Operating Instructions: Gas Engine 12 V 4000 Lx2 XX 16 V 4000 Lx2 XX

Operating Instructions

Gas engine
12 V 4000 Lx2 xx
16 V 4000 Lx2 xx

MS150115/00E

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Engine model kW/cyl. Application group
12V4000L32FB 100 kW/cyl. 3A, continuous operation, unrestricted
16V4000L32FB 100 kW/cyl. 3A, continuous operation, unrestricted
Table 1: Applicability
Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Table of Contents
1 Safety 3.8 Engine – Shutdown 45
3.9 Emergency engine shutdown 46
1.1 Important provisions for all products 5 3.10 After stopping the engine – Engine remains
1.2 Personnel and organizational requirements 6 ready for operation 48
1.3 Transport 7 3.11 After stopping the engine – Putting the
1.4 Safety regulations for startup and operation 8 engine out of operation 49
1.5 Safety regulations for startup and operation,
special instructions for applications with
4 Maintenance
gaseous fuel 9
1.6 Safety regulations for maintenance and 4.1 50-hours check 50
repair work 10 4.2 Maintenance task reference table [QL1] 51
1.7 Safety regulations for maintenance and
repair work, special instructions for 5 Troubleshooting
applications with gaseous fuel 13
1.8 Fire prevention and environmental 5.1 Fault messages - Key 52
protection, fluids and lubricants, auxiliary 5.2 Fault messages in communication protocol
materials 14 to genset control system 54
1.9 Fire prevention and environmental 5.3 Fault messages of the engine governor 96
protection, fluids and lubricants, auxiliary
materials, special instructions for 6 Task Description
applications with gaseous fuel 16
6.1 Engine 130
1.10 Standards for safety notices in the text 17
6.1.1 Engine – Barring manually 130
6.1.2 Checking machine room for smell of gas 131
2 Product Summary
6.2 Crankcase Breather 132
2.1 Engine layout 18 6.2.1 Oil separator – Filter replacement 132
2.2 Engine side and cylinder designations 20 6.3 Ignition System 134
2.3 Main engine dimensions 21 6.3.1 Spark plug – Replacement 134
2.4 Ignition order 22 6.3.2 Spark plug – Removal 135
2.5 Technical Data 23 6.3.3 Spark plug – Installation 136
2.5.1 12 V 4000 L32FB, 16 V 4000 L32FB engine 6.3.4 Spark plug connector – Replacement 138
data, fuel optimized (TA-Luft) 23 6.3.5 Spark plug connector – Removal 139
2.5.2 12 V 4000 L32FB, 16 V 4000 L32FB engine 6.3.6 Spark plug connector – Installing 140
data, tropical applications (TA-Luft) 28 6.3.7 Ignition system – Ignition timing check 143
2.6 Monitoring, Control and Regulation 6.4 Valve Drive 144
Equipment 33 6.4.1 Valve depth – Measurement 144
2.6.1 Gas engine phase 3 system – Overview 33 6.4.2 Valve clearance – Check and adjustment 147
2.6.2 Purpose of the units 35 6.4.3 Valve gear – Lubrication 150
6.4.4 Cylinder head cover – Removal 151
6.4.5 Cylinder head cover – Installation 152
3 Operation
6.5 Gas System 153
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3.1 Runtimes at partial load 37 6.5.1 Gas supply - Checking gas lines for leaks 153
3.2 Putting the engine into operation after
6.6 Air Filter 154
extended out-of-service periods (>3 months) 38 6.6.1 Air filter – Replacement 154
3.3 Putting the engine into operation after 6.6.2 Air filter – Removal and installation 155
scheduled out-of-service-period 39
3.4 Control, starting and stopping sequences 40 6.7 Lube Oil System, Lube Oil Circuit 156
6.7.1 Engine oil – Level check 156
3.5 Engine – Start 42
6.7.2 Engine oil – Change 157
3.6 Operational checks 43
6.7.3 Engine oil – Sample extraction and analysis 158
3.7 Emission values – Check 44
MS150115/00E 2013-10 | Table of Contents | 3

6.8 Oil Filtration / Cooling 159 6.10.4 Mixture coolant – Filling 169
6.8.1 Engine oil filter – Replacement 159
6.11 Wiring (General) for Engine/Gearbox/Unit 170
6.9 Coolant Circuit, General, High-Temperature 6.11.1 Engine wiring – Check 170
Circuit 160 6.11.2 Sensors – Overview 171
6.9.1 Engine coolant – Level check 160
6.9.2 Engine coolant – Change 161
6.9.3 Engine coolant – Draining 162
7 Appendix A
6.9.4 Engine coolant – Filling 164 7.1 Abbreviations 175
6.9.5 Vent line of engine coolant circuit –
7.2 MTU Onsite Energy contacts / service
Replacement 165
partners 177
6.10 Low-Temperature Circuit 166
6.10.1 Mixture coolant – Level check 166 8 Appendix B
6.10.2 Mixture coolant – Change 167
6.10.3 Mixture coolant – Draining 168 8.1 Special Tools 178
8.2 Index 182
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4 | Table of Contents | MS150115/00E 2013-10

1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
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The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
MS150115/00E 2013-10 | Safety | 5

1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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6 | Safety | MS150115/00E 2013-10

1.3 Transport
Transport
Only use the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear-
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport

Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
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MS150115/00E 2013-10 | Safety | 7

1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance the manufacturer's specifications
before putting the product into service.
Before the product is put into operation for the first time, all official authorizations must be available
and commissioning preconditions met.
When putting the product into operation, always ensure that
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All personnel is clear of the danger zone surrounding moving parts of the machine.
• The service room is adequately ventilated.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems work properly.
Safety regulations for equipment operation

The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re-
gard to present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

The procedures for cases of emergency, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is recognized or reported by the sys-
tem:
• Inform supervisor(s) in charge.
• Analyze the message.
• If required, carry out emergency operations e.g. emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely neces-
sary.
Keep a safe distance away from the product if at all possible. Do not touch the product unless expressly
instructed to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder
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agent.
Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
8 | Safety | MS150115/00E 2013-10

1.5 Safety regulations for startup and operation, special
instructions for applications with gaseous fuel
Gas system
Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device. This
must be designed by the plant designer according to site conditions.
The connection to the gas supply network is made by the plant designer in accordance with regulations
of the DVGW (DVGW490, G490/I). The plant designer must use certified gas trains for the fuel supply
to the product and connection to the gas supply network. The connection conditions and dimensions
must be coordinated with the manufacturer.
In flow direction, gas trains have:
• a manual shutoff fitting
• a gas filter
• two gas shutoff valves
• a pressure regulating device
The gas train must be fitted with an automatic leak check.
The gas shutoff valves are activated via two different paths from the control system, whereby one gas
shutoff valve respectively is activated via one of the paths.
Gas trains must be monitored to detect minimum pressure.
The plant designer must ensure that the gas train is positioned directly in front of the engine, however a
maximum of three meters before the interface of the engine. The interface is the flange in front of the
gas volume regulator of the product.
In the case of network supply pressures higher than 120 mbar, additional equipment is required on the
gas train.
The gas pressure regulator must be equipped with an approved safety shut-off valve and a safety dis-
charge valve to ensure safety in case of excessive outlet pressure at the pressure regulator.Gas dis-
charge must be routed to a safe area (to atmosphere).
If the gas supply is connected to a vessel or if gases containing oxygen are used, the gas train must be
equipped with a temperature-monitored flame arrester.
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MS150115/00E 2013-10 | Safety | 9

1.6 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion
of oil vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
• Expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Secure the product against unintentional starting, e.g. with start interlock.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock contactors.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following applies to starters with copper-beryllium alloy pinions:
• Wear breathing protection of filter class P3 during maintenance work. Do not blow out the interior of
the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a
class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
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Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
10 | Safety | MS150115/00E 2013-10

Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths
and cable ties).
Safety regulations after completion of maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).
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.
• 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
going on. Risk of explosion or fire due to oil vapors and 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 may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal jig, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

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Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear goggles and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
MS150115/00E 2013-10 | Safety | 11

Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged dur-
ing operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a function check on completion of all repair work. In partic-
ular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be equipped with the protective devices necessary for safe operation according
to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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12 | Safety | MS150115/00E 2013-10

1.7 Safety regulations for maintenance and repair work, special
instructions for applications with gaseous fuel
Safety regulations prior to maintenance and repair work
Installation and connection of the gas supply must only be carried out by a specialized company with
staff that has been trained and authorized for this task.
Have all work on gas-carrying components carried out by authorized, specialized companies.
Prior to starting maintenance work, shut off the gas supply to the product. Activate the emergency stop
at the interface switchgear cabinet or by turning the key switch (if fitted).
In case of scheduled shutdowns of the product, coolant pump operation must continue for a certain
time.
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MS150115/00E 2013-10 | Safety | 13

1.8 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including 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, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Consumable fluids and materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
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coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
14 | Safety | MS150115/00E 2013-10

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Paints and varnishes

• Observe the relevant safety data sheet for all materials.
• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

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• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.
MS150115/00E 2013-10 | Safety | 15

1.9 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials, special instructions for
applications with gaseous fuel
Natural gas
Observe the safety data sheet.
Caution: Highly flammable gas, forms an explosive mixture with air/oxygen.
Caution: Weak narcotic gas, risk of suffocation at very high concentration.
All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during
operation.
Procedure in the case of accidental release of gaseous fuel:
• If safely feasible: Shut off main gas supply.
• If safely feasible: Carry out emergency stop.
• Cordon off danger zone.
• Ensure sufficient ventilation!
• Do not enter danger zone before measurements with a suitable gas detector have confirmed that gas
concentration is not hazardous.
Biogenic gases from fermentation processes

Observe the safety data sheet.
Caution: Highly flammable gas, forms an explosive mixture with air/oxygen.
Caution: Can be life threatening depending on concentration. Some gases can no longer be detected by
sense of smell in higher concentrations.
Caution: Risk of poisoning due to hazardous byproducts. The absorption of even small quantities of hy-
drogen sulfide or ammonium may be lethal.
Caution: Danger of suffocation. Due to the lack of oxygen, the absorption of methane can occasionally
lead to increased breathing frequency (hyperventilation) and heart rates, low blood pressure, numbness
of the extremities, drowsiness, mental confusion and loss of memory!
Biogenic gases tend to segregate. In low-lying areas of the plant, carbon dioxide enrichment is possible.
All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during
operation.
Procedure in the case of accidental release of gaseous fuel:
• If safely feasible: Shut off main gas supply.
• If safely feasible: Carry out emergency stop.
• Cordon off danger zone.
• Ensure sufficient ventilation!
• Do not enter danger zone before measurements with a suitable gas detector have confirmed that gas
concentration is not hazardous.
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16 | Safety | MS150115/00E 2013-10

1.10 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
u This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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MS150115/00E 2013-10 | Safety | 17

2 Product Summary
2.1 Engine layout
1 Throttle, A side 6 Engine lifting equipment 11 Starter

2 Engine governor/engine 7 Capacitor discharge igni- 12 Flywheel
monitoring tion system KS Driving end
3 Air filter/air inlet 8 Engine mounting bracket,
4 Mixture cooler free end
5 Exhaust turbocharger 9 Oil pan
10 Engine mounting bracket,
driving end
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18 | Product Summary | MS150115/00E 2013-10

1 Crankcase breather, oil 7 Spark plug 13 Connection: engine cool-
separator 8 Cylinder head cover ant inlet
2 Exhaust outlet 9 Cylinder head 14 Engine oil heat exchanger
3 Gas control valve 10 Engine oil sampling con- 15 Connection: engine cool-
4 Gas inlet connection nection ant outlet
5 Ignition coil 11 Engine oil filter KGS Free end
6 Throttle 12 Oil level switch
Engine model designation

Key to the engine model designations 12/16V 4000 L32 FB
12/16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
L Application: L = Gas engine
3 Load profile
2 Design index
F Additional feature: F = 50Hz
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B Additional feature: B = Biogases from fermentation proc-

esses
Table 2: Engine model designation
MS150115/00E 2013-10 | Product Summary | 19

2.2 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS) (4).
For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on
the left-hand side of the engine and the letter "B" (3) to refer to the cylinders on the right-hand side. The
cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of other engine components also starts with no. 1 at the driving end.
1 Left-hand side of engine 3 Right-hand side of engine

2 Free end 4 Driving end
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2.3 Main engine dimensions
Main engine dimensions
Also valid for 12V engines.
Length (A) for 12V approx. 2858 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. 2156 mm
Height (C) for 16V approx. 2175 mm
Crankshaft center to oil pan (D) approx. 636 mm
Crankshaft center to engine mount (E) approx. 280.5 mm
Table 3: Main engine dimensions

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2.4 Ignition order
Ignition order
12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
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2.5 Technical Data
2.5.1 12 V 4000 L32FB, 16 V 4000 L32FB engine data, fuel optimized (TA-Luft)
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 12V 4000 16V 4000
L32FB L32FB
Application group 3A 3A
Intake air temperature °C 25 25
Charge-air coolant temperature °C 40 40
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
Table 4: Reference conditions
Power-related data (power ratings are net brake power to ISO 3046)
Number of cylinders 12 16
Rated engine speed A rpm 1500 1500
Mean piston speed m/s 10.5 10.5
Continuous power as per ISO 3046 A kW 1200 1600
Mean effective pressure (pme) (continuous power ISO 3046) bar 16.8 16.8
Table 5: Power-related data (power ratings are net brake power to ISO 3046)
General conditions (for max. power)

Relative air humidity A % 30 30
Intake air temperature A °C 25 25
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Intake air temperature, min. L °C 20 20

Intake air temperature, max. L °C 30 30
Mixture temperature after mixture cooler A °C 52 53
Ambient intake depression, max. L mbar 3 3
Pressure loss over air filter, max. L mbar 30 30
Exhaust back pressure, max. L mbar 60 60

Gas type: Biogas X X
Methane number, min. L 120 120
Table 6: General conditions (for max. power)
Consumption
Lube oil consumption after 1000 h runtime g/kWh 0.2 0.2
Table 7: Consumption
Model-related data (basic design)

Operating method: Four-stroke cycle, Otto engine, single-acting X X
Combustion method: Mixture charging, spark ignition X X
Cylinder arrangement: V angle Degrees 90 90
(°)
Bore mm 170 170
Stroke mm 210 210
Displacement of a cylinder Liters 4.77 4.77
Total displacement Liters 57.20 76.27
Compression ratio 13.9 13.9
Standard housing connecting flange (engine main PTO) SAE 00 00
Table 8: Model-related data (basic design)
Coolant system (HT circuit)

Coolant temperature (at engine connection: outlet to cooling A °C 90 88
equipment) (w/o antifreeze)
Coolant temperature (at engine connection: inlet from cooling A °C 78 78
equipment (w/o antifreeze)
Coolant temperature after engine, warning R °C 95 95
Coolant temperature after engine, shutdown L °C 98 98
Coolant temperature to enable load application, min. L °C 40 40
Coolant antifreeze content, max. L % 50 50
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Coolant pump: Volumetric flow L m³/h 43 59

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 1.3 1.3
Thermostat: Starts to open R °C 68 68
Thermostat: Opening stops (thermostat fully open and bypass A °C 78 78
closed)
Table 9: Coolant system (HT circuit)

Coolant system (LT circuit)
Coolant temperature before mixture cooler (at engine connection: A °C 40 40
inlet from cooling equipment (w/o antifreeze)
Coolant pump: Volumetric flow A m³/h 21 27
Pressure loss over mixture cooler (at nominal flow rate 8.56) bar 0.2 0.6
Table 10: Coolant system (LT circuit)
Coolant system (MT circuit)

Coolant temperature before mixture cooler (at engine connection: A °C - 70
Coolant antifreeze content, max. L % - 50
Coolant pump: Volumetric flow A m³/h - 32
Pressure in cooling system, max. L bar - 6.0
Pressure loss over MT mixture cooler (at nominal flow rate 8.56) bar - 3.4
Table 11: Coolant system (MT circuit)
Lube oil system

Lube oil operating temperature after oil heat exchanger, from R °C 82 82
Lube oil operating temperature after oil heat exchanger, to R °C 90 90
Lube oil operating temperature after oil heat exchanger, warning R °C 93 93
Lube oil operating temperature after oil heat exchanger, engine L °C 97 97
shutdown
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
Table 12: Lube oil system
Fuel system
Gas temperature before engine, min. L °C 10 10
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Gas temperature before engine, max. L °C 50 50

Gas flow pressure before Tecjet, min. L mbar 30 30
Gas flow pressure before Tecjet, max. L mbar 120 120
Table 13: Fuel system

General operating data
Cold start capability: Air temperature (w/o starting aid, with pre- R °C 15 15
heating) - (case C)
Site condition (for case C): Engine coolant temperature R °C 40 40
Minimum idling speed A rpm 1500 1500
Limit speed for overspeed alarm/emergency shutdown L rpm 1900 1900
Table 14: General operating data
Starting (electric)
Rarted starter power (standard design) R kW 2x9 2x9
Rated starter voltage (standard design) R V 24 24
Starter current consumption, max. (standard design) R A 2 x 2500 2 x 2500
Starting-attempt duration, max. L s 15 15
Number of teeth on starter ring gear 182 182
Table 15: Starting (electric)
Capacities
Engine coolant capacity, engine side (without cooling equipment) R Liters 200 255
Mixture coolant, engine side (without cooling system) R Liters 20 25
Total engine oil capacity for initial filling (standard oil system) R Liters 260 285
Oil change capacity, max. (standard oil system) R Liters 220 250
Table 16: Capacities
Weights / main dimensions

Dry engine weight (basic-configuration engine) R kg 6380 7890
Heaviest component to be lifted during extended component R kg 450 450
maintenance (QL3)
Table 17: Weights / main dimensions
Exhaust emissions
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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 180 187
ides (NOx) (in dry exhaust gas)
Table 18: Exhaust emissions

Acoustics
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)
Table 19: Acoustics

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2.5.2 12 V 4000 L32FB, 16 V 4000 L32FB engine data, tropical applications (TA-Luft)
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 12V 4000 16V 4000
L32FB L32FB
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
Table 20: Reference conditions
Power-related data (power ratings are net brake power to ISO 3046)
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 21: Power-related data (power ratings are net brake power to ISO 3046)
General conditions (for max. power)

Relative air humidity A % 60 60
Intake air temperature A °C 35 35
Intake air temperature, min. L °C 30 30
Intake air temperature, max. L °C 40 40
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Mixture temperature after mixture cooler A °C 63 65

Ambient intake depression, max. L mbar 3 3
Pressure loss over air filter, max. L mbar 30 30
Exhaust back pressure, max. L mbar 60 60
Gas type: Biogas X X
Methane number, min. L 120 120
Table 22: General conditions (for max. power)

Consumption
Lube oil consumption after 1000 h runtime g/kWh 0.2 0.2
Table 23: Consumption
Model-related data (basic design)

Operating method: Four-stroke cycle, Otto engine, single-acting X X
Combustion method: Mixture charging, spark ignition X X
Cylinder arrangement: V angle Degrees 90 90
(°)
Bore mm 170 170
Stroke mm 210 210
Displacement of a cylinder Liters 4.77 4.77
Total displacement Liters 57.20 76.27
Compression ratio 13.9 13.9
Standard housing connecting flange (engine main PTO) SAE 00 00
Table 24: Model-related data (basic design)
Coolant system (HT circuit)

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, warning R °C 95 95
Coolant temperature after engine, shutdown L °C 98 98
Coolant temperature to enable load application, min. L °C 40 40
Coolant pump: Volumetric flow L m³/h 45 67
Filling pressure in cooling system (cold) R bar 0.5 0.5
Pressure loss over engine (at nominal flow rate 7.27) bar 1.5 1.6
Thermostat: Starts to open R °C 68 68
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Thermostat: Opening stops (thermostat fully open and bypass A °C 78 78

closed)
Table 25: Coolant system (HT circuit)

Coolant system (LT circuit)
Coolant temperature before mixture cooler (at engine connection: A °C 53 53
Coolant pump: Volumetric flow A m³/h 31 40
Pressure loss over mixture cooler (at nominal flow rate 8.56) bar 0.2 0.6
Table 26: Coolant system (LT circuit)
Coolant system (MT circuit)

Coolant temperature before mixture cooler (at engine connection: A °C - 70
Coolant antifreeze content, max. L % - 50
Coolant pump: Volumetric flow A m³/h - 30
Pressure in cooling system, max. L bar - 6.0
Pressure loss over MT mixture cooler (at nominal flow rate 8.56) bar - 2.9
Table 27: Coolant system (MT circuit)
Lube oil system

Lube oil operating temperature after oil heat exchanger, from R °C 82 82
Lube oil operating temperature after oil heat exchanger, to R °C 90 90
Lube oil operating temperature after oil heat exchanger, warning R °C 93 93
Lube oil operating temperature after oil heat exchanger, engine L °C 97 97
shutdown
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
Table 28: Lube oil system
Fuel system
Gas temperature before engine, min. L °C 10 10
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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 120 120
Table 29: Fuel system

General operating data
Cold start capability: Air temperature (w/o starting aid, with pre- R °C 15 15
heating) - (case C)
Site condition (for case C): Engine coolant temperature R °C 40 40
Minimum idling speed A rpm 1500 1500
Limit speed for overspeed alarm/emergency shutdown L rpm 1900 1900
Table 30: General operating data
Starting (electric)
Rated starter power (standard design) R kW 2x9 2x9
Rated starter voltage (standard design) R V 24 24
Starter current consumption, max. (standard design) R A 2 x 2500 2 x 2500
Starting-attempt duration, max. L s 15 15
Number of teeth on starter ring gear 182 182
Table 31: Starting (electric)
Capacities
Engine coolant capacity, engine side (without cooling equipment) R Liters 200 255
Mixture coolant, engine side (without cooling system) R Liters 20 25
Total engine oil capacity for initial filling (standard oil system) R Liters 260 285
Oil change capacity, max. (standard oil system) R Liters 220 250
Table 32: Capacities
Weights / main dimensions

Dry engine weight (basic-configuration engine) R kg 6380 7890
Heaviest component to be lifted during extended component R kg 450 450
maintenance (QL3)
Table 33: Weights / main dimensions
Exhaust emissions
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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 186 192
ides (NOx) (in dry exhaust gas)
Table 34: Exhaust emissions

Acoustics
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)
Table 35: Acoustics
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2.6 Monitoring, Control and Regulation Equipment
2.6.1 Gas engine phase 3 system – Overview
General overview
1 Plant system 5 Engine Monitoring Unit 9 Ignition

2 Engine system 6 Throttles 10 Compressor bypass
3 Plant 7 Gas dosing unit 11 NOx sensor (optional)
4 Engine Control Unit 8 Knock module
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
Engine Monitoring Unit EMU 8

TIM-ID: 0000044676 - 001
• Monitors second gas solenoid in gas train to engine
Compressor bypass (F series)

• Controls throttle reserve, prevents compressor surges
Ignition system IC922

• Adjusts ignition timing for cylinders

Anti-knock control AKR
• Controls monitored cylinders with regard to knock characteristics. If knocking is detected, ignition is
delayed for the cylinder concerned. The power is reduced if this does not lead to improvement.
Gas control valve TecJet110

• Controls the required amount of gas
Mixture throttles (P Series)

• Mixture throttles in the mixture lines which are controlled by the Engine Control Unit
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2.6.2 Purpose of the units
ECU 9 engine governor
Central control and monitoring unit for the engine

• Communication with other devices and higher-level systems via CAN bus
• Control of throttles (mixture and gas)
• Registration and analysis of engine operating states
• Limit value monitoring
• Self-monitoring and diagnostics
– Integral status/fault display
– Fault memory
• Extensive I/O features:
• Engine and genset-related parameter settings in flash memory
• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine
stop or emergency engine stop (configurable)
• Diagnostic function via CAN interface (Default CAN1, connection for dialog unit provided)
Software structure:
• One data record for engine software
• One data record for genset software
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Engine Monitoring Unit EMU 8
EMU = Engine Monitoring Unit

Monitoring unit for the engine
• Acquisition and processing of cylinder exhaust temperatures
Self-monitoring
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3 Operation
3.1 Runtimes at partial load
Gas engines were designed and optimized for continuous operation at 100 % load.
The following restrictions apply to ensure maximum operational availability of the engine plant and to
reduce maintenance to a minimum:
Power, referenced to nominal Recommended maximum run- Recommended minimum run-

load time time
at this load in subsequent operation
at load > 50 %
0 % to 30 % 30 minutes 120 minutes
30 % to 50 % 120 minutes 120 minutes
50 % to 100 % No restriction No restriction
Table 36: Runtimes at partial load
A minimum operating time of 2 hours per start is recommended to counteract increased engine loading
resulting from temperature changes (cold start to engine operating temperature).
TIM-ID: 0000043223 - 001
MS150115/00E 2013-10 | Operation | 37

3.2 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation after extended out-of-service-periods (>3

months)
Item Measure
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Engine Bar engine manually (→ Page 130).
Valve gear Standstill ≥ 6 months: Lubricate valve gear (→ Page 150).
Lube oil system Check engine oil level (→ Page 156);
Check oil level in oil storage tank (→ Page 156).
Coolant circuit Standstill > 1 year: Change engine coolant (→ Page 161);
Change mixture coolant (→ Page 167)
Coolant circuit Check engine coolant level (→ Page 160);
Check mixture coolant level (→ Page 166)
Engine cabling Check plug-in connections (→ Page 170).
Gas supply The gas shut-off valves with control solenoids are not included in the scope
of supply of the engine. The components are controlled by the engine elec-
tronics.
Engine management system Check for fault messages.
Starting system Check power supply to electric starter.
TIM-ID: 0000029117 - 002
38 | Operation | MS150115/00E 2013-10

3.3 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
☑Engine shut down and starting disabled.
Putting into operation

Item Measure
Lube oil system Check oil level in oil storage tank (→ Page 156).
Coolant circuit Check engine coolant level (→ Page 160);
Check mixture coolant level (→ Page 166)
Engine management system Check for fault messages.
TIM-ID: 0000010660 - 002
MS150115/00E 2013-10 | Operation | 39

3.4 Control, starting and stopping sequences
NOTICE
Risk of engine damage due to incorrect action.
Risk of severe damage to property!
• Ensure engine is ready for operation before starting. See engine documentation.
Starting and stopping sequences

The starting sequence is software-controlled and depends on the place of start command input.
To ensure that no mixture is in the engine when ignition is switched on or off, which is a specific re-
quirement for gas engines, special procedures for engine start / stop are specified.
The maximum number of attempted starts is limited to three. After this, an extended scavenging phase
is initiated with the gas shut-off valves closed and the ignition off in order to purge the intake duct,
engine cylinders and exhaust duct (up to the exhaust turbine outlet elbow) with air. The combustion gas
line of the plant up to the gas control valve and the exhaust gas system after the turbine must be venti-
lated or inerted by means of suitable systems in the facility. A contact is provided to activate such sys-
tems.
Starting sequence
The following steps are performed automatically when a start command is activated with the engine at
standstill:
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. Runup 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
The following steps are performed automatically when a stop command is activated:
TIM-ID: 0000043157 - 001
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
40 | Operation | MS150115/00E 2013-10

Emergency stop sequence
If an emergency stop command is activated, the following steps are carried out automatically:
1. Closing gas supply solenoid valves
2. Closing mixture throttles
4. Deactivating ignition
Restarting after emergency stop

A scavenging phase and a request for external ventilation by contact ensue following a start request
after emergency shutdown.
2. Activating starter
3. Waiting for starting speed
4. Flushing the engine
5. Disengaging starter
7. Resetting start counter
8. Awaiting start request
Oil refill sequence

1. Waiting for engine running
2. Engine running for a minimum (programmed) time period
3. Oil refilling enabled
4. When oil refill request is received
5. Refilling oil (automatically)
6. When oil refill request is canceled
7. Stopping oil refilling (automatically)
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MS150115/00E 2013-10 | Operation | 41

3.5 Engine – Start
Preconditions
☑Generator not connected to network.
☑Start interlock not active.
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 en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
Starting engine
u Start engine in accordance with starting sequence specifications (→ Page 40).
TIM-ID: 0000042719 - 001
42 | Operation | MS150115/00E 2013-10

3.6 Operational checks
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operational checks
Item Action
Machine room Check machine room for smell of gas (→ Page 131).
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 available) Document operating parameters
• This is especially useful for fault localization and fast remedial action.
Engine under load, Visually inspect engine/plant and all pipework for leaks, rectify any leaks
engine at rated speed with the engine stopped;
check for abnormal running noises and vibration.
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MS150115/00E 2013-10 | Operation | 43

3.7 Emission values – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Gas detection and alarm unit (not stocked by MTU) -
DANGER
WARNING
WARNING
Exhaust gases are hot and pressurized.
Risk of injury and burning!
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
Exhaust gases are harmful to health.
Risk of poisoning!
• Ensure that the engine room is well ventilated.
• Repair leaking exhaust pipework immediately.
Emission values – Check

1. Insert exhaust probe (1) in the exhaust gas
flow of the exhaust pipe bellows (3) at tur-
bocharger (4).
2. Carry out measurement ans read off meas-
ured value for NOx rel (ppm).
3. Compare measured value with limit value
(tolerance = − 10 %), make adjustments if
the limit value is exceeded.
• NOx limit value, fuel optimized (TA-Luft)
(→ Page 23).
• NOx limit value, tropical application (TA-
Luft) (→ Page 28).
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44 | Operation | MS150115/00E 2013-10

3.8 Engine – Shutdown
Preconditions
☑Generator is not connected to network.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.
Shutting down engine

u Shut down engine in accordance with stopping sequence specifications (→ Page 40).
TIM-ID: 0000042720 - 001
MS150115/00E 2013-10 | Operation | 45

3.9 Emergency engine shutdown
WARNING
Escaping residual gas may create an explosive atmosphere in case of emergency stop.
Explosion hazard!
• Ensure that any escaping residual gas is routed out by means of appropriate facility ventilation
and use of an SBV (safety blow-off valve) to prevent any risk of explosive atmosphere.
• Install an SAV (safety shut-off valve) in the gas control system when using gas control systems
with inlet pressures in excess of 0.1 bar.
• Install an SAV (safety shut-off valve) and an SBV (safety blow-off valve) in the gas control system
when using single-stage gas control systems with inlet pressures in excess of 1 bar.
NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Emergency engine shutdown

Item Action
Gas shut-off solenoids Two contacts are provided for electrical connection. Close gas shut-off sole-
noids.
• Engine is stopped.
Ignition, ignition system In the case of an external EMERGENCY STOP, the ignition remains on until
the engine has run down to a standstill in order to safely burn off uncombust-
ed fuel/air mixture.
• The ignition is only switched off in case of an overspeed violation or an
internal ignition fault.
Throttles The throttles are always closed in case of EMERGENCY STOP. Closing the
throttles impedes the scavenging of residual gas. External ventilation and in-
erting systems must therefore be activated following an emergency engine
stop.
Room ventilation, facility Residual gas may escape from the fuel line in case of EMERGENCY STOP.
ventilation • A contact is provided to request room and facility ventilation.
Table 37: Emergency engine shutdown
Remedy the cause, re-enable starting

Item Action
Engine Control System Determine cause of emergency stop and take remedial action; contact Serv-
ice if the fault cannot be corrected.
Fault acknowledgment is possible in engine stop mode only . Automatic se-
lection and remote start immediately following an emergency engine stop is
not admissible.
TIM-ID: 0000043159 - 001
Plant control system An extended scavenging phase with the ignition off precedes engine starting
when selected again following an emergency engine stop. Suitable exhaust
gas ventilation equipment must be provided in the facility to ensure that the
exhaust gas system downstream of the engine is safely purged.
46 | Operation | MS150115/00E 2013-10

Item Action
• A contact is provided to request the ventilation system in the scaveng-
ing phase.
Note: • The gas control system must be equipped with an SAV (safety shut-off
Gas train valve) when using gas control systems with inlet pressures in excess
of 0.1 bar. If the SAV is tripped by an EMERGENCY STOP it must be
reset manually. SAV tripping is not indicated by the engine.
Table 38: Remedy the cause, re-enable starting
TIM-ID: 0000043159 - 001
MS150115/00E 2013-10 | Operation | 47

3.10 After stopping the engine – Engine remains ready for
operation
After stopping the engine

Item Action
Engine/generator control Select operating mode, e.g. HAND, MANUAL, AUTO, AUTOMATIC.
(manufacturer-specific)
TIM-ID: 0000002329 - 002
48 | Operation | MS150115/00E 2013-10

3.11 After stopping the engine – Putting the engine out of
operation
Preconditions

Item Action
Coolant circuit Drain engine coolant (→ Page 162)
Drain mixture coolant (→ Page 168) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but coolant has no antifreeze additive;
• the engine room is not heated;
• the engine coolant is not maintained at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tem-
perature;
• antifreeze concentration is 50 % and engine-room temperature is be-
low -40 °C.
Power supply to engine con- Switch off.
trol system
Gas supply Close gas shut-off valve.
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tems gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ MTU Preservation and Represerva-
tion Specifications A001070/..).
The corrosion-inhibiting effect of the engine coolant may be used as an alter-
native in case of out-of-service periods lasting for more than 1 month, by run-
ning the engine for at least 2 hours at rated power once a month.
Starter battery (batteries) Charge regularly (trickle charge).
Control-voltage battery (bat- If fitted: Charge regularly (trickle charge).
teries)
Table 39: After stopping the engine

TIM-ID: 0000043160 - 003
MS150115/00E 2013-10 | Operation | 49

4 Maintenance
4.1 50-hours check
50-hours check
One-time operations to be carried out after the first 50 operating hours of the cylinder head (with a new
engine, after installation of new cylinder heads, after component maintenance or extended component
maintenance).
When installing a cylinder head with run-in mating faces (e.g. after piston replacement), a repeated
check after the first 50 operating hours is not necessary.
Qualifi- Interval Item Tasks Task
cation [hours] [years]
QL1 - - Valve gear Check valve clearance (→ Page 147) -
TIM-ID: 0000002785 - 001
50 | Maintenance | MS150115/00E 2013-10

4.2 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W0501 Visually inspect engine for leaks and general condition. (→ Page 43)
W0509 Check machine room for smell of gas. (→ Page 131)
W0523 Check for abnormal running noises and vibrations. -
W0527 Check engine oil level in storage tank. (→ Page 156)
W1002 Check valve clearance, adjust if necessary. (→ Page 147)
W1005 Replace air filter. (→ Page 154)
W1008 Replace engine oil filter when changing engine oil, or when the (→ Page 159)
interval (years) is reached, at the latest.
W1089 Check gas lines for leaks, repair if required. (→ Page 153)
W1091 Check ignition timing, adjust if required. (→ Page 143)
W1341 Check emission values, adjust if required. (→ Page 44)
W1382 Replace vent line of engine coolant circuit (8/12/16V only). (→ Page 165)
W1616 Replace spark plugs and seal in spark plug connector. (→ Page 134)
W1688 Replace spark plug connectors. (→ Page 138)
W1689 Measure valve depth. (→ Page 144)
W1798 Replace fine filter. (→ Page 132)
W1813 Carry out visual inspection when replacing air filters. (→ Page 155)
Table 40: Maintenance task reference table [QL1]

TIM-ID: 0000045341 - 001
MS150115/00E 2013-10 | Maintenance | 51

5 Troubleshooting
5.1 Fault messages - Key
The fault messages are applicable to 8V, 12V, 16V and 20V engines.
Explanation of the abbreviations used

The following abbreviations are used in the texts for the fault messages:
Abbreviation Meaning
DL <number> Default Lost: The device with designation <number> has lost its connec-
tion to the default CAN bus.
RL <number> Redundant Lost: The device with designation <number> has lost its con-
nection to the redundant CAN bus.
SD <sensor designation> Sensor defect: The sensor with the designation <sensor designation> is
not sending an analyzable signal.
MD Missing Data: Data is missing from a measuring point.
AL Alarm: Alarm message
SS Safety System: The safety system has reacted in some way.
TD Transmitter Deviation: Two sensors that record the measured values for
the same medium are sending different measured values.
HI High: The first limit value has been exceeded.
HIHI High High: The second limit value has been exceeded.
LO Low: The first limit value has not been attained.
LOLO Low Low: The second limit value 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 Anti Knock Control GET
Important information about fault messages from the engine governor/engine

monitoring
Fault messages from the engine governor are represented in the fault code list (→ Page 96).
Information pertaining to alarm colors and automatic engine shutdown in the fault code list refer to the
(default) factory settings of the engine governor on delivery. Different system response may be possible
due to changes to the genset control system made by the OEM (see documentation of the genset man-
ufacturer).
TIM-ID: 0000027852 - 002
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.
Recommended action in case of alarm

Yellow alarm:
The engine can still be operated providing that automatic engine shutdown to protect the engine has
not been configured or is not tripped. Contact Service immediately/start fault rectification.
52 | Troubleshooting | MS150115/00E 2013-10

Red alarm:
Caution, the engine is running at its limits. Shut down manually without further delay if the engine does
not shut itself down immediately after a red alarm is signaled.
TIM-ID: 0000027852 - 002
MS150115/00E 2013-10 | Troubleshooting | 53

5.2 Fault messages in communication protocol to genset control
system
112222 – HI T-Exhaust Mean
Yellow alarm. Initiated by EMU.
Cause Corrective action
Weighted average of all 1. Check emission values.
individual exhaust gas 2. Check ignition timing (→ Page 143).
temperatures is too high. 3. Check valve drive (exhaust valves do not close).
112223 – HIHI T-Exhaust Mean

Red alarm. Initiated by EMU.
Weighted average of all 1. Check emission values.
individual exhaust gas 2. Check ignition timing (→ Page 143).
temperatures is too high. 3. Check valve drive (exhaust valves do not close).
112301 – HI T-Exhaust A1
The exhaust temperature of this 1. Check emission values.
cylinder is too high as compared 2. Check ignition timing (→ Page 143).
with the average value. 3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000038611 - 002



TIM-ID: 0000038611 - 002


112311 – HI T-Exhaust B1
TIM-ID: 0000038611 - 002



112401 – LO T-Exhaust A1
The exhaust temperature of this 1. Check spark plug.
cylinder is too high as compared 2. Check emission values.
with the average value. 3. Check ignition timing (→ Page 143).
4. Check valve drive.
TIM-ID: 0000038611 - 002


TIM-ID: 0000038611 - 002



112411 – LO T-Exhaust B1
TIM-ID: 0000038611 - 002


TIM-ID: 0000038611 - 002



112501 – HIHI T-Exhaust A1

cylinder is too high as compared 2. Check ignition timing (→ Page 143)

TIM-ID: 0000038611 - 002







TIM-ID: 0000038611 - 002


112511 – HIHI T-Exhaust B1





TIM-ID: 0000038611 - 002






112601 – LOLO T-Exhaust A1

TIM-ID: 0000038611 - 002

cylinder is too low as compared 2. Check emission values.





TIM-ID: 0000038611 - 002





with the average value. 3. Check ignition timing.
4. Check valve drive (→ Page 143).
112611 – LOLO T-Exhaust B1

TIM-ID: 0000038611 - 002






TIM-ID: 0000038611 - 002





112701 – HIHI T-Exhaust A1 (abs)

Individual exhaust gas 1. Check emission values.
temperature of this cylinder is 2. Check ignition timing (→ Page 143).
TIM-ID: 0000038611 - 002
too high. 3. Check valve drive (exhaust valves do not close).


temperature of this cylinder is 2. Check ignition timing(→ Page 143).





TIM-ID: 0000038611 - 002



112711 – HIHI T-Exhaust B1 (abs)




TIM-ID: 0000038611 - 002







TIM-ID: 0000038611 - 002


112923 – MD/SD T-Exhaust
Combined alarm (for details, u Combined alarm (for details, refer to the source alarm).
refer to the source alarm).
113200 – Communication Lost ECU

Red alarm. Initiated by SAM.
No communication with ECU 1. Check supply voltage.
CAN. 2. Check connecting line.
113601 – AL Gas Valve 1 feedback

Feedback signal from valve 1 u Check valve 1 and cabling.
does not correspond with
setpoint signal.
113902 – SS Local Initiated Emerg. Stop

Emergency stop detected. 1. Clear emergency stop.
Emergency stop was released 2. Check governor.
manually (button), or ignition 3. Check throttle closing position.
system reported overspeed.
1.4510.186 – Error Status

Red alarm. Initiated by anti-knock control.
GET combined alarm. At least u Rectify cause of alarm.
one other GET alarm is pending.
1.4510.187 – Combined Error

TIM-ID: 0000038611 - 002


1.4510.188 – Internal Error
Hardware not ready for u Restart knock module.
operation.
1.4510.189 – Error Camshaft

No signal from camshaft sensor u Check cabling. Check sensor B 1.3 and replace as necessary.
for anti-knock control.
1.4510.192 – Knock Sensor Error A1

No signal from this knock 1. Check cabling.
sensor. 2. Check sensor (tightening torque, damage), replace as
necessary.

necessary.

necessary.

TIM-ID: 0000038611 - 002

necessary.

necessary.

necessary.

necessary.

necessary.

necessary.

TIM-ID: 0000038611 - 002

necessary.

1.4510.202 – Knock Sensor Error B1
necessary.

necessary.

necessary.

necessary.

necessary.

TIM-ID: 0000038611 - 002

necessary.

necessary.

necessary.

necessary.

necessary.
1.4520.232 – Error Missing Ring Gear Signal

Red alarm. Initiated by IC922.
Missing crankshaft signal. u Check sensor, sensor distance and cabling, replace as
necessary.
1.4520.233 – Error Missing Reset Signal

TIM-ID: 0000038611 - 002

Missing reset signal. u Check sensor, sensor distance and cabling, replace as
necessary.

1.4520.234 – Error Missing Camshaft Signal
No camshaft signal. u Check sensor, sensor distance and cabling, replace as
necessary.
1.4520.235 – Error Number of Teeth

Incorrect number of teeth on 1. Check timing wheel.
timing wheel detected. 2. Check settings.
1.4520.236 – Unknown Engine Appl. Code

Ignition setting is not correct. u Check setting.
1.4520.237 – OverSpeed Shutdown

Genset has exceeded admissible u Restart ignition.
speed.
1.4520.238 – E2PROM Checksum Error

Hardware not ready for u Restart ignition.
operation.
1.4520.239 – Global Timing out of Range

Yellow alarm. Initiated by IC922.
Specified global ignition timing u Adjust value.
is beyond the valid range.
TIM-ID: 0000038611 - 002
1.4520.240 – Unknown Timing or Energy Level

No global ignition timing and u Check cabling and setting.
power level received, CAN bus
connection is faulty.

1.4520.241 – Individual Timing out of Range
Specified individual ignition u Adjust value.
timing is beyond the valid range.
1.4520.242 – Selftest Shutdown

Self-test is active with the u Restart ignition.
engine rotating.
1.4520.243 – Open Primary Rate Exceeded

Admissible summation of 1. Check associated cabling.
discharge faults is reached. 2. Check ignition coils.
1.4520.245 – Open Primary, Channel 1

Ignition energy was not 1. Check cabling to ignition coil.
discharged. 2. Check ignition coils.


TIM-ID: 0000038611 - 002







TIM-ID: 0000038611 - 002







TIM-ID: 0000038611 - 002



1.4520.270 – Warn. Missing Ring Gear Signal

Crankshaft speed signal 182 u Sensor B 13.3, check sensor, sensor distance and cabling,
teeth is missing. replace as necessary.
1.4520.271 – Warning Missing Reset Signal

Reset signal from crankshaft is u Sensor B 75, check sensor, sensor distance and cabling,
missing. replace as necessary.
1.4520.272 – Warn. Missing Camshaft Signal

Missing camshaft signal for u Sensor B 1.2, check sensor, sensor distance and cabling,
ignition system. replace as necessary.
1.4520.273 – SCR Fault Odd

operation.
TIM-ID: 0000038611 - 002
1.4520.274 – SCR Fault Even

operation.

1.4520.275 – Odd Energy Level out of Range
Specified energy level is beyond u Adjust value.
the valid range.
1.4520.276 – Even Energy Level out of Range

Specified energy level is beyond u Adjust value.
the valid range.
1.4530.007 – Shutdown
Red alarm. Initiated by F-series.
Hardware not ready for u Restart F-series.
operation.
1.4530.008 – Alarm
Yellow alarm. Initiated by F-series.
1.4530.009 – Derating Active

1.4530.010 – PWM Input High Duty Cycle Error

F-series setting is incorrect. u Check setting.
TIM-ID: 0000038611 - 002
1.4530.011 – PWM Input Low Duty Cycle Error


1.4530.012 – Analog Input High Error
1.4530.013 – Analog Input Low Error

1.4530.014 – Input Supply Voltage High Error

Supply voltage has reached 1. Check supply voltage.
maximum limit value. 2. Check cabling.
1.4530.015 – Input Supply Voltage Low Error

minimum limit value. 2. Check cabling.
1.4530.016 – Electronics Temperature High Error

operation.
1.4530.017 – Electronics Temperature Low Error

operation.
TIM-ID: 0000038611 - 002
1.4530.018 – Position Error

Position specification and 1. Check mechanical system.
feedback signal do not match 2. Restart F-series.

1.4530.019 – Run Enable not active
1.4530.020 – Spring Check Failed

1.4530.021 – Internal Fault

operation.
1.4530.022 – CAN Fault

CAN bus connection faulty. u Check cabling and setting.
1.4540.009 – Zero Pressure Detected

Yellow alarm. Initiated by TecJet.
No gas pressure/gas flow u Check gas pressure.
detected.
1.4540.010 – Zero Flow Detected

No gas pressure/gas flow u Check gas pressure.
detected.
1.4540.011 – Flow Not Reached

TIM-ID: 0000038611 - 002
Red alarm. Initiated by TecJet.

No gas flow detected. 1. Check inlet and outlet.
2. Check gas pressure, gas quality, gas filter, gas line for
obstruction.
3. Check engine for overloading.

1.4540.012 – Valve Position Error
Hardware not ready for u Restart TecJet.
operation.
1.4540.013 – High Elec Temp

operation.
1.4540.014 – Elec Temp Fail High

operation.
1.4540.015 – FGT Fail High

operation.
1.4540.016 – Delta P Fail High

Differential pressure at TecJet 1. Check gas pressure.
too high. 2. Check TecJet for dirt.
1.4540.017 – FGP Fail High

operation.
TIM-ID: 0000038611 - 002
1.4540.018 – Coil Current Fail High

operation.

1.4540.019 – Position Fail High
operation.
1.4540.020 – Elec Temp Fail Low

operation.
1.4540.021 – FGT Fail Low

Gas temperature before TecJet u Check TecJet and configuration.
is below the preset limit value.
1.4540.022 – Delta P Fail Low

Delta-p via TecJet below set limit u Check TecJet and configuration.
value.
1.4540.023 – FGP Fail Low

Gas pressure before TecJet is u Check TecJet and configuration.
below the preset limit value.
1.4540.024 – Coil Current Fail Low

operation.
TIM-ID: 0000038611 - 002
1.4540.025 – Position Fail Low

operation.

1.4540.026 – Analog Input Low Error
TecJet setting is not correct. u Check setting.
1.4540.027 – Analog Input High Error

1.4540.028 – PWM Duty Cycle Low Error

1.4540.029 – Battery Volt Low Error

minimum limit value. 2. Check cabling.
1.4540.030 – FGT Low Limit Error

operation.
1.4540.031 – Delta P Low Limit Error

operation.
1.4540.032 – FGP Low Limit Error

TIM-ID: 0000038611 - 002

Configured limit value was not u Check position direction of TecJet.
attained.

1.4540.033 – Battery Volt High Error
maximum limit value. 2. Check cabling.
1.4540.034 – FGT High Limit Error

operation.
1.4540.035 – Delta P High Limit Error

operation.
1.4540.036 – FGP High Limit Error

operation.
1.4540.037 – Watchdog Reset

operation.
1.4540.038 – CAN Flow Demand Failed

TIM-ID: 0000038611 - 002
1.4540.040 – TecJet Shutdown

TecJet combined alarm. At least u Rectify cause of alarm.
one other TecJet alarm is
pending.

1.4540.041 – TecJet Internal Fault
operation.
1.4540.042 – Keyswitch State

Keyswitch cabling missing. u Check cabling.
1.4540.043 – Parameter Error

operation.
1.4540.044 – Parameter Version Error

operation.
1.4540.045 – Main EEP Read Fail

operation.
1.4540.046 – Main EEP Write Fail

operation.
TIM-ID: 0000038611 - 002
1.4540.047 – Reading Parameters

operation.

1.4540.048 – SPI ADC Error
operation.
1.4540.049 – Sense 5V Error

operation.
1.4540.050 – Sense -9V Error

operation.
1.4540.051 – Sense 12V Error

operation.
1.4540.052 – ADC Test Error

operation.
1.4540.053 – CAN Timing Changed

Change of CAN baud rate 1. Check settings.
detected. 2. Check cabling.
TIM-ID: 0000038611 - 002
1.4540.054 – Exception Error

operation.

1.4540.055 – Factory CAL Error
operation.
1.4540.056 – PWM Duty Cycle High Error

1.4550.031 – A - Internal Fault

Red alarm. Initiated by ProAct A-Bank.
Hardware not ready for u Restart ProAct.
operation.
1.4550.032 – A - Stop commanded (Run/Stop)

Yellow alarm. Initiated by ProAct A-Bank.
ProAct setting is incorrect. u Check setting.
1.4550.033 – A - Input (Supply) Voltage Fault

maximum or minimum limit 2. Check cabling.
value.
1.4550.034 – A - Position Error

Position specification and u Check mechanical system. Restart ProAct.
feedback signal do not match
TIM-ID: 0000038611 - 002
1.4550.035 – A - Temperature Sensor Fault

operation.

1.4550.036 – A - Temperature derating active
The internal temperature is 1. Check temperature in room. Restart ProAct.
higher than the limit. 2. Restart ProAct.
1.4550.037 – A - Temperature above 120 °C

1.4550.038 – A - Loss of Position Demand

Position specification missing or 1. Check setting.
is outside the range 2. Check cabling.
1.4550.039 – A - Demand Tracking Fault

1.4550.040 – A - Analog Position Demand Failed

1.4550.041 – A - PWM Position Demand Failed

1.4550.042 – A - CAN Position Demand Failed

TIM-ID: 0000038611 - 002

Position specification not u Check cabling and setting.
received or received too late

1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad)
1.4550.044 – A - CAN Stop Command

“Stop” input signal received via u Check setting.
CAN bus
1.4550.131 – B - Internal Fault

Red alarm. Initiated by ProAct B-Bank.
operation.
1.4550.132 – B - Stop commanded (Run/Stop)

Yellow alarm. Initiated by ProAct B-Bank.
1.4550.133 – B - Input (Supply) Voltage Fault

maximum or minimum limit 2. Check cabling.
value.
1.4550.134 – B - Position Error

Position specification and 1. Check mechanical system.
feedback signal do not match 2. Restart ProAct.
TIM-ID: 0000038611 - 002
1.4550.135 – B - Temperature Sensor Fault

operation.

1.4550.136 – B - Temperature derating active
1.4550.137 – A - Temperature above 120 °C

1.4550.138 – B - Loss of Position Demand

Position specification missing or 1. Check setting.
is outside the range 2. Check cabling.
1.4550.139 – B - Demand Tracking Fault

1.4550.140 – B - Analog Position Demand Failed

1.4550.141 – B - PWM Position Demand Failed

1.4550.142 – B - CAN Position Demand Failed

TIM-ID: 0000038611 - 002

Position specification not u Check cabling and setting.
received or received too late

1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad)
1.4550.144 – B - CAN Stop Command

“Stop” input signal received via u Check setting.
CAN bus
TIM-ID: 0000038611 - 002

5.3 Fault messages of the engine governor
015 – LO P-Lube Oil
Yellow alarm.
Associated parameter 2.0100.921
Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger.
value 1). No oil in engine, engine 2. Replace oil filter (→ Page 159).
speed too low, oil lines, oil heat 3. Take oil sample and analyze (→ Page 158).
exchanger clogged, oil pump
faulty.
016 – SS P-Lube Oil

Red alarm. Engine shutdown.
Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger.
value 2). No oil in engine, engine 2. Replace oil filter (→ Page 159).
speed too low, oil lines, oil heat 3. Take oil sample and analyze (→ Page 158).
exchanger clogged, oil pump
faulty.
019 – HI T-Exhaust A
Yellow alarm.
Exhaust gas temperature (A 1. Check exhaust turbocharger.
side) after turbine too high (limit 2. Check ignition timing (→ Page 143).
value 1). Incorrect ignition 3. Check mixture setting.
timing, mixture too lean or too
rich, damage to turbine.
020 – SS T-Exhaust A
Yellow alarm.
TIM-ID: 0000044738 - 001
Exhaust gas temperature (A 1. Check exhaust turbocharger.

timing, mixture too lean or too 4. Check spark plugs.

021 – HI T-Exhaust B
Yellow alarm.
Exhaust gas temperature (B 1. Check exhaust turbocharger.
022 – SS T-Exhaust B
Yellow alarm.
Exhaust gas temperature (B 1. Check exhaust turbocharger.
025 – HI P-Diff Lube Oil

Yellow alarm.
Pressure loss via oil filter too 1. Replace oil filter (→ Page 159).
high (limit value 1). 2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil if required
(→ Page 157).
026 – SS P-Diff. Lube Oil

Pressure loss via oil filter too 1. Replace oil filter (→ Page 159).
high (limit value 2). 2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil if required
(→ Page 157).
TIM-ID: 0000044738 - 001

030 – SS Engine Overspeed
Overspeed detected by ECU. 1. Check governor.
This usually fault message 2. Check throttle closing position.
usually follows other fault
messages. Check governor,
throttle closing position.
031 – HI ETC1 Overspeed

Yellow alarm.
Speed of primary turbocharger u Turbocharger speed sensor is not fitted at present. Check ECU
too high (limit value 1). setting for this input.
032 – SS ETC1 Overspeed

Speed of primary turbocharger u Turbocharger speed sensor is not fitted at present. Check ECU
too high (limit value 2). setting for this input.
036 – HI ETC2 Overspeed

Yellow alarm.
Speed of 1st secondary u Turbocharger speed sensor is not fitted at present. Check ECU
turbocharger too high (limit setting for this input.
value 1).
037 – SS ETC2 Overspeed

TIM-ID: 0000044738 - 001

Speed of 1st secondary u Turbocharger speed sensor is not fitted at present. Check ECU
turbocharger too high (limit setting for this input.
value 2).

051 – HI T-Lube Oil
Yellow alarm.
Engine oil temperature after oil 1. Check engine coolant circuit.
heat exchanger too high (limit 2. Check oil heat exchanger.
value 1). Oil heat exchanger 3. Check oil level (→ Page 156).
contaminated, coolant
temperature too high. Oil
volume flow insufficient.
052 – SS T-Lube Oil

Engine oil temperature after oil 1. Check engine coolant circuit.
heat exchanger too high (limit 2. Check oil heat exchanger.
value 2). Oil heat exchanger 3. Check oil level (→ Page 156).
contaminated, coolant
temperature too high. Oil
volume flow insufficient.
053 – HI T-Intake Air

Yellow alarm.
Intake air temperature too high u Check ventilation system.
(limit value 1).
054 – HIHI T-Intake Air

Yellow alarm.
Intake air temperature too high 1. Check ventilation system.
(limit value 2). 2. Reduce power.
057 – LO P-Coolant
TIM-ID: 0000044738 - 001
Yellow alarm.
Coolant pressure after engine u Check engine coolant circuit (pressure and flow).
too low (limit value 1).
Insufficient volume flow, static
pressure too low.

058 – SS P-Coolant
pressure too low.
063 – HI P-Crankcase
Yellow alarm.
Crankcase pressure too high 1. Check crank drive:
(limit value 1). Restrictor valve in • Bar engine (→ Page 130).
crankcase breather is closed too • Endoscope combustion chambers from bottom dead center
far, air filter is defective, oil to top dead center.
separator is clogged, piston 2. Check air filter for contamination, replace if contamination is
rings are seized, other damage visible (→ Page 154).
to crank drive. 3. Check setting of blow-by restrictor valve.
4. Check oil separator condition, replace as necessary
(→ Page 132).
064 – SS P-Crankcase
Crankcase pressure too high 1. Check crank drive: Bar engine (→ Page 130), endoscope
(limit value 2). Restrictor valve in combustion chambers from bottom dead center to top dead
crankcase breather is closed too center.
far, air filter is defective, oil 2. Check air filter for contamination, replace if contamination is
separator is clogged, piston visible (→ Page 154).
rings are seized, other damage 3. Check setting of blow-by restrictor valve.
to crank drive. 4. Check oil separator condition, replace as necessary
(→ Page 132).
067 – HI T-Coolant
Yellow alarm.
TIM-ID: 0000044738 - 001

Coolant temperature after u Check engine coolant circuit.
engine too high (limit value 1).
Engine coolant pump failure,
volumetric flow too low, air in
engine coolant circuit.

068 – SS T-Coolant
Coolant temperature after u Check engine coolant circuit.
089 – SS Engine Speed too Low

Engine stalls. In normal 1. In parallel operation connected to mains:
operation the engine speed is • Check mains for frequency drop.
below the limit set in parameter • Check generator and coupling for damage.
2.2500.027 (Engine stall speed 2. In isolated operation:
limit) without an engine stop • Check throttle position.
having taken place. The engine • Check throttles for implausible closing. If throttles are fully
is shutdown for safety reasons. open: Check if load step values are admissible.
• Check bypass position.
• Check air filter for contamination, replace if contamination is
visible (→ Page 154).
• Check exhaust back pressure.
• Check differential pressure over mixture cooler.
• Check emissions and injection timing (→ Page 143).
• Check oil separator efficiency (oil in compressor intake
elbow), clean compressor as necessary.
• Check valve clearance (→ Page 147).
• Check gasket between mixture line and cylinder head for
correct installation position.
090 – SS Starter Speed Not Reached

Red alarm. Start terminated.
Idle speed not reached. 1. Check ignition.
2. Check gas supply.
3. Check mixture setting.
TIM-ID: 0000044738 - 001
091 – SS Release Speed Not Reached

Yellow alarm
Gas temperature sensor 1. Not installed in all engine versions (optional).
defective, short circuit or wire 2. Check sensor and cabling (B38), replace as necessary.
break.

092 – SS Starter Speed Not Reached
Minimum speed for flushing u Check starter system.
process and ignition release was
not attained.
093 – SS T-Preheat
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.
094 – LO T-Preheat
Yellow alarm.
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.
095 – AL Prelubrication Fault

Oil priming fault. 1. Check oil pressure, oil temperature, oil level.
2. Check oil priming pump.
104 – AL Eng Hours Counter Defect

Yellow alarm.
TIM-ID: 0000044738 - 001

Operating hours meter u Replace Engine Control Unit.
defective. Internal Engine
Control Unit fault.

118 – LO ECU Power Supply Voltage
Yellow alarm.
Supply voltage too low (limit 1. Check supply voltage.
value 1). 2. Check cabling.
119 – LOLO ECU Power Supply Voltage

Red alarm.
Supply voltage too low (limit 1. Check supply voltage.
120 – HI ECU Power Supply Voltage

Yellow alarm.
Supply voltage too high (limit 1. Check supply voltage.
121 – HIHI ECU Power Supply Voltage

Red alarm.
Supply voltage too high (limit 1. Check supply voltage.
122 – HI T-ECU
Yellow alarm.
Electronics temperature too high u Provide improved cooling for ECU. Reduce room temperature,
(limit value 1). check air flow to ADEC.
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180 – AL CAN1 Node Lost

Yellow alarm.
Bus node (SAM or EMU) lost on u Check operation of bus nodes and cabling. Buses (CAN bus 1
CAN bus 1. and CAN bus 2) are redundant.

181 – AL CAN2 Node Lost
Yellow alarm.
Bus node (SAM or EMU) lost on u Check operation of bus nodes and cabling. Buses (CAN bus 1
CAN bus 2. and CAN bus 2) are redundant.
182 – AL CAN Wrong Parameters

Red alarm.
Incorrect parameter values u Contact Service (configuration fault).
entered in data record.
183 – AL CAN No PU-Data

Red alarm.
The selected CAN mode u Contact Service (configuration fault).
initializes communication by
means of the PU data module.
However, the necessary PU data
module is not present or is
invalid.
184 – AL CAN PU-Data Flash Error

Red alarm.
A programming error occurred u Contact Service (configuration fault).
when attempting to copy a
received PU data module into
the Flash module.
186 – AL CAN1 Bus Off

Yellow alarm.
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CAN controller 1 is in “Bus Off” u Check operation of bus nodes and cabling.
status. Automatic switching to
CAN bus 2. Bus users (ECU,
SAM or EMU) faulty.

187 – AL CAN1 Error Passive
Yellow alarm.
CAN controller 1 has indicated a u Check operation of bus nodes and cabling.
warning. Bus users (ECU, SAM
or EMU) are faulty.

Yellow alarm.
status. Automatic switching to
CAN bus 1. Bus users (ECU,
SAM or EMU) faulty.

Yellow alarm.
warning. Possible causes may
be, e.g. missing node, minor
malfunctions or temporary bus
overload.
190 – AL EMU Parameter Not Supported

Red alarm.
EMU parameters are not u Contact Service (configuration fault).
supported.
201 – SD T-Coolant
TIM-ID: 0000044738 - 001

Coolant temperature sensor at u Check sensor and cabling (B6.1), replace as necessary. Fault is
engine outlet defective, short rectified following engine restart.
circuit or wire break.

204 – SD Level Lube Oil
Engine oil level sensor defective, u Check sensor and cabling (B24), replace as necessary. Fault is
short circuit or wire break. rectified following engine restart.
206 – SD T-Exhaust A
Yellow alarm.
Exhaust temperature sensor on u Check sensor and cabling (B4.21), replace as necessary. Fault
A side defective, short circuit or is rectified following engine restart.
wire break.
207 – SD T-Exhaust B
Yellow alarm.
Exhaust temperature sensor on u Check sensor and cabling (B4.22), replace as necessary. Fault
B side defective, short circuit or is rectified following engine restart.
wire break.
211 – SD P-Lube Oil

Engine oil pressure sensor after u Check sensor and cabling (B5.1), replace as necessary. Fault is
filter defective, short circuit or rectified following engine restart.
wire break.
212 – SD P-Coolant
Red alarm.
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Coolant pressure sensor after u Check sensor and cabling (B16.1), replace as necessary. Fault
engine defective, short circuit or is rectified following engine restart.
wire break.

214 – SD P-Crankcase
Red alarm.
Crankcase pressure sensor u Check sensor and cabling (B50), replace as necessary. Fault is
defective, short circuit or wire rectified following engine restart.
break.
216 – SD T-Lube Oil

Engine oil temperature sensor u Check sensor and cabling (B7), replace as necessary. Fault is
after oil heat exchanger rectified following engine restart.
defective, short circuit or wire
break.
219 – SD T-Intake Air

Yellow alarm.
Intake air temperature sensor u Check sensor and cabling (B49.2), replace as necessary. Fault
defective, short circuit or wire is rectified when engine is restarted.
break.
221 – SD P-Diff Lube Oil

Red alarm.
Engine oil pressure sensors u Check sensor and cabling before filter (B5.3) and after
defective, short circuit or wire filter (B5.1), replace as necessary. Fault is rectified following
break. engine restart.
227 – SD P- Lube Oil before Filter

Yellow alarm.
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Engine oil pressure sensor u Check sensor and cabling (B5.3), replace as necessary. Fault is
before filter defective, short rectified following engine restart.

229 – AL Stop Camshaft Sensor Defect
Engine stop due to camshaft u Check sensor and cabling (B1.1), replace as necessary. Fault is
sensor fault (and a previous rectified following engine restart.
crankshaft sensor fault in the
same operating cycle).
231 – SD Camshaft Speed

Camshaft sensor defective, u Check sensor and cabling (B1.1), replace as necessary. Fault is
short circuit or wire break. rectified following engine restart.
232 – SD ETC Speed 1

Yellow alarm.
Speed sensor of primary u Turbocharger speed sensor is not fitted at present.
turbocharger defective, short
233 – SD ETC Speed 2

Yellow alarm.
Speed sensor of secondary u Turbocharger speed sensor is not fitted at present.
turbocharger defective, short
245 – SD ECU Power Supply Voltage

Red alarm.
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Internal Engine Control Unit u Replace ADEC Engine Control Unit.
fault.

266 – SD Speed Demand
Red alarm.
Speed setting signal can no u Check signal and cabling between plant and ADEC.
longer be transmitted from
plant.
381 – AL Wiring TOP 1

Yellow alarm.
Short circuit or wire break at u Check cabling.
transistor output, plant-side 1
(TOP 1). Activation of yellow
combined alarm faulty.

Red alarm.
(TOP 2). Activation of red
combined alarm faulty.

Red alarm.
(TOP 3). Activation of gas supply
solenoid valve No.1 faulty.

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Red alarm.
(TOP 4). Activation of gas supply
solenoid valve No.2 faulty.

418 – SD T-Intake Air B
Yellow alarm.
Intake air temperature sensor u Check sensor and cabling (B49.2), replace as necessary.
defective, short circuit or wire
break.
419 – SD T-Coolant before Engine

Red alarm.
Coolant temperature sensor at u Check sensor and cabling (B6.3), replace as necessary.
engine inlet defective, short
423 – LO P-Coolant Diff.

Coolant differential pressure too u Check engine coolant circuit (pressure and flow).
low (limit value 1). Insufficient
volume flow.
429 – HI P-Coolant
too high (limit value 3).
430 – LO P-Coolant before Engine

Yellow alarm.
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Coolant pressure before engine u Check engine coolant circuit (pressure and flow).
pressure too low.

431 – SS P-Coolant before Engine
Coolant pressure before engine u Check engine coolant circuit (pressure and flow).
pressure too low.
434 – HI T-Coolant before Engine

Yellow alarm.
Coolant temperature before u Check engine coolant circuit (pressure and flow).
435 – SS T-Coolant before Engine

Coolant temperature before u Check engine coolant circuit (pressure and flow).
443 – HI P-Charge Mix Diff.

Yellow alarm.
Difference in mixture pressures 1. Check throttles for varying positions and malfunction.
sensed on A and B side is too 2. Check mixture lines for leakage.
high (limit value 1). 3. Check sensors and cabling (B79.22, B79.21).
TIM-ID: 0000044738 - 001
445 – SD P-Ambient Air

Yellow alarm.
Ambient air pressure sensor on u Check sensor and cabling, replace as necessary. Fault is
ECU faulty. rectified following engine restart.

447 – HIHI P-Charge Mix Diff.
Difference in mixture pressures 1. Check throttles for varying positions and malfunction.
sensed on A and B side is too 2. Check mixture lines for leakage.
high (limit value 2). 3. Check sensors and cabling (B79.22, B79.21).
451 – HI T-Charge Mix

Yellow alarm.
Mixture temperature is too high 1. Check mixture cooling circuit.
(limit value 1). Mixture coolant 2. Check mixture cooler for dirt.
pump failure, volumetric flow
too low, cooling system inlet
temperature too high, mixture
cooler clogged.
452 – HIHI T-Charge Mix

Mixture temperature too high 1. Check mixture cooling circuit.
(limit value 2). Mixture coolant 2. Check mixture cooler for dirt.
pump failure, volumetric flow
too low, cooling system inlet
temperature too high, mixture
cooler clogged.
453 – LO T-Charge Mix

Yellow alarm.
Mixture temperature is too low 1. Check intake air temperature.
(limit value 3). 2. Check mixture cooling circuit.
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454 – SS Power Reduction Active

Yellow alarm.
Power reduction activated. u Rectify limit value violation of the source alarm (e.g. reduce
intake temperature).

457 – LO T-Intake Air
Yellow alarm.
Intake air temperature is too low u Check ventilation system.
(limit value 3).
458 – LOLO T-Intake Air

Intake air temperature is too low u Check ventilation system.
(limit value 4).
459 – SD P-Coolant b. Engine

Red alarm.
Coolant pressure sensor before u Check sensor and cabling (B16.3), replace as necessary. Fault
engine defective, short circuit or is rectified following engine restart.
wire break.
470 – SD T-ECU
Red alarm.
Temperature sensor for Engine u Check sensor and cabling, replace as necessary. Fault is
Control Unit defective, short rectified following engine restart.
472 – AL Stop SD
Engine stop, since all shutdown u Combined alarm (for details, refer to the source alarm).
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channels have “sensor failure”.
476 – AL Crash Rec.Init Fault

Red alarm.
Initialization error of crash u Contact Service.
recorder.

478 – AL Comb. Alarm Yel (Plant)
Yellow alarm.
Combined YELLOW alarm from u Combined alarm (for details, refer to the source alarm).
plant.
479 – AL Comb. Alarm Red (Plant)

Combined RED alarm from plant. u Combined alarm (for details, refer to the source alarm).
496 – SD P-Charge Mix A

Mixture pressure sensor on A u Check sensor and cabling (B79.21), replace as necessary. Fault
side defective, short circuit or is rectified following engine restart.
wire break.
497 – SD P-Charge Mix B

Mixture pressure sensor on B u Check sensor and cabling (B79.22), replace as necessary. Fault
side defective, short circuit or is rectified following engine restart.
wire break.
498 – SD P-Charge Mix Diff

Red alarm.
Mixture differential pressure u Check sensors and cabling (B79.21, B79.22), replace as
sensor on A or B side defective, necessary. Fault is rectified following engine restart.
TIM-ID: 0000044738 - 001
short circuit or wire break.

499 – SD T-Charge Mix
Red alarm.
Mixture temperature sensor u Check sensor and cabling (B73), replace as necessary. Fault is
defective, short circuit or wire rectified following engine restart.
break.
511 – HIHI P-Charge Mix A

Mixture pressure on A side too 1. Check emissions.
high (limit value 2). 2. Check ignition timing (→ Page 143).
3. Check exhaust back pressure.
4. Check valve clearance (→ Page 147).
5. Check throttle.
6. Check mixture coolant system.
512 – HIHI P-Charge Mix B

Mixture pressure on B side too 1. Check emissions.
high (limit value 2). 2. Check ignition timing (→ Page 143).
3. Check exhaust back pressure.
4. Check valve clearance (→ Page 147).
5. Check throttle.
6. Check mixture coolant system.
513 – SD P-Coolant Diff

Red alarm.
Coolant differential pressure u Check sensors and cabling (B16.1, B16.3), replace as
sensor defective, short circuit or necessary. Fault is rectified following engine restart.
wire break.
TIM-ID: 0000044738 - 001
515 – AL Starter Not Engaged

Yellow alarm.
break.

517 – SD P-Charge Mix before Throttle
Red alarm.
Mixture pressure sensor before u Check sensor and cabling (B79.23), replace as necessary. Fault
throttle defective, short circuit is rectified following engine restart.
or wire break.
520 – SD P-Intake Air after Filter A

Yellow alarm.
Intake air pressure sensor after u Check sensor and cabling (B81.1), replace as necessary. Fault
filter on A side defective, short is rectified following engine restart.
522 – SD P-Intake Air after Filter B

Yellow alarm.
Intake air pressure sensor after u Check sensor and cabling (B81.2), replace as necessary. Fault
filter on B side defective, short is rectified following engine restart.
536 – AL Wiring PWM_CM1

Red alarm.
Cable break or short circuit on u Check ignition cabling.
channel PWM_CM1.
552 – AL GasControlCheck Fault

Red alarm.
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Gas train test was not 1. Check gas train.

successful. Alarm is activated if 2. Check cabling.
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.

554 – AL Ignition Fault
Red alarm.
Ignition failure. Alarm is 1. Check ignition system.
activated if the feedback signal 2. Check cabling.
from ignition system is not
received within a specified time-
out period. Either the ignition
could not be activated, the
timeout period is set too short,
or communication is faulty.
556 – AL GasValve Fault

Red alarm.
Gas supply solenoid valve faulty. 1. Check gas train.
Alarm is active if there are 2. Check cabling.
problems with the gas supply
solenoid valves. Either the gas
supply solenoid valves are
faulty, the timeout period is set
too short, or communication is
faulty.
557 – AL speed drop fault

Speed drop. Alarm is activated if u Check gas train.
engine speed drops during
starting sequence.
559 – AL mixture throttle A fault

TIM-ID: 0000044738 - 001
A problem related to mixture u Check mixture throttle on A side and cabling. Replace mixture
throttle on A side occurred. throttle on A side as necessary.
Possible causes: Mixture throttle
defective, no power supply to
throttle, cabling of feedback
and/or position signal faulty.

560 – Mixture throttle B
A problem related to mixture u Check mixture throttle on B side and cabling. Replace mixture
throttle on B side occurred. throttle on B side as necessary.
Possible causes: Mixture throttle
defective, no power supply to
throttle, cabling of feedback
and/or position signal faulty.
565 – AL L1 P-Intake Air after Filter A

Yellow alarm.
Pressure loss over air filter on A u Replace air filter (→ Page 154).
side is too high.
566 – AL L2 P-Intake Air after Filter A

Yellow alarm.
Pressure loss over air filter on A u Replace air filter (→ Page 154).
side is too high.
567 – AL L1 P-Intake Air after Filter B

Yellow alarm.
Pressure loss over air filter on B u Replace air filter (→ Page 154).
side is too high.
568 – AL L2 P-Intake Air after Filter B

Yellow alarm.
TIM-ID: 0000044738 - 001

Pressure loss over air filter on B u Replace air filter (→ Page 154).
side is too high.

569 – AL SAM Missing Data Fault
Red alarm.
This alarm is activated if the u Check the cabling/connectors of the devices connected to
ECU does not receive some SAM and ECU bus. Replace devices as necessary.
messages to be transmitted
from SAM. Possible problem
related to CAN bus, SAM does
not work properly or a device
connected to SAM does not
work properly so that SAM
cannot transmit the messages
from this device successfully.
570 – L1 Al CAN Max. Retarded Timing

Yellow alarm.
The cylinder set to maximum 1. Check emissions.
retarded timing due to knocking 2. Check ignition timing (→ Page 143).
has violated the first limit value. 3. Check combustion chamber.
4. Check gas quality if feasible (methane number).

Yellow alarm. Power reduction.
has violated the second limit 3. Check combustion chamber.
value. Power reduction is 4. Check gas quality if feasible (methane number).
initiated.

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has violated the third limit value. 3. Check combustion chamber.
4. Check gas quality if feasible (methane number).

583 – AL GLS closed
Generator load switch does not 1. Check generator load switch.
open when engine stops. Engine 2. Manually disconnect generator switch.
is motoring. 3. Open any existing mains circuit breaker.
4. Where possible, do not operate manual emergency stop.
609 – AL Wiring PWM_CM7

Red alarm.
Cable break or short circuit on u Check cabling to NOx sensors and air humidity sensor.
channel PWM_CM7.
617 – LO Current Heat Value of Fuel

Yellow alarm.
Fuel calorific value has u Check gas quality if feasible.
undershot the first limit value.
618 – LOLO Current Heat Value of Fuel

Yellow alarm.
undershot the second limit
value.
619 – HI Current Heat Value of Fuel

Yellow alarm.
TIM-ID: 0000044738 - 001

exceeded the first limit value.

620 – HIHI Current Heat Value of Fuel
Yellow alarm.
undershot the second limit
value.
621 – LO NOx Value

Yellow alarm.
NOx emissions have undershot 1. Check gas quality if feasible.
the first limit value. 2. Check gas pressure.
3. Check NOx sensor.
4. Check emissions.
622 – LOLO NOx Value

Yellow alarm.
NOx emissions have undershot 1. Check gas quality if feasible.
the second limit value. 2. Check gas pressure.
3. Check NOx sensor.
4. Check emissions.
623 – HI NOx Value

Yellow alarm.
NOx emissions have exceeded 1. Check gas quality if feasible.
the first limit value. 2. Check NOx sensor.
3. Check emissions.
624 – HIHI NOx Value

Yellow alarm.
TIM-ID: 0000044738 - 001

NOx emissions have exceeded 1. Check gas quality if feasible.
the second limit value. 2. Check NOx sensor.
3. Check emissions.

642 – SD Electr. Motor Power AI2
Yellow alarm.
Engine power sensor defect 1. Generator eff. power not correctly transmitted.
(analog input 2). 2. Generator eff. power can also be transmitted via CAN bus as an
option.
3. Check configuration of plant control system.
646 – Al Knock Intensity

Red alarm.
Knock intensity exceeded 1. Check gas quality if feasible (methane number).
(extreme knocking detected). 2. Check emissions.
3. Check combustion chamber.
649 – Al Req Angle Throttle A

Red alarm.
Opening angle of throttles A 1. Check charge-air pressure reserve.
exceeded. 2. Intake air temperature outside TVU data.
3. Check compressor for contamination.
4. Reduce power.
650 – Al Req Angle Throttle B

Red alarm.
Opening angle of throttles B 1. Check charge-air pressure reserve.
exceeded. 2. Intake air temperature outside TVU data.
3. Check compressor for contamination.
4. Reduce power.
651 – AL Preheating Error

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Yellow alarm.
Engine preheating faulty. 1. Low coolant.
2. Missing differential pressure in coolant system.
3. Coolant pump does not start, is faulty.

652 – AL GET Comm Lost
Red alarm.
CAN bus communication for 1. Check cabling.
knock control faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU & knock control.
4. Check settings with device-specific dialog software (XD10).
653 – AL IC92x Comm Lost

Red alarm.
ignition system faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU & knock control.
4. Check settings with device-specific dialog software (in device).
654 – AL FSeries Comm Lost

Red alarm.
bypass flap faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU & bypass flap.
4. Check settings with device-specific dialog software (XD50.3).
655 – AL TecJet Comm Lost

Red alarm.
CAN bus communication for gas 1. Check cabling.
control valve faulty 2. Check power supply.
(alternatively, a stepper motor 3. Carry out restart of ECU, EMU & gas control valve.
with gas mixer can be installed). 4. Check settings with device-specific dialog software (XD11).
656 – AL ProActA Comm Lost

TIM-ID: 0000044738 - 001
Red alarm.
throttle A faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU & throttle A.

657 – AL ProActB Comm Lost
Red alarm.
throttle B faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU & throttle B.
658 – AL NOxA Comm Lost

Red alarm.
NOx sensor A faulty. 2. Check power supply.
3. Carry out restart of ECU and EMU.
4. Replace sensor.
659 – AL NOxB Comm Lost

Red alarm.
NOx sensor B faulty. 2. Check power supply.
3. Carry out restart of ECU and EMU.
4. Replace sensor.
664 – AL Oil Refill Error

Red alarm.
Combined alarm for automatic u After initiation of the alarms “HI Oil Refill” and
oil replenishment faulty. “HI Lube Oil Level refill” a programmable timeout period starts.
The engine is stopped when this time expires.
665 – AL GET Yellow

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Yellow alarm.
An internal combined alarm in u An exact fault designation is transmitted via CAN bus to the
knock control was detected. genset control system.

666 – AL IC92x Yellow
Yellow alarm.
the ignition system was genset control system.
detected.
667 – AL FSeries Yellow

Yellow alarm.
the bypass flap was detected. genset control system.
668 – AL TecJet Yellow

Yellow alarm.
the gas control valve was genset control system.
detected.
669 – AL ProActA Yellow

Yellow alarm.
throttle A was detected. genset control system.
670 – AL ProActB Yellow

Yellow alarm.
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throttle B was detected. genset control system.
671 – AL NOxA Yellow

Yellow alarm.
An internal combined alarm at u An exact fault designation is transmitted via CAN bus to the
NOx sensor A was detected. genset control system.

672 – AL NOxB Yellow
Yellow alarm.
NOx sensor B was detected. genset control system.
675 – AL GET Red

Red alarm.
knock control was detected. genset control system.
676 – AL IC92x Red

Red alarm.
the ignition system was genset control system.
detected.
677 – AL FSeries Red

Red alarm.
the bypass flap was detected. genset control system.
678 – AL TecJet Red

Red alarm.
the gas control valve was genset control system.
TIM-ID: 0000044738 - 001
detected.
679 – AL ProActA Red

Red alarm.
throttle A was detected. genset control system.

680 – AL ProActB Red
Red alarm.
throttle B was detected. genset control system.
681 – AL NOxA Red

Red alarm.
NOx sensor A was detected. genset control system.
682 – AL NOxB Red

Red alarm.
NOx sensor B was detected. genset control system.
685 – AL Lube Oil Min

Red alarm.
Minimum engine oil filling level 1. Check engine oil level (→ Page 156).
detected. 2. Check replenishment system.
3. Fill oil.
686 – AL Lube Oil Max

Red alarm.
Maximum engine oil filling level 1. Check engine oil level (→ Page 156).
detected. 2. Check replenishment system.
TIM-ID: 0000044738 - 001
3. Drain oil.
688 – LO Oil Refill

Yellow alarm.
No oil replenishment within a u Check oil replenishment system.
programmable time.

689 – HI Oil Refill
Yellow alarm.
Engine oil was refilled too often u Check engine oil level (→ Page 156). Check oil supply.
within a certain time interval.
691 – HI Lube Oil Level Refill.

Yellow alarm.
Engine oil was refilled too often u Check engine oil level. Check oil supply.
within a certain time interval.
694 – SD T-Gas
Yellow alarm.
break.
719 – AL T-Gas L1
Yellow alarm.
Limit value 1 exceeded. u Check gas supply.
720 – AL T-Gas L2
Yellow alarm.
Limit value 2 exceeded. u Check gas supply.
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842 – AL Fuel Throttle Pos. L1

Yellow alarm.
TecJet throttle position has u Check gas supply.
exceeded limit value 1.

891 – AL Scavenging Active
Yellow alarm.
Engine was shut down by u None.
emergency stop and has failed
to successfully complete the
starting sequence several times.
948 – AL ESI active

Red alarm.
Emergency stop input is active 1. Rectify fault leading to this failure.
2. Check cabling.

Yellow alarm.
status. Bus nodes (ignition, anti-
knock module, throttles or gas
mixer) are faulty.

Yellow alarm.
warning. Bus nodes (ignition,
anti-knock module, throttles or
gas mixer) are faulty.
TIM-ID: 0000044738 - 001

6 Task Description
6.1 Engine
6.1.1 Engine – Barring manually
Preconditions

Barring gear F6555766 1
Ratchet head with extension F30006212 1
DANGER
gine's danger zone.
Barring engine manually

1. Remove guard plate.
2. Engage barring gear (2) in ring gear (3) and
install on flywheel housing.
3. Apply ratchet (1) to barring gear (2).
4. Rotate crankshaft in direction of engine ro-
tation. Apart from compression resistance,
there should be no abnormal resistance.
5. Remove barring gear in reverse order.
TIM-ID: 0000002531 - 002
130 | Task Description | MS150115/00E 2013-10

6.1.2 Checking machine room for smell of gas
Gas detection and alarm unit (not stocked by MTU) -
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.
Checking machine room for smell of gas

1. Check machine room to localize gas supply leaks using gas detection and alarm unit.
2. If the gas detection and alarm unit responds:
• Avoid naked flames!
• Avoid sparks! Do not use electrical appliances (including switches, connectors/sockets, telephone,
bell).
• Do not smoke!
• Close the magnetic gas shutoff valves.
• Open windows and doors!
• Warn residents and leave building!
• Call gas supplier from outside the building!
TIM-ID: 0000029125 - 002
MS150115/00E 2013-10 | Task Description | 131

6.2 Crankcase Breather
6.2.1 Oil separator – Filter replacement
Preconditions

Filter element (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Oils/oil vapors are combustible/explosive.
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
Oil separator – Filter replace-

ment
1. Release clamp (2) on both sides and re-
move it.
2. Remove housing cover (1).
TIM-ID: 0000029127 - 004

3. Remove locknut (1).
4. Remove filter cover (3) with washer (2).
5. Carefully lift out fine filter (6).
6. Carefully lift out coalescence filter (5).
7. Clean sealing faces and inside of housing.
8. Check condition of gaskets on new fine fil-
ter and new coalescence filter.
Note: The fine filter (6) must be installed in the
correct position in the housing.
9. Place fine filter (6) in housing, ensuring it is
straight.
Note: The coalescence filter (5) must be installed
in the correct position in the housing.
10. Place coalescence filter (5) in housing, en-
suring it is straight.
11. Fit filter cover (3), ensuring it is positioned
correctly.
12. Screw on washer (2) with new locknut (1) and tighten to specified tightening torque with torque wrench.
Name Size Type Lubricant Value/Standard
Locknut Tightening torque 15 Nm
13. Fit housing cover (1).
14. Fit clamp (2) neatly and tighten to specified torque using a torque wrench.
Clamp Tightening torque 5 Nm
TIM-ID: 0000029127 - 004

6.3 Ignition System
6.3.1 Spark plug – Replacement
Spark plug (→ Spare Parts Catalog)
Replacing spark plug

1. Remove spark plug (→ Page 135).
2. Install new spark plug (→ Page 136).
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6.3.2 Spark plug – Removal
Preconditions
☑Open protective packing of new spark plug just immediately prior to installation.

Special wrench, 20.8 mm F30452574 1
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.
WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
Spark plug – Removal

1. Remove spark plug connector (1)
(→ Page 139).
2. Unscrew spark plug a few turns.
3. Clean spark plug bore with compressed air.
4. Unscrew spark plug from cylinder head and
remove from spark plug bore.
TIM-ID: 0000043424 - 002

6.3.3 Spark plug – Installation
Preconditions
☑Open protective packing of new spark plug just immediately prior to installation.

Torque wrench, 10-60 Nm F30452769 1
Special wrench, 20.8 mm F30452574 1
Assembly compound (Molykote P 37) 50564 1
Spark plug (→ Spare Parts Catalog)
Spark plug connector with ignition line (→ Spare Parts Catalog)
Locking plate (→ Spare Parts Catalog)
DANGER
WARNING
Component is hot.
Risk of burning!
WARNING
Spark plug – Installation

1. Clean and dry the mating surfaces on spark
plug (1), sealing ring (2) and cylinder head.
2. Fit new sealing ring (2) on spark plug (1)
with the flat side facing the isolator.
3. Check condition of spark plug connector
and ignition cable, replace parts if dam-
aged.
TIM-ID: 0000043425 - 002
4. Apply thin coat of assembly compound to

spark plug.

5. Screw spark plug into cylinder head.
Note: The temperature of spark plug and cylinder head must be the same prior to tightening.
6. Tighten spark plug to specified tightening torque using a torque wrench.
Spark plug M18 x 1.5 Tightening torque (Assembly compound 50 +5 Nm
(Molykote P 37))
7. Install spark plug connector (1) (→ Page 140).
TIM-ID: 0000043425 - 002

6.3.4 Spark plug connector – Replacement
Spark plug connector (→ Spare Parts Catalog)
Replacing spark plug connector

1. Remove spark plug connector (→ Page 139).
2. Install spark plug connector (→ Page 140).
TIM-ID: 0000035897 - 004

6.3.5 Spark plug connector – Removal
Preconditions
☑Open protective packing of new spark plug connector only immediately prior to installation.
DANGER
WARNING
Component is hot.
Risk of burning!
WARNING
Spark plug connector – Removal

1. Loosen screws (4) on cylinder head cov-
er (7) turning them back approx. one revo-
lution.
2. Turn flange (6) counterclockwise out of un-
ion (4).
3. Pull protective cap (2) up and back to gain
access to threaded connection of the igni-
tion lead underneath.
4. Loosen threaded connection of the ignition
lead on ignition coil (1) and disconnect igni-
tion cable (3).
5. Grip ignition lead connector (5) by
flange (6) and disconnect from spark plug
before fully extracting it from spark plug
bore.
TIM-ID: 0000043225 - 002

6.3.6 Spark plug connector – Installing
Preconditions
☑Open protective packing of new spark plug connector only immediately prior to installation.

Spark plug connector with ignition line (→ Spare Parts Catalog)
Tab washer (→ Spare Parts Catalog)
DANGER
WARNING
Component is hot.
Risk of burning!
WARNING
Installing spark plug connector

1. If necessary, remove the ignition line's low-
er sealing ring and replace with a new seal-
ing ring.
2. Remove any dust and impurities from the
ignition line connector's Teflon body - on
the outside and inside on the spark plug
side.
3. Check the spark plug isolator sealing ring
for damage. If damaged, install a new spark
plug isolator sealing ring (→ Page 141).
4. Insert the ignition line connector (5) into
TIM-ID: 0000043226 - 004
the spark plug duct, press down the igni-

tion line flange (6) against the spring force
and screw into the straight union until they
abut the bolts (4) on both sides. The item
number on the flange is in the 6 o'clock po-
sition.
5. Tighten the bolts (4) of the ignition line
flange (6). Check for correct alignment of
the ignition line flange (6) while doing this.
The bolt slots of the flange (6) abut the
threads of the bolts (4) on both sides.

6. Fasten the ring eyelet of the ignition line (3) to the ignition coil (1) with the bolt and spring washer.
Bolt M6 Tightening torque 10 Nm
7. Fit the protective cap (2) and check for correct seating.
Exchanging spark plug isolator

sealing ring
1. Insert screwdriver (3) between Teflon
sleeve (1) and sealing ring (2).
2. Pry out and pull out sealing ring (2).
3. Fold together new sealing ring (2).

4. Insert sealing ring (2) into the hole in Teflon
sleeve (1) with the article number facing
downwards.
TIM-ID: 0000043226 - 004

5. Carefully press sealing ring (1) into the
groove until it is flush with the hole in Tef-
lon sleeve (2).
TIM-ID: 0000043226 - 004

6.3.7 Ignition system – Ignition timing check
Preconditions
☑Operating voltage of genset control system is present.
☑Genset is disconnected from the mains.

Stroboscope (Not stocked by MTU) -
DANGER
DANGER
gine's danger zone.
WARNING
Ignition system – Ignition timing

check
Note: The service tool Diasys and a dongle with
access rights 1A or higher is required to
determine the ignition setpoint.
1. Stop engine (→ Page 45).
2. Install stroboscope clamp on cylinder A1
ignition cable.
3. Start engine (→ Page 42).
4. Using the stroboscope, check ignition tim-
ing on flywheel mark and compare with the
engine-specific setpoint value.
5. If the ignition timing deviates from the
specification, it must be adjusted by cor-
recting the reset position in the ignition
TIM-ID: 0000043949 - 003
system. The reset position is corrected in

the engine governor with the Diasys service
tool.
6. Check ignition timing.
7. Disconnect stroboscope.
8. Stop engine (→ Page 45).

6.4 Valve Drive
6.4.1 Valve depth – Measurement
Preconditions

Sliding depth gauge, 200 mm Y20000918 1
Preparatory steps
1. Remove spark plugs (→ Page 135).
2. Remove cylinder head covers (→ Page 151).
3. Remove sleeves (arrow).
4. Install barring device (→ Page 130).
5. Rotate crankshaft with barring device in en-

gine direction of rotation until marking
“OT” and pointer are aligned.
TIM-ID: 0000043220 - 002

Measuring valve depth
1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Measure valve depth for each valve in two crankshaft positions (firing TDC and overlap TDC for cylinder
A1) according to the diagram. Diagram (→ Page 147).
3. Release 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 spark plug
bore with depth gauge (see figure).
• The specified value for a new cylinder
head: 93.8 mm.
• Admissible wear: 3 mm.
• If the measured value is > 96.8 mm, re-
place the relevant cylinder head ahead
of schedule.
5. Install valve bridge.
6. Adjust valve clearance (→ Page 147).
Final steps
TIM-ID: 0000043220 - 002
1. Remove barring device (→ Page 130).

2. Check condition of O-rings at the sleeves, replace if damaged.

3. Install sleeves (arrow).
4. Install cylinder head covers (→ Page 152).
5. Install spark plugs with new sealing rings
(→ Page 136).
TIM-ID: 0000043220 - 002

6.4.2 Valve clearance – Check and adjustment
Preconditions
☑Engine coolant temperature is max. 40 °C.
☑Valves are closed.

Feeler gage Y20098771 1
Angular screw driver F30452765 1
Socket wrench, 24 mm F30029815 1
Engine oil
Preparatory steps
1. Remove cylinder head cover (→ Page 151).
2. Install barring device (→ Page 130).
3. Rotate crankshaft with barring device in en-
gine direction of rotation until marking
“OT” and pointer are aligned.
TIM-ID: 0000043221 - 001

Diagram for 12V engines – Two
crankshaft positions
Diagram for 16V engines – Two

crankshaft positions
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet valves (long rocker arm) = 0.3 mm
• Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
TIM-ID: 0000043221 - 001
per diagram.
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.

Adjust valve clearance
1. Release locknut (1).
2. Insert feeler gauge (3) between valve
bridge and rocker arm.
3. Using angular screw driver, set adjusting
screw (2) so that the specified valve clear-
ance is provided.
4. Feeler gauge (3) must just pass through
the gap.
5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting
screw (2) to prevent it from turning.
Locknut M16 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 130).
2. Install cylinder head cover (→ Page 152).
TIM-ID: 0000043221 - 001

6.4.3 Valve gear – Lubrication
Preconditions

Engine oil
Lubricating valve gear

1. Remove cylinder head covers
(→ Page 151).
2. Fill oil chambers of rocker arms and adjust-
ing screws with oil.
3. Install cylinder head covers (→ Page 152).
TIM-ID: 0000043352 - 001

6.4.4 Cylinder head cover – Removal
Preconditions
Removing cylinder head cover

1. Clean very dirty cylinder head covers (1)
prior to removal.
2. Remove spark plug connector
(→ Page 139).
3. Remove screws (2).
4. Remove cylinder head cover with gasket
from cylinder head.
TIM-ID: 0000042136 - 001

6.4.5 Cylinder head cover – Installation
Gasket (→ Spare Parts Catalog)
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
Installing cylinder head cover

1. Clean mounting surface.
2. Check condition of gasket, replace if dam-
aged.
3. Position gasket and cylinder head cover (1)
on cylinder head.
4. Insert screws (2) in cylinder head cover and
tighten them.
Note: The locking plate must be removed from
the cylinder head cover.
5. Install spark plug connector (→ Page 140).
TIM-ID: 0000042137 - 001

6.5 Gas System
6.5.1 Gas supply - Checking gas lines for leaks
Preconditions
☑Engine shut down and starting disabled.

Leak identification spray
Soap suds
WARNING
Gaseous fuels are combustible/explosive.
• Avoid open flames, electrical sparks and ignition sources.
• Carry gas-warning unit (part of the personal safety equipment).
• Do not smoke.
Gas supply, checking gas lines for leaks

1. Coat all connections of the gas supply line with soap solution or spray with leakage detection spray
from a distance of 30 to 50 cm.
• Leaks are indicated by the formation of bubbles or foam.
2. Replace leaking parts.
TIM-ID: 0000029135 - 001

6.6 Air Filter
6.6.1 Air filter – Replacement
Air filter (→ Spare Parts Catalog)
Prefilter made of fleece (option) (→ Spare Parts Catalog)
Note: Air filter condition is monitored by a sensor. Replace air filter and/or (optional) fleece prefilter when the
corresponding fault message appears.
Replacing air filter

1. Remove air filter (→ Page 155).
2. Install new air filter (→ Page 155).
TIM-ID: 0000013394 - 002

6.6.2 Air filter – Removal and installation
Preconditions
Air filter – Removal and installa-

tion
1. Loosen clamp (2).
2. Remove air filter (3) and clamp (2) from
connecting flange (1) of intake housing.
3. Clean connecting flange (1) of the intake
housing and check for obstructions.
4. Place new air filter (3) with clamp (2) onto
intake housing (1).
5. Tighten clamp (2).
TIM-ID: 0000044568 - 002

6.7 Lube Oil System, Lube Oil Circuit
6.7.1 Engine oil – Level check
Preconditions
WARNING
Hot oil.
WARNING
• Do not smoke.
Oil level check prior to engine

start
1. Withdraw oil dipstick from 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: After extended standstill, the oil level may
exceed the mark (1) by up to 2 cm. The
cause of this may be that oil, e.g. from the
oil filter and oil heat exchanger flows back
into the oil pan.
3. The oil level must reach the mark (2) or ex-
ceed the mark (1) by up to 2 cm.
Note: Topping up oil manually is not required. The
oil level check is only intended to confirm
that the automatic oil replenishment fea-
ture works properly.
4. Insert oil dipstick into guide tube up to the
stop.
TIM-ID: 0000006169 - 004
Oil level check after the engine is stopped

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 automat-
ic 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.

6.7.2 Engine oil – Change
Preconditions
☑Engine is at operating temperature.

Engine oil
WARNING
Hot oil.
WARNING
• Do not smoke.
Engine oil extraction

1. Open shut-off valve(s) in extraction line from engine and waste-oil tank.
2. Extract all oil from oil pan using the electric pump.
3. Close shut-off valve(s).
Filling with new engine oil

1. Determine oil change quantity, fuel optimized (→ Page 23) or for tropical applications (→ Page 28).
2. Use electric pump to fill engine with oil from new-oil tank until the "max." mark on the oil dipstick is
reached.
3. Check engine oil level (→ Page 156).
TIM-ID: 0000045239 - 001

6.7.3 Engine oil – Sample extraction and analysis
Preconditions
DANGER
WARNING
Hot oil.
WARNING
• Do not smoke.
WARNING
Engine oil – Sample extraction

1. Connect sampling hose (genset manufac-
turer's scope of delivery) to sampling
neck (arrow) with engine running at operat-
ing temperature.
2. Take oil samples in accordance with the
MTU Fluids and Lubricants Specifications
(A001061/..) and have them analyzed by a
certified laboratory. TIM-ID: 0000029139 - 002

6.8 Oil Filtration / Cooling
6.8.1 Engine oil filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
• Do not smoke.
Replacing engine oil filter

1. Remove oil filter using filter wrench.
2. Clean sealing surface of connecting piece.
3. Check condition of new oil filter sealing
ring and coat it with oil.
4. Screw on and tighten new oil filter by hand.
5. Replace other oil filters in the same way.
6. Check oil level (→ Page 156).
TIM-ID: 0000029141 - 003

6.9 Coolant Circuit, General, High-Temperature Circuit
6.9.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Engine coolant – Level check

1. Read off system filling pressure, fuel-optimized (→ Page 23) or for tropical applications (→ Page 28) at
pressure gauge.
2. Top up with treated coolant as necessary (→ Page 164).
TIM-ID: 0000044678 - 001

6.9.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 162).
2. Fill with engine coolant (→ Page 164).
TIM-ID: 0000000036 - 031

6.9.3 Engine coolant – Draining
Preconditions

WARNING
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheater, if installed.
Engine coolant – Draining

1. Open drain valves and drain coolant at the
following points:
• At the crankcase free end, left and right
side
TIM-ID: 0000006751 - 002

2. Draining of residual coolant:
• At coolant distribution housing.
3. Close all open drain points.
TIM-ID: 0000006751 - 002

6.9.4 Engine coolant – Filling
Preconditions

Engine coolant
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Filling with coolant

1. Fill with treated coolant using a pressure pump until the system filling pressure, fuel-optimized
(→ Page 23) or for tropical applications (→ Page 28) has been reached.
2. Vent engine coolant circuit at vent line.
3. Start engine and run at idle speed for a few minutes.
4. Check coolant level (→ Page 160).
TIM-ID: 0000044679 - 001

6.9.5 Vent line of engine coolant circuit – Replacement
Preconditions
WARNING
Replacing coolant vent line

1. Drain engine coolant (→ Page 162).
2. Release union nuts (1) and (3).
3. Remove coolant vent line (2).
4. Install new coolant vent line (2).
5. Fill with engine coolant (→ Page 164).
TIM-ID: 0000029143 - 003

6.10 Low-Temperature Circuit
6.10.1 Mixture coolant – Level check
Preconditions
WARNING
Mixture coolant – Level check

1. Read off system filling pressure, fuel-optimized (→ Page 23) or for tropical applications (→ Page 28) at
pressure gauge.
2. Top up with treated coolant as necessary (→ Page 169).
TIM-ID: 0000045193 - 001

6.10.2 Mixture coolant – Change
Mixture coolant
Mixture coolant – Change

1. Drain mixture coolant (→ Page 168).
2. Fill with fresh mixture coolant (→ Page 169).
TIM-ID: 0000007027 - 004

6.10.3 Mixture coolant – Draining
Preconditions
WARNING
Draining mixture coolant

1. Provide a suitable receptacle to catch the coolant.
2. Open drain valve at drain point in coolant line to mixture coolant cooler and drain coolant.
TIM-ID: 0000042774 - 001

6.10.4 Mixture coolant – Filling
Preconditions

Mixture coolant
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Filling with coolant

1. Fill with treated coolant using a pressure pump until the system filling pressure, fuel-optimized
(→ Page 23) or for tropical applications (→ Page 28) has been reached.
2. Vent mixture coolant circuit via system.
3. Start engine and run at idle speed for a few minutes.
4. Check coolant level (→ Page 166).
TIM-ID: 0000044680 - 001

6.11 Wiring (General) for Engine/Gearbox/Unit
6.11.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Checking engine wiring

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable clamps are firm, tighten loose cable clamps.
4. Replace faulty cable clamps.
5. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
6. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
7. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 019

6.11.2 Sensors – Overview
Sensors on B side
Illustrations are also applicable to 12V.
Item Designation Monitoring of

1 B49.2 Intake air temperature
2 B81.2 Intake air 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 on B side

The knocking sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads.
TIM-ID: 0000045314 - 001

Sensors on engine driving end

1 B79.23 Mixture pressure before throttle
2 B75 Crankshaft speed, reset ignition system
3 B13.3 Crankshaft speed ignition
Table 42: Sensors on engine driving end
TIM-ID: 0000045314 - 001

Sensors on A side

1 B79.21 Mixture pressure A-side
2 B50 Crankcase pressure
3 B5.3 Engine oil pressure before filter
4 B7 Engine oil temperature
5 B5.1 Engine oil pressure after filter
6 B44.1 Turbocharger speed (optional)
Table 43: Sensors on A side

TIM-ID: 0000045314 - 001

Sensors on engine free end

1 B4.21 Exhaust bulk temperature after turbocharger
2 B6.3 Coolant temperature before engine
3 B1.2 Camshaft speed for engine governor
4 B1.3 Camshaft speed for anti-knock control
5 B1.1 Camshaft speed for engine governor
6 B24 Lube oil level
7 B16.3 Coolant pressure before engine
8 B6.1 Coolant temperature after engine
Table 44: Sensors on engine free end TIM-ID: 0000045314 - 001

7 Appendix A
7.1 Abbreviations
Abbreviation Meaning Explanation
AL Alarm Alarm message
ANSI American National Standards Institute Association of American standardization organ-
izations
ATL Abgasturbolader Exhaust turbocharger (ETC)
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Pub-
lication No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CKT Circuit
DIN Deutsches Institut für Normung e. V. At the same time identifier of German stand-
ards
DL Default Lost Alarm: Default CAN bus failure
DVGW Deutsche Vereinigung des Gas- und German technical and scientific association for
Wasserfaches gas and water
ECU Engine Control Unit Engine governor
EMU Engine Monitoring Unit Monitoring unit for engine
EN Europäische Norm European standard
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
HI High Alarm: Measured value exceeds 1st maxi-
mum limit value
HIHI High High Alarm: Measured value exceeds 2nd maxi-
mum limit value
HT High Temperature
ICFN ISO - Continuous - Fuel stop - Net brake Fuel stop power ISO International coding for
power power output of combustion engines
ISO International Organization for Standardi- International umbrella organization for all na-
zation tional standardization institutes
KGS Kraftgegenseite Engine free end in accordance with
DIN ISO 1204
KS Kraftseite Engine driving end in accordance with
DIN ISO 1204
LED Light Emitting Diode
TIM-ID: 0000009960 - 004
LO Low Alarm: Measured value lower than 1st mini-

mum limit value
LOLO Low Low Alarm: Measured value lower than 2nd mini-
mum limit value
LT Low temperature
MD Missing Data A measuring point does not provide data
MG Message General message
MTU Motoren- und Turbinen-Union
OEG Onsite Energy MTU Onsite Energy
MS150115/00E 2013-10 | Appendix A | 175

Abbreviation Meaning Explanation
OEM Original Equipment Manufacturer
ORFS O-Ring Face Seal
OT Oberer Totpunkt Top dead center (TDC)
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Pulse Width Modulation Modulated signal
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SAV Sicherheitsabsperrventil Safety shut-off valve
SBV Sicherheitsabbalseventil Safety discharge valve
SD Sensor Defect Alarm: Sensor failure
SS Safety System Safety system alarm
TA-Luft Technische Anleitung zur Reinhaltung General administrative instruction for federal
der Luft emission control law in Germany
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom dead center (BDC)
WZK Werkzeugkatalog Tool Catalog (TC)
ZZP Zündzeitpunkt Ignition timing
TIM-ID: 0000009960 - 004
176 | Appendix A | MS150115/00E 2013-10

7.2 MTU Onsite Energy contacts / service partners
Service
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and
customer service centers ensure fast and direct support on site and ensure the high availability of our
products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For our locally available support, go to MTU's Internet site:

• http://www.mtuonsiteenergy.com/haendlersuche/index.de.htm
24h Hotline
With our 24h 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 oper-
ating conditions, or for spare parts supply.
For our locally available support, go to MTU's Internet site:
• http://www.mtuonsiteenergy.com/haendlersuche/index.de.html
Your contact at Headquarters:
• [email protected]
Spare Parts Service

Quick, easy and correct identification of the spare part required for your system. The right spare part at
the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system.
Your contact at Headquarters:
Germany:
• Tel.: +49 821 74802255
• Fax: +49 821 74802289
• E-mail: [email protected]
Worldwide:
• Tel.: +49 7541 908555
• Fax: +49 7541 908121
• E-mail: [email protected]
TIM-ID: 0000002624 - 003
MS150115/00E 2013-10 | Appendix A | 177

8 Appendix B
8.1 Special Tools
Angular screw driver
Part No.: F30452765
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment
(→ Page 147)
Barring gear
Part No.: F6555766
Qty.: 1
Used in: 6.1.1 Engine – Barring manually (→ Page 130)
Feeler gage
Part No.: Y20098771
Qty.: 1
(→ Page 147)
DCL-ID: 0000029696 - 001
178 | Appendix B | MS150115/00E 2013-10

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 6.8.1 Engine oil filter – Replacement (→ Page 159)
Gas detection and alarm unit (not stocked by MTU)

Part No.: -
Qty.:
Used in: 3.7 Emission values – Check (→ Page 44)
Qty.:
Used in: 6.1.2 Checking machine room for smell of gas
(→ Page 131)
Ratchet head with extension

Part No.: F30006212
Qty.: 1
Used in: 6.1.1 Engine – Barring manually (→ Page 130)
Sliding depth gauge, 200 mm

Part No.: Y20000918
Qty.: 1
Used in: 6.4.1 Valve depth – Measurement (→ Page 144)
DCL-ID: 0000029696 - 001
MS150115/00E 2013-10 | Appendix B | 179

Socket wrench, 24 mm
Part No.: F30029815
Qty.: 1
(→ Page 147)
Special wrench, 20.8 mm

Part No.: F30452574
Qty.: 1
Used in: 6.3.2 Spark plug – Removal (→ Page 135)
Qty.: 1
Used in: 6.3.3 Spark plug – Installation (→ Page 136)
Stroboscope (Not stocked by MTU)

Part No.: -
Qty.:
Used in: 6.3.7 Ignition system – Ignition timing check
(→ Page 143)
Torque wrench, 10-60 Nm

Part No.: F30452769
Qty.: 1
Used in: 6.3.3 Spark plug – Installation (→ Page 136)
Qty.: 1
Used in: 6.3.6 Spark plug connector – Installing (→ Page 140) DCL-ID: 0000029696 - 001
180 | Appendix B | MS150115/00E 2013-10

Torque wrench, 60-320 Nm
Part No.: F30452768
Qty.: 1
(→ Page 147)
DCL-ID: 0000029696 - 001
MS150115/00E 2013-10 | Appendix B | 181

8.2 Index
Numerics Engine oil
12 V 4000 L32FB engine data – Chgange 157
– Fuel optimized (TA-Luft) 23 – Sample extraction and analysis 158
– Tropical applications (TA-Luft) 28 Engine oil filter
16 V 4000 L32FB engine data – Replacement 159
– Fuel optimized (TA-Luft) 23 Engine oil level
– Tropical applications (TA-Luft) 28 – Check 156
50-hours check 50 Engine sides
– Designation 20
A Engine wiring
After extended out-of-service periods (>3 months) – Check 170
– Putting the engine into operation 38
F
– Engine remains ready for operation 48 Fault messages
– Putting the engine out of operation 49 – Engine governor 96
Air filter – Key 52
– Installation 155 – Protocol to genset control system 54
– Removal 155
G
– Replacement 154
Gas engine system
C – Overview 33
Contacts Gas supply
– MTU Onsite Energy 177 – Checking gas lines for leaks 153
Control, starting and stopping sequences 40
I
Coolant
– Change 161 Ignition order 22
Cylinder Ignition system
– Designation 20 – Ignition timing check 143
Cylinder head cover
L
– Installation 152
– Removal 151 List of abbreviations 175
D M
Designations Machine room

– Engine sides and cylinders 20 – Checking for smell of gas 131
Main dimensions
E – Engine 21
Emission values Maintenance schedule
– Check 44 – Maintenance task reference table [QL1] 51
Engine Mixture coolant
– After stopping – Change 167
– Putting out of operation 49 – Draining 168
– Barring manually 130 – Filling 169
– Emergency shutdown 46 Mixture coolant level
– Main dimensions 21 – Check 166
DCL-ID: 0000029696 - 001
– Shutdown 45 MTU Onsite Energy

– Start 42 – Contacts 177
– Wiring check 170 – Service partners 177
Engine coolant
O
– Change 161
– Draining 162 Oil separator
– Filling 164 – Filter replacement 132
– Level check 160 Operational checks 43
Engine layout 18 Overview
– Gas engine system 33
– Sensors 171
182 | Appendix B | MS150115/00E 2013-10

P V
Purpose of the units 35 Valve clearance
Putting the engine into operation – Adjustment 147
– After extended out-of-service periods (>3 months) 38 – Check 147
Putting the engine into operation after scheduled out-of- Valve depth
service-period 39 – Measurement 144
Valve gear
R – Lubrication 150
Runtimes at partial load 37 Vent line of engine coolant circuit
– Replacement 165
S
Safety notices, standards 17
Safety regulations
– Auxiliary materials, special instructions for applica-
tions with gaseous fuel 16
– Consumables 14
– Environmental protection 14
– Environmental protection, special instructions for ap-
plications with gaseous fuel 16
– Fire prevention 14
– Fire prevention, special instructions for applications
with gaseous fuel 16
– Fluids and lubricants 14
– Fluids and lubricants, special instructions for applica-
– Important provisions 5
– Maintenance work 10
– Maintenance work, special instructions for applica-
– Operation 8
– Operation, special instructions for applications with
gaseous fuel 9
– Organizational requirements 6
– Personnel requirements 6
– Repair work 10
– Repair work, special instructions for applications with
gaseous fuel 13
– Safety notices, standards 17
– Startup 8
– Startup, special instructions for applications with gas-
eous fuel 9
Sensors
– Overview 171
Service partners
– MTU Onsite Energy 177
Spark plug
– Installation 136
DCL-ID: 0000029696 - 001
– Removal 135
– Replacement 134
Spark plug connector
– Installing 140
– Removal 139
– Replacement 138
T
Transport 7
MS150115/00E 2013-10 | Appendix B | 183


Operating Instructions: Gas Engine 12 V 4000 Lx2 XX 16 V 4000 Lx2 XX

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MS150115/00E 2013-10 | Table of Contents | 3

DCL-ID: 0000029696 - 001

4 | Table of Contents | MS150115/00E 2013-10

MS150115/00E 2013-10 | Safety | 5

Working clothes and personal protective equipment

TIM-ID: 0000040531 - 002

6 | Safety | MS150115/00E 2013-10

Setting the engine down after transport

MS150115/00E 2013-10 | Safety | 7

Safety regulations for equipment operation

Malfunctions and emergency stop

Operation of electrical equipment

8 | Safety | MS150115/00E 2013-10

MS150115/00E 2013-10 | Safety | 9

Safety regulations during maintenance and repair work

10 | Safety | MS150115/00E 2013-10

Safety regulations after completion of maintenance and repair work

Hydraulic installation and removal

Working with batteries

MS150115/00E 2013-10 | Safety | 11

Working with laser equipment

TIM-ID: 0000040535 - 003

12 | Safety | MS150115/00E 2013-10

MS150115/00E 2013-10 | Safety | 13

Environmental protection and disposal

Consumable fluids and materials

coming into contact with ignition sources and do not smoke.

14 | Safety | MS150115/00E 2013-10

Paints and varnishes

Acids/alkaline solutions/urea (AdBlue®, DEF)

• Observe the relevant safety data sheet for all materials.

MS150115/00E 2013-10 | Safety | 15

Biogenic gases from fermentation processes

16 | Safety | MS150115/00E 2013-10

MS150115/00E 2013-10 | Safety | 17

1 Throttle, A side 6 Engine lifting equipment 11 Starter

18 | Product Summary | MS150115/00E 2013-10

Engine model designation

B Additional feature: B = Biogases from fermentation proc-

Table 2: Engine model designation

MS150115/00E 2013-10 | Product Summary | 19

1 Left-hand side of engine 3 Right-hand side of engine

TIM-ID: 0000002185 - 012

20 | Product Summary | MS150115/00E 2013-10

Length (A) for 12V approx. 2858 mm

Table 3: Main engine dimensions

MS150115/00E 2013-10 | Product Summary | 21

TIM-ID: 0000002806 - 001

22 | Product Summary | MS150115/00E 2013-10

Table 4: Reference conditions

General conditions (for max. power)

Intake air temperature, min. L °C 20 20

MS150115/00E 2013-10 | Product Summary | 23

Table 6: General conditions (for max. power)

Model-related data (basic design)

Table 8: Model-related data (basic design)