MTU 12 V 4000 L63 Скачать руководство пользователя страница 46

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4 Maintenance

4.1 50-hours check

50-hours check

One-time operations to be carried out after the first 50 operating hours of the cylinder head (with a new

engine, after installation of new cylinder heads, after component maintenance or extended component

maintenance).
When installing a cylinder head with run-in mating faces (e.g. after piston replacement), a repeated

check after the first 50 operating hours is not necessary.

Qualifica‐

tion

Interval

Item

Tasks

Task

[hours]

[years]

QL1

Valve gear

Check valve clearance (→ Page 145)

46 | Maintenance | MS150058/01E 2012-07

TIM-ID: 0000002785 - 001

Содержание 12 V 4000 L63

Страница 1: ...Operating Instructions Gas engine 12 V 4000 L63 16 V 4000 L63 MS150058 01E...

Страница 2: ...ten permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation micro filming and storage or processing on electronic systems including data bases and on...

Страница 3: ...ter stopping the engine Putting the engine out of operation 45 4 Maintenance 4 1 50 hours check 46 4 2 Maintenance task reference table QL1 47 5 Troubleshooting 5 1 Fault indication on SAM display 48...

Страница 4: ...nge 166 6 10 3 Mixture coolant Draining 167 6 10 4 Mixture coolant Filling 168 6 11 Wiring General for Engine Gearbox Unit 169 6 11 1 Engine wiring Check 169 6 11 2 Sensors Overview 170 7 Appendix A 7...

Страница 5: ...it on delivery Any other use is considered improper use The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case The responsibility is borne by the user alon...

Страница 6: ...to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety relevant i...

Страница 7: ...or the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transport...

Страница 8: ...ion the display instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must...

Страница 9: ...and vent the compressed air line when air starters are fitted Disconnect the control device from the assembly or plant Only use adequate calibrated tools During assembly and disassembly observe the s...

Страница 10: ...re starting the pressing procedure Bleed air from the device for force fitting removing parts pumps and piping at the points provided for the system concerned e g open threaded vent plugs pump until n...

Страница 11: ...es When working with laser equipment always wear special laser protection goggles eye injury through strongly concentrated beam Laser devices must be equipped in accordance with their class and usage...

Страница 12: ...main tained exchanged or repaired if the components used for this purpose are approved by MTU Noncom pliance with these guidelines might represent a violation of the Clean Air Act and could involve th...

Страница 13: ...gregate In low lying areas of the plant carbon dioxide enrichment is possible All gas carrying lines must be checked for leaks prior to commissioning and at regular intervals during operation Procedur...

Страница 14: ...oses or to check for leaks results in a risk of bursting Carry out the leak check as specified Painting When carrying out painting work outside the spray stands provided with fume extraction systems e...

Страница 15: ...on involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety warnings in accordance...

Страница 16: ...6V 1 Engine governor engine monitoring 2 Mixture cooler 3 Exhaust outlet 4 Gas mixer 5 Crankcase breather oil separator 6 Coolant distribution housing 7 Engine mounting bracket 8 Flywheel 9 Starter KS...

Страница 17: ...5 Engine oil sampling connection 16 Oil level switch 17 Engine coolant inlet connection from cooler 18 Engine oil heat ex changer 19 Engine coolant inlet connection to cooler KGS Free end Engine model...

Страница 18: ...d A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end Other components are numbered in the same way i e star...

Страница 19: ...Height C 12V approx 2160 mm Height C 16V approx 2170 mm Crankshaft center to oil pan D 12 V approx 636 mm Crankshaft center to oil pan D 16 V approx 636 mm Crankshaft center to engine mount E 12 V ap...

Страница 20: ...2 4 Ignition order Ignition order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20 Product Summary MS150058 01E 2012 07 TIM ID 0000002806 001...

Страница 21: ...tional availability of the engine plant and to re duce maintenance to a minimum Power referenced to nominal load Recommended maximum run time at this load Recommended minimum runtime in subsequent ope...

Страница 22: ...net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046 A kW 1320 1760 Mean effective pressure pme co...

Страница 23: ...Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature at engine connection inlet from cooling equipment w o antif...

Страница 24: ...re after oil heat exchanger engine shutdown L C 97 97 Lube oil pressure after oil filter bar 5 0 5 0 Lube oil pressure after oil filter warning R bar 5 0 5 0 Lube oil pressure after oil filter shutdow...

Страница 25: ...250 Table 14 Capacities Weights main dimensions Number of cylinders 12 16 Dry engine weight basic configuration engine R kg 5855 7750 Heaviest component to be lifted during extended component maintena...

Страница 26: ...are net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046 A kW 1320 1760 Mean effective pressure pme...

Страница 27: ...t Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature at engine connection inlet from cooling equipment w o anti...

Страница 28: ...re after oil heat exchanger engine shutdown L C 97 97 Lube oil pressure after oil filter bar 5 0 5 0 Lube oil pressure after oil filter warning R bar 5 0 5 0 Lube oil pressure after oil filter shutdow...

Страница 29: ...250 Table 29 Capacities Weights main dimensions Number of cylinders 12 16 Dry engine weight basic configuration engine R kg 5855 7750 Heaviest component to be lifted during extended component mainten...

Страница 30: ...Controls engine starting stopping and emergency stop Monitors engine operating parameters Controls throttles and sets gas mixture for requested speed power Monitors first gas solenoid in gas train to...

Страница 31: ...knock characteristics If knocking is found the ignition tim ing is retarded on the cylinder in question If this does not result in an improvement the power is re duced Gas control valve TecJet50 Contr...

Страница 32: ...4 Terminal block 5 Automatic cutout 32A 6 Automatic cutout 16A 7 Emergency stop key switch Fuses F001 Starter A bank starter B bank F002 Throttle A bank throttle B bank F003 Ignition system F004 Anti...

Страница 33: ...rge number of inputs outputs provided Genset side 14 inputs 7 outputs 2 serial interfaces Engine side 39 inputs 28 outputs 1 serial interface Engine and genset related parameter settings in flash memo...

Страница 34: ...g design SAM functions Display of fault codes from engine governor and SAM 3 Backup function engine life data are stored every hour after every engine stop after every emergency engine stop Interface...

Страница 35: ...V etc 4 frequency inputs 1 dialog interface Extendable with MCS 5 PIM I O cards CANOpen and SAE J1939 interface For CANOpen and J1939 interface a type CCB2 printed circuit board 1 is inserted in slot...

Страница 36: ...Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 36 Product Summary MS150058 01E 2012 07 TIM ID 0000017541 001...

Страница 37: ...e Out of service period 6 months Grease valve drive Page 144 Lube oil system Check engine oil level Page 155 Checking oil level in oil storage tank Page 155 Coolant circuit Out of service period more...

Страница 38: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 155 Coolant circuit Check engine coolant level Page 159 Check mixture coolant level Page...

Страница 39: ...for starter disengagement speed 9 Disengaging starter 10 Waiting for idling speed 11 Runup to rated speed Stop sequence If a stop command is activated the following steps are carried out automatically...

Страница 40: ...components Risk of serious injury danger to life Before barring or starting the engine make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear...

Страница 41: ...ay SAM Check for fault messages If fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressures Operation log if provided Docume...

Страница 42: ...ses extreme stress to the engine Risk of overheating damage to components Before stopping the engine operate it at idle speed until operating temperatures decrease and stable values are indicated Stop...

Страница 43: ...Emergency stop button Press Engine is stopped Safety measures Item Task Emergency stop button Remove key Rectifying cause Item Task Engine control system Determine cause for emergency stop and take re...

Страница 44: ...emains ready for operation After stopping the engine Item Measure Engine genset control system Engine is in stop mode For engine restart refer to documentation Genset control system 44 Operation MS150...

Страница 45: ...antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Power supply to engine control system Switch OFF Gas...

Страница 46: ...ylinder heads after component maintenance or extended component maintenance When installing a cylinder head with run in mating faces e g after piston replacement a repeated check after the first 50 op...

Страница 47: ...ge tank Page 155 W1002 Check valve clearance Page 145 W1005 Replace air filter Page 153 W1008 Replace engine oil filter at each oil change or when the time limit years is reached at the latest Page 15...

Страница 48: ...esponded in one of the specified ways TD Transmitter Deviation Two sensors which acquire the measured val ues of the same medium provide different measured values HI High The first limit value has bee...

Страница 49: ...ult code from the SAM EC This is an alarm message from the engine governor This code is always followed by a 3 digit number 3 indicating the fault code from the engine governor 2nd line plain text mes...

Страница 50: ...immediately start fault rectification Red alarm Caution the engine is running at its limits Shut down manually without further delay if the engine does not shut itself down immediately after a red al...

Страница 51: ...e text 26 I O Module Slot8 Defect 27 Download Server Collision 28 not projected node 29 Device specific error 30 not projected node 31 Device specific error MS150058 01E 2012 07 Troubleshooting 51 TIM...

Страница 52: ...gnition timing Page 137 3 Check valve drive exhaust valves do not close 112302 HI T Exhaust A2 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hig...

Страница 53: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112308 HI T Exhaust A8 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Страница 54: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112314 HI T Exhaust B4 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Страница 55: ...Check ignition timing Page 137 3 Check valve drive exhaust valves do not close 112320 HI T Exhaust B10 Yellow alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is...

Страница 56: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Страница 57: ...orrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive...

Страница 58: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Страница 59: ...es 3 Check ignition timing Page 137 4 Check valve drive 112501 HIHI T Exhaust A1 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as compared wit...

Страница 60: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112507 HIHI T Exhaust A7 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high as...

Страница 61: ...ition timing Page 137 3 Check valve drive exhaust valves do not close 112513 HIHI T Exhaust B3 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too high a...

Страница 62: ...ignition timing Page 137 3 Check valve drive exhaust valves do not close 112519 HIHI T Exhaust B9 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hi...

Страница 63: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Страница 64: ...rective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 11...

Страница 65: ...rrective action The exhaust temperature of this cylinder is too low as compared with the average value 1 Check spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 1...

Страница 66: ...k spark plug 2 Check emission values 3 Check ignition timing Page 137 4 Check valve drive 112620 LOLO T Exhaust B10 Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this c...

Страница 67: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112706 HIHI T Exhaust A6 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hig...

Страница 68: ...ition timing Page 137 3 Check valve drive exhaust valves do not close 112712 HIHI T Exhaust B2 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hi...

Страница 69: ...tion timing Page 137 3 Check valve drive exhaust valves do not close 112718 HIHI T Exhaust B8 abs Red alarm Initiated by EMU Cause Corrective action The exhaust temperature of this cylinder is too hig...

Страница 70: ...ystem Page 155 150200 Communication Lost ECU Red alarm Initiated by SAM Cause Corrective action No communication with ECU CAN 1 Check supply voltage 2 Check connecting line 150201 Communication Lost E...

Страница 71: ...s pressure applied 1 Check initial gas pressure and gas line 2 Check cabling 150399 SS Coolant too Low Red alarm Initiated by SAM Cause Corrective action Lack of coolant in cooling system feedback sig...

Страница 72: ...Initiated by SAM Cause Corrective action Actual power signal out of valid range 1 Check cabling 2 Check signal 150504 LO Engine Power Yellow alarm Initiated by SAM Cause Corrective action The engine...

Страница 73: ...ot Reached Red alarm Initiated by TecJet Cause Corrective action No gas flow detected 1 Check inlet and outlet 2 Check gas pressure gas quality gas filter gas line for obstruction 3 Check engine for o...

Страница 74: ...151032 Coil Current Fail High Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151035 Position Fail High Red alarm Initiated by TecJet Cause Cor...

Страница 75: ...Low Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151048 Analog Input Low Error Red alarm Initiated by TecJet Cause Corrective action TecJet s...

Страница 76: ...TecJet 151054 Delta P Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Hardware not ready for operation u Restart TecJet 151055 FGP Low Limit Error Red alarm Initiated by TecJet...

Страница 77: ...arm Initiated by TecJet Cause Corrective action TecJet setting is not correct u Switch over setting to PWM input Check PWM signal 151066 TecJet Shutdown Red alarm Initiated by TecJet Cause Corrective...

Страница 78: ...ion Camshaft signal for ignition is missing u Check sensor B1 2 check sensor clearance and cabling replace if necessary Restart of ignition system required to restart the engine 152014 Error Number of...

Страница 79: ...value 152023 Selftest Shutdown Cause Corrective action Self test is active with the engine rotating u Restart ignition system 152024 Open Primary Rate Exceeded Red alarm Initiated by IC922 Cause Corre...

Страница 80: ...Channel 6 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152032 Open Primary Channel 7 Yellow alarm...

Страница 81: ...Channel 13 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152039 Open Primary Channel 14 Yellow alar...

Страница 82: ...Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil 2 Check ignition coil 152050 Warn Missing Ring Gear Signal Yellow alarm Initiated by IC922 Cause Corrective actio...

Страница 83: ...22 Cause Corrective action Specified energy level is beyond the valid range u Adjust value 153101 Error Status Red alarm Initiated by antiknock control Cause Corrective action AKR combined alarm At le...

Страница 84: ...2 Check sensor tightening torque damage replace as necessary 153113 Knock Sensor Error A3 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock sensor 1 C...

Страница 85: ...cabling 2 Check sensor tightening torque damage replace as necessary 153119 Knock Sensor Error A9 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock se...

Страница 86: ...cabling 2 Check sensor tightening torque damage replace as necessary 153125 Knock Sensor Error B5 Red alarm Initiated by antiknock control Cause Corrective action No signal received from this knock se...

Страница 87: ...Readjustment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas qua...

Страница 88: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality...

Страница 89: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality...

Страница 90: ...justment of ignition timing beyond a limit value because knocking was detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality...

Страница 91: ...grator A1 Red alarm Initiated by SAM Cause Corrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chambe...

Страница 92: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Страница 93: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Страница 94: ...orrective action Emergency stop due to knocking detected in this cylinder 1 Check emission values 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane nu...

Страница 95: ...by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153262 HI Misfire Integrator A2 Yellow alarm Initiated by...

Страница 96: ...8 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153269 HI Misfire Integrator A9...

Страница 97: ...5 Yellow alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153276 HI Misfire Integrator B6...

Страница 98: ...or A2 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153283 HIHI Misfire Integrator...

Страница 99: ...A9 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153290 HIHI Misfire Integrator A1...

Страница 100: ...B6 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system 153297 HIHI Misfire Integrator B7...

Страница 101: ...B10 Red alarm Initiated by SAM Cause Corrective action Misfiring was detected in this cylinder 1 Check emission values 2 Check spark plug energy level ignition system MS150058 01E 2012 07 Troubleshoo...

Страница 102: ...Corrective action Engine oil pressure too low limit value 2 Lack of engine oil engine speed too low oil lines oil heat exchanger clogged oil pump defective 1 Check oil system oil heat exchanger 2 Repl...

Страница 103: ...er 2 Check ignition timing Page 137 3 Check mixture setting 4 Check spark plugs 022 SS T Exhaust B ZKP Number Yellow alarm Associated parameter 2 0127 932 Cause Corrective action Exhaust gas temperatu...

Страница 104: ...lue 2 This usually fault message usually follows other fault messages 1 Check governor 2 Check throttle closing position 031 HI ETC1 Overspeed ZKP Number Yellow alarm Associated parameter 2 3011 931 C...

Страница 105: ...be Oil ZKP Number Yellow alarm Associated parameter 2 0125 931 Cause Corrective action Engine oil temperature after oil heat exchanger too high limit value 1 Oil heat exchanger clogged coolant tempera...

Страница 106: ...ant ZKP Number Yellow alarm Associated parameter 2 0101 921 Cause Corrective action Coolant pressure after engine too low limit value 1 Volumetric flow too low static pressure too low u Check engine c...

Страница 107: ...ameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restrictor valve in crankcase breather is closed too much air filter is defective oil separator is clogged piston ri...

Страница 108: ...ator and coupling for damage 2 In isolated operation Check throttle position Check throttles for implausible closing If throttles are fully open Check if load step values are admissible Check bypass p...

Страница 109: ...d u Check starter system 093 SS T Preheat ZKP Number Red alarm Engine shutdown Associated parameter 2 1090 922 Cause Corrective action Preheating temperature too low limit value 2 Coolant temperature...

Страница 110: ...CU Supply Voltage ZKP Number Yellow alarm Associated parameter 2 0140 921 Cause Corrective action Supply voltage too low limit value 1 1 Check supply voltage 2 Check cabling 119 LOLO ECU Supply Voltag...

Страница 111: ...ber Red alarm Associated parameter 2 4000 004 Cause Corrective action No suitable LifeData backup system available after expiry of timeout following ECU reset Backup system has no LifeData feature or...

Страница 112: ...ing Busses CAN bus 1 and CAN bus 2 are redundant 182 AL CAN Wrong Parameters ZKP Number Red alarm Associated parameter 2 0500 682 Cause Corrective action Incorrect parameter values entered in data rec...

Страница 113: ...CAN bus 2 Bus users ECU SAM or EMU faulty u Check operation of nodes and cabling 187 AL CAN1 Error Passive ZKP Number Yellow alarm Associated parameter 2 0500 687 Cause Corrective action CAN controll...

Страница 114: ...ice configuration fault 201 SD T Coolant ZKP Number Red alarm Engine shutdown Associated parameter 1 8004 570 Cause Corrective action Coolant temperature sensor at engine outlet defective short circui...

Страница 115: ...eplace if necessary Fault is rectified when engine is restarted 211 SD P Lube Oil ZKP Number Red alarm Engine shutdown Associated parameter 1 8004 563 Cause Corrective action Engine oil pressure senso...

Страница 116: ...eplace as necessary Fault is rectified when engine is restarted 219 SD T Intake Air ZKP Number Yellow alarm Associated parameter 1 8004 573 Cause Corrective action Intake air temperature sensor defect...

Страница 117: ...ult in the same operating cycle u Check sensor and cabling B1 1 replace if necessary Fault is rectified when engine is restarted 231 SD Camshaft Speed ZKP Number Red alarm Engine shutdown Associated p...

Страница 118: ...nal governor fault u Replace ADEC engine governor 266 SD Speed Demand ZKP Number Red alarm Associated parameter 2 8006 586 Cause Corrective action Speed setting signal can no longer be transmitted fro...

Страница 119: ...ctivation of gas supply solenoid valve No 1 faulty u Check cabling 384 AL Wiring TOP 4 ZKP Number Red alarm Associated parameter 2 8006 641 Cause Corrective action Short circuit or wire break on trans...

Страница 120: ...Check engine coolant circuit pressure and volumetric flow 429 HI P Coolant ZKP Number Red alarm Engine shutdown Associated parameter 2 0101 931 Cause Corrective action Coolant pressure after engine to...

Страница 121: ...coolant circuit pressure and volumetric flow 435 SS T Coolant before Engine ZKP Number Red alarm Engine shutdown Associated parameter 2 0173 932 Cause Corrective action Coolant temperature before eng...

Страница 122: ...ng system inlet temperature too high mixture cooler clogged 1 Check mixture cooling circuit 2 Check mixture cooler for dirt 452 HIHI T Charge Mix ZKP Number Red alarm Engine shutdown Associated parame...

Страница 123: ...Corrective action Intake air temperature is too low limit value 4 u Check ventilation system 459 SD P Coolant b Engine ZKP Number Red alarm Associated parameter 1 8004 627 Cause Corrective action Coo...

Страница 124: ...ttle if necessary 476 AL Crash Rec Init Fault ZKP Number Red alarm Associated parameter 1 8010 007 Cause Corrective action Crash recorder initialization error u Contact Service 478 AL Comb Alarm Yel P...

Страница 125: ...ing B79 22 replace if necessary Fault is rectified when engine is restarted 498 SD P Charge Mix Diff ZKP Number Red alarm Associated parameter 1 8004 630 Cause Corrective action Mixture differential p...

Страница 126: ...ions 2 Check ignition timing Page 137 3 Check exhaust back pressure 4 Check valve clearance Page 145 5 Check throttle 6 Check mixture coolant system 513 SD P Coolant Diff ZKP Number Red alarm Associat...

Страница 127: ...break u Check sensor and cabling B81 1 replace if necessary Fault is rectified when engine is restarted 522 SD P Intake Air after Filter B ZKP Number Yellow alarm Associated parameter 1 0187 900 Cause...

Страница 128: ...xture throttle on B side replace mixture throttle on B side if necessary 543 AL Multiple FDH Slaves ZKP Number Yellow alarm Associated parameter 2 0555 005 Cause Corrective action More than one device...

Страница 129: ...1090 122 Cause Corrective action Ignition failure Alarm is activated if the feedback signal from ignition system is not received within a specified time out period Either the ignition could not be act...

Страница 130: ...ttle on A side and cabling Replace mixture throttle on A side if necessary 560 AL mixture throttle B fault ZKP Number Red alarm Engine shutdown Associated parameter 1 1450 013 Cause Corrective action...

Страница 131: ...ameter 2 0187 931 Cause Corrective action Pressure loss over air filter on B side is too high u Replace air filter Page 153 569 AL SAM Missing Data Fault ZKP Number Red alarm Associated parameter 2 10...

Страница 132: ...uction is initiated 1 Check emissions 2 Check ignition timing Page 137 3 Check combustion chamber 4 Check gas quality if feasible methane number 572 L3 AI CAN Max Retarded Timing ZKP Number Red alarm...

Страница 133: ...sk of serious injury Danger to life Before barring the engine ensure that nobody is in the danger zone Engine barring manually 1 Remove guard plate 2 Engage barring tool 2 with ring gear 3 and install...

Страница 134: ...of gas 1 Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit 2 If smell of gas is detected or the gas detection and alarm unit is triggered Avoid naked...

Страница 135: ...G Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil...

Страница 136: ...uring it is straight Note The coalescence filter 5 must be installed in correct position in housing 10 Place coalescence filter 5 in housing en suring it is straight 11 Fit filter cover 3 ensuring it...

Страница 137: ...ger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Ignition system Ignition timing check Note For the specified ignition timing contact your Service partner 1 St...

Страница 138: ...ement Special tools Material Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Remove spark plug connector and install new one u Page 140 138 Task Description MS150058 0...

Страница 139: ...eplacement Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Remove spark plug and install new one u Page 140 MS150058 01E 2012 07 Task Description 139 TIM...

Страница 140: ...Catalog Sealing ring Spare Parts Catalog WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protecti...

Страница 141: ...eve of ignition line 2 Fit spark plug connector 6 with ignition ca ble 4 on spark plug 3 Fit locking plate 7 on cylinder head cover 4 Screw screw 2 with spring washer onto ig nition coil 1 5 Push prot...

Страница 142: ...pare Parts Catalog WARNING Component is hot Risk of burning Wear protective gloves WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask...

Страница 143: ...g 6 Fit new sealing ring 2 on spark plug 1 positioning it correctly 7 Screw spark plug into cylinder head Note The temperature of spark plug and cylinder head must be the same prior to tightening 8 Ti...

Страница 144: ...cial tools Material Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 151 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3...

Страница 145: ...No Qty Feeler gauge Y20098771 1 Angular screw driver F30452765 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30029815 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 151...

Страница 146: ...ing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 3 mm Exhaust valves short rocker arm 0 5 m...

Страница 147: ...the gap 5 Tighten locknut 1 with torque wrench to the specified torque holding adjusting screw 2 firm Name Size Type Lubricant Value Standard Locknut M16 Tightening torque Engine oil 90 Nm 9 Nm 6 Rep...

Страница 148: ...Depth gauge Y20095775 1 Preparatory steps 1 Remove spark plugs Page 140 2 Remove cylinder head covers Page 151 3 Remove sleeves arrow 4 Install barring device Page 133 5 Rotate crankshaft with barrin...

Страница 149: ...1 and remove valve bridge Do not remove rocker arm 2 4 Measure distance between valve stem end and cylinder head top at the spark plug bore with depth gauge see figure The specified value for a new cy...

Страница 150: ...3 Install sleeves arrow 4 Install cylinder head covers Page 151 5 Install spark plugs with new sealing rings Page 140 150 Task Description MS150058 01E 2012 07 TIM ID 0000012015 002...

Страница 151: ...plug connector Page 140 3 Unscrew screws 2 4 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1 Clean mounting surface 2 Check condition of gasket replace if d...

Страница 152: ...as is combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Gas supply Checking gas lines for leaks 1 Coat all connections of the gas supply line...

Страница 153: ...e Parts Catalog Fleece prefilter optional Spare Parts Catalog Note Air filter condition is monitored by a sensor Replace air filter and or optional fleece prefilter when the corresponding fault messag...

Страница 154: ...tallation 1 Release clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and clean it 4 Place new air filt...

Страница 155: ...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 b...

Страница 156: ...gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Extracting engine oil 1 Open shut off valve s in extraction line from engine and waste oil tank 2 Extract all oil from o...

Страница 157: ...Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear e...

Страница 158: ...health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filter with filte...

Страница 159: ...lable WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant Level check 1 Read off syste...

Страница 160: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 161 2 Fill with engine coolant Page 163 160 Task Description MS150058 01E 201...

Страница 161: ...e Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Provide an appropriate container to drain the coolant into 2 Switch o...

Страница 162: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 162 Task Description MS150058 01E 2012 07 TIM ID 0000006751 001...

Страница 163: ...es and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Engine coolant filling 1 Fill with tr...

Страница 164: ...of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 161 2 Release union nuts 1 and 3 3 Remov...

Страница 165: ...Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Checking mixture coolant level 1 Read off system pressur...

Страница 166: ...Change Special tools Material Spare parts Designation Use Part No Qty Mixture coolant Drain mixture coolant u Page 167 Fill mixture coolant system u Page 168 166 Task Description MS150058 01E 2012 07...

Страница 167: ...ding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining charge air coolant 1 Provide a suitable receptacle to catch the coolant 2 Open drain valve in the coolant...

Страница 168: ...goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Filling with coolant 1 Fill with treated co...

Страница 169: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Страница 170: ...ilter 3 B16 1 Coolant pressure after engine 4 B4 XX Exhaust gas temperature after cylinder XX 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 34 Sensors on right engine side The knock...

Страница 171: ...B13 2 Crankshaft speed for ignition system 2 B79 23 Mixture pressure before throttle 3 B75 Crankshaft speed reset for ignition system Table 35 Sensors on driving end MS150058 01E 2012 07 Task Descrip...

Страница 172: ...case pressure 3 B5 3 Engine oil pressure before filter 4 B5 1 Engine oil pressure after filter 5 B44 1 Turbocharger speed currently not installed 6 B7 Engine oil temperature Table 36 Sensors on left e...

Страница 173: ...ngine 3 B1 3 Camshaft speed for AKR 4 B1 2 Camshaft speed for ignition system 4 B1 1 Camshaft speed for engine governor 5 B24 Engine oil level 6 B6 3 Coolant temperature before engine 7 B6 1 Coolant t...

Страница 174: ...the flexibility of our service staff we are always ready to assist you either during operation for preventive maintenance corrective work in case of malfunction or changed operat ing conditions or for...

Страница 175: ...ICFN ISO Continuous Fuel stop brake power Fuel stop power ISO International coding for power output of combustion engines ISO International Organization for Stand ardization International umbrella org...

Страница 176: ...S 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...

Страница 177: ...age 145 Barring tool Part No F6555766 Qty Used in 1 6 1 1 Engine Barring manually Page 133 Depth gauge Part No Y20095775 Qty Used in 1 6 4 3 Valve depth Measurement Page 148 Feeler gauge Part No Y2009...

Страница 178: ...No Qty Used in 6 1 2 Checking machine room for smell of gas Page 134 MTU test kit Part No 5605892099 00 Qty Used in 1 6 7 3 Engine oil Sampling and analysis Page 157 Ratchet head with extension Part...

Страница 179: ...lug wrench Part No F30452574 Qty Used in 1 6 3 4 Spark plug connector Removal and installation Page 140 Stroboscope Part No Qty Used in 6 3 1 Ignition system Ignition timing check Page 137 Torque wren...

Страница 180: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 6 4 2 Valve clearance Check and adjustment Page 145 180 Appendix B MS150058 01E 2012 07 DCL ID 0000005843 005...

Страница 181: ...ty Used in 6 4 2 Valve clearance Check and adjustment Page 145 Qty Used in 6 7 2 Engine oil Change Page 156 Qty Used in 6 8 1 Engine oil filter Replacement Page 158 Isopropyl alcohol Part No X00058037...

Страница 182: ...Soap solution Part No Qty Used in 6 5 1 Gas supply Checking gas lines for leaks Page 152 182 Appendix B MS150058 01E 2012 07 DCL ID 0000005843 005...

Страница 183: ...4 Cylinder head cover Removal and installation Page 151 Locking plate Part No Qty Used in 6 3 4 Spark plug connector Removal and installation Page 140 Qty Used in 6 3 5 Spark plug Removal and installa...

Страница 184: ...Used in 6 3 3 Spark plug Replacement Page 139 Qty Used in 6 3 5 Spark plug Removal and installation Page 142 Spark plug connector Part No Qty Used in 6 3 2 Spark plug connector Replacement Page 138 S...

Страница 185: ...ne Barring manually 133 F Fault indication on SAM display 48 Fire and environmental protection 12 Fluids and lubricants 12 G Gas engine phase 3 system Overview 30 Gas supply Checking gas lines for lea...

Страница 186: ...earance Check and adjustment 145 Valve depth Measurement 148 Valve gear Lubrication 144 Vent line of engine coolant circuit Replacement 164 W Wiring engine Check 169 186 Appendix B MS150058 01E 2012 0...

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MTU 12 V 4000 L63, Руководство по эксплуатации

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