MTU 8V4000Lx4 Operating Instructions Manual Download Page 160

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6.3.5 Spark plug connector – Removal

Preconditions

☑

Engine is stopped and starting disabled.

☑

Open protective packing of new spark plug connector only immediately prior to installation.

WARNING

Hot components/surfaces.

Risk of burns!

• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

Removing spark plug connector

Loosen screws (4) on cylinder head cov-
er (7) turning them back approx. one revo-
lution.

Turn flange (6) counterclockwise out of un-
ion (4).

Pull protective cap (2) up and back to gain
access to threaded connection of the igni-
tion lead underneath.

Loosen threaded connection of the ignition
lead on ignition coil (1) and disconnect igni-
tion cable (3).

Grip ignition lead connector (5) by
flange (6) and disconnect from spark plug
before fully extracting it from spark plug
bore.

160 | Task Description | MS15026/00E 2015-05

TIM-ID: 0000043225 - 004

Summary of Contents for 8V4000Lx4

Page 1: ...Operating Instructions Gas engine 8V4000Lx4 MS15026 00E...

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: ...40 3 5 Engine Start 42 3 6 Operational checks 43 3 7 Emission values Check 44 3 8 Engine Shutdown 45 3 9 Emergency engine shutdown 46 3 10 After stopping the engine Engine remains ready for operation...

Page 4: ...t 184 6 10 1 Mixture coolant level Check 184 6 10 2 Mixture coolant Change 185 6 10 3 Mixture coolant Draining 186 6 10 4 Mixture coolant Filling 187 6 11 Wiring General for Engine Gearbox Unit 188 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: ...must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical...

Page 8: ...y instruments as well as the monitoring signaling and alarm systems are working properly Smoking is prohibited in the area of the product Safety regulations during operation The operator must be famil...

Page 9: ...Observe the warning information applicable to the devices MS15026 00E 2015 05 Safety 9 TIM ID 0000040533 010...

Page 10: ...o gas shutoff valves a pressure regulating device The gas train must be fitted with an automatic leak check The gas shutoff valves are activated via two different paths from the control system whereby...

Page 11: ...e mounts damping elements couplings and V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to...

Page 12: ...cable straps Welding work Welding operations on the product or mounted units are not permitted Cover the product when welding in its vicinity Before starting welding work Switch off the power supply m...

Page 13: ...hat cabling cannot be dam aged during operation by Contact with sharp edges Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to sec...

Page 14: ...as been trained and authorized for this task All work on gas carrying components must only be resourced to authorized specialized companies Shut off the gas supply to the product and aivate the emerge...

Page 15: ...with its handling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating danger are drowned Wear ear protectors in workplaces with a sound pres...

Page 16: ...test in accordance with the specifications Painting Observe the relevant safety data sheet for all materials When carrying out painting work outside the spray stands provided with fume extraction syst...

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: ...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 20: ...tion 5 Throttle 6 Ignition coil 7 Spark plug 8 Cylinder head cover 9 Cylinder head 10 Engine oil sampling port 11 Engine oil filter 12 Oil level switch 13 Engine coolant inlet con nection 14 Engine oi...

Page 21: ...nting bracket free end 8 Oil pan 9 Engine mounting bracket driving end 10 Starter 11 Flywheel KS Driving end Engine model designation Key to the engine model designation 8V4000L64 8 Number of cylinder...

Page 22: ...accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and lett...

Page 23: ...ns Length A approx 2484 mm Width B approx 1742 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 Main engine dimension...

Page 24: ...2 4 Firing order Firing order Number of cylinders Firing order 8 V A1 A3 A4 A2 B3 B4 B2 B1 24 Product Summary MS15026 00E 2015 05 TIM ID 0000002807 003...

Page 25: ...Power related data power ratings are net brake power to 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 1040 Mean effectiv...

Page 26: ...flange engine main PTO SAE 00 Table 8 Model related data basic design Coolant system HT circuit Number of cylinders 8 Coolant temperature at engine connection outlet to cooler system w o anti freeze A...

Page 27: ...ating temperature after oil heat exchanger warning R C 93 Lube oil operating temperature after oil heat exchanger engine shutdown L C 97 Lube oil pressure after oil filter bar 5 5 Lube oil pressure af...

Page 28: ...able 15 Capacities Weights main dimensions Number of cylinders 8 Dry engine weight basic configuration engine R kg 5200 Heaviest component to be lifted during maintenance level W5 R kg 280 Table 16 We...

Page 29: ...ower to 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 1040 Mean effective pressure pme continuous power ISO 3046 bar 21...

Page 30: ...t temperature at engine connection outlet to cooler system w o anti freeze A C 90 Coolant temperature at engine connection inlet from cooler system w o an tifreeze A C 78 Coolant temperature after eng...

Page 31: ...l pressure after oil filter bar 5 5 Lube oil pressure after oil filter warning R bar 5 0 Lube oil pressure after oil filter shutdown L bar 4 5 Table 26 Lube oil system Fuel system Number of cylinders...

Page 32: ...cylinders 8 Dry engine weight basic configuration engine R kg 5200 Heaviest component to be lifted during maintenance level W5 R kg 280 Table 31 Weights main dimensions Exhaust gas emissions Number o...

Page 33: ...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 34: ...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 35: ...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 36: ...oring Unit EMU 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 36 Product Summary MS15026 00E 2015 05 TIM ID 000...

Page 37: ...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 38: ...e 167 Lube oil system Check engine oil level Page 175 Check oil level in oil storage tank Page 175 Coolant circuit Standstill 1 year Change engine coolant Page 180 Change mixture coolant Page 185 Cool...

Page 39: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 175 Coolant circuit Check engine coolant level Page 179 Check mixture coolant level Page...

Page 40: ...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 41: ...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 42: ...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 43: ...e room for smell of gas Page 152 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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC 48 Operation MS15026 00E 2015...

Page 49: ...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 50: ...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 51: ...W0527 Check engine oil level in storage tank Page 175 W1002 Check valve clearance adjust if required Page 168 W1005 Replace air filter Page 173 W1008 Replace engine oil filter when changing engine oi...

Page 52: ...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 53: ...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 MS15026 00E 2015 05 Troubleshooting 53 TIM...

Page 54: ...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 163 3 Check valve gear exhaust valves do no...

Page 55: ...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 163 3 Check valve gear exhaust valves do...

Page 56: ...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 163 3 Check valve gear exhaust valves do...

Page 57: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 163 3 Check valve gear exhaust valves do...

Page 58: ...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 163 4 C...

Page 59: ...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 163 4 Check valve...

Page 60: ...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 163 4 Check valve...

Page 61: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 163 4 Check valve...

Page 62: ...ividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 163 3 Check valve gear exhaust valves do not close...

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 163 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 163 3 Check valve gear exhaust valves do...

Page 65: ...ction Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values 2 Check ignition timing Page 163 3 Check valve gear exhaust valves do...

Page 66: ...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 163 4 Ch...

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 163 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 163 4 Check valve...

Page 69: ...ive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 163 4 Check valve...

Page 70: ...sion values 2 Check ignition timing Page 163 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 71: ...ition timing Page 163 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 72: ...nition timing Page 163 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 73: ...s temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 163 3 Check valve gear exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated by...

Page 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...eries 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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...l system oil heat exchanger 2 Replace oil filter Page 178 3 Take oil sample and analyze Page 177 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas tem...

Page 113: ...parameter 2 0154 931 Cause Corrective action Pressure loss via oil filter too high limit value 1 1 Replace oil filter Page 178 2 If this fault occurs again after unexpectedly short filter runtime che...

Page 114: ...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 115: ...is too high Insufficient oil volume flow rate 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 175 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cau...

Page 116: ...alve 4 Check oil separator condition replace if necessary Page 153 064 SS P Crankcase Red alarm Engine stop Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit va...

Page 117: ...ck if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 173 Check exhaust back pressure Check differential pressure over...

Page 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 163 3 Check ex...

Page 132: ...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 133: ...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 134: ...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 135: ...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 136: ...ng Page 163 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 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...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 152: ...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 153: ...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 154: ...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 155: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 156 2 Install new spark plug Page 157 MS15026 00E 2015 0...

Page 156: ...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 157: ...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 158: ...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 159: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 160 2 Install spark plug connector Page 161 MS150...

Page 160: ...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 161: ...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 162: ...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 163: ...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 164: ...Qty Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 156 2 Remove cylinder head covers Page 170 3 Remove sleeves arrow 4 Install barring device Page 151 5 Rotate cran...

Page 165: ...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 166: ...3 Install sleeves arrow 4 Install cylinder head covers Page 171 5 Install spark plugs with new sealing rings Page 157 166 Task Description MS15026 00E 2015 05 TIM ID 0000043220 002...

Page 167: ...ls Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 170 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install...

Page 168: ...ve cylinder head cover Page 170 2 Install barring device Page 151 3 Rotate crankshaft with barring tool in en gine direction of rotation until TDC marking and pointer are aligned Diagram for 8 V engin...

Page 169: ...rom 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 adj...

Page 170: ...g disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 160 3 Remove screws 2 4 Remove cylinder head cover with gasket from...

Page 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ...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 177: ...k 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 ex...

Page 178: ...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 179: ...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 180: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 181 2 Fill with engine coolant Page 183 180 Task Description MS15026 00E 2015...

Page 181: ...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 182: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 182 Task Description MS15026 00E 2015 05 TIM ID 0000006751 002...

Page 183: ...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 184: ...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 185: ...al tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 186 2 Fill with fresh mixture coolant Page 187 MS15026 00E 2015 05 Task De...

Page 186: ...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 187: ...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 188: ...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 189: ...6 1 Coolant pressure after engine 4 B4 X Exhaust temperature after cylinder 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 39 Sensors on right engine side The knocking sensors B80 XX...

Page 190: ...n Monitoring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset ignition system 3 B13 2 Crankshaft speed ignition system Table 40 Sensors on driving end 190 Task Description MS1...

Page 191: ...9 21 Mixture pressure A side 2 B50 Crankcase pressure 3 B7 Engine oil temperature 4 B5 3 Engine oil pressure before filter 5 B5 1 Engine oil pressure after filter Table 41 Sensors on A side MS15026 00...

Page 192: ...engine 3 B1 3 Camshaft speed knock module 4 B1 1 Camshaft speed engine governor 5 B1 2 Camshaft speed ignition system 6 B24 Engine oil level 7 B6 3 Coolant temperature before engine 8 B6 1 Coolant te...

Page 193: ...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 194: ...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 195: ...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 196: ...ar Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 151 Feeler gauge Part No Y20098771 Qty Used in 1 6 4 3 Valve clearance Check and adjustment Page 168 Gas detection and alarm unit n...

Page 197: ...o F30379104 Qty Used in 1 6 8 1 Engine oil filter Replacement Page 178 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Engine Barring manually Page 151 Sliding depth gauge 200 mm Par...

Page 198: ...l Page 156 Qty Used in 1 6 3 3 Spark plug Installation Page 157 Stroboscope Not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 163 Torque wrench 10 60 Nm Part No F...

Page 199: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 3 Valve clearance Check and adjustment Page 168 MS15026 00E 2015 05 Appendix B 199 DCL ID 0000029553 001...

Page 200: ...hutdown 45 Start 42 Engine cabling Check 188 Engine Control Unit Fault messages 112 Engine coolant Change 180 Draining 181 Filling 183 Level check 179 Engine driving end Definition 22 Engine free end...

Page 201: ...a tions with gaseous fuel 17 Important provisions 5 Maintenance work 11 Operation 8 Organizational requirements 7 Personnel requirements 7 Repair work 11 Startup 8 Safety requirements Maintenance work...

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MTU 8V4000Lx4, Operating Instructions Manual

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