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MTU MS150033/05E, Operating Instructions Manual

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MTU MS150033/05E Operating Instructions Manual Download Page 173

6.10.2 Mixture coolant – Change

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Mixture coolant

Mixture coolant – Change

1.

Drain mixture coolant (→ Page 174).

2.

Fill with fresh mixture coolant (→ Page 175).

MS150033/05E 2013-10

| Task Description | 173

TIM-ID: 0000007027 - 004

Summary of Contents for MS150033/05E

Page 1: ...Operating Instructions Gas Engine 12 V 4000 Lx2 16 V 4000 Lx2 MS150033 05E ...

Page 2: ...right and may not be used in 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 processing on electronic systems including data bases and online services This handbook is provided for use by maintenance and operating personnel in order to avoid malfunct...

Page 3: ...uled out of service period 40 3 4 Control starting and stopping sequences 41 3 5 Engine Start 43 3 6 Operational checks 44 3 7 Emission values Check 45 3 8 Engine Shutdown 46 3 9 Emergency stop 47 3 10 After stopping the engine Engine remains ready for operation 48 3 11 After stopping the engine Putting the engine out of operation 49 4 Maintenance 4 1 50 hours check 50 4 2 Maintenance task referen...

Page 4: ...cuit Replacement 171 6 10 Low Temperature Circuit 172 6 10 1 Mixture coolant level Check 172 6 10 2 Mixture coolant Change 173 6 10 3 Mixture coolant Draining 174 6 10 4 Mixture coolant Filling 175 6 11 Wiring General for Engine Gearbox Unit 176 6 11 1 Engine wiring Check 176 6 11 2 Sensors Overview 177 7 Appendix A 7 1 Abbreviations 181 7 2 MTU Onsite Energy contacts service partners 183 8 Append...

Page 5: ...onfiguration 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 accordance with the maintenance requirements over the entire service life of the product Main tenance Schedule In compliance with the maintenance and repair instructions contained in this manual in particular...

Page 6: ...ork 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 Training Center of the manufacturer Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation maintenance r...

Page 7: ...for 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 In particular when going down inclines or ramps the engine must be secured against moving and tilting Setting the engine down after transport Only set down engine on a firm level surface Make sure t...

Page 8: ...ith 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 values and warning or alarm messages Malfunctions and emergency stop The procedures for cases of emergency in particular emergency stop must be practiced regularly The following steps must be taken if...

Page 9: ...alves are activated via two different paths from the control system whereby one gas shutoff valve respectively is activated via one of the paths Gas trains must be monitored to detect minimum pressure The plant designer must ensure that the gas train is positioned directly in front of the engine however a maximum of three meters before the interface of the engine The interface is the flange in fro...

Page 10: ...e 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 Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the product Cover the screw or plug with a rag to prevent fluids escaping under press...

Page 11: ...uct 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 removal installation procedures Observe the max permissible force on pressure specified for the jig fixture Do not attempt to bend or apply force to lines Before starting work pay attention to the fol...

Page 12: ...y 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 for repair i e protected in particular against moisture and impact and wrapped in antistatic foil if necessary Working with laser equipment When working with laser equipment always wear special laser ...

Page 13: ...f 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 to the product Activate the emergency stop at the interface switchgear cabinet or by turning the key switch if fitted In case of scheduled shutdowns of the product coolant pump operation must continu...

Page 14: ...product 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 Noncompliance with these guidelines will invalidate the design type approval issued by the emissions regulation authorities The manufacturer does not accept any liability for violations of the emission r...

Page 15: ...ly 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 in areas other than spray booths equipped with extractors ensure good ventilation Make sure that neighboring work areas are not adversely affected There must be no naked flames in the vicinity No smo...

Page 16: ...an be life threatening depending on concentration Some gases can no longer be detected by sense of smell in higher concentrations Caution Risk of poisoning due to hazardous byproducts The absorption of even small quantities of hy drogen sulfide or ammonium may be lethal Caution Danger of suffocation Due to the lack of oxygen the absorption of methane can occasionally lead to increased breathing fr...

Page 17: ...e 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 Consequences Material damage Remedial action Additional product information Safety notices u This manual with all safety instructions and safety notices must be issued to all personnel involved in operation...

Page 18: ...ilter air inlet 4 Mixture cooler 5 Exhaust turbocharger 6 Engine lifting equipment 7 Capacitor ignition system 8 Engine mounting bracket free end 9 Oil pan 10 Engine mounting bracket driving end 11 Starter 12 Flywheel KS Driving end 18 Product Summary MS150033 05E 2013 10 TIM ID 0000038827 002 ...

Page 19: ...filter 12 Oil level 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 12 16V 4000 L62 12 16 Number of cylinders V Cylinder arrangement V engine 4000 Series L Application L Gas engine 6 Load profile 2 Design index Table 2 Engine model designation MS150033 05E 2013 10 ...

Page 20: ...the 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 numbering of other engine components also starts with no 1 at the driving end 1 Left hand side of engine 2 Free end 3 Right hand side of engine 4 Driving end 20 Product Summary MS150033 05E 2013 10 TIM I...

Page 21: ...Approx 3348 mm Width B for 12V Approx 1751 mm Width B for 16V Approx 1751 mm Height C for 12V Approx 2156 mm Height C for 16V Approx 2166 mm Crankshaft center to oil pan D Approx 636 mm Crankshaft center to engine mount E Approx 281 mm Table 3 Main engine dimensions MS150033 05E 2013 10 Product Summary 21 TIM ID 0000038829 002 ...

Page 22: ...2 4 Ignition order Ignition order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 22 Product Summary MS150033 05E 2013 10 TIM ID 0000002806 001 ...

Page 23: ...Reference conditions Power related data power ratings are net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046 A kW 1200 1600 Mean effective pressure pme continuous power ISO 3046 bar 16 8 16 8 Table 5 Power related data power ratings are net brake power to ISO 3046 General conditions for max power...

Page 24: ...e 8 Model related data basic design Coolant system HT circuit Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature at engine connection inlet from cooling equipment w o antifreeze A C 78 78 Coolant temperature after engine warning R C 95 95 Coolant temperature after engine shutdown L C 98 98 Coolant temperature ...

Page 25: ...e after oil filter bar 5 0 5 0 Lube oil pressure after oil filter warning R bar 5 0 5 0 Lube oil pressure after oil filter shutdown L bar 4 5 4 5 Table 11 Lube oil system Fuel system Number of cylinders 12 16 Gas temperature before engine min L C 10 10 Gas temperature before engine max L C 40 40 Gas flow pressure before Tecjet min L mbar 80 80 Gas flow pressure before Tecjet max L mbar 200 200 Tab...

Page 26: ...cylinders 12 16 Dry engine weight basic configuration engine R kg 5850 7750 Heaviest component to be lifted during extended component maintenance QL3 R kg 415 440 Table 16 Weights main dimensions Exhaust emissions Number of cylinders 12 16 Exhaust emission before catalytic converter at 100 DL nitric ox ides NOx in dry exhaust gas 5 O2 G mg m3 n 500 500 Exhaust emission before catalytic converter a...

Page 27: ... are net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046 A kW 1200 1600 Mean effective pressure pme continuous power ISO 3046 bar 16 8 16 8 Table 20 Power related data power ratings are net brake power to ISO 3046 General conditions for max power Number of cylinders 12 16 Relative air humidity A 3...

Page 28: ...it Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature at engine connection inlet from cooling equipment w o antifreeze A C 78 78 Coolant temperature after engine warning R C 95 95 Coolant temperature after engine shutdown L C 98 98 Coolant temperature to enable load application min L C 40 40 Coolant antifreeze...

Page 29: ...e after oil filter bar 5 0 5 0 Lube oil pressure after oil filter warning R bar 5 0 5 0 Lube oil pressure after oil filter shutdown L bar 4 5 4 5 Table 26 Lube oil system Fuel system Number of cylinders 12 16 Gas temperature before engine min L C 10 10 Gas temperature before engine max L C 40 40 Gas flow pressure before Tecjet min L mbar 80 80 Gas flow pressure before Tecjet max L mbar 200 200 Tab...

Page 30: ... cylinders 12 16 Dry engine weight basic configuration engine R kg 5850 7750 Heaviest component to be lifted during extended component maintenance QL3 R kg 415 440 Table 31 Weights main dimensions Exhaust emissions Number of cylinders 12 16 Exhaust emission before catalytic converter at 100 DL nitric ox ides NOx in dry exhaust gas 5 O2 G mg m3 n 250 250 Exhaust emission before catalytic converter ...

Page 31: ... 7 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 SAM Interface module to unit control Monitors second gas solenoid in gas train to engine Diagnostic interface Engine Monitoring Unit EMU Evaluation unit for PT 1000 temperature sensor to det...

Page 32: ...o knock characteristics If knocking is found the ignition timing is retarded on the cylinder in question If this does not result in an improvement the power is reduced Gas control valve TecJet50 Controls the required amount of gas Mixture throttles ProAct The mixture throttles in the mixture lines which are controlled by the engine governor 32 Product Summary MS150033 05E 2013 10 TIM ID 0000017542...

Page 33: ...ay 4 Terminal block 5 Automatic cutout 32A 6 Automatic cutout 16A 7 Emergency stop key switch Fuses F001 Starter A bank starter B bank F002 Throttle A bank throttle B bank F003 Ignition system F004 Anti knock control AKR F005 Emergency stop system F006 TecJet50 F007 SAM F008 ADEC ECU 7 EMU F009 Bypass throttle MS150033 05E 2013 10 Product Summary 33 TIM ID 0000017700 001 ...

Page 34: ...arge number of inputs outputs provided Genset 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 case of inadmissible states and limit value violations Initiation of power reduction engine stop or emergency engine stop configurable Diagnostic function via CAN interface Default CAN1 connect...

Page 35: ...ng de sign SAM functions Display of fault codes from engine governor and SAM 3 Backup function engine life data are stored every hour after every engine stop after every emergency engine stop Interface for dialog unit Diagnosis Straightforward diagnosis by fault code display Self diagnosis by diagnostic lamp 5 Steady SAM is OK Flashing SAM is faulty contact Service Dark Supply voltage missing MS15...

Page 36: ... V etc 4 frequency inputs 1 dialog interface Extendable with MCS 5 PIM I O cards CANOpen and SAE J1939 interface For CANOpen and J1939 interface a type CCB2 printed circuit board 1 is inserted in slot 3 of the SAM unit Engine Monitoring Unit EMU EMU Engine Monitoring Unit 36 Product Summary MS150033 05E 2013 10 TIM ID 0000017541 001 ...

Page 37: ...Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring MS150033 05E 2013 10 Product Summary 37 TIM ID 0000017541 001 ...

Page 38: ...load Recommended maximum run time at this load Recommended minimum run time in subsequent operation at load 50 0 to 30 30 minutes 120 minutes 30 to 50 120 minutes 120 minutes 50 to 100 No restriction No restriction Table 34 Runtimes at partial load A minimum operating time of 2 hours per start is recommended to counteract increased engine loading resulting from temperature changes cold start to en...

Page 39: ... 137 Valve gear Standstill 6 months Lubricate valve gear Page 156 Lube oil system Check engine oil level Page 162 Check oil level in oil storage tank Page 162 Coolant circuit Standstill 1 year Change engine coolant Page 167 Change mixture coolant Page 173 Coolant circuit Check engine coolant level Page 166 Check mixture coolant level Page 172 Engine cabling Check plug connections Page 176 Gas supp...

Page 40: ...d starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 162 Coolant circuit Check engine coolant level Page 166 Check mixture coolant level Page 172 Engine management system Check for fault messages 40 Operation MS150033 05E 2013 10 TIM ID 0000010660 002 ...

Page 41: ...eld 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 Setting start counter 2 Prelubricating until the desired oil pressure is reached optional 3 Checking gas supply solenoid valves for leaks 4 Activating starter 5 Waiting for starting speed 6 Purging e...

Page 42: ... 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 engine with air 5 Starter disengagement stop actuation 6 Engine coasting down to standstill 7 Resetting start counter 8 Waiting for start request Oil refill sequence 1 Waiting for engine running 2 Engi...

Page 43: ...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 WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Starting engine u Start engine in accordance with starting sequence specifications Page 41 MS150033 05E 2013 10 Operation 43 TIM ID 0000042719 001 ...

Page 44: ...lay SAM Check for fault messages If fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Operation log if provided Document operating parameters This is especially useful for fault localization and fast remedial action Engine under load Engine at nominal speed Check engine plant and all pipework visually for leaks rect...

Page 45: ...k 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 leaking exhaust pipework immediately Emission values Check 1 Insert exhaust probe 1 in the exhaust gas flow of the exhaust pipe bellows 3 at tur bocharger 4 2 Carry out measurement ans read off meas ured ...

Page 46: ...and mechanical stresses Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Shutting down engine u Shut down engine in accordance with stopping sequence specifications Page 41 46 Operation MS150033 05E 2013 10 TIM ID 0000042720 001 ...

Page 47: ...p pushbutton Press pushbutton Engine will be shut down Safety measures Item Measure Emergency stop pushbutton Remove key Rectifying cause Item Measure Engine Control System Determine cause for emergency stop and take remedial action if the fault cannot be corrected contact Service Prior to re starting the engine Item Measure Emergency stop button key switch Unlock MS150033 05E 2013 10 Operation 47...

Page 48: ...e 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 48 Operation MS150033 05E 2013 10 TIM ID 0000002329 002 ...

Page 49: ...e is be low 40 C Power supply to engine con trol system Switch off Gas supply Close gas shut off valve Air intake and exhaust sys tems If the engine is to remain out of service for more than 1 week seal the en gine s air and exhaust sides If the engine is to remain out of service for more than 1 month carry out preservation MTU Preservation and Represerva tion Specifications A001070 The corrosion ...

Page 50: ...cylinder 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 operating hours is not necessary Qualifi cation Interval Item Tasks Task hours years QL1 Valve gear Check valve clearance Page 153 50 Maintenance MS150033 05E 2013 10 TIM ID 0000002785 001 ...

Page 51: ...arance adjust as necessary Page 153 W1005 Replace air filter Page 160 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the lat est Page 165 W1089 Check gas lines for leaks seal if required Page 159 W1091 Check ignition timing adjust as necessary Page 149 W1341 Check exhaust emissions adjust if required Page 45 W1382 X Replace vent line of engine coo...

Page 52: ...ety system has reacted in some way TD Transmitter Deviation Two sensors that record the measured values for the same medium are sending different measured values HI High The first limit value has been exceeded HIHI High High The second limit value has been exceeded LO Low The first limit value has been deceeded LOLO Low Low The second limit value has been deceeded MG Message General message SE Sys...

Page 53: ...e from the SAM This code is always followed by a 6 digit number indicating the fault code from the SAM EC This is an alarm message from the engine governor This code is always followed by a 3 digit num ber 3 indicating the fault code from the engine governor 2nd line plain text message that rolls if the text has more than 16 characters providing more information about the faults currently displaye...

Page 54: ...roviding that automatic engine shutdown to protect the engine has not been configured or is not tripped Contact Service immediately start fault rectification Red alarm Caution the engine is running at its limits Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled SE System Error alarms SE no Error message text 0 Sensor Temperat...

Page 55: ...fect 25 I O Module Slot7 Defect 26 I O Module Slot8 Defect 27 Download Server Collision 28 not projected node 29 Device specific error 30 not projected node 31 Device specific error Table 38 SE System Error alarms MS150033 05E 2013 10 Troubleshooting 55 TIM ID 0000017545 002 ...

Page 56: ...ignition timing Page 149 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 cylinder is too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112303 HI T Exhaust A3 Yellow alarm Initiated by EMU Caus...

Page 57: ...ition timing Page 149 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 as compared with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112309 HI T Exhaust A9 Yellow alarm Initiated by EMU Cause C...

Page 58: ...ition timing Page 149 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 as compared with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112315 HI T Exhaust B5 Yellow alarm Initiated by EMU Cause C...

Page 59: ... Check ignition timing Page 149 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 too high as compared with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112401 LO T Exhaust A1 Yellow alarm Initiated by ...

Page 60: ...orrective 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 149 4 Check valve drive 112406 LO T Exhaust A6 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission ...

Page 61: ...Corrective 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 149 4 Check valve drive 112411 LO T Exhaust B1 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission...

Page 62: ...orrective 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 149 4 Check valve drive 112416 LO T Exhaust B6 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission ...

Page 63: ...ues 3 Check ignition timing Page 149 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 with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112502 HIHI T Exhaust A2 Red alarm Initiated by EMU Cause Corrective actio...

Page 64: ...ition timing Page 149 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 compared with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112508 HIHI T Exhaust A8 Red alarm Initiated by EMU Cause Cor...

Page 65: ...nition timing Page 149 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 as compared with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112514 HIHI T Exhaust B4 Red alarm Initiated by EMU Cause Co...

Page 66: ...k ignition timing Page 149 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 high as compared with the average value 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112520 HIHI T Exhaust B10 Red alarm Initiated by EMU Cau...

Page 67: ...orrective 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 149 4 Check valve drive 112605 LOLO T Exhaust A5 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission v...

Page 68: ...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 149 4 Check valve drive 112610 LOLO T Exhaust A10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission v...

Page 69: ...orrective 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 149 4 Check valve drive 112615 LOLO T Exhaust B5 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission v...

Page 70: ...ck spark plug 2 Check emission values 3 Check ignition timing Page 149 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective 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 149 4 Check valve drive 112701 HIHI T Exhaust A1 abs Red alarm Initiated ...

Page 71: ...ition timing Page 149 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112707 HIHI T Exhaust A7 abs Red alarm Initiated by EMU Cause Corrective action The exhaust ...

Page 72: ...nition timing Page 149 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112713 HIHI T Exhaust B3 abs Red alarm Initiated by EMU Cause Corrective action The exhaust...

Page 73: ...ition timing Page 149 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high 1 Check emission values 2 Check ignition timing Page 149 3 Check valve drive exhaust valves do not close 112719 HIHI T Exhaust B9 abs Red alarm Initiated by EMU Cause Corrective action The exhaust ...

Page 74: ...system Page 162 150200 Communication Lost ECU Red alarm Initiated by SAM Cause Corrective action No communication with ECU CAN 1 Check supply voltage 2 Check connecting line 150201 Communication Lost EMU Red alarm Initiated by SAM Cause Corrective action No communication with EMU CAN 1 Check supply voltage 2 Check connecting line 150202 Comm Lost Knock Module Red alarm Initiated by SAM Cause Corre...

Page 75: ...as pressure applied 1 Check initial gas pressure and gas line 2 Check cabling 150399 SS Coolant too Low Red alarm Initiated by SAM Cause Corrective action Lack of coolant in cooling system feedback signal from level sensor missing 1 Check sensor and cabling replace as necessary 2 Check coolant level 3 Pinpoint leakage 150400 AL Preheating Error Yellow alarm Initiated by SAM Cause Corrective action...

Page 76: ...m Initiated by SAM Cause Corrective action Actual power signal out of valid range 1 Check cabling 2 Check signal 150504 LO Engine Power Yellow alarm Initiated by SAM Cause Corrective action The engine is running below minimum load u Check power setpoint signal 150601 AL Gas Valve 1 feedback Red alarm Initiated by SAM Cause Corrective action Feedback signal from valve 1 does not correspond with set...

Page 77: ...Not Reached Red alarm Initiated by TecJet Cause Corrective action No gas flow detected 1 Check inlet and outlet 2 Check gas pressure gas quality gas filter gas line for obstruction 3 Check engine for overloading 151025 Valve Position Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151026 High Elec Temp Red alarm Initiated by TecJet Caus...

Page 78: ...t 151032 Coil Current Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151035 Position Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151036 Elec Temp Fail Low Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1510...

Page 79: ... Low Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151048 Analog Input Low Error Red alarm Initiated by TecJet Cause Corrective action TecJet setting is not correct u Check setting and switch over to PWM input Check PWM signal 151049 Analog Input High Error Red alarm Initiated by TecJet Cause Corrective action TecJet setting is not correct ...

Page 80: ...t TecJet 151054 Delta P Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151055 FGP Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Configured limit value was not attained u Check position direction of TecJet 151056 Battery Volt High Error Red alarm Initiated by TecJet Cause Corrective action Supply voltag...

Page 81: ...larm Initiated by TecJet Cause Corrective action TecJet setting is not correct u Switch over setting to PWM input Check PWM signal 151066 TecJet Shutdown Red alarm Initiated by TecJet Cause Corrective action TecJet combined alarm At least one additional TecJet alarm is pending u Rectify the cause of the source alarm 151067 TecJet Internal Fault Red alarm Initiated by TecJet Cause Corrective action...

Page 82: ...tion Camshaft signal for ignition is missing u Check sensor B1 2 check sensor clearance and cabling replace if necessary Restart of ignition system required to restart the engine 152014 Error Number of Teeth Red alarm Initiated by IC922 Cause Corrective action Incorrect number of teeth on timing wheel detected 1 Check timing wheel 2 Check settings 152015 Unknown Engine Appl Code Red alarm Initiate...

Page 83: ... value 152023 Selftest Shutdown Cause Corrective action Self test is active with the engine rotating u Restart ignition system 152024 Open Primary Rate Exceeded Red alarm Initiated by IC922 Cause Corrective action Admissible summation of discharge faults is reached 1 Check associated cabling 2 Check ignition coils 152026 Open Primary Channel 1 Yellow alarm Initiated by IC922 Cause Corrective actio...

Page 84: ...y Channel 6 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152032 Open Primary Channel 7 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152033 Open Primary Channel 8 Yellow alarm Initiated by IC922 Caus...

Page 85: ...y Channel 13 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152039 Open Primary Channel 14 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152040 Open Primary Channel 15 Yellow alarm Initiated by IC922 C...

Page 86: ...e Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152050 Warn Missing Ring Gear Signal Yellow alarm Initiated by IC922 Cause Corrective action Crankshaft signal 182 teeth is missing u Check sensor B13 2 check sensor clearance and cabling replace if necessary 152051 Warning Missing Reset Signal Yellow alarm Initiated by IC922 Cause Correct...

Page 87: ...922 Cause Corrective action Specified energy level is beyond the valid range u Adjust value 153101 Error Status Red alarm Initiated by antiknock control Cause Corrective action AKR combined alarm At least one additional AKR alarm is pending u Rectify the cause of the source alarm 153102 Combined Error Red alarm Initiated by antiknock control Cause Corrective action Combined alarm for details refer...

Page 88: ... 2 Check sensor tightening torque damage replace as necessary 153113 Knock Sensor Error A3 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 153114 Knock Sensor Error A4 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this kn...

Page 89: ... cabling 2 Check sensor tightening torque damage replace as necessary 153119 Knock Sensor Error A9 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 153120 Knock Sensor Error A10 Red alarm Initiated by antiknock control Cause Corrective action No signal received fro...

Page 90: ... cabling 2 Check sensor tightening torque damage replace as necessary 153125 Knock Sensor Error B5 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock sensor 1 Check cabling 2 Check sensor tightening torque damage replace as necessary 153126 Knock Sensor Error B6 Red alarm Initiated by antiknock control Cause Corrective action No signal received from...

Page 91: ...n Readjustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153222 HI Knock Integrator A2 Yellow alarm Initiated by SAM Cause Corrective action Readjustment of ignition timing beyond a limit value because knocking was detected ...

Page 92: ...djustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153227 HI Knock Integrator A7 Yellow alarm Initiated by SAM Cause Corrective action Readjustment of ignition timing beyond a limit value because knocking was detected in th...

Page 93: ...djustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153232 HI Knock Integrator B2 Yellow alarm Initiated by SAM Cause Corrective action Readjustment of ignition timing beyond a limit value because knocking was detected in th...

Page 94: ...djustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153237 HI Knock Integrator B7 Yellow alarm Initiated by SAM Cause Corrective action Readjustment of ignition timing beyond a limit value because knocking was detected in th...

Page 95: ...egrator A1 Red alarm Initiated by SAM Cause Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153242 HIHI Knock Integrator A2 Red alarm Initiated by SAM Cause Corrective action Emergency stop due to knocking detected in this cylinder 1 Check em...

Page 96: ...Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153247 HIHI Knock Integrator A7 Red alarm Initiated by SAM Cause Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 1...

Page 97: ...Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153252 HIHI Knock Integrator B2 Red alarm Initiated by SAM Cause Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 1...

Page 98: ...Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 153257 HIHI Knock Integrator B7 Red alarm Initiated by SAM Cause Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 1...

Page 99: ... by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153262 HI Misfire Integrator A2 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153263 HI Misfire Integrator A3 Yellow alarm Initiated by ...

Page 100: ...8 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153269 HI Misfire Integrator A9 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153270 HI Misfire Integrator A10 Y...

Page 101: ...B5 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153276 HI Misfire Integrator B6 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153277 HI Misfire Integrator B7 Y...

Page 102: ...tor A2 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153283 HIHI Misfire Integrator A3 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153284 HIHI Misfire Integrator A4...

Page 103: ...r A9 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153290 HIHI Misfire Integrator A10 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153291 HIHI Misfire Integrator B1 ...

Page 104: ...r B6 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153297 HIHI Misfire Integrator B7 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153298 HIHI Misfire Integrator B8 R...

Page 105: ...r B10 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system MS150033 05E 2013 10 Troubleshooting 105 TIM ID 0000017543 001 ...

Page 106: ... Corrective action Engine oil pressure too low limit value 2 Lack of engine oil engine speed too low oil lines oil heat exchanger clogged oil pump defective 1 Check oil system oil heat exchanger 2 Replace oil filter Page 165 3 Take oil sample and analyze Page 164 019 HI T Exhaust A ZKP Number Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas temperature A side after ...

Page 107: ...ger 2 Check ignition timing Page 149 3 Check mixture setting 4 Check spark plugs 022 SS T Exhaust B ZKP Number Yellow alarm Associated parameter 2 0127 932 Cause Corrective action Exhaust gas temperature B side after turbine too high limit value 2 Incorrect ignition timing mixture too lean or too rich damage to turbine 1 Check exhaust turbocharger 2 Check ignition timing Page 149 3 Check mixture s...

Page 108: ...alue 2 This usually fault message usually follows other fault messages 1 Check governor 2 Check throttle closing position 031 HI ETC1 Overspeed ZKP Number Yellow alarm Associated parameter 2 3011 931 Cause Corrective action Speed of primary turbocharger too high limit value 1 u Turbocharger speed sensor is not fitted at present Check ECU setting for this input 032 SS ETC1 Overspeed ZKP Number Red ...

Page 109: ...ube Oil ZKP Number Yellow alarm Associated parameter 2 0125 931 Cause Corrective action Engine oil temperature after oil heat exchanger too high limit value 1 Oil heat exchanger clogged coolant temperature too high oil flow too low 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 162 052 SS T Lube Oil ZKP Number Red alarm Engine shutdown Associated parameter 2 0125 ...

Page 110: ...lant ZKP Number Yellow alarm Associated parameter 2 0101 921 Cause Corrective action Coolant pressure after engine too low limit value 1 Volumetric flow too low static pressure too low u Check engine coolant circuit pressure and volumetric flow 058 SS P Coolant ZKP Number Red alarm Engine shutdown Associated parameter 2 0101 922 Cause Corrective action Coolant pressure after engine too low limit v...

Page 111: ...rameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restrictor valve in crankcase breather is closed too much air filter is defective oil separator is clogged piston rings are seized other damage to crank drive 1 Check crank drive Crank engine Page 137 Endoscope combustion chambers from bottom dead center to top dead center 2 Check air filter for contamination repl...

Page 112: ...rator and coupling for damage 2 In isolated operation Check throttle position Check throttles for implausible closing If throttles are fully open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 160 Check exhaust back pressure Check differential pressure over mixture cooler Check emissions and injection timin...

Page 113: ...ed u Check starter system 093 SS T Preheat ZKP Number Red alarm Engine shutdown Associated parameter 2 1090 922 Cause Corrective action Preheating temperature too low limit value 2 Coolant temperature too low for engine start 1 Check preheating 2 Check differential coolant pressure 3 Check heating elements 4 Check cabling 094 LO T Preheat ZKP Number Yellow alarm Associated parameter 2 1090 921 Cau...

Page 114: ...ECU Supply Voltage ZKP Number Yellow alarm Associated parameter 2 0140 921 Cause Corrective action Supply voltage too low limit value 1 1 Check supply voltage 2 Check cabling 119 LOLO ECU Supply Voltage ZKP Number Red alarm Associated parameter 2 0140 922 Cause Corrective action Supply voltage too low limit value 2 1 Check supply voltage 2 Check cabling 120 HI ECU Supply Voltage ZKP Number Yellow ...

Page 115: ...mber Red alarm Associated parameter 2 4000 004 Cause Corrective action No suitable LifeData backup system available after expiry of timeout following ECU reset Backup system has no LifeData feature or CAN bus to backup system is disrupted u Contact Service error on project data 177 AL LifeData restore incomplete ZKP Number Red alarm Associated parameter 2 4000 006 Cause Corrective action This faul...

Page 116: ...ling Busses CAN bus 1 and CAN bus 2 are redundant 182 AL CAN Wrong Parameters ZKP Number Red alarm Associated parameter 2 0500 682 Cause Corrective action Incorrect parameter values entered in data record u Contact Service configuration fault 183 AL CAN No PU Data ZKP Number Red alarm Associated parameter 2 0500 683 Cause Corrective action A CAN mode has been selected in which communication with t...

Page 117: ...o CAN bus 2 Bus users ECU SAM or EMU faulty u Check operation of nodes and cabling 187 AL CAN1 Error Passive ZKP Number Yellow alarm Associated parameter 2 0500 687 Cause Corrective action CAN controller 1 has signaled a warning Bus nodes ECU SAM or EMU are faulty u Check operation of nodes and cabling 188 AL CAN2 Bus Off ZKP Number Yellow alarm Associated parameter 2 0500 688 Cause Corrective act...

Page 118: ...vice configuration fault 201 SD T Coolant ZKP Number Red alarm Engine shutdown Associated parameter 1 8004 570 Cause Corrective action Coolant temperature sensor at engine outlet defective short circuit or wire break u Check sensor and cabling B6 1 replace if necessary Fault is rectified when engine is restarted 204 SD Level Lube Oil ZKP Number Red alarm Engine shutdown Associated parameter 1 8004...

Page 119: ...replace if necessary Fault is rectified when engine is restarted 211 SD P Lube Oil ZKP Number Red alarm Engine shutdown Associated parameter 1 8004 563 Cause Corrective action Engine oil pressure sensor after filter defective short circuit or wire break u Check sensor and cabling B5 1 replace as necessary Fault is rectified when engine is restarted 212 SD P Coolant ZKP Number Red alarm Associated ...

Page 120: ...replace as necessary Fault is rectified when engine is restarted 219 SD T Intake Air ZKP Number Yellow alarm Associated parameter 1 8004 573 Cause Corrective action Intake air temperature sensor defective short circuit or wire break u Check sensor and cabling B49 2 replace as necessary Fault is rectified when engine is restarted 221 SD P Diff Lube Oil ZKP Number Red alarm Associated parameter 1 80...

Page 121: ...ault in the same operating cycle u Check sensor and cabling B1 1 replace if necessary Fault is rectified when engine is restarted 231 SD Camshaft Speed ZKP Number Red alarm Engine shutdown Associated parameter 1 8004 499 Cause Corrective action Camshaft sensor defective short circuit or wire break u Check sensor and cabling B1 1 replace if necessary Fault is rectified when engine is restarted 232 ...

Page 122: ...rnal governor fault u Replace ADEC engine governor 266 SD Speed Demand ZKP Number Red alarm Associated parameter 2 8006 586 Cause Corrective action Speed setting signal can no longer be transmitted from plant u Check signal and cabling between plant and ADEC 381 AL Wiring TOP 1 ZKP Number Yellow alarm Associated parameter 2 8006 638 Cause Corrective action Short circuit or wire break on transistor...

Page 123: ...Activation of gas supply solenoid valve No 1 faulty u Check cabling 384 AL Wiring TOP 4 ZKP Number Red alarm Associated parameter 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 ZKP Number Yellow alarm Associated parameter 1 8004 603 Cause Corrective acti...

Page 124: ... Check engine coolant circuit pressure and volumetric flow 429 HI P Coolant ZKP Number Red alarm Engine shutdown Associated parameter 2 0101 931 Cause Corrective action Coolant pressure after engine too high limit value 3 u Check engine coolant circuit pressure and volumetric flow 430 LO P Coolant before Engine ZKP Number Yellow alarm Associated parameter 2 0168 921 Cause Corrective action Coolant...

Page 125: ...e coolant circuit pressure and volumetric flow 435 SS T Coolant before Engine ZKP Number Red alarm Engine shutdown Associated parameter 2 0173 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure volumetric flow too low air in engine coolant circuit u Check engine coolant circuit pressure and volumetric flow 443 HI P Charge Mix Diff ZKP N...

Page 126: ...ing system inlet temperature too high mixture cooler clogged 1 Check mixture cooling circuit 2 Check mixture cooler for dirt 452 HIHI T Charge Mix ZKP Number Red alarm Engine shutdown Associated parameter 2 0169 932 Cause Corrective action Mixture temperature is too high limit value 2 Mixture coolant pump failure volumetric flow too low cooling system inlet temperature too high mixture cooler clog...

Page 127: ...e Corrective action Intake air temperature is too low limit value 4 u Check ventilation system 459 SD P Coolant b Engine ZKP Number Red alarm Associated parameter 1 8004 627 Cause Corrective action Coolant pressure sensor before engine defective short circuit or wire break u Check sensor and cabling B16 3 replace if necessary Fault is rectified when engine is restarted 470 SD T ECU ZKP Number Red ...

Page 128: ...ottle if necessary 476 AL Crash Rec Init Fault ZKP Number Red alarm Associated parameter 1 8010 007 Cause Corrective action Crash recorder initialization error u Contact Service 478 AL Comb Alarm Yel Plant ZKP Number Yellow alarm Associated parameter 2 8006 001 Cause Corrective action Combined alarm YELLOW from plant u Combined alarm for details refer to the source alarm 479 AL Comb Alarm Red Plan...

Page 129: ...ling B79 22 replace if necessary Fault is rectified when engine is restarted 498 SD P Charge Mix Diff ZKP Number Red alarm Associated parameter 1 8004 630 Cause Corrective action Mixture differential pressure sensor on A or B side defective short circuit or wire break u Check sensors and cabling B79 21 B79 22 replace if necessary Fault is rectified when engine is restarted 499 SD T Charge Mix ZKP ...

Page 130: ...sions 2 Check ignition timing Page 149 3 Check exhaust back pressure 4 Check valve clearance Page 153 5 Check throttle 6 Check mixture coolant system 513 SD P Coolant Diff ZKP Number 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 B16 1 B16 3 replace if necessary Fault is rectif...

Page 131: ... break u Check sensor and cabling B81 1 replace if necessary Fault is rectified when engine is restarted 522 SD P Intake Air after Filter B ZKP Number 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 sensor and cabling B81 2 replace if necessary Fault is rectified when engine is rest...

Page 132: ...ixture throttle on B side replace mixture throttle on B side if necessary 543 AL Multiple FDH Slaves ZKP Number Yellow alarm Associated parameter 2 0555 005 Cause Corrective action More than one device is activated as backup medium for FDH u Contact Service configuration fault 544 AL Configuration Changed ZKP Number Yellow alarm Associated parameter 2 0555 003 Cause Corrective action This alarm is...

Page 133: ... 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 Either the ignition could not be activated the time out period is set too short or communication is faulty u Check ignition system and cabling 556 AL GasValve Fault ZKP Number Red alarm Associated parameter 2 1090 124 Cause Corrective ...

Page 134: ...ottle on A side and cabling Replace mixture throttle on A side if necessary 560 AL mixture throttle B fault ZKP Number Red alarm Engine shutdown 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 supply to throttle cabling of feedback and or position signal faulty u Check mixture throt...

Page 135: ...rameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Page 160 569 AL SAM Missing Data Fault ZKP Number Red alarm Associated parameter 2 1090 128 Cause Corrective action This alarm is activated if the ECU does not receive some messages to be transmitted from SAM Possible problem related to CAN bus SAM does not work properly or a device ...

Page 136: ...duction is initiated 1 Check emissions 2 Check ignition timing Page 149 3 Check combustion chamber 4 Check gas quality if feasible methane number 572 L3 AI CAN Max Retarded Timing ZKP Number Red alarm Engine shutdown Associated parameter 2 1200 932 Cause Corrective action The cylinder set to maximum retarded timing due to knocking has violated the third limit value 1 Check emissions 2 Check igniti...

Page 137: ...body being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Barring engine manually 1 Remove guard plate 2 Engage barring gear 2 in ring gear 3 and install on flywheel housing 3 Apply ratchet 1 to barring gear 2 4 Rotate crankshaft in direction of engine ro tation Apart from compression resistance there should be no...

Page 138: ... smoke Checking machine room for smell of gas 1 Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit 2 If smell of gas is detected or the gas detection and alarm unit is triggered Avoid naked flames Avoid sparks Do not use electrical appliances including switches connectors sockets telephone bell Do not smoke Close main gas shut off device Open window...

Page 139: ...oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Oil separator Filter replace ment 1 Release clamp 2 on...

Page 140: ...lescence filter 5 must be installed in the correct position in the housing 10 Place coalescence filter 5 in housing en suring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12 Screw on washer 2 with new locknut 1 and tighten to specified tightening torque with torque wrench Name Size Type Lubricant Value Standard Locknut Tightening torque 15 Nm 13 Fit housing cover 1 14 F...

Page 141: ...ment Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 142 2 Install new spark plug Page 143 MS150033 05E 2013 10 Task Description 141 TIM ID 0000004224 002 ...

Page 142: ...ear 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 wear safety goggles face mask and ear defenders Spark plug Removal 1 Remove ignition cable 2 from ignition coil 2 Remove screws 5 and tab washer 4 from cylinder head cover 1 3 Remove spark plug connecto...

Page 143: ...cable 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 rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Spark plug Installation 1 Remove dust and deposits from ignition line on side facing spark pl...

Page 144: ...rk 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 connector 3 with ignition cable 2 on spark plug 10 Install tab washer 4 with screws 5 on cylinder head cover 1 11 Install ignition cable on ignition coil 144 Task Description MS150033 05E 2013 10 TIM ID ...

Page 145: ...rial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 146 2 Install spark plug connector Page 147 MS150033 05E 2013 10 Task Description 145 TIM ID 0000035897 004 ...

Page 146: ...e 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 wear safety goggles face mask and ear defenders Spark plug connector Removal 1 Remove protective cap 3 from ignition coil 1 2 Remove screw 2 take off spring washer 3 Remove screws 5 and tab washer 7 from cylinder he...

Page 147: ...ching the ignition cable 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 rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Spark plug connector Installa tion 1 Clean sleeve and install new sealing ...

Page 148: ...5 Push protective cap 3 onto ignition coil 148 Task Description MS150033 05E 2013 10 TIM ID 0000042718 001 ...

Page 149: ...ARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note The service tool Diasys and a dongle with access rights 1A or higher is required to determine the ignition timing specification 1 Stop engine Page 46 2 Install stroboscope clamp on cylinder A1 ignition cable 3 Start engine Page 43 4 Using the strobos...

Page 150: ...y Sliding depth gauge 200 mm Y20000918 1 Preparatory steps 1 Remove spark plugs Page 142 2 Remove cylinder head covers Page 157 3 Remove sleeves arrow 4 Install barring device Page 137 5 Rotate crankshaft with barring device in en gine direction of rotation until marking OT and pointer are aligned 150 Task Description MS150033 05E 2013 10 TIM ID 0000012015 003 ...

Page 151: ... screw 1 and remove valve bridge Do not remove rocker arm 2 4 Measure distance between valve stem end and cylinder head top at the spark plug bore with depth gauge see figure The specified value for a new cylinder head 93 8 mm Admissible wear 3 mm If the measured value is 96 8 mm have the relevant cylinder head replaced by authorized pesonnel ahead of sched ule 5 Install valve bridge 6 Adjust valv...

Page 152: ...3 Install sleeves arrow 4 Install cylinder head covers Page 158 5 Install spark plugs with new sealing rings Page 143 152 Task Description MS150033 05E 2013 10 TIM ID 0000012015 003 ...

Page 153: ...o Qty Feeler gage Y20098771 1 Offset screwdriver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Plug in open end wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 157 2 Install barring gear Page 137 3 Rotate crankshaft with barring gear in en gine direction of rotation until marking OT and pointer are aligned MS150033 05E 2013 10 Task Description 153 TIM ID 0...

Page 154: ...in firing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance adjustment with cold engine Inlet valves long rocker arm 0 3 mm Exhaust valves short rocker arm 0 5 mm 3 Check all valve clearances in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 4 Use feeler gage to determine the distance between valve bridge an...

Page 155: ...nut 1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 Tightening torque Engine oil 90 Nm 9 Nm 6 Replace or rectify adjusting screws and or locknuts which do not move freely 7 Check valve clearance Final steps 1 Remove barring gear Page 137 2 Install cylinder head cover Page 158 MS1500...

Page 156: ...ols Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 157 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install cylinder head covers Page 158 156 Task Description MS150033 05E 2013 10 TIM ID 0000043352 001 ...

Page 157: ...g disabled Removing cylinder head cover 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 146 3 Remove screws 2 4 Remove cylinder head cover with gasket from cylinder head MS150033 05E 2013 10 Task Description 157 TIM ID 0000042136 001 ...

Page 158: ...omponents 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 Insert screws 2 in cylinder head cover and tighten them Note The locking plate must be removed from the cylinder head cover 5 Install spark plug connector Page 147 158 Task Description MS150033 05E 2...

Page 159: ...gas is combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Gas supply Checking gas lines for leaks 1 Coat all connections of the gas supply line with soap solution or spray with leakage detection spray from a distance of 30 to 50 cm Leaks are indicated by the formation of bubbles or foam 2 Replace leaking parts MS150033 05E 2013 10 Task Desc...

Page 160: ...ilter made of fleece option Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the corresponding fault message appears Replacing air filter 1 Remove air filter Page 161 2 Install new air filter Page 161 160 Task Description MS150033 05E 2013 10 TIM ID 0000013394 002 ...

Page 161: ...talla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from connecting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air filter 3 with clamp 2 onto intake housing 1 5 Tighten clamp 2 MS150033 05E 2013 10 Task Description 161 TIM ID 0000044568 002 ...

Page 162: ...o 2 cm The cause of this may be that oil e g from the oil filter and oil heat exchanger flows back into the oil pan 3 The oil level must reach the mark 2 or ex ceed the mark 1 by up to 2 cm Note Topping up oil manually is not required The oil level check is only intended to confirm that the automatic oil replenishment fea ture works properly 4 Insert oil dipstick into guide tube up to the stop Oil...

Page 163: ... 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 extraction line on engine and waste oil tank 2 Extract all oil from oil pan using the electric pump 3 Close shut off valve s Filling with new engine oil 1 Determine oil change quantity for fuel optimized P...

Page 164: ...ask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine oil Sample extraction 1 Connect sampling hose genset manufac turer s scope of delivery t...

Page 165: ...loves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke Replacing engine oil filter 1 Remove oil filter using filter wrench 2 Clean sealing surface of connecting piece 3 Check condition of new oil filter sealing ring and coat it with...

Page 166: ... 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 optimized Page 23 or emissions optimized Page 27 system filling pressure at pres sure gage 2 Top up with treated coolant as necessary Page 170 166 Task Description MS150033 05E 2013 10 TIM ID 0000006768...

Page 167: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 168 2 Fill with engine coolant Page 170 MS150033 05E 2013 10 Task Description 167 TIM ID 0000000036 031 ...

Page 168: ...e Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch off preheater if installed Engine coolant Draining 1 Open drain valves and drain coolant at the following points At the crankcase free end left and right side 168 Task Description MS150033 05E 2013 10 ...

Page 169: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points MS150033 05E 2013 10 Task Description 169 TIM ID 0000006751 002 ...

Page 170: ... gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with coolant 1 Fill with treated coolant using a pressure pump until the fuel optimized Page 23 or emissions opti mized Page 27 system filling pressure has been reached 2 Vent engine coolant circuit at vent line 3 St...

Page 171: ... 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 168 2 Release union nuts 1 and 3 3 Remove coolant vent line 2 4 Install new coolant vent line 2 5 Fill with engine coolant Page 170 MS150033 05E 2013 10 Task Description 171 TIM ID 0000029143 003 ...

Page 172: ...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 pressure fuel optimized Page 23 or emissions optimized Page 27 at pres sure gauge 2 Top up with treated coolant as necessary Page 175 172 Task Description MS150033 05E 2013 10 TIM ID 0000007032 003 ...

Page 173: ...al tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 174 2 Fill with fresh mixture coolant Page 175 MS150033 05E 2013 10 Task Description 173 TIM ID 0000007027 004 ...

Page 174: ... injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining mixture coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve at drain point in coolant line to mixture coolant cooler and drain coolant 174 Task Description MS150033 05E 2013 10 TIM ID 0000042774 001 ...

Page 175: ...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 with coolant 1 Fill with treated coolant until the fuel optimized Page 23 or emissions optimized Page 27 system filling pressure has been reached 2 Vent mixture coolant circuit via system 3 Start engine ...

Page 176: ...t 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 Contacts Sockets Cables and terminals Plug in contacts Result Contact Service if cable conductors are damaged Note Close male connectors that are not plugged in with the protective cap supplied 6 Clean di...

Page 177: ...air pressure after filter B side 3 B16 1 Coolant pressure after engine 4 B4 XX Exhaust gas temperature after cylinder XX 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 39 Sensors on B side The knocking sensors B80 XX are arranged on the crankcase right and left below the cylinder heads MS150033 05E 2013 10 Task Description 177 TIM ID 0000036119 003 ...

Page 178: ...ation Monitoring of 1 B79 23 Mixture pressure before throttle 2 B75 Crankshaft speed reset ignition system 3 B13 2 Crankshaft speed ignition Table 40 Sensors on driving end 178 Task Description MS150033 05E 2013 10 TIM ID 0000036119 003 ...

Page 179: ...sure A side 2 B50 Crankcase pressure 3 B5 1 Engine oil pressure before filter 4 B7 Engine oil temperature 5 B44 1 Turbocharger speed optional 6 B5 1 Engine oil pressure after filter Table 41 Sensors on A side MS150033 05E 2013 10 Task Description 179 TIM ID 0000036119 003 ...

Page 180: ...fore engine 3 B1 3 Camshaft speed knock module 4 B1 2 Camshaft speed ignition system 5 B1 1 Camshaft speed Engine Control Unit 6 B24 Engine oil level 7 B6 3 Coolant temperature before engine 8 B6 1 Coolant temperature after engine Table 42 Sensors on free end 180 Task Description MS150033 05E 2013 10 TIM ID 0000036119 003 ...

Page 181: ...tandard 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 Temperature ICFN ISO Continuous Fuel stop Net brake power Fuel stop power ISO International coding for power output of combustion engines ISO International Organization for Standardi zation International umb...

Page 182: ...ization 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 Technische Anleitung zur Reinhaltung der Luft General administrative instruction for federal emission control law in Germany TD Transmitter Deviation Alarm Sensor comparison fault UT Unterer Totpunkt Bottom...

Page 183: ...uring operation for preventive maintenance corrective work in case of malfunction or changed oper ating conditions or for spare parts supply For our locally available support go to MTU s Internet site http www mtuonsiteenergy com haendlersuche index de html Your contact at Headquarters support oeg mtu online com Spare Parts Service Quick easy and correct identification of the spare part required f...

Page 184: ...98771 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 153 Filter wrench Part No F30379104 Qty Used in 1 6 8 1 Engine oil filter Replacement Page 165 Gas detection and alarm unit not stocked by MTU Part No Qty Used in 6 1 2 Machine room Check for smell of gas Page 138 184 Appendix B MS150033 05E 2013 10 DCL ID 0000016352 004 ...

Page 185: ...765 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 153 Plug in open end wrench 24 mm Part No F30029815 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 153 Ratchet head with extension Part No F30006212 Qty Used in 1 6 1 1 Engine Barring manually Page 137 MS150033 05E 2013 10 Appendix B 185 DCL ID 0000016352 004 ...

Page 186: ...Page 142 Qty Used in 1 6 3 3 Spark plug Installation Page 143 Stroboscope not stocked by MTU Part No Qty Used in 6 3 7 Ignition system Ignition timing check Page 149 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 6 3 3 Spark plug Installation Page 143 Qty Used in 1 6 3 6 Spark plug connector Installation Page 147 186 Appendix B MS150033 05E 2013 10 DCL ID 0000016352 004 ...

Page 187: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 153 MS150033 05E 2013 10 Appendix B 187 DCL ID 0000016352 004 ...

Page 188: ...7 Emergency stop 47 Main dimensions 21 Shutdown 46 Start 43 Wiring check 176 Engine coolant Change 167 Draining 168 Filling 170 Level check 166 Engine governor Fault messages 106 Engine oil Change 163 Sample extraction and analysis 164 Engine oil filter Replacement 165 Engine oil level Check 162 Engine sides Designation 20 Engine wiring Check 176 Engine Overview 18 F Fault messages SAM On the disp...

Page 189: ...intenance work 10 Maintenance work special instructions for applica tions with gaseous fuel 13 Operation 8 Operation special instructions for applications with gaseous fuel 9 Organizational requirements 6 Personnel requirements 6 Repair work 10 Repair work special instructions for applications with gaseous fuel 13 Safety notices standards 17 Startup 8 Startup special instructions for applications ...

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