MTU 8V4000L62FB Operating Instructions Manual Download

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Operating Instructions

Gas engine

8 V 4000 Lx2 xx

MS150097/01E

Summary of Contents for 8V4000L62FB

Page 1: ...Operating Instructions Gas engine 8 V 4000 Lx2 xx MS150097 01E...

Page 2: ...n any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation mi crofilming and storage or...

Page 3: ...l checks 37 3 7 Emission values Check 38 3 8 Engine Shutdown 39 3 9 Emergency stop 40 3 10 After stopping the engine Engine remains ready for operation 41 3 11 After stopping the engine Putting the en...

Page 4: ...ture Circuit 160 6 10 1 Mixture coolant level Check 160 6 10 2 Mixture coolant Change 161 6 10 3 Mixture coolant Draining 162 6 10 4 Mixture coolant Filling 163 6 11 Wiring General for Engine Gearbox...

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

Page 6: ...or the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transport...

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

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

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

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

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

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

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

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

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

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

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

Page 18: ...et 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 Start...

Page 19: ...gine cool ant inlet 14 Engine oil heat exchanger 15 Connection engine cool ant outlet KGS Free end Engine model designation Key to the engine model designation 8 V 4000 L62 FB 8 Number of cylinders v...

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

Page 21: ...rox 1751 3 mm Height C approx 2140 2 mm Crankshaft center to oil pan D approx 625 mm Crankshaft center to engine mount E approx 280 5 mm Heat shield A side to crankshaft center F approx 734 3 mm Table...

Page 22: ...2 4 Firing order Firing order 8V A1 A3 A4 A2 B3 B4 B2 B1 22 Product Summary MS150097 01E 2013 10 TIM ID 0000002807 002...

Page 23: ...ble 4 Reference 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 I...

Page 24: ...d 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 connection...

Page 25: ...il filter bar 5 0 Lube oil pressure after oil filter warning 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 temperature...

Page 26: ...ght basic configuration engine r kg 4400 Heaviest component to be lifted during extended component maintenance QL3 r kg 280 Table 16 Weights main dimensions Exhaust emissions Number of cylinders 8 Exh...

Page 27: ...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 28: ...und the ignition timing is re tarded on the cylinder in question If this does not result in an improvement the power is reduced Gas control valve TecJet110 Controls the required amount of gas Mixture...

Page 29: ...ustomer side 14 inputs 7 outputs 2 serial interfaces Engine side 39 inputs 28 outputs 1 serial interface Engine and genset related parameter settings in flash memory In the event of inadmissible state...

Page 30: ...Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 30 Product Summary MS150097 01E 2013 10 TIM ID 0000027848 002...

Page 31: ...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 32: ...e 138 Lube oil system Check engine oil level Page 150 Check oil level in oil storage tank Page 150 Coolant circuit Standstill 1 year Change engine coolant Page 155 Change mixture coolant Page 161 Cool...

Page 33: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 150 Coolant circuit Check engine coolant level Page 154 Check mixture coolant level Page...

Page 34: ...ld gas A 24V digital output is provided to activate such systems Start sequence If a start command is activated with the engine being at standstill the following steps are carried out automatically 1...

Page 35: ...activa tion request for external ventilation is sent via the 24V digital output 1 Activation request for external ventilation via contact 2 Activating starter 3 Waiting for starting speed 4 Purging en...

Page 36: ...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 37: ...not smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Operational checks Item Measure Machine room Check machine room for smell of gas...

Page 38: ...e hot and pressurized Risk 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 we...

Page 39: ...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 40: ...re Gas shut off valves with con trol solenoids Two contacts are available for connection to the electrical system Gas shut off valves with control solenoids close Engine will be shut down Rectifying c...

Page 41: ...Engine remains ready for operation After stopping the engine Item Action Engine generator control manufacturer specific Select operating mode e g HAND MANUAL AUTO AUTOMATIC MS150097 01E 2013 10 Opera...

Page 42: ...e room tem perature antifreeze concentration is 50 and engine room temperature is be low 40 C Power supply to engine con trol system Switch off Gas supply The gas shut off valves with control solenoid...

Page 43: ...ylinder heads after component maintenance or extended component maintenance When installing a cylinder head with run in mating faces e g after piston replacement a repeated check after the first 50 op...

Page 44: ...djust if necessary Page 139 W1005 Replace air filter Page 148 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 153 W1089 Check gas line...

Page 45: ...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 46: ...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 46 Troubleshooting MS150097 01E 2013 10 TI...

Page 47: ...on Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do no...

Page 48: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do...

Page 49: ...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 137 3 Check valve drive exhaust valves do...

Page 50: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do...

Page 51: ...Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Che...

Page 52: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve...

Page 53: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve...

Page 54: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve...

Page 55: ...ividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do not clos...

Page 56: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do...

Page 57: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do...

Page 58: ...tion Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do...

Page 59: ...Corrective action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Che...

Page 60: ...e action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve d...

Page 61: ...ve action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve...

Page 62: ...e action Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve d...

Page 63: ...sion values 2 Check ignition timing Page 137 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 temp...

Page 64: ...tion timing Page 137 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...

Page 65: ...tion timing Page 137 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...

Page 66: ...s temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 137 3 Check valve drive exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated by...

Page 67: ...use Corrective action No gas pressure gas flow detected u Check gas pressure 1 4540 010 Zero Flow Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow detected u...

Page 68: ...Fail High Red alarm Initiated by TecJet Cause Corrective action Differential pressure at TecJet too high 1 Check gas pressure 2 Check TecJet for dirt 1 4540 017 FGP Fail High Red alarm Initiated by Te...

Page 69: ...configuration 1 4540 023 FGP Fail Low Red alarm Initiated by TecJet Cause Corrective action Gas pressure before TecJet is below the preset limit value u Check TecJet and configuration 1 4540 024 Coil...

Page 70: ...r 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 TecJ...

Page 71: ...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 72: ...alarm Initiated by IC922 Cause Corrective action Missing reset signal u Check sensor sensor distance and cabling replace as necessary 1 4520 234 Error Missing Camshaft Signal Red alarm Initiated by I...

Page 73: ...922 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...

Page 74: ...ry 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...

Page 75: ...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...

Page 76: ...low 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 Initiate...

Page 77: ...y 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...

Page 78: ...r B 1 3 and replace if necessary 1 4510 192 Knock Sensor Error A1 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling 2 Check sensor tigh...

Page 79: ...cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 198 Knock Sensor Error A7 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...

Page 80: ...k cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 204 Knock Sensor Error B3 Red alarm Initiated by antiknock control Cause Corrective action No signal from this knock senso...

Page 81: ...o signal from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 1 4510 210 Knock Sensor Error B9 Red alarm Initiated by anti knock control Cause Corrective...

Page 82: ...ncorrect 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 incorrect u Check setting 1 4530 012 Analog Input High...

Page 83: ...u Restart F series 1 4530 018 Position Error Red alarm Initiated by F series Cause Corrective action Position specification and feedback signal do not match 1 Check mechanical system 2 Restart F serie...

Page 84: ...tion Supply voltage has reached maximum or minimum limit value 1 Check supply voltage 2 Check cabling 1 4550 034 A Position Error Red alarm Initiated by ProAct A Bank Cause Corrective action Position...

Page 85: ...u Check setting 1 4550 040 A Analog Position Demand Failed Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 041 A PWM Position Demand...

Page 86: ...ective action Supply voltage has reached maximum or minimum limit value 1 Check supply voltage 2 Check cabling 1 4550 134 B Position Error Red alarm Initiated by ProAct A Bank Cause Corrective action...

Page 87: ...u Check setting 1 4550 140 B Analog Position Demand Failed Yellow alarm Initiated by ProAct A Bank Cause Corrective action ProAct setting is incorrect u Check setting 1 4550 141 B PWM Position Demand...

Page 88: ...144 B CAN Stop Command Yellow alarm Initiated by ProAct A Bank Cause Corrective action Stop specification received via CAN bus u Check setting 88 Troubleshooting MS150097 01E 2013 10 TIM ID 000002785...

Page 89: ...Replace oil filter Page 153 3 Take oil sample and analyze Page 152 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas temperature A side after turbine...

Page 90: ...bine 1 Check exhaust turbocharger 2 Check ignition timing Page 137 3 Check mixture setting 4 Check spark plugs 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective acti...

Page 91: ...gine 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 th...

Page 92: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 150 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...

Page 93: ...Check oil separator condition replace if necessary Page 127 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value...

Page 94: ...lly open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 148 Check exhaust back pressure Check differential p...

Page 95: ...T Preheat 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 diff...

Page 96: ...w alarm Associated parameter 2 0140 931 Cause Corrective action Supply voltage too high limit value 1 1 Check supply voltage 2 Check cabling 121 HIHI ECU Power Supply Voltage Red alarm Associated para...

Page 97: ...upload is incomplete u Power up ECU contact Service 180 AL CAN1 Node Lost Yellow alarm Associated parameter 2 0500 680 Cause Corrective action Bus node SAM or EMU lost on CAN bus 1 u Check operation...

Page 98: ...us Off Yellow alarm Associated parameter 2 0500 686 Cause Corrective action CAN controller 1 is in Bus Off status Automatic switching to CAN bus 2 Bus users ECU SAM or EMU faulty u Check operation of...

Page 99: ...emperature sensor at engine outlet defective short circuit or wire break u Check sensor and cabling B6 1 replace if necessary Fault is rectified following engine restart 204 SD Level Lube Oil Red alar...

Page 100: ...Cause Corrective action Coolant pressure sensor after engine defective short circuit or wire break u Check sensor and cabling B16 1 replace if necessary Fault is rectified following engine restart 21...

Page 101: ...rective action Engine oil pressure sensor before filter defective short circuit or wire break u Check sensor and cabling B5 3 replace as necessary Fault is rectified following engine restart 229 AL St...

Page 102: ...t 245 SD ECU Power Supply Voltage Red alarm Associated parameter 2 8006 589 Cause Corrective action Internal governor fault u Replace ADEC engine governor 266 SD Speed Setting Red alarm Associated par...

Page 103: ...er 2 8006 641 Cause Corrective action Short circuit or wire break on transistor output plant side 4 TOP 4 Activation of gas supply solenoid valve No 2 faulty u Check cabling 418 SD T Intake Air B Yell...

Page 104: ...ssure before engine too low limit value 1 Insufficient volume flow static pressure too low u Check engine coolant circuit pressure and flow 431 SS P Coolant Before Engine Red alarm Engine shutdown Ass...

Page 105: ...kage 3 Check sensors and cabling B79 22 B79 21 447 HIHI P Charge Mix Diff Red alarm Engine shutdown Associated parameter 2 0183 932 Cause Corrective action Difference in mixture pressures sensed on A...

Page 106: ...3 1 Check intake air temperature 2 Check mixture cooling circuit 454 SS Power Limitation Active Yellow alarm Associated parameter 2 7000 011 Cause Corrective action Power limitation activated u Rectif...

Page 107: ...r 2 8006 593 Cause Corrective action Engine stop since all shutdown channels have sensor faulty u Combined alarm for details refer to the source alarm 473 AL Cabling PWM_CM2 Red alarm Engine shutdown...

Page 108: ...on Mixture pressure sensor on B side defective short circuit or wire break u Check sensor and cabling B79 22 replace if necessary Fault is rectified following engine restart 498 SD P Charge Mix Diff R...

Page 109: ...nt system 513 SD P Coolant Diff Red alarm Associated parameter 1 8004 610 Cause Corrective action Coolant differential pressure sensor defective short circuit or wire break u Check sensors and cabling...

Page 110: ...ctified following engine restart 531 AL Wiring PWM_CM1 Red alarm Associated parameter 1 1044 900 Cause Corrective action Cable break or short circuit on channel PWM_CM1 u Check cabling to TecJet throt...

Page 111: ...118 Cause Corrective action Gas train test was not successful Alarm is activated if the gas train does not report OK within a specified time out period Either the gas train leak test was not successf...

Page 112: ...ngine shutdown Associated parameter 1 1450 010 Cause Corrective action A problem related to mixture throttle on A side occurred Possible causes Mixture throttle defective no power supply to throttle c...

Page 113: ...r filter Page 148 568 AL L2 P Intake Air after Filter B Yellow alarm Associated parameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Pa...

Page 114: ...Retarded Timing Red alarm Engine shutdown Associated parameter 2 1200 933 Cause Corrective action The cylinder set to maximum retarded timing due to knocking has violated the third limit value 1 Check...

Page 115: ...meter 2 1210 009 Cause Corrective action Fuel calorific value has undershot the second limit value u Check gas quality if feasible 621 LO NOx Value Yellow alarm Associated parameter 2 3050 024 Cause C...

Page 116: ...tly not in standard scope of delivery 634 SD T0 Ambient Air HDT2800 none Associated parameter 1 0700 089 Cause Corrective action Air moisture sensor defect u Sensor currently not in standard scope of...

Page 117: ...0 936 Cause Corrective action Opening angle of throttles B exceeded 1 Check charge air pressure reserve 2 Intake air temperature outside TVU data 3 Check compressor for contamination 4 Reduce power 65...

Page 118: ...communication for gas control valve faulty alternatively a step motor with gas mixer can be installed 1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU gas control valve 4 Check sett...

Page 119: ...1 Check cabling 2 Check power supply 3 Carry out restart of ECU EMU throttle B 4 Check settings with device specific dialog software XD11 1 661 AL PhytronB Comm Lost Red alarm Associated parameter 1...

Page 120: ...designation is transmitted via CAN bus to the genset control system 668 AL TecJet Yellow Yellow alarm Associated parameter 1 4540 993 Cause Corrective action An internal combined alarm in the gas con...

Page 121: ...lt designation is transmitted via CAN bus to the genset control system 674 AL PhyB Yellow Yellow alarm Associated parameter 1 4570 193 Cause Corrective action An internal combined alarm at step motor...

Page 122: ...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 123: ...gine oil filling level detected 1 Check engine oil level Page 150 2 Check replenishment system 3 Fill oil 686 AL Lube Oil Max Red alarm Associated parameter 1 1480 309 Cause Corrective action Maximum...

Page 124: ...tion Gas temperature sensor defective short circuit or wire break 1 Not installed in all engine versions optional 2 Check sensor and cabling B38 replace as necessary 719 AL T Gas L1 Yellow alarm Assoc...

Page 125: ...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 126: ...afety equipment Do not smoke Checking machine room for smell of gas 1 Check machine room to localize gas supply leaks using gas detection and alarm unit 2 If the gas detection and alarm unit responds...

Page 127: ...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 128: ...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 129: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 130 2 Install new spark plug Page 131 MS150097 01E 2013...

Page 130: ...ar protective gloves 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 wea...

Page 131: ...able in operation WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of ruptur...

Page 132: ...k plug to specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Spark plug M18 x 1 5 Tightening torque Assembly compound Molycote P 37 50 5 Nm 9 Fit spark plug conn...

Page 133: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 134 2 Install spark plug connector Page 135 MS150...

Page 134: ...et 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 Spark plug co...

Page 135: ...operation WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing int...

Page 136: ...6 Fit protective cap 2 and check for correct seating 136 Task Description MS150097 01E 2013 10 TIM ID 0000043642 001...

Page 137: ...RNING 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 ri...

Page 138: ...cial tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 145 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3...

Page 139: ...No Qty Feeler gage Y20098771 1 Angular screw driver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 145 2...

Page 140: ...per diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation from the set value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Rel...

Page 141: ...Final steps 1 Remove barring device Page 125 2 Install cylinder head cover Page 146 MS150097 01E 2013 10 Task Description 141 TIM ID 0000004369 003...

Page 142: ...depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 130 2 Remove cylinder head covers Page 145 3 Remove sleeves arrow 4 Install barring device Page 125 5 Rotate crankshaft with...

Page 143: ...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...

Page 144: ...3 Install sleeves arrow 4 Install cylinder head covers Page 146 5 Install spark plugs with new sealing rings Page 131 144 Task Description MS150097 01E 2013 10 TIM ID 0000012015 003...

Page 145: ...disabled Removing cylinder head cover 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 134 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 146: ...mponents for special cleanliness Installing cylinder head cover 1 Clean mounting surface 2 Check condition of gasket replace if dam aged 3 Position gasket and cylinder head cover 1 on cylinder head 4...

Page 147: ...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 148: ...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 149: ...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 150: ...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 151: ...t 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 Engine oil extraction 1 Open shut of...

Page 152: ...sk Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke WARN...

Page 153: ...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 154: ...e available 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 Engine coolant Level check 1 Read off...

Page 155: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 156 2 Fill with engine coolant Page 158 MS150097 01E 2013 10 Task Description...

Page 156: ...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 157: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points MS150097 01E 2013 10 Task Description 157 TIM ID 0000006751 002...

Page 158: ...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 Engine coolant...

Page 159: ...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 156 2 Release union nuts 1 and 3 3 Remov...

Page 160: ...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 Mixture coolant level Check 1 Read off system fil...

Page 161: ...l tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 162 2 Fill with fresh mixture coolant Page 163 MS150097 01E 2013 10 Task De...

Page 162: ...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 163: ...ve 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 Engine coolan...

Page 164: ...swing freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Conta...

Page 165: ...st temperature downstream of cylinder 4 B16 1 Coolant pressure after engine 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 22 Sensors on B side Overview The knocking sensors B80 XX a...

Page 166: ...3 2 Crankshaft speed ignition 2 B79 23 Mixture pressure before throttle 3 B75 Crankshaft speed reset ignition system Table 23 Sensors on engine driving end Overview 166 Task Description MS150097 01E 2...

Page 167: ...e pressure 3 B5 1 Engine oil pressure after filter 4 B7 Engine oil temperature 5 B5 3 Engine oil pressure before filter 6 B4 21 Exhaust bulk temperature after turbocharger Table 24 Sensors on A side O...

Page 168: ...trol 3 B1 2 Camshaft speed for ignition system 4 B1 1 Camshaft speed for engine governor 5 B24 Engine oil level 6 B6 3 Coolant temperature before engine 7 B6 1 Coolant temperature after engine Table 2...

Page 169: ...andard ETK Ersatzteilkatalog Spare Parts Catalog SPC HI High Alarm Measured value exceeds 1st maxi mum limit value HIHI High High Alarm Measured value exceeds 2nd maxi mum limit value HT High Temperat...

Page 170: ...zation SAV Sicherheitsabsperrventil Safety shut off valve SBV Sicherheitsabbalseventil Safety discharge valve SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technis...

Page 171: ...ring operation for preventive maintenance corrective work in case of malfunction or changed oper ating conditions or for spare parts supply For our locally available support go to MTU s Internet site...

Page 172: ...4 2 Valve clearance Check and adjustment Page 139 Barring gear Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 125 Feeler gage Part No Y20098771 Qty Used in 1 6 4 2 Valve clearance C...

Page 173: ...n 3 7 Emission values Check Page 38 Qty Used in 6 1 2 Checking machine room for smell of gas Page 126 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Engine Barring manually Page 125...

Page 174: ...l Page 130 Qty Used in 1 6 3 3 Spark plug Installation Page 131 Stroboscope not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 137 Torque wrench 10 60 Nm Part No F...

Page 175: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 139 MS150097 01E 2013 10 Appendix B 175 DCL ID 0000010329 003...

Page 176: ...Start 36 Wiring check 164 Engine coolant Change 155 Draining 156 Filling 158 Level check 154 Engine layout 18 Engine oil Change 151 Sample extraction and analysis 152 Engine oil filter Replacement 153...

Page 177: ...6 Important provisions 5 Maintenance work 10 Maintenance work special instructions for applica tions with gaseous fuel 13 Operation 8 Operation special instructions for applications with gaseous fuel...

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MTU 8V4000L62FB, Operating Instructions Manual

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Summary of Contents for 8V4000L62FB

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