 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...

Page 125: ...ult 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...

Page 126: ...ct fault designation is transmitted via CAN bus to the genset control system 680 AL ProActB Red Red alarm Associated parameter 1 4550 191 Cause Corrective action An internal combined alarm in throttle...

Page 127: ...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 paramet...

Page 128: ...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...

Page 129: ...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 130: ...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 an...

Page 131: ...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 132: ...escence filter 5 must be installed in the correct position in the housing 10 Place coalescence filter 5 in housing en suring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12...

Page 133: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 134 2 Install new spark plug Page 135 MS150103 01E 2015...

Page 134: ...le 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 ruptu...

Page 135: ...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 136: ...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 N...

Page 137: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 138 2 Install spark plug connector Page 139 MS150...

Page 138: ...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 139: ...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...

Page 140: ...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...

Page 141: ...ING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note The service tool Diasys and a dongle with access righ...

Page 142: ...Qty Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 134 2 Remove cylinder head covers Page 148 3 Remove sleeves arrow 4 Install barring device Page 129 5 Rotate cran...

Page 143: ...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 144: ...3 Install sleeves arrow 4 Install cylinder head covers Page 149 5 Install spark plugs with new sealing rings Page 135 144 Task Description MS150103 01E 2015 03 TIM ID 0000043220 002...

Page 145: ...e cylinder head cover Page 148 2 Install barring device Page 129 3 Rotate crankshaft with barring tool in en gine direction of rotation until TDC marking and pointer are aligned Diagram for 8 V engine...

Page 146: ...om the set value exceeds 0 1 mm adjust valve clearance Valve clearance Adjustment 1 Release locknut 1 2 Insert feeler gauge 3 between valve bridge and rocker arm 3 Use angular screw driver to set adju...

Page 147: ...ls Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 148 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install...

Page 148: ...disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 138 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 149: ...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 150: ...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 all...

Page 151: ...lter made of fleece option Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the corresponding fault message appears Repla...

Page 152: ...alla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from connecting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air fil...

Page 153: ...2 cm The cause of this may be that oil e g from the oil filter and oil heat exchanger flows back into the oil pan 3 The oil level must reach the mark 2 or ex ceed the mark 1 by up to 2 cm Note Toppin...

Page 154: ...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 extrac...

Page 155: ...Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Oils oil vapors are combustible exp...

Page 156: ...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 157: ...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 158: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 159 2 Fill with engine coolant Page 161 158 Task Description MS150103 01E 201...

Page 159: ...Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch of...

Page 160: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 160 Task Description MS150103 01E 2015 03 TIM ID 0000006751 002...

Page 161: ...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 162: ...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 159 2 Release union nuts 1 and 3 3 Remov...

Page 163: ...lant 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 pressu...

Page 164: ...l tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 165 2 Fill with fresh mixture coolant Page 166 164 Task Description MS15010...

Page 165: ...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 166: ...ive clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with...

Page 167: ...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 168: ...after filter B side 3 B16 1 Coolant pressure after engine 4 B4 X Exhaust temperature after cylinder 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 40 Sensors B side Knock sensors B80...

Page 169: ...88 Nitric oxide values in exhaust gas NOx 2 B79 23 Mixture pressure before throttle 3 B75 Crankshaft speed reset 3 B13 3 Crankshaft speed ignition system Table 41 Sensors driving end MS150103 01E 2015...

Page 170: ...optional 2 B79 21 Mixture pressure A side 3 B50 Crankcase pressure 4 B5 1 Engine oil pressure after filter 5 B5 3 Engine oil pressure before filter 6 B7 Engine oil temperature Table 42 Sensors A side...

Page 171: ...re engine 3 B1 3 Camshaft speed knock module 4 B1 2 Camshaft speed ignition system 5 B1 1 Camshaft speed engine governor 6 B24 Engine oil level 7 B6 3 Coolant temperature before engine 8 B6 1 Coolant...

Page 172: ...void 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 WA...

Page 173: ...ng general information Arrangement and position of sensor Page 168 2 Unfasten electrical connector 2 and re move 3 Unscrew electronics box 1 at the eyelets 4 Remove sensor via nut 3 MS150103 01E 2015...

Page 174: ...e 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 o...

Page 175: ...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 176: ...otive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische...

Page 177: ...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 si...

Page 178: ...ar Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 129 Feeler gauge Part No Y20098771 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 145 Gas detection and alarm unit n...

Page 179: ...y Used in 1 6 8 1 Engine oil filter Replacement Page 156 Ratchet adapter Part No F30027340 Qty Used in 1 6 11 3 Sensors Removal Page 172 Qty Used in 1 6 11 4 Sensor Installation Page 174 Ratchet head...

Page 180: ...6 4 2 Valve clearance Check and adjustment Page 145 Special wrench 20 8 mm Part No F30452574 Qty Used in 1 6 3 2 Spark plug Removal Page 134 Qty Used in 1 6 3 3 Spark plug Installation Page 135 Strobo...

Page 181: ...6 3 6 Spark plug connector Installation Page 139 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 6 11 4 Sensor Installation Page 174 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4...

Page 182: ...Engine cabling Check 167 Engine coolant Change 158 Draining 159 Filling 161 Level check 157 Engine driving end Definition 21 Engine free end Definition 21 Engine oil Change 154 Sample Analysis 155 Ex...

Page 183: ...e work 11 Operation 9 Organizational requirements 7 Personnel requirements 7 Repair work 11 Startup 9 Safety requirements Maintenance work special instructions for applica tions with gaseous fuel 14 O...

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