Professional Documents
Culture Documents
Gas engine
12V 4000 L32 F
16V 4000 L32 F
MS150104/02E
Engine model kW/cyl. Application group
12V4000L32F 100 kW/cyl. 3A, continuous power, unrestricted
16V4000L32F 100 kW/cyl. 3A, continuous power, unrestricted
Table 1: Applicability
3.6 Monitoring, Control and Regulation 7.4.1 Valve protrusion – Measurement 176
Equipment 35 7.4.2 Valve clearance – Check and adjustment 179
3.6.1 Gas engine phase 4 system – Overview 35 7.4.3 Valve gear – Lubrication 181
3.6.2 Purpose of the units 37 7.4.4 Cylinder head cover ‒ Removal 182
7.4.5 Cylinder head cover ‒ Installation 183
Nameplates
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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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 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 influence of alcohol, drugs or strong medication.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
TIM-ID: 0000040533 - 014
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Keep fuel injection lines and connections clean.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is in
progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
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Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
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 accident if acoustic signals, warning shouts or noises indicating dan-
ger are drowned.
Used oil
Used oil contains harmful combustion residue.
Wear protective gloves!
Wash relevant areas after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Avoid direct contact with lead or pastes containing lead.
• Do not inhale lead vapors.
• Wash affected areas after contact with lead or substances containing lead.
Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that the working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.
Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
Transport
• Lift the engine/genset/system only with the lifting eyes provided.
• Only use transport and lifting devices approved by MTU.
• The engine/genset/system must only be transported in installation position.
• Max. permissible diagonal pull 10°.
• If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes of the
trestle or use a means of transportation which is appropriate for the given 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 imperative to install the transport locks for the en-
gine mounts.
• Secure the engine/genset/system such as to preclude tipping during transport.
• Secure the engine/system/genset as to preclude slipping and tipping when driving up or down inclines
and ramps.
Item Dimensions
Length (A) for 12V approx. 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 (D) approx. 636 mm
Crankshaft center to engine mount (E) approx. 280.5 mm
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Reference conditions
Engine model 12V 4000 16V 4000
L32F L32F
Application group 3A 3A
Intake air temperature °C 35 35
Charge air coolant temperature °C 53 53
Barometric pressure mbar 1000 1000
Site altitude above sea level M 100 100
Power-related data (power ratings are net brake power to ISO 3046)
Number of cylinders 12 16
Rated engine speed A rpm 1500 1500
Mean piston speed m/s 10.5 10.5
Continuous power as per ISO 3046 A kW 1200 1600
Mean effective pressure (pme) (continuous power ISO 3046) bar 16.8 16.8
Table 5: Power-related data (power ratings are net brake power to ISO 3046)
Consumption
Number of cylinders 12 16
Lube oil consumption after 1000 h runtime g/kWh 0.2 0.2
Table 7: Consumption
Coolant system (HT circuit, referenced to max. power without HT heat extraction)
Number of cylinders 12 16
Coolant temperature (at engine connection: outlet to cooling A °C 90 90
equipment) (w/o antifreeze)
Coolant temperature (at engine connection: inlet from cooling A °C 78 78
equipment (w/o antifreeze)
Coolant temperature after engine, alarm R °C 95 95
Coolant temperature after engine, shutdown L °C 98 98
Coolant temperature to enable load application, min. L °C 40 40
Coolant antifreeze content, max. L % 50 50
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Table 9: Coolant system (HT circuit, referenced to max. power without HT heat extraction)
Table 10: Coolant system (LT circuit, referenced to max. power without HT heat extraction)
Table 11: Lube oil system (referenced to max. power without HT heat extraction)
Fuel system
Number of cylinders 12 16
Gas temperature before engine, min. L °C 10 10
Gas temperature before engine, max. L °C 50 50
Gas flow pressure before Tecjet, min. L mbar 80 80
Gas flow pressure before Tecjet, max. L mbar 200 200
Starting (electric)
Number of cylinders 12 16
Rated starter power (standard design) R kW 9 2x9
Rated starter voltage (standard design) R V 24 24
Capacities
Number of cylinders 12 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 200 270
Mixture coolant, engine side (without cooling system) R Liters 20 22
Total engine oil capacity for initial filling (standard oil system) R Liters 320 365
Oil change capacity, max. (standard oil system) R Liters 280 330
Exhaust emissions
Number of cylinders 12 16
Exhaust emission before catalytic converter at 100 % DL nitric ox- G mg/m n 3 500 500
ides (NOx) (in dry exhaust gas, 5 % O2)
Exhaust emission before catalytic converter at 100 % DL nitric ox- A ppm 171 167
ides (NOx) (in dry exhaust gas)
Acoustics
Number of cylinders 12 16
Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) 119 119
Genset surface noise with attenuated intake noise filter) - DL R dB(A) 118 117
(sound power level LW, ISO 8528-10)
Reference conditions
Engine model 12V 4000 16V 4000
L32F L32F
Application group 3A 3A
Intake air temperature °C 35 35
Charge air coolant temperature °C 53 53
Barometric pressure mbar 1000 1000
Site altitude above sea level M 100 100
Power-related data (power ratings are net brake power to ISO 3046)
Number of cylinders 12 16
Rated engine speed A rpm 1500 1500
Mean piston speed m/s 10.5 10.5
Continuous power as per ISO 3046 A kW 1200 1600
Mean effective pressure (pme) (continuous power ISO 3046) bar 16.8 16.8
Table 20: Power-related data (power ratings are net brake power to ISO 3046)
Coolant system (HT circuit, referenced to max. power without HT heat extraction)
Number of cylinders 12 16
Coolant temperature (at engine connection: outlet to cooling A °C 90 90
equipment) (w/o antifreeze)
Coolant temperature (at engine connection: inlet from cooling A °C 78 78
equipment (w/o antifreeze)
Coolant temperature after engine, alarm R °C 95 95
Coolant temperature after engine, shutdown L °C 97 98
Coolant temperature to enable load application, min. L °C 40 40
Coolant antifreeze content, max. L % 50 50
Coolant pump: Volumetric fllow L m³/h 47 72
Filling pressure in cooling system (cold) R bar 0.5 0.5
Pressure in cooling system, max. L bar 6.0 6.0
Pressure loss over engine (at nominal flow rate 7.27) bar 2.2 2.8
Thermostat: Starts to open R °C 68 68
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Table 24: Coolant system (HT circuit, referenced to max. power without HT heat extraction)
Table 25: Coolant system (LT circuit, referenced to max. power without HT heat extraction)
Table 26: Lube oil system (referenced to max. power without HT heat extraction)
Fuel system
Number of cylinders 12 16
Gas temperature before engine, min. L °C 10 10
Gas temperature before engine, max. L °C 50 50
Gas flow pressure before Tecjet, min. L mbar 80 80
Gas flow pressure before Tecjet, max. L mbar 200 200
Starting (electric)
Number of cylinders 12 16
Rated starter power (standard design) R kW 9 2x9
Rated starter voltage (standard design) R V 24 24
Capacities
Number of cylinders 12 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 200 270
Mixture coolant, engine side (without cooling system) R Liters 20 22
Total engine oil capacity for initial filling (standard oil system) R Liters 320 365
Oil change capacity, max. (standard oil system) R Liters 280 330
Exhaust emissions
Number of cylinders 12 16
Exhaust emission before catalytic converter at 100 % DL nitric ox- G mg/m n 3 250 250
ides (NOx) (in dry exhaust gas, 5 % O2)
Exhaust emission before catalytic converter at 100 % DL nitric ox- A ppm 84 83
ides (NOx) (in dry exhaust gas)
Acoustics
Number of cylinders 12 16
Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) 121 119
Genset surface noise with attenuated intake noise filter) - DL R dB(A) 121 120
(sound power level LW, ISO 8528-10)
Governing/control/monitoring
Engine Control Unit ECU-9
• Controls engine starting, stopping and emergency stop
• Monitors engine operating parameters
• Controls throttles and sets gas mixture for requested speed/power
• Monitors first gas solenoid in gas train to engine
A minimum operating time of 2 hours per start is recommended to counteract increased engine loading re-
sulting from temperature changes (cold start to engine operating temperature).
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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 speed
6. Scavenging the engine
7. Ignition
8. Opening gas supply solenoid valves
9. Waiting for starter disengagement speed
10. Disengaging starter
11. Waiting for idling speed
12. Ramping-up to rated speed
Start termination
1. The maximum number of attempted starts is limited to three following start termination
2. An alarm is then signaled
3. Requesting external ventilation by contact
4. A new engine start request is only possible following fault acknowledgment
Stopping sequence
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The following steps are performed automatically when a stop command is activated:
1. Closing gas supply solenoid valves
2. Opening mixture throttles, scavenging residual gas
3. Engine running down to standstill
4. Deactivating ignition
5. Closing mixture throttles
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the 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.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Operational checks
Item Measure
Machine room Check machine 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, pressures)
Operation log (if provided) Document operating parameters.
• This is especially useful for fault localization and fast remedial action.
Engine under load, Check engine/plant and all pipework visually for leaks, rectify any leaks with
engine at nominal speed the engine stopped;
Check for abnormal running noises and vibration.
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WARNING
Engine operation at high load/speed when measuring emissions.
Risk of injury!
• Conduct measuring in a room which offers safe protection from the engine if at all possible. If this is
not feasible, keep the greatest possible distance away when measuring, e.g. using wireless data
transmission or long cables.
WARNING
Installing/removing measuring equipment – exhaust gases are hot and pressurized.
Risk of injury and burning!
• Only install/remove measuring equipment when the engine is at standstill.
• Wear protective clothing, protective gloves and goggles/safety mask.
WARNING
High level 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.
• 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, 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.
NOTICE
Non-compliance with exhaust emission limits.
Emission agencies may revoke the operating license!
• Adjust the exhaust emissions such as to ensure compliance with statutory limits.
• Use tested measuring equipment only.
• Exhaust emissions shall be checked and adjusted at the intervals specified in the Maintenance
Schedule.
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NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal 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.
NOTICE
An emergency stop subjects the engine system to an extremely high load.
Risk of overheating, damage to components!
• Trigger an emergency stop only in emergency situations.
Task Measures
W0501 Visually inspect engine for leaks and general condition. (→ Page 45)
W0509 Check machine room for smell of gas. (→ Page 163)
W0523 Check for abnormal running noises and vibrations. (→ Page 45)
W0527 X Check engine oil level in storage tank. See manufacturer‘s docu-
mentation
W1005 Replace air filter. (→ Page 185)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 190)
the interval (years) is reached, at the latest.
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! (→ Page 179)
First adjustment after 1,000 operating hours on a new en-
gine and 1,000 operating hours following each overhaul of
the cylinder heads.
W1525 X Replace sensor. (→ Page 206)
W1616 Replace spark plug and seal in spark plug connector. (→ Page 166)
W1689 Measure valve projection. (→ Page 176)
W1798 Replace fine filter. (→ Page 164)
W1799 Replace coarse filter (coalescer filter). (→ Page 164)
W4137 If spark plug is replaced: Clean and check spark plug con- (→ Page 172)
nector, replace if required.
W4138 Replace flexible hose of coolant line (only 8V, 12V, and (→ Page 196)
16V).
W8660 Check exhaust emissions, adjust if required. Comply with lo- (→ Page 46)
cal emissions regulations.
A prerequisite for performing the measures to rectify faults is corresponding qualification/training at MTU.
Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
112301 – HI T-Exhaust A1
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112302 – HI T-Exhaust A2
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112303 – HI T-Exhaust A3
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
TIM-ID: 0000038611 - 003
112305 – HI T-Exhaust A5
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112306 – HI T-Exhaust A6
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112307 – HI T-Exhaust A7
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112308 – HI T-Exhaust A8
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
TIM-ID: 0000038611 - 003
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112311 – HI T-Exhaust B1
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112312 – HI T-Exhaust B2
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112313 – HI T-Exhaust B3
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
TIM-ID: 0000038611 - 003
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112315 – HI T-Exhaust B5
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112316 – HI T-Exhaust B6
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112317 – HI T-Exhaust B7
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112318 – HI T-Exhaust B8
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 175).
TIM-ID: 0000038611 - 003
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
112401 – LO T-Exhaust A1
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112402 – LO T-Exhaust A2
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112403 – LO T-Exhaust A3
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
TIM-ID: 0000038611 - 003
112405 – LO T-Exhaust A5
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112406 – LO T-Exhaust A6
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112407 – LO T-Exhaust A7
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112408 – LO T-Exhaust A8
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
TIM-ID: 0000038611 - 003
112411 – LO T-Exhaust B1
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112412 – LO T-Exhaust B2
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112413 – LO T-Exhaust B3
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
TIM-ID: 0000038611 - 003
112415 – LO T-Exhaust B5
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112416 – LO T-Exhaust B6
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112417 – LO T-Exhaust B7
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 175).
average. 4. Check valve drive.
112418 – LO T-Exhaust B8
Yellow alarm. Initiated by EMU.
Cause Corrective action
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
TIM-ID: 0000038611 - 003
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
3. Check igniters.
pulse sensor 1 (B1.2). wheel. Replace sensor as necessary. (→ Page 202) (→ Page 201)
Unable to detect polarity of pulse u Check sensor, sensor gap, cabling, data record settings and timing
sensor 3 (B13.2). wheel. Replace sensor as necessary. (→ Page 202) (→ Page 201)
(B13.2) detected too early or wheel. Replace sensor as necessary. (→ Page 202) (→ Page 201)
faulty.
1.4530.007 – Shutdown
Red alarm. Initiated by compressor bypass.
Cause Corrective action
Hardware not ready for operation. 1. Restart compressor bypass flap.
2. Replace compressor bypass flap.
1.4530.008 – Alarm
Yellow alarm. Initiated by compressor bypass.
Cause Corrective action
Summary alarm (for details, refer u Rectify cause of alarm.
to the source alarm).
3. Replace TecJet.
019 – HI T-Exhaust A
Yellow alarm.
Associated parameter 2.0126.931
Cause Corrective action
Exhaust gas temperature (A side) 1. Check exhaust turbocharger.
after turbine too high (limit value 2. Check ignition timing (→ Page 175).
1). Incorrect ignition timing, 3. Check mixture setting.
mixture too lean or too rich,
damage to turbine.
020 – SS T-Exhaust A
Yellow alarm.
Associated parameter 2.0126.932
Cause Corrective action
TIM-ID: 0000038612 - 002
022 – SS T-Exhaust B
Yellow alarm.
Associated parameter 2.0127.932
Cause Corrective action
Exhaust gas temperature (B side) 1. Check exhaust turbocharger.
after turbine too high (limit value 2. Check ignition timing (→ Page 175).
2). Incorrect ignition timing, 3. Check mixture setting.
mixture too lean or too rich, 4. Check igniters.
damage to turbine.
057 – LO P-Coolant
TIM-ID: 0000038612 - 002
Yellow alarm.
Associated parameter 2.0101.921
Cause Corrective action
Coolant pressure after engine too u Check engine coolant circuit (pressure and flow).
low (limit value 1). Insufficient
volume flow, static pressure too
low.
063 – HI P-Crankcase
Yellow alarm.
Associated parameter 2.0106.931
Cause Corrective action
Crankcase pressure too high (limit 1. Check crank drive:
value 1). Restrictor valve in • Bar engine (→ Page 162).
crankcase breather is closed too • Endoscope combustion chambers from bottom dead center to
much, air filter is faulty, oil top dead center.
separator is clogged, piston rings 2. Check air filter for contamination, replace if contamination is
are seized, other damage to crank visible (→ Page 185).
drive. 3. Check setting of blow-by restrictor valve.
4. Check oil 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 1. Check crank drive: Bar engine (→ Page 162), endoscope
value 2). Restrictor valve in combustion chambers from bottom dead center to top dead
crankcase breather is closed too center.
much, air filter is faulty, oil 2. Check air filter for contamination, replace if contamination is
separator is clogged, piston rings visible (→ Page 185).
are seized, other damage to crank 3. Check setting of blow-by restrictor valve.
drive. 4. Check oil separator condition, replace as necessary (→ Page 164).
067 – HI T-Coolant
Yellow alarm. Power reduction.
Associated parameter 2.0120.931
Cause Corrective action
TIM-ID: 0000038612 - 002
093 – SS T-Preheat
Red alarm. Engine shutdown.
Associated parameter 2.1090.922
Cause Corrective action
Preheating temperature too low 1. Check preheating.
(limit value 2). coolant 2. Check differential coolant pressure.
temperature too low for engine 3. Check heating elements.
start. 4. Check cabling (→ Page 201).
094 – LO T-Preheat
Yellow alarm.
Associated parameter 2.1090.921
Cause Corrective action
Preheating temperature too low 1. Check preheating.
(limit value 1). coolant 2. Check differential coolant pressure.
temperature too low for engine 3. Check heating elements.
start. 4. Check cabling (→ Page 201).
122 – HI T-ECU
Yellow alarm.
Associated parameter 2.0132.921
Cause Corrective action
Temperature of electronics too 1. Provide improved cooling for ECU. Reduce room temperature,
high (limit value 1). check air flow to ECU.
TIM-ID: 0000038612 - 002
201 – SD T-Coolant
Red alarm. Engine shutdown.
TIM-ID: 0000038612 - 002
206 – SD T-Exhaust A
Yellow alarm.
Associated parameter 1.8004.576
Cause Corrective action
Exhaust temperature sensor on A u Check sensor and cabling (B4.21), replace as necessary
side faulty, short circuit or wire (→ Page 202) (→ Page 201). Error cleared after restarting the
break. engine.
207 – SD T-Exhaust B
Yellow alarm.
Associated parameter 1.8004.577
Cause Corrective action
Exhaust temperature sensor on B u Check sensor and cabling (B4.22), replace as necessary
side faulty, short circuit or wire (→ Page 202) (→ Page 201). Error cleared after restarting the
break. engine.
212 – SD P-Coolant
Red alarm.
Associated parameter 1.8004.564
TIM-ID: 0000038612 - 002
Red alarm.
Associated parameter 2.8006.589
Cause Corrective action
Internal Engine Control Unit fault. u Replace Engine Control Unit ECU.
Red alarm.
Associated parameter 2.8006.641
Cause Corrective action
Short circuit or line break at u Check cabling (→ Page 201).
transistor output 4 system-side
(TOP 4). Activation of gas supply
solenoid valve No.2 faulty.
429 – HI P-Coolant
Red alarm. Engine shutdown.
Associated parameter 2.0101.931
Cause Corrective action
Coolant pressure after engine too u Check engine coolant circuit (pressure and flow).
high (limit value 3).
470 – SD T-ECU
Red alarm.
Associated parameter 1.8004.587
Cause Corrective action
Temperature sensor in Engine u Replace Engine Control Unit ECU.
Control Unit faulty.
472 – AL Stop SD
Red alarm. Engine shutdown.
Associated parameter 2.8006.593
Cause Corrective action
Engine stopped because channel u Summary alarm (for details, refer to the source alarm).
TIM-ID: 0000038612 - 002
sensor on A or B side faulty, short (→ Page 202) (→ Page 201). Error cleared after restarting the
circuit or wire break. engine.
Red alarm.
Associated parameter 1.4540.996
Cause Corrective action
CAN bus communication for gas 1. Check cabling (→ Page 201).
control valve faulty (alternatively, 2. Check power supply.
a stepper motor with gas mixer 3. Carry out restart of ECU, EMU and gas control valve.
can be installed). 4. Check settings with device-specific dialog software (XD11).
Red alarm.
Associated parameter 1.1480.305
Cause Corrective action
Summary alarm for automatic oil u After initiation of the alarms “HI Oil Refill” and
replenishment. “HI Lube Oil Level refill” a programmable timeout period starts. The
engine is stopped when this time expires.
3. Fill oil.
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.
Associated parameter 2.8006.035
Cause Corrective action
2nd lower limit value violated. u Check gas supply.
Yellow alarm.
Associated parameter 1.0610.953
Cause Corrective action
Engine number in EIL differs from 1. Check the engine number in the ECU. Check that the ECU
engine number in ECU. Two parameter record matches this engine.
further attempts at engine 2. Check EIL.
starting remain after the first
occurrence before engine starting
is disabled.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the 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.
WARNING
Gaseous fuels are combustible/explosive.
Risk 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.
WARNING
Engine oil is hot.
Engine oil can contain combustion residues 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 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, electric sparks and ignition sources.
• Do not smoke.
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
14. Fit clamp (2) neatly and use torque wrench to tighten to specified tightening torque.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 5 Nm
TIM-ID: 0000029127 - 006
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
Note: The temperature of spark plug and cylinder head must be the same 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 50 +5 Nm
(Molykote P 37))
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
7. Fit the protective cap (2) and check for correct seating.
DANGER
Live components, flash-over.
Risk of serious injury - danger to life!
• Always wear electrical gloves (class 4 minimum) when touching the ignition cable in operation.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the 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.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparatory steps
1. Remove igniters (→ Page 167).
2. Remove cylinder head covers (→ Page 182).
3. Remove sleeves (arrowed).
4. Install barring tool (→ Page 162).
Final steps
1. Remove barring tool (→ Page 162).
TIM-ID: 0000043220 - 003
Preparatory steps
1. Remove cylinder head cover (→ Page 182).
2. Install barring device (→ Page 162).
3. Rotate crankshaft with barring tool in engine
direction of rotation until marking “OT” and
pointer are aligned.
5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to
prevent it from turning.
TIM-ID: 0000043221 - 003
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 162).
2. Install cylinder head cover (→ Page 183).
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
WARNING
Gaseous fuels are combustible/explosive.
Risk 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.
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
Note: Air filter condition is monitored by a sensor. Replace air filter and/or (optional) fleece prefilter when the cor-
responding fault message appears.
WARNING
Engine oil is hot.
Engine oil can contain combustion residues 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 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, electric sparks and ignition sources.
• Do not smoke.
1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
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.
3. Oil level must be between marks (1) and (2).
4. Insert oil dipstick into guide tube up to the stop.
WARNING
Engine oil is hot.
Engine oil can contain combustion residues 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 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, electric sparks and ignition sources.
• Do not smoke.
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.
WARNING
Engine oil is hot.
Engine oil can contain combustion residues 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 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, 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.
WARNING
Engine oil is hot.
Engine oil can contain combustion residues 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 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, electric sparks and ignition sources.
• Do not smoke.
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.
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.
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheater, if installed.
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.
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.
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.
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.
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.
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.
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.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Engine oil is hot.
Engine oil can contain combustion residues 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 protection.
• Avoid contact with skin.
• Do not inhale oil vapor.
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.
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
NOTICE
High voltage.
Risk of damage to components!
• Switch off ignition before replacing components.
TIM-ID: 0000054588 - 004
NOTICE
Ceramic cell breakage due to shock or impact.
Risk of damage to components!
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
4. If necessary, roll up sensor cable to correct length and secure with cable clamps.
5. Screw on electronics box (1) at the eyelets.
6. Connect connector (2) and engage it.
TIM-ID: 0000054589 - 004
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
24-h Hotline
With our 24-h hotline and 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 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:
• support-oeg@mtu-online.com
Barring gear
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 162)
Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 7.4.2 Valve clearance – Check and adjustment
(→ Page 179)
DCL-ID: 0000027547 - 003
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.11.3 Sensors – Removal (→ Page 206)
Qty.: 1
Used in: 7.11.4 Sensors – Installation (→ Page 208)
DCL-ID: 0000027547 - 003
Socket wrench, 24 mm
Part No.: F30029815
Qty.: 1
Used in: 7.4.2 Valve clearance – Check and adjustment
(→ Page 179)
Engine cabling
– Check 201 – Change 198
Engine coolant – Draining 199
– Change 192 – Filling 200
– Draining 193 Mixture coolant level
– Filling 195 – Check 197
– Level check 191 MTU Onsite Energy
Engine data 12 V 4000 L32 – Contact person 211
– Emission optimized (1/2 TA-Luft) 31 – Service partner 211
Engine data 12 V 4000 L32F
– Fuel optimized (TA-Luft) 27
– Installation 208
– Overview 202
– Removal 206
Service partner
– MTU Onsite Energy 211
Spark plug
– Installation 168
– Removal 167
– Replacement 166
T
transport 21
V
Valve clearance
– Adjustment 179
– Check 179
Valve gear
– Lubrication 181
Valve protrusion
– Measurement 176
Vent line of engine coolant circuit
– Replacement 196