Operating Instructions: Gas Engine 20 V 4000 L32 FB

Operating Instructions
Gas engine
20 V 4000 L32 FB
MS150116/02E
Engine model kW/cyl. Application group
20V4000L32FB 100 kW/cyl. 3A, continuous operation, unrestricted
Table 1: Applicability
© 2016 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 4.3 Putting the engine into operation after
scheduled out-of-service-period 41
1.1 Important provisions for all products 5 4.4 Control, starting and stopping sequences 42
1.2 Correct use for all products 6 4.5 Engine – Start 44
1.3 Personnel and organizational requirements 7 4.6 Operational checks 45
1.4 Safety regulations for startup and operation 8 4.7 Emission values – Check 46
1.5 Safety regulations for startup and operation, 4.8 Engine – Shutdown 48
specific information for gaseous fuel or dual 4.9 Engine – Emergency shutdown 49
fuel supply applications 10 4.10 After stopping the engine – Engine remains
1.6 Safety regulations for maintenance and ready for operation 51
repair work 12 4.11 After stopping the engine – Putting the
1.7 Safety regulations for maintenance and engine out of operation 52
servicing work, specific information for
gaseous fuel and dual fuel supply or
5 Maintenance
applications 15
1.8 Fire prevention and environmental 5.1 50-hours check 53
protection, fluids and lubricants, auxiliary 5.2 Maintenance task reference table [QL1] 54
materials 16
1.9 Fire prevention and environmental 6 Troubleshooting
protection, fluids and lubricants, auxiliary
materials, specific information for gaseous 6.1 Fault messages - Key 55
fuel supply in gaseous-fuel or dual-fuel 6.2 Fault messages in genset control system log 57
applications 18 6.3 Engine Control Unit – Fault messages 122
1.10 Standards for safety notices in the text 19
7 Task Description
2 Transport
7.1 Engine 162
2.1 Transport 20 7.1.1 Engine – Barring manually 162
7.1.2 Checking machine room for smell of gas 163
3 Product Summary 7.2 Crankcase Breather 164

7.2.1 Oil separator – Filter replacement 164
3.1 Engine layout 21
3.2 Engine side and cylinder designations 23 7.3 Ignition System 166
7.3.1 Spark plug – Replacement 166
3.3 Engine – Main dimensions 24
7.3.2 Spark plug – Removal 167
3.4 Firing order 25 7.3.3 Spark plug – Installation 168
3.5 Technical Data 26 7.3.4 Spark plug connector – Replacement 170
3.5.1 20V 4000 L32FB engine data, fuel optimized 7.3.5 Spark plug connector – Removal 171
(TA-Luft) 26 7.3.6 Spark plug connector – Installation 172
3.5.2 20V 4000 L32FB engine data, tropical 7.3.7 Ignition system – Ignition timing check 174
application (TA-Luft) 31
7.4 Valve Drive 175
3.6 Monitoring, Control and Regulation 7.4.1 Valve protrusion – Measurement 175
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Equipment 35 7.4.2 Valve gear – Lubrication 178

3.6.1 Gas engine phase 4 system – Overview 35 7.4.3 Valve clearance – Check and adjustment 179
3.6.2 Purpose of the units 37 7.4.4 Cylinder head cover ‒ Removal 181
7.4.5 Cylinder head cover ‒ Installation 182
4 Operation 7.5 Gas System 183

7.5.1 Gas supply - Checking gas lines for leaks 183
4.1 Runtimes at partial load 39
4.2 Putting the engine into operation after 7.6 Air Filter 184
7.6.1 Air filter – Replacement 184
extended out-of-service periods (>3 months) 40
7.6.2 Air filter – Removal and installation 185
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7.7 Lube Oil System, Lube Oil Circuit 186 7.10.2 Mixture coolant – Change 197
7.7.1 Engine oil level – Check 186 7.10.3 Mixture coolant – Draining 198
7.7.2 Engine oil – Change 187 7.10.4 Mixture coolant – Filling 199
7.7.3 Engine oil – Sample extraction and analysis 188
7.11 Wiring (General) for Engine/Gearbox/Unit 200
7.8 Oil Filtration / Cooling 189 7.11.1 Engine cabling – Check 200
7.8.1 Engine oil filter – Replacement 189 7.11.2 Sensors – Overview 201
7.9 Coolant Circuit, General, High-Temperature

Circuit 190 8 Appendix A
7.9.1 Engine coolant – Level check 190
7.9.2 Engine coolant – Change 191 8.1 Abbreviations 205
7.9.3 Engine coolant – Draining 192 8.2 MTU Onsite Energy contact person / service
7.9.4 Engine coolant – Filling 194 partner 207
7.9.5 Vent line of engine coolant circuit –
Replacement 195 9 Appendix B
7.10 Low-Temperature Circuit 196
9.1 Special Tools 208
7.10.1 Mixture coolant – Level check 196
9.2 Index 212
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.
Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.
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MS150116/02E 2016-07 | Safety | 5

1.2 Correct use for all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
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1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation

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

Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
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to do so following a written procedure.

Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.
Operation of electrical equipment

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.
8 | Safety | MS150116/02E 2016-07

Follow the applicable warning instructions pertaining to such devices.
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MS150116/02E 2016-07 | Safety | 9

1.5 Safety regulations for startup and operation, specific
information for gaseous fuel or dual fuel supply applications
General safety regulations
Requirement for the user: Check the gas train every time the product is started.
During operation, the surface temperature of the gas-bearing parts must not fall below 5 °C anywhere within
the vicinity of the product.
Gas system, general requirements

The plant manufacturer/user shall establish the connection to the gas supply in accordance with the applica-
ble statutory requirements, e.g. DVGW, G490/I, G491/I, DIN EN 12186, NFPA37.
Gas supply shut-off: The plant manufacturer/user shall ensure that the gas shut-off device complies with lo-
cal regulations.
To handle the situation where the pressure at the outlet of the gas pressure regulator is too high, the pres-
sure regulator shall be equipped with an approved safety shut-off valve and a safety exhaust valve. The gas
has to be vented to a hazard-free zone (atmosphere).
If the gas supply system is connected to a vessel or if oxygen-containing gases are used, the gas train shall
be equipped with a temperature-monitored flame arrester.
The gas shut-off valves are activated via two different paths from the control system, with one path assigned
to one gas shut-off valve and the other path to the other valve.
The gas train shall feature minimum pressure monitoring.
If the
• gas supply pressure exceeds 100 mbar
• gas volume flow exceeds 200 m³/h
• fuel efficiency exceeds 600 KW
additional equipment may be necessary in the gas train, e.g. maximum pressure monitoring.
Safety regulations for initial startup in dual fuel applications

Whenever the product is put into service, ensure that:
• Mobile application: The product shall only be used in the open.
• Stationary application: The product shall only be used with adequate ventilation.
Gas system, requirements for gas operation

The plant manufacturer/user shall use tested gas trains for the fuel supply of the product and connection to
the gas supply network. With regard to the connection conditions and the dimensions, the manufacturer has
to be consulted.
Gas trains have the following components fitted in the flow direction:
• a manual shut-off valve
• a gas filter
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• two gas shut-off valves

• a pressure regulating device
The gas train shall be fitted with an automatic leakage monitor.
The plant manufacturer/user shall ensure that the gas train is positioned directly in front of the product, but
no more than 3 meters upstream of the product interface. The interface is the flange of the gas flow control-
ler or the connection of the gas/air mixer of the product.
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Gas system, requirements for dual fuel applications
Gas trains feature the following components in the direction of flow (plant manufacturer/user scope of sup-
ply):
• a gas filter
Gas trains feature the following components in the direction of flow (MTU scope of supply):
• two gas shut-off valves (automatic)
• a pressure regulating device
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MS150116/02E 2016-07 | Safety | 11

1.6 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They must only be installed after painting the engine or must be covered before painting work is carried out.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.
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Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
12 | Safety | MS150116/02E 2016-07

Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all mounts and dampers are installed correctly.
Ensure that O-rings are not installed in a slanted/twisted condition.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly. If necessary, coat the com-
ponents with a suitable corrosion inhibitor.
Safety regulations following maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring device).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv-
ably damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, devices and fixtures to be used. Use only
the specified devices and fixtures for hydraulic removal/installation procedures.
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Observe the max. permissible force-on pressure specified for the device/fixture.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• 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 device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
MS150116/02E 2016-07 | Safety | 13

During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the
component being pressed.
Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in-
jury through the sudden discharge of acid or bursting of the battery body.
Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. Check cor-
rect execution of the emergency stop function in particular.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Work with laser devices

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur-
ing safe operation.
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Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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1.7 Safety regulations for maintenance and servicing work,
specific information for gaseous fuel and dual fuel supply or
applications
Safety regulations to be complied with prior to commencing maintenance and
servicing work
Assembly work shall be performed by specially trained/qualified and authorized personnel only.
The gas supply shall be connected by trained/qualified and authorized personnel only.
Work on the gas-bearing parts of the product shall be performed by specially trained/qualified and author-
ized personnel only.
Ensure adequate – possibly increased – ventilation before opening the gas system.
Shut down the gas supply to the product by closing the manual shut-off valve.
Lock-out / tag-out the drive unit to prevent starting.
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1.8 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Flames, naked light and smoking are prohibited.
When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.
Always 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 dan-
ger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Auxiliary materials
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.
Used oil
Used oil contains combustion residues that are harmful to health.
Wear protective gloves!
Wash relevant areas after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.
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Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing or replacing pneumatic equipment in the supply line. To de-
pressurize compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out leak test in accordance with the specifications.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• 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 safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
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1.9 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials, specific information for
gaseous fuel supply in gaseous-fuel or dual-fuel applications
General notes on gas
Observe the information contained in the safety data sheet of the gas used. Consult with gas supplier/utility.
The gas used must comply with the (→ Fluids and Lubricants Specifications of the manufacturer).
Caution: Risk of poisoning due to hazardous impurities. The ingestion of even small quantities of hydrogen
sulfide or ammonia can be fatal.
Caution: Gas can be dangerous to life depending on concentration. Some gases can no longer be detected
by smell in higher concentrations.
Conduct in case of accidental release of gases:
• If safe to do so: Shut off main gas supply.
• If safe to do so: Execute an emergency stop.
• Cordon off a large area around the hazard zone.
• Ensure rooms are sufficiently ventilated.
• Do not enter the hazard zone until it has been established (via measurement of the gas concentration with
a suitable gas detector) that the atmosphere is no longer hazardous!
Check all gas conveying lines for tightness prior to initial operation and at regular intervals during operation.
Natural gas (pipeline quality)

Caution: Highly flammable gas; forms an explosive mixture with air/oxygen.
Caution: Weakly narcotic gas; risk of suffocation at high concentrations.
Biogenic gases from fermentation processes

Caution: Highly flammable gas; forms an explosive mixture with air/oxygen.
Caution: Risk of poisoning due to hydrogen sulfide from the fermentation process. The ingestion of even
small quantities of hydrogen sulfide can be fatal.
Caution: Weakly narcotic gas; risk of suffocation at high concentrations.
Biogenic gases have a tendency to segregate. In low-lying areas of the plant, carbon dioxide enrichment is
possible.
TIM-ID: 0000040537 - 004
18 | Safety | MS150116/02E 2016-07

1.10 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
TIM-ID: 0000040578 - 005
MS150116/02E 2016-07 | Safety | 19

2 Transport
2.1 Transport
Taking the engine's center of gravity into account
For information regarding the center of gravity of the engine, refer to the installation/arrangement drawing
of the engine/genset/system.
Transport
• Lift the engine/genset/system only with the lifting eyes provided.
• Only use transport and lifting devices approved by MTU.
• The engine/genset/system must only be transported in installation position.
• Max. permissible diagonal pull 10°.
• If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes of the
trestle or use a means of transportation which is appropriate for the given weight (forklift truck).
• Prior to transporting the engine/genset/system, it is imperative to install the transport locking device for
the crankshaft.
• Prior to transporting the engine/genset/system, it is imperative to install the transport locks for the en-
gine mounts.
• Secure the engine/genset/system such as to preclude tipping during transport.
• Secure the engine/system/genset as to preclude slipping and tipping when driving up or down inclines
and ramps.
Setting the engine down after transport

• Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
• Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU
on a case-to-case basis.
• Place the engine/genset/system on a firm, flat surface only.
TIM-ID: 0000002614 - 004
20 | Transport | MS150116/02E 2016-07

3 Product Summary
3.1 Engine layout
1 Air filter/air inlet 6 Capacitor discharge ignition 11 Throttle

2 Mixture cooler system 12 Flywheel
3 Exhaust turbocharger, left- 7 Engine mounting bracket, 13 Engine governor/engine
hand side free end monitoring
4 Exhaust turbocharger, right- 8 Oil pan KS
hand side 9 Engine mounting bracket,
5 Engine lifting eye driving end
10 Starter
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MS150116/02E 2016-07 | Product Summary | 21

1 Crankcase breather, oil sep- 6 Throttle 11 Engine oil filter
arator 7 Spark plug 12 Oil level switch
2 Exhaust outlet 8 Cylinder head cover 13 Engine oil heat exchanger
3 Gas control valve 9 Cylinder head KGS Free end
4 Gas inlet connection 10 Engine oil sampling port
5 Ignition coil
Engine model designation

Key to the engine model designation 20 V 4000 L32FB
20 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
L Application: L = Gas engine
3 Load profile
2 Design index
F Additional feature: F = 50 Hertz
B Additional feature: B = Biogas from fermentation processes
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Table 2: Engine model designation
22 | Product Summary | MS150116/02E 2016-07

3.2 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
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3.3 Engine – Main dimensions
Engine – Main dimensions
Item Dimensions
Length (A) for 20V approx. 3896 mm
Width (B) for 20V approx. 1584 mm
Height (C) for 20V approx. 2293 mm
Crankshaft center to approx. 636 mm
oil pan (D)
Crankshaft center to approx. 280.5 mm
engine mount (E)
Table 3: Engine – Main dimensions

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24 | Product Summary | MS150116/02E 2016-07

3.4 Firing order
Firing order
Number of cylin- Firing order
ders
20V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
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3.5 Technical Data
3.5.1 20V 4000 L32FB engine data, fuel optimized (TA-Luft)
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 20V 4000
L32FB
Application group 3A
Intake air temperature °C 25
Charge-air coolant temperature °C 40
Barometric pressure mbar 1000
Site altitude above sea level m 100
Table 4: Reference conditions
Power-related data (power ratings are net brake power to ISO 3046)
Number of cylinders 20
Rated engine speed A rpm 1500
Mean piston speed m/s 10.5
Continuous power as per ISO 3046 A kW 2000
Mean effective pressure (pme) (continuous power ISO 3046) bar 16.8
Table 5: Power-related data (power ratings are net brake power to ISO 3046)
General conditions (for max. power)

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

Intake air temperature, max. L °C 30
Mixture temperature after mixture cooler A °C 52
Ambient intake depression, max. L mbar 3
Pressure loss over air filter, max. L mbar 30
Exhaust back pressure, max. L mbar 60
26 | Technical Data | MS150116/02E 2016-07

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

Operating method: Four-stroke cycle, Otto engine, single-acting X
Combustion method: Mixture charging, spark ignition X
Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 170
Stroke mm 210
Cylinder displacement Liters 4.77
Total displacement Liters 95.33
Compression ratio 13.9
Standard housing connecting flange (engine main PTO) SAE 00
Table 8: Model-related data (basic design)
Coolant system (HT circuit)

Coolant temperature (at engine connection: outlet to cooling equipment) (w/o A °C 87
antifreeze)
Coolant temperature (at engine connection: inlet from cooling system (w/o A °C 78
antifreeze)
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
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Coolant pump: Volumetric flow L m³/h 80

Filling pressure in cooling system (cold) R bar 0.5
Pressure in cooling system, max. L bar 6.0
Pressure loss over engine (at nominal flow rate 7.27) bar 2.1
Thermostat: Starts to open R °C 68
Thermostat: Opening stops (thermostat fully open and bypass closed) A °C 78
Table 9: Coolant system (HT circuit)
MS150116/02E 2016-07 | Technical Data | 27

Coolant system (LT circuit)
Coolant temperature before mixture cooler (at engine connection: inlet from A °C 40
cooling system (w/o antifreeze)
Coolant pump: Volumetric flow A m³/h 39
Pressure loss over LT mixture cooler (at nominal flow rate 8.56) bar 0.8
Table 10: Coolant system (LT circuit)
Coolant system (MT circuit)

Pressure loss over MT mixture cooler (at nominal flow rate 8.56) bar 2.4
Table 11: Coolant system (MT circuit)
Lube oil system

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, shutdown L °C 97
Lube oil pressure after oil filter bar 5.0
Lube oil pressure after oil filter, warning R bar 3.5
Lube oil pressure after oil filter, shutdown L bar 2.5
Table 12: Lube oil system
Fuel system
Gas temperature before engine, min. L °C 10
Gas temperature before engine, max. L °C 50
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Gas flow pressure before gas-flow control valve, min. L mbar 30

Gas flow pressure before gas-flow control valve, max. L mbar 120
Table 13: Fuel system

General operating data
Cold start capability: Air temperature (w/o starting aid, with preheating) - R °C 15
(case C)
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
Table 14: General operating data
Starting (electric)
Rated starter power (standard design) R kW 2x9
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 182
Table 15: Starting (electric)
Capacities
Engine coolant capacity, engine side (without cooling equipment) R Liters 290
Engine coolant, mixture cooler side (without cooling system) R Liters 25
Engine coolant, MT mixture cooler side (without cooling system) R Liters 30
Total engine oil capacity for initial filling (standard oil system) R Liters 478
Oil change capacity, max. (standard oil system) R Liters 450
Table 16: Capacities
Weights / main dimensions

Engine dry weight (basic configuration engine) R kg 9700
Heaviest component to be lifted during extended component maintenance R kg 440
(QL3)
Table 17: Weights / main dimensions
Exhaust emissions
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Exhaust emission before catalytic converter at 100 % DL nitric oxides (NOx) (in G mg/m n 3 500
dry exhaust gas, 5 % O2)
Exhaust emission before catalytic converter at 100 % DL nitric oxides (NOx) (in A ppm 178
dry exhaust gas)
Table 18: Exhaust emissions

Acoustics
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 R dB(A) 123
level LW, ISO 8528-10)
Table 19: Acoustics
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3.5.2 20V 4000 L32FB engine data, tropical application (TA-Luft)
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 20V 4000
L32FB
Application group 3A
Intake air temperature °C 35
Charge-air coolant temperature °C 53
Barometric pressure mbar 1000
Site altitude above sea level m 100
Table 20: Reference conditions
Power-related data (power ratings are net brake power to ISO 3046)
Rated engine speed A rpm 1500
Mean piston speed m/s 10.5
Continuous power as per ISO 3046 A kW 2000
Mean effective pressure (pme) (continuous power ISO 3046) bar 16.8
Table 21: Power-related data (power ratings are net brake power to ISO 3046)
General conditions (for max. power)

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

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: Biogas X
Methane number, min. L 120
Table 22: General conditions (for max. power)

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

Operating method: Four-stroke cycle, Otto engine, single-acting X
Combustion method: Mixture charging, spark ignition X
Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 170
Stroke mm 210
Cylinder displacement Liters 4.77
Total displacement Liters 95.33
Compression ratio 13.9
Standard housing connecting flange (engine main PTO) SAE 00
Table 24: Model-related data (basic design)
Coolant system (HT circuit)

Coolant temperature (at engine connection: outlet to cooling equipment) (w/o A °C 87
antifreeze)
Coolant temperature (at engine connection: inlet from cooling system (w/o A °C 78
antifreeze)
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 pump: Volumetric flow L m³/h 85
Filling pressure in cooling system (cold) R bar 0.5
Pressure loss over engine (at nominal flow rate 7.27) bar 2.2
Thermostat: Starts to open R °C 68
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Thermostat: Opening stops (thermostat fully open and bypass closed) A °C 78
Table 25: Coolant system (HT circuit)
Coolant system (LT circuit)


Pressure loss over LT mixture cooler (at nominal flow rate 8.56) bar 0.8
Table 26: Coolant system (LT circuit)
Coolant system (MT circuit)

Pressure loss over MT mixture cooler (at nominal flow rate 8.56) bar 2.4
Table 27: Coolant system (MT circuit)
Lube oil system

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, shutdown L °C 97
Lube oil pressure after oil filter bar 5.0
Lube oil pressure after oil filter, warning R bar 3.5
Lube oil pressure after oil filter, shutdown L bar 2.5
Table 28: Lube oil system
Fuel system
Gas temperature before engine, min. L °C 10
Gas temperature before engine, max. L °C 50
Gas flow pressure before gas-flow control valve, min. L mbar 30
Gas flow pressure before gas-flow control valve, max. L mbar 120
Table 29: Fuel system

TIM-ID: 0000044675 - 002
General operating data

Cold start capability: Air temperature (w/o starting aid, with preheating) - R °C 15
(case C)
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
Table 30: General operating data

Starting (electric)
Rated starter power (standard design) R kW 2x9
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 182
Table 31: Starting (electric)
Capacities
Engine coolant capacity, engine side (without cooling equipment) R Liters 290
Engine coolant, mixture cooler side (without cooling system) R Liters 25
Engine coolant, MT mixture cooler side (without cooling system) R Liters 30
Total engine oil capacity for initial filling (standard oil system) R Liters 478
Oil change capacity, max. (standard oil system) R Liters 450
Table 32: Capacities
Weights / main dimensions

Engine dry weight (basic configuration engine) R kg 9700
Heaviest component to be lifted during extended component maintenance R kg 440
(QL3)
Table 33: Weights / main dimensions
EXHAUST EMISSIONS
Exhaust emission before catalytic converter at 100 % DL nitric oxides (NOx) (in G mg/m n 3 500
dry exhaust gas, 5 % O2)
Exhaust emission before catalytic converter at 100 % DL nitric oxides (NOx) (in A ppm 185
dry exhaust gas)
Acoustics
Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) 113
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Genset surface noise with attenuated intake noise (filter) - DL (sound power R dB(A) 123
level LW, ISO 8528-10)
Table 34: Acoustics

3.6 Monitoring, Control and Regulation Equipment
3.6.1 Gas engine phase 4 system – Overview
General overview
1 Unit system 5 Engine Monitoring Unit 9 Ignition

2 Engine system 6 Throttle flaps 10 Compressor bypass
3 System 7 Gas dosing unit 11 NOx sensor (optional)
4 Engine Control Unit 8 Knock module
Regulation/control/monitoring
Engine Control Unit ECU-9
• Controls engine starting, stopping and emergency stop
• Monitors engine operating parameters
• Controls throttle flaps and sets gas mixture for requested speed/power
• Monitors first gas solenoid in gas train to engine
Engine Monitoring Unit EMU 8

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• Monitors second gas solenoid in gas train to engine
Compressor bypass (F series)

• Controls throttle flap reserve, prevents compressor surges
Woodward or Motortech ignition system (depending on design)

• Adjusts ignition timing for cylinders
MS150116/02E 2016-07 | Monitoring, Control and Regulation Equipment | 35

Anti-knock regulation AKR
• Controls monitored cylinders re. knock characteristics. If knocking is found, the ignition timing is retarded
on the cylinder in question. If this does not result in an improvement, the power is reduced.
Gas control valve TecJet110

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

• The mixture throttle flaps in the mixture lines which are controlled by the Engine Control Unit
TIM-ID: 0000044676 - 002
36 | Monitoring, Control and Regulation Equipment | MS150116/02E 2016-07

3.6.2 Purpose of the units
ECU 9 engine governor
Central control and monitoring unit for the engine

• Communication with other devices and higher-level systems via CAN bus
• Control of throttles (mixture and gas)
• Registration and analysis of engine operating states
• Limit value monitoring
• Self-monitoring and diagnostics
– Integral status/fault display
– Fault memory
• Extensive I/O features:
• Engine and genset-related parameter settings in flash memory
• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine stop or
emergency engine stop (configurable)
• Diagnostic function via CAN interface (Default CAN1, connection for dialog unit provided)
Software structure:
• One data record for engine software
• One data record for genset software
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MS150116/02E 2016-07 | Monitoring, Control and Regulation Equipment | 37

Engine Monitoring Unit EMU 8
EMU = Engine Monitoring Unit

Monitoring unit for the engine
• Acquisition and processing of cylinder exhaust temperatures
Self-monitoring
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38 | Monitoring, Control and Regulation Equipment | MS150116/02E 2016-07

4 Operation
4.1 Runtimes at partial load
Gas engines are designed and optimized for continuous operation at 100 % load.
The following restrictions apply to ensure maximum operational availability of the engine plant and to reduce
maintenance to a minimum:
Power range [kWmech/ Recommended max. Recommended min. Emission compliance as

cyl.] time under this load time in subsequent op- specified in technical
eration data
at load > 50 kWmech/cyl.
0 to 30 30 minutes 120 minutes No
30 to 50 120 minutes 120 minutes No
50 to full load No restriction No restriction Yes
Table 35: Runtimes at partial load
A minimum operating time of 2 hours per start is recommended to counteract increased engine loading re-
sulting from temperature changes (cold start to engine operating temperature).
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MS150116/02E 2016-07 | Operation | 39

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

months)
Item Measure
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Engine Bar engine manually (→ Page 162).
Valve gear Standstill ≥ 6 months: Lubricate valve gear (→ Page 178).
Lube oil system Check engine oil level (→ Page 186);
Check oil level in oil storage tank (→ Page 186).
Coolant circuit Standstill > 1 year: Change engine coolant (→ Page 191);
Change mixture coolant (→ Page 197)
Coolant circuit Check engine coolant level (→ Page 190);
Check mixture coolant level (→ Page 196)
Engine cabling Check plug-in connections (→ Page 200).
Gas supply The gas shut-off valves with control solenoids are not included in the scope
of supply of the engine. The components are controlled by the engine elec-
tronics.
Engine management system Check for fault messages.
Starting system Check power supply to electric starter.
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40 | Operation | MS150116/02E 2016-07

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

Item Measure
Lube oil system Check oil level in oil storage tank (→ Page 186).
Coolant circuit Check engine coolant level (→ Page 190);
Check mixture coolant level (→ Page 196)
Engine management system Check for fault messages.
TIM-ID: 0000010660 - 002
MS150116/02E 2016-07 | Operation | 41

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

The starting sequence is software-controlled and depends on the place of start command input.
To ensure that no mixture is in the engine when ignition is switched on or off, which is a specific requirement
for gas engines, special procedures for engine start / stop are specified.
The maximum number of attempted starts is limited to three. After this, an extended scavenging phase is
initiated with the gas shut-off valves closed and the ignition off in order to purge the intake duct, engine cyl-
inders and exhaust duct (up to the exhaust turbine outlet elbow) with air. The operator shall ensure by means
of structural safeguards that flammable gases or vapors do not arise in hazardous quantities or concentra-
tions in the surroundings of the installation (gas pipework up to gas control valve and exhaust gas system
after turbine). A contact is designated to initiate such safety measures.
Starting sequence
The following steps are performed automatically when a start command is activated with the engine at stand-
still:
1. Setting start counter
2. Priming (optional)
3. Checking gas supply solenoid valves for leaks
4. Activating starter
5. Waiting for starting speed
6. Scavenging the engine
7. Ignition
8. Opening gas supply solenoid valves
9. Waiting for starter disengagement speed
10. Disengaging starter
11. Waiting for idling speed
12. Ramping-up to rated speed
Start termination
1. The maximum number of attempted starts is limited to three following start termination
2. An alarm is then signaled
3. Requesting external ventilation by contact
4. A new engine start request is only possible following fault acknowledgment
Stopping sequence
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The following steps are performed automatically when a stop command is activated:
1. Closing gas supply solenoid valves
2. Opening mixture throttles, scavenging residual gas
3. Engine running down to standstill
4. Deactivating ignition
5. Closing mixture throttles
42 | Operation | MS150116/02E 2016-07

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

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

1. Waiting for engine running
2. Engine running for a minimum (programmed) time period
3. Oil refilling enabled
4. When oil refill request is received
5. Refilling oil (automatically)
6. When oil refill request is canceled
7. Stopping oil refilling (automatically)
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MS150116/02E 2016-07 | Operation | 43

4.5 Engine – Start
Preconditions
☑ Generator is not connected to network.
☑ Start interlock is not active.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Starting the engine

Note: A max. of 5 engine starting attempts are permitted at a max. fuel supply opening time of 15 seconds respec-
tively. After a max. of 5 unsuccessful start attempts, the fuel supply must be locked. Before attempting to
start the engine again, allow time for sufficient inertization of the exhaust section.
u Initiate specified engine starting sequence (→ Page 42).
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44 | Operation | MS150116/02E 2016-07

4.6 Operational checks
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Operational checks
Item Action
Machine room Check machine room for smell of gas (→ Page 163).
ECU Check for fault messages;
if fault messages are displayed: Determine the cause, rectify the fault.
Check indicated operating parameters (speed, temperatures, pressures).
Operation log (if available) Document operating parameters
• This is especially useful for fault localization and fast remedial action.
Engine under load, Visually inspect engine/plant and all pipework for leaks, rectify any leaks
engine at rated speed with the engine stopped;
check for abnormal running noises and vibration.
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MS150116/02E 2016-07 | Operation | 45

4.7 Emission values – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Gas measuring and warning device (not stocked by MTU) -
WARNING
Engine operation at high load/speed when measuring emissions.
Risk of injury!
• Conduct measuring in a room which offers safe protection from the engine if at all possible. If this is
not feasible, keep the greatest possible distance away when measuring, e.g. using wireless data
transmission or long cables.
WARNING
Installing/removing measuring equipment – exhaust gases are hot and pressurized.
Risk of injury and burning!
• Only install/remove measuring equipment when the engine is at standstill.
• Wear protective clothing, protective gloves and goggles/safety mask.
WARNING
WARNING
Exhaust gases are harmful to health.
Risk of poisoning!
• Ensure that the engine room is well ventilated.
• Repair leaking exhaust pipework immediately.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress-
es.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant
levels are indicated.
NOTICE
Non-compliance with exhaust emission limits.
Emission agencies may revoke the operating license!
• Adjust the exhaust emissions such as to ensure compliance with statutory limits.
• Use tested measuring equipment only.
• Exhaust emissions shall be checked and adjusted at the intervals specified in the Maintenance
Schedule.
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46 | Operation | MS150116/02E 2016-07

Checking emission values
Note: Open the exhaust gas test section and in-
stall/remove measuring equipment only
when the engine is at standstill.
1. Apply the exhaust probe (1) at the measuring
point (2).
2. Start engine.
3. Approach the measuring point until a stable
operating state has been reached.
4. Carry out measurement and read-off meas-
ured value for NOx rel (ppm).
5. Compare the measured value with the appli-
cable national limit value, adjust exhaust
emissions in case of any deviation.
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MS150116/02E 2016-07 | Operation | 47

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

u Shut down engine in accordance with stopping sequence specifications (→ Page 42).
TIM-ID: 0000042720 - 001
48 | Operation | MS150116/02E 2016-07

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

Item Measure
Gas shut-off solenoids Two contacts are provided for electrical connection. Close gas shut-off sole-
noids.
• engine stop.
Ignition, ignition system In the case of an external EMERGENCY STOP, the ignition remains on until
the engine has run down to a standstill in order to safely burn off uncombust-
ed fuel/air mixture.
• The ignition is only switched off in case of an overspeed violation or an
internal ignition fault.
Throttle flaps The throttle flaps are always closed in case of EMERGENCY STOP. Closing
the throttle flaps impedes the scavenging of residual gas. External ventilation
and inerting systems shall therefore be activated following an emergency en-
gine stop.
Room ventilation, facility Residual gas may escape from the fuel line in case of EMERGENCY STOP.
ventilation • A contact is provided to request room and facility ventilation.
Table 36: Emergency engine shutdown

TIM-ID: 0000043159 - 003
MS150116/02E 2016-07 | Operation | 49

Remedy the cause, re-enable starting
Item Measure
Engine control system Determine cause for emergency stop and take remedial action; if the fault
cannot be corrected, contact Service.
Fault acknowledgment is possible in engine stop mode only . Automatic se-
lection and remote start immediately following an emergency engine stop is
not admissible.
Plant control system An extended scavenging phase with the ignition off precedes engine starting
when selected again following an emergency engine stop. Suitable exhaust
gas ventilation equipment shall be provided in the facility to ensure that the
exhaust gas system downstream of the engine is safely purged.
• A contact is provided to request the ventilation system in the scavenging
phase.
Note: • The gas control system shall be equipped with an SAV (safety shut-off
Gas train valve) when using gas control systems with inlet pressures in excess of
0.1 bar. If the SAV is tripped by an EMERGENCY STOP it shall be reset
manually. SAV tripping is not indicated by the engine.
Table 37: Remedy the cause, re-enable starting
TIM-ID: 0000043159 - 003
50 | Operation | MS150116/02E 2016-07

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

Item Action
Engine/generator controller Select operating mode, e.g. MANUAL, AUTOMATIC.
(manufacturer-specific)
TIM-ID: 0000002329 - 003
MS150116/02E 2016-07 | Operation | 51

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

Item Action
Coolant circuit Drain engine coolant (→ Page 192)
Drain mixture coolant (→ Page 198) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but coolant has no antifreeze additive;
• the engine room is not heated;
• the engine coolant is not maintained at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Operating voltage for engine Switch off.
management
Gas supply Close manual gas shutoff valve.
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tems gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ MTU Preservation and Represerva-
tion Specifications A001070/..).
The corrosion-inhibiting effect of the engine coolant may be used as an alter-
native in case of out-of-service periods lasting for more than 1 month, by run-
ning the engine for at least 2 hours at rated power once a month.
Starter battery (batteries) Charge regularly (trickle charge).
Control-voltage battery (bat- If fitted: Charge regularly (trickle charge).
teries)
Table 38: After stopping the engine

TIM-ID: 0000043160 - 004
52 | Operation | MS150116/02E 2016-07

5 Maintenance
5.1 50-hours check
50-hours check
One-time operations to be carried out after a test run or after the first 10 to 50 operating hours of the cylin-
der head (with a new engine, after installation of new cylinder heads, after component maintenance or ex-
tended component maintenance).
When installing a cylinder head with run-in mating faces (e.g. after piston replacement), a repeated check
after the first 50 operating hours is not necessary.
Qualifi- Interval Item Maintenance tasks Task
cation [h] [a]
QL1 - - Valve gear Check valve clearance (→ Page 179) -
Table 39: 50-hours check

TIM-ID: 0000002785 - 002
MS150116/02E 2016-07 | Maintenance | 53

5.2 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a standalone 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 45)
W0509 Check machine room for smell of gas. (→ Page 163)
W0523 Check for abnormal running noises and vibrations. (→ Page 45)
W0527 Check engine oil level in storage tank. See manufacturer‘s documen-
tation
W1002 Check valve clearance and adjust as necessary. (→ Page 179)
W1005 Replace air filter. (→ Page 184)
W1008 Replace engine oil filter when changing engine oil, or when the (→ Page 189)
interval (years) is reached, at the latest.
W1089 Check gas lines for leaks, repair if required. (→ Page 183)
W1091 Check ignition timing, adjust if required. (→ Page 174)
W1382 Replace vent line of engine coolant circuit (8/12/16V only). (→ Page 195)
W1616 Replace igniters and seal in igniter connector. (→ Page 166)
W1688 Replace igniter connectors. (→ Page 170)
W1689 Measure valve depth. (→ Page 175)
W1798 Replace fine filter. (→ Page 164)
W1813 Carry out visual inspection when replacing air filters. (→ Page 185)
W8660 Check emission values, adjust if required. Observe local emis- (→ Page 46)
sions regulations.
Table 40: Maintenance task reference table [QL1]
TIM-ID: 0000044941 - 002
54 | Maintenance | MS150116/02E 2016-07

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

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

monitoring
Fault messages from the engine governor are represented in the fault code list (→ Page 122).
Information pertaining to alarm colors and automatic engine shutdown in the fault code list refer to the (de-
fault) 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 manufacturer).
TIM-ID: 0000027852 - 002
A prerequisite for performing the measures to rectify faults is corresponding qualification/training at MTU.
Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.
Recommended action in case of alarm

Yellow alarm:
The engine can still be operated providing that automatic engine shutdown to protect the engine has not
been configured or is not tripped. Contact Service immediately/start fault rectification.
Red alarm:
MS150116/02E 2016-07 | Troubleshooting | 55

Caution, the engine is running at its limits. Shut down manually without further delay if the engine does not
shut itself down immediately after a red alarm is signaled.
TIM-ID: 0000027852 - 002
56 | Troubleshooting | MS150116/02E 2016-07

6.2 Fault messages in genset control system log
112222 – HI T-Exhaust Mean
Yellow alarm. Initiated by EMU.
Cause Corrective action
Weighted average of all individual 1. Check emission values (→ Page 46).
exhaust gas temperatures is too 2. Check ignition timing (→ Page 174).
high. 3. Check valve drive (exhaust valves do not close).
112223 – HIHI T-Exhaust Mean

Red alarm. Initiated by EMU.
Weighted average of all individual 1. Check emission values (→ Page 46).
exhaust gas temperatures is too 2. Check ignition timing (→ Page 174).
112301 – HI T-Exhaust A1
Individual exhaust gas 1. Check emission values (→ Page 46).
temperature of this cylinder is too 2. Check ignition timing (→ Page 174).
high in comparison with weighted 3. Check valve drive (exhaust valves do not close).
average.
average.
TIM-ID: 0000038611 - 003

average.

average.
average.
average.
average.
TIM-ID: 0000038611 - 003
average.

average.

average.
112311 – HI T-Exhaust B1
average.
average.
TIM-ID: 0000038611 - 003
average.

average.
average.
average.
average.
TIM-ID: 0000038611 - 003
average.

average.

average.
112401 – LO T-Exhaust A1
Individual exhaust gas 1. Check igniter.
temperature of this cylinder is too 2. Check emission values (→ Page 46).
low in comparison with weighted 3. Check ignition timing (→ Page 174).
average. 4. Check valve drive.
TIM-ID: 0000038611 - 003


TIM-ID: 0000038611 - 003



112411 – LO T-Exhaust B1
TIM-ID: 0000038611 - 003


TIM-ID: 0000038611 - 003



112501 – HIHI T-Exhaust A1

average.

average.

TIM-ID: 0000038611 - 003
average.

average.

average.

average.

average.

TIM-ID: 0000038611 - 003
average.

average.

average.
112511 – HIHI T-Exhaust B1

average.

average.

TIM-ID: 0000038611 - 003
average.

average.

average.

Individual exhaust gas 1. Check emission values(→ Page 46).
average.

average.

TIM-ID: 0000038611 - 003
average.

average.

average.
112601 – LOLO T-Exhaust A1



TIM-ID: 0000038611 - 003




temperature of this cylinder is too 2. Check emission values(→ Page 46).


TIM-ID: 0000038611 - 003



average. 4. Check valve drive (→ Page 174).
112611 – LOLO T-Exhaust B1



TIM-ID: 0000038611 - 003






TIM-ID: 0000038611 - 003



112701 – HIHI T-Exhaust A1 (abs)



temperature of this cylinder is too 2. Check ignition timing(→ Page 174).
TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003

Individual exhaust gas 1. Check emission values(→ Page 46).

112711 – HIHI T-Exhaust B1 (abs)





TIM-ID: 0000038611 - 003





112923 – MD/SD T-Exhaust

Summary alarm (for details, refer u Summary alarm (for details, refer to the source alarm).
to the source alarm).
113200 – Communication Lost ECU

TIM-ID: 0000038611 - 003

No communication with ECU on 1. Check ECU supply voltage.
CAN. 2. Check CAN connecting line.

113601 – AL Gas Valve 1 feedback
Summary alarm, gas solenoid 1. Check valve 1 and cabling (→ Page 200).
valve 1 feedback does not 2. Rectify cause of alarm.
correspond with setpoint signal.
113602 – AL Gas Valve status (internal)

Wire break or short circuit at u Check cabling and external diode and resistor circuitry
channel TO1-OUT or TO2-OUT. (→ Page 200).
113603 – AL Gas Valve feedback (internal)

Gas solenoid valve 1 logic u Check valve 1.
feedback does not correspond
with setpoint signal.
113902 – SS Local Initiated Emerg. Stop

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

Red alarm. Initiated by anti-knock control.
Summary alarm (for details, refer 1. Rectify cause of alarm.
to the source alarm). 2. Restart knock module.
1.4510.187 – Combined Error

TIM-ID: 0000038611 - 003

Summary alarm (for details, refer u Rectify cause of alarm.

1.4510.188 – Internal Error
Hardware not ready for operation. 1. Restart knock module.
2. Replace knock module.
1.4510.189 – Error Camshaft

No signal from camshaft sensor 1. Check cabling (→ Page 200).
for anti-knock control. 2. Check sensor B1.3, replace as necessary (→ Page 201).
1.4510.192 – Knock Sensor Error A1

No signal from this knock sensor. 1. Check cabling (→ Page 200).
2. Check sensor (tightening torque, damage), replace as necessary
(→ Page 201).

(→ Page 201).

(→ Page 201).

TIM-ID: 0000038611 - 003

(→ Page 201).

(→ Page 201).

(→ Page 201).

(→ Page 201).

(→ Page 201).

(→ Page 201).

TIM-ID: 0000038611 - 003

(→ Page 201).

1.4510.202 – Knock Sensor Error B1
(→ Page 201).

(→ Page 201).

(→ Page 201).

(→ Page 201).

(→ Page 201).

TIM-ID: 0000038611 - 003

(→ Page 201).

(→ Page 201).

(→ Page 201).

(→ Page 201).

(→ Page 201).
1.4520.232 – Error Missing Ring Gear Signal

Red alarm. Initiated by IC922.
Crankshaft signal 182 teeth is u Check sensor B13.3, check sensor clearance and cabling, replace
missing. as necessary (→ Page 201) (→ Page 200).
1.4520.233 – Error Missing Reset Signal

TIM-ID: 0000038611 - 003

Reset signal from crankshaft is u Check sensor B75, check sensor clearance and cabling, replace as
missing. necessary (→ Page 201) (→ Page 200).

1.4520.234 – Error Missing Camshaft Signal
Missing camshaft signal for u Check sensor B1.2, check sensor clearance and cabling, replace as
ignition system. necessary (→ Page 201) (→ Page 200).
1.4520.235 – Error Number of Teeth

Incorrect number of teeth on 1. Check settings at ignition system.
timing wheel detected. 2. Check sensor and sensor gaps (→ Page 201).
1.4520.236 – Unknown Engine Appl. Code

Ignition setting is not correct. u Check settings at ignition system.
1.4520.237 – OverSpeed Shutdown

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

Hardware not ready for operation. 1. Restart ignition.
2. Replace ignition.
1.4520.239 – Global Timing out of Range

Yellow alarm. Initiated by IC922.
Specified global ignition timing is 1. Adapt value in ECU parameter record.
beyond the valid range. 2. Check settings at ignition system.
TIM-ID: 0000038611 - 003
1.4520.240 – Unknown Timing or Energy Level

No global ignition timing and u Check cabling and setting (→ Page 200).
power level received, CAN bus
connection is faulty.

1.4520.241 – Individual Timing out of Range
Specified individual ignition timing 1. Adapt value in ECU parameter record.
is beyond the valid range. 2. Check settings at ignition system.
1.4520.242 – Selftest Shutdown

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

Admissible summation of 1. Check associated cabling (→ Page 200).
discharge faults is reached. 2. Check ignition coils.
1.4520.245 – Open Primary, Channel 1

Ignition energy was not 1. Check cabling to ignition coil (→ Page 200).
discharged. 2. Check ignition coils.


TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003



1.4520.270 – Warn. Missing Ring Gear Signal

Crankshaft signal 182 teeth is u Sensor B 13.3, check sensor, sensor gap and cabling, replace as
1.4520.271 – Warning Missing Reset Signal

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

Missing camshaft signal for u Sensor B 1.2, check sensor, sensor gap and cabling, replace as
ignition system. necessary (→ Page 201) (→ Page 200).
1.4520.273 – SCR Fault Odd

2. Check cabling to ignition coil (→ Page 200).
TIM-ID: 0000038611 - 003
1.4520.274 – SCR Fault Even

2. Check cabling to ignition coil (→ Page 200).

1.4520.275 – Odd Energy Level out of Range
Specified energy level is beyond u Adapt value in ECU parameter record.
the valid range.
1.4520.276 – Even Energy Level out of Range

Specified energy level is beyond u Adapt value in ECU parameter record.
the valid range.
1.4520.508 – MIC5 Stat Operational error

Red alarm. Initiated by MIC5.
An operational error has occurred. 1. Rectify cause of alarm.
2. Restart ignition control unit.
1.4520.509 – MIC5 Stat System error

A system error has occurred. 1. Rectify cause of alarm.
1.4520.520 – MIC5 Stat W: temperat limit reached

Yellow alarm. Initiated by MIC5.
The device temperature is too u Ensure that the genset room is adequately ventilated.
high.
1.4520.521 – MIC5 Stat W: pow output lim reached

Power output is too high. 1. Check ignition system settings in the Engine Control Unit.
2. Check ignition coils.
TIM-ID: 0000038611 - 003
3. Check igniters.
1.4520.522 – MIC5 Stat W: invalid coil data

The ignitions system settings are 1. Check ignition system settings in the Engine Control Unit.
invalid. 2. Restart ignition control unit.

1.4520.523 – MIC5 Stat W: invalid configuration
1.4520.524 – MIC5 Stat W: invalid trigger config

1.4520.525 – MIC5 Stat W: conf data checksum err

1.4520.526 – MIC5 Stat Analogue current sig fail

Failure of the current signal to u Check settings in ignitions control unit.
adjust the ignition point.
1.4520.527 – MIC5 Stat Analogue voltage sig fail

Failure of the voltage signal to u Check settings in ignitions control unit.
adjust the ignition point.
1.4520.528 – MIC5 Stat Aux inp supply volt. fail

Malfunction in the auxiliary supply 1. Check settings.
voltage for the analog inputs. 2. Restart ignition control unit.
TIM-ID: 0000038611 - 003
3. Replace ignition control unit.

1.4520.529 – MIC5 Stat Trigger supply volt. fail
Malfunction in the auxiliary supply 1. Check cabling to sensor B1.2 (→ Page 200).
voltage for the pulse sensor. 2. Check sensor B1.2 (→ Page 201).
1.4520.530 – MIC5 Stat Global timing limited

The global ignition point is beyond u Check Engine Control Unit settings.
the valid range.
1.4520.540 – MIC5 E1 General fault

A general fault has occurred. 1. Check Engine Control Unit settings.
2. Check cabling (→ Page 200).
1.4520.541 – MIC5 E1 Overspeed

The overspeed limit was reached. 1. Check Engine Control Unit settings.
2. Check the speed sensors of the ignition system (→ Page 201).
1.4520.542 – MIC5 E1 Speed sig during selftest

Pulse sensor signals were u Restart ignition control unit.
detected during the self-test.
1.4520.543 – MIC5 E1 Shutdown due to alarm

TIM-ID: 0000038611 - 003

Shutdown due to alarm. 1. Rectify cause of alarm.

1.4520.544 – MIC5 E1 Id of output board failed
The characteristic data of the 1. Restart ignition control unit.
output board is illegible or 2. Replace ignition control unit.
corrupt.
1.4520.545 – MIC5 E1 Fail hi-voltage pow supply

The high voltage power supply 1. Restart ignition control unit.
unit is faulty. 2. Replace ignition control unit.
1.4520.546 – MIC5 E1 Failure temperature sensor

The temperature sensor is faulty. 1. Restart ignition control unit.
1.4520.547 – MIC5 E1 Failure current sensor

The current sensor is faulty. 1. Restart ignition control unit.
1.4520.548 – MIC5 E1 Temperature limit reached

The device temperature has 1. Ensure that the genset room is adequately ventilated.
exceeded the admissible value. 2. Restart ignition control unit.
1.4520.549 – MIC5 E1 Power output limit reached

The power output has exceeded 1. Check ignition system settings in the Engine Control Unit.
TIM-ID: 0000038611 - 003
the admissible value. 2. Check ignition coils.

3. Check igniters.

1.4520.550 – MIC5 E1 Tr1 synchronisation fault
Unable to synchronize with signal u Check sensor, sensor gap, cabling, data record settings and timing
from pulse sensor 1 (B1.2). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.551 – MIC5 E1 Tr1 operational error

Pulse sensor 1 (B1.2) has tripped 1. Check sensor, sensor gap, cabling, data record settings and timing
an operational error. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.552 – MIC5 E1 Tr1 no signal detected

No signal from pulse sensor 1 u Check sensor, sensor gap, cabling, data record settings and timing
(B1.2). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.553 – MIC5 E1 Tr1 polarity detection fail

Unable to detect polarity of pulse u Check sensor, sensor gap, cabling, data record settings and timing
sensor 1 (B1.2). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.554 – MIC5 E1 Tr1 wrong polarity

Pulse sensor 1 (B1.2) has wrong u Check sensor, sensor gap, cabling, data record settings and timing
polarity. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.555 – MIC5 E1 Tr1 no index mark detected

Unable to detect index mark of u Check sensor, sensor gap, cabling, data record settings and timing
TIM-ID: 0000038611 - 003
pulse sensor 1 (B1.2). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.556 – MIC5 E1 Tr1 wrong n of trigg events

Incorrect number of events from u Check sensor, sensor gap, cabling, data record settings and timing

1.4520.557 – MIC5 E1 Tr1 signal missing
Expected signal from pulse sensor u Check sensor, sensor gap, cabling, data record settings and timing
1 (B1.2) is missing. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.558 – MIC5 E1 Tr1 signal faulty

Unexpected signal from pulse u Check sensor, sensor gap, cabling, data record settings and timing
sensor 1 (B1.2) detected. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.559 – MIC5 E1 Tr1 index mark not detected

pulse sensor 1 (B1.2) in wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
operation.
1.4520.560 – MIC5 E1 Tr1 index to early / faulty

Index mark of pulse sensor 1 u Check sensor, sensor gap, cabling, data record settings and timing
(B1.2) detected too early or faulty. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
1.4520.561 – MIC5 E1 Tr1 index to late / missing

(B1.2) detected too late or wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
missing.
1.4520.570 – MIC5 IPE Primary Open Cylinder 1

TIM-ID: 0000038611 - 003
Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 200).

cylinder 1 in ignition sequence. 2. Check ignition coil.







TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003





1.4520.590 – MIC5 IPE Prim Short Circuit Cyl 1

Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 200).

TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003




1.4520.610 – MIC5 ISE Secondary Open Cylinder 1

Disruption in secondary circuit of 1. Check ignition lead, connector and igniter.


TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003







TIM-ID: 0000038611 - 003



1.4520.630 – MIC5 ISE Secon Short Circuit Cyl 1

Short circuit in secondary circuit 1. Check ignition lead, connector and igniter.
of cylinder 1 in ignition sequence. 2. Check ignition coil.



TIM-ID: 0000038611 - 003






of cylinder 10 in ignition 2. Check ignition coil.
sequence.

TIM-ID: 0000038611 - 003

sequence.

sequence.

sequence.

sequence.

sequence.

sequence.

TIM-ID: 0000038611 - 003

sequence.

sequence.

sequence.

sequence.

from pulse sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

Pulse sensor 2 (B75) has tripped 1. Check sensor, sensor gap, cabling, data record settings and timing
an operational error. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

TIM-ID: 0000038611 - 003

(B75). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

Pulse sensor 2 (B75) has wrong u Check sensor, sensor gap, cabling, data record settings and timing

pulse sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

pulse sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

2 (B75) is missing. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

sensor 2 (B75) detected. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
TIM-ID: 0000038611 - 003

pulse sensor 2 (B75) in operation. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

(B75) detected too early or faulty. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

(B75) detected too late or wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
missing.

from pulse sensor 3 (B13.2). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

Pulse sensor 3 (B13.2) has 1. Check sensor, sensor gap, cabling, data record settings and timing
tripped an operational error. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

(B13.2). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

TIM-ID: 0000038611 - 003
sensor 3 (B13.2). wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

Pulse sensor 3 (B13.2) has wrong u Check sensor, sensor gap, cabling, data record settings and timing



3 (B13.2) is missing. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

sensor 3 (B13.2) detected. wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)

pulse sensor 3 (B13.2) in wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
operation.

TIM-ID: 0000038611 - 003
(B13.2) detected too early or wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
faulty.

(B13.2) detected too late or wheel. Replace sensor as necessary. (→ Page 201) (→ Page 200)
missing.
1.4530.007 – Shutdown
Red alarm. Initiated by compressor bypass.
Hardware not ready for operation. 1. Restart compressor bypass flap.
2. Replace compressor bypass flap.
1.4530.008 – Alarm
Yellow alarm. Initiated by compressor bypass.
1.4530.009 – Derating Active

Internal temperature too high. 1. Check room temperature and ventilation.
Adjustment rate is reduced. 2. Check mechanical system.
3. Restart compressor bypass flap.
1.4530.010 – PWM Input High Duty Cycle Error

Compressor bypass setting is not u Check compressor bypass setting.
correct.
1.4530.011 – PWM Input Low Duty Cycle Error

TIM-ID: 0000038611 - 003

correct.
1.4530.012 – Analog Input High Error

correct.

1.4530.013 – Analog Input Low Error
correct.
1.4530.014 – Input Supply Voltage High Error

Supply voltage has reached 1. Check supply voltage.
maximum limit value. 2. Check cabling (→ Page 200).
1.4530.015 – Input Supply Voltage Low Error

minimum limit value. 2. Check cabling (→ Page 200).
1.4530.016 – Electronics Temperature High Error

Temperature of the electronics 1. Check room temperature and ventilation.
above 140ºC or internal 2. Compare device temperature with temperature gage in Service
temperature sensor faulty. tool.
1.4530.017 – Electronics Temperature Low Error

Temperature of the electronics 1. Check room temperature and ventilation.
below -45ºC or internal 2. Compare device temperature with temperature gage in Service
temperature sensor faulty. tool.
1.4530.018 – Position Error

TIM-ID: 0000038611 - 003

Position specification and 1. Check mechanical system.
feedback signal do not match. 2. Restart compressor bypass flap.

1.4530.019 – Run Enable not active
Compressor bypass setting is not u Check compressor bypass flap settings.
correct.
1.4530.020 – Spring Check Failed

Compressor bypass setting is not u Check compressor bypass flap settings.
correct.
1.4530.021 – Internal Fault

Hardware not ready for operation. 1. Restart compressor bypass flap.
1.4530.022 – CAN Fault

CAN bus connection faulty. 1. Check cabling (→ Page 200).
2. Check compressor bypass flap settings.
1.4540.009 – Zero Pressure Detected

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

No gas pressure/gas flow u Check gas pressure.
detected.
TIM-ID: 0000038611 - 003
1.4540.011 – Flow Not Reached

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

1.4540.012 – Valve Position Error
Unable to set the requested flap 1. Restart TecJet.
control. 2. Check mechanical system.
3. Replace TecJet.
1.4540.013 – High Elec Temp

Ambient temperature too high. 1. Restart TecJet.
2. Check room temperature and ventilation.
1.4540.014 – Elec Temp Fail High

Internal temperature sensor 1. Restart TecJet.
faulty. 2. Replace TecJet.
1.4540.015 – FGT Fail High

Internal gas temperature sensor 1. Restart TecJet.
1.4540.016 – Delta P Fail High

Internal differential gas pressure 1. Restart TecJet.
sensor faulty. 2. Replace TecJet.
1.4540.017 – FGP Fail High

Internal gas pressure sensor 1. Restart TecJet.
TIM-ID: 0000038611 - 003
1.4540.018 – Coil Current Fail High

Actuator current limit reached. 1. Restart TecJet.
2. Check mechanical system.
3. Replace TecJet.

1.4540.019 – Position Fail High
Internal position sensor faulty. 1. Restart TecJet.
2. Replace TecJet.
1.4540.020 – Elec Temp Fail Low

Internal temperature sensor 1. Restart TecJet.
1.4540.021 – FGT Fail Low

Internal gas temperature sensor 1. Restart TecJet.
1.4540.022 – Delta P Fail Low

Internal differential gas pressure 1. Restart TecJet.
sensor faulty. 2. Replace TecJet.
1.4540.023 – FGP Fail Low

Internal gas pressure sensor 1. Restart TecJet.
1.4540.024 – Coil Current Fail Low

Actuator current limit reached. 1. Restart TecJet.
2. Check mechanical system.
TIM-ID: 0000038611 - 003
3. Replace TecJet.
1.4540.025 – Position Fail Low

Internal position sensor faulty. 1. Restart TecJet.
2. Replace TecJet.

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

1.4540.028 – PWM Duty Cycle Low Error

1.4540.029 – Battery Volt Low Error

minimum limit value. 2. Check cabling (→ Page 200).
1.4540.030 – FGT Low Limit Error

Gas temperature before TecJet is 1. Check TecJet settings.
below the preset limit value. 2. Check gas temperature.
1.4540.031 – Delta P Low Limit Error

Pressure difference through 1. Check TecJet settings.
TecJet below the preset limit 2. Check TecJet installation direction.
value.
TIM-ID: 0000038611 - 003
1.4540.032 – FGP Low Limit Error

Gas pressure before TecJet is 1. Check TecJet settings.
below the preset limit value. 2. Check gas pressure.

1.4540.033 – Battery Volt High Error
maximum limit value. 2. Check cabling (→ Page 200).
1.4540.034 – FGT High Limit Error

Gas temperature before TecJet is 1. Check TecJet settings.
above the preset limit value. 2. Check gas temperature.
1.4540.035 – Delta P High Limit Error

Pressure difference through 1. Check TecJet settings.
TecJet above the preset limit 2. Check gas pressure.
value.
1.4540.036 – FGP High Limit Error

Gas pressure before TecJet is 1. Check TecJet settings.
above the preset limit value. 2. Check gas pressure.
1.4540.037 – Watchdog Reset

Hardware not ready for operation. u Restart TecJet.
1.4540.038 – CAN Flow Demand Failed

Position setpoint not received or 1. Check TecJet setting.
received too late. 2. Check cabling (→ Page 200).
TIM-ID: 0000038611 - 003
1.4540.040 – TecJet Shutdown


1.4540.041 – TecJet Internal Fault
Hardware not ready for operation. 1. Restart TecJet.
2. Replace TecJet.
1.4540.042 – Keyswitch State

Secondary alarm following 1. Rectify cause of alarm.
emergency engine stop. 2. Check cabling (→ Page 200).
1.4540.043 – Parameter Error

2. Replace TecJet.
1.4540.044 – Parameter Version Error

2. Replace TecJet.
1.4540.045 – Main EEP Read Fail

2. Replace TecJet.
1.4540.046 – Main EEP Write Fail

2. Replace TecJet.
TIM-ID: 0000038611 - 003
1.4540.047 – Reading Parameters

2. Replace TecJet.

1.4540.048 – SPI ADC Error
2. Replace TecJet.
1.4540.049 – Sense 5V Error

2. Replace TecJet.
1.4540.050 – Sense -9V Error

2. Replace TecJet.
1.4540.051 – Sense 12V Error

2. Replace TecJet.
1.4540.052 – ADC Test Error

2. Replace TecJet.
1.4540.053 – CAN Timing Changed

Change of CAN baud rate 1. Check TecJet settings.
detected. 2. Check cabling (→ Page 200).
TIM-ID: 0000038611 - 003
1.4540.054 – Exception Error

2. Replace TecJet.

1.4540.055 – Factory CAL Error
2. Replace TecJet.
1.4540.056 – PWM Duty Cycle High Error

1.4550.031 – A - Internal Fault

Red alarm. Initiated by throttle flap A-Bank.
Hardware not ready for operation. 1. Restart throttle flap.
2. Replace throttle flap.
1.4550.032 – A - Stop commanded (Run/Stop)

Yellow alarm. Initiated by throttle flap A-Bank.
Throttle flap setting is not correct. u Check throttle flap setting.
1.4550.033 – A - Input (Supply) Voltage Fault

maximum or minimum limit value. 2. Check cabling (→ Page 200).
1.4550.034 – A - Position Error

feedback signal do not match. 2. Restart throttle flap.
TIM-ID: 0000038611 - 003
1.4550.035 – A - Temperature Sensor Fault

Red alarm. Initiated by ProAct A-Bank.
Internal temperature sensor 1. Restart throttle flap.
faulty. 2. Replace throttle flap.

1.4550.036 – A - Temperature derating active
Internal temperature above 1. Check room temperature and ventilation.
100ºC. Adjustment rate is 2. Restart throttle flap.
reduced.
1.4550.037 – A - Temperature above 120 °C

120ºC. 2. Restart throttle flap.
1.4550.038 – A - Loss of Position Demand

Position setpoint missing or out of 1. Check throttle flap settings.
range. 2. Check cabling (→ Page 200).
1.4550.039 – A - Demand Tracking Fault

Throttle flap setting is not correct. u Check throttle flap settings.
1.4550.040 – A - Analog Position Demand Failed

1.4550.041 – A - PWM Position Demand Failed

TIM-ID: 0000038611 - 003
1.4550.042 – A - CAN Position Demand Failed

Position setpoint not received or 1. Check throttle flap settings.

1.4550.043 – A - CAN Fault (CAN Bus Off, CAN Ad)
2. Check throttle flap settings.
1.4550.044 – A - CAN Stop Command

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

Red alarm. Initiated by throttle flap B-Bank.
Hardware not ready for operation. 1. Restart throttle flap.
2. Replace throttle flap.
1.4550.132 – B - Stop commanded (Run/Stop)

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

maximum or minimum limit value. 2. Check cabling (→ Page 200).
1.4550.134 – B - Position Error

feedback signal do not match . 2. Restart throttle flap.
TIM-ID: 0000038611 - 003
1.4550.135 – B - Temperature Sensor Fault

Internal temperature sensor 1. Restart throttle flap.
faulty. 2. Replace throttle flap.

1.4550.136 – B - Temperature derating active
100ºC. Adjustment rate is 2. Restart throttle flap.
reduced.
1.4550.137 – B - Temperature above 120°C

120ºC. 2. Restart throttle flap.
1.4550.138 – B - Loss of Position Demand

Position setpoint missing or out of 1. Check throttle flap settings.
range. 2. Check cabling (→ Page 200).
1.4550.139 – B - Demand Tracking Fault

1.4550.140 – B - Analog Position Demand Failed

1.4550.141 – B - PWM Position Demand Failed

TIM-ID: 0000038611 - 003
1.4550.142 – B - CAN Position Demand Failed

Position setpoint not received or 1. Check throttle flap settings.

1.4550.143 – B - CAN Fault (CAN Bus Off, CAN Ad)
2. Check throttle flap settings.
1.4550.144 – B - CAN Stop Command

“Stop” input signal received via u Check throttle flap settings.
CAN bus.
TIM-ID: 0000038611 - 003

6.3 Engine Control Unit – Fault messages
015 – LO P-Lube Oil
Yellow alarm.
Associated parameter 2.0100.921
Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger.
value 1). No oil in engine, engine 2. Replace oil filter (→ Page 189).
speed too low, oil lines, oil heat 3. Take oil sample and analyze (→ Page 188).
exchanger clogged, oil pump
faulty.
016 – SS P-Lube Oil

Red alarm. Engine shutdown.
Engine oil pressure too low (limit 1. Check oil system, oil heat exchanger.
value 2). No oil in engine, engine 2. Replace oil filter (→ Page 189).
speed too low, oil lines, oil heat 3. Take oil sample and analyze (→ Page 188).
exchanger clogged, oil pump
faulty.
019 – HI T-Exhaust A
Yellow alarm.
Exhaust gas temperature (A side) 1. Check exhaust turbocharger.
after turbine too high (limit value 2. Check ignition timing (→ Page 174).
1). Incorrect ignition timing, 3. Check mixture setting.
mixture too lean or too rich,
damage to turbine.
020 – SS T-Exhaust A
Yellow alarm.
TIM-ID: 0000038612 - 002
Exhaust gas temperature (A side) 1. Check exhaust turbocharger.

mixture too lean or too rich, 4. Check igniters.
damage to turbine.

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

Yellow alarm.
Pressure loss via oil filter too high 1. Replace oil filter (→ Page 189).
(limit value 1). 2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil if required
(→ Page 187).
026 – SS P-Diff. Lube Oil

Pressure loss via oil filter too high 1. Replace oil filter (→ Page 189).
(limit value 2). 2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil if required
(→ Page 187).
TIM-ID: 0000038612 - 002

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

Yellow alarm. Power reduction.
Speed of turbocharger 1 too high 1. Check intake air temperature.
(limit value 1). 2. Check emissions (→ Page 46).
3. If the sensor is not obstructed, check the conditions for activating
this monitoring feature in the ECU parameter record.
032 – SS ETC1 Speed

036 – HI ETC2 Speed

TIM-ID: 0000038612 - 002
037 – SS ETC2 Speed


051 – HI T-Lube Oil
Yellow alarm.
Engine oil temperature after oil 1. Check engine coolant circuit.
heat exchanger too high (limit 2. Check oil heat exchanger.
value 1). Oil heat exchanger 3. Check oil level (→ Page 186).
contaminated, coolant
temperature too high. Oil volume
flow insufficient.
052 – SS T-Lube Oil

Engine oil temperature after oil 1. Check engine coolant circuit.
heat exchanger too high (limit 2. Check oil heat exchanger.
value 2). Oil heat exchanger 3. Check oil level (→ Page 186).
contaminated, coolant
temperature too high. Oil volume
flow insufficient.
053 – HI T-Intake Air

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

Yellow alarm.
Intake air temperature too high 1. Check ventilation system.
(limit value 2). 2. Reduce power.
057 – LO P-Coolant
TIM-ID: 0000038612 - 002
Yellow alarm.
Coolant pressure after engine too u Check engine coolant circuit (pressure and flow).
low (limit value 1). Insufficient
volume flow, static pressure too
low.

058 – SS P-Coolant
low.
063 – HI P-Crankcase
Yellow alarm.
Crankcase pressure too high (limit 1. Check crank drive:
value 1). Restrictor valve in • Bar engine (→ Page 162).
crankcase breather is closed too • Endoscope combustion chambers from bottom dead center to
much, air filter is faulty, oil top dead center.
separator is clogged, piston rings 2. Check air filter for contamination, replace if contamination is
are seized, other damage to crank visible (→ Page 184).
drive. 3. Check setting of blow-by restrictor valve.
4. Check oil separator condition, replace as necessary (→ Page 164).
064 – SS P-Crankcase
Crankcase pressure too high (limit 1. Check crank drive: Bar engine (→ Page 162), endoscope
value 2). Restrictor valve in combustion chambers from bottom dead center to top dead
crankcase breather is closed too center.
much, air filter is faulty, oil 2. Check air filter for contamination, replace if contamination is
separator is clogged, piston rings visible (→ Page 184).
are seized, other damage to crank 3. Check setting of blow-by restrictor valve.
drive. 4. Check oil separator condition, replace as necessary (→ Page 164).
067 – HI T-Coolant
TIM-ID: 0000038612 - 002
Coolant temperature after engine u Check engine coolant circuit.

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

068 – SS T-Coolant
Coolant temperature after engine u Check engine coolant circuit.
too high (limit value 2). Engine
coolant pump failure, volumetric
flow too low, air in engine coolant
circuit.
089 – SS Engine Speed too Low

Engine stalls. In normal operation 1. In parallel operation connected to mains:
the engine speed is below the • Check mains for frequency drop.
limit set in parameter 2.2500.027 • Check generator and coupling for damage.
(Engine stall speed limit) without 2. In isolated operation:
an engine stop having taken • Check throttle flap position.
place. The engine is shutdown for • Check throttle flaps for implausible closing. If throttle flaps are
safety reasons. fully open: Check if load step values are admissible.
• Check bypass position.
• Check air filter for contamination, replace if contamination is
visible (→ Page 184).
• Check exhaust back pressure.
• Check differential pressure over mixture cooler.
• Check emissions and injection timing (→ Page 46) (→ Page 174).
• Check oil separator efficiency (oil in compressor intake elbow),
clean compressor as necessary.
• Check valve clearance (→ Page 179).
• Check gasket between mixture line and cylinder head for
correct installation position.
090 – SS No Idling Speed

Red alarm. start is terminated.
Idling speed was not attained. 1. Check ignition.
2. Check gas supply.
3. Check mixture setting.
TIM-ID: 0000038612 - 002
091 – SS No Runup Speed

Yellow alarm.
The speed (starter DISENGAGE) 1. Check ignition.
was not attained, ignition not 2. Check gas supply.
working or no gas available. 3. Check mixture setting.

092 – SS No Starter Speed
Minimum speed for flushing u Check starter system.
process and ignition release was
not attained.
093 – SS T-Preheat
Preheating temperature too low 1. Check preheating.
(limit value 2). coolant 2. Check differential coolant pressure.
temperature too low for engine 3. Check heating elements.
start. 4. Check cabling (→ Page 200).
094 – LO T-Preheat
Yellow alarm.
Preheating temperature too low 1. Check preheating.
(limit value 1). coolant 2. Check differential coolant pressure.
temperature too low for engine 3. Check heating elements.
start. 4. Check cabling (→ Page 200).
095 – AL Prelube Fault

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

Yellow alarm.
TIM-ID: 0000038612 - 002

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

118 – LO ECU Supply Voltage
Yellow alarm.
Supply voltage too low (limit value 1. Check supply voltage.
1). 2. Check cabling (→ Page 200).
119 – LOLO ECU Supply Voltage

Red alarm.
Supply voltage too low (limit value 1. Check supply voltage.
2). 2. Check cabling (→ Page 200).
120 – HI ECU Supply Voltage

Yellow alarm.
Supply voltage too high (limit 1. Check supply voltage.
value 1). 2. Check cabling (→ Page 200).
121 – HIHI ECU Supply Voltage

Red alarm.
Supply voltage too high (limit 1. Check supply voltage.
value 2). 2. Check cabling (→ Page 200).
122 – HI T-ECU
Yellow alarm.
Temperature of electronics too 1. Provide improved cooling for ECU. Reduce room temperature,
high (limit value 1). check air flow to ECU.
TIM-ID: 0000038612 - 002
2. Compare device temperature with temperature gage in DiaSys.
180 – AL CAN1 Node Lost

Bus node (EMU) lost on CAN bus u Check operation of bus users and cabling. Buses (CAN bus 1 and
1. CAN bus 2) are redundant.

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

Red alarm.
Incorrect parameters set in data u Contact Service (configuration error).
record.
183 – AL CAN No PU-Data

Red alarm.
A CAN mode has been selected u Contact Service (configuration error).
that initiates communications
with help of the PU data module.
However, the necessary PU data
module is not present or is invalid.
184 – AL CAN PU-Data Flash Error

Red alarm.
A program error occurred while u Contact Service (configuration error).
trying to copy a received PU data
module to the flash module.
186 – AL CAN1 Bus Off

Yellow alarm.
TIM-ID: 0000038612 - 002

CAN controller 1 is in “Bus-Off” u Check operation of bus users and cabling.
mode. Automatic switching to
CAN bus 2. Bus users (ECU or
EMU) faulty.

187 – AL CAN1 Error Passive
Yellow alarm.
CAN controller 1 signaled a u Check operation of bus users and cabling.
warning. Possible causes may be,
e.g. missing node, minor faults or
temporary bus overload.

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

Yellow alarm.
CAN controller 2 has signaled a u Check operation of bus users and cabling.
warning. Possible causes may be,
e.g. missing node, minor faults or
temporary bus overload.
190 – AL EMU Parameter Not Supported

Red alarm.
EMU parameters are not u Contact Service (configuration error).
supported.
201 – SD T-Coolant
TIM-ID: 0000038612 - 002

Coolant temperature sensor at u Check sensor and cabling (B6.1), replace as necessary
engine outlet faulty, short circuit (→ Page 201) (→ Page 200). Error cleared after restarting the
or wire break. engine.

204 – SD Level Lube Oil
Engine oil level sensor faulty, u Check sensor and cabling (B24), replace as necessary
short circuit or wire break. (→ Page 201) (→ Page 200). Error cleared after restarting the
engine.
206 – SD T-Exhaust A
Yellow alarm.
Exhaust temperature sensor on A u Check sensor and cabling (B4.21), replace as necessary
side faulty, short circuit or wire (→ Page 201) (→ Page 200). Error cleared after restarting the
break. engine.
207 – SD T-Exhaust B
Yellow alarm.
Exhaust temperature sensor on B u Check sensor and cabling (B4.22), replace as necessary
side faulty, short circuit or wire (→ Page 201) (→ Page 200). Error cleared after restarting the
break. engine.
211 – SD P-Lube Oil

Engine oil pressure sensor after u Check sensor and cabling (B5.1), replace as necessary
filter faulty, short circuit or wire (→ Page 201) (→ Page 200). Error cleared after restarting the
break. engine.
212 – SD P-Coolant
Red alarm.
TIM-ID: 0000038612 - 002

Coolant pressure sensor after u Check sensor and cabling (B16.1), replace as necessary
engine faulty, short circuit or wire (→ Page 201) (→ Page 200). Error cleared after restarting the
break. engine.

214 – SD P-Crankcase
Red alarm.
Crankcase pressure sensor faulty, u Check sensor and cabling (B50), replace as necessary
short circuit or wire break. (→ Page 201) (→ Page 200). Error cleared after restarting the
engine.
216 – SD T-Lube Oil

Engine oil temperature sensor u Check sensor and cabling (B7), replace as necessary (→ Page 201)
after oil heat exchanger faulty, (→ Page 200). Error cleared after restarting the engine.
short circuit or wire break.
219 – SD T-Intake Air

Yellow alarm.
Intake air temperature sensor u Check sensor and cabling (B49.1 / B90), replace as necessary
faulty, short circuit or wire break. (→ Page 201) (→ Page 200). Error cleared after restarting the
engine.
221 – SD P-Diff-Lube Oil

Red alarm.
Engine oil pressure sensors faulty, u Check sensor and cabling before filter (B5.3) and after filter (B5.1),
short circuit or wire break. replace as necessary (→ Page 201) (→ Page 200). Error cleared
after restarting the engine.
227 – SD P-Lube Oil before Filter

Yellow alarm.
TIM-ID: 0000038612 - 002

Engine oil pressure sensor before u Check sensor and cabling (B5.3), replace as necessary
filter faulty, short circuit or wire (→ Page 201) (→ Page 200). Error cleared after restarting the
break. engine.

229 – AL Stop Camshaft Sensor Defect
Engine stop due to camshaft u Check sensor and cabling (B1.1), replace as necessary
sensor failure. (→ Page 201) (→ Page 200). Error cleared after restarting the
engine.
231 – SD Camshaft Speed

Camshaft sensor faulty, short u Check sensor and cabling (B1.1), replace as necessary
circuit or wire break. (→ Page 201) (→ Page 200). Error cleared after restarting the
engine.
232 – SD Charger 1 Speed

Red alarm.
Speed sensor of turbocharger 1 1. Check sensor and cabling (B44.1), replace as necessary
engine.
233 – SD Charger 2 Speed

Red alarm.
Speed sensor of turbocharger 2 1. Check sensor and cabling (B44.2), replace as necessary
engine.
245 – SD ECU Supply Voltage

TIM-ID: 0000038612 - 002
Red alarm.
Internal Engine Control Unit fault. u Replace Engine Control Unit ECU.

266 – SD Speed Demand
Red alarm.
Speed setting signal can no longer 1. Check Engine Control Unit setting (default setting is speed demand
be transmitted from plant. via CAN bus).
2. Check signal and cabling between plant and ECU.
381 – AL Wiring TOP 1

Yellow alarm.
Short circuit or line break at u Check cabling (→ Page 200).
transistor output 1 system-side
(TOP 1). Activation of yellow
summary alarm faulty.

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

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

TIM-ID: 0000038612 - 002
Red alarm.
(TOP 4). Activation of gas supply
solenoid valve No.2 faulty.

418 – SD T-Intake Air B
Yellow alarm.
Intake air temperature sensor u Check sensor and cabling (B49.2), replace as necessary
faulty, short circuit or wire break. (→ Page 201) (→ Page 200).
419 – SD T-Coolant b.Engine

Red alarm.
Coolant temperature sensor at u Check sensor and cabling (B6.3), replace as necessary
engine inlet faulty, short circuit or (→ Page 201) (→ Page 200).
wire break.
423 – LO P-Coolant Diff.

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

Yellow alarm.
u Check engine coolant circuit (pressure and flow).
TIM-ID: 0000038612 - 002
Coolant pressure before engine

too low (limit value 1). Insufficient
low.

431 – SS P-Coolant Before Engine
Coolant pressure before engine u Check engine coolant circuit (pressure and flow).
too low (limit value 2). Insufficient
low.
434 – HI T-Coolant Before Engine

Yellow alarm.
Coolant temperature before u Check engine coolant circuit (pressure and flow).
engine too high (limit value 1).
Engine coolant pump failure, flow
too low, air in engine cooling
system.
435 – SS T-Coolant Before Engine

Coolant temperature before u Check engine coolant circuit (pressure and flow).
engine too high (limit value 2).
Engine coolant pump failure, flow
too low, air in engine cooling
system.
443 – HI P-Charge Mix Diff.

Yellow alarm.
Difference in mixture pressures 1. Check throttle flaps for varying positions and malfunction.
sensed on A and B side is too high 2. Check mixture lines for leakage.
(limit value 1). 3. Check sensors and cabling (B79.22, B79.21) (→ Page 201)
(→ Page 200).
TIM-ID: 0000038612 - 002
445 – SD P-Ambient Air

Yellow alarm.
Ambient air pressure sensor on u Replace Engine Control Unit ECU.
ECU faulty.

447 – HIHI P-Charge Mix Diff.
Difference in mixture pressures 1. Check throttle flaps for varying positions and malfunction.
sensed on A and B side is too high 2. Check mixture lines for leakage.
(limit value 2). 3. Check sensors and cabling (B79.22, B79.21) (→ Page 201)
(→ Page 200).
451 – HI T-Charge Mix

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

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

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

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

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

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

Red alarm.
Coolant pressure sensor before u Check sensor and cabling (B16.3), replace as necessary
engine faulty, short circuit or wire (→ Page 201) (→ Page 200). Error cleared after restarting the
break. engine.
470 – SD T-ECU
Red alarm.
Temperature sensor in Engine u Replace Engine Control Unit ECU.
Control Unit faulty.
472 – AL Stop SD
Engine stopped because channel u Summary alarm (for details, refer to the source alarm).
TIM-ID: 0000038612 - 002
has a “Faulty sensor”.
476 – AL Crash Rec.Init Fault

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

478 – AL Combined Alarm Yellow (System)
Yellow alarm.
Summary alarm YELLOW from u Summary alarm (for details, refer to the source alarm).
system.
479 – AL Combined Alarm Red (System)

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

Mixture pressure sensor on A side u Check sensor and cabling (B79.21), replace as necessary
engine.
497 – SD P-Charge Mix B

Mixture pressure sensor on B side u Check sensor and cabling (B79.22), replace as necessary
engine.
498 – SD P-Charge Mix Diff

Red alarm.
Mixture differential pressure u Check sensors and cabling (B79.21, B79.22), replace as necessary
TIM-ID: 0000038612 - 002
sensor on A or B side faulty, short (→ Page 201) (→ Page 200). Error cleared after restarting the
circuit or wire break. engine.

499 – SD T-Charge Mix
Red alarm.
Mixture temperature sensor u Check sensor and cabling (B73), replace as necessary
engine.
511 – HIHI P-Charge Mix A

Mixture pressure on A side too 1. Check emissions (→ Page 46).
high (limit value 2). 2. Check ignition timing (→ Page 174).
3. Check exhaust back pressure.
4. Check valve clearance (→ Page 179).
5. Check throttle flap.
6. Check mixture coolant system.
512 – HIHI P-Charge Mix B

Mixture pressure on B side too 1. Check emissions (→ Page 46).
high (limit value 2). 2. Check ignition timing (→ Page 174).
3. Check exhaust back pressure.
4. Check valve clearance (→ Page 179).
5. Check throttle flap.
6. Check mixture coolant system.
513 – SD P-Coolant Diff

Red alarm.
Coolant differential pressure u Check sensors and cabling (B16.1, B16.3), replace as necessary
sensor faulty, short circuit or wire (→ Page 201) (→ Page 200). Error cleared after restarting the
break. engine.
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515 – AL Starter Not Engaged
Yellow alarm.
Starter not engaged. ECU does 1. Check starter.
not detect engine speed during 2. Check cabling (→ Page 200).
starting sequence. 3. Check speed sensor B1.1 if speed is not indicated although engine
is turning (→ Page 201).
517 – SD P-Charge Mix before Throttle

Red alarm.
Mixture pressure sensor before u Check sensor and cabling (B79.23), replace as necessary
throttle flap faulty, short circuit or (→ Page 201) (→ Page 200). Error cleared after restarting the
wire break. engine.
520 – SD P-Intake Air after Filter A

Yellow alarm.
Intake air pressure sensor after u Check sensor and cabling (B81.1), replace as necessary
filter on A side faulty, short circuit (→ Page 201) (→ Page 200). Error cleared after restarting the
522 – SD P-Intake Air after Filter B

Yellow alarm.
Intake air pressure sensor after u Check sensor and cabling (B81.2), replace as necessary
filter on B side faulty, short circuit (→ Page 201) (→ Page 200). Error cleared after restarting the
534 – HIHI Power Difference

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Set and actual power deviate 1. Check converter.
excessively from each other. 2. Check fuel settings.
3. Check emissions (→ Page 46).

535 – LOLO Power Difference
Set and actual power deviate 1. Check converter.
excessively from each other. 2. Check fuel settings.
536 – AL Wiring PWM_CM1

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

Red alarm.
Gas train test was not successful. 1. Check gas train.
Alarm is activated if the gas train 2. Check cabling (→ Page 200).
does not report OK within a
specified time-out period. Either
the gas train leak test was not
successful, the time-out period is
set too short, or communication is
faulty.
554 – AL Ignition Fault

Red alarm.
Ignition failure. Alarm is activated 1. Check ignition system.
if the feedback signal from 2. Check ignition system speed sensors (→ Page 201).
ignition system is not received 3. Check cabling (→ Page 200).
within a specified time-out period.
Either the ignition could not be
TIM-ID: 0000038612 - 002
activated, the timeout period is

set too short, or communication is
faulty.

556 – AL GasValve Fault
Red alarm.
Gas supply solenoid valve faulty. 1. Check gas train.
Alarm is active if there are 2. Check cabling (→ Page 200).
problems with the gas supply
solenoid valves. Either the gas
supply solenoid valves are faulty,
the timeout period is set too
short, or communication is faulty.
557 – AL speed drop fault

Speed drop. Alarm is activated if u Check gas train.
engine speed drops during
starting sequence.

Red alarm.
Wire break or short circuit on u Check setting at Engine Control Unit.
channel PWM_CM2.
559 – AL mixture throttle A fault

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

Yellow alarm.
Pressure loss over air filter on A u Replace air filter (→ Page 184).
side is too high.
566 – AL L2 P-Intake Air after Filter A

Yellow alarm.
Pressure loss over air filter on A u Replace air filter (→ Page 184).
side is too high.
567 – AL L1 P-Intake Air after Filter B

Yellow alarm.
Pressure loss over air filter on B u Replace air filter (→ Page 184).
side is too high.
568 – AL L2 P-Intake Air after Filter B

Yellow alarm.
TIM-ID: 0000038612 - 002

Pressure loss over air filter on B u Replace air filter (→ Page 184).
side is too high.

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

Yellow alarm.
The cylinder set to maximum 1. Check emissions (→ Page 46).
retarded timing due to knocking 2. Check ignition timing (→ Page 174).
has violated the first limit value. 3. Check combustion chamber.
4. Check gas quality if feasible (methane number).

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

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

Red alarm.
channel PWM_CM3.
583 – AL GLS closed

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

Red alarm.
channel PWM_CM4.
596 – AL Develop PR Set

Red alarm.
The ECU parameter record in use u Load series parameter record on ECU.
is a test version.

Red alarm.
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channel PWM_CM5.
603 – SD Air Humidity

Yellow alarm.
Air humidity sensor faulty. Short u Check cabling and sensor (→ Page 200).
circuit or wire break.

604 – AL Hut Changespeed max.
Yellow alarm.
Excessively rapid change in gas u Check gas system.
quality.
606 – AL Double Nodes Lost CAN 1 + 2

Yellow alarm.
Bus node (EMU) lost on CAN bus u Check operation of bus nodes and cabling (→ Page 200).
1 and 2.

Red alarm.
channel PWM_CM6.

Red alarm.
Wire break or short circuit on u Check cabling to NOx sensor on A side (→ Page 200).
channel PWM_CM7.
615 – AL EIL Protection

Red alarm.
Response to faulty or manipulated u Check EIL.
EIL.
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616 – AL EIL Error

Red alarm.
Faulty or manipulated EIL. u Check EIL.

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

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

Yellow alarm.
Fuel calorific value has exceeded u Check gas quality if feasible.
the first limit value.
620 – HIHI Current Heat Value of Fuel

Yellow alarm.
the second limit value.
621 – LO NOx Value

Yellow alarm.
NOx emissions have undershot 1. Check gas quality if feasible.
the first limit value. 2. Check gas pressure.
TIM-ID: 0000038612 - 002
3. Check NOx sensor (→ Page 201).


622 – LOLO NOx Value
Yellow alarm.
NOx emissions have undershot 1. Check gas quality if feasible.
the second limit value. 2. Check gas pressure.
3. Check NOx sensor (→ Page 201).
623 – HI NOx Value

Yellow alarm.
NOx emissions have exceeded the 1. Check gas quality if feasible.
first limit value. 2. Check NOx sensor (→ Page 201).
624 – HIHI NOx Value

Yellow alarm.
NOx emissions have exceeded the 1. Check gas quality if feasible.
second limit value. 2. Check NOx sensor (→ Page 201).

Red alarm.
Wire break or short circuit on u Check cabling to NOx sensor on B side (→ Page 200).
channel PWM_CM8.

Red alarm.
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channel PWM_CM9.

Red alarm.
channel PWM_CM10.
642 – SD Electr. Motor Power AI2

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

Knock intensity exceeded 1. Check gas quality if feasible (methane number).
(extreme knocking detected). 2. Check emissions (→ Page 46).
3. Check combustion chamber.
649 – Al Req Angle Throttle A

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

TIM-ID: 0000038612 - 002

Opening angle of throttle flaps B 1. Check charge-air pressure reserve.
exceeded. 2. Intake air temperature outside TVU data.
3. Check compressor for contamination.
4. Reduce power.

651 – AL Preheating Error
Yellow alarm.
Engine preheating faulty. 1. Low coolant.
2. Missing differential pressure in coolant system.
3. Coolant pump does not start, is faulty.
652 – AL GET Comm Lost

Red alarm.
CAN bus communication for 1. Check cabling (→ Page 200).
knock control faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU and knock control.
4. Check settings with device-specific dialog software (XD10).
653 – AL IC92x Comm Lost

Red alarm.
ignition system faulty. 2. Check power supply.
3. Restart ECU, EMU and ignition system.
4. Check settings with device-specific dialog software.
654 – AL FSeries Comm Lost

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

TIM-ID: 0000038612 - 002
Red alarm.
CAN bus communication for gas 1. Check cabling (→ Page 200).
control valve faulty (alternatively, 2. Check power supply.
a stepper motor with gas mixer 3. Carry out restart of ECU, EMU and gas control valve.
can be installed). 4. Check settings with device-specific dialog software (XD11).

656 – AL ProActA Comm Lost
Red alarm.
throttle flap A faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU and throttle flap A.
657 – AL ProActB Comm Lost

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

Red alarm.
CAN bus communication for NOx 1. Check cabling (→ Page 200).
sensor A faulty. 2. Check power supply.
3. Restart ECU.
4. Replace sensor (→ Page 201).
659 – AL NOxB Comm Lost

Red alarm.
CAN bus communication for NOx 1. Check cabling (→ Page 200).
sensor B faulty. 2. Check power supply.
3. Restart ECU.
4. Replace sensor (→ Page 201).
664 – AL Oil Refill Error

TIM-ID: 0000038612 - 002
Red alarm.
Summary alarm for automatic oil u After initiation of the alarms “HI Oil Refill” and
replenishment. “HI Lube Oil Level refill” a programmable timeout period starts. The
engine is stopped when this time expires.

665 – AL GET Yellow
Yellow alarm.
An internal summary alarm in u An exact fault designation is transmitted via CAN bus to the genset
knock control was detected. control system.
666 – AL IC92x Yellow

Yellow alarm.
An internal summary alarm in the u An exact fault designation is transmitted via CAN bus to the genset
ignition system was detected. control system.
667 – AL FSeries Yellow

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

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

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

Yellow alarm.
throttle flap B was detected. control system.

671 – AL NOxA Yellow
Yellow alarm.
An internal summary alarm at NOx u An exact fault designation is transmitted via CAN bus to the genset
sensor A was detected. control system.
672 – AL NOxB Yellow

Yellow alarm.
sensor B was detected. control system.
675 – AL GET Red

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

Red alarm.
677 – AL FSeries Red

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

Red alarm.
gas control valve was detected. control system.

679 – AL ProActA Red
Red alarm.
throttle flap A was detected. control system.
680 – AL ProActB Red

Red alarm.
throttle flap B was detected. control system.
681 – AL NOxA Red

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

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

Red alarm.
Minimum engine oil filling level 1. Check engine oil level (→ Page 186).
detected. 2. Check replenishment system.
TIM-ID: 0000038612 - 002
3. Fill oil.
686 – AL Lube Oil Max

Red alarm.
Maximum engine oil filling level 1. Check engine oil level (→ Page 186).
detected. 2. Check replenishment system.
3. Drain oil.

688 – LO Oil Refill
Yellow alarm.
No oil replenishment within a u Check oil replenishment system.
programmable time.
689 – HI Oil Refill

Yellow alarm.
Engine oil was refilled too often u Check engine oil level (→ Page 186). Check oil supply.
within a certain time interval.
691 – HI Lube Oil Level Refill.

Yellow alarm.
Engine oil was refilled too often u Check engine oil level. Check oil supply.
within a certain time interval.
719 – AL T-Gas L1
Yellow alarm.
1st lower limit value violated. u Check gas supply.
720 – AL T-Gas L2
Red alarm.
2nd lower limit value violated. u Check gas supply.
832 – AL EIL Different Engine Number

TIM-ID: 0000038612 - 002
Yellow alarm.
Engine number in EIL differs from 1. Check the engine number in the ECU. Check that the ECU
engine number in ECU. Two parameter record matches this engine.
further attempts at engine 2. Check EIL.
starting remain after the first
occurrence before engine starting
is disabled.

842 – AL Fuel Throttle Pos. L1
TecJet throttle flap position has u Check gas supply.
exceeded limit value 1.
848 – AL Rel. Humidity L1

Calculated air humidity has u Check air humidity.
exceeded limit value 1.
891 – AL Scavenging Active

Yellow alarm.
Engine was shut down by 1. Await end of scavenging phase.
emergency stop and has failed to 2. Check engine speed. A speed of at least 80 rpm must be reached.
successfully complete the starting
sequence several times.
932 – AL MIC5 Yellow

Yellow alarm.
933 – AL MIC5 Red

Red alarm.
u An exact fault designation is transmitted via CAN bus to the genset
TIM-ID: 0000038612 - 002
An internal summary alarm in the

934 – AL MIC5 Comm Lost

Red alarm.
CAN bus communication for u Check cabling (→ Page 200).
ignition system faulty.

948 – AL ESI activated
Red alarm.
Emergency stop input has been 1. Rectify fault at source.
activated. 2. Check cabling (→ Page 200).
972 – AL MIC5 Signature difference

Red alarm.
The ignition system has not 1. Restart ECU.
accepted the configuration from 2. Check setting at Engine Control Unit.
the Engine Control Unit.

Yellow alarm.
CAN controller 3 is in “Bus Off” u Check operation of bus users and cabling.
status. Bus nodes (ignition, knock
module, throttle flaps or gas
mixture) malfunctioning.

Yellow alarm.
CAN controller 3 has indicated a u Check operation of bus users and cabling.
warning. Bus nodes (ignition,
knock module, throttle flaps or
gas mixture) malfunctioning.

Yellow alarm.
TIM-ID: 0000038612 - 002

CAN controller 4 is in “Bus Off” u Check operation of bus users and cabling.
status. Bus nodes (ignition, knock
module, throttle flaps or gas
mixture) malfunctioning.

Yellow alarm.
CAN controller 4 has indicated a u None
warning.
1012 – AL MIC5 parameter download active

Yellow alarm.
Parameter download from the u Wait until parameter downloading has been completed. Max. time
ECU to the Ignition system is is approx. 2 min.
active.
1013 – HI Delta NOx (A-B)

Yellow alarm.
NOx values measured for banks A 1. Check emissions (→ Page 46).
and B are two far apart (limit value 2. Check NOx sensors (→ Page 201).
1). 3. Check ignition points. (→ Page 174)
1014 – HIHI Delta NOx (A-B)

Red alarm.
and B are two far apart (limit value 2. Check NOx sensors (→ Page 201).
2). 3. Check ignition points. (→ Page 174)
1017 – HI Delta p5 for NOx

Yellow alarm.
TIM-ID: 0000038612 - 002

and B are two far away from the 2. Check NOx sensors (→ Page 201).
assumed NOx value (limit value 3. Check ignition points. (→ Page 174)
1).

1030 – LO P-Crank Case
Yellow alarm.
Crankcase pressure too low (limit 1. Check air filter for damage, replace if damage is visible .
value 1). Restrictor valve in 2. Check setting of blow-by restrictor valve.
crankcase breather is open too
wide, air filter is faulty.
1031 – LOLO P-Crank Case

Crankcase pressure too low (limit 1. Check air filter for damage, replace if damage is visible .
value 2). Restrictor valve in 2. Check setting of blow-by restrictor valve.
crankcase breather is open too
wide, air filter is faulty.
TIM-ID: 0000038612 - 002

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

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

1. Remove guard plate.
2. Engage barring gear (2) in ring gear (3) and
install on flywheel housing.
3. Apply ratchet (1) to barring gear (2).
4. Rotate crankshaft in direction of engine rota-
tion. Apart from compression resistance,
there should be no abnormal resistance.
5. Remove barring gear in reverse order.
TIM-ID: 0000002531 - 002
162 | Task Description | MS150116/02E 2016-07

7.1.2 Checking machine room for smell of gas
Gas detection and alarm unit (not stocked by MTU) -
WARNING
Gaseous fuels are combustible/explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Carry gas-warning unit (part of the personal safety equipment).
• Do not smoke.
Checking machine room for smell of gas

1. Check machine room to localize gas supply leaks using gas detection and alarm unit.
2. If the gas detection and alarm unit responds:
• Avoid naked flames!
• Avoid sparks! Do not use electrical appliances (including switches, connectors/sockets, telephone, bell).
• Do not smoke!
• Close the magnetic gas shutoff valves.
• Open windows and doors!
• Warn residents and leave building!
• Call gas supplier from outside the building!
TIM-ID: 0000029125 - 002
MS150116/02E 2016-07 | Engine | 163

7.2 Crankcase Breather
7.2.1 Oil separator – Filter replacement
Preconditions

Filter element (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Engine oil is hot.
Engine oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Allow the engine to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Oils/oil vapors are combustible/explosive.
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
Replacing oil separator filter

1. Release clamp (2) on both sides and remove
it.
2. Remove housing cover (1).
TIM-ID: 0000029127 - 005
164 | Crankcase Breather | MS150116/02E 2016-07

3. Remove locknut (1).
4. Remove filter cover (3) with washer (2).
5. Carefully lift out fine filter (6).
6. Carefully lift out coalescence filter (5).
7. Clean sealing faces and inside of housing.
8. Check condition of gaskets on new fine filter
and new coalescence filter.
Note: The fine filter (6) must be installed in the cor-
rect position in the housing.
9. Place fine filter (6) in housing, ensuring it is
straight.
Note: The coalescence filter (5) must be installed in
the correct position in the housing.
10. Place coalescence filter (5) in housing, ensur-
ing it is straight.
11. Fit filter cover (3), ensuring it is positioned
correctly.
12. Screw on washer (2) with new locknut (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Locknut Tightening torque 15 Nm
13. Fit housing cover (1).
14. Fit clamp (2) neatly and tighten to specified torque using a torque wrench.
Clamp Tightening torque 5 Nm
TIM-ID: 0000029127 - 005
MS150116/02E 2016-07 | Crankcase Breather | 165

7.3 Ignition System
7.3.1 Spark plug – Replacement
Spark plug (→ Spare Parts Catalog)
Replacing spark plug

1. Remove spark plug (→ Page 167).
2. Install new spark plug (→ Page 168).
TIM-ID: 0000004224 - 002
166 | Ignition System | MS150116/02E 2016-07

7.3.2 Spark plug – Removal
Preconditions
☑ Open protective packing of new spark plug only immediately prior to installation.

Special wrench, 20.8 mm F30452574 1
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
Removing spark plug

1. Remove spark plug connector (1)
(→ Page 171).
2. Unscrew spark plug a few turns.
3. Clean spark plug bore with compressed air.
4. Unscrew spark plug from cylinder head and
remove from spark plug bore.
TIM-ID: 0000043424 - 004
MS150116/02E 2016-07 | Ignition System | 167

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

Torque wrench, 10–60 Nm F30452769 1
Special wrench, 20.8 mm F30452574 1
Assembly compound (Molykote P 37) 50564 1
Spark plug (→ Spare Parts Catalog)
Spark plug connector with ignition line (→ Spare Parts Catalog)
WARNING
Risk of burns!
WARNING
Installing spark plug

1. Clean and dry the mating surfaces on spark
plug (1), sealing ring (2) and cylinder head.
2. Fit new sealing ring (2) on spark plug (1) with
the flat side facing the insulator.
3. Check satisfactory condition of spark plug
connector and ignition cable, replace parts if
damaged.
4. Apply thin coat of assembly compound to
spark plug thread.
TIM-ID: 0000043425 - 004

5. Screw spark plug into cylinder head.
Note: The temperature of spark plug and cylinder head must be the same prior to tightening.
6. Tighten spark plug to specified torque using a torque wrench.
Spark plug M18 x 1.5 Tightening torque (Assembly compound 50 +5 Nm
(Molykote P 37))
7. Install spark plug connector (1) (→ Page 172).

TIM-ID: 0000043425 - 004

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

1. Remove spark plug connector (→ Page 171).
2. Install spark plug connector (→ Page 172).
TIM-ID: 0000035897 - 004

7.3.5 Spark plug connector – Removal
Preconditions
☑ Open protective packing of new spark plug connector only immediately prior to installation.
WARNING
Risk of burns!
WARNING
Removing spark plug connector

1. Loosen screws (4) on cylinder head cover (7)
turning them back approx. one revolution.
2. Turn flange (6) counterclockwise out of un-
ion (4).
3. Pull protective cap (2) up and back to gain
access to threaded connection of the ignition
lead underneath.
4. Loosen threaded connection of the ignition
lead on ignition coil (1) and disconnect igni-
tion cable (3).
5. Grip ignition lead connector (5) by flange (6)
and disconnect from spark plug before fully
extracting it from spark plug bore.
TIM-ID: 0000043225 - 004

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

Spark plug connector with ignition line (→ Spare Parts Catalog)
WARNING
Risk of burns!
WARNING
Installing spark plug connector

1. If necessary, remove the ignition line's lower
sealing ring and replace with a new sealing
ring.
2. Remove any dust and impurities from the ig-
nition line connector's Teflon body - on the
outside and inside on the spark plug side.
3. Check the spark plug isolator sealing ring for
damage. If damaged, install a new spark plug
isolator sealing ring (→ Page 173).
4. Insert the ignition line connector (5) into the
spark plug duct, press down the ignition line
flange (6) against the spring force and screw
into the straight union until they abut the
bolts (4) on both sides. The item number on
the flange is in the 6 o'clock position.
5. Tighten the bolts (4) of the ignition line
flange (6). Check for correct alignment of the
TIM-ID: 0000043226 - 006
ignition line flange (6) while doing this. The

bolt slots of the flange (6) abut the threads of
the bolts (4) on both sides.
6. Fasten the ring eyelet of the ignition line (3) to the ignition coil (1) with the bolt and spring washer.
Screw M6 Tightening torque 10 Nm
7. Fit the protective cap (2) and check for correct seating.

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

4. Insert sealing ring (2) into the bore in Teflon
sleeve (1) with the article number facing
downwards.
5. Carefully press sealing ring (1) into the

groove until it is flush with the bore in Teflon
sleeve (2).
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7.3.7 Ignition system – Ignition timing check
Preconditions
☑ Operating voltage of genset control system is present.
☑ Genset is disconnected from the mains.

Stroboscope (not stocked by MTU) -
DANGER
Live components, flash-over.
Risk of serious injury - danger to life!
• Always wear electrical gloves (class 4 minimum) when touching the ignition cable in operation.
DANGER
danger zone.
WARNING
Checking ignition timing

Note: Service tool DiaSys® and a 1A level dongle
(or higher), or the Woodward IC900 series
service tool (for Woodward ignition systems
only), are required to determine the ignition
timing setting.
1. Stop engine (→ Page 48).
2. Install stroboscope clamp on cylinder A1 igni-
tion cable.
3. Start engine (→ Page 44).
4. Using the stroboscope, check ignition timing
on flywheel mark and compare with the en-
gine-specific setpoint value.
5. If the ignition timing deviates from the speci-
fication, it shall be adjusted by correcting the
reset position in the ignition system. Correct
TIM-ID: 0000043949 - 004
the reset position with DiaSys® (for Motor-

tech ignition systems only) or the Woodward
IC900 series service tool (for Woodward igni-
tion systems only).
6. Check ignition timing.
7. Disconnect stroboscope.
8. Stop engine (→ Page 48).

7.4 Valve Drive
7.4.1 Valve protrusion – Measurement
Preconditions

Sliding depth gage, 200 mm Y20000918 1
Preparatory steps
1. Remove igniters (→ Page 167).
2. Remove cylinder head covers (→ Page 181).
3. Remove sleeves (arrowed).
4. Install barring tool (→ Page 162).
5. Rotate crankshaft with barring tool in engine

direction of rotation until marking “OT” and
pointer are aligned.
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MS150116/02E 2016-07 | Valve Drive | 175

Measuring valve protrusion
1. Check TDC position of piston in cylinder A1:
• The piston is at firing TDC when the rocker arms on cylinder A1 are unloaded.
• The piston is at overlap TDC when the rocker arms on cylinder A1 are loaded.
2. Measure protrusion at each valve in two crankshaft positions (firing TDC and overlap TDC) according to the
diagram. Diagram (→ Page 179).
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 igniter bore with
depth gage (see figure).
• The specified value for a new cylinder
head: 93.8 mm.
• Admissible wear: 3 mm.
• If the measured value is > 96.8 mm, re-
place the relevant cylinder head ahead of
schedule.
5. Install valve bridge.
6. Adjust valve clearance (→ Page 179).
Final steps
1. Remove barring tool (→ Page 162).
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2. Check condition of O-rings at the sleeves, replace if damaged.
176 | Valve Drive | MS150116/02E 2016-07

3. Install sleeves (arrowed).
4. Install cylinder head covers (→ Page 182).
5. Install igniters with new sealing rings
(→ Page 168).
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MS150116/02E 2016-07 | Valve Drive | 177

7.4.2 Valve gear – Lubrication
Preconditions

Engine oil
Lubricating valve gear

1. Remove cylinder head covers (→ Page 181).
2. Fill oil chambers of rocker arms and adjusting
screws with oil.
3. Install cylinder head covers (→ Page 182).
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178 | Valve Drive | MS150116/02E 2016-07

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

Feeler gauge Y20098771 1
Angular screw driver F30452765 1
Socket wrench, 24 mm F30029815 1
Engine oil
Preparatory steps
1. Remove cylinder head cover (→ Page 181).
2. Install barring device (→ Page 162).
3. Rotate crankshaft with barring device in en-
gine direction of rotation until marking “OT”
and pointer are aligned.
Scheme for 20V – Two crankshaft adjustments

Position Cylin- 1 2 3 4 5 6 7 8 9 10
der
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20V
Firing TDC in cylinder A1 Bank A IX –X –– I– –X I– –X IX I– ––
Bank B I– –X –– I– IX –– –X IX I– –X
I Inlet: Valve clearance adjustment of inlet valve is permitted
X Exhaust: Valve clearance adjustment of exhaust valve is permitted
– Valve clearance adjustment is not permitted
MS150116/02E 2016-07 | Valve Drive | 179

Position Cylin- 1 2 3 4 5 6 7 8 9 10
der
Overlap TDC in cylinder Bank A –– I– IX –X I– –X I– –– –X IX
A1 Bank B –X I– IX –X –– IX I– –– –X I–
I Inlet: Valve clearance adjustment of inlet valve is permitted
X Exhaust: Valve clearance adjustment of exhaust valve is permitted
– Valve clearance adjustment is not permitted
Table 41: Scheme for valve clearance adjustment
Valve clearance at two crankshaft positions – Check

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

1. Release locknut (1).
2. Insert feeler gauge (3) between valve bridge
and rocker arm.
3. Use angular screw driver to set adjusting
screw (2) so that the specified valve clear-
ance is provided.
4. Feeler gauge (3) must just pass through the
gap.
5. Use torque wrench to tighten locknut (1) to the specified tightening torque, holding the adjusting screw (2)
to prevent it from turning.
Locknut M16 Tightening torque (Engine oil) 90 Nm+9 Nm
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6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 162).
2. Install cylinder head cover (→ Page 182).
180 | Valve Drive | MS150116/02E 2016-07

7.4.4 Cylinder head cover ‒ Removal
Preconditions
Cylinder head cover ‒ Removal

1. Clean very dirty cylinder head covers (1) prior
to removal.
2. Remove spark plug connector (→ Page 171).
3. Remove screws (2).
4. Remove cylinder head cover with gasket from
cylinder head.
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MS150116/02E 2016-07 | Valve Drive | 181

7.4.5 Cylinder head cover ‒ Installation
Gasket (→ Spare Parts Catalog)
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
Cylinder head cover ‒ Installa-

tion
1. Clean mounting surface.
2. Check condition of gasket, replace if dam-
aged.
3. Position gasket and cylinder head cover (1)
on cylinder head.
4. Insert screws (2) in cylinder head cover and
tighten them.
Note: The locking plate must be removed from the
cylinder head cover.
5. Install spark plug connector (→ Page 172).
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182 | Valve Drive | MS150116/02E 2016-07

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

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

1. Coat all connections of the gas supply line with soap solution or spray with leakage detection spray from a
distance of 30 to 50 cm.
• Leaks are indicated by the formation of bubbles or foam.
2. Replace leaking parts.
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MS150116/02E 2016-07 | Gas System | 183

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

1. Remove air filter (→ Page 185).
2. Install new air filter (→ Page 185).
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184 | Air Filter | MS150116/02E 2016-07

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

tion
1. Loosen clamp (2).
2. Remove air filter (3) and clamp (2) from con-
necting flange (1) of intake housing.
3. Clean connecting flange (1) of the intake
housing and check for obstructions.
4. Place new air filter (3) with clamp (2) onto in-
take housing (1).
5. Tighten clamp (2).
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MS150116/02E 2016-07 | Air Filter | 185

7.7 Lube Oil System, Lube Oil Circuit
7.7.1 Engine oil level – Check
Preconditions
WARNING
Engine oil is hot.
WARNING
• Do not smoke.
Checking oil level prior to en-

gine start
1. Pull out dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop,
withdraw after approx. 10 seconds and check
oil level.
Note: After extended standstill, the oil level may ex-
ceed the mark (1) by up to 2 cm. The cause
of this may be that oil, e.g. from the oil filter
and oil heat exchanger flows back into the oil
pan.
3. The oil level must reach the mark (2) or ex-
ceed the mark (1) by up to 2 cm.
Note: Topping up oil manually is not required. The
oil level check is only intended to confirm
that the automatic oil replenishment feature
works properly.
4. Insert oil dipstick into guide tube up to the
stop.
Checking oil level after the engine is stopped

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1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
Note: Topping up oil manually is not required. The oil level check is only intended to confirm that the automatic oil
replenishment feature works properly.
3. Oil level must be between marks (1) and (2).
4. Insert oil dipstick into guide tube up to the stop.
186 | Lube Oil System, Lube Oil Circuit | MS150116/02E 2016-07

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

Engine oil
WARNING
Engine oil is hot.
WARNING
• Do not smoke.
Extracting engine oil

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

1. Determine oil change quantity, fuel optimized (→ Page 26) or for tropical applications (→ Page 31).
2. Use electric pump to fill engine with oil from new-oil tank until the “max.” mark on the oil dipstick is reached.
3. Check engine oil level (→ Page 186).
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MS150116/02E 2016-07 | Lube Oil System, Lube Oil Circuit | 187

7.7.3 Engine oil – Sample extraction and analysis
Preconditions
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Engine oil is hot.
WARNING
• Do not smoke.
WARNING
Taking engine oil sample

1. Connect sampling hose (unit manufacturer
scope of delivery) to sampling neck (arrowed)
with engine running at operating tempera-
ture.
2. Take oil samples in accordance with the MTU
Fluids and Lubricants Specifications
(A001061/..) and have them analyzed by a
certified laboratory.
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188 | Lube Oil System, Lube Oil Circuit | MS150116/02E 2016-07

7.8 Oil Filtration / Cooling
7.8.1 Engine oil filter – Replacement
Preconditions

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

1. Unscrew oil filter with oil filter wrench.
2. Clean the sealing surface on the connecting
piece.
3. Check condition of the new sealing ring and
coat it with oil.
4. Screw on and tighten new oil filter by hand.
5. Replace other oil filters in the same way.
6. Check oil level (→ Page 186).
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MS150116/02E 2016-07 | Oil Filtration / Cooling | 189

7.9 Coolant Circuit, General, High-Temperature Circuit
7.9.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Engine coolant – Level check

1. Read off system filling pressure, fuel-optimized (→ Page 26) or for tropical applications (→ Page 31) at pres-
sure gauge.
2. Top up with treated coolant as necessary (→ Page 194).
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190 | Coolant Circuit, General, High-Temperature Circuit | MS150116/02E 2016-07

7.9.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 192).
2. Fill with engine coolant (→ Page 194).
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MS150116/02E 2016-07 | Coolant Circuit, General, High-Temperature Circuit | 191

7.9.3 Engine coolant – Draining
Preconditions

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

1. Open drain valves and drain coolant at the
following points:
• At the crankcase free end, left and right
side
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2. Draining of residual coolant:
• At coolant distribution housing.
3. Close all open drain points.
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7.9.4 Engine coolant – Filling
Preconditions

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

1. Fill with treated coolant using a pressure pump until the system filling pressure, fuel-optimized (→ Page 26)
or for tropical applications (→ Page 31) has been reached.
2. Vent engine coolant circuit at vent line.
3. Start engine and run at idle speed for a few minutes.
4. Check coolant level (→ Page 190).
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7.9.5 Vent line of engine coolant circuit – Replacement
Preconditions
WARNING
Replacing coolant vent line

1. Drain engine coolant (→ Page 192).
2. Release union nuts (1) and (3).
3. Remove coolant vent line (2).
4. Install new coolant vent line (2).
5. Fill with engine coolant (→ Page 194).
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7.10 Low-Temperature Circuit
7.10.1 Mixture coolant – Level check
Preconditions
WARNING
Mixture coolant – Level check

1. Read off system filling pressure, fuel-optimized (→ Page 26) or for tropical applications (→ Page 31) at pres-
sure gauge.
2. Top up with treated coolant as necessary (→ Page 199).
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196 | Low-Temperature Circuit | MS150116/02E 2016-07

7.10.2 Mixture coolant – Change
Mixture coolant
Mixture coolant – Change

1. Drain mixture coolant (→ Page 198).
2. Fill with fresh mixture coolant (→ Page 199).
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MS150116/02E 2016-07 | Low-Temperature Circuit | 197

7.10.3 Mixture coolant – Draining
Preconditions
WARNING
Draining mixture coolant

1. Provide a suitable receptacle to catch the coolant.
2. Open drain valve at drain point in coolant line to mixture coolant cooler and drain coolant.
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198 | Low-Temperature Circuit | MS150116/02E 2016-07

7.10.4 Mixture coolant – Filling
Preconditions

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

1. Fill with treated coolant using a pressure pump until the system filling pressure, fuel-optimized (→ Page 26)
or for tropical applications (→ Page 31) has been reached.
2. Vent mixture coolant circuit via system.
3. Start engine and run at idle speed for a few minutes.
4. Check coolant level (→ Page 196).
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MS150116/02E 2016-07 | Low-Temperature Circuit | 199

7.11 Wiring (General) for Engine/Gearbox/Unit
7.11.1 Engine cabling – Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
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200 | Wiring (General) for Engine/Gearbox/Unit | MS150116/02E 2016-07

7.11.2 Sensors – Overview
Item Description Monitors

1 B49.2 Intake air temperature B side
2 B81.2 Intake air pressure after filter B side
3 B44.2 Turbocharger speed, B side
4 B16.1 Coolant pressure after engine
5 B4.XX Exhaust gas temperature after cylinder XX
6 B79.22 Mixture pressure, B side
7 B73 Mixture temperature
Table 42: Sensors on B side

The knock sensors (B80.XX) are mounted on the right and left sides of the crankcase below the mixture
lines.
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MS150116/02E 2016-07 | Wiring (General) for Engine/Gearbox/Unit | 201

1 B79.23 Mixture pressure before throttle
2 B75 Crankshaft speed, ignition system reset
3 B13.2 Crankshaft speed, ignition
Table 43: Sensors on driving end
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1 B44.1 Turbocharger speed, A side
2 B81.1 Intake air pressure after filter A side
3 B49.1 Intake air temperature A side
4 B79.21 Mixture pressure, A side
5 B50 Crankcase pressure
6 B5.3 Engine oil pressure before filter
7 B7 Engine oil temperature
8 B5.1 Engine oil pressure after filter
Table 44: Sensors on A side

TIM-ID: 0000044681 - 002
MS150116/02E 2016-07 | Wiring (General) for Engine/Gearbox/Unit | 203

1 B88.X Nitrogen oxide in exhaust gas (NOx)
2 B4.21 Exhaust bulk temperature after turbocharger, A side
3 B16.3 Coolant pressure before engine
4 B1.3 Camshaft speed for anti-knock control
5 B1.1 Camshaft speed for engine governor
6 B24 Engine oil level
7 B1.2 Camshaft speed ignition system
8 B6.3 Coolant temperature before engine
9 B6.1 Coolant temperature after engine
10 B4.22 Exhaust bulk temperature after turbocharger, B side
Table 45: Sensors on free end

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8 Appendix A
8.1 Abbreviations
Abbreviation Meaning Explanation
AL Alarm Alarm message
ANSI American National Standards Institute Association of American standardization organ-
izations
ETC Exhaust turbocharger
BR Series
BV Betriebsstoffvorschrift 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 (DIN = “Deutsche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DVGW Deutsche Vereinigung des Gas- und
Wasserfaches
ECU Engine Control Unit Engine governor
EMU Engine Monitoring Unit Engine monitoring unit
EN Europäische Norm (European Standard)
ETK Spare Parts Catalog
HI High Alarm: Measured value exceeds 1st maximum
limit value
HIHI High High Alarm: Measured value exceeds 2nd maximum
limit value
HT High Temperature High temperature
ICFN ISO - Continuous - Fuel stop - brake Fuel stop power acc. to ISO; international cod-
power ing for the power specification of combustion
engines
ISO International Organization for Standardi- International umbrella organization for all na-
zation tional standardization institutes
KGS Engine free end Engine free end in accordance with DIN ISO
1204
KS Engine driving end Engine driving end in accordance with DIN ISO
1204
LED Light Emitting Diode Light emitting diode
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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
NT Niedertemperatur
OEG Onsite Energy MTU Onsite Energy
OEM Original Equipment Manufacturer
MS150116/02E 2016-07 | Appendix A | 205

Abbreviation Meaning Explanation
ORFS O-Ring Face Seal O-ring seal
OT Top Dead Center
PAN Panel Control panel
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
SAV Sicherheitsabsperrventil
SBV Sicherheitsabbalseventil
SD Sensor Defect Alarm: Sensor failure
SS Safety System Safety system alarm
TA-Luft Technische Anleitung zur Reinhaltung General administrative instruction for federal
der Luft emission control law in Germany
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Bottom Dead Center
WZK Tool Catalog
ZZP Zündzeitpunkt
TIM-ID: 0000009960 - 006
206 | Appendix A | MS150116/02E 2016-07

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

• http://www.mtuonsiteenergy.com/haendlersuche/index.de.html
24-h Hotline
With our 24-h hotline and the flexibility of our service staff, we are always ready to assist you - either during
operation, for preventive maintenance, corrective work in case of malfunction or changed operating condi-
tions, or for spare parts supply.
For our locally available support, go to MTU's Internet site:
• http://www.mtuonsiteenergy.com/haendlersuche/index.de.html
Your contact at Headquarters:
• support-oeg@mtu-online.com
Spare Parts Service

Quick, easy and correct identification of the spare part required for your system. The right spare part at the
right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system.
Your contact at Headquarters:
Germany:
• Phone: +49 821 74800
• Fax: +49 821 74802289
• E-mail: spareparts-oeg@mtu-online.com
Worldwide:
• Phone: +49 7541 908555
• Fax: +49 7541 908121
• E-mail: spare.parts@mtu-online.com
TIM-ID: 0000002624 - 005
MS150116/02E 2016-07 | Appendix A | 207

9 Appendix B
9.1 Special Tools
Angular screw driver
Part No.: F30452765
Qty.: 1
Used in: 7.4.3 Valve clearance – Check and adjustment
(→ Page 179)
Barring gear
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 162)
Feeler gauge
Part No.: Y20098771
Qty.: 1
(→ Page 179)
DCL-ID: 0000028554 - 004
Gas detection and alarm unit (not stocked by MTU)

Part No.: -
Qty.:
Used in: 7.1.2 Checking machine room for smell of gas
(→ Page 163)
208 | Appendix B | MS150116/02E 2016-07

Gas measuring and warning device (not stocked by MTU)
Part No.: -
Qty.:
Used in: 4.7 Emission values – Check (→ Page 46)
Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Engine oil filter – Replacement (→ Page 189)
Ratchet head with extension

Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 162)
Sliding depth gage, 200 mm

Part No.: Y20000918
Qty.: 1
Used in: 7.4.1 Valve protrusion – Measurement (→ Page 175)
DCL-ID: 0000028554 - 004
MS150116/02E 2016-07 | Special Tools | 209

Socket wrench, 24 mm
Part No.: F30029815
Qty.: 1
(→ Page 179)
Special wrench, 20.8 mm

Part No.: F30452574
Qty.: 1
Used in: 7.3.2 Spark plug – Removal (→ Page 167)
Qty.: 1
Used in: 7.3.3 Spark plug – Installation (→ Page 168)
Stroboscope (not stocked by MTU)

Part No.: -
Qty.:
Used in: 7.3.7 Ignition system – Ignition timing check (→ Page 174)
Torque wrench, 10–60 Nm

Part No.: F30452769
Qty.: 1
Used in: 7.3.3 Spark plug – Installation (→ Page 168)
Qty.: 1
Used in: 7.3.6 Spark plug connector – Installation (→ Page 172)
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210 | Special Tools | MS150116/02E 2016-07

Torque wrench, 60–320 Nm
Part No.: F30452768
Qty.: 1
(→ Page 179)
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MS150116/02E 2016-07 | Special Tools | 211

9.2 Index
Numerics Engine driving end
20V 4000 L32FB engine data – Definition 23
– Fuel-optimized (TA-Luft) 26 Engine free end
– Tropical application (TA-Luft) 31 – Definition 23
50-hours check 53 Engine oil
– Change 187
A – Sample extraction and analysis 188
Abbreviations 205 Engine oil filter
After extended out-of-service periods (>3 months) – Replacement 189
– Putting the engine into operation 40 Engine oil level
After stopping the engine – Check 186
– Engine remains ready for operation 51 Engine sides
– Putting the engine out of operation 52 – Designation 23
Air filter
F
– Installation 185
– Removal 185 Fault messages
– Replacement 184 – Engine Control Unit 122
– Genset control system log 57
C – Key 55
Cabling Firing order 25
– Check
G
– On engine 200
Contact person Gas engine system
– MTU Onsite Energy 207 – Overview 35
Control 42 Gas supply
Coolant – Checking gas lines for leaks 183
– Change 191
I
Cylinder
– Designation 23 Ignition system
Cylinder head cover – Ignition timing check 174
M
– Removal 181
Machine room
E – Checking for smell of gas 163
Emergency stop Main dimensions
– Engine 49 – Engine 24
Emission values Maintenance Schedule
– Check 46 – Maintenance task reference table [QL1] 54
Engine Mixture coolant
– After stopping – Change 197
– Putting out of operation 52 – Draining 198
– Barring manually 162 – Filling 199
– Emergency shutdown 49 Mixture coolant level
– Check 196
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– Main dimensions 24

– Overview 21 MTU Onsite Energy
– Shutdown 48 – Contact person 207
– Start 44 – Service partner 207
Engine cabling
O
– Check 200
Engine coolant Oil separator
– Change 191 – Filter replacement 164
– Draining 192 Operational checks 45
– Filling 194
– Level check 190
212 | Index | MS150116/02E 2016-07

Overview Safety regulations
– Engine 21 – Auxiliary materials 16
– Gas engine system 35 – Auxiliary materials, specific information for dual fuel
– Sensors 201 applications 18
– Auxiliary materials, specific information for gaseous
P fuel supply applications 18
Purpose of the units 37 – Environmental protection 16
Putting the engine into operation – Environmental protection, specific information for dual
– After extended out-of-service periods (>3 months) 40 fuel applications 18
Putting the engine into operation after scheduled out-of- – Environmental protection, specific information for gas-
service-period 41 eous fuel supply applications 18
– Fire prevention 16
R – Fire prevention, specific information for dual fuel ap-
Runtimes at partial load 39 plications 18
– Fire prevention, specific information for gaseous fuel
S
supply applications 18
Safety notices, standards 19 – Fluids and lubricants 16
– Fluids and lubricants, specific information for dual fuel
applications 18
– Fluids and lubricants, specific information for gaseous
fuel supply applications 18
– Important provisions 5, 6
– Maintenance work 12
– Maintenance work, specific information for dual fuel
– Maintenance work, specific information for gaseous
fuel supply applications 15
– Operation 8
– Operation, specific information for dual fuel supply ap-
plications 10
– Operation, specific information for gaseous fuel supply
applications 10
– Organizational requirements 7
– Personnel requirements 7
– Repair work 12
– Servicing work, specific information for dual fuel sup-
ply applications 15
– Servicing work, specific information for gaseous fuel
– Startup 8
– Startup, specific information for dual fuel supply appli-
cations 10
– Startup, specific information for gaseous fuel supply
applications 10
Safety requirements
– Safety notices, standards 19
Sensors
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– Overview 201
Service partner
– MTU Onsite Energy 207
Spark plug
– Removal 167
– Replacement 166
Spark plug connector
– Removal 171
– Replacement 170
Starting sequence 42
MS150116/02E 2016-07 | Index | 213

Stopping sequence 42
T
transport 20
V
Valve clearance
– Adjustment 179
– Check 179
Valve gear
– Lubrication 178
Valve protrusion
– Measurement 175
Vent line of engine coolant circuit
– Replacement 195
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214 | Index | MS150116/02E 2016-07

Operating Instructions: Gas Engine 20 V 4000 L32 FB

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Operating Instructions

© 2016 Copyright MTU Friedrichshafen GmbH

3 Product Summary 7.2 Crankcase Breather 164

Equipment 35 7.4.2 Valve gear – Lubrication 178

4 Operation 7.5 Gas System 183

MS150116/02E 2016-07 | Table of Contents | 3

7.9 Coolant Circuit, General, High-Temperature

DCL-ID: 0000028554 - 004

4 | Table of Contents | MS150116/02E 2016-07

Emission regulations and emission labels

Replacing components with emission labels

MS150116/02E 2016-07 | Safety | 5

6 | Safety | MS150116/02E 2016-07

Clothing and personal protective equipment

MS150116/02E 2016-07 | Safety | 7

Safety regulations during operation

Malfunctions and emergency stop

to do so following a written procedure.

Operation of electrical equipment

8 | Safety | MS150116/02E 2016-07

MS150116/02E 2016-07 | Safety | 9

Gas system, general requirements

Safety regulations for initial startup in dual fuel applications

Gas system, requirements for gas operation

• two gas shut-off valves

10 | Safety | MS150116/02E 2016-07

MS150116/02E 2016-07 | Safety | 11

Safety regulations during maintenance and repair work

Never use the product as a climbing aid.

12 | Safety | MS150116/02E 2016-07

Safety regulations following maintenance and repair work

Hydraulic installation and removal

MS150116/02E 2016-07 | Safety | 13

Working with batteries

Working on electrical and electronic assemblies

Work with laser devices

Measuring component dimensions

14 | Safety | MS150116/02E 2016-07

MS150116/02E 2016-07 | Safety | 15

Environmental protection and disposal

16 | Safety | MS150116/02E 2016-07

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

MS150116/02E 2016-07 | Safety | 17

Natural gas (pipeline quality)

Biogenic gases from fermentation processes

18 | Safety | MS150116/02E 2016-07

MS150116/02E 2016-07 | Safety | 19

Setting the engine down after transport

TIM-ID: 0000002614 - 004

20 | Transport | MS150116/02E 2016-07

1 Air filter/air inlet 6 Capacitor discharge ignition 11 Throttle

MS150116/02E 2016-07 | Product Summary | 21

Engine model designation

Table 2: Engine model designation

22 | Product Summary | MS150116/02E 2016-07

1 Left engine side (A-side) 3 Right engine side (B-side)

MS150116/02E 2016-07 | Product Summary | 23

Table 3: Engine – Main dimensions