Measuring component dimensions
Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-perature of 20 °C.
MS150104/02E 2016-11
| Safety | 15
TIM-ID: 0000040535 - 015
Страница 1: ...Operating Instructions Gas engine 12V 4000 L32 F 16V 4000 L32 F MS150104 02E...
Страница 2: ...er in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and storage or proces...
Страница 3: ...on after extended out of service periods 3 months 40 4 3 Putting the engine into operation after scheduled out of service period 41 4 4 Control starting and stopping sequences 42 4 5 Engine Start 44 4...
Страница 4: ...4 Engine coolant Filling 195 7 9 5 Vent line of engine coolant circuit Replacement 196 7 10 Low Temperature Circuit 197 7 10 1 Mixture coolant level Check 197 7 10 2 Mixture coolant Change 198 7 10 3...
Страница 5: ...the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex ch...
Страница 6: ...regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops authorized by the man...
Страница 7: ...se personnel must be instructed repeatedly Personnel requirements All work on the product must be carried out by trained instructed and qualified personnel only Training at the Training Center of the...
Страница 8: ...that all connections have been correctly allocated e g polarity direction Immediately after putting the product into operation make sure that all control and display instruments as well as the signali...
Страница 9: ...quipment 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...
Страница 10: ...control system with one path assigned to each of the gas shut off valves The gas train shall feature minimum pressure monitoring Additional equipment may be necessary in the gas train e g maximum pres...
Страница 11: ...f flow plant manufacturer user scope of sup ply a manual shut off valve a gas filter Gas trains feature the following components in the direction of flow MTU scope of supply two gas shut off valves au...
Страница 12: ...mer components e g engine mounts damping elements couplings and V belts must not be painted Only install them after painting the engine or mask them prior to painting The following applies to starters...
Страница 13: ...installed and that all tools and loose parts have been removed especially the barring tool Ensure that no unattached parts have been left in on the product e g including rags and cable straps Ensure...
Страница 14: ...prior to working on assemblies ESD Work on electrostatically endangered components which could be damaged by electrostatic discharge ESD must always be carried out with appropriate equipment Appropri...
Страница 15: ...easuring component dimensions Workpieces components and measuring equipment lie in the specified tolerance range at a reference tem perature of 20 C MS150104 02E 2016 11 Safety 15 TIM ID 0000040535 01...
Страница 16: ...nnel only The gas supply shall be connected by trained qualified and authorized personnel only Work on the gas bearing parts of the product shall be performed by specially trained qualified and author...
Страница 17: ...always available and that staff are familiar with their correct handling Noise Wear ear protectors in work areas with a sound pressure level in excess of 85 dB A Noise can lead to an increased risk of...
Страница 18: ...stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not impaired Avoid open flames in the vicinity No smoking Observe fire p...
Страница 19: ...emergency stop Cordon off danger 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 tha...
Страница 20: ...n NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with...
Страница 21: ...en weight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking device for the crankshaft Prior to transporting the engine genset system it is...
Страница 22: ...filter air inlet 4 Mixture cooler 5 Exhaust turbocharger 6 Engine lifting equipment 7 Capacitor ignition system 8 Engine mounting bracket free end 9 Oil pan 10 Engine mounting bracket driving end 11 S...
Страница 23: ...l switch 13 Connection engine coolant inlet 14 Engine oil heat exchanger 15 Connection engine coolant outlet KGS Free end Engine model designation Key to the engine model designations 12 16 V 4000 L32...
Страница 24: ...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 lette...
Страница 25: ...prox 2868 mm Length A for 16V approx 3372 mm Width B for 12V approx 1743 mm Width B for 16V approx 1789 mm Height C for 12V approx 2146 mm Height C for 16V approx 2156 mm Crankshaft center to oil pan...
Страница 26: ...g order Firing order Number of cylinders Firing 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 26 Product Summary MS150104 02E 2016 11 TIM ID 00000...
Страница 27: ...ence conditions Power related data power ratings are net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per IS...
Страница 28: ...circuit referenced to max power without HT heat extraction Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment w o antifreeze A C 90 90 Coolant temperature a...
Страница 29: ...xchanger 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 3 5 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 2 5 Tab...
Страница 30: ...cylinders 12 16 Dry engine weight basic configuration engine R kg 6500 8000 Heaviest component to be lifted during extended component maintenance QL3 R kg 450 450 Table 16 Weights main dimensions Exha...
Страница 31: ...net brake power to ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 1500 1500 Mean piston speed m s 10 5 10 5 Continuous power as per ISO 3046 A kW 1200 1600 Mean effective pressure pme co...
Страница 32: ...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 antifr...
Страница 33: ...xchanger 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 3 5 3 5 Lube oil pressure after oil filter shutdown L bar 2 5 2 5 Tab...
Страница 34: ...cylinders 12 16 Dry engine weight basic configuration engine R kg 6500 8000 Heaviest component to be lifted during extended component maintenance QL3 R kg 450 450 Table 31 Weights main dimensions Exh...
Страница 35: ...rols 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 engi...
Страница 36: ...r in question If this does not result in an improvement the power is reduced Gas control valve TecJet52 Controls the required amount of gas Mixture throttles P Series The mixture throttles in the mixt...
Страница 37: ...atus 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 r...
Страница 38: ...8 EMU Engine Monitoring Unit Monitoring unit for the engine Acquisition and processing of cylinder exhaust temperatures Self monitoring 38 Monitoring Control and Regulation Equipment MS150104 02E 201...
Страница 39: ...d Recommended min time in subsequent op eration at load 50 kWmech cyl Emission compliance as specified in technical data 0 to 30 30 minutes 120 minutes No 30 to 50 120 minutes 120 minutes No 50 to ful...
Страница 40: ...162 Valve gear Standstill 6 months Lubricate valve gear Page 181 Lube oil system Check engine oil level Page 187 Check oil level in oil storage tank Page 187 Coolant circuit Standstill 1 year Change e...
Страница 41: ...starting disabled Putting into operation Item Measure Lube oil system Check oil level in oil storage tank Page 187 Coolant circuit Check engine coolant level Page 191 Check mixture coolant level Page...
Страница 42: ...n gas pipework up to gas control valve and exhaust gas system after turbine A contact is designated to initiate such safety measures Starting sequence The following steps are performed automatically w...
Страница 43: ...wing 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 runn...
Страница 44: ...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 5 engine starting attempts are permitted at a max fuel supply open...
Страница 45: ...achine room for smell of gas Page 163 ECU Check for fault messages If fault messages are displayed Determine the cause rectify the fault Check indicated operating parameters speed temperatures pressur...
Страница 46: ...l of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Exhaust gases are harmful to health Risk of poisoning Ensure that the engine room is well ventilated...
Страница 47: ...1 at the measuring point 2 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...
Страница 48: ...nd 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 in...
Страница 49: ...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 sy...
Страница 50: ...ain 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 co...
Страница 51: ...gine Engine remains ready for operation After stopping the engine Item Action Engine generator controller manufacturer specific Select operating mode e g MANUAL AUTOMATIC MS150104 02E 2016 11 Operatio...
Страница 52: ...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...
Страница 53: ...linder 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 op...
Страница 54: ...age 190 W1089 Check gas lines for leaks seal if required Page 184 W1091 Check ignition timing adjust as necessary Page 175 W1207 Check valve clearance and adjust if necessary IMPORTANT First adjustmen...
Страница 55: ...lue has not been attained MG Message General message SE System Error Warning due to node failure on the default field bus PB Push Button Status indication due to activation of certain control keys AKR...
Страница 56: ...gine is running at its limits Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled 56 Troubleshooting MS150104 02E 2016 11 TIM ID...
Страница 57: ...ndividual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves d...
Страница 58: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...
Страница 59: ...n Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valve...
Страница 60: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...
Страница 61: ...se Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175...
Страница 62: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valv...
Страница 63: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valv...
Страница 64: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valv...
Страница 65: ...exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves do not clos...
Страница 66: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...
Страница 67: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...
Страница 68: ...Individual exhaust gas temperature of this cylinder is too high in comparison with weighted average 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves...
Страница 69: ...se Corrective action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175...
Страница 70: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valve...
Страница 71: ...tive action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check...
Страница 72: ...action Individual exhaust gas temperature of this cylinder is too low in comparison with weighted average 1 Check igniter 2 Check emission values Page 46 3 Check ignition timing Page 175 4 Check valve...
Страница 73: ...Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves do not close 112702 HIHI T Exhaust A2 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperat...
Страница 74: ...tion timing Page 175 3 Check valve drive exhaust valves do not close 112708 HIHI T Exhaust A8 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...
Страница 75: ...tion timing Page 175 3 Check valve drive exhaust valves do not close 112714 HIHI T Exhaust B4 abs Red alarm Initiated by EMU Cause Corrective action Individual exhaust gas temperature of this cylinder...
Страница 76: ...perature of this cylinder is too high 1 Check emission values Page 46 2 Check ignition timing Page 175 3 Check valve drive exhaust valves do not close 112720 HIHI T Exhaust B10 abs Red alarm Initiated...
Страница 77: ...back does not correspond with setpoint signal u Check valve 1 113902 SS Local Initiated Emerg Stop Red alarm Initiated by EMU Cause Corrective action Emergency stop detected Emergency stop was release...
Страница 78: ...damage replace as necessary Page 202 1 4510 193 Knock Sensor Error A2 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor 1 Check cabling Page 201 2 Che...
Страница 79: ...Check sensor tightening torque damage replace as necessary Page 202 1 4510 199 Knock Sensor Error A8 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...
Страница 80: ...Check sensor tightening torque damage replace as necessary Page 202 1 4510 205 Knock Sensor Error B4 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock sensor...
Страница 81: ...Check sensor tightening torque damage replace as necessary Page 202 1 4510 211 Knock Sensor Error B10 Red alarm Initiated by anti knock control Cause Corrective action No signal from this knock senso...
Страница 82: ...em 1 4520 237 OverSpeed Shutdown Red alarm Initiated by IC922 Cause Corrective action Genset has exceeded admissible speed u Restart ignition 1 4520 238 E2PROM Checksum Error Red alarm Initiated by IC...
Страница 83: ...imary Channel 1 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 201 2 Check ignition coils 1 4520 246 Open Primary Chan...
Страница 84: ...nnel 8 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 201 2 Check ignition coils 1 4520 253 Open Primary Channel 9 Yel...
Страница 85: ...annel 15 Yellow alarm Initiated by IC922 Cause Corrective action Ignition energy was not discharged 1 Check cabling to ignition coil Page 201 2 Check ignition coils 1 4520 260 Open Primary Channel 16...
Страница 86: ...Reset Signal Yellow alarm Initiated by IC922 Cause Corrective action Reset signal from crankshaft is missing u Sensor B 75 check sensor sensor gap and cabling replace as necessary Page 202 Page 201 1...
Страница 87: ...use Corrective action A system error has occurred 1 Rectify cause of alarm 2 Restart ignition control unit 1 4520 520 MIC5 Stat W temperat limit reached Yellow alarm Initiated by MIC5 Cause Corrective...
Страница 88: ...valid 1 Check ignition system settings in the Engine Control Unit 2 Restart ignition control unit 1 4520 526 MIC5 Stat Analogue current sig fail Red alarm Initiated by MIC5 Cause Corrective action Fai...
Страница 89: ...urred 1 Check Engine Control Unit settings 2 Check cabling Page 201 3 Restart ignition control unit 4 Replace ignition control unit 1 4520 541 MIC5 E1 Overspeed Red alarm Initiated by MIC5 Cause Corre...
Страница 90: ...Replace ignition control unit 1 4520 547 MIC5 E1 Failure current sensor Red alarm Initiated by MIC5 Cause Corrective action The current sensor is faulty 1 Restart ignition control unit 2 Replace ignit...
Страница 91: ...low alarm Initiated by MIC5 Cause Corrective action Unable to detect polarity of pulse sensor 1 B1 2 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary...
Страница 92: ...early faulty Yellow alarm Initiated by MIC5 Cause Corrective action Index mark of pulse sensor 1 B1 2 detected too early or faulty u Check sensor sensor gap cabling data record settings and timing whe...
Страница 93: ...Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 6 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 576 MIC5 IP...
Страница 94: ...Red alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 13 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 583 MIC5 I...
Страница 95: ...d alarm Initiated by MIC5 Cause Corrective action Disruption in primary circuit of cylinder 20 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 590 MIC5 IPE...
Страница 96: ...ed alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 7 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 597 MIC5 I...
Страница 97: ...Red alarm Initiated by MIC5 Cause Corrective action Short circuit in primary circuit of cylinder 14 in ignition sequence 1 Check cabling to ignition coil Page 201 2 Check ignition coil 1 4520 604 MIC5...
Страница 98: ...alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 1 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 611 MIC5 IS...
Страница 99: ...ow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 8 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 618 MIC5...
Страница 100: ...llow alarm Initiated by MIC5 Cause Corrective action Disruption in secondary circuit of cylinder 15 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 625 MI...
Страница 101: ...w alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circuit of cylinder 2 in ignition sequence 1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 632 MIC...
Страница 102: ...1 Check ignition lead connector and igniter 2 Check ignition coil 1 4520 638 MIC5 ISE Secon Short Circuit Cyl 9 Yellow alarm Initiated by MIC5 Cause Corrective action Short circuit in secondary circu...
Страница 103: ...ce 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 Corrective action Short circuit in secondary ci...
Страница 104: ...ck ignition coil 1 4520 658 MIC5 E2 Tr2 synchronisation fault Yellow alarm Initiated by MIC5 Cause Corrective action Unable to synchronize with signal from pulse sensor 2 B75 u Check sensor sensor gap...
Страница 105: ...Cause Corrective action Incorrect number of events from pulse sensor 2 B75 u Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary Page 202 Page 201 1 4520...
Страница 106: ...arm Initiated by MIC5 Cause Corrective action Pulse sensor 3 B13 2 has tripped an operational error 1 Check sensor sensor gap cabling data record settings and timing wheel Replace sensor as necessary...
Страница 107: ...iming wheel Replace sensor as necessary Page 202 Page 201 1 4520 678 MIC5 E2 Tr3 signal faulty Yellow alarm Initiated by MIC5 Cause Corrective action Unexpected signal from pulse sensor 3 B13 2 detect...
Страница 108: ...g Active 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...
Страница 109: ...pressor bypass Cause Corrective action Temperature of the electronics above 140 C or internal temperature sensor faulty 1 Check room temperature and ventilation 2 Compare device temperature with tempe...
Страница 110: ...1 4530 022 CAN Fault Red alarm Initiated by compressor bypass Cause Corrective action CAN bus connection faulty 1 Check cabling Page 201 2 Check compressor bypass flap settings 1 4540 009 Zero Pressur...
Страница 111: ...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...
Страница 112: ...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...
Страница 113: ...ached minimum limit value 1 Check supply voltage 2 Check cabling Page 201 1 4540 030 FGT Low Limit Error Red alarm Initiated by TecJet Cause Corrective action Gas temperature before TecJet is below th...
Страница 114: ...ngs 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 Chec...
Страница 115: ...Jet 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...
Страница 116: ...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 Correct...
Страница 117: ...Cause Corrective action Throttle flap setting is not correct u Check throttle flap setting 1 4550 033 A Input Supply Voltage Fault Yellow alarm Initiated by throttle flap A Bank Cause Corrective actio...
Страница 118: ...bling Page 201 1 4550 039 A Demand Tracking Fault Yellow alarm Initiated by throttle flap A Bank Cause Corrective action Throttle flap setting is not correct u Check throttle flap settings 1 4550 040...
Страница 119: ...tiated by throttle flap B Bank Cause Corrective action Throttle flap setting is not correct u Check throttle flap settings 1 4550 133 B Input Supply Voltage Fault Yellow alarm Initiated by throttle fl...
Страница 120: ...bling Page 201 1 4550 139 B Demand Tracking Fault Yellow alarm Initiated by throttle flap B Bank Cause Corrective action Throttle flap setting is not correct u Check throttle flap settings 1 4550 140...
Страница 121: ...bus connection faulty 1 Check cabling Page 201 2 Check throttle flap settings 1 4550 144 B CAN Stop Command Yellow alarm Initiated by throttle flap B Bank Cause Corrective action Stop input signal re...
Страница 122: ...il system oil heat exchanger 2 Replace oil filter Page 190 3 Take oil sample and analyze Page 189 019 HI T Exhaust A Yellow alarm Associated parameter 2 0126 931 Cause Corrective action Exhaust gas te...
Страница 123: ...harger 2 Check ignition timing Page 175 3 Check mixture setting 4 Check igniters 025 HI P Diff Lube Oil Yellow alarm Associated parameter 2 0154 931 Cause Corrective action Pressure loss via oil filte...
Страница 124: ...d of turbocharger 1 too high limit value 2 1 Check intake air temperature 2 Check emissions Page 46 3 If the sensor is not obstructed check the conditions for activating this monitoring feature in the...
Страница 125: ...high Oil volume flow insufficient 1 Check engine coolant circuit 2 Check oil heat exchanger 3 Check oil level Page 187 053 HI T Intake Air Yellow alarm Associated parameter 2 0123 931 Cause Correctiv...
Страница 126: ...separator condition replace as necessary Page 164 064 SS P Crankcase Red alarm Engine shutdown Associated parameter 2 0106 932 Cause Corrective action Crankcase pressure too high limit value 2 Restri...
Страница 127: ...tle flaps are fully open Check if load step values are admissible Check bypass position Check air filter for contamination replace if contamination is visible Page 185 Check exhaust back pressure Chec...
Страница 128: ...Yellow alarm Associated parameter 2 1090 921 Cause Corrective action Preheating temperature too low limit value 1 coolant temperature too low for engine start 1 Check preheating 2 Check differential...
Страница 129: ...121 HIHI ECU Supply Voltage Red alarm Associated parameter 2 0140 932 Cause Corrective action Supply voltage too high limit value 2 1 Check supply voltage 2 Check cabling Page 201 122 HI T ECU Yellow...
Страница 130: ...een selected that initiates communications with help of the PU data module However the necessary PU data module is not present or is invalid u Contact Service configuration error 184 AL CAN PU Data Fl...
Страница 131: ...parameter 2 0500 689 Cause Corrective action CAN controller 2 has signaled a warning Possible causes may be e g missing node minor faults or temporary bus overload u Check operation of bus users and c...
Страница 132: ...rrective action Exhaust temperature sensor on B side faulty short circuit or wire break u Check sensor and cabling B4 22 replace as necessary Page 202 Page 201 Error cleared after restarting the engin...
Страница 133: ...ction Intake air temperature sensor faulty short circuit or wire break u Check sensor and cabling B49 1 B90 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 221 SD P Di...
Страница 134: ...circuit or wire break 1 Check sensor and cabling B44 1 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 2 If the sensor is not obstructed check the conditions for acti...
Страница 135: ...d alarm Associated parameter 2 8006 639 Cause Corrective action Short circuit or line break at transistor output 2 system side TOP 2 Activation of red summary alarm faulty u Check cabling Page 201 383...
Страница 136: ...shutdown Associated parameter 2 0180 921 Cause Corrective action Coolant differential pressure too low limit value 1 Insufficient volume flow u Check engine coolant circuit pressure and flow 429 HI P...
Страница 137: ...wn Associated parameter 2 0173 932 Cause Corrective action Coolant temperature before engine too high limit value 2 Engine coolant pump failure flow too low air in engine cooling system u Check engine...
Страница 138: ...2 Check mixture cooler for dirt 452 HIHI T Charge Mix Red alarm Engine shutdown Associated parameter 2 0169 932 Cause Corrective action Mixture temperature too high limit value 2 Mixture coolant pump...
Страница 139: ...e break u Check sensor and cabling B16 3 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 470 SD T ECU Red alarm Associated parameter 1 8004 587 Cause Corrective action...
Страница 140: ...Check sensor and cabling B79 21 replace as necessary Page 202 Page 201 Error cleared after restarting the engine 497 SD P Charge Mix B Red alarm Engine shutdown Associated parameter 1 8004 629 Cause...
Страница 141: ...179 5 Check throttle flap 6 Check mixture coolant system 512 HIHI P Charge Mix B Red alarm Engine shutdown Associated parameter 2 0182 932 Cause Corrective action Mixture pressure on B side too high...
Страница 142: ...sociated parameter 1 0186 900 Cause Corrective action Intake air pressure sensor after filter on A side faulty short circuit or wire break u Check sensor and cabling B81 1 replace as necessary Page 20...
Страница 143: ...is activated if the gas train does not report OK within a specified time out period Either the gas train leak test was not successful the time out period is set too short or communication is faulty 1...
Страница 144: ...eed drops during starting sequence u Check gas train 558 AL Wiring PWM_CM2 Red alarm Associated parameter 1 1041 922 Cause Corrective action Wire break or short circuit on channel PWM_CM2 u Check sett...
Страница 145: ...n Pressure loss over air filter on A side is too high u Replace air filter Page 185 566 AL L2 P Intake Air after Filter A Yellow alarm Associated parameter 2 0186 931 Cause Corrective action Pressure...
Страница 146: ...ge 46 2 Check ignition timing Page 175 3 Check combustion chamber 4 Check gas quality if feasible methane number 571 L2 Al CAN Max Retarded Timing Yellow alarm Power reduction Associated parameter 2 1...
Страница 147: ...larm Associated parameter 1 1041 924 Cause Corrective action Wire break or short circuit on channel PWM_CM4 u Check setting at Engine Control Unit 596 AL Develop PR Set Red alarm Associated parameter...
Страница 148: ...se Corrective action Wire break or short circuit on channel PWM_CM6 u Check setting at Engine Control Unit 609 AL Wiring PWM_CM7 Red alarm Associated parameter 1 1041 927 Cause Corrective action Wire...
Страница 149: ...ated parameter 2 1210 008 Cause Corrective action Fuel calorific value has exceeded the first limit value u Check gas quality if feasible 620 HIHI Current Heat Value of Fuel Yellow alarm Associated pa...
Страница 150: ...ons Page 46 624 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 NOx senso...
Страница 151: ...Knock intensity exceeded extreme knocking detected 1 Check gas quality if feasible methane number 2 Check emissions Page 46 3 Check combustion chamber 649 Al Req Angle Throttle A Yellow alarm Power r...
Страница 152: ...Check cabling Page 201 2 Check power supply 3 Restart ECU EMU and ignition system 4 Check settings with device specific dialog software 654 AL FSeries Comm Lost Red alarm Associated parameter 1 4530 9...
Страница 153: ...658 AL NOxA Comm Lost Red alarm Associated parameter 1 4560 096 Cause Corrective action CAN bus communication for NOx sensor A faulty 1 Check cabling Page 201 2 Check power supply 3 Restart ECU 4 Repl...
Страница 154: ...gnation is transmitted via CAN bus to the genset control system 668 AL TecJet Yellow Yellow alarm Associated parameter 1 4540 993 Cause Corrective action An internal summary alarm in the gas control v...
Страница 155: ...ation 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 alarm in the ignition system was de...
Страница 156: ...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 internal summary alar...
Страница 157: ...ck engine oil level Check oil supply 719 AL T Gas L1 Yellow alarm Associated parameter 2 8006 034 Cause Corrective action 1st lower limit value violated u Check gas supply 720 AL T Gas L2 Red alarm As...
Страница 158: ...wait end of scavenging phase 2 Check engine speed A speed of at least 80 rpm must be reached 932 AL MIC5 Yellow Yellow alarm Associated parameter 1 4520 933 Cause Corrective action An internal summary...
Страница 159: ...ller 3 is in Bus Off status Bus nodes ignition knock module throttle flaps or gas mixture malfunctioning u Check operation of bus users and cabling 975 AL CAN3 Error Passive Yellow alarm Associated pa...
Страница 160: ...A and B are two far apart limit value 1 1 Check emissions Page 46 2 Check NOx sensors Page 202 3 Check ignition points Page 175 1014 HIHI Delta NOx A B Red alarm Associated parameter 2 3050 121 Cause...
Страница 161: ...amage is visible 2 Check setting of blow by restrictor valve 1031 LOLO P Crank Case Red alarm Engine shutdown Associated parameter 2 0106 936 Cause Corrective action Crankcase pressure too low limit v...
Страница 162: ...ody 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 barri...
Страница 163: ...not smoke Checking machine room for smell of gas 1 Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit 2 If smell of gas is detected or the gas detecti...
Страница 164: ...ues which are harmful to health Risk of injury and poisoning Allow the engine to cool to below 50 C before beginning work Wear protective clothing protective gloves and safety glasses facial protectio...
Страница 165: ...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 w...
Страница 166: ...ent Special tools Material Spare parts Designation Use Part No Qty Spark plug Spare Parts Catalog Replacing spark plug 1 Remove spark plug Page 167 2 Install new spark plug Page 168 166 Ignition Syste...
Страница 167: ...ble protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupt...
Страница 168: ...before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes a...
Страница 169: ...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...
Страница 170: ...ial Spare parts Designation Use Part No Qty Spark plug connector Spare Parts Catalog Replacing spark plug connector 1 Remove spark plug connector Page 171 2 Install spark plug connector Page 173 170 I...
Страница 171: ...earing 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...
Страница 172: ...ning and check 1 Remove spark plug connector Page 171 2 Remove spark plug isolator sealing ring Page 173 3 Check spark plug connector 1 and ignition line 2 visually for kinks pinching points and britt...
Страница 173: ...ne 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 th...
Страница 174: ...d 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...
Страница 175: ...of damage to hearing Wear ear protectors Checking ignition timing Note Service tool DiaSys and a 1A level dongle or higher or the Woodward IC900 series service tool for Woodward ignition systems only...
Страница 176: ...rt No Qty Sliding depth gage 200 mm Y20000918 1 Preparatory steps 1 Remove igniters Page 167 2 Remove cylinder head covers Page 182 3 Remove sleeves arrowed 4 Install barring tool Page 162 5 Rotate cr...
Страница 177: ...se 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 val...
Страница 178: ...3 Install sleeves arrowed 4 Install cylinder head covers Page 183 5 Install igniters with new sealing rings Page 168 178 Valve Drive MS150104 02E 2016 11 TIM ID 0000043220 003...
Страница 179: ...82 2 Install barring device Page 162 3 Rotate crankshaft with barring tool in engine direction of rotation until marking OT and pointer are aligned Diagram for 12 16 V engines Two crankshaft positions...
Страница 180: ...valve clearances in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviatio...
Страница 181: ...tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 182 2 Fill oil chambers of rocker arms and adjusting screws with oil 3 Insta...
Страница 182: ...ing disabled Cylinder head cover Removal 1 Clean very dirty cylinder head covers 1 prior to removal 2 Remove spark plug connector Page 171 3 Remove screws 2 4 Remove cylinder head cover with gasket fr...
Страница 183: ...omponents 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 hea...
Страница 184: ...part of the personal safety equipment Do not smoke WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment th...
Страница 185: ...efilter 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 R...
Страница 186: ...stalla tion 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from con necting flange 1 of intake housing 3 Clean connecting flange 1 of the intake housing and check for obstructions 4 Place new air...
Страница 187: ...e oil level may 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 e...
Страница 188: ...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 Extracting en...
Страница 189: ...ctive gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electri...
Страница 190: ...protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion...
Страница 191: ...is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Checking engine coolant level 1 Read off fuel optimized Page 27 o...
Страница 192: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 193 2 Fill with engine coolant Page 195 192 Coolant Circuit General High Temperature Circuit...
Страница 193: ...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 i...
Страница 194: ...2 Draining of residual coolant At coolant distribution housing 3 Close all open drain points 194 Coolant Circuit General High Temperature Circuit MS150104 02E 2016 11 TIM ID 0000006751 002...
Страница 195: ...es 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...
Страница 196: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant vent line 1 Drain engine coolant Page 193 2 Release union nuts 1 and 3 3 Remove coolant vent l...
Страница 197: ...t 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...
Страница 198: ...ools Material Spare parts Designation Use Part No Qty Mixture coolant Mixture coolant Change 1 Drain mixture coolant Page 199 2 Fill with fresh mixture coolant Page 200 198 Low Temperature Circuit MS1...
Страница 199: ...ry 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 dra...
Страница 200: ...clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Filling with coo...
Страница 201: ...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 h...
Страница 202: ...r pressure after filter 3 B16 1 Coolant pressure after engine 4 B4 X Exhaust temperature after cylinder 5 B79 22 Mixture pressure B side 6 B73 Mixture temperature Table 41 Sensors B side The knock sen...
Страница 203: ...concentration in the exhaust gas 2 B79 23 Mixture pressure before restrictor flap 3 B75 Crankshaft speed reset ignition system 4 B13 3 Crankshaft speed ignition Table 42 Sensors Engine driving end MS1...
Страница 204: ...al 2 B79 21 Mixture pressure A side 3 B50 Crankcase pressure 4 B5 3 Engine oil pressure before filter 5 B7 Engine oil temperature 6 B5 1 Engine oil pressure after filter Table 43 Sensors A side 204 Wi...
Страница 205: ...bocharg er 3 B6 3 Coolant temperature before engine 4 B1 2 Camshaft speed for ignition system 5 B1 3 Camshaft speed for AKR 6 B1 1 Camshaft speed for engine governor 7 B24 Lube oil level 8 B16 3 Coola...
Страница 206: ...g work Wear protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING Coolant is hot and under pressure Risk of injury and scal...
Страница 207: ...eral information Arrangement and position of sensor Page 202 2 Loosen and disconnect connector 2 3 Unscrew electronics box 1 at the eyelets 4 Remove sensor via nut 3 MS150104 02E 2016 11 Wiring Genera...
Страница 208: ...re assembly Note Do not wipe off thread grease of manufactur er If necessary coat thread with high tem perature anti corrosion thread grease Too much grease can contaminate the sensor during operation...
Страница 209: ...ximum limit value HIHI High High Alarm Measured value exceeds 2nd maximum limit value HT High Temperature High temperature ICFN ISO Continuous Fuel stop brake power Fuel stop power acc to ISO internat...
Страница 210: ...otive Engineers U S standardization organization SAV Sicherheitsabsperrventil SBV Sicherheitsabbalseventil SD Sensor Defect Alarm Sensor failure SS Safety System Safety system alarm TA Luft Technische...
Страница 211: ...r 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 s...
Страница 212: ...2 Valve clearance Check and adjustment Page 179 Barring gear Part No F6555766 Qty Used in 1 7 1 1 Engine Barring manually Page 162 Feeler gauge Part No Y20098771 Qty Used in 1 7 4 2 Valve clearance C...
Страница 213: ...stocked by MTU Part No Qty Used in 4 7 Emission values Check Page 46 Oil filter wrench Part No F30379104 Qty Used in 1 7 8 1 Engine oil filter Replacement Page 190 Ratchet adapter Part No F30027340 Qt...
Страница 214: ...1 7 4 1 Valve protrusion Measurement Page 176 Socket wrench 24 mm Part No F30029815 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 179 Special wrench 20 8 mm Part No F30452574 Qty Used...
Страница 215: ...2769 Qty Used in 1 7 3 3 Spark plug Installation Page 168 Qty Used in 1 7 3 7 Spark plug connector Installation Page 173 Qty Used in 1 7 11 4 Sensors Installation Page 208 Torque wrench 60 320 Nm Part...
Страница 216: ...32 Emission optimized 1 2 TA Luft 31 Engine data 12 V 4000 L32F Fuel optimized TA Luft 27 Engine data 16 V 4000 L32 Emission optimized 1 2 TA Luft 31 Engine data 16 V 4000 L32F Fuel optiimized TA Luft...
Страница 217: ...information for dual fuel applications 19 Fluids and lubricants specific information for gaseous fuel supply applications 19 Important provisions 5 6 Indirect materials 17 Initial start up 8 Maintena...
Страница 218: ...acement 170 Starting sequence 42 Stopping sequence 42 T transport 21 V Valve clearance Adjustment 179 Check 179 Valve gear Lubrication 181 Valve protrusion Measurement 176 Vent line of engine coolant...
