MTU 20V4000L32FB Operating Instructions Manual Download

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Operating Instructions

Gas engine

20V4000L32FB

MS150116/04E

Summary of Contents for 20V4000L32FB

Page 1: ...Operating Instructions Gas engine 20V4000L32FB MS150116 04E ...

Page 2: ...ithout the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and storage or processing in electronic systems including databases and online services All information in this publication was the latest information available at the time of going to print MTU Friedrichshafen GmbH reserves the right to change ...

Page 3: ... 4 Engine Main dimensions 48 5 Operation 5 1 Runtimes at partial load 49 5 2 Putting the engine into operation after extended out of service periods 3 months 50 5 3 Putting the engine into operation after scheduled out of service period 51 5 4 Re starting the engine following an automatic safety shutdown 52 5 5 Control starting and stopping sequences 53 5 6 Engine Start 55 5 7 Operational checks 5...

Page 4: ...ysis 215 8 10 Oil Filtration Cooling 216 8 10 1 Engine oil filter Replacement 216 8 11 Coolant Circuit General High Temperature Circuit 217 8 11 1 Engine coolant Level check 217 8 11 2 Engine coolant Change 218 8 11 3 Engine coolant Draining 219 8 11 4 Engine coolant Filling 221 8 11 5 Coolant vent line engine coolant circuit Replacement 222 8 12 Low Temperature Circuit 223 8 12 1 Mixture coolant ...

Page 5: ... are approved by the manufacturer Noncompliance with these specifications will invalidate the design type approval or certification issued by the emissions regulation authorities The manufacturer does not accept any liability for violations of the emission regulations The product must be operated over its entire life cycle according to the conditions defined as Intended use Page 7 Emission certifi...

Page 6: ...following when replacing components with emission labels The relevant emission labels must be affixed to the spare part Emission labels shall not be transferred from the replaced part to the spare part The emission labels must be removed from the replaced part and destroyed 6 Safety MS150116 04E 2018 04 TIM ID 0000040530 012 ...

Page 7: ...ions contained in this manual in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such use and approval has been granted Any other use particularly misuse is considered as being con...

Page 8: ...d instructed and qualified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering The operator must define the responsibilities of the personnel involved in operation maintenance repair as sembly installation and transport in writing Personnel shall not report for duty under the infl...

Page 9: ...rator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediately after putting the product into operation make sure that all control and display instruments as well as the monitoring signaling and alarm systems work properly Smoking is prohibited in the area of the product Safety regu...

Page 10: ...ids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrically live Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times 10 Safety MS150116 04E 2018 04 TIM ID 0000040533 020 ...

Page 11: ...ystem with one path assigned to each of the gas shutoff valves The gas train shall feature minimum pressure monitoring Additional equipment may be necessary in the gas train e g maximum pressure monitoring if gas supply pressure exceeds 100 mbar gas volume flow exceeds 200 m h fuel efficiency exceeds 600 KW Safety regulations for initial startup in gas mixture dual fuel applications Whenever the p...

Page 12: ...Gas trains feature the following components in the direction of flow plant manufacturer user scope of sup ply a manual shutoff valve a gas filter Gas trains feature the following components in the direction of flow MTU scope of supply two gas shutoff valves automatic a pressure regulating device a manual shutoff valve 12 Safety MS150116 04E 2018 04 TIM ID 0000040550 009 ...

Page 13: ... fitted Lock circuit breakers Before starting work on CaPoS if used Switch off the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the UltraCap modules with a suitable wire jumper Close the main valve on the compressed air system and vent the compressed air line when air starters are fitted Before working on the exhaust gas aftertreatme...

Page 14: ...lines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when work ing on exhaust components Clean the work area with a dust extraction machine of class H Wear protective gloves and goggles for protection against acidic condensate Do not touch elastomeric seals e ...

Page 15: ...nd the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic installation removal jig with central expansion pressure supply screw spindle into shaft end until correct sealing is established During hydraulic installation and removal of components ensure that no...

Page 16: ...erly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in antistatic foil as necessary Working with laser equipment Work with laser devices shall be carried out by trained and qualified personnel only Follow the safety in structions in the manufacturer s u...

Page 17: ...t shall be performed by specially trained qualified and author ized personnel only Ensure adequate possibly increased ventilation before opening the gas system Shut down the gas supply to the product by closing the manual shutoff valve Lock out tag out the drive unit to prevent starting Additional safety regulations for marine application engines engines with multipoint gas injection Depressurize ...

Page 18: ...s fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wear protective gloves when handling compo nents and wear additional personal protective equipment is necessary Noise Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB A Noise can lead to an increased risk of a...

Page 19: ...ovided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smoking Observe fire prevention regulations Always wear a mask providing protection against paint and solvent vapors Liquid nitrogen Observe the relevant safety data sheet for all materials Work with liquid nitroge...

Page 20: ...zone Ensure sufficient ventilation Do not enter the hazard zone until it has been established via measurement of the gas concentration with a suitable gas detector that the atmosphere is no longer hazardous Check all gas conveying lines for tightness prior to initial operation and at regular intervals during operation Natural gas pipeline quality or treated Compressed Natural Gas CNG or Liquified ...

Page 21: ...t Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in oper ation maintenance repair assembly installation or transportation 2 The highest level warning notice is used if several hazards apply at the same time Warnings related to per sonal injury shall b...

Page 22: ...ngine 6 Always raise lower the engine slowly The lifting ropes or chains must not butt against the engine or its com ponents during the lifting procedure Readjust lifting gear as necessary 7 For special packaging with aluminum foil Suspend engine by lifting eyes on bearing pedestal or transport by means of handling equipment forklift truck capable of bearing load 8 Secure the engine against tippin...

Page 23: ...Wear personal protective equipment e g protective helmet safety shoes 1 Max permissible diagonal pull 10 2 Center of gravity Taking note of the engine center of gravity Refer to the installation arrangement drawings for details of the center of gravity of the system or the center of gravity of the engine generator MS150116 04E 2018 04 Transport 23 TIM ID 0000081919 002 ...

Page 24: ...installed If the generator is al ready mounted on the engine ensure that the transport locking device of the generator is removed 3 Prior to every engine transport reinstall the transport locking device on both sides according to the instruc tions If the engine is to be moved together with the generator install the transport locking device of the gen erator 4 Always use the screws supplied with or...

Page 25: ...housing 5 Tighten screw 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M10 Tightening torque Engine oil 30 Nm 3 Nm 6 Fit locknut 2 of screw 1 on plate 6 and secure Removing the transport locking device from driving end KS 1 Release the locknuts 2 on both sides of the flywheel housing remove screw 1 and take off holder 3 2 Unscrew screws 4 and remove together with wa...

Page 26: ...gnated in 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 letter Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also s...

Page 27: ...arger right hand side 5 Engine lifting eye 6 Capacitor discharge ignition system 7 Engine mounting bracket free end 8 Oil pan 9 Engine mounting bracket driving end 10 Starter 11 Throttle 12 Flywheel 13 Engine governor engine monitoring KS Driving end MS150116 04E 2018 04 General Information 27 TIM ID 0000044673 003 ...

Page 28: ...vel switch 13 Engine oil heat exchanger KGS Free end Engine model designation Key to engine model designation20V4000L32FB 20 Number of cylinders V Cylinder arrangement V engine 4000 Series L Application L Gas engine 3 Load profile 2 Design index F Additional feature F 50 Hertz B Additional feature B Biogas from fermentation processes Table 2 Engine model designation 28 General Information MS150116...

Page 29: ...rols engine starting stopping and emergency stop Monitors engine operating parameters Controls throttle flaps and sets gas mixture for requested speed power Monitors first gas solenoid in gas train to engine Engine Monitoring Unit EMU 8 Monitors second gas solenoid in gas train to engine Compressor bypass F series Controls throttle flap reserve prevents compressor surges Woodward or Motortech igni...

Page 30: ...question If this does not result in an improvement the power is reduced Gas control valve TecJet110 Controls the required amount of gas Mixture throttle flaps P Series The mixture throttle flaps in the mixture lines which are controlled by the Engine Control Unit 30 Monitoring Control and Regulation Equipment MS150116 04E 2018 04 TIM ID 0000044676 002 ...

Page 31: ...tatus 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 Initiation of power reduction engine stop or emergency engine stop configurable Diagnostic function via CAN interface Default CAN1 connection for dialog unit provided Software structure One data record for engine softwar...

Page 32: ...U 8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 32 Monitoring Control and Regulation Equipment MS150116 04E 2018 04 TIM ID 0000040818 002 ...

Page 33: ... 4 B16 1 Coolant pressure after engine 5 B4 XX Exhaust gas temperature after cylinder XX 6 B79 22 Mixture pressure B side 7 B73 Mixture temperature Table 3 Sensors on B side The knock sensors B80 XX are mounted on the right and left sides of the crankcase below the mixture lines MS150116 04E 2018 04 Monitoring Control and Regulation Equipment 33 TIM ID 0000044681 002 ...

Page 34: ...3 Mixture pressure before throttle 2 B75 Crankshaft speed ignition system reset 3 B13 2 Crankshaft speed ignition Table 4 Sensors on driving end 34 Monitoring Control and Regulation Equipment MS150116 04E 2018 04 TIM ID 0000044681 002 ...

Page 35: ... 1 Intake air temperature A side 4 B79 21 Mixture pressure A side 5 B50 Crankcase pressure 6 B5 3 Engine oil pressure before filter 7 B7 Engine oil temperature 8 B5 1 Engine oil pressure after filter Table 5 Sensors on A side MS150116 04E 2018 04 Monitoring Control and Regulation Equipment 35 TIM ID 0000044681 002 ...

Page 36: ...ed for anti knock control 5 B1 1 Camshaft speed for engine governor 6 B24 Engine oil level 7 B1 2 Camshaft speed ignition system 8 B6 3 Coolant temperature before engine 9 B6 1 Coolant temperature after engine 10 B4 22 Exhaust bulk temperature after turbocharger B side Table 6 Sensors on free end 36 Monitoring Control and Regulation Equipment MS150116 04E 2018 04 TIM ID 0000044681 002 ...

Page 37: ...Reference conditions Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 2000 Mean effective pressure pme continuous power ISO 3046 bar 16 8 Table 8 Power related data power ratings are net brake power as per ISO 3046 Site conditions for max power Number of cylinde...

Page 38: ...AE 00 Table 11 Model related data basic design Coolant system HT circuit Number of cylinders 20 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 87 Coolant temperature at engine connection inlet from cooling equipment w o antifreeze A C 78 Coolant temperature after engine warning R C 95 Coolant temperature after engine shutdown L C 98 Coolant temperature for ...

Page 39: ...ow A m h 28 Pressure in cooling system max L bar 6 0 Pressure loss over MT mixture cooler at nominal flow rate 8 56 bar 2 4 Table 14 Coolant system MT circuit Lube oil system Number of cylinders 20 Lube oil operating temperature after oil heat exchanger from R C 82 Lube oil operating temperature after oil heat exchanger to R C 90 Lube oil operating temperature after oil heat exchanger warning R C ...

Page 40: ...oling equipment R Liters 290 Engine coolant mixture cooler side w o cooling equipment R Liters 25 Engine coolant MT mixture cooler side w o cooling equipment R Liters 30 Total engine oil capacity for initial filling standard oil system R Liters 478 Oil change capacity max standard oil system R Liters 450 Table 19 Capacities Weights main dimensions Number of cylinders 20 Engine dry weight basic con...

Page 41: ...oise unsilenced DL sound power level LW ISO 6798 R dB A 113 Genset surface noise with attenuated intake noise filter DL sound power level LW ISO 8528 10 R dB A 123 Table 22 Acoustics MS150116 04E 2018 04 Technical Data 41 TIM ID 0000044674 003 ...

Page 42: ...ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 1500 Mean piston speed m s 10 5 Continuous power as per ISO 3046 A kW 2000 Mean effective pressure pme continuous power ISO 3046 bar 16 8 Table 24 Power related data power ratings are net brake power as per ISO 3046 Site conditions for max power Number of cylinders 20 Relative humidity A 60 Intake air tempe...

Page 43: ...ine connection outlet to cooling equipment w o antifreeze A C 87 Coolant temperature at engine connection inlet from cooling equipment w o antifreeze A C 78 Coolant temperature after engine warning R C 95 Coolant temperature after engine shutdown L C 98 Coolant temperature for release of load application max 10 kWmech cylin der L C 40 Coolant temperature for release of load application 10 kWmech c...

Page 44: ...e cooler at nominal flow rate 8 56 bar 2 4 Table 30 Coolant system LT circuit Lube oil system Number of cylinders 20 Lube oil operating temperature after oil heat exchanger from R C 82 Lube oil operating temperature after oil heat exchanger to R C 90 Lube oil operating temperature after oil heat exchanger warning R C 93 Lube oil operating temperature after oil heat exchanger shutdown L C 97 Lube o...

Page 45: ...e side w o cooling equipment R Liters 290 Engine coolant mixture cooler side w o cooling equipment R Liters 25 Engine coolant MT mixture cooler side w o cooling equipment R Liters 30 Total engine oil capacity for initial filling standard oil system R Liters 478 Oil change capacity max standard oil system R Liters 450 Table 35 Capacities Weights main dimensions Number of cylinders 20 Engine dry wei...

Page 46: ...oise unsilenced DL sound power level LW ISO 6798 R dB A 113 Genset surface noise with attenuated intake noise filter DL sound power level LW ISO 8528 10 R dB A 123 Table 37 Acoustics 46 Technical Data MS150116 04E 2018 04 TIM ID 0000044675 003 ...

Page 47: ...4 3 Firing order Firing order Number of cylin ders Firing order 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 MS150116 04E 2018 04 Technical Data 47 TIM ID 0000010710 004 ...

Page 48: ... for 20V approx 3896 mm Width B for 20V approx 1584 mm Height C for 20V approx 2293 mm Crankshaft center to oil pan D approx 636 mm Crankshaft center to engine mount E approx 280 5 mm Table 38 Engine Main dimensions 48 Technical Data MS150116 04E 2018 04 TIM ID 0000045087 002 ...

Page 49: ...Wmech cylinder max 5 hours without interruption max 25 hours per year 120 minutes 50 to 100 kWmech cylinder No restriction No restriction Engine operation below a load of 5 kWmech cylinder is to be reduced to a minimum only for start up and shut down operations A minimum operating time of 2 hours per start is recommended to counteract increased engine loading re sulting from temperature changes co...

Page 50: ...ge 192 Lube oil system Check engine oil level Page 213 Check oil level in oil storage tank Page 213 Coolant circuit Standstill 1 year Change engine coolant Page 218 Change mixture coolant Page 224 Coolant circuit Check engine coolant level Page 217 Check mixture coolant level Page 223 Engine cabling Check plug in connections Page 227 Gas supply The gas shut off valves with control solenoids are no...

Page 51: ...d starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 213 Coolant circuit Check engine coolant level Page 217 Check mixture coolant level Page 223 Engine management system Check for fault messages MS150116 04E 2018 04 Operation 51 TIM ID 0000010660 002 ...

Page 52: ...tified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an automatic safety shutdown 1 Eliminate fault 2 If the root cause cannot be identified or eliminated contact Service Important The function Overdrive safety system if fitted which is only used in emerg...

Page 53: ...on 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 when a start command is activated with the engine at stand still 1 Setting start counter 2 Priming optional 3 Checking gas supply solenoid valves for leaks 4 Activating starter 5 Waiting for starting ...

Page 54: ...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 running down to standstill 7 Resetting start counter 8 Awaiting start request Oil refill sequence 1 Waiting for engine running 2 Engine running for a minimum programmed time period 3 Oil refilling enable...

Page 55: ... High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Starting the engine Note A max of 3 engine starting attempts are permitted at a max fuel supply opening time of 15 seconds respec tively After a max of 3 unsuccessful start attempts the fuel supply must be locked Before attempting to start the engine again allow time for sufficient inertization of ...

Page 56: ...machine room for smell of gas Page 174 ECU 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 a...

Page 57: ...n the engine is running Risk of damage to hearing Wear ear protectors WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress es Overheating of and the...

Page 58: ... 1 at the measuring point 2 Start engine 3 Approach the measuring point until a stable operating state has been reached 4 Carry out measurement and read off meas ured value for NOx rel ppm 5 Compare the measured value with the appli cable national limit value adjust exhaust emissions in case of any deviation 58 Operation MS150116 04E 2018 04 TIM ID 0000063508 004 ...

Page 59: ...and mechanical stress es 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 53 MS150116 04E 2018 04 Operation 59 TIM ID 0000042720 001 ...

Page 60: ...y in emergency situations Emergency engine shutdown Item Measure Gas shut off solenoids Two contacts are provided for electrical connection Close gas shut off sole noids engine stop Ignition ignition system In the case of an external EMERGENCY STOP the ignition remains on until the engine has run down to a standstill in order to safely burn off uncombust ed fuel air mixture The ignition is only sw...

Page 61: ...gain following an emergency engine stop Suitable exhaust gas ventilation equipment shall be provided in the facility to ensure that the exhaust gas system downstream of the engine is safely purged A contact is provided to request the ventilation system in the scavenging phase Note Gas train The gas control system shall be equipped with an SAV safety shut off valve when using gas control systems wi...

Page 62: ...ngine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC 62 Operation MS150116 04E 2018 04 TIM ID 0000002329 003 ...

Page 63: ...s 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 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 corrosi...

Page 64: ...ylinder heads after component maintenance or ex tended 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 Maintenance tasks Task h a QL1 Valve gear Check valve clearance Page 187 Table 42 50 hours check 64 Maintenance MS150116 04E 2018 04 TIM ID...

Page 65: ...FILTRATION COOLING Replace oil filter at each oil change or when the time limit years is reached at the latest Page 216 WM00510 CRANKCASE BREATHER Check crankcase pressure control and adjust as necessary Page 177 WM00076 AIR FILTER Replace air filter Page 207 WM00433 GAS PIPING FOR GAS ENGINES Check gas lines for leaks seal as necessary Page 206 WM00434 ENGINE GENERAL Check ignition timing adjust ...

Page 66: ...ailure on the default field bus PB Pushbutton Status indication due to activation of certain control keys AKR Anti Knock Control GET Important information about fault messages from the Engine Control Unit Engine Monitoring Unit Fault messages from the Engine Control Unit are represented in the fault code list Page 133 Information pertaining to alarm colors and automatic engine shutdown in the faul...

Page 67: ...Procedure following an automatic safety shutdown Page 52 MS150116 04E 2018 04 Troubleshooting 67 TIM ID 0000027852 003 ...

Page 68: ...ition timing Page 186 3 Check valve drive exhaust valves do not close 112301 HI T Exhaust A1 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EM...

Page 69: ...ition timing Page 186 3 Check valve drive exhaust valves do not close 112307 HI T Exhaust A7 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112308 HI T Exhaust A8 Yellow alarm Initiated by EM...

Page 70: ...ming Page 186 3 Check valve drive exhaust valves do not close 112313 HI T Exhaust B3 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112314 HI T Exhaust B4 Yellow alarm Initiated by EMU Cause ...

Page 71: ...drive exhaust valves do not close 112319 HI T Exhaust B9 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112320 HI T Exhaust B10 Yellow alarm Initiated by EMU Cause Corrective action Exhaust g...

Page 72: ... on the ignition rail ignition coil for thermal and mechanical damage 112404 LO T Exhaust A4 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal an...

Page 73: ... on the ignition rail ignition coil for thermal and mechanical damage 112408 LO T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal an...

Page 74: ...g on the ignition rail ignition coil for thermal and mechanical damage 112412 LO T Exhaust B2 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal a...

Page 75: ... on the ignition rail ignition coil for thermal and mechanical damage 112416 LO T Exhaust B6 Yellow alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal an...

Page 76: ...arm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal and mechanical damage 112501 HIHI T Exhaust A1 Red alarm Initiated by EMU Cause Corrective action Exhaus...

Page 77: ...ition timing Page 186 3 Check valve drive exhaust valves do not close 112506 HIHI T Exhaust A6 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112507 HIHI T Exhaust A7 Red alarm Initiated by EMU ...

Page 78: ...nition timing Page 186 3 Check valve drive exhaust valves do not close 112512 HIHI T Exhaust B2 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112513 HIHI T Exhaust B3 Red alarm Initiated by EMU...

Page 79: ...ition timing Page 186 3 Check valve drive exhaust valves do not close 112518 HIHI T Exhaust B8 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112519 HIHI T Exhaust B9 Red alarm Initiated by EMU ...

Page 80: ... on the ignition rail ignition coil for thermal and mechanical damage 112603 LOLO T Exhaust A3 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal and...

Page 81: ... on the ignition rail ignition coil for thermal and mechanical damage 112607 LOLO T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal and...

Page 82: ...iring on the ignition rail ignition coil for thermal and mechanical damage 112611 LOLO T Exhaust B1 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for therma...

Page 83: ... on the ignition rail ignition coil for thermal and mechanical damage 112615 LOLO T Exhaust B5 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal and...

Page 84: ...ause Corrective action Exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 57 3 Check ignition timing Page 186 4 Check valve drive 5 Check wiring on the ignition rail ignition coil for thermal and mechanical damage 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of ...

Page 85: ...ition timing Page 186 3 Check valve drive exhaust valves do not close 112705 HIHI T Exhaust A5 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action Exha...

Page 86: ...nition timing Page 186 3 Check valve drive exhaust valves do not close 112711 HIHI T Exhaust B1 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action Exh...

Page 87: ...ition timing Page 186 3 Check valve drive exhaust valves do not close 112717 HIHI T Exhaust B7 abs Red alarm Initiated by EMU Cause Corrective action Exhaust gas temperature of this cylinder is too high 1 Check emission values Page 57 2 Check ignition timing Page 186 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action Exha...

Page 88: ...N 1 Check ECU supply voltage 2 Check CAN connecting line 113601 AL Gas Valve 1 feedback Red alarm Initiated by EMU Cause Corrective action Summary alarm gas solenoid valve 1 feedback does not correspond with setpoint signal 1 Check valve 1 and cabling Page 227 2 Rectify cause of alarm 113602 AL Gas Valve status internal Red alarm Initiated by EMU Cause Corrective action Wire break or short circuit...

Page 89: ... Summary alarm for details refer to the source alarm u Rectify cause of alarm 1 4510 188 Internal Error Red alarm Initiated by anti knock control Cause Corrective action Hardware not ready for operation 1 Restart knock module 2 Replace knock module 1 4510 189 Error Camshaft Red alarm Initiated by anti knock control Cause Corrective action No signal from camshaft sensor for anti knock control 1 Che...

Page 90: ... 2 Check sensor tightening torque damage replace as necessary Page 33 1 4510 196 Knock Sensor Error A5 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling Page 227 2 Check sensor tightening torque damage replace as necessary Page 33 1 4510 197 Knock Sensor Error A6 Red alarm Initiated by anti knock control Cause Corrective action No si...

Page 91: ...7 2 Check sensor tightening torque damage replace as necessary Page 33 1 4510 202 Knock Sensor Error B1 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling Page 227 2 Check sensor tightening torque damage replace as necessary Page 33 1 4510 203 Knock Sensor Error B2 Red alarm Initiated by anti knock control Cause Corrective action No s...

Page 92: ... 2 Check sensor tightening torque damage replace as necessary Page 33 1 4510 208 Knock Sensor Error B7 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling Page 227 2 Check sensor tightening torque damage replace as necessary Page 33 1 4510 209 Knock Sensor Error B8 Red alarm Initiated by anti knock control Cause Corrective action No si...

Page 93: ...ling replace as necessary Page 33 Page 227 1 4520 234 Error Missing Camshaft Signal Red alarm Initiated by IC922 Cause Corrective action Missing camshaft signal for ignition system u Check sensor B1 2 check sensor clearance and cabling replace as necessary Page 33 Page 227 1 4520 235 Error Number of Teeth Red alarm Initiated by IC922 Cause Corrective action Incorrect number of teeth on timing whee...

Page 94: ...l Timing out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified individual ignition timing is beyond the valid range 1 Adapt value in ECU parameter record 2 Check settings at ignition system 1 4520 242 Selftest Shutdown Yellow alarm Initiated by IC922 Cause Corrective action Self test is active with the engine rotating u Restart ignition 1 4520 243 Open Primary Rate Exceede...

Page 95: ...hannel 5 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 227 2 Check ignition coils 1 4520 250 Open Primary Channel 6 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 227 2 Check ignition coils 1 4520 251 Open Primary Channel 7 Yellow alar...

Page 96: ...annel 12 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 227 2 Check ignition coils 1 4520 257 Open Primary Channel 13 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 227 2 Check ignition coils 1 4520 258 Open Primary Channel 14 Yellow al...

Page 97: ...C922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 227 2 Check ignition coils 1 4520 265 Open Primary Channel 20 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 227 2 Check ignition coils 1 4520 270 Warn Missing Ring Gear Signal Yellow alarm Initiated by IC922 Cause C...

Page 98: ...20 275 Odd Energy Level out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified energy level is beyond the valid range u Adapt value in ECU parameter record 1 4520 276 Even Energy Level out of Range Yellow alarm Initiated by IC922 Cause Corrective action Specified energy level is beyond the valid range u Adapt value in ECU parameter record 1 4520 508 MIC5 Stat Operational er...

Page 99: ...Initiated by MIC5 Cause Corrective action The ignition system settings are invalid 1 Check ignition system settings in the Engine Control Unit 2 Restart ignition control unit 1 4520 524 MIC5 Stat W invalid trigger config Yellow alarm Initiated by MIC5 Cause Corrective action The ignition system settings are invalid 1 Check ignition system settings in the Engine Control Unit 2 Restart ignition cont...

Page 100: ... B1 2 Page 227 2 Check B1 2 sensor Page 33 3 Restart ignition control unit 4 Replace ignition control unit 1 4520 530 MIC5 Stat Global timing limited Yellow alarm Initiated by MIC5 Cause Corrective action The global ignition point is beyond the valid range u Check Engine Control Unit settings 1 4520 540 MIC5 E1 General fault Red alarm Initiated by MIC5 Cause Corrective action A general fault has o...

Page 101: ...arm Initiated by MIC5 Cause Corrective action The high voltage power supply unit is faulty 1 Restart ignition control unit 2 Replace ignition control unit 1 4520 546 MIC5 E1 Failure temperature sensor Red alarm Initiated by MIC5 Cause Corrective action The temperature sensor is faulty 1 Restart ignition control unit 2 Replace ignition control unit 1 4520 547 MIC5 E1 Failure current sensor Red alar...

Page 102: ...ta record settings and timing wheel Replace sensor as necessary Page 33 Page 227 2 Restart ignition control unit 1 4520 552 MIC5 E1 Tr1 no signal detected Yellow alarm Initiated by MIC5 Cause Corrective action No signal from pulse sensor 1 B1 2 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 33 Page 227 1 4520 553 MIC5 E1 Tr1 polarity detect...

Page 103: ...ive action Unexpected signal from pulse sensor 1 B1 2 detected u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 33 Page 227 1 4520 559 MIC5 E1 Tr1 index mark not detected Yellow alarm Initiated by MIC5 Cause Corrective action Unable to detect index mark of pulse sensor 1 B1 2 in operation u Check sensor sensor gap cabling data record settings...

Page 104: ... Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 4 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignition coil 1 4520 574 MIC5 IPE Primary Open Cylinder 5 Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 5 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignitio...

Page 105: ...ed alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 11 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignition coil 1 4520 581 MIC5 IPE Primary Open Cylinder 12 Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 12 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check igniti...

Page 106: ...Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 18 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignition coil 1 4520 588 MIC5 IPE Primary Open Cylinder 19 Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 19 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignit...

Page 107: ...Red alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 5 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignition coil 1 4520 595 MIC5 IPE Prim Short Circuit Cyl 6 Red alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 6 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check i...

Page 108: ...ed alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 12 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignition coil 1 4520 602 MIC5 IPE Prim Short Circuit Cyl 13 Red alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 13 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check...

Page 109: ... alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 19 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check ignition coil 1 4520 609 MIC5 IPE Prim Short Circuit Cyl 20 Red alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 20 in ignition sequence 1 Check cabling to ignition coil Page 227 2 Check i...

Page 110: ...ellow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 6 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 616 MIC5 ISE Secondary Open Cylinder 7 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 7 in ignition sequence 1 Check ignition lead connector and igniter 2...

Page 111: ...ellow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 13 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 623 MIC5 ISE Secondary Open Cylinder 14 Yellow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 14 in ignition sequence 1 Check ignition lead connector and ignite...

Page 112: ...low alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 20 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 630 MIC5 ISE Secon Short Circuit Cyl 1 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 1 in ignition sequence 1 Check ignition lead connector and igniter...

Page 113: ...ow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 7 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 637 MIC5 ISE Secon Short Circuit Cyl 8 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 8 in ignition sequence 1 Check ignition lead connector and ignite...

Page 114: ...nce 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 643 MIC5 ISE Secon Short Circuit Cyl 14 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 14 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 644 MIC5 ISE Secon Short Circuit Cyl 15 Yellow alarm Initiated by MIC5 Cause Correct...

Page 115: ...r 2 Check ignition coil 1 4520 649 MIC5 ISE Secon Short Circuit Cyl 20 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 20 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 658 MIC5 E2 Tr2 synchronisation fault Yellow alarm Initiated by MIC5 Cause Corrective action Unable to synchronize with signal fro...

Page 116: ...ause Corrective action Unable to detect index mark of pulse sensor 2 B75 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 33 Page 227 1 4520 664 MIC5 E2 Tr2 wrong n of trigg events Yellow alarm Initiated by MIC5 Cause Corrective action Incorrect number of events from pulse sensor 2 B75 u Check sensor sensor gap cabling data record settings an...

Page 117: ...m Initiated by MIC5 Cause Corrective action Unable to synchronize with signal from pulse sensor 3 B13 2 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 33 Page 227 1 4520 671 MIC5 E2 Tr3 operational error Red alarm Initiated by MIC5 Cause Corrective action Pulse sensor 3 B13 2 has tripped an operational error 1 Check sensor sensor gap cablin...

Page 118: ...ective action Expected signal from pulse sensor 3 B13 2 is missing u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 33 Page 227 1 4520 678 MIC5 E2 Tr3 signal faulty Yellow alarm Initiated by MIC5 Cause Corrective action Unexpected signal from pulse sensor 3 B13 2 detected u Check sensor sensor gap cabling data record settings and timing wheel...

Page 119: ...e Yellow alarm Initiated by compressor bypass Cause Corrective action Internal temperature too high Adjustment rate is reduced 1 Check room temperature and ventilation 2 Check mechanical system 3 Restart compressor bypass flap 1 4530 010 PWM Input High Duty Cycle Error Yellow alarm Initiated by compressor bypass Cause Corrective action Compressor bypass setting is not correct u Check compressor by...

Page 120: ...mpressor bypass Cause Corrective action Temperature of the electronics above 140 ºC or internal temperature sensor faulty 1 Check room temperature and ventilation 2 Compare device temperature with temperature gauge in Service tool 3 Replace compressor bypass flap 1 4530 017 Electronics Temperature Low Error Red alarm Initiated by compressor bypass Cause Corrective action Temperature of the electro...

Page 121: ... 1 4530 022 CAN Fault Red alarm Initiated by compressor bypass Cause Corrective action CAN bus connection faulty 1 Check cabling Page 227 2 Check compressor bypass flap settings 1 4540 009 Zero Pressure Detected Yellow alarm Initiated by TecJet Cause Corrective action No gas pressure gas flow detected u Check gas pressure 1 4540 010 Zero Flow Detected Yellow alarm Initiated by TecJet Cause Correct...

Page 122: ... 1 4540 015 FGT Fail High Red alarm Initiated by TecJet Cause Corrective action Internal gas temperature sensor faulty 1 Restart TecJet 2 Replace TecJet 1 4540 016 Delta P Fail High Red alarm Initiated by TecJet Cause Corrective action Internal differential gas pressure sensor faulty 1 Restart TecJet 2 Replace TecJet 1 4540 017 FGP Fail High Red alarm Initiated by TecJet Cause Corrective action In...

Page 123: ... Low Red alarm Initiated by TecJet Cause Corrective action Internal differential gas pressure sensor faulty 1 Restart TecJet 2 Replace TecJet 1 4540 023 FGP Fail Low Red alarm Initiated by TecJet Cause Corrective action Internal gas pressure sensor faulty 1 Restart TecJet 2 Replace TecJet 1 4540 024 Coil Current Fail Low Red alarm Initiated by TecJet Cause Corrective action Actuator current limit ...

Page 124: ...eached minimum limit value 1 Check supply voltage 2 Check cabling Page 227 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Gas temperature before TecJet is below the preset limit value 1 Check TecJet settings 2 Check gas temperature 1 4540 031 Delta P Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Pressure difference through TecJet below ...

Page 125: ...ings 2 Check gas pressure 1 4540 036 FGP High Limit Error Red alarm Initiated by TecJet Cause Corrective action Gas pressure before TecJet is above the preset limit value 1 Check TecJet settings 2 Check gas pressure 1 4540 037 Watchdog Reset Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 1 4540 038 CAN Flow Demand Failed Red alarm Initiated ...

Page 126: ...cJet 1 4540 044 Parameter Version Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation 1 Restart TecJet 2 Replace TecJet 1 4540 045 Main EEP Read Fail Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation 1 Restart TecJet 2 Replace TecJet 1 4540 046 Main EEP Write Fail Red alarm Initiated by TecJet Cause Corrective action Har...

Page 127: ... 12V Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation 1 Restart TecJet 2 Replace TecJet 1 4540 052 ADC Test Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation 1 Restart TecJet 2 Replace TecJet 1 4540 053 CAN Timing Changed Yellow alarm Initiated by TecJet Cause Corrective action Change of CAN baud rate detected 1...

Page 128: ... A Cause Corrective action Throttle setting is not correct u Check throttle setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by throttle of cylinder bank A Cause Corrective action Supply voltage has reached maximum or minimum limit value 1 Check supply voltage 2 Check cabling Page 227 1 4550 034 A Position Error Red alarm Initiated by throttle of cylinder bank A Cause Correct...

Page 129: ...2 Check cabling Page 227 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by throttle of cylinder bank A Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550 040 A Analog Position Demand Failed Yellow alarm Initiated by throttle of cylinder bank A Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550 041 A PWM Position...

Page 130: ...tiated by throttle of cylinder bank B Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by throttle of cylinder bank B Cause Corrective action Supply voltage has reached maximum or minimum limit value 1 Check supply voltage 2 Check cabling Page 227 1 4550 134 B Position Error Red alarm Initiated by throt...

Page 131: ...2 Check cabling Page 227 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by throttle of cylinder bank B Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550 140 B Analog Position Demand Failed Yellow alarm Initiated by throttle of cylinder bank B Cause Corrective action Throttle setting is not correct u Check throttle settings 1 4550 141 B PWM Position...

Page 132: ...on CAN bus connection faulty 1 Check cabling Page 227 2 Check throttle settings 1 4550 144 B CAN Stop Command Yellow alarm Initiated by throttle of cylinder bank B Cause Corrective action Stop input signal received via CAN bus u Check throttle settings 132 Troubleshooting MS150116 04E 2018 04 TIM ID 0000038611 006 ...

Page 133: ...il filter Page 216 3 Take oil sample and analyze Page 215 016 SS P Lube Oil Red alarm Engine shutdown Associated parameter 2 0100 922 Cause Corrective action Engine oil pressure too low limit value 2 No oil in engine engine speed too low oil lines oil heat exchanger clogged oil pump faulty 1 Check oil system oil heat exchanger 2 Replace oil filter Page 216 3 Take oil sample and analyze Page 215 01...

Page 134: ...rger 2 Check ignition timing Page 186 3 Check mixture setting 4 Check igniters 022 SS T Exhaust B 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 186 3 Check mixture setting 4 Chec...

Page 135: ...d of turbocharger 1 too high limit value 1 1 Check intake air temperature 2 Check emissions Page 57 3 If the sensor is not obstructed check the conditions for activating this monitoring feature in the ECU parameter record 032 SS ETC1 Overspeed Red alarm Engine shutdown Associated parameter 2 3012 932 Cause Corrective action Speed of turbocharger 1 too high limit value 2 1 Check intake air temperat...

Page 136: ...uit 2 Check oil heat exchanger 3 Check oil level Page 213 052 SS T Lube Oil Red alarm Engine shutdown Associated parameter 2 0125 932 Cause Corrective action Engine oil temperature after oil heat exchanger too high limit value 2 Oil heat exchanger contaminated coolant temperature too high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page ...

Page 137: ...rive 1 Check crank drive Bar engine Page 173 Endoscope combustion chambers from bottom dead center to top dead center 2 Check air filter for contamination replace if contamination is visible Page 207 3 Check setting of blow by restrictor valve 4 Check oil separator condition replace as necessary Page 175 064 SS P Crank Case Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective...

Page 138: ... limit set in parameter 2 2500 027 engine stall speed limit and no engine stop is applied The engine is shutdown for safety reasons 1 In mains parallel operation Check mains for frequency drop Check generator and coupling for damage 2 In isolated operation Check restrictor flap position Check restrictor flaps for implausible closing If restrictor flaps are fully open Check if load step values are ...

Page 139: ...rective action Minimum speed for flushing process and ignition release was not attained u Check starter system 093 SS T Preheat 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 Pa...

Page 140: ...pply voltage too low limit value 1 1 Check supply voltage 2 Check cabling Page 227 119 LOLO ECU Power Supply Voltage Red alarm Associated parameter 2 0140 922 Cause Corrective action Supply voltage too low limit value 2 1 Check supply voltage 2 Check cabling Page 227 120 HI ECU Power Supply Voltage Yellow alarm Associated parameter 2 0140 931 Cause Corrective action Supply voltage too high limit v...

Page 141: ... alarm Engine shutdown Associated parameter 2 0500 681 Cause Corrective action Bus node EMU lost on CAN bus 2 u Check operation of bus users and cabling Buses CAN bus 1 and CAN bus 2 are redundant 182 AL CAN Wrong Parameters Red alarm Associated parameter 2 0500 682 Cause Corrective action Wrong parameter value entered in data record u Contact Service configuration error 183 AL CAN No PU Data Red ...

Page 142: ...ause Corrective action CAN controller 1 signaled a warning Possible causes may be e g missing node minor faults or temporary bus overload u Check operation of bus users and cabling 188 AL CAN2 Bus Off Yellow alarm Associated parameter 2 0500 688 Cause Corrective action CAN controller 2 is in Bus Off mode Automatic switching to CAN bus 1 Bus users ECU or EMU faulty u Check operation of bus users an...

Page 143: ...ne oil level sensor faulty short circuit or wire break u Check sensor and cabling B24 replace as necessary Page 33 Page 227 Error cleared after restarting the engine 206 SD T Exhaust A Yellow alarm Associated parameter 1 8004 576 Cause Corrective action Exhaust temperature sensor on A side faulty short circuit or wire break u Check sensor and wiring B4 21 replace as necessary Page 33 Page 227 Erro...

Page 144: ... Corrective action Crankcase pressure sensor faulty short circuit or wire break u Check sensor and wiring B50 replace as necessary Page 33 Page 227 Error cleared after restarting the engine 216 SD T Lube Oil Red alarm Engine shutdown Associated parameter 1 8004 575 Cause Corrective action Engine oil temperature sensor after oil heat exchanger faulty short circuit or wire break u Check sensor and w...

Page 145: ...orrective action Engine stop due to camshaft sensor failure u Check sensor and cabling B1 1 replace as necessary Page 33 Page 227 Error cleared after restarting the engine 231 SD Camshaft Speed Red alarm Engine shutdown Associated parameter 1 8004 499 Cause Corrective action Camshaft sensor faulty short circuit or wire break u Check sensor and cabling B1 1 replace as necessary Page 33 Page 227 Err...

Page 146: ...ed alarm Associated parameter 2 8006 586 Cause Corrective action Speed setting signal can no longer be transmitted from plant 1 Check Engine Control Unit setting default setting is speed demand via CAN bus 2 Check signal and cabling between plant and ECU 381 AL Wiring TOP 1 Yellow alarm Associated parameter 2 8006 638 Cause Corrective action Short circuit or wire break at transistor output 1 plant...

Page 147: ...meter 1 8004 603 Cause Corrective action Intake air temperature sensor faulty short circuit or wire break u Check sensor and cabling B49 2 replace as necessary Page 33 Page 227 419 SD T Coolant before Engine Red alarm Associated parameter 1 8004 604 Cause Corrective action Coolant temperature sensor at engine inlet faulty short circuit or wire break u Check sensor and cabling B6 3 replace as neces...

Page 148: ...t pressure before engine too low limit value 2 Insufficient volume flow static pressure too low u Check engine coolant circuit pressure and flow 434 HI T Coolant Before Engine Yellow alarm Associated parameter 2 0173 931 Cause Corrective action Coolant temperature before engine too high limit value 1 Engine coolant pump failure flow too low air in engine cooling system u Check engine coolant circu...

Page 149: ...iff Red alarm Engine shutdown Associated parameter 2 0183 932 Cause Corrective action Difference in mixture pressures sensed on A and B side is too high limit value 2 1 Check restrictor flaps for varying positions and malfunction 2 Check mixture lines for leakage 3 Check sensors and cabling B79 22 B79 21 Page 33 Page 227 451 HI T Charge Mix Yellow alarm Associated parameter 2 0169 931 Cause Correc...

Page 150: ...2 Check mixture cooling circuit 454 SS Power Reduction Active Yellow alarm Associated parameter 2 7000 011 Cause Corrective action Power reduction activated 1 Rectify limit value violation of the source alarm e g reduce intake temperature 2 Check exhaust system components for leaks cracks 457 LO T Intake Air Yellow alarm Associated parameter 2 0123 921 Cause Corrective action Intake air temperatur...

Page 151: ... action Engine stop since all shutdown channels have sensor failure u Summary alarm for details refer to the source alarm 476 AL Crash Rec Init Fault Red alarm Associated parameter 1 8010 007 Cause Corrective action Crash recorder initialization error u Contact Service 478 AL Comb Alarm Yel Plant Yellow alarm Associated parameter 2 8006 001 Cause Corrective action Summary alarm YELLOW from system ...

Page 152: ... Mixture differential pressure sensor on A or B side faulty short circuit or wire break u Check sensors and cabling B79 21 B79 22 replace as necessary Page 33 Page 227 Error cleared after restarting the engine 499 SD T Charge Mix Red alarm Associated parameter 1 8004 632 Cause Corrective action Mixture temperature sensor faulty short circuit or wire break u Check sensor and cabling B73 replace as ...

Page 153: ...use Corrective action Starter not engaged ECU does not detect engine speed during starting sequence 1 Check starter 2 Check cabling Page 227 3 Check speed sensor B1 1 if speed is not indicated although engine is turning Page 33 517 SD P Charge Mix before Throttle Red alarm Associated parameter 1 8004 631 Cause Corrective action Mixture pressure sensor before restrictor flap faulty short circuit or...

Page 154: ...own Associated parameter 2 1005 921 Cause Corrective action Set and actual power deviate excessively from each other 1 Check converter 2 Check fuel settings 3 Check emissions Page 57 536 AL Wiring PWM_CM1 Red alarm Associated parameter 1 1041 921 Cause Corrective action Wire break or short circuit on channel PWM_CM1 u Check ignition cabling 552 AL GasControlCheck Fault Red alarm Associated paramet...

Page 155: ... Gas supply solenoid valve faulty Alarm is active if there are problems with the gas supply solenoid valves Either the gas supply solenoid valves are faulty the timeout period is set too short or communication is faulty 1 Check gas train 2 Check cabling Page 227 557 AL EngineSpeedCollapse Fault Red alarm Engine shutdown Associated parameter 2 1090 126 Cause Corrective action Speed dip Alarm is act...

Page 156: ...lap faulty no power supply to restrictor flap cabling of feedback and or position signal faulty u Check mixture restrictor flap on B side and cabling Replace mixture restrictor flap on B side as necessary 565 AL L1 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 921 Cause Corrective action Pressure loss over air filter on A side is too high u Replace air filter Page 207 566 AL...

Page 157: ...MU and ECU bus Replace devices as necessary 570 L1 Al CAN Max Retarded Timing Yellow alarm Associated parameter 2 1200 931 Cause Corrective action Due to detected knocking the cylinder set to maximum retarded timing has violated the limit value 1 Check emissions Page 57 2 Check ignition timing Page 186 3 Check combustion chamber 4 Check gas quality if feasible methane number 571 L2 Al CAN Max Reta...

Page 158: ...er Closed Red alarm Engine shutdown Associated parameter 2 0451 115 Cause Corrective action Generator load switch does not open when engine stops Engine is motoring 1 Check generator load switch 2 Manually disconnect generator switch 3 Open any existing mains circuit breaker 4 Where possible do not operate manual emergency stop 587 AL Wiring PWM_CM4 Red alarm Associated parameter 1 1041 924 Cause ...

Page 159: ...ly rapid change in gas quality u Check gas system 606 AL Double Nodes Lost CAN 1 2 Yellow alarm Associated parameter 2 0500 691 Cause Corrective action Bus node EMU lost on CAN bus 1 and 2 u Check operation of bus nodes and cabling Page 227 608 AL Wiring PWM_CM6 Red alarm Associated parameter 1 1041 926 Cause Corrective action Wire break or short circuit on channel PWM_CM6 u Check setting at Engin...

Page 160: ...ity if feasible 618 LOLO Actual Value Hu Yellow alarm Associated parameter 2 1210 007 Cause Corrective action Fuel calorific value has undershot the second limit value u Check gas quality if feasible 619 HI Actual Value Hu Yellow alarm Associated parameter 2 1210 008 Cause Corrective action Fuel calorific value has exceeded the first limit value u Check gas quality if feasible 620 HIHI Actual Valu...

Page 161: ...623 HI NOx Value Yellow alarm Associated parameter 2 3050 026 Cause Corrective action NOx emissions have exceeded the first limit value 1 Check gas quality if feasible 2 Check NOx sensor Page 33 3 Check emissions Page 57 624 HIHI NOx Value Yellow alarm Associated parameter 2 3050 027 Cause Corrective action NOx emissions have exceeded the second limit value 1 Check gas quality if feasible 2 Check ...

Page 162: ...r eff power can also be transmitted via CAN bus as an option 3 Check configuration of plant control system 646 Al Knock Intensity Red alarm Engine shutdown Associated parameter 2 1200 934 Cause Corrective action Knock intensity exceeded extreme knocking detected 1 Check gas quality if feasible methane number 2 Check emissions Page 57 3 Check combustion chamber 649 Al Req Angle Throttle A Yellow al...

Page 163: ...ion CAN bus communication for knock control faulty 1 Check cabling Page 227 2 Check power supply 3 Carry out restart of ECU EMU and knock control 4 Check settings with device specific dialog software XD10 653 AL IC92x Comm Lost Red alarm Associated parameter 1 4520 996 Cause Corrective action CAN bus communication for ignition system faulty 1 Check cabling Page 227 2 Check power supply 3 Restart E...

Page 164: ...pecific dialog software XD50 1 657 AL ProActB Comm Lost Red alarm Associated parameter 1 4550 196 Cause Corrective action CAN bus communication for restrictor flap B faulty 1 Check cabling Page 227 2 Check power supply 3 Carry out restart of ECU EMU and restrictor flap B 4 Check settings with device specific dialog software XD50 2 658 AL NOxA Comm Lost Red alarm Associated parameter 1 4560 096 Cau...

Page 165: ...detected u An exact fault designation is transmitted via CAN bus to the genset control system 667 AL FSeries Yellow Yellow alarm Associated parameter 1 4530 993 Cause Corrective action An internal summary alarm in the bypass flap was detected u An exact fault designation is transmitted via CAN bus to the genset control system 668 AL TecJet Yellow Yellow alarm Associated parameter 1 4540 993 Cause ...

Page 166: ...t fault designation is transmitted via CAN bus to the genset control system 675 AL GET Red Red alarm Associated parameter 1 4510 991 Cause Corrective action An internal summary alarm in knock control was detected u An exact fault designation is transmitted via CAN bus to the genset control system 676 AL IC92x Red Red alarm Associated parameter 1 4520 991 Cause Corrective action An internal summary...

Page 167: ...etected u An exact fault designation is transmitted via CAN bus to the genset control system 681 AL NOxA Red Red alarm Associated parameter 1 4560 091 Cause Corrective action An internal summary alarm at NOx sensor A was detected u An exact fault designation is transmitted via CAN bus to the genset control system 682 AL NOxB Red Red alarm Associated parameter 1 4560 191 Cause Corrective action An ...

Page 168: ...tion Engine oil was refilled too often within a certain time interval u Check engine oil level Page 213 Check oil supply 691 HI Lube Oil Level Refill Yellow alarm Associated parameter 1 1480 311 Cause Corrective action Engine oil was refilled too often within a certain time interval u Check engine oil level Check oil supply 719 AL T Gas L1 Yellow alarm Associated parameter 2 8006 034 Cause Correct...

Page 169: ...l Humidity L1 Yellow alarm Power reduction Associated parameter 2 8006 039 Cause Corrective action Calculated air humidity has exceeded limit value 1 u Check air humidity 891 AL Scavenging Active Yellow alarm Associated parameter 2 1090 048 Cause Corrective action Engine was shut down by emergency stop and has failed to successfully complete the starting sequence several times 1 Await end of scave...

Page 170: ...se Corrective action Emergency stop input has been activated 1 Rectify fault at source 2 Check cabling Page 227 972 AL MIC5 Signature difference Red alarm Associated parameter 1 4520 969 Cause Corrective action The ignition system has not accepted the configuration from the Engine Control Unit 1 Restart ECU 2 Check setting at Engine Control Unit 974 AL CAN3 Bus Off Yellow alarm Associated paramete...

Page 171: ...g 977 AL CAN4 Error Passive Yellow alarm Associated parameter 2 0500 695 Cause Corrective action CAN controller 4 has indicated a warning u None 1012 AL MIC5 parameter download active Yellow alarm Associated parameter 1 4520 966 Cause Corrective action Parameter download from the ECU to the ignition system is active u Wait until parameter downloading has been completed Max time is approx 2 min 101...

Page 172: ... points Page 186 1030 LO P Crank Case Yellow alarm Associated parameter 2 0106 935 Cause Corrective action Crankcase pressure too low limit value 1 Restrictor valve in crankcase breather too widely open faulty air filter 1 Check air filter for damage replace if damage is visible 2 Check setting of blow by restrictor valve 1031 LOLO P Crank Case Red alarm Engine shutdown Associated parameter 2 0106...

Page 173: ...body being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the engine 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 rota tion Apart from compression resistance there should be no ...

Page 174: ...onal safety equipment Do not smoke Checking machine room for smell of gas 1 Check machine room to localize gas supply leaks using gas detection and alarm unit 2 If the gas detection and alarm unit responds Avoid naked flames Avoid sparks Do not use electrical appliances including switches connectors sockets telephone bell Do not smoke Close the magnetic gas shutoff valves Open windows and doors Wa...

Page 175: ...nces which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective 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 Replacing oil se...

Page 176: ... filter 5 must be installed in the correct position in the housing 10 Place coalescer filter 5 in housing ensuring it is straight 11 Fit filter cover 3 ensuring it is positioned correctly 12 Screw on washer 2 with new locknut 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standard Locknut Tightening torque 8 Nm 13 Fit housing cover 1 14 Fit clamp 2...

Page 177: ... disabled Pressure control Check and adjustment 1 Check crankcase pressure adjust if required 2 To adjust pressure control turn ball valve 1 Performance at engine setting Setting value 100 10 mbar 2 mbar Table 44 Pressure control setting value MS150116 04E 2018 04 Crankcase Breather 177 TIM ID 0000077731 001 ...

Page 178: ...ment Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 179 2 Install new spark plug Page 180 178 Ignition System MS150116 04E 2018 04 TIM ID 0000004224 002 ...

Page 179: ...able 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 1 Remove spark plug connector 1 Page 183 2 Unscrew spark plug a few tur...

Page 180: ...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 Installing spark plug 1 Clean and dry the mating surfaces ...

Page 181: ...e 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 Nm 7 Install spark plug connector 1 Page 184 MS150116 04E 2018 04 Ignition System 181 TIM ID 0000043425 004 ...

Page 182: ...rial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 183 2 Install spark plug connector Page 184 182 Ignition System MS150116 04E 2018 04 TIM ID 0000035897 004 ...

Page 183: ...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 1 Loosen screws 4 on cylinder head cover 7 turning them back approx one revolution 2 Turn flange 6 counterclockwise out of un ion 4 3 Pull protective cap 2 up and back to gain access to threaded connection of the ignition lead underneath 4 Lo...

Page 184: ...ine s lower sealing ring and replace with a new sealing ring 2 Remove any dust and impurities from the ig nition line connector s Teflon body on the outside and inside on the spark plug side 3 Check the spark plug isolator sealing ring for damage If damaged install a new spark plug isolator sealing ring Page 185 4 Insert the ignition line connector 5 into the spark plug duct press down the ignitio...

Page 185: ...nd pull out sealing ring 2 3 Fold together new sealing ring 2 4 Insert sealing ring 2 into the bore in Teflon sleeve 1 with the article number facing downwards 5 Carefully press sealing ring 1 into the groove until it is flush with the bore in Teflon sleeve 2 MS150116 04E 2018 04 Ignition System 185 TIM ID 0000043226 006 ...

Page 186: ...unning Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note Service tool DiaSys and a 1A level dongle or higher as well as the Woodward IC900 series service tool for Woodward ignition systems only are required to determine the ignition timing setting 1 Stop engine Page 59 2 Install stroboscope clamp on cylinder A1 igni tion cable 3 Start engine Page 55 4 Use str...

Page 187: ...ps 1 Remove cylinder head cover Page 193 2 Install barring device Page 173 3 Rotate crankshaft with barring device in en gine direction of rotation until marking OT and pointer are aligned Scheme for 20V Two crankshaft adjustments Position Cylin der 1 2 3 4 5 6 7 8 9 10 20V Firing TDC in cylinder A1 Bank A I X X I X I X I X I Bank B I X I I X X I X I X I Inlet Valve clearance adjustment of inlet v...

Page 188: ...ions firing TDC and overlap TDC of cylinder A1 as per diagram 4 Use feeler gauge to determine distance between valve bridge and rocker arm 5 If the deviation from the specified 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 adjusting screw 2 so that the specifie...

Page 189: ...ty Sliding depth gage 200 mm Y20000918 1 Preparatory steps 1 Remove igniters Page 179 2 Remove cylinder head covers Page 193 3 Remove sleeves arrowed 4 Install barring tool Page 173 5 Rotate crankshaft with barring tool in engine direction of rotation until marking OT and pointer are aligned MS150116 04E 2018 04 Valve Drive 189 TIM ID 0000043220 003 ...

Page 190: ...ase 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 igniter bore with depth gage 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 re place the relevant cylinder head ahead of schedule 5 Install valve bridge 6 Adjust valve clearance Page 187...

Page 191: ...3 Install sleeves arrowed 4 Install cylinder head covers Page 194 5 Install igniters with new sealing rings Page 180 MS150116 04E 2018 04 Valve Drive 191 TIM ID 0000043220 003 ...

Page 192: ... tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 193 2 Fill oil chambers of rocker arms and adjusting screws with oil 3 Install cylinder head covers Page 194 192 Valve Drive MS150116 04E 2018 04 TIM ID 0000043352 001 ...

Page 193: ...ting disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 183 3 Remove screws 2 4 Remove cylinder head cover with gasket from cylinder head MS150116 04E 2018 04 Valve Drive 193 TIM ID 0000042136 002 ...

Page 194: ...components for special cleanliness Cylinder head cover Installa tion 1 Clean mounting surface 2 Check condition of gasket replace if dam aged 3 Position gasket and cylinder head cover 1 on cylinder head 4 Insert screws 2 in cylinder head cover and tighten them Note The locking plate must be removed from the cylinder head cover 5 Install spark plug connector Page 184 194 Valve Drive MS150116 04E 20...

Page 195: ...omponents 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 Chemical substances in cleaners Risk of irritation and chemical burns Always obey manufacturer s instructions for use WARNING Cleaner is extremely caustic Risk of injury and suffocation Avoid contact...

Page 196: ...are installed so that they are never under tension or strain Ensure correct installation position of components NOTICE Contamination of components Damage to component Observe manufacturer s instructions Check components for special cleanliness Note Exhaust turbocharger may remain installed for cleaning Preparatory steps 1 Remove insulation 2 Drain engine coolant Page 219 3 Loosen clamps 1 4 Loosen...

Page 197: ...overs 10 Loosen V band clamp 1 11 Remove intake neck 3 from compressor housing 12 Remove O ring 2 from intake housing 3 13 Remove temperature sensor 1 14 Loosen nuts 6 on stud 5 15 Take off exhaust elbow 2 with flange seg ments 3 and gasket 4 MS150116 04E 2018 04 Exhaust Turbocharger 197 TIM ID 0000081654 001 ...

Page 198: ...on of compressor housing relative to bearing housing 3 2 Remove screws from compressor hous ing 1 Note The O ring on the insert wall is not 100 leak tight If oil penetrates the compressor hous ing the cause can be found in the oil separa tor 3 Axially remove compressor housing 1 from bearing housing 3 4 Remove O ring 5 Unscrew screws 1 with locating washers 6 Remove diffuser from compressor housin...

Page 199: ... the functional and sealing surfaces 1 Remove all deposits from functional areas and sealing faces 2 Clean compressor wheel turbine wheel nozzle ring compressor housing turbine housing and diffuser with cleaner 3 Clean diffuser if necessary with wire brush 4 Thoroughly clean securing tabs 5 Dry all functional and sealing surfaces using a clean lint free cloth MS150116 04E 2018 04 Exhaust Turbochar...

Page 200: ...ially and install on bearing housing 2 3 Tighten screw connections 3 on turbine housing 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Assembly compound Molykote P 37 45 Nm 5 Nm 200 Exhaust Turbocharger MS150116 04E 2018 04 TIM ID 0000081654 001 ...

Page 201: ...d Kluthe Hakuform 30 15 7 Place O ring in wall 8 Install compressor housing 1 on bearing housing 3 9 Tighten screw connections 2 on compressor housing 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque Assembly compound Molykote P 37 70 Nm 5 Nm MS150116 04E 2018 04 Exhaust Turbocharger 201 TIM ID 0000081654 001 ...

Page 202: ... to specified tightening torque Name Size Type Lubricant Value Standard Screw connection M16 Tightening torque Assembly compound Ultra Therm MTU Assembly compound Molykote P 37 30 Nm 5 Nm 4 Coat studs 5 on exhaust turbocharger with assembly compound Molykote P 37 5 Position exhaust elbow 2 with flange seg ments 3 and new gasket 4 on exhaust tur bocharger Note Use new nuts 6 6 Screw on nuts 6 and u...

Page 203: ...ening torque 40 Nm 5 Nm 10 Insert sensor in union 2 11 Tighten union nut 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M10 Tightening torque 35 Nm 5 Nm 12 Position V band clamp 1 Note Use new O ring 2 13 Coat O ring 2 with assembly compound Kluthe Hakuform 30 15 14 Insert O ring 2 in groove of intake hous ing 3 and insert intake housing in compres so...

Page 204: ... Assembly compound Ultra Therm MTU Assembly compound Molykote P 37 60 Nm 5 Nm 18 Remove covers Note Use new gaskets 2 19 Install bellows 4 5 between intake housing 1 and gas mixer 20 Tighten screw connections 3 on bellows 4 5 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw connection M10 Tightening torque Engine oil 42 Nm 2 Nm 204 Exhaust Turbocharger MS1501...

Page 205: ... Tightening torque 8 Nm 1 Nm 25 Fill with engine coolant Page 221 26 Install insulation 27 After engine start a Visually inspect oil lines and coolant lines for leaks b Check crankcase pressure adjust if required Page 177 28 Check exhaust gas emissions adjust as necessary This work should be performed by service personnel MS150116 04E 2018 04 Exhaust Turbocharger 205 TIM ID 0000081654 001 ...

Page 206: ...k of fire and explosion Avoid open flames electrical sparks and ignition sources Carry gas warning unit part of the personal safety equipment Do not smoke Gas supply checking gas lines for leaks 1 Coat all 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 leaki...

Page 207: ...refilter 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 cor responding fault message appears Replacing air filter 1 Remove air filter Page 208 2 Install new air filter Page 208 MS150116 04E 2018 04 Air Filter 207 TIM ID 0000013394 002 ...

Page 208: ...ter Removal and installa tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from con necting flange 1 of intake housing 3 Check connecting flange 1 of intake hous ing for obstruction 4 Use suitable cleaning agent to clean contact surfaces of intake housing and air filter Note The contact surfaces must be dry and free from grease 5 Place new air filter 3 with clamp 2 onto in take housing 1 6 U...

Page 209: ...placement Special tools Material Spare parts Designation Use Part No Qty Starter Spare Parts Catalog Replacing starter 1 Remove starter Page 210 2 Install new starter Page 211 MS150116 04E 2018 04 Starting System 209 TIM ID 0000064198 002 ...

Page 210: ...of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes Disconnecting starter 1 Prior to disconnecting mark all cables with writable adhesive tape 1 Terminal 50 Control cable EIM 2 Terminal 30 Positive cable 3 Terminal 30 b Starter relay output 4 Terminal 45 Engine supply 5 Terminal 31 ground cable to battery 2 Disconnect all cables on starter 3 Protect all cables f...

Page 211: ... is switched off before starting work Secure against unintentional switching on WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes Starter Installation 1 Coat the starter pinion with grease and turn it back into its initial position as necessary Note Do not secure crane to engagemen...

Page 212: ...ze Type Lubricant Value Standard Nut M5x0 8 Tightening torque 2 5 Nm 0 5 Nm 3 Screw nuts 2 3 4 5 onto terminals 30 30 b 45 31 and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M12x1 75 Tightening torque 30 Nm 3 Nm 4 Check starter operation 212 Starting System MS150116 04E 2018 04 TIM ID 0000014016 011 ...

Page 213: ...ay ex ceed the mark 1 by up to 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 feature works properly 4 Insert oil dipstick into g...

Page 214: ...ontact 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 Engine oil Extracting 1 Open shut off valve s in extraction line from engine and waste oil tank 2 Use electric pump to extract all oil from oil pan 3 Close shut off valve s New engine oil Filling 1 Determine oil ch...

Page 215: ...ive 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 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 unit manufa...

Page 216: ...rk Wear protective clothing protective 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 Engine oil filter Replacement 1 Unscrew oil filter with oil filter wrench 2 Clean sealing surface on connecting piece 3 Check condition o...

Page 217: ...is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant Level check 1 Read off system filling pressure fuel optimized Page 37 or for tropical applications Page 42 at pres sure gauge 2 Top up with treated coolant as necessary Page 221 MS150116 04E 2018 04 Coolant Circuit General High Temperature Circuit 21...

Page 218: ... Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 219 2 Fill with engine coolant Page 221 218 Coolant Circuit General High Temperature Circuit MS150116 04E 2018 04 TIM ID 0000000036 031 ...

Page 219: ...y 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 MS150116 04E 2018 04 Coolant Circuit General High Tempera...

Page 220: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 220 Coolant Circuit General High Temperature Circuit MS150116 04E 2018 04 TIM ID 0000006751 002 ...

Page 221: ...s 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 system filling pressure fuel optimized Page 37 or for tropical applications Page 42 has been reached 2 Vent engine coolant circuit at vent line 3 Start engine an...

Page 222: ... scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Coolant vent line Replacement 1 Drain engine coolant Page 219 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 221 222 Coolant Circuit General High Temperature Circuit MS150116 04E 2018 04 TIM ID 0000029143 004 ...

Page 223: ...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 37 or for tropical applications Page 42 at pres sure gauge 2 Top up with treated coolant as necessary Page 226 MS150116 04E 2018 04 Low Temperature Circuit 223 TIM ID 0000045193 001 ...

Page 224: ...tools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 225 2 Fill with fresh mixture coolant Page 226 224 Low Temperature Circuit MS150116 04E 2018 04 TIM ID 0000007027 004 ...

Page 225: ...ury 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 MS150116 04E 2018 04 Low Temperature Circuit 225 TIM ID 0000042774 001 ...

Page 226: ...ves 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 system filling pressure fuel optimized Page 37 or for tropical applications Page 42 has been reached 2 Vent mixture coolant circuit via system 3 St...

Page 227: ... 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 Connector housings Contacts Plug connectors Cables and terminals Plug in contacts Result If cable conductors are damaged contact Service Note Close connectors that are not plugged in with the protective cap sup...

Page 228: ...aximum 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 international cod ing for the power specification of combustion engines ISO International Organization for Standardi zation International umbrella organization for all na tional standardization institutes KG...

Page 229: ...motive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil 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 Bottom Dead Center WZK Too...

Page 230: ...her during operation for preventive maintenance corrective work in case of malfunction or changed operating condi tions 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 info cac mtuonsiteenergy com Spare Parts Service Quick easy and correct identification of the spare part req...

Page 231: ...5 Qty Used in 1 8 4 1 Valve clearance Check and adjustment Page 187 Barring gear Part No F6555766 Qty Used in 1 8 1 1 Engine Barring manually Page 173 Crossbeam Part No T80092210 Qty Used in 1 2 1 Transport Page 22 MS150116 04E 2018 04 Appendix B 231 DCL ID 0000028554 006 ...

Page 232: ...tion and alarm unit not stocked by MTU Part No Qty Used in 5 8 Emission values Check Page 57 Gas detection and alarm unit not stocked by MTU Part No Qty Used in 8 1 2 Checking machine room for smell of gas Page 174 Oil filter wrench Part No F30379104 Qty Used in 1 8 10 1 Engine oil filter Replacement Page 216 232 Special Tools MS150116 04E 2018 04 DCL ID 0000028554 006 ...

Page 233: ... 211 Ratchet bit Part No F30027340 Qty Used in 1 8 5 1 Exhaust turbocharger Cleaning Page 195 Ratchet bit Part No F30027341 Qty Used in 1 8 5 1 Exhaust turbocharger Cleaning Page 195 Ratchet head with extension Part No F30006212 Qty Used in 1 8 1 1 Engine Barring manually Page 173 MS150116 04E 2018 04 Special Tools 233 DCL ID 0000028554 006 ...

Page 234: ...000918 Qty Used in 1 8 4 2 Valve protrusion Measurement Page 189 Socket screwdriver 14 mm Part No F30378499 Qty Used in 1 8 8 3 Starter Installation Page 211 Socket wrench 24 mm Part No F30029815 Qty Used in 1 8 4 1 Valve clearance Check and adjustment Page 187 234 Special Tools MS150116 04E 2018 04 DCL ID 0000028554 006 ...

Page 235: ... 5 0 Nm Part No F30452774 Qty Used in 1 8 8 3 Starter Installation Page 211 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 2 3 Crankshaft transport locking device Page 24 Qty Used in 1 8 3 3 Spark plug Installation Page 180 Qty Used in 1 8 3 6 Spark plug connector Installation Page 184 Qty Used in 1 8 5 1 Exhaust turbocharger Cleaning Page 195 Qty Used in 1 8 8 3 Starter Installation Page ...

Page 236: ...sport locking device Page 24 Qty Used in 1 8 4 1 Valve clearance Check and adjustment Page 187 Qty Used in 1 8 5 1 Exhaust turbocharger Cleaning Page 195 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 8 5 1 Exhaust turbocharger Cleaning Page 195 Qty Used in 1 8 7 2 Air filter Removal and installation Page 208 236 Special Tools MS150116 04E 2018 04 DCL ID 0000028554 006 ...

Page 237: ... 26 Cylinder head cover Installation 194 Removal 193 E Emergency stop Engine 60 Emission values Check 57 Engine After stopping Putting out of operation 63 Barring manually 173 Emergency shutdown 60 Main dimensions 48 Overview 27 Shutdown 59 Start 55 Engine cabling Check 227 Engine coolant Change 218 Draining 219 Filling 221 Level check 217 Engine driving end Definition 26 Engine free end Definitio...

Page 238: ...formation for gas eous fuel supply applications 20 Fire prevention 18 Fire prevention specific information for dual fuel ap plications 20 Fire prevention specific information for gaseous fuel supply applications 20 Fluids and lubricants 18 Fluids and lubricants specific information for dual fuel applications 20 Fluids and lubricants specific information for gaseous fuel supply applications 20 Impo...

Page 239: ...val 210 Replacement 209 Starting sequence 53 Stopping sequence 53 T Transport Description 22 Lifting specifications 23 V Valve clearance Adjustment 187 Check 187 Valve gear Lubrication 192 Valve protrusion Measurement 189 W Warning notices standards 21 MS150116 04E 2018 04 Index 239 DCL ID 0000028554 006 ...

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MTU 20V4000L32FB, Operating Instructions Manual

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