Operating Instructions Gas engine
Operating Instructions
Gas engine
20 V 4000 L62
MS150034/02E
Printed in Germany
© 2012 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, micro‐
filming 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
4 Maintenance
1 Safety
1.1
1.2
1.3
1.4
1.5
General conditions
Personnel and organizational requirements
Transport
Safety regulations for startup and operation
Safety requirements for maintenance and
repair work
1.6 Fluids and lubricants, fire prevention and
environmental protection
1.7 Conventions for safety instructions in the
text
5
6
7
8
9
12
15
Engine – Overview
Engine side and cylinder designations
Engine – Main dimensions
Firing order
Technical Data
2.5.1 Runtimes at partial load
2.5.2 20V 4000 L62 engine data, fuel optimized
(TA-Luft)
2.5.3 20 V 4000 L62 engine data, optimized
exhaust emissions (1/2 TA-Luft)
2.6 Monitoring, Control and Regulation
Equipment
2.6.1 Gas engine phase 3 system – Overview
2.6.2 Control cabinet MIS – Overview
2.6.3 Purpose of the units
16
18
19
20
21
21
22
26
30
30
32
33
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3 Operation
3.1 Putting the engine into operation after
extended out-of-service-periods (>3
months)
3.2 Putting the engine into operation after
scheduled out-of-service-period
3.3 Control, starting and stopping sequences
3.4 Starting the engine
3.5 Operational checks
3.6 Stopping the engine
3.7 Emergency stop
3.8 After stopping the engine – Engine remains
ready for operation
3.9 After stopping the engine – Putting the
engine out of operation
46
47
5 Troubleshooting
5.1 Fault indication on SAM display
5.2 SAM – Fault messages
5.3 Engine governor – Fault messages
48
52
102
6 Task Description
2 Product Summary
2.1
2.2
2.3
2.4
2.5
4.1 50-hours check
4.2 Maintenance task reference table [QL1]
6.1 Engine
133
6.2 Crankcase Breather
135
6.3 Ignition System
137
6.1.1 Engine – Barring manually
6.1.2 Checking machine room for smell of gas
6.2.1 Oil separator – Filter element replacement
6.3.1 Ignition system – Ignition timing check
6.3.2 Spark plug connector – Replacement
6.3.3 Spark plug connector – Removal and
installation
6.3.4 Spark plug – Replacement
6.3.5 Spark plug – Removal and installation
6.4 Valve Drive
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
Valve gear – Lubrication
Valve clearance – Check and adjustment
Valve depth – Measurement
Valve gear – Lubrication
Cylinder head cover – Removal and
installation
38
39
40
41
42
43
44
45
135
137
138
139
141
142
144
144
145
148
151
152
6.5 Gas System
153
6.6 Air Filter
154
6.7 Lube Oil System, Lube Oil Circuit
156
6.8 Oil Filtration / Cooling
159
6.9 Coolant Circuit, General, HighTemperature Circuit
160
6.5.1 Gas supply – Checking gas lines for leaks
37
133
134
6.6.1 Air filter – Replacement
6.6.2 Air filter – Removal and installation
6.7.1 Engine oil level – Check
6.7.2 Engine oil – Change
6.7.3 Engine oil – Sampling and analysis
6.8.1 Engine oil filter – Replacement
6.9.1 Engine coolant – Level check
153
154
155
156
157
158
159
160
MS150034/02E 2012-07 | Table of Contents | 3
6.9.2
6.9.3
6.9.4
6.9.5
Engine coolant – Change
Engine coolant – Draining
Engine coolant – Filling
Vent line of engine coolant circuit –
Replacement
6.10 Low-Temperature Circuit
6.10.1
6.10.2
6.10.3
6.10.4
Mixture coolant level - Check
Mixture coolant - Change
Mixture coolant - Draining
Mixture coolant - Filling
6.11 Wiring (General) for Engine/Gearbox/Unit
165
7 Appendix A
7.1 Abbreviations
7.2 MTU Onsite Energy contact / service
partner
174
176
166
166
167
168
169
170
170
171
8 Appendix B
8.1
8.2
8.3
8.4
Special Tools
Consumables
Spare Parts
Index
177
180
182
184
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6.11.1 Engine wiring – Check
6.11.2 Sensors – Overview
161
162
164
4 | Table of Contents | MS150034/02E 2012-07
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present 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
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
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Repair or engine overhaul must be carried out in workshops authorized by MTU.
MS150034/02E 2012-07 | Safety | 5
1.2 Personnel and organizational requirements
Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Working clothes and protective equipment
Wear proper protective clothing for all work.
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Use the necessary protective equipment for the given work to be done.
6 | Safety | MS150034/02E 2012-07
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.
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Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-tocase basis.
MS150034/02E 2012-07 | Safety | 7
1.4 Safety regulations for startup and operation
Safety precautions when putting the equipment into operation
Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐
tions and check the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems are working properly.
Safety regulations for equipment operation
Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of all operations to be 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.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
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Observe the safety instructions for these devices.
8 | Safety | MS150034/02E 2012-07
1.5 Safety requirements for maintenance and repair work
Safety requirements for maintenance and repair work
Maintenance and repair work may only be carried out by authorized, qualified personnel.
All work on gas-carrying components must be carried out by authorized, specialized companies.
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.
Before starting maintenance work, allow the engine to cool down (danger of explosion due to vapors),
shut off the gas supply to the engine and activate the emergency stop at the engine interface switch cabi‐
net (MIS) or by turning the keyswitch, if fitted.
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from engine. Cover the screw or plug with a
rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ risk of burning.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Prior to all work, allow the engine / genset to cool down.
Observe maintenance and repair instructions.
Never perform care or maintenance work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting.
With electric starter, disconnect the battery.
Close the main valve on the compressed-air system and vent the compressed-air line when air starters
are fitted.
Disconnect the control device from the assembly or plant.
Only use adequate, calibrated tools. During assembly and disassembly, observe the specified tightening
torques.
Carry out work only on assemblies or plants that are secured as specified.
Do not use lines as climbing aids.
Only use fuel lines or fuel system components that have been approved for the application in question.
Keep fuel lines and connections clean.
Always fit caps/covers to close off any openings exposed by removing or opening lines.
Take care to avoid damaging fuel lines in the course of care and maintenance work.
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Ensure that all mounts and dampers are correctly installed.
Ensure that all fuel lines and pressurized oil lines have sufficient distance to other components to avoid
contact with them. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) if they have carbonized or resinous appearance.
Note cooling period for components which are heated for installation or removal ⇒ Risk of burning!
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness during maintenance and repair work on the assembly or plant. After comple‐
tion of maintenance and repair work, make sure that no loose objects are in/on the assembly or plant.
Ensure that all personnel is clear of danger zones before turning the engine. Check that all guards have
been reinstalled and that all tools and loose parts have been removed after working on the engine.
MS150034/02E 2012-07 | Safety | 9
If starters with beryllium copper pinions are installed, the following also applies:
• To avoid health risks with the pinion containing beryllium, breathing protection of filter class P2 must
be worn during maintenance work. Do not blow out the interior of the flywheel housing and the starter
with compressed air. The interior of the flywheel housing must be additionally cleaned with a dustremoval machine of class H.
Welding work
Never carry out welding work on the assembly or engine plant or mounted units. Cover the engine when
welding in its vicinity.
Observe the following before starting welding work on the MTU electronic system:
• Switch the main power switch to "OFF".
• Disconnect the cables and the negative and positive poles of the battery.
Do not use the assembly or plant as a ground terminal.
Never place the welding cable across or near wiring harnesses of MTU plants. The welding current may
otherwise induce an interference voltage in the wiring harnesses which could damage the electrical sys‐
tem.
If welding has to be carried out on components (e.g. exhaust manifold), these components must first be
removed from the engine.
Hydraulic installation and removal
Check the tools and devices to be used for perfect operation and safe condition. Only use the specified
devices for force-fitting/removing parts.
Observe the maximum press-on pressure for the device for force-fitting/removing parts.
Do not attempt to bend or exert force on H.P. lines.
Observe the following before starting the pressing procedure:
• Bleed air from the device for force-fitting/removing parts, pumps and piping at the points provided for
the system concerned (e.g. open threaded vent plugs, pump until no bubbles can be discerned in the
oil, close threaded vent plugs).
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of
the component being pressed.
Working on electrical/electronic assemblies
Before starting any maintenance or repair work, or before switching off any electronic components nec‐
essary to carry out the work, permission must first be obtained from the relevant manager or supervisor.
Do not damage wiring during the removal work. When reinstalling, ensure that the wiring cannot be dam‐
aged during engine operation through contact with sharp edges, rubbing against a component or through
contact with a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable clamps to secure the lines.
Observe the following when working with batteries:
• Avoid sparks and naked flames.
• Keep electrolyte away from the skin and clothing. Wear protective goggles.
• Do not place tools on the battery.
• Before connecting the cable to the battery, check the battery polarity.
10 | Safety | MS150034/02E 2012-07
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Before work is carried out on the assemblies, the power supply to the relevant areas must be switched
off.
Only tighten union nuts of connectors with connector pliers.
On completion of all repair work, the device or system must undergo a function check.
Before replacement, ensure that spare parts are correctly stored, i.e. in particular, protected against
moisture. Defective electronic components and assemblies must be suitably packed when dispatched for
repair, i.e. in particular, protected against moisture and impact and wrapped in antistatic foil if necessary.
Work with laser devices
When working with laser equipment, always wear special laser-protection goggles ⇒ eye injury through
strongly concentrated beam.
Laser devices must be equipped, in accordance with their class and usage, with protective devices for
ensuring safe operation.
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For conducting light-beam procedures and measurement work, only the following laser devices may be
used:
• Laser devices in 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 have been designed in
such a way as to prevent any risk to the eyes.
MS150034/02E 2012-07 | Safety | 11
1.6 Fluids and lubricants, fire prevention and environmental
protection
Fire prevention
Correct fuel or oil leaks immediately. Quantities of oil or fuel on hot components can cause fires – there‐
fore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying on or near the assembly or plant. Do not store inflammable material near the assembly or plant.
Do not weld 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 have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with
its handling.
Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating
danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors.
Environmental protection and disposal
Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU. Noncom‐
pliance with these guidelines might represent a violation of the Clean Air Act and could involve the termi‐
nation of the operating license by the emission authorities. MTU does not accept any liability for viola‐
tions of the emission regulations. MTU will provide assistance and advice if emission-relevant compo‐
nents are intended to be modified. The MTU Maintenance Schedules ensure the reliability and perform‐
ance of MTU engines and must be complied with over the entire life cycle of the engine.
Only fuels of the specified quality required to achieve emission limits must be used.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Batteries can be returned within the EU to MTU FN / MTU Onsite Energy free of charge for correct recy‐
cling/disposal.
Fluids and lubricants
Fluids and lubricants must be kept in suitable, correctly labeled containers. When using fluids, lubricants
and other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
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.
12 | Safety | MS150034/02E 2012-07
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Use only fluids and lubricants that have been tested and approved by MTU.
Procedure in the case of accidental release of combustible gas:
•
•
•
•
•
Seal point of gas escape!
Remove ignition sources!
Cordon off danger zone.
Ensure sufficient ventilation!
Do not enter danger zone before measurements have confirmed that gas concentration is not hazard‐
ous.
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! Can no longer be detected by sense of
smell in higher concentrations.
Caution: There is always a risk 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 pres‐
sure, numbness of the extremeties, drowsiness, mental confusion and loss of memory!
Tendency 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 combustible gas:
• Seal point of gas escape!
• Remove ignition sources!
• Cordon off danger zone.
• Ensure sufficient ventilation!
• Do not enter danger zone before measurements have confirmed that gas concentration is not hazard‐
ous.
Used oil
Used oil contains combustion residue harmful to health.
Rub your hands with skin protection cream.
Wash your hands after contact with used oil.
Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Prevent the buildup of white powder of lead.
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash your hands!
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Compressed air
When working with compressed air, safety precautions must be constantly observed:
MS150034/02E 2012-07 | Safety | 13
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Assemblies or plants to be connected must either be designed for this pressure, or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing valve
and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Always wear protective goggles when blowing off tools or extracting chips.
• Provide the mouthpiece of the air nozzle with a protective disk (e.g. made of rubber).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting!
• Carry out the leak check as specified.
Painting
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No naked flames!
• No smoking!
• Observe all 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 specified containers without fixed covers.
Avoid body contact (eyes, hands).
Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask!
Make sure that working area is well ventilated.
Take great care not to subject containers, fittings and tools to impact or shock.
Acids/alkaline solutions
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• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective
clothing.
• If acids or alkalis are spilled onto clothing, remove the affected clothing immediately!
• Rinse injured parts of the body thoroughly with clean water!
• Rinse eyes immediately with eyedrops or clean mains water!
14 | Safety | MS150034/02E 2012-07
1.7 Conventions for safety instructions in the text
DANGER
WARNING
CAUTION
NOTICE
Note:
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
Read and familiarize yourself with all safety notices before starting up or repairing the product.
Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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1.
2.
MS150034/02E 2012-07 | Safety | 15
2 Product Summary
2.1 Engine – Overview
8 Coolant distribution
housing
9 Capacitor ignition sys‐
tem
10 Spark plug
11 Cylinder head cover
12 Ignition coil
13 Cylinder head
14 Starter (right side)
15 Flywheel
16 Starter (left side)
17 Engine governor/engine
monitoring
18 Throttle (right side)
KS Driving end
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1 Air filter/air inlet
2 Engine coolant outlet
connection from cooler
3 Engine coolant inlet
connection to cooler
4 Gas inlet connection
5 Gas dosing and mixing
unit (Tecjet)
6 Gas outlet
7 Engine oil heat ex‐
changer
16 | Product Summary | MS150034/02E 2012-07
1 Engine coolant inlet
connection from cooler
2 Crankcase breather/oil
separator
3 Exhaust turbocharger
4 Gas mixer
5 Throttle (left side)
6 Engine lifting equipment,
driving end
7 Engine mounting brack‐
et, driving end
8 Oil pan
9 Engine lifting equipment,
free end
10 Engine mounting brack‐
et, free end
11
12
13
14
Engine oil filter
Engine oil sampling port
Oil level switch
Engine coolant inlet
connection to cooler
KGS Free end
Engine model designation
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Explanation of the engine model designation 20V 4000 L62/L63
20
Number of cylinders
V
Cylinder arrangement: V engine
4000
Series
L
Application: L = Gas engine
6
Application segment
2, 3
Design index
MS150034/02E 2012-07 | Product Summary | 17
2.2 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
3 Right engine side
4 KS = Driving end
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1 Left engine side
2 KGS = Free end
18 | Product Summary | MS150034/02E 2012-07
2.3 Engine – Main dimensions
Main engine dimensions
Length (A)
approx. 3800 mm
Width (B)
approx. 1487 mm
Height (C)
approx. 2250 mm
Crankshaft center to oil pan (D)
approx. 636 mm
Crankshaft center to engine mount (E)
approx. 281 mm
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Table 1: Main engine dimensions
MS150034/02E 2012-07 | Product Summary | 19
2.4 Firing order
Firing order
A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
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20 V
20 | Product Summary | MS150034/02E 2012-07
2.5 Technical Data
2.5.1
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 re‐
duce maintenance to a minimum:
Power, referenced to nominal
load
Recommended maximum run‐
time
at this load
Recommended minimum runtime
in subsequent operation
at load > 50 %
30 minutes
120 minutes
30 % to 50 %
120 minutes
120 minutes
50 % to 100 %
No restriction
No restriction
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0 % to 30 %
MS150034/02E 2012-07 | Product Summary | 21
2.5.2
20V 4000 L62 engine data, fuel optimized (TA-Luft)
Explanation:
DL
BL
A
G
R
L
N
X
Reference value: Continuous power
Reference value: Fuel stop power
Design value
Guaranteed value
Guideline value
Limit value, up to which the engine can be operated, without change (e.g. of power setting)
Not yet defined value
Not applicable
Applicable
Reference conditions
Engine model
20V 4000
L62
Application group
3A
Intake air temperature
°C
25
Charge-air coolant temperature
°C
40
Barometric pressure
mbar
Site altitude above sea level
m
1000
100
Table 2: Reference conditions
Power-related data (power ratings are net brake power to ISO 3046)
Number of cylinders
Rated engine speed
20
A
Mean piston speed
Continuous power as per ISO 3046
A
Mean effective pressure (pme) (continuous power ISO 3046)
rpm
1500
m/s
10.5
kW
2000
bar
16.8
Table 3: Power-related data (power ratings are net brake power to ISO 3046)
General conditions (for max. power)
20
Relative air humidity
A
%
30
Intake air temperature
A
°C
25
Intake air temperature, min.
L
°C
20
Intake air temperature, max.
L
°C
30
Mixture temperature after mixture cooler
A
°C
50
Ambient intake depression, max.
L
mbar
3
Pressure loss over air filter, max.
L
mbar
30
Exhaust back pressure, max.
L
mbar
60
Gas type: natural gas
Methane number, min.
Table 4: General conditions (for max. power)
22 | Product Summary | MS150034/02E 2012-07
X
L
70
TIM-ID: 0000010824 - 002
Number of cylinders
Consumption
Number of cylinders
20
Lube oil consumption after 1000 h runtime
g/kWh
0.2
Table 5: Consumption
Model-related data (basic design)
Number of cylinders
20
Operating method: Four-stroke cycle, Otto engine, single-acting
X
Combustion method: Mixture charging, spark ignition
X
Number of cylinders
20
Cylinder arrangement: V angle
Degrees
(°)
Bore
mm
170
Stroke
mm
210
Displacement of a cylinder
Liters
4.77
Total displacement
Liters
95.33
Compression ratio
90
12.9
Standard housing connecting flange (engine main PTO)
SAE
00
Table 6: Model-related data (basic design)
Coolant system (HT circuit)
Number of cylinders
20
Coolant temperature (at engine connection: outlet to cooling equipment) (w/ A
o antifreeze)
°C
90
Coolant temperature (at engine connection: inlet from cooling equipment
(w/o antifreeze)
A
°C
78
Coolant temperature after engine, warning
R
°C
95
Coolant temperature after engine, shutdown
L
°C
98
Coolant temperature to enable load application, min.
L
°C
40
Coolant antifreeze content, max.
L
%
50
Coolant pump: Volumetric flow
L
m³/h
77
Filling pressure in cooling system (cold)
R
bar
0.5
Pressure in cooling system, max.
L
bar
6.0
bar
1.8
TIM-ID: 0000010824 - 002
Pressure loss over engine (at nominal flow rate 7.27)
Thermostat: Starts to open
R
°C
68
Thermostat: Opening stops (thermostat fully open and bypass closed)
A
°C
74
Table 7: Coolant system (HT circuit)
Coolant system (LT circuit)
Number of cylinders
20
Coolant temperature before mixture cooler (at engine connection: inlet from A
cooling equipment (w/o antifreeze)
°C
40
Coolant antifreeze content, max.
%
50
L
MS150034/02E 2012-07 | Product Summary | 23
Number of cylinders
20
Coolant pump: Volumetric flow
A
m³/h
31
Pressure in cooling system, max.
L
bar
6.0
bar
1.0
Pressure loss over mixture cooler (at nominal flow rate 8.56)
Table 8: Coolant system (LT circuit)
Lube oil system
Number of cylinders
20
Lube oil operating temperature after oil heat exchanger, from
R
°C
82
Lube oil operating temperature after oil heat exchanger, to
R
°C
90
Lube oil operating temperature after oil heat exchanger, warning
R
°C
93
Lube oil operating temperature after oil heat exchanger, engine shutdown
L
°C
97
bar
5.0
Lube oil pressure after oil filter
Lube oil pressure after oil filter, warning
R
bar
5.0
Lube oil pressure after oil filter, shutdown
L
bar
4.5
Table 9: Lube oil system
Fuel system
Number of cylinders
20
Gas temperature before engine, min.
L
°C
10
Gas temperature before engine, max.
L
°C
40
Gas flow pressure before Tecjet, min.
L
mbar
80
Gas flow pressure before Tecjet, max.
L
mbar
200
Table 10: Fuel system
General operating data
Number of cylinders
20
Cold start capability: Air temperature (w/o starting aid, with preheating) (case C)
R
°C
15
Site condition (for case C): Engine coolant temperature
R
°C
40
Minimum idling speed
A
rpm
1500
Limit speed for overspeed alarm/emergency shutdown
L
rpm
1900
Starting (electric)
Number of cylinders
20
Starter, rated power (standard design)
R
kW
Rated starter voltage (standard design)
R
V
24
Starter, current consumption, max. (standard design)
R
A
2 x 2500
Starting-attempt duration, max.
L
s
15
Number of teeth on starter ring gear
Table 12: Starting (electric)
24 | Product Summary | MS150034/02E 2012-07
2x9
182
TIM-ID: 0000010824 - 002
Table 11: General operating data
Capacities
Number of cylinders
20
Engine coolant capacity, engine side (without cooling equipment)
R
Liters
310
Mixture coolant, engine side (without cooling system)
R
Liters
23
Total engine oil capacity for initial filling (standard oil system)
R
Liters
378
Oil change capacity, max. (standard oil system)
R
Liters
350
Table 13: Capacities
Weights / main dimensions
Number of cylinders
20
Dry engine weight (basic-configuration engine)
R
kg
9217
Heaviest component to be lifted during extended component maintenance
(QL3)
R
kg
440
Exhaust emission before catalytic converter at 100 % DL nitric oxides
(NOx) (in dry exhaust gas, 5 % O2)
G
mg/m n
500
Exhaust emission before catalytic converter at 100 % DL nitric oxides
(NOx) (in dry exhaust gas)
A
ppm
176
Table 14: Weights / main dimensions
Exhaust emissions
Number of cylinders
20
3
Table 15: Exhaust emissions
Acoustics
Number of cylinders
20
Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798)
R
dB(A)
113
Genset surface noise with attenuated intake noise filter) - DL (sound power
level LW, ISO 8528-10)
R
dB(A)
123
TIM-ID: 0000010824 - 002
Table 16: Acoustics
MS150034/02E 2012-07 | Product Summary | 25
2.5.3
20 V 4000 L62 engine data, optimized exhaust emissions (1/2 TA-Luft)
Explanation:
DL
BL
A
G
R
L
N
X
Reference value: Continuous power
Reference value: Fuel stop power
Design value
Guaranteed value
Guideline value
Limit value, up to which the engine can be operated, without change (e.g. of power setting)
Not yet defined value
Not applicable
Applicable
Reference conditions
Engine model
20V 4000
L62
Application group
3A
Intake air temperature
°C
25
Charge-air coolant temperature
°C
40
Barometric pressure
mbar
Site altitude above sea level
m
1000
100
Table 17: Reference conditions
Power-related data (power ratings are net brake power to ISO 3046)
Number of cylinders
Rated engine speed
20
A
Mean piston speed
Continuous power as per ISO 3046
A
Mean effective pressure (pme) (continuous power ISO 3046)
rpm
1500
m/s
10.5
kW
2000
bar
16.8
Table 18: Power-related data (power ratings are net brake power to ISO 3046)
General conditions (for max. power)
20
Relative air humidity
A
%
30
Intake air temperature
A
°C
25
Intake air temperature, min.
L
°C
20
Intake air temperature, max.
L
°C
30
Mixture temperature after mixture cooler
A
°C
50
Ambient intake depression, max.
L
mbar
3
Pressure loss over air filter, max.
L
mbar
30
Exhaust back pressure, max.
L
mbar
60
Gas type: natural gas
Methane number, min.
Table 19: General conditions (for max. power)
26 | Product Summary | MS150034/02E 2012-07
X
L
70
TIM-ID: 0000010858 - 002
Number of cylinders
Consumption
Number of cylinders
20
Lube oil consumption after 1000 h runtime
g/kWh
0.2
Table 20: Consumption
Model-related data (basic design)
Number of cylinders
20
Operating method: Four-stroke cycle, Otto engine, single-acting
X
Combustion method: Mixture charging, spark ignition
X
Number of cylinders
20
Cylinder arrangement: V angle
Degrees
(°)
Bore
mm
170
Stroke
mm
210
Displacement of a cylinder
Liters
4.77
Total displacement
Liters
95.33
Compression ratio
90
12.9
Standard housing connecting flange (engine main PTO)
SAE
00
Table 21: Model-related data (basic design)
Coolant system (HT circuit)
Number of cylinders
20
Coolant temperature (at engine connection: outlet to cooling equipment) (w/ A
o antifreeze)
°C
90
Coolant temperature (at engine connection: inlet from cooling equipment
(w/o antifreeze)
A
°C
78
Coolant temperature after engine, warning
R
°C
95
Coolant temperature after engine, shutdown
L
°C
98
Coolant temperature to enable load application, min.
L
°C
40
Coolant antifreeze content, max.
L
%
50
Coolant pump: Volumetric flow
L
m³/h
77
Filling pressure in cooling system (cold)
R
bar
0.5
Pressure in cooling system, max.
L
bar
6.0
bar
1.8
TIM-ID: 0000010858 - 002
Pressure loss over engine (at nominal flow rate 7.27)
Thermostat: Starts to open
R
°C
68
Thermostat: Opening stops (thermostat fully open and bypass closed)
A
°C
74
Table 22: Coolant system (HT circuit)
Coolant system (LT circuit)
Number of cylinders
20
Coolant temperature before mixture cooler (at engine connection: inlet from A
cooling equipment (w/o antifreeze)
°C
40
Coolant antifreeze content, max.
%
50
L
MS150034/02E 2012-07 | Product Summary | 27
Number of cylinders
20
Coolant pump: Volumetric flow
A
m³/h
31
Pressure in cooling system, max.
L
bar
6.0
bar
1.0
Pressure loss over mixture cooler (at nominal flow rate 8.56)
Table 23: Coolant system (LT circuit)
Lube oil system
Number of cylinders
20
Lube oil operating temperature after oil heat exchanger, from
R
°C
82
Lube oil operating temperature after oil heat exchanger, to
R
°C
90
Lube oil operating temperature after oil heat exchanger, warning
R
°C
93
Lube oil operating temperature after oil heat exchanger, engine shutdown
L
°C
97
bar
5.0
Lube oil pressure after oil filter
Lube oil pressure after oil filter, warning
R
bar
5.0
Lube oil pressure after oil filter, shutdown
L
bar
4.5
Table 24: Lube oil system
Fuel system
Number of cylinders
20
Gas temperature before engine, min.
L
°C
10
Gas temperature before engine, max.
L
°C
40
Gas flow pressure before Tecjet, min.
L
mbar
80
Gas flow pressure before Tecjet, max.
L
mbar
200
Table 25: Fuel system
General operating data
Number of cylinders
20
Cold start capability: Air temperature (w/o starting aid, with preheating) (case C)
R
°C
15
Site condition (for case C): Engine coolant temperature
R
°C
40
Minimum idling speed
A
rpm
1500
Limit speed for overspeed alarm/emergency shutdown
L
rpm
1900
Starting (electric)
Number of cylinders
20
Starter, rated power (standard design)
R
kW
Rated starter voltage (standard design)
R
V
24
Starter, current consumption, max. (standard design)
R
A
2 x 2500
Starting-attempt duration, max.
L
s
15
Number of teeth on starter ring gear
Table 27: Starting (electric)
28 | Product Summary | MS150034/02E 2012-07
2x9
182
TIM-ID: 0000010858 - 002
Table 26: General operating data
Capacities
Number of cylinders
20
Engine coolant capacity, engine side (without cooling equipment)
R
Liters
310
Mixture coolant, engine side (without cooling system)
R
Liters
23
Total engine oil capacity for initial filling (standard oil system)
R
Liters
378
Oil change capacity, max. (standard oil system)
R
Liters
350
Table 28: Capacities
Weights / main dimensions
Number of cylinders
20
Dry engine weight (basic-configuration engine)
R
kg
9217
Heaviest component to be lifted during extended component maintenance
(QL3)
R
kg
440
Exhaust emission before catalytic converter at 100 % DL nitric oxides
(NOx) (in dry exhaust gas, 5 % O2)
G
mg/m n
Exhaust emission before catalytic converter at 100 % DL nitric oxides
(NOx) (in dry exhaust gas)
A
ppm
Table 29: Weights / main dimensions
EXHAUST EMISSIONS
Number of cylinders
20
3
250
87
Acoustics
Number of cylinders
20
Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798)
R
dB(A)
113
Genset surface noise with attenuated intake noise filter) - DL (sound power
level LW, ISO 8528-10)
R
dB(A)
123
TIM-ID: 0000010858 - 002
Table 30: Acoustics
MS150034/02E 2012-07 | Product Summary | 29
2.6 Monitoring, Control and Regulation Equipment
2.6.1
Gas engine phase 3 system – Overview
Overview
1
2
3
4
Genset system
Engine system
Genset
Engine governor
5
6
7
8
Engine monitoring
NOx sensor
Compressor bypass
Ignition
9 Knock module
10 Gas metering unit
11 Throttles
Governing/control/monitoring
•
•
•
•
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
SAM
• Interface module to unit control
• Monitors second gas solenoid in gas train to engine
• Diagnostic interface
Engine Monitoring Unit EMU
• Evaluation unit for PT 1000 temperature sensor to determine and monitor exhaust temperatures of in‐
dividual cylinders
30 | Product Summary | MS150034/02E 2012-07
TIM-ID: 0000017542 - 002
Engine governor ADEC (ECU-7)
Compressor bypass (F-series)
• Controls throttle reserve, blocks compressor pumps
Ignition system IC922
• Adjusts ignition timing for cylinders
Anti-knock control AKR
• Controls monitored cylinders with regard to knock characteristics. If knocking is found, the ignition tim‐
ing is retarded on the cylinder in question. If this does not result in an improvement, the power is re‐
duced.
Gas control valve TecJet50+
• Controls the required amount of gas
Mixture throttles ProAct
TIM-ID: 0000017542 - 002
• The mixture throttles in the mixture lines which are controlled by the engine governor
MS150034/02E 2012-07 | Product Summary | 31
2.6.2
Control cabinet MIS – Overview
Phase 3 gas engine control cabinet MIS – Overview
A Control cabinet door,
external side
B Mounting plate
1 SAM
2 Automatic cutout 6A
3 Relay
4 Terminal block
5 Automatic cutout 32A
6 Automatic cutout 16A
7 Emergency stop (key
switch)
F001
Starter A bank, starter B bank
F002
Throttle A bank, throttle B bank
F003
Ignition system
F004
Anti knock control AKR
F005
Emergency stop system
F006
TecJet50+
F007
SAM
F008
ADEC (ECU 7), EMU
F009
Bypass throttle
32 | Product Summary | MS150034/02E 2012-07
TIM-ID: 0000017700 - 001
Fuses
2.6.3
Purpose of the units
Engine governor ADEC (ECU 7)
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)
Acquisition and evaluation of engine operating states
Limit value monitoring
Self-monitoring and self-diagnostic functions
• Integral status/fault display
• Fault memory
Large number of inputs/outputs provided:
• Genset side: 14 inputs, 7 outputs, 2 serial interfaces,
• Engine side: 39 inputs, 28 outputs, 1 serial interface
Engine and genset-related parameter settings in flash memory
In case 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)
TIM-ID: 0000017541 - 001
Software structure:
• One data record for engine software
• One data record for genset software
MS150034/02E 2012-07 | Product Summary | 33
Service and Automation Module SAM
1 Module cassette, slots
for additional I/O PIM
cards
2 Compact Flash Memory
card
3 Display for fault code
and Mini Dialog
4 Control keys for Mini Di‐
alog
5 Diagnostic lamp
6 Interface for dialog unit
7 Connector with spring
design
SAM functions
• Display of fault codes from engine governor and SAM (3).
• Backup function, engine life data are stored
• every hour,
• after every engine stop
• after every emergency engine stop.
• Interface for dialog unit.
• Straightforward diagnosis by fault code display.
• Self-diagnosis by diagnostic lamp (5).
• Steady = SAM is OK.
• Flashing = SAM is faulty, contact Service.
• Dark = Supply voltage missing.
34 | Product Summary | MS150034/02E 2012-07
TIM-ID: 0000017541 - 001
Diagnosis
Customer interface
•
•
•
•
•
•
•
•
24 binary outputs
3 PWM outputs
8 display outputs
28 channel binary input
10 analog inputs (e.g. PT100, 4–20 mA, 0-10 V, etc.)
4 frequency inputs
1 dialog interface
Extendable with MCS 5 PIM I/O cards
CANOpen and SAE-J1939 interface
For CANOpen and J1939 interface, a type CCB2 printed circuit board (1) is inserted in slot 3 of the SAM
unit.
TIM-ID: 0000017541 - 001
Engine Monitoring Unit EMU
EMU = Engine Monitoring Unit
MS150034/02E 2012-07 | Product Summary | 35
Monitoring unit for the engine
• Acquisition and processing of cylinder exhaust temperatures
TIM-ID: 0000017541 - 001
Self-monitoring
36 | Product Summary | MS150034/02E 2012-07
3 Operation
3.1 Putting the engine into operation after extended out-ofservice-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
Task
Engine
Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Engine
Bar engine manually (→ Page 133)
Valve drive
Out-of-service period ≥ 6 months: Grease valve drive (→ Page 144).
Lube oil system
Check engine oil level (→ Page 156);
Checking oil level in oil storage tank (→ Page 156).
Coolant circuit
Out-of-service period more than 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)
Check plug connections (→ Page 170).
Gas supply
Open gas shut-off valve
Engine management sys‐
tem
Check for fault messages.
Battery
Check, fill with electrolyte (manufacturer's specifications).
TIM-ID: 0000010102 - 001
Engine wiring
MS150034/02E 2012-07 | Operation | 37
3.2 Putting the engine into operation after scheduled out-ofservice-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)
Check for fault messages.
TIM-ID: 0000010660 - 002
Engine management sys‐
tem
38 | Operation | MS150034/02E 2012-07
3.3 Control, starting and stopping sequences
Starting and stopping sequences
The start 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 require‐
ment for gas engines, special procedures for engine start / stop are specified.
Start sequence
If a start command is activated with the engine being at standstill, the following steps are carried out au‐
tomatically:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
(Optional) Prelubricating until the desired oil pressure is reached
Checking gas supply solenoid valves for leaks
Activating starter
Waiting for starting speed
Flushing the engine
Ignition
Opening gas supply solenoid valves
Waiting for starter disengagement speed
Disengaging starter
Waiting for idling speed
Runup to rated speed
Stop sequence
If a stop command is activated, the following steps are carried out automatically:
1. Closing gas supply solenoid valves
2. Coasting down engine to standstill or for a maximum coasting period
3. Deactivating ignition
Emergency stop sequence
If an emergency stop command is activated, the following steps are carried out automatically:
1. Closing gas supply solenoid valves and mixture throttles
2. Coasting down engine to standstill for a maximum coasting period
3. Deactivating ignition
TIM-ID: 0000017305 - 002
Oil refill sequence
1.
2.
3.
4.
5.
6.
7.
Waiting for engine running
Engine running for a minimum (parameterized) time period
Oil refilling enabled
When oil refill request is received
Refilling oil (automatically)
When oil refill request is canceled
Stopping oil refilling (automatically)
MS150034/02E 2012-07 | Operation | 39
3.4 Starting the engine
Preconditions
☑ Generator not connected to network
☑ Start interlock is not active.
DANGER
WARNING
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
TIM-ID: 0000010119 - 003
Engine starting (for control operations, see “Genset control system” documentation)
40 | Operation | MS150034/02E 2012-07
3.5 Operational checks
DANGER
WARNING
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Operational checks
Item
Task
Machine room
Check machine room for smell of gas (→ Page 134).
Display SAM
Check for fault messages;
If fault messages are displayed: Determine the cause, rectify the fault.
Check indicated operating parameters (speed, temperatures, pressures)
Operation log (if provided)
Document operating parameters.
• This is especially useful for fault localization and fast remedial action.
Engine under load,
Check engine/plant and all pipework visually for leaks, rectify any leaks
with the engine stopped;
Check for abnormal running noises and vibration.
TIM-ID: 0000010134 - 001
Engine at nominal speed
MS150034/02E 2012-07 | Operation | 41
3.6 Stopping the engine
Preconditions
☑ Generator is not connected to network.
CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.
TIM-ID: 0000010152 - 002
Stopping the engine (For control operations, refer to documentation “Genset control
system”)
42 | Operation | MS150034/02E 2012-07
3.7 Emergency stop
CAUTION
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Emergency stop
Item
Task
Emergency stop button
Press.
• Engine is stopped.
Safety measures
Item
Task
Emergency stop button
Remove key.
Rectifying cause
Item
Task
Engine control system
Determine cause for emergency stop and take remedial action;
if the fault cannot be corrected, contact Service.
Prior to re-starting the engine
Task
Emergency stop button
(key switch)
Unlock.
TIM-ID: 0000010162 - 001
Item
MS150034/02E 2012-07 | Operation | 43
3.8 After stopping the engine – Engine remains ready for
operation
After stopping the engine
Item
Measure
Engine / genset control
system
• Engine is in stop mode.
TIM-ID: 0000010170 - 002
For engine restart, refer to documentation “Genset control system”.
44 | Operation | MS150034/02E 2012-07
3.9 After stopping the engine – Putting the engine out of
operation
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
After stopping the engine
Item
Task
Coolant system
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 coolant is not maintained at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Power supply to engine
control system
Switch OFF.
Gas supply
Close gas shutoff valve.
Air intake and exhaust sys‐ If the engine is to remain out of service for more than 1 week, seal the
tems
engine's air and exhaust sides. If the engine is to remain out of operation
for more than 1 month, preserve engine (→ MTU Fluids and Lubricants
Specifications A001061/.. ).
Charge regularly (trickle charge).
Control-voltage battery
(batteries)
If fitted: Charge regularly (trickle charge).
TIM-ID: 0000002710 - 001
Starter battery (batteries)
MS150034/02E 2012-07 | Operation | 45
4 Maintenance
4.1 50-hours check
50-hours check
One-time operations to be carried out after the first 50 operating hours of the cylinder head (with a new
engine, after installation of new cylinder heads, after component maintenance or extended component
maintenance).
When installing a cylinder head with run-in mating faces (e.g. after piston replacement), a repeated
check after the first 50 operating hours is not necessary.
Qualifica‐ Interval
tion
[hours]
[years]
QL1
-
Tasks
Task
Valve gear
Check valve clearance (→ Page 145)
-
TIM-ID: 0000002785 - 001
-
Item
46 | Maintenance | MS150034/02E 2012-07
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
Measures
W0501
Visually inspect engine for leaks and general condition
(→ Page 41)
W0509
Check machine room for smell of gas
(→ Page 134)
W0523
Check for abnormal running noises and vibrations
–
W0527
Check engine oil level in storage tank
(→ Page 156)
W1002
Check valve clearance
(→ Page 145)
W1005
Replace air filter
(→ Page 154)
W1008
Replace engine oil filter at each oil change or when the time
limit (years) is reached, at the latest
(→ Page 159)
W1046
Crankcase breather: Replace filter or filter element
(→ Page 135)
W1089
Check gas lines for leaks, seal if required
(→ Page 153)
W1091
Check ignition timing, readjust as necessary
(→ Page 137)
W1168
Replace spark plugs
(→ Page 142)
W1341
Check exhaust emissions, adjust if required
–
W1382
Replace vent line of engine coolant circuit (8/12/16V only)
(→ Page 165)
W1688
Replace spark plug connectors
(→ Page 138)
W1689
Measure valve depth
(→ Page 148)
TIM-ID: 0000035884 - 003
Table 31: Maintenance task reference table [QL1]
MS150034/02E 2012-07 | Maintenance | 47
5 Troubleshooting
5.1 Fault indication on SAM display
General abbreviations used
The following general abbreviations are used in the fault message texts:
Abbreviation
Meaning
DL <Number>
Default Lost: The device identified by <number> has no connection to
the Default CAN bus.
RL <number>
Redundant Lost: The device identified by <number> has no connection
to the Redundant CAN bus.
SD <sensor designation>
Sensor defect: The sensor identified by <sensor designation> does not
provide an evaluable signal.
MD
Missing Data: A measuring point does not provide data.
AL
Alarm: Alarm message
SS
Safety System: The safety system responded in one of the specified
ways.
TD
Transmitter Deviation: Two sensors which acquire the measured val‐
ues of the same medium provide different measured values.
HI
High: The first limit value has 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 a node failure on the Default field bus.
PB
Push Button: Condition after activating certain control buttons.
AKR
AntiKlopfRegelung (Anti Knock Control GET)
Fault indication on SAM display
TIM-ID: 0000017545 - 001
The fault messages are generated by the engine governor ADEC (ECU) and by the SAM unit and trans‐
mitted to the SAM display (4).
48 | Troubleshooting | MS150034/02E 2012-07
The two lines (16-digit) on the alarm side have the following structure:
• 1st line: fault description
The following information is given here:
• Time window (1)
The letter indicates when the fault occurred. It is updated automatically:
• A: currently active alarm
• B: within the last hour (active alarms switch to B immediately)
• C: within the past 1-4 hours
• D: within the past 4-12 hours
• E: more than 12 hours ago
• Fault type code (2)
These two letters indicate the source of a fault:
• SE
Stands for System Error. The fault number (→ Page 50) and the number of the device that
caused the fault indicated in the following.
• ECU (ADEC) – 02
• EMU – 03
• SAM – 06
• AL
This is a fault message from the SAM. This code is always followed by a 6-digit number indicat‐
ing the fault code from the SAM.
• EC
This is an alarm message from the engine governor. This code is always followed by a 3-digit
number (3) indicating the fault code from the engine governor.
• 2nd line: plain text message that rolls if the text has more than 16 characters, providing more informa‐
tion about the faults currently displayed.
TIM-ID: 0000017545 - 001
Proceed to the next alarm by pressing key (↓ ↑).
Important information about fault messages from the SAM
Fault messages from the SAM are represented in the fault code list (→ Page 52).
Only persons with a corresponding qualification/training at MTU are allowed to carry out the measures
listed below.
Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
Important information about fault messages from the engine governor
Fault messages from the engine governor are represented in the fault code list (→ Page 102).
MS150034/02E 2012-07 | Troubleshooting | 49
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 manu‐
facturer).
Only persons with a corresponding qualification/training at MTU are allowed to carry out the measures
listed below.
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.
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.
SE No.
Fault message text
0
Sensor Temperature Defect
1
Temperature failure
2
Sensor Voltage Defect
3
Voltage failure
4
CAN Bus- 1 Error/Bus Defec
5
CAN Bus- 1 Overrun
6
CAN Bus- 2 Error/Bus Defec
7
CAN Bus- 2 Overrun
8
Temperature Compensation Error
9
I/O-Module Slot2 Defect
10
I/O-Module Slot3 Defect
11
I/O-Module Slot4 Defect
12
Serial Connection Lost
13
CAN Bus- 3 Error/Bus Defec
14
CAN Bus- 3 Overrun
15
S/A Bus Faulty
16
PAN 1 Defect
17
PAN 2 Defect
18
PAN 3 Defect
19
PAN 4 Defect
20
PAN 5 Defect
21
PAN 6 Defect
22
I/O-Module Slot1 Defect
23
I/O-Module Slot5 Defect
24
I/O-Module Slot6 Defect
25
I/O-Module Slot7 Defect
50 | Troubleshooting | MS150034/02E 2012-07
TIM-ID: 0000017545 - 001
SE (System Error) alarms
Fault message text
26
I/O-Module Slot8 Defect
27
Download Server Collision
28
not projected node
29
Device specific error
30
not projected node
31
Device specific error
TIM-ID: 0000017545 - 001
SE No.
MS150034/02E 2012-07 | Troubleshooting | 51
5.2 SAM – Fault messages
112222 – HI T-Exhaust Mean
Yellow alarm. Initiated by EMU.
Cause
The average value of all
individual cylinder exhaust
temperatures is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112223 – HIHI T-Exhaust Mean
Red alarm. Initiated by EMU.
Cause
The average value of all
individual cylinder exhaust
temperatures is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112301 – HI T-Exhaust A1
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112302 – HI T-Exhaust A2
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112303 – HI T-Exhaust A3
Yellow alarm. Initiated by EMU.
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112304 – HI T-Exhaust A4
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
52 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
Cause
112305 – HI T-Exhaust A5
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112306 – HI T-Exhaust A6
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112307 – HI T-Exhaust A7
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112308 – HI T-Exhaust A8
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112309 – HI T-Exhaust A9
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
112310 – HI T-Exhaust A10
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
MS150034/02E 2012-07 | Troubleshooting | 53
112311 – HI T-Exhaust B1
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112312 – HI T-Exhaust B2
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112313 – HI T-Exhaust B3
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112314 – HI T-Exhaust B4
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112315 – HI T-Exhaust B5
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
54 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
112316 – HI T-Exhaust B6
112317 – HI T-Exhaust B7
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112318 – HI T-Exhaust B8
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112319 – HI T-Exhaust B9
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112320 – HI T-Exhaust B10
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112401 – LO T-Exhaust A1
Yellow alarm. Initiated by EMU.
Cause
TIM-ID: 0000017543 - 001
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112402 – LO T-Exhaust A2
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
MS150034/02E 2012-07 | Troubleshooting | 55
112403 – LO T-Exhaust A3
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112404 – LO T-Exhaust A4
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112405 – LO T-Exhaust A5
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112406 – LO T-Exhaust A6
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112407 – LO T-Exhaust A7
Yellow alarm. Initiated by EMU.
The exhaust temperature of this
cylinder is too low as compared
with the average value.
56 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
TIM-ID: 0000017543 - 001
Cause
112408 – LO T-Exhaust A8
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112409 – LO T-Exhaust A9
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112410 – LO T-Exhaust A10
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112411 – LO T-Exhaust B1
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112412 – LO T-Exhaust B2
Yellow alarm. Initiated by EMU.
TIM-ID: 0000017543 - 001
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
MS150034/02E 2012-07 | Troubleshooting | 57
112413 – LO T-Exhaust B3
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112414 – LO T-Exhaust B4
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112415 – LO T-Exhaust B5
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112416 – LO T-Exhaust B6
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112417 – LO T-Exhaust B7
Yellow alarm. Initiated by EMU.
The exhaust temperature of this
cylinder is too low as compared
with the average value.
58 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
TIM-ID: 0000017543 - 001
Cause
112418 – LO T-Exhaust B8
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112419 – LO T-Exhaust B9
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112420 – LO T-Exhaust B10
Yellow alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112501 – HIHI T-Exhaust A1
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112502 – HIHI T-Exhaust A2
Red alarm. Initiated by EMU.
TIM-ID: 0000017543 - 001
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112503 – HIHI T-Exhaust A3
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
MS150034/02E 2012-07 | Troubleshooting | 59
112504 – HIHI T-Exhaust A4
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112505 – HIHI T-Exhaust A5
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112506 – HIHI T-Exhaust A6
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112507 – HIHI T-Exhaust A7
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112508 – HIHI T-Exhaust A8
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
60 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
112509 – HIHI T-Exhaust A9
112510 – HIHI T-Exhaust A10
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112511 – HIHI T-Exhaust B1
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112512 – HIHI T-Exhaust B2
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112513 – HIHI T-Exhaust B3
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112514 – HIHI T-Exhaust B4
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
112515 – HIHI T-Exhaust B5
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high as compared
with the average value.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
MS150034/02E 2012-07 | Troubleshooting | 61
112516 – HIHI T-Exhaust B6
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too high as compared
with the average value.
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112517 – HIHI T-Exhaust B7
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too high as compared
with the average value.
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112518 – HIHI T-Exhaust B8
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too high as compared
with the average value.
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112519 – HIHI T-Exhaust B9
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too high as compared
with the average value.
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112520 – HIHI T-Exhaust B10
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too high as compared
with the average value.
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
62 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
TIM-ID: 0000017543 - 001
112601 – LOLO T-Exhaust A1
112602 – LOLO T-Exhaust A2
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112603 – LOLO T-Exhaust A3
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112604 – LOLO T-Exhaust A4
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112605 – LOLO T-Exhaust A5
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112606 – LOLO T-Exhaust A6
Red alarm. Initiated by EMU.
TIM-ID: 0000017543 - 001
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
MS150034/02E 2012-07 | Troubleshooting | 63
112607 – LOLO T-Exhaust A7
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112608 – LOLO T-Exhaust A8
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112609 – LOLO T-Exhaust A9
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112610 – LOLO T-Exhaust A10
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112611 – LOLO T-Exhaust B1
Red alarm. Initiated by EMU.
The exhaust temperature of this
cylinder is too low as compared
with the average value.
64 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
TIM-ID: 0000017543 - 001
Cause
112612 – LOLO T-Exhaust B2
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112613 – LOLO T-Exhaust B3
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112614 – LOLO T-Exhaust B4
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112615 – LOLO T-Exhaust B5
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112616 – LOLO T-Exhaust B6
Red alarm. Initiated by EMU.
TIM-ID: 0000017543 - 001
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
MS150034/02E 2012-07 | Troubleshooting | 65
112617 – LOLO T-Exhaust B7
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112618 – LOLO T-Exhaust B8
Red alarm. Initiated by EMU.
Cause
Corrective action
The exhaust temperature of this
cylinder is too low as compared
with the average value.
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112619 – LOLO T-Exhaust B9
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112620 – LOLO T-Exhaust B10
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too low as compared
with the average value.
Corrective action
1. Check spark plug.
2. Check emission values.
3. Check ignition timing (→ Page 137).
4. Check valve drive.
112701 – HIHI T-Exhaust A1 (abs)
Red alarm. Initiated by EMU.
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112702 – HIHI T-Exhaust A2 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
66 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
Cause
112703 – HIHI T-Exhaust A3 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112704 – HIHI T-Exhaust A4 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112705 – HIHI T-Exhaust A5 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112706 – HIHI T-Exhaust A6 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112707 – HIHI T-Exhaust A7 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
112708 – HIHI T-Exhaust A8 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
MS150034/02E 2012-07 | Troubleshooting | 67
112709 – HIHI T-Exhaust A9 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112710 – HIHI T-Exhaust A10 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112711 – HIHI T-Exhaust B1 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112712 – HIHI T-Exhaust B2 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112713 – HIHI T-Exhaust B3 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
68 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
112714 – HIHI T-Exhaust B4 (abs)
112715 – HIHI T-Exhaust B5 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112716 – HIHI T-Exhaust B6 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112717 – HIHI T-Exhaust B7 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112718 – HIHI T-Exhaust B8 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
112719 – HIHI T-Exhaust B9 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000017543 - 001
112720 – HIHI T-Exhaust B10 (abs)
Red alarm. Initiated by EMU.
Cause
The exhaust temperature of this
cylinder is too high.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check valve drive (exhaust valves do not close).
MS150034/02E 2012-07 | Troubleshooting | 69
112923 – MD/SD T-Exhaust
Red alarm. Initiated by EMU.
Cause
Corrective action
Combined alarm (for details,
refer to the source alarm).
u Combined alarm (for details, refer to the source alarm).
150176 – Lube Oil Min
Red alarm. Initiated by SAM.
Cause
Corrective action
Minimum engine oil level
detected.
1. Check engine oil level (→ Page 156).
2. Check replenishment system (→ Page 156).
150178 – Lube Oil Max
Red alarm. Initiated by SAM.
Cause
Corrective action
Maximum engine oil level
detected.
1. Check engine oil level (→ Page 156).
2. Check replenishment system (→ Page 156).
150200 – Communication Lost ECU
Red alarm. Initiated by SAM.
Cause
Corrective action
No communication with ECU
CAN.
1. Check supply voltage.
2. Check connecting line.
150201 – Communication Lost EMU
Red alarm. Initiated by SAM.
Cause
Corrective action
No communication with EMU
CAN.
1. Check supply voltage.
2. Check connecting line.
150202 – Comm. Lost Knock Module
Red alarm. Initiated by SAM.
Corrective action
No communication with knocking
module CAN.
1. Check supply voltage.
2. Check connecting line.
150203 – Comm. Lost Ignition
Red alarm. Initiated by SAM.
Cause
No communication with ignition
CAN.
70 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check supply voltage.
2. Check connecting line.
TIM-ID: 0000017543 - 001
Cause
150204 – Comm. Lost Mixer (TecJet)
Red alarm. Initiated by SAM.
Cause
Corrective action
No communication with mixer
(TecJet) CAN.
1. Check supply voltage.
2. Check connecting line.
150352 – SS Release Circuit Breaker
Red alarm. Initiated by SAM.
Cause
Corrective action
Circuit breaker release detected.
u Check circuit breakers.
150358 – HI Lube Oil Level refill
Yellow alarm. Initiated by SAM.
Cause
Corrective action
Engine oil was refilled too often
within a certain time interval.
1. Check engine oil level (→ Page 156).
2. Check oil supply (→ Page 156).
150365 – SS Gas Pressure MIN
Red alarm. Initiated by SAM.
Cause
Corrective action
Minimum gas pressure applied.
1. Check initial gas pressure and gas line.
2. Check cabling.
150399 – SS Coolant too Low
Red alarm. Initiated by SAM.
Cause
Corrective action
Lack of coolant in cooling
system, feedback signal from
level sensor missing.
1. Check sensor and cabling, replace as necessary.
2. Check coolant level.
3. Pinpoint leakage.
150400 – AL Preheating Error
Yellow alarm. Initiated by SAM.
TIM-ID: 0000017543 - 001
Cause
Preheating fault, coolant
differential pressure over engine
is below the specified value.
Corrective action
1. Check differential coolant pressure.
2. Check operation of coolant pumps.
150401 – HI Oil Refill
Yellow alarm. Initiated by SAM.
Cause
Too many pulses received for
lube oil replenishment.
Corrective action
1. Check engine oil level (→ Page 156).
2. Check oil supply (→ Page 156).
MS150034/02E 2012-07 | Troubleshooting | 71
150402 – LO Oil Refill
Yellow alarm. Initiated by SAM.
Cause
No oil replenishment within a
configurable time.
Corrective action
u Check oil replenishment system.
150403 – AL Oil Refill Error
Red alarm. Initiated by SAM.
Cause
After initiation of the alarms
“HI Oil Refill” and
“HI Lube Oil Level refill” a
configurable time-out period
starts. When this time-out period
is expired, the engine is stopped.
Corrective action
1. Check engine oil level (→ Page 156).
2. Check oil supply (→ Page 156).
150410 – MD/SD MesPower
Red alarm. Initiated by SAM.
Cause
Actual power signal out of valid
range.
Corrective action
1. Check cabling.
2. Check signal.
150504 – LO Engine Power
Yellow alarm. Initiated by SAM.
Cause
The engine is running below
minimum load.
Corrective action
u Check power setpoint signal.
150601 – AL Gas Valve 1 feedback
Red alarm. Initiated by SAM.
Cause
Feedback signal from valve 1
does not correspond with
setpoint signal.
Corrective action
u Check valve 1 and cabling.
Red alarm. Initiated by SAM.
Cause
Emergency stop detected.
Emergency stop was released
manually (button), or ignition
system reported overspeed.
72 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u
TIM-ID: 0000017543 - 001
150902 – SS Local Initiated Emerg. Stop
151021 – Warning Hold Position
Yellow alarm. Initiated by TecJet.
Cause
Corrective action
Hold position is activated.
u Deactivate setting or interrupt serial communication.
151022 – Zero Pressure Detected
Yellow alarm. Initiated by TecJet.
Cause
Corrective action
No gas pressure/gas flow
detected.
u Check gas pressure.
151023 – Zero Flow Detected
Yellow alarm. Initiated by TecJet.
Cause
Corrective action
No gas pressure/gas flow
detected.
u Check gas pressure.
151024 – Flow Not Reached
Red alarm. Initiated by TecJet.
Cause
Corrective action
No gas flow detected.
1. Check inlet and outlet.
2. Check gas pressure, gas quality, gas filter, gas line for
obstruction.
3. Check engine for overloading.
151025 – Valve Position Error
Red alarm. Initiated by TecJet.
Cause
Corrective action
Hardware not ready for
operation.
u Restart TecJet.
151026 – High Elec Temp
Red alarm. Initiated by TecJet.
TIM-ID: 0000017543 - 001
Cause
Corrective action
Hardware not ready for
operation.
u Restart TecJet.
151028 – Elec Temp Fail High
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
MS150034/02E 2012-07 | Troubleshooting | 73
151029 – FGT Fail High
Red alarm. Initiated by TecJet.
Cause
Corrective action
Hardware not ready for
operation.
u Restart TecJet.
151030 – Delta P Fail High
Red alarm. Initiated by TecJet.
Cause
Corrective action
Excessive differential pressure
over TecJet detected.
1. Check gas pressure.
2. Check TecJet for dirt.
151031 – FGP Fail High
Red alarm. Initiated by TecJet.
Cause
Corrective action
Hardware not ready for
operation.
u Restart TecJet.
151032 – Coil Current Fail High
Red alarm. Initiated by TecJet.
Cause
Corrective action
Hardware not ready for
operation.
u Restart TecJet.
151035 – Position Fail High
Red alarm. Initiated by TecJet.
Cause
Corrective action
Hardware not ready for
operation.
u Restart TecJet.
151036 – Elec Temp Fail Low
Red alarm. Initiated by TecJet.
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
TIM-ID: 0000017543 - 001
Cause
151037 – FGT Fail Low
Red alarm. Initiated by TecJet.
Cause
Gas temperature before TecJet
is below the preset limit value.
74 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Check TecJet and configuration.
151038 – Delta P Fail Low
Red alarm. Initiated by TecJet.
Cause
Differential pressure at TecJet is
below the preset limit value.
Corrective action
u Check TecJet and configuration.
151039 – FGP Fail Low
Red alarm. Initiated by TecJet.
Cause
Gas pressure before TecJet is
below the preset limit value.
Corrective action
u Check TecJet and configuration.
151040 – Coil Current Fail Low
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151043 – Position Fail Low
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151048 – Analog Input Low Error
Red alarm. Initiated by TecJet.
Cause
TecJet setting is not correct.
Corrective action
u Check setting and switch over to PWM input. Check PWM
signal.
151049 – Analog Input High Error
Red alarm. Initiated by TecJet.
Cause
TIM-ID: 0000017543 - 001
TecJet setting is not correct.
Corrective action
u Check setting and switch over to PWM input. Check PWM
signal.
151050 – PWM Duty Cycle Low Error
Red alarm. Initiated by TecJet.
Cause
PWM signal is beyond the valid
range.
Corrective action
1. Check cabling.
2. Check frequency.
3. Check signal.
MS150034/02E 2012-07 | Troubleshooting | 75
151051 – PWM Duty Cycle High Error
Red alarm. Initiated by TecJet.
Cause
Corrective action
PWM signal is beyond the valid
range.
1. Check cabling.
2. Check frequency.
3. Check signal.
151052 – Battery Volt Low Error
Red alarm. Initiated by TecJet.
Cause
Corrective action
Supply voltage has reached
minimum limit value.
1. Check supply voltage.
2. Check cabling.
151053 – FGT Low Limit Error
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151054 – Delta P Low Limit Error
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151055 – FGP Low Limit Error
Red alarm. Initiated by TecJet.
Cause
Configured limit value was not
attained.
Corrective action
u Check position direction of TecJet.
151056 – Battery Volt High Error
Red alarm. Initiated by TecJet.
Supply voltage has reached
maximum limit value.
Corrective action
1. Check supply voltage.
2. Check cabling.
151057 – FGT High Limit Error
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
76 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Restart TecJet.
TIM-ID: 0000017543 - 001
Cause
151058 – Delta P High Limit Error
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151059 – FGP High Limit Error
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151061 – Watchdog Reset
Red alarm. Initiated by TecJet.
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151064 – CAN Flow Demand Failed
Red alarm. Initiated by TecJet.
Cause
TecJet setting is not correct.
Corrective action
u Switch over setting to PWM input. Check PWM signal.
151066 – TecJet Shutdown
Red alarm. Initiated by TecJet.
Cause
TecJet combined alarm. At least
one additional TecJet alarm is
pending.
Corrective action
u Rectify the cause of the source alarm.
151067 – TecJet Internal Fault
Red alarm. Initiated by TecJet.
TIM-ID: 0000017543 - 001
Cause
Hardware not ready for
operation.
Corrective action
u Restart TecJet.
151069 – Keyswitch State
Red alarm. Initiated by TecJet.
Cause
Keyswitch cabling missing.
Corrective action
u Check cabling.
MS150034/02E 2012-07 | Troubleshooting | 77
152011 – Error Missing Ring Gear Signal
Red alarm. Initiated by IC922.
Cause
Crankshaft signal for ignition
speed 182 teeth missing.
Corrective action
u Check sensor B13.2, check sensor clearance and cabling,
replace if necessary. Restart of ignition system required to
restart the engine.
152012 – Error Missing Reset Signal
Red alarm. Initiated by IC922.
Cause
Reset signal from crankshaft is
missing.
Corrective action
u Check sensor B75, check sensor clearance and cabling, replace
if necessary. Restart of ignition system required to restart the
engine.
152013 – Error Missing Camshaft Signal
Red alarm. Initiated by IC922.
Cause
Camshaft signal for ignition is
missing.
Corrective action
u Check sensor B1.2, check sensor clearance and cabling,
replace if necessary. Restart of ignition system required to
restart the engine.
152014 – Error Number of Teeth
Red alarm. Initiated by IC922.
Cause
Incorrect number of teeth on
timing wheel detected.
Corrective action
1. Check timing wheel.
2. Check settings.
152015 – Unknown Engine Appl. Code
Red alarm. Initiated by IC922.
Cause
Ignition setting is not correct.
Corrective action
u Check setting.
152016 – OverSpeed Shutdown
Cause
Genset has exceeded
admissible speed.
Corrective action
u Restart ignition system.
152018 – E2PROM Checksum Error
Red alarm. Initiated by IC922.
Cause
Hardware not ready for
operation.
78 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Restart ignition system.
TIM-ID: 0000017543 - 001
Red alarm. Initiated by IC922.
152019 – Global Timing out of Range
Yellow alarm. Initiated by IC922.
Cause
Specified global ignition timing is
beyond the valid range.
Corrective action
u Adjust value.
152020 – Unknown Timing or Energy Level
Red alarm. Initiated by IC922.
Cause
No global ignition timing and
power level received, CAN bus
connection is faulty.
Corrective action
u Check cabling and setting.
152021 – Individual Timing out of Range
Yellow alarm. Initiated by IC922.
Cause
Specified individual ignition
timing is beyond the valid range.
Corrective action
u Adjust value.
152023 – Selftest Shutdown
Cause
Self-test is active with the engine
rotating.
Corrective action
u Restart ignition system.
152024 – Open Primary Rate Exceeded
Red alarm. Initiated by IC922.
Cause
Admissible summation of
discharge faults is reached.
Corrective action
1. Check associated cabling.
2. Check ignition coils.
152026 – Open Primary, Channel 1
Yellow alarm. Initiated by IC922.
TIM-ID: 0000017543 - 001
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152027 – Open Primary, Channel 2
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
MS150034/02E 2012-07 | Troubleshooting | 79
152028 – Open Primary, Channel 3
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152029 – Open Primary, Channel 4
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152030 – Open Primary, Channel 5
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152031 – Open Primary, Channel 6
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152032 – Open Primary, Channel 7
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152033 – Open Primary, Channel 8
Yellow alarm. Initiated by IC922.
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152034 – Open Primary, Channel 9
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
80 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
TIM-ID: 0000017543 - 001
Cause
152035 – Open Primary, Channel 10
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152036 – Open Primary, Channel 11
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152037 – Open Primary, Channel 12
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152038 – Open Primary, Channel 13
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152039 – Open Primary, Channel 14
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152040 – Open Primary, Channel 15
Yellow alarm. Initiated by IC922.
TIM-ID: 0000017543 - 001
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152041 – Open Primary, Channel 16
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
MS150034/02E 2012-07 | Troubleshooting | 81
152042 – Open Primary, Channel 17
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152043 – Open Primary, Channel 18
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152044 – Open Primary, Channel 19
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152045 – Open Primary, Channel 20
Yellow alarm. Initiated by IC922.
Cause
Ignition energy was not
discharged.
Corrective action
1. Check cabling to ignition coil.
2. Check ignition coil.
152050 – Warn. Missing Ring Gear Signal
Yellow alarm. Initiated by IC922.
Cause
Crankshaft signal 182 teeth is
missing.
Corrective action
u Check sensor B13.2, check sensor clearance and cabling,
replace if necessary.
152051 – Warning Missing Reset Signal
Yellow alarm. Initiated by IC922.
Reset signal from crankshaft is
missing.
Corrective action
u Check sensor B75, check sensor clearance and cabling, replace
if necessary.
152052 – Warn. Missing Camshaft Signal
Yellow alarm. Initiated by IC922.
Cause
Missing camshaft signal for
ignition system.
82 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Check sensor B1.2, check sensor clearance and cabling,
replace if necessary.
TIM-ID: 0000017543 - 001
Cause
152054 – SCR Fault Odd
Red alarm. Initiated by IC922.
Cause
Hardware not ready for
operation.
Corrective action
u Restart ignition system.
152055 – SCR Fault Even
Red alarm. Initiated by IC922.
Cause
Hardware not ready for
operation.
Corrective action
u Restart ignition system.
152056 – Odd Energy Level out of Range
Yellow alarm. Initiated by IC922.
Cause
Specified energy level is beyond
the valid range.
Corrective action
u Adjust value.
152057 – Even Energy Level out of Range
Yellow alarm. Initiated by IC922.
Cause
Specified energy level is beyond
the valid range.
Corrective action
u Adjust value.
153101 – Error Status
Red alarm. Initiated by antiknock control.
Cause
AKR combined alarm. At least
one additional AKR alarm is
pending.
Corrective action
u Rectify the cause of the source alarm.
153102 – Combined Error
Red alarm. Initiated by antiknock control.
TIM-ID: 0000017543 - 001
Cause
Combined alarm (for details,
refer to the source alarm).
Corrective action
u Combined alarm (for details, refer to the source alarm).
153103 – Internal Error
Red alarm. Initiated by antiknock control.
Cause
Hardware not ready for
operation.
Corrective action
u Restart antiknock control system.
MS150034/02E 2012-07 | Troubleshooting | 83
153104 – Error Camshaft
Red alarm. Initiated by antiknock control.
Cause
No signal from camshaft sensor
for antiknock control.
Corrective action
1. Check cabling.
2. Check sensor B1.3, replace as necessary.
153111 – Knock Sensor Error A1
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153112 – Knock Sensor Error A2
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153113 – Knock Sensor Error A3
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153114 – Knock Sensor Error A4
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
84 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
TIM-ID: 0000017543 - 001
153115 – Knock Sensor Error A5
153116 – Knock Sensor Error A6
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153117 – Knock Sensor Error A7
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153118 – Knock Sensor Error A8
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153119 – Knock Sensor Error A9
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153120 – Knock Sensor Error A10
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
TIM-ID: 0000017543 - 001
153121 – Knock Sensor Error B1
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
MS150034/02E 2012-07 | Troubleshooting | 85
153122 – Knock Sensor Error B2
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153123 – Knock Sensor Error B3
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153124 – Knock Sensor Error B4
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153125 – Knock Sensor Error B5
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153126 – Knock Sensor Error B6
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
86 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
TIM-ID: 0000017543 - 001
153127 – Knock Sensor Error B7
153128 – Knock Sensor Error B8
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153129 – Knock Sensor Error B9
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153130 – Knock Sensor Error B10
Red alarm. Initiated by antiknock control.
Cause
No signal received from this
knock sensor.
Corrective action
1. Check cabling.
2. Check sensor (tightening torque, damage), replace as
necessary.
153221 – HI Knock Integrator A1
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153222 – HI Knock Integrator A2
Yellow alarm. Initiated by SAM.
Cause
TIM-ID: 0000017543 - 001
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153223 – HI Knock Integrator A3
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
MS150034/02E 2012-07 | Troubleshooting | 87
153224 – HI Knock Integrator A4
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153225 – HI Knock Integrator A5
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153226 – HI Knock Integrator A6
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153227 – HI Knock Integrator A7
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153228 – HI Knock Integrator A8
Yellow alarm. Initiated by SAM.
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
88 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
TIM-ID: 0000017543 - 001
Cause
153229 – HI Knock Integrator A9
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153230 – HI Knock Integrator A10
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153231 – HI Knock Integrator B1
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153232 – HI Knock Integrator B2
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153233 – HI Knock Integrator B3
Yellow alarm. Initiated by SAM.
TIM-ID: 0000017543 - 001
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
MS150034/02E 2012-07 | Troubleshooting | 89
153234 – HI Knock Integrator B4
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153235 – HI Knock Integrator B5
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153236 – HI Knock Integrator B6
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153237 – HI Knock Integrator B7
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153238 – HI Knock Integrator B8
Yellow alarm. Initiated by SAM.
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
90 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
TIM-ID: 0000017543 - 001
Cause
153239 – HI Knock Integrator B9
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153240 – HI Knock Integrator B10
Yellow alarm. Initiated by SAM.
Cause
Readjustment of ignition timing
beyond a limit value because
knocking was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153241 – HIHI Knock Integrator A1
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153242 – HIHI Knock Integrator A2
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153243 – HIHI Knock Integrator A3
Red alarm. Initiated by SAM.
TIM-ID: 0000017543 - 001
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
MS150034/02E 2012-07 | Troubleshooting | 91
153244 – HIHI Knock Integrator A4
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153245 – HIHI Knock Integrator A5
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153246 – HIHI Knock Integrator A6
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153247 – HIHI Knock Integrator A7
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153248 – HIHI Knock Integrator A8
Red alarm. Initiated by SAM.
Emergency stop due to knocking
detected in this cylinder.
92 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
TIM-ID: 0000017543 - 001
Cause
153249 – HIHI Knock Integrator A9
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153250 – HIHI Knock Integrator A10
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153251 – HIHI Knock Integrator B1
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153252 – HIHI Knock Integrator B2
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153253 – HIHI Knock Integrator B3
Red alarm. Initiated by SAM.
TIM-ID: 0000017543 - 001
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
MS150034/02E 2012-07 | Troubleshooting | 93
153254 – HIHI Knock Integrator B4
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153255 – HIHI Knock Integrator B5
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153256 – HIHI Knock Integrator B6
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153257 – HIHI Knock Integrator B7
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153258 – HIHI Knock Integrator B8
Red alarm. Initiated by SAM.
Emergency stop due to knocking
detected in this cylinder.
94 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
TIM-ID: 0000017543 - 001
Cause
153259 – HIHI Knock Integrator B9
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153260 – HIHI Knock Integrator B10
Red alarm. Initiated by SAM.
Cause
Emergency stop due to knocking
detected in this cylinder.
Corrective action
1. Check emission values.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
153261 – HI Misfire Integrator A1
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153262 – HI Misfire Integrator A2
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153263 – HI Misfire Integrator A3
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
TIM-ID: 0000017543 - 001
153264 – HI Misfire Integrator A4
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
MS150034/02E 2012-07 | Troubleshooting | 95
153265 – HI Misfire Integrator A5
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153266 – HI Misfire Integrator A6
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153267 – HI Misfire Integrator A7
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153268 – HI Misfire Integrator A8
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153269 – HI Misfire Integrator A9
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153270 – HI Misfire Integrator A10
Yellow alarm. Initiated by SAM.
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153271 – HI Misfire Integrator B1
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
96 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
TIM-ID: 0000017543 - 001
Cause
153272 – HI Misfire Integrator B2
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153273 – HI Misfire Integrator B3
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153274 – HI Misfire Integrator B4
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153275 – HI Misfire Integrator B5
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153276 – HI Misfire Integrator B6
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153277 – HI Misfire Integrator B7
Yellow alarm. Initiated by SAM.
TIM-ID: 0000017543 - 001
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153278 – HI Misfire Integrator B8
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
MS150034/02E 2012-07 | Troubleshooting | 97
153279 – HI Misfire Integrator B9
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153280 – HI Misfire Integrator B10
Yellow alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153281 – HIHI Misfire Integrator A1
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153282 – HIHI Misfire Integrator A2
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153283 – HIHI Misfire Integrator A3
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153284 – HIHI Misfire Integrator A4
Red alarm. Initiated by SAM.
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153285 – HIHI Misfire Integrator A5
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
98 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
TIM-ID: 0000017543 - 001
Cause
153286 – HIHI Misfire Integrator A6
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153287 – HIHI Misfire Integrator A7
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153288 – HIHI Misfire Integrator A8
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153289 – HIHI Misfire Integrator A9
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153290 – HIHI Misfire Integrator A10
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153291 – HIHI Misfire Integrator B1
Red alarm. Initiated by SAM.
TIM-ID: 0000017543 - 001
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153292 – HIHI Misfire Integrator B2
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
MS150034/02E 2012-07 | Troubleshooting | 99
153293 – HIHI Misfire Integrator B3
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153294 – HIHI Misfire Integrator B4
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153295 – HIHI Misfire Integrator B5
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153296 – HIHI Misfire Integrator B6
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153297 – HIHI Misfire Integrator B7
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153298 – HIHI Misfire Integrator B8
Red alarm. Initiated by SAM.
Misfiring was detected in this
cylinder.
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
153299 – HIHI Misfire Integrator B9
Red alarm. Initiated by SAM.
Cause
Misfiring was detected in this
cylinder.
100 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check emission values.
2. Check spark plug (energy level ignition system).
TIM-ID: 0000017543 - 001
Cause
153300 – HIHI Misfire Integrator B10
Red alarm. Initiated by SAM.
Cause
1. Check emission values.
2. Check spark plug (energy level ignition system).
TIM-ID: 0000017543 - 001
Misfiring was detected in this
cylinder.
Corrective action
MS150034/02E 2012-07 | Troubleshooting | 101
5.3 Engine governor – Fault messages
015 – LO P-Lube Oil
ZKP-Number:
Yellow alarm.
Associated parameter 2.0100.921
Cause
Engine oil pressure too low (limit
value 1). Lack of engine oil,
engine speed too low, oil lines,
oil heat exchanger clogged, oil
pump defective.
Corrective action
1. Check oil system, oil heat exchanger.
2. Replace oil filter (→ Page 159).
3. Take oil sample and analyze (→ Page 158).
016 – SS P-Lube Oil
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0100.922
Cause
Engine oil pressure too low (limit
value 2). Lack of engine oil,
engine speed too low, oil lines,
oil heat exchanger clogged, oil
pump defective.
Corrective action
1. Check oil system, oil heat exchanger.
2. Replace oil filter (→ Page 159).
3. Take oil sample and analyze (→ Page 158).
019 – HI T-Exhaust A
ZKP-Number:
Yellow alarm.
Associated parameter 2.0126.931
Cause
1. Check exhaust turbocharger.
2. Check ignition timing (→ Page 137).
3. Check mixture setting.
4. Check spark plugs.
TIM-ID: 0000017544 - 001
Exhaust gas temperature (A
side) after turbine too high (limit
value 1). Incorrect ignition timing,
mixture too lean or too rich,
damage to turbine.
Corrective action
102 | Troubleshooting | MS150034/02E 2012-07
020 – SS T-Exhaust A
ZKP-Number:
Yellow alarm.
Associated parameter 2.0126.932
Cause
Exhaust gas temperature (A
side) after turbine too high (limit
value 2). Incorrect ignition timing,
mixture too lean or too rich,
damage to turbine.
Corrective action
1. Check exhaust turbocharger.
2. Check ignition timing (→ Page 137).
3. Check mixture setting.
4. Check spark plugs.
021 – HI T-Exhaust B
ZKP-Number:
Yellow alarm.
Associated parameter 2.0127.931
Cause
Exhaust gas temperature (B
side) after turbine too high (limit
value 1). Incorrect ignition timing,
mixture too lean or too rich,
damage to turbine.
Corrective action
1. Check exhaust turbocharger.
2. Check ignition timing (→ Page 137).
3. Check mixture setting.
4. Check spark plugs.
022 – SS T-Exhaust B
ZKP-Number:
Yellow alarm.
Associated parameter 2.0127.932
Cause
Exhaust gas temperature (B
side) after turbine too high (limit
value 2). Incorrect ignition timing,
mixture too lean or too rich,
damage to turbine.
Corrective action
1. Check exhaust turbocharger.
2. Check ignition timing (→ Page 137).
3. Check mixture setting.
4. Check spark plugs.
025 – HI P-Diff-Lube Oil
TIM-ID: 0000017544 - 001
ZKP-Number:
Yellow alarm.
Associated parameter 2.0154.931
Cause
Pressure loss via oil filter too
high (limit value 1).
Corrective action
1. Replace oil filter (→ Page 159).
2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil if required
(→ Page 157).
MS150034/02E 2012-07 | Troubleshooting | 103
026 – HI P-Diff-Lube Oil
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0154.932
Cause
Pressure loss via oil filter too
high (limit value 2).
Corrective action
1. Replace oil filter (→ Page 159).
2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil if required
(→ Page 157).
030 – SS Engine Overspeed
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.2510.932
Cause
Engine overspeed (limit value 2).
This usually fault message
usually follows other fault
messages.
Corrective action
1. Check governor.
2. Check throttle closing position.
031 – HI ETC1 Overspeed
ZKP-Number:
Yellow alarm.
Associated parameter 2.3011.931
Cause
Speed of primary turbocharger
too high (limit value 1).
Corrective action
u Turbocharger speed sensor is not fitted at present. Check ECU
setting for this input.
032 – SS ETC1 Overspeed
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.3012.932
Speed of primary turbocharger
too high (limit value 2).
104 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Turbocharger speed sensor is not fitted at present. Check ECU
setting for this input.
TIM-ID: 0000017544 - 001
Cause
036 – HI ETC2 Overspeed
ZKP-Number:
Yellow alarm.
Associated parameter 2.3013.931
Cause
Speed of 1st secondary
turbocharger too high (limit value
1).
Corrective action
u Turbocharger speed sensor is not fitted at present. Check ECU
setting for this input.
037 – SS ETC2 Overspeed
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.3013.912
Cause
Speed of 1st secondary
turbocharger too high (limit value
2).
Corrective action
u Turbocharger speed sensor is not fitted at present. Check ECU
setting for this input.
051 – HI T-Lube Oil
ZKP-Number:
Yellow alarm.
Associated parameter 2.0125.931
Cause
Engine oil temperature after oil
heat exchanger too high (limit
value 1). Oil heat exchanger
clogged, coolant temperature too
high, oil flow too low.
Corrective action
1. Check engine coolant circuit.
2. Check oil heat exchanger.
3. Check oil level (→ Page 156).
052 – SS T-Lube Oil
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0125.932
TIM-ID: 0000017544 - 001
Cause
Engine oil temperature after oil
heat exchanger too high (limit
value 2). Oil heat exchanger
clogged, coolant temperature too
high, oil flow too low.
Corrective action
1. Check engine coolant circuit.
2. Check oil heat exchanger.
3. Check oil level (→ Page 156).
MS150034/02E 2012-07 | Troubleshooting | 105
053 – HI T-Intake Air
ZKP-Number:
Yellow alarm.
Associated parameter 2.0123.931
Cause
Intake air temperature too high
(limit value 1).
Corrective action
u Check ventilation system.
054 – HIHI T-Intake Air
ZKP-Number:
Yellow alarm.
Associated parameter 2.0123.932
Cause
Intake air temperature too high
(limit value 2).
Corrective action
1. Check ventilation system.
2. Reduce power.
057 – LO P-Coolant
ZKP-Number:
Yellow alarm.
Associated parameter 2.0101.921
Cause
Coolant pressure after engine
too low (limit value 1). Volumetric
flow too low, static pressure too
low.
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
058 – SS P-Coolant
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0101.922
Coolant pressure after engine
too low (limit value 2). Volumetric
flow too low, static pressure too
low.
106 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
TIM-ID: 0000017544 - 001
Cause
063 – HI P-Crank Case
ZKP-Number:
Yellow alarm.
Associated parameter 2.0106.931
Cause
Crankcase pressure too high
(limit value 1). Restrictor valve in
crankcase breather is closed too
much, air filter is defective, oil
separator is clogged, piston rings
are seized, other damage to
crank drive.
Corrective action
1. Check crank drive:
• Crank engine (→ Page 133).
• Endoscope combustion chambers from bottom dead center to
top dead center.
2. Check air filter for contamination, replace if contamination is
visible (→ Page 154),
3. Check setting of BlowBy restrictor valve.
4. Check oil separator condition, replace if necessary
(→ Page 135).
064 – SS P-Crank Case
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0106.932
Cause
Crankcase pressure too high
(limit value 2). Restrictor valve in
crankcase breather is closed too
much, air filter is defective, oil
separator is clogged, piston rings
are seized, other damage to
crank drive.
Corrective action
1. Check crank drive:
• Crank engine (→ Page 133).
• Endoscope combustion chambers from bottom dead center to
top dead center.
2. Check air filter for contamination, replace if contamination is
visible (→ Page 154),
3. Check setting of BlowBy restrictor valve.
4. Check oil separator condition, replace if necessary
(→ Page 135).
067 – HI T-Coolant
ZKP-Number:
Yellow alarm.
Associated parameter 2.0120.931
TIM-ID: 0000017544 - 001
Cause
Coolant temperature after engine
too high (limit value 1). Engine
coolant pump failure, volumetric
flow too low, air in engine
coolant circuit.
Corrective action
u Check engine coolant circuit.
MS150034/02E 2012-07 | Troubleshooting | 107
068 – SS T-Coolant
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0120.932
Cause
Coolant temperature after engine
too high (limit value 2). Engine
coolant pump failure, volumetric
flow too low, air in engine
coolant circuit.
Corrective action
u Check engine coolant circuit.
089 – SS Engine Speed too Low
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.2500.030
Cause
Engine is stalled. Engine speed
in normal operation has fallen
below the limit value of
parameter 2.2500.027 (speed
limit for stalling) without an active
stop command. The engine is
shutdown for safety reasons.
Corrective action
1. In parallel operation connected to mains:
• Check mains for frequency drop.
• Check generator and coupling for damage.
2. In isolated operation:
• Check throttle position.
• Check throttles for implausible closing. If throttles are fully
open: Check if load step values are admissible.
• Check bypass 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 137).
• Check oil separator efficiency (oil in compressor intake
elbow), clean compressor if necessary.
• Check valve clearance (→ Page 145).
• Check gasket between mixture line and cylinder head for
correct installation position.
090 – SS Idle Speed Not Reached
ZKP-Number:
Associated parameter 2.1090.925
Cause
Idling speed not attained.
108 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check ignition.
2. Check gas supply.
3. Check mixture setting.
TIM-ID: 0000017544 - 001
Red alarm. Start terminated.
091 – SS Release Speed Not Reached
ZKP-Number:
Red alarm. Start terminated.
Associated parameter 2.1090.924
Cause
The speed (starter
DISENGAGE) was not attained,
ignition not working or no gas
available.
Corrective action
1. Check ignition.
2. Check gas supply.
3. Check mixture setting.
092 – SS Starter Speed Not Reached
ZKP-Number:
Red alarm. Start terminated.
Associated parameter 2.1090.923
Cause
Minimum speed for flushing
process and ignition release was
not attained.
Corrective action
u Check starter system.
093 – SS T-Preheat
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.1090.922
Cause
Preheating temperature too low
(limit value 2). Coolant
temperature too low for engine
start.
Corrective action
1. Check preheating.
2. Check differential coolant pressure.
3. Check heating elements.
4. Check cabling.
094 – LO T-Preheat
ZKP-Number:
Yellow alarm.
Associated parameter 2.1090.921
TIM-ID: 0000017544 - 001
Cause
Preheating temperature too low
(limit value 1). Coolant
temperature too low for engine
start.
Corrective action
1. Check preheating.
2. Check differential coolant pressure.
3. Check heating elements.
4. Check cabling.
MS150034/02E 2012-07 | Troubleshooting | 109
095 – AL Prelubrication Fault
ZKP-Number:
Red alarm. Start terminated.
Associated parameter 2.1090.920
Cause
Corrective action
Oil priming fault.
1. Check oil pressure, oil temperature, oil level.
2. Check oil priming pump.
104 – AL Eng Hours Counter Defect
ZKP-Number:
Yellow alarm.
Associated parameter 1.8004.623
Cause
Corrective action
Hour meter faulty. Internal
governor fault.
u Replace engine governor.
118 – LO ECU Supply Voltage
ZKP-Number:
Yellow alarm.
Associated parameter 2.0140.921
Cause
Corrective action
Supply voltage too low (limit
value 1).
1. Check supply voltage.
2. Check cabling.
119 – LOLO ECU Supply Voltage
ZKP-Number:
Red alarm.
Associated parameter 2.0140.922
Cause
Corrective action
Supply voltage too low (limit
value 2).
1. Check supply voltage.
2. Check cabling.
ZKP-Number:
Yellow alarm.
Associated parameter 2.0140.931
Cause
Supply voltage too high (limit
value 1).
110 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check supply voltage.
2. Check cabling.
TIM-ID: 0000017544 - 001
120 – HI ECU Supply Voltage
121 – HIHI ECU Supply Voltage
ZKP-Number:
Red alarm.
Associated parameter 2.0140.932
Cause
Supply voltage too high (limit
value 2).
Corrective action
1. Check supply voltage.
2. Check cabling.
122 – HI T-ECU
ZKP-Number:
Yellow alarm.
Associated parameter 2.0132.921
Cause
Electronics temperature too high
(limit value 1).
Corrective action
u Improve cooling of governor. Reduce room temperature, check
air flow to ADEC.
176 – AL LifeData not available
ZKP-Number:
Red alarm.
Associated parameter 2.4000.004
Cause
No (suitable) LifeData backup
system available after expiry of
timeout following ECU reset.
Backup system has no LifeData
feature or CAN bus to backup
system is disrupted.
Corrective action
u Contact Service. (error on project data).
177 – AL LifeData restore incomplete
ZKP-Number:
Red alarm.
Associated parameter 2.4000.006
TIM-ID: 0000017544 - 001
Cause
This fault message is generated
if a CRC is faulty (is indicated for
each module) during a restore
data upload (in the ADEC) or if
the upload is incomplete.
Corrective action
u Power up ECU, contact Service.
MS150034/02E 2012-07 | Troubleshooting | 111
180 – AL CAN1 Node Lost
ZKP-Number:
Yellow alarm.
Associated parameter 2.0500.680
Cause
Bus node (SAM or EMU) lost on
CAN bus 1.
Corrective action
u Check operation of nodes and cabling. Busses (CAN bus 1 and
CAN bus 2) are redundant.
181 – AL CAN2 Node Lost
ZKP-Number:
Yellow alarm.
Associated parameter 2.0500.681
Cause
Bus node (SAM or EMU) lost on
CAN bus 2.
Corrective action
u Check operation of nodes and cabling. Busses (CAN bus 1 and
CAN bus 2) are redundant.
182 – AL CAN Wrong Parameters
ZKP-Number:
Red alarm.
Associated parameter 2.0500.682
Cause
Incorrect parameter values
entered in data record.
Corrective action
u Contact Service (configuration fault).
183 – AL CAN No PU-Data
ZKP-Number:
Red alarm.
Associated parameter 2.0500.683
A CAN mode has been selected
in which communication with the
PU data module is initialized.
However, the required PU data
module is not available or not
valid.
112 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Contact Service (configuration fault).
TIM-ID: 0000017544 - 001
Cause
184 – AL CAN PU-Data Flash Error
ZKP-Number:
Red alarm.
Associated parameter 2.0500.684
Cause
A programming error occurred
when attempting to copy a
received PU data module into
the Flash module.
Corrective action
u Contact Service (configuration fault).
186 – AL CAN1 Bus Off
ZKP-Number:
Yellow alarm.
Associated parameter 2.0500.686
Cause
CAN controller 1 is in “Bus-Off”
status. Automatic switching to
CAN bus 2. Bus users (ECU,
SAM or EMU) faulty.
Corrective action
u Check operation of nodes and cabling.
187 – AL CAN1 Error Passive
ZKP-Number:
Yellow alarm.
Associated parameter 2.0500.687
Cause
CAN controller 1 has signaled a
warning. Bus nodes (ECU, SAM
or EMU) are faulty.
Corrective action
u Check operation of nodes and cabling.
188 – AL CAN2 Bus Off
ZKP-Number:
Yellow alarm.
Associated parameter 2.0500.688
TIM-ID: 0000017544 - 001
Cause
CAN controller 2 is in “Bus-Off”
status. Automatic switching to
CAN bus 1. Bus users (ECU,
SAM or EMU) faulty.
Corrective action
u Check operation of nodes and cabling.
MS150034/02E 2012-07 | Troubleshooting | 113
189 – AL CAN2 Error Passive
ZKP-Number:
Yellow alarm.
Associated parameter 2.0500.689
Cause
CAN controller 2 has signaled a
warning. The cause may be e.g.
missing listening nodes, minor
malfunctions or temporary bus
overload.
Corrective action
u Check operation of nodes (ECU, SAM or EMU) and cabling.
190 – AL EMU Parameter Not Supported
ZKP-Number:
Red alarm.
Associated parameter 2.0500.690
Cause
EMU parameters are not
supported.
Corrective action
u Contact Service (configuration fault).
201 – SD T-Coolant
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.570
Cause
Coolant temperature sensor at
engine outlet defective, short
circuit or wire break.
Corrective action
u Check sensor and cabling (B6.1), replace if necessary. Fault is
rectified when engine is restarted.
204 – SD Level Lube Oil
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.602
Engine oil level sensor defective,
short circuit or wire break.
114 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Check sensor and cabling (B24), replace as necessary. Fault is
rectified when engine is restarted.
TIM-ID: 0000017544 - 001
Cause
206 – SD T-Exhaust A
ZKP-Number:
Yellow alarm.
Associated parameter 1.8004.576
Cause
Exhaust temperature sensor on
A side defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B4.21), replace if necessary. Fault is
rectified when engine is restarted.
207 – SD T-Exhaust B
ZKP-Number:
Yellow alarm.
Associated parameter 1.8004.577
Cause
Exhaust temperature sensor on
B side defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B4.22), replace if necessary. Fault is
rectified when engine is restarted.
211 – SD P-Lube Oil
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.563
Cause
Engine oil pressure sensor after
filter defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B5.1), replace as necessary. Fault is
rectified when engine is restarted.
212 – SD P-Coolant
ZKP-Number:
Red alarm.
Associated parameter 1.8004.564
TIM-ID: 0000017544 - 001
Cause
Coolant pressure sensor after
engine defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B16.1), replace if necessary. Fault is
rectified when engine is restarted.
MS150034/02E 2012-07 | Troubleshooting | 115
214 – SD P-Crank Case
ZKP-Number:
Red alarm.
Associated parameter 1.8004.568
Cause
Crankcase pressure sensor
defective, short circuit or wire
break.
Corrective action
u Check sensor and cabling (B50), replace as necessary. Fault is
rectified when engine is restarted.
216 – SD T-Lube Oil
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.575
Cause
Engine oil temperature sensor
after oil heat exchanger
defective, short circuit or wire
break.
Corrective action
u Check sensor and cabling (B7), replace as necessary. Fault is
rectified when engine is restarted.
219 – SD T-Intake Air
ZKP-Number:
Yellow alarm.
Associated parameter 1.8004.573
Cause
Intake air temperature sensor
defective, short circuit or wire
break.
Corrective action
u Check sensor and cabling (B49.2), replace as necessary. Fault
is rectified when engine is restarted.
221 – SD P-Diff Lube Oil
ZKP-Number:
Red alarm.
Associated parameter 1.8004.585
Engine oil pressure sensors
defective, short circuit or wire
break.
116 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Check sensor and cabling before filter (B5.3) and after
filter (B5.1), replace as necessary. Fault is rectified when engine
is restarted.
TIM-ID: 0000017544 - 001
Cause
227 – SD P- Lube Oil before Filter
ZKP-Number:
Yellow alarm.
Associated parameter 1.8004.620
Cause
Engine oil pressure sensor
before filter defective, short
circuit or wire break.
Corrective action
u Check sensor and cabling (B5.3), replace as necessary. Fault is
rectified when engine is restarted.
229 – AL Stop Camshaft Sensor Defect
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.562
Cause
Engine stop due to camshaft
sensor fault (and a prior
crankshaft sensor fault in the
same operating cycle).
Corrective action
u Check sensor and cabling (B1.1), replace if necessary. Fault is
rectified when engine is restarted.
231 – SD Camshaft Speed
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.499
Cause
Camshaft sensor defective, short
circuit or wire break.
Corrective action
u Check sensor and cabling (B1.1), replace if necessary. Fault is
rectified when engine is restarted.
232 – SD Charger 1 Speed
ZKP-Number:
Yellow alarm.
Associated parameter 1.3011.128
TIM-ID: 0000017544 - 001
Cause
Speed sensor of primary
turbocharger defective, short
circuit or wire break.
Corrective action
u Turbocharger speed sensor is not fitted at present.
MS150034/02E 2012-07 | Troubleshooting | 117
233 – SD Charger 2 Speed
ZKP-Number:
Yellow alarm.
Associated parameter 1.3011.129
Cause
Speed sensor of secondary
turbocharger defective, short
circuit or wire break.
Corrective action
u Turbocharger speed sensor is not fitted at present.
245 – SD ECU Power Supply Voltage
ZKP-Number:
Red alarm.
Associated parameter 2.8006.589
Cause
Internal governor fault.
Corrective action
u Replace ADEC engine governor.
266 – SD Speed Demand
ZKP-Number:
Red alarm.
Associated parameter 2.8006.586
Cause
Speed setting signal can no
longer be transmitted from plant.
Corrective action
u Check signal and cabling between plant and ADEC.
381 – AL Wiring TOP 1
ZKP-Number:
Yellow alarm.
Associated parameter 2.8006.638
Cause
u Check cabling.
TIM-ID: 0000017544 - 001
Short circuit or wire break on
transistor output, plant-side 1
(TOP 1). Activation of yellow
combined alarm faulty.
Corrective action
118 | Troubleshooting | MS150034/02E 2012-07
382 – AL Wiring TOP 2
ZKP-Number:
Red alarm.
Associated parameter 2.8006.639
Cause
Short circuit or wire break on
transistor output, plant-side 2
(TOP 2). Activation of red
combined alarm faulty.
Corrective action
u Check cabling.
383 – AL Wiring TOP 3
ZKP-Number:
Red alarm.
Associated parameter 2.8006.640
Cause
Short circuit or wire break on
transistor output, plant-side 3
(TOP 3). Activation of gas supply
solenoid valve No.1 faulty.
Corrective action
u Check cabling.
384 – AL Wiring TOP 4
ZKP-Number:
Red alarm.
Associated parameter 2.8006.641
Cause
Short circuit or wire break on
transistor output, plant-side 4
(TOP 4). Activation of gas supply
solenoid valve No.2 faulty.
Corrective action
u Check cabling.
418 – SD T-Intake Air B
ZKP-Number:
Yellow alarm.
TIM-ID: 0000017544 - 001
Associated parameter 1.8004.603
Cause
Intake air temperature sensor
defective, short circuit or wire
break.
Corrective action
u Check sensor and cabling (B49.2), replace if necessary.
MS150034/02E 2012-07 | Troubleshooting | 119
419 – SD T-Coolant b. Engine
ZKP-Number:
Red alarm.
Associated parameter 1.8004.604
Cause
Coolant temperature sensor at
engine inlet defective, short
circuit or wire break.
Corrective action
u Check sensor and cabling (B6.3), replace if necessary.
423 – LO P-Coolant Diff.
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0180.921
Cause
Coolant differential pressure too
low. Volumetric flow too low.
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
429 – HI P-Coolant
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0101.931
Cause
Coolant pressure after engine
too high (limit value 3).
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
430 – LO P-Coolant before Engine
ZKP-Number:
Yellow alarm.
Associated parameter 2.0168.921
Coolant pressure before engine
too low (limit value 1). Volumetric
flow too low, static pressure too
low.
120 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
TIM-ID: 0000017544 - 001
Cause
431 – SS P-Coolant before Engine
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0168.922
Cause
Coolant pressure before engine
too low (limit value 2). Volumetric
flow too low, static pressure too
low.
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
434 – HI T-Coolant before Engine
ZKP-Number:
Yellow alarm.
Associated parameter 2.0173.931
Cause
Coolant temperature before
engine too high (limit value 1).
Engine coolant pump failure,
volumetric flow too low, air in
engine coolant circuit.
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
435 – SS T-Coolant before Engine
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0173.932
Cause
Coolant temperature before
engine too high (limit value 2).
Engine coolant pump failure,
volumetric flow too low, air in
engine coolant circuit.
Corrective action
u Check engine coolant circuit (pressure and volumetric flow).
443 – HI P-Charge Mix Diff.
ZKP-Number:
TIM-ID: 0000017544 - 001
Yellow alarm.
Associated parameter 2.0183.931
Cause
Difference in mixture pressures
sensed on A and B side is too
high (limit value 1).
Corrective action
1. Check throttles for varying positions and malfunction.
2. Check mixture lines for leakage.
3. Check sensors and cabling (B79.22, B79.21).
MS150034/02E 2012-07 | Troubleshooting | 121
447 – HIHI P-Charge Mix Diff.
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0183.932
Cause
Difference in mixture pressures
sensed on A and B side is too
high (limit value 2).
Corrective action
1. Check throttles for varying positions and malfunction.
2. Check mixture lines for leakage.
3. Check sensors and cabling (B79.22, B79.21).
451 – HI T-Charge Mix
ZKP-Number:
Yellow alarm.
Associated parameter 2.0169.931
Cause
Mixture temperature is too high
(limit value 1). Mixture coolant
pump failure, volumetric flow too
low, cooling system inlet
temperature too high, mixture
cooler clogged.
Corrective action
1. Check mixture cooling circuit.
2. Check mixture cooler for dirt.
452 – HIHI T-Charge Mix
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0169.932
Cause
Mixture temperature is too high
(limit value 2). Mixture coolant
pump failure, volumetric flow too
low, cooling system inlet
temperature too high, mixture
cooler clogged.
Corrective action
1. Check mixture cooling circuit.
2. Check mixture cooler for dirt.
453 – LO T-Charge Mix
Yellow alarm.
Associated parameter 2.0169.921
Cause
Mixture temperature is too low
(limit value 3).
122 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check intake air temperature.
2. Check mixture cooling circuit.
TIM-ID: 0000017544 - 001
ZKP-Number:
454 – SS Power Reduction Active
ZKP-Number:
Yellow alarm.
Associated parameter 2.7000.011
Cause
Corrective action
Power reduction activated.
u Rectify limit value violation of the source alarm (e.g. reduce
intake air temperature).
457 – LO T-Intake Air
ZKP-Number:
Yellow alarm.
Associated parameter 2.0123.921
Cause
Corrective action
Intake air temperature is too low
(limit value 3).
u Check ventilation system.
458 – LOLO T-Intake Air
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0123.922
Cause
Corrective action
Intake air temperature is too low
(limit value 4).
u Check ventilation system.
459 – SD P-Coolant b. Engine
ZKP-Number:
Red alarm.
Associated parameter 1.8004.627
Cause
TIM-ID: 0000017544 - 001
Coolant pressure sensor before
engine defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B16.3), replace if necessary. Fault is
rectified when engine is restarted.
470 – SD T-ECU
ZKP-Number:
Red alarm.
Associated parameter 1.8004.587
Cause
Temperature sensor for engine
governor defective, short circuit
or wire break.
Corrective action
u Check sensor and cabling, replace as necessary. Fault is
rectified when engine is restarted.
MS150034/02E 2012-07 | Troubleshooting | 123
472 – AL Stop SD
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.8006.593
Cause
Corrective action
Engine stop, since all shutdown
channels detect “sensor defect".
u Combined alarm (for details, refer to the source alarm).
473 – AL Wiring PWM_CM2
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.593
Cause
Corrective action
Cable break or short circuit on
channel PWM_CM2.
u Check cabling to bypass throttle, replace bypass throttle if
necessary.
476 – AL Crash Rec.Init Fault
ZKP-Number:
Red alarm.
Associated parameter 1.8010.007
Cause
Crash recorder initialization
error.
Corrective action
u Contact Service.
478 – AL Comb. Alarm Yel (Plant)
ZKP-Number:
Yellow alarm.
Associated parameter 2.8006.001
Cause
Combined alarm YELLOW from
plant.
Corrective action
u Combined alarm (for details, refer to the source alarm).
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.8006.002
Cause
Combined alarm RED from
plant.
124 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Combined alarm (for details, refer to the source alarm).
TIM-ID: 0000017544 - 001
479 – AL Comb. Alarm Red (Plant)
496 – SD P-Charge Mix A
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.628
Cause
Mixture pressure sensor on A
side defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B79.21), replace if necessary. Fault
is rectified when engine is restarted.
497 – SD P-Charge Mix B
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.8004.629
Cause
Mixture pressure sensor on B
side defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B79.22), replace if necessary. Fault
is rectified when engine is restarted.
498 – SD P-Charge Mix Diff
ZKP-Number:
Red alarm.
Associated parameter 1.8004.630
Cause
Mixture differential pressure
sensor on A or B side defective,
short circuit or wire break.
Corrective action
u Check sensors and cabling (B79.21, B79.22), replace if
necessary. Fault is rectified when engine is restarted.
499 – SD T-Charge Mix
ZKP-Number:
Red alarm.
Associated parameter 1.8004.632
TIM-ID: 0000017544 - 001
Cause
Mixture temperature sensor
defective, short circuit or wire
break.
Corrective action
u Check sensor and cabling (B73), replace as necessary. Fault is
rectified when engine is restarted.
MS150034/02E 2012-07 | Troubleshooting | 125
511 – HIHI P-Charge Mix A
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0181.932
Cause
Corrective action
Mixture pressure on A side too
high (limit value 2).
1. Check emissions.
2. Check ignition timing (→ Page 137).
3. Check exhaust back pressure.
4. Check valve clearance (→ Page 145).
5. Check throttle.
6. Check mixture coolant system.
512 – HIHI P-Charge Mix B
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.0182.932
Cause
Corrective action
Mixture pressure on B side too
high (limit value 2).
1. Check emissions.
2. Check ignition timing (→ Page 137).
3. Check exhaust back pressure.
4. Check valve clearance (→ Page 145).
5. Check throttle.
6. Check mixture coolant system.
513 – SD P-Coolant Diff
ZKP-Number:
Red alarm.
Associated parameter 1.8004.610
Cause
Corrective action
Coolant differential pressure
sensor defective, short circuit or
wire break.
u Check sensors and cabling (B16.1, B16.3), replace if necessary.
Fault is rectified when engine is restarted.
515 – AL Starter Not Engaged
Yellow alarm.
Associated parameter 2.1090.926
Cause
ECU does not detect engine
speed during starting sequence.
126 | Troubleshooting | MS150034/02E 2012-07
Corrective action
1. Check starter.
2. Check cabling.
3. Check speed sensor.
TIM-ID: 0000017544 - 001
ZKP-Number:
517 – SD P-Charge Mix before Throttle
ZKP-Number:
Red alarm.
Associated parameter 1.8004.631
Cause
Mixture pressure sensor before
throttle defective, short circuit or
wire break.
Corrective action
u Check sensor and cabling (B79.23), replace if necessary. Fault
is rectified when engine is restarted.
520 – SD P-Intake Air after Filter A
ZKP-Number:
Yellow alarm.
Associated parameter 1.0186.900
Cause
Intake air pressure sensor after
filter on A side defective, short
circuit or wire break.
Corrective action
u Check sensor and cabling (B81.1), replace if necessary. Fault is
rectified when engine is restarted.
522 – SD P-Intake Air after Filter B
ZKP-Number:
Yellow alarm.
Associated parameter 1.0187.900
Cause
Intake air pressure sensor after
filter on B side defective, short
circuit or wire break.
Corrective action
u Check sensor and cabling (B81.2), replace if necessary. Fault is
rectified when engine is restarted.
531 – AL Wiring PWM_CM1
ZKP-Number:
Red alarm.
Associated parameter 1.1044.900
TIM-ID: 0000017544 - 001
Cause
Cable break or short circuit on
channel PWM_CM1.
Corrective action
u Check cabling to TecJet throttle, replace TecJet throttle if
necessary.
MS150034/02E 2012-07 | Troubleshooting | 127
532 – AL Wiring PWM1
ZKP-Number:
Red alarm.
Associated parameter 1.1046.900
Cause
Corrective action
Wire break or short circuit on
channel PWM1.
u Check wiring to mixture throttle on A side, replace mixture
throttle on A side if necessary.
533 – AL Wiring PWM2
ZKP-Number:
Red alarm.
Associated parameter 1.1047.900
Cause
Corrective action
Wire break or short circuit on
channel PWM2.
u Check wiring to mixture throttle on B side, replace mixture
throttle on B side if necessary.
543 – AL Multiple FDH Slaves
ZKP-Number:
Yellow alarm.
Associated parameter 2.0555.005
Cause
More than one device is
activated as backup medium for
FDH.
Corrective action
u Contact Service (configuration fault).
544 – AL Configuration Changed
ZKP-Number:
Yellow alarm.
Associated parameter 2.0555.003
This alarm is activated when the
system configuration was
changed, e.g. because the ECU
or SAM was exchanged.
128 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Contact Service (configuration fault).
TIM-ID: 0000017544 - 001
Cause
552 – AL GasControlCheck Fault
ZKP-Number:
Red alarm.
Associated parameter 2.1090.118
Cause
Gas train test was not
successful. Alarm is activated if
the gas train does not report OK
within a specified time-out
period. Either the gas train leak
test was not successful, the
time-out period is set too short,
or communication is faulty.
Corrective action
1. Check gas train.
2. Check cabling.
554 – AL Ignition Fault
ZKP-Number:
Red alarm.
Associated parameter 2.1090.122
Cause
Ignition failure. Alarm is activated
if the feedback signal from
ignition system is not received
within a specified time-out
period. Either the ignition could
not be activated, the time-out
period is set too short, or
communication is faulty.
Corrective action
u Check ignition system and cabling.
556 – AL GasValve Fault
ZKP-Number:
Red alarm.
Associated parameter 2.1090.124
TIM-ID: 0000017544 - 001
Cause
Gas supply solenoid valve faulty.
Either the gas supply solenoid
valves are faulty, the time-out
period is set too short, or
communication is faulty.
Corrective action
u Check gas train and cabling.
MS150034/02E 2012-07 | Troubleshooting | 129
557 – AL speed drop fault
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.1090.126
Cause
Speed drop. Alarm is activated if
engine speed drops during
starting sequence.
Corrective action
u Check gas train.
559 – AL mixture throttle A fault
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.1450.010
Cause
A problem related to mixture
throttle on A side occurred.
Possible causes: Mixture throttle
defective, no power supply to
throttle, cabling of feedback and/
or position signal faulty.
Corrective action
u Check mixture throttle on A side and cabling. Replace mixture
throttle on A side if necessary.
560 – AL mixture throttle B fault
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 1.1450.013
Cause
A problem related to mixture
throttle on B side occurred.
Possible causes: Mixture throttle
defective, no power supply to
throttle, cabling of feedback and/
or position signal faulty.
Corrective action
u Check mixture throttle on B side and cabling. Replace mixture
throttle on B side if necessary.
565 – AL L1 P-Intake Air after Filter A
Yellow alarm.
Associated parameter 2.0186.921
Cause
Pressure loss over air filter on A
side is too high.
130 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Replace air filter (→ Page 154).
TIM-ID: 0000017544 - 001
ZKP-Number:
566 – AL L2 P-Intake Air after Filter A
ZKP-Number:
Yellow alarm.
Associated parameter 2.0186.931
Cause
Pressure loss over air filter on A
side is too high.
Corrective action
u Replace air filter (→ Page 154).
567 – AL L1 P-Intake Air after Filter B
ZKP-Number:
Yellow alarm.
Associated parameter 2.0187.921
Cause
Pressure loss over air filter on B
side is too high.
Corrective action
u Replace air filter (→ Page 154).
568 – AL L2 P-Intake Air after Filter B
ZKP-Number:
Yellow alarm.
Associated parameter 2.0187.931
Cause
Pressure loss over air filter on B
side is too high.
Corrective action
u Replace air filter (→ Page 154).
569 – AL SAM Missing Data Fault
ZKP-Number:
Red alarm.
Associated parameter 2.1090.128
TIM-ID: 0000017544 - 001
Cause
This alarm is activated if the
ECU does not receive some
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.
Corrective action
u Check the cabling/connectors of the devices connected to SAM
and ECU bus. Replace devices if necessary.
MS150034/02E 2012-07 | Troubleshooting | 131
570 – L1 AI CAN Max Retarded Timing
ZKP-Number:
Yellow alarm.
Associated parameter 2.1200.931
Cause
The cylinder set to maximum
retarded timing due to knocking
has violated the first limit value.
Corrective action
1. Check emissions.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
571 – L2 AI CAN Max Retarded Timing
ZKP-Number:
Yellow alarm. Power reduction.
Associated parameter 2.1200.932
Cause
The cylinder set to maximum
retarded timing due to knocking
has violated the second limit
value. Power reduction is
initiated.
Corrective action
1. Check emissions.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
572 – L3 AI CAN Max Retarded Timing
ZKP-Number:
Red alarm. Engine shutdown.
Associated parameter 2.1200.932
Cause
The cylinder set to maximum
retarded timing due to knocking
has violated the third limit value.
Corrective action
1. Check emissions.
2. Check ignition timing (→ Page 137).
3. Check combustion chamber.
4. Check gas quality if feasible (methane number).
583 – AL GLS closed
ZKP-Number:
Associated parameter 2.0451.005
Cause
Generator load switch does not
open when engine stops. Engine
is motoring.
132 | Troubleshooting | MS150034/02E 2012-07
Corrective action
u Check generator load switch.
TIM-ID: 0000017544 - 001
Red alarm. Engine shutdown.
6 Task Description
6.1 Engine
6.1.1
Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
DANGER
Part No.
Qty.
Barring tool
F6555766
1
Ratchet head with extension
F30006212
1
Unguarded rotating and moving engine components.
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Engine, barring manually
1.
2.
3.
4.
TIM-ID: 0000002531 - 001
5.
Remove guard plate.
Engage barring tool (2) with ring gear (3)
and install on flywheel housing.
Apply ratchet (1) to barring gear (2).
Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no abnormal re‐
sistance.
Remove barring tool in reverse order.
MS150034/02E 2012-07 | Task Description | 133
6.1.2
Checking machine room for smell of gas
Special tools, Material, Spare parts
Designation / Use
Gas detection and alarm unit
WARNING
Part No.
Qty.
(→ Tools Catalog)
Natural gas is combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Checking machine room for smell of gas
Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit.
If smell of gas is detected or the gas detection and alarm unit is triggered:
• Avoid naked flames!
• Avoid sparks! Do not use electrical appliances (including switches, connectors/sockets, telephone,
bell).
• Do not smoke!
• Close main gas shutoff device!
• Open windows and doors!
• Warn residents and leave building!
• Call gas supplier from outside the building!
TIM-ID: 0000002533 - 001
1.
2.
134 | Task Description | MS150034/02E 2012-07
6.2 Crankcase Breather
6.2.1
Oil separator – Filter element replacement
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
WARNING
Part No.
Qty.
Filter element
(→ Spare Parts Catalog)
2
Sealing ring
(→ Spare Parts Catalog)
2
O-ring
(→ Spare Parts Catalog)
4
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Oil separator – Filter element
replacement
Loosen clamp (1).
Open clamping ring (3).
Take off oil separator upper section (2) with
filter element.
TIM-ID: 0000011588 - 001
1.
2.
3.
MS150034/02E 2012-07 | Task Description | 135
4.
5.
6.
7.
Back off screws (3) on tie bolt.
Remove cover (2).
Replace filter element (1).
Fit cover (2) and tighten screws (3).
8.
Replace O-rings (arrowed) at oil drain nip‐
ple.
9.
Replace sealing ring in oil separator hous‐
ing.
Fit oil separator upper section (2) with filter
element.
Close clamping ring (3).
Align clamp (1) and secure.
10.
TIM-ID: 0000011588 - 001
11.
12.
Replace filter element of second oil separator in the same way.
136 | Task Description | MS150034/02E 2012-07
6.3 Ignition System
6.3.1
Ignition system – Ignition timing check
Preconditions
☑ Operating voltage of genset control system is present.
☑ Genset is disconnected from the mains.
Special tools, Material, Spare parts
Designation / Use
Stroboscope
DANGER
WARNING
Part No.
Qty.
(→ Tools Catalog)
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Ignition system – Ignition timing
check
Note:
1.
2.
3.
4.
5.
TIM-ID: 0000016810 - 002
6.
7.
8.
For the specified ignition timing, contact
your Service partner.
Stop engine (→ Page 42).
Install stroboscope clamp on cylinder A1 ig‐
nition cable.
Start engine (→ Page 40).
Using the stroboscope, check ignition tim‐
ing on flywheel mark.
If the value does not correspond to specifi‐
cation, set ignition timing (see manufactur‐
er's documentation for ignition system).
Check ignition timing.
Disconnect stroboscope.
Stop engine (→ Page 42).
MS150034/02E 2012-07 | Task Description | 137
6.3.2
Spark plug connector – Replacement
Special tools, Material, Spare parts
Designation / Use
Spark plug connector
Part No.
Qty.
(→ Spare Parts Catalog)
Remove spark plug connector and install new one.
(→ Page 142)
TIM-ID: 0000035897 - 003
u
138 | Task Description | MS150034/02E 2012-07
6.3.3
Spark plug connector – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Open protective packing of new spark plug connector only immediately prior to installation.
Special tools, Material, Spare parts
Designation / Use
WARNING
WARNING
Part No.
Qty.
Torque wrench, 10-60 Nm
F30452769
1
Spark plug wrench
F30452574
1
Spark plug connector with ignition line
(→ Spare Parts Catalog)
Locking plate
(→ Spare Parts Catalog)
Sealing ring
(→ Spare Parts Catalog)
Component is hot.
Risk of burning!
• Wear protective gloves.
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Removing spark plug connector
1.
2.
3.
4.
TIM-ID: 0000035898 - 003
5.
Remove protective cap (3) from ignition coil
(1).
Remove screw (2), take off spring washer.
Remove screws (5) and tab washer (7)
from cylinder head cover.
Remove spark plug connector (6) with igni‐
tion cable (4) from spark plug.
Remove sealing ring from Teflon sleeve of
ignition line.
MS150034/02E 2012-07 | Task Description | 139
Installing spark plug connector
1.
2.
3.
4.
TIM-ID: 0000035898 - 003
5.
Clean Teflon sleeve and install new sealing
ring in Teflon sleeve of ignition line.
Fit spark plug connector (6) with ignition ca‐
ble (4) on spark plug.
Fit locking plate (7) on cylinder head cover.
Screw screw (2) with spring washer onto ig‐
nition coil (1).
Push protective cap (3) onto ignition coil.
140 | Task Description | MS150034/02E 2012-07
6.3.4
Spark plug – Replacement
Special tools, Material, Spare parts
Designation / Use
Spark plug
Part No.
Qty.
(→ Spare Parts Catalog)
Remove spark plug and install new one .
(→ Page 142)
TIM-ID: 0000004224 - 001
u
MS150034/02E 2012-07 | Task Description | 141
6.3.5
Spark plug – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Open protective packing of new spark plug only immediately prior to installation.
Special tools, Material, Spare parts
Designation / Use
WARNING
WARNING
Part No.
Qty.
Torque wrench, 10-60 Nm
F30452769
1
Spark plug socket wrench, 20.8 mm
F30452574
1
Assembly compound (Molykote P 37)
50564
1
Spark plug
(→ Spare Parts Catalog)
Sealing ring
(→ Spare Parts Catalog)
Spark plug connector with ignition cable
(→ Spare Parts Catalog)
Locking plate
(→ Spare Parts Catalog)
Component is hot.
Risk of burning!
• Wear protective gloves.
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
1.
2.
3.
4.
5.
6.
7.
Remove ignition cable (2) from ignition coil.
Remove screws (4) and locking plate (5)
from cylinder head cover (1).
Remove spark plug connector (3) with igni‐
tion cable (2) from spark plug.
Unscrew spark plug a few threads.
Clean spark-plug recess with compressed
air.
Unscrew spark plug from cylinder head.
Remove the lower gasket on ignition line
(see instructions for changing ignition line
gasket).
142 | Task Description | MS150034/02E 2012-07
TIM-ID: 0000029131 - 002
Removing spark plug
Installing spark plug
1.
2.
3.
4.
5.
6.
7.
Note:
8.
The temperature of spark plug and cylinder head must be the same prior to tightening.
Tighten spark plug to specified tightening torque using a torque wrench.
Name
Size
Type
Spark plug
M18 x 1.5 Tightening torque
Lubricant
Value/Standard
(Assembly compound 50 Nm
(Molykote P 37))
Fit spark plug connector with ignition cable on spark plug.
Install locking plates on cylinder head cover.
Install ignition cable on ignition coil.
TIM-ID: 0000029131 - 002
9.
10.
11.
Remove dust and deposits from ignition line
on side facing spark plugs so that perfect is
achieved when reused.
Install a new lower gasket in the ignition
line.
Check spark plug connector and ignition ca‐
ble for perfect condition and replace any
damaged parts.
Clean mating faces on spark plug, sealing
ring and cylinder head.
Apply thin coat of assembly compound to
spark plug.
Fit new sealing ring (2) on spark plug (1),
positioning it correctly.
Screw spark plug into cylinder head.
MS150034/02E 2012-07 | Task Description | 143
6.4 Valve Drive
6.4.1
Valve gear – Lubrication
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Engine oil
Valve gear – Lubrication
1.
2.
TIM-ID: 0000004337 - 004
3.
Remove cylinder head covers
(→ Page 152).
Fill oil chambers of rocker arms and adjust‐
ing screws with oil.
Install cylinder head covers (→ Page 152).
144 | Task Description | MS150034/02E 2012-07
6.4.2
Valve clearance – Check and adjustment
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Feeler gauge
Y20098771
1
Offset screwdriver
F30452765
1
Torque wrench, 60-320 Nm
F30452768
1
Socket wrench, 24 mm
F30029815
1
Engine oil
Preparatory steps
Cylinder head cover removal (→ Page 152)
Barring tool installation (→ Page 133)
3.
Rotate crankshaft with barring tool in en‐
gine direction of rotation until marking “OT”
and pointer are aligned.
TIM-ID: 0000012227 - 002
1.
2.
MS150034/02E 2012-07 | Task Description | 145
Diagram-wo crankshaft positions
1
2
I
X
Cylinder A1 is in firing TDC
Cylinder A1 is in overlap TDC
Inlet valve
Exhaust valve
Checking valve clearance at two crankshaft positions
1.
2.
3.
4.
5.
Check TDC position of piston in cylinder A1:
• If the rocker arms are not under load 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.
Check valve clearance with cold engine:
• Inlet valves (long rocker arm) = 0.3 mm
• Exhaust valves (short rocker arm) = 0.5 mm
Check all valve clearances in two crankshaft positions (firing and overlap TDC for cylinder A1) as per
diagram.
Check distance between valve bridge and rocker arm using a feeler gauge.
If the deviation from the desired value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance
3.
4.
5.
6.
7.
Release locknut (1).
Insert feeler gauge between valve bridge
and rocker arm.
Using offset screwdriver, set adjusting
screw (2) so that the specified valve clear‐
ance is provided.
Feeler gauge must just pass through the
gap.
Tighten locknut (1) to specified tightening torque using a torque wrench securing adjusting screw (2) in
so doing.
Name
Size
Type
Lubricant
Value/Standard
Locknut
M16
Tightening torque
(Engine oil)
90 Nm+9 Nm
Replace or rectify adjusting screws and/or locknuts which do not move freely.
Check valve clearance
146 | Task Description | MS150034/02E 2012-07
TIM-ID: 0000012227 - 002
1.
2.
Final steps
Barring tool removal (→ Page 133)
Cylinder head cover installation (→ Page 152)
TIM-ID: 0000012227 - 002
1.
2.
MS150034/02E 2012-07 | Task Description | 147
6.4.3
Valve depth – Measurement
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Depth gauge
Part No.
Qty.
Y20095775
1
Preparatory steps
Remove spark plugs (→ Page 139).
Remove cylinder head covers (→ Page 152).
3.
4.
Remove sleeves (arrow).
Install barring device (→ Page 133).
5.
Rotate crankshaft with barring device in en‐
gine direction of rotation until marking “OT”
and pointer are aligned.
TIM-ID: 0000012015 - 002
1.
2.
148 | Task Description | MS150034/02E 2012-07
Measuring valve depth
1.
2.
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.
Measure valve depth for each valve in two crankshaft positions (firing TDC and overlap TDC for cylinder
A1) according to the diagram. Diagram (→ Page 145).
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 (→ Instructions for Overhaul of
Assemblies).
Install valve bridge.
Adjust valve clearance (→ Page 145)
5.
6.
TIM-ID: 0000012015 - 002
Final steps
1.
2.
Remove barring device (→ Page 133).
Check condition of O-rings at the sleeves, replace if damaged.
MS150034/02E 2012-07 | Task Description | 149
Install sleeves (arrow).
Install cylinder head covers (→ Page 152).
Install spark plugs with new sealing rings
(→ Page 139).
TIM-ID: 0000012015 - 002
3.
4.
5.
150 | Task Description | MS150034/02E 2012-07
6.4.4
Valve gear – Lubrication
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Engine oil
Valve gear – Lubrication
1.
2.
TIM-ID: 0000004337 - 004
3.
Remove cylinder head covers
(→ Page 152).
Fill oil chambers of rocker arms and adjust‐
ing screws with oil.
Install cylinder head covers (→ Page 152).
MS150034/02E 2012-07 | Task Description | 151
6.4.5
Cylinder head cover – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Gasket
Part No.
Qty.
(→ Spare Parts Catalog)
Removing cylinder head cover
1.
2.
3.
4.
5.
Clean very dirty cylinder head covers prior
to removal.
Remove spark plug (2) (→ Page 142).
Close off opening with suitable plug.
Remove screws (1).
Remove cylinder head cover with gasket
from cylinder head.
Installing cylinder head cover
Clean mating faces.
Check condition of gasket, replace if damaged.
Place gasket and cylinder head cover on cylinder head.
Cylinder head cover installation
Remove plug.
Install spark plug (2) (→ Page 142).
TIM-ID: 0000012318 - 001
1.
2.
3.
4.
5.
6.
152 | Task Description | MS150034/02E 2012-07
6.5 Gas System
6.5.1
Gas supply – Checking gas lines for leaks
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Leakage detection spray
Soap solution
WARNING
Natural gas is combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Gas supply – Checking gas lines for leaks
1.
TIM-ID: 0000004996 - 001
2.
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.
Replace leaking parts.
MS150034/02E 2012-07 | Task Description | 153
6.6 Air Filter
6.6.1
Air filter – Replacement
Special tools, Material, Spare parts
Designation / Use
Note:
Part No.
Air filter
(→ Spare Parts Catalog)
Fleece prefilter (optional)
(→ Spare Parts Catalog)
Qty.
Air filter condition is monitored by a sensor. Replace air filter and/or (optional) fleece prefilter when the
corresponding fault message appears.
Remove air filter and install new one .
(→ Page 155)
TIM-ID: 0000013394 - 001
u
154 | Task Description | MS150034/02E 2012-07
6.6.2
Air filter – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
Air filter – Removal and installation
1.
2.
3.
4.
TIM-ID: 0000000904 - 009
5.
Release clamp (2).
Remove air filter (3) and clamp (2) from
flange of intake housing (1).
Verify that there are no objects in the flange
of the intake housing (1) and clean it.
Place new air filter (3) with clamp (2) onto
intake housing (1).
Tighten clamp (2).
MS150034/02E 2012-07 | Task Description | 155
6.7 Lube Oil System, Lube Oil Circuit
6.7.1
Engine oil level – Check
Preconditions
☑ Engine shut down and starting disabled.
WARNING
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Oils/oil vapors are combustible.
Risk of fire!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
Oil level check prior to engine start
1.
2.
Note:
3.
4.
5.
Withdraw oil dipstick from guide tube and
wipe it.
Insert dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds
and check oil level.
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.
The oil level must reach the mark (2) or ex‐
ceed the mark (1) by up to 2 cm.
If necessary, top up to the mark (1)
(→ Page 157).
Insert oil dipstick into guide tube up to the
stop.
1.
2.
3.
4.
5.
5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
Oil level must be between marks (1) and (2).
If necessary, top up to the mark (1) (→ Page 157).
Insert oil dipstick into guide tube up to the stop.
Checking oil level in oil storage tank
1.
2.
3.
Check oil level.
Oil level must be between “min.” and “max.” marks.
If necessary, top up to "max." mark (→ Page 157).
156 | Task Description | MS150034/02E 2012-07
TIM-ID: 0000006169 - 002
Oil level check after the engine is stopped
6.7.2
Engine oil – Change
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specification (A001061/..) is available.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Engine oil
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Extracting engine oil
1.
2.
3.
Open shut-off valve(s) in extraction line from engine and waste-oil tank.
Extract all oil from oil pan using the electric pump.
Close shut-off valve(s).
Filling with new engine oil
1.
2.
TIM-ID: 0000006160 - 001
3.
Determine amount of engine oil required for oil change (→ Product Summary - Technical Data).
Use electric pump to fill engine with oil from new-oil tank until the "max." mark on the oil dipstick is
reached.
Check engine oil level (→ Page 156).
MS150034/02E 2012-07 | Task Description | 157
6.7.3
Engine oil – Sampling and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Special tools, Material, Spare parts
Designation / Use
MTU test kit
DANGER
WARNING
WARNING
Part No.
Qty.
5605892099/00
1
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Engine oil – Sample extraction and
analysis
1.
2.
TIM-ID: 0000014117 - 001
3.
Connect sampling hose (unit manufacturer
scope of delivery) to sampling neck (ar‐
rowed) with engine running at operating
temperature.
Drain approx. 0.5 liter engine oil into a
clean container.
Using the equipment and chemicals of the
MTU test kit, examine engine oil for:
• Dispersing capacity (spot test);
• Water content.
158 | Task Description | MS150034/02E 2012-07
6.8 Oil Filtration / Cooling
6.8.1
Engine oil filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Filter wrench
Engine oil
Oil filter
WARNING
Part No.
Qty.
F30379104
1
(→ Spare Parts Catalog)
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Engine oil filter – Replacement
1.
2.
3.
4.
5.
TIM-ID: 0000006398 - 002
6.
Remove oil filter with filter wrench.
Clean the sealing face on the adapter.
Check condition of new oil filter sealing ring
and coat it with oil.
Screw on and tighten new engine oil filter
by hand.
Replace other engine oil filters in the same
way.
Check engine oil level (→ Page 156).
MS150034/02E 2012-07 | Task Description | 159
6.9 Coolant Circuit, General, High-Temperature Circuit
6.9.1
Engine coolant – Level check
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specification (A001061/..) is available.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Engine coolant – Level check
1.
TIM-ID: 0000006768 - 001
2.
Read off system pressure at pressure gauge, for system pressure (→ Product Summary - Technical Da‐
ta).
If required, top up with treated coolant (→ Page 164).
160 | Task Description | MS150034/02E 2012-07
6.9.2
Engine coolant – Change
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Coolant
Engine coolant – Change
Drain engine coolant (→ Page 162).
Fill with engine coolant (→ Page 164).
TIM-ID: 0000000036 - 030
1.
2.
MS150034/02E 2012-07 | Task Description | 161
6.9.3
Engine coolant – Draining
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Sealing ring
WARNING
Part No.
Qty.
(→ Spare Parts Catalog)
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Preparatory steps
1.
2.
Provide an appropriate container to drain the coolant into.
Switch off preheating unit if installed.
Engine coolant – Draining
Open drain valves and drain coolant at the
following points:
• At the crankcase free end, LHS and RHS
TIM-ID: 0000006751 - 001
1.
162 | Task Description | MS150034/02E 2012-07
2.
TIM-ID: 0000006751 - 001
3.
Draining of residual coolant:
• At coolant distribution housing.
Close all open drain points.
MS150034/02E 2012-07 | Task Description | 163
6.9.4
Engine coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Engine coolant
WARNING
CAUTION
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Engine coolant filling
1.
TIM-ID: 0000014575 - 001
2.
3.
4.
Fill with treated coolant until the specified system pressure (→ Product Summary - Technical Data) is pro‐
vided.
Vent engine coolant circuit (see documentation of genset manufacturer).
Start the engine and operate it at idle speed for some minutes.
Check coolant level (→ Page 160) and top up if required.
164 | Task Description | MS150034/02E 2012-07
6.9.5
Vent line of engine coolant circuit – Replacement
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Replacing coolant vent line
Drain engine coolant (→ Page 162).
Release union nuts (1) and (3).
Remove coolant vent line (2).
Install new coolant vent line (2).
Fill with engine coolant (→ Page 164).
TIM-ID: 0000029143 - 002
1.
2.
3.
4.
5.
MS150034/02E 2012-07 | Task Description | 165
6.10 Low-Temperature Circuit
6.10.1
Mixture coolant level - Check
Preconditions
☑ Engine shut down and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Checking mixture coolant level
1.
TIM-ID: 0000007032 - 002
2.
Read off system pressure at pressure gauge, for system pressure (→ Product Summary - Technical Da‐
ta).
Top up with treated coolant as necessary (→ Page 169).
166 | Task Description | MS150034/02E 2012-07
6.10.2
Mixture coolant - Change
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Mixture coolant
Drain mixture coolant .
u
(→ Page 168)
Fill mixture coolant system .
(→ Page 169)
TIM-ID: 0000007027 - 002
u
MS150034/02E 2012-07 | Task Description | 167
6.10.3
Mixture coolant - Draining
Preconditions
☑ Engine shut down and starting disabled.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Draining charge-air coolant
Provide a suitable receptacle to catch the coolant.
Open drain valve in the coolant line to the mixture cooler (see documentation of genset manufacturer)
and drain coolant.
TIM-ID: 0000007024 - 002
1.
2.
168 | Task Description | MS150034/02E 2012-07
6.10.4
Mixture coolant - Filling
Preconditions
☑ Engine shut down and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Mixture coolant
WARNING
CAUTION
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Filling with coolant
1.
TIM-ID: 0000014853 - 002
2.
3.
4.
Fill with treated coolant until the specified system pressure (→ Product Summary - Technical Data) is pro‐
vided.
Vent mixture coolant circuit (see documentation of genset manufacturer).
Start the engine and operate it at idle speed for some minutes.
Check coolant level (→ Page 166) and top up engine coolant as required.
MS150034/02E 2012-07 | Task Description | 169
6.11 Wiring (General) for Engine/Gearbox/Unit
6.11.1
Engine wiring – Check
Preconditions
☑ Engine is stopped and starting disabled.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Isopropyl alcohol
X00058037
1
Engine wiring – Check
1.
2.
3.
4.
5.
6.
Close male connectors that are not plugged in with the protective cap supplied.
Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 018
Note:
7.
8.
Check securing screws of cable clamps on engine and tighten loose threaded connections.
Ensure that cables are fixed in their clamps and cannot swing freely.
Check that cable ties are firm, tighten loose cable ties.
Replace faulty cable ties.
Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
(→ Contact Service) if cable conductors are damaged.
170 | Task Description | MS150034/02E 2012-07
6.11.2
Sensors – Overview
Pos.
Designation
Monitoring of
1
B49.2
Intake air temperature B side
2
B81.2
Intake air pressure after filter B side
3
B4.XX
Exhaust gas temperature after cylinder XX
4
B79.22
Mixture pressure B side
5
B73
Mixture temperature
TIM-ID: 0000012950 - 001
The knocking sensors (B80.XX) are arranged on the crankcase (right and left) below the cylinder heads.
MS150034/02E 2012-07 | Task Description | 171
Designation
Monitoring of
1
B79.23
Mixture pressure before throttle
2
B75
Crankshaft speed reset
3
B13.2
Crankshaft speed ignition
TIM-ID: 0000012950 - 001
Pos.
172 | Task Description | MS150034/02E 2012-07
TIM-ID: 0000012950 - 001
Pos.
Designation
Monitoring of
1
B49.1
Intake air temperature A side
2
B81.1
Intake air pressure after filter A side
3
B79.21
Mixture pressure A side
4
B50
Crankcase pressure
5
B5.3
Engine oil pressure before filter
6
B7
Engine oil temperature
7
B5.1
Engine oil pressure after filter
8
B4.21
Combined exhaust gas temperature A side
Pos.
Designation
Monitoring of
1
B16.3
Coolant pressure before engine
2
B1.3/B1.1
Crankshaft speed for AKR/engine governor
3
B24
Engine oil level
4
B1.2
Camshaft speed for ignition system
5
B6.3
Coolant temperature before engine
6
B6.1
Coolant temperature after engine
7
B16.1
Coolant pressure after engine
8
B4.22
Combined exhaust gas temperature B side
MS150034/02E 2012-07 | Task Description | 173
7 Appendix A
Abbreviation
Meaning
Explanation
AL
Alarm
Alarm message
ANSI
American National Standards Institute
Association of American standardization or‐
ganizations
ETC
Exhaust turbocharger
BR
Series
BV
Fluids and Lubricants Specifications
MTU Publication 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
ECU
Engine Control Unit
Engine governor
EMU
Engine Monitoring Unit
Monitoring unit for engine
SPC
Spare Parts Catalog
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
High temperature
ICFN
ISO - Continuous - Fuel stop - brake
power
Fuel stop power ISO International coding for
power output of combustion engines
ISO
International Organization for Stand‐
ardization
International umbrella organization for all na‐
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
Light emitting diode
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
MD
Missing Data
A measuring point does not provide data.
MG
Message
General message
LT
Low temperature
OEM
Original Equipment Manufacturer
TDC
Top Dead Center
PAN
Panel
174 | Appendix A | MS150034/02E 2012-07
Control panel
TIM-ID: 0000009960 - 002
7.1 Abbreviations
Meaning
Explanation
PIM
Peripheral Interface Module
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
SD
Sensor Defect
Alarm: Sensor failure
SS
Safety System
Safety system alarm
TA-Luft
Technische Anleitung zur Reinhaltung
der Luft
General administrative instruction for federal
emission control law in Germany
TD
Transmitter Deviation
Alarm: Sensor comparison fault
BDC
Bottom Dead Center
TC
Tool Catalog
ZZP
Ignition timing
TIM-ID: 0000009960 - 002
Abbreviation
MS150034/02E 2012-07 | Appendix A | 175
7.2 MTU Onsite Energy contact / service partner
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.mtu-online.com/mtuonsiteenergy/
kontakt
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 operat‐
ing conditions, or for spare parts supply.
Your contact at Headquarters: service-oeg@mtu-online.com
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:
E-mail: spareparts-oeg@mtu-online.com
Germany:
• Tel.: 0800 5633000
• Fax: 0800 5644000
TIM-ID: 0000002624 - 002
Worldwide:
• Tel.: +49 821 7480331
• Fax: +49 821 7480288
176 | Appendix A | MS150034/02E 2012-07
8 Appendix B
8.1 Special Tools
Barring tool
Part No.:
F6555766
Qty.:
Used in:
1
6.1.1 Engine – Barring manually (→ Page 133)
Part No.:
Y20095775
Qty.:
Used in:
1
6.4.3 Valve depth – Measurement (→ Page 148)
Part No.:
Y20098771
Qty.:
Used in:
1
6.4.2 Valve clearance – Check and adjustment (→ Page
145)
Part No.:
F30379104
Qty.:
Used in:
1
6.8.1 Engine oil filter – Replacement (→ Page 159)
Depth gauge
Feeler gauge
DCL-ID: 0000016353 - 003
Filter wrench
MS150034/02E 2012-07 | Appendix B | 177
Gas detection and alarm unit
Part No.:
Qty.:
Used in:
6.1.2 Checking machine room for smell of gas (→ Page
134)
MTU test kit
Part No.:
5605892099/00
Qty.:
Used in:
1
6.7.3 Engine oil – Sampling and analysis (→ Page 158)
Part No.:
F30452765
Qty.:
Used in:
1
6.4.2 Valve clearance – Check and adjustment (→ Page
145)
Part No.:
F30006212
Qty.:
Used in:
1
6.1.1 Engine – Barring manually (→ Page 133)
Part No.:
F30029815
Qty.:
Used in:
1
6.4.2 Valve clearance – Check and adjustment (→ Page
145)
Offset screwdriver
Ratchet head with extension
178 | Appendix B | MS150034/02E 2012-07
DCL-ID: 0000016353 - 003
Socket wrench, 24 mm
Spark plug socket wrench, 20.8 mm
Part No.:
F30452574
Qty.:
Used in:
1
6.3.5 Spark plug – Removal and installation (→ Page
142)
Part No.:
F30452574
Qty.:
Used in:
1
6.3.3 Spark plug connector – Removal and installation
(→ Page 139)
Spark plug wrench
Stroboscope
Part No.:
Qty.:
Used in:
6.3.1 Ignition system – Ignition timing check (→ Page
137)
Torque wrench, 10-60 Nm
Part No.:
F30452769
Qty.:
Used in:
1
6.3.3 Spark plug connector – Removal and installation
(→ Page 139)
Qty.:
Used in:
1
6.3.5 Spark plug – Removal and installation (→ Page
142)
Part No.:
F30452768
Qty.:
Used in:
1
6.4.2 Valve clearance – Check and adjustment (→ Page
145)
DCL-ID: 0000016353 - 003
Torque wrench, 60-320 Nm
MS150034/02E 2012-07 | Appendix B | 179
8.2 Consumables
Assembly compound (Molykote P 37)
Part No.:
50564
Qty.:
Used in:
1
6.3.5 Spark plug – Removal and installation (→ Page 142)
Coolant
Part No.:
Qty.:
Used in:
6.9.2 Engine coolant – Change (→ Page 161)
Engine coolant
Part No.:
Qty.:
Used in:
6.9.4 Engine coolant – Filling (→ Page 164)
Engine oil
Part No.:
Qty.:
Used in:
6.4.1 Valve gear – Lubrication (→ Page 144)
Qty.:
Used in:
6.4.2 Valve clearance – Check and adjustment (→ Page 145)
Qty.:
Used in:
6.4.4 Valve gear – Lubrication (→ Page 151)
Qty.:
Used in:
6.7.2 Engine oil – Change (→ Page 157)
Qty.:
Used in:
6.8.1 Engine oil filter – Replacement (→ Page 159)
Isopropyl alcohol
Part No.:
X00058037
Qty.:
Used in:
1
6.11.1 Engine wiring – Check (→ Page 170)
Leakage detection spray
Qty.:
Used in:
6.5.1 Gas supply – Checking gas lines for leaks (→ Page 153)
Mixture coolant
Part No.:
Qty.:
Used in:
6.10.2 Mixture coolant - Change (→ Page 167)
Qty.:
Used in:
6.10.4 Mixture coolant - Filling (→ Page 169)
180 | Appendix B | MS150034/02E 2012-07
DCL-ID: 0000016353 - 003
Part No.:
Soap solution
Part No.:
6.5.1 Gas supply – Checking gas lines for leaks (→ Page 153)
DCL-ID: 0000016353 - 003
Qty.:
Used in:
MS150034/02E 2012-07 | Appendix B | 181
8.3 Spare Parts
Air filter
Part No.:
Qty.:
Used in:
6.6.1 Air filter – Replacement (→ Page 154)
Filter element
Part No.:
Qty.:
Used in:
2
6.2.1 Oil separator – Filter element replacement (→ Page 135)
Fleece prefilter (optional)
Part No.:
Qty.:
Used in:
6.6.1 Air filter – Replacement (→ Page 154)
Gasket
Part No.:
Qty.:
Used in:
6.4.5 Cylinder head cover – Removal and installation (→ Page 152)
Locking plate
Part No.:
Qty.:
Used in:
6.3.3 Spark plug connector – Removal and installation (→ Page 139)
Qty.:
Used in:
6.3.5 Spark plug – Removal and installation (→ Page 142)
O-ring
Part No.:
Qty.:
Used in:
4
6.2.1 Oil separator – Filter element replacement (→ Page 135)
Oil filter
Qty.:
Used in:
6.8.1 Engine oil filter – Replacement (→ Page 159)
182 | Appendix B | MS150034/02E 2012-07
DCL-ID: 0000016353 - 003
Part No.:
Sealing ring
Part No.:
Qty.:
Used in:
2
6.2.1 Oil separator – Filter element replacement (→ Page 135)
Qty.:
Used in:
6.3.3 Spark plug connector – Removal and installation (→ Page 139)
Qty.:
Used in:
6.3.5 Spark plug – Removal and installation (→ Page 142)
Qty.:
Used in:
6.9.3 Engine coolant – Draining (→ Page 162)
Spark plug
Part No.:
Qty.:
Used in:
6.3.4 Spark plug – Replacement (→ Page 141)
Qty.:
Used in:
6.3.5 Spark plug – Removal and installation (→ Page 142)
Spark plug connector
Part No.:
Qty.:
Used in:
6.3.2 Spark plug connector – Replacement (→ Page 138)
Spark plug connector with ignition cable
Part No.:
Qty.:
Used in:
6.3.5 Spark plug – Removal and installation (→ Page 142)
Spark plug connector with ignition line
Part No.:
6.3.3 Spark plug connector – Removal and installation (→ Page 139)
DCL-ID: 0000016353 - 003
Qty.:
Used in:
MS150034/02E 2012-07 | Appendix B | 183
8.4 Index
A
Abbreviations 174
After stopping the engine – Engine remains ready for op‐
eration 44
After stopping the engine – Putting the engine out of op‐
eration 45
Air filter
– Installation 155
– Removal 155
Air filter – Replacement 154
C
Checking machine room for smell of gas 134
Control cabinet MIS – Overview 32
Control, starting and stopping sequences 39
Cylinder
– Designation 18
Cylinder head cover – Removal and installation 152
Gas supply – Checking gas lines for leaks 153
General conditions 5
I
Ignition system
– Ignition timing check 137
M
Maintenance and repair work
– Safety requirements 9
Mixture coolant
– Draining 168
– Filling 169
– Replacement 167
Mixture coolant level
– Check 166
MTU Onsite Energy contact / service partner 176
O
Oil separator – Filter element replacement 135
Operation
– Safety regulations 8
Operational checks 41
E
P
Emergency stop 43
Engine
– Main dimensions 19
– Wiring check 170
Engine coolant
– Change 161
Engine coolant – Draining 162
Engine coolant – Filling 164
Engine coolant – Level check 160
Engine governor – Fault messages 102
Engine oil filter – Replacement 159
Engine oil level
– Check 156
Engine oil – Change 157
Engine oil – Sampling and analysis 158
Engine side
– Designation 18
Engine wiring
– Check 170
Engine – Barring manually 133
Engine – Overview 16
Personnel and organizational requirements 6
Purpose of the units 33
Putting the engine into operation after extended out-ofservice-periods (>3 months) 37
Putting the engine into operation after scheduled out-ofservice-period 38
F
Fault indication on SAM display 48
Fire and environmental protection 12
Firing order 20
Fluids and lubricants 12
G
Gas engine phase 3 system
– Overview 30
184 | Appendix B | MS150034/02E 2012-07
R
Runtimes at partial load 21
S
Safety instructions 15
Safety regulations 8
SAM – Fault messages 52
Sensors – Overview 171
Spark plug
– Removal and installation 142
Spark plug connector
– Removal and Installation 139
– Replacement 138
Spark plug – Replacement 141
Starting the engine 40
Startup
– Safety regulations 8
Stopping the engine 42
T
Transport 7
V
Valve clearance – Check and adjustment 145
DCL-ID: 0000016353 - 003
20 V 4000 L62 engine data, optimized exhaust emissions
(1/2 TA-Luft) 26
20V 4000 L62 engine data, fuel optimized (TA-Luft) 22
50-hours check 46
Valve depth
– Measurement 148
Valve gear
– Lubrication 144, 151
Vent line of engine coolant circuit
– Replacement 165
W
DCL-ID: 0000016353 - 003
Wiring - engine
– Check 170
MS150034/02E 2012-07 | Appendix B | 185
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