L64FN & FNER Operation and Maintenance Manual - SS180152 - 04 - E

Operating Instructions
Gas engine-generator sets

MTU 8V4000 GS – GG08V4000A1/A2 with engine 8V4000L64
MTU 8V4000 GS – GG08V4000A1/A2 with engine 8V4000L64FNER
MTU 12V4000 GS – GG12V4000A1/A2 with engine
12V4000L64FNER
16V4000L64FNER
20V4000L64FNER
SS180152/04E
System designation Engine model Application group Option
Product name Model number
MTU 8V4000 GS GG08V4000A1 8V4000L64 3A, continuous operation,
8V4000L64FNER unrestricted
MTU 16V4000 GS GG16V4000A1 16V4000L64 3A, continuous operation, Fast Start 120 s.
© 2020 Copyright MTU

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. This particularly applies to its reproduction, distribution, editing, translation, microfilming and storage
and/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 reserves the right to
change, delete or supplement the information or data provided as and when required.
Table of Contents
1 Preface 4.2.2 Engine-generator set – Application group 50
4.2.3 Engine-generator set – Nameplate and
1.1 Preface 6 designation 51
4.2.4 Engine-generator set – Standard scope of
2 Safety supply 54
4.2.5 Engine-generator set – Optional scope of
2.1 Important provisions for all products 7 supply 64
2.2 Gas systems – Intended use 9 4.2.6 Engine-generator set – Operating modes 65
2.3 Personnel and organizational requirements 11 4.3 Engine 66
2.4 Safety regulations for initial start-up and 4.3.1 Engine – Overview 66
operation 12 4.3.2 Engine side and cylinder designations 73
2.5 Safety regulations for commissioning and 4.3.3 Sensors – Overview 74
operation, specific information for gaseous 4.3.4 Mixture formation, turbocharging and exhaust
fuel supply or and dual fuel applications 14 system 78
2.6 Safety regulations for assembly, 4.3.5 Lube oil system 81
maintenance, and repair work 16 4.3.6 Cooling system 83
2.7 Safety regulations for assembly, 4.4 Gearbox / Transmission 88
maintenance and servicing work, specific 4.4.1 Gearbox 88
information for gaseous fuel and dual fuel
4.5 Generator 90
supply or applications 20 4.5.1 Generator – General information 90
2.8 Fire and environmental protection, indirect 4.5.2 Coupling 91
materials 21
2.9 Fire prevention and environmental 4.6 Monitoring and Control 92
4.6.1 MIP and MMC control system 92
protection, fluids and lubricants, auxiliary
materials, specific information for gaseous 4.7 Charge-air System and Gas System 93
fuel supply in gaseous-fuel or dual-fuel 4.7.1 Gas train 93
applications 24 4.7.2 Air filter 95
2.10 Standards for warning notices in the text 4.8 Exhaust System 97
and highlighted information 25 4.8.1 Exhaust gas heat exchanger 97
2.11 Conventions for warning notices on safety 4.8.2 Catalytic converter 99
signs on the engine-generator set 26 4.8.3 Exhaust silencer 100
2.12 Safety signs on engine-generator set –
4.9 Lube Oil System 101
Overview 28 4.9.1 Lube oil system – Engine-generator set 101
2.13 Overview of protective devices on the 4.9.2 Oil priming pump 103
engine-generator set 30
4.10 Cooling System and Heating Water System 104
4.10.1 Cooling system – Engine-generator set 104
3 Transport
4.10.2 Heat module 108
3.1 Transport 32 4.11 Base Frame 113
3.2 Transport locking device for engine 4.11.1 Mounting 113
mounting 39
4.12 Monitoring, Control and Regulation
3.3 Transport locking device of generator
DCL-ID: 0000048557 - 009
Equipment 115
mounting 40
4.12.1 Gas engine phase 4 system – Overview 115
3.4 Crankshaft transport locking device 42 4.12.2 Purpose of the units 117
3.5 Tie-down instructions 44
4.13 Electrical System 119
4 Functional Description 4.13.1 Starter battery 119
4.13.2 Battery charger 120
4.1 Chapter overview 48 4.14 Gas Alarm and Fire Alarm 121
4.2 Engine-Generator Set 49 4.14.1 Gas alarm system 121
4.2.1 General description 49 4.14.2 Fire detector 122
SS180152/04E 2020-06 | Table of Contents | 3

9.3.2 Engine – Barring manually 444
9.3.3 Oil separator – Filter replacement 445
5 Technical Data 9.3.4 Crankcase breather – Pressure control check
and adjustment 447
5.1 Technical data 124 9.3.5 Spark plug – Replacement 448
9.3.6 Spark plug – Removal 449
6 Operation 9.3.7 Spark plug – Installation 450
9.3.8 Spark plug connector – Replacement 452
6.1 Chapter overview 125 9.3.9 Spark plug connector – Removal 453
6.2 Conduct in case of activated gas alarm 126 9.3.10 Spark plug connector – Cleaning and check 454
6.3 Conduct in case of activated fire alarm 127 9.3.11 Spark plug connector – Installation 455
6.4 Conduct in case of activation of safety 9.3.12 Ignition system – Ignition timing check 457
functions 128 9.3.13 Valve protrusion – Measurement 458
6.5 Operating room – Check for smell of gas 129 9.3.14 Valve gear – Lubrication 461
6.6 Lockout/tagout procedure 130 9.3.15 Valve clearance – Check and adjustment 462
6.7 Unlocking procedure 132 9.3.16 Cylinder head cover ‒ Removal 465
9.3.17 Cylinder head cover ‒ Installation 466
6.8 Control, starting and stopping sequences 134
9.3.18 Starter – Replacement 467
6.9 Runtimes at partial load 137 9.3.19 Engine oil level – Check 470
6.10 Automatic start and shutdown 138 9.3.20 Engine oil – Change 471
6.11 Engine-generator set – Starting in Manual 9.3.21 Engine oil – Sample extraction and analysis 472
mode 139 9.3.22 Engine oil filter – Replacement 474
6.12 Status signals 141 9.3.23 Engine coolant level – Check 476
6.13 Operational monitoring 155 9.3.24 Engine coolant – Change 477
6.14 Engine-generator set – Shutdown in Manual 9.3.25 Engine coolant – Draining 478
mode 157 9.3.26 Engine coolant – Filling 480
6.15 Emergency shutdown 158 9.3.27 Coolant vent line (engine coolant circuit) –
Replacement 481
6.16 After shutdown 159
9.3.28 Mixture coolant level – Check 482
6.17 Re-starting the engine following an 9.3.29 Mixture coolant – Change 483
automatic safety shutdown 160 9.3.30 Mixture coolant – Draining 484
6.18 Putting the engine-generator set into 9.3.31 Mixture coolant – Filling 485
operation after extended out-of-service- 9.3.32 Еngine mounting ‒ Check 486
period 161 9.3.33 Engine mounting – Checking securing screws
for secure seating 487
7 Troubleshooting 9.3.34 Engine cabling – Check 488
9.3.35 NOx sensor – Replacement 489
7.1 Chapter overview 164
9.4 Gearbox / Transmission 491
7.2 Fault messages – Key 165 9.4.1 Gearbox and oil circulation system – Check 491
7.3 Fault messages in genset control system log 166 9.4.2 Ring gear of transmission oil pump –
7.4 MMC controller – Fault messages 231 Replacement 492
7.5 Engine Control Unit – Fault messages 393 9.4.3 Gear oil – Sample extraction 495
9.4.4 Gear oil – Change 497
8 Maintenance 9.4.5 Gearbox – Cleaning 499
9.4.6 Oil filter – Removal and installation 500
8.1 Maintenance task reference table [QL1] 435 9.4.7 Oil filter – Cleaning 502
9.4.8 Bearing and housing temperature – Check 503
DCL-ID: 0000048557 - 009
9 Task Description 9.5 Generator 504

9.5.1 Cummins Generator 504
9.1 Chapter overview 438
9.5.1.1 Bearing and winding temperature – Check 504
9.2 Engine-Generator Set 439 9.5.1.2 Intake grill – Cleaning 505
9.2.1 Performing test run 439
9.5.1.3 Air filter – Replacement 506
9.2.2 Operating data check after 3000 hours 440
9.5.1.4 Antifriction bearings – Lubrication 507
9.2.3 Shutdown criteria – Check 442
9.5.1.5 Antifriction bearings – Replacement 509
9.3 Engine 443 9.5.1.6 Oil separator – Cleaning 510
9.3.1 Work with special qualifications 443 9.5.1.7 Coupling element – Check 512
4 | Table of Contents | SS180152/04E 2020-06

9.5.2 Leroy-Somer Generator 514 9.9.3 Coolant pump – Check 545
9.5.2.1 Bearing and winding temperature – Check 514
9.5.2.2 Intake grill – Cleaning 515
9.10 Electrical System 547
9.10.1 Working in the control cabinet 547
9.5.2.3 Antifriction bearings – Lubrication 517
9.10.2 Starter battery – Check 548
9.5.2.4 Coupling element – Check 519
9.10.3 Control cabinet – Filter fan contamination
9.6 Air Intake / Mixture Supply 521 check 549
9.6.1 Prefilter – Replacement 521 9.10.4 Control cabinet – Filter mat replacement 550
9.6.2 Air filter – Replacement 522 9.10.5 Control cabinet – Filter fan and noise
9.6.3 Air filter – Removal and installation 523 generation check 551
9.10.6 Control cabinet – Cooling unit noise
9.7 Gas System 524 generation check 552
9.7.1 Gas filter differential pressure – Check 524
9.10.7 Control cabinet – Cooling unit cooling function
9.7.2 Gas filter – Replacement 526
check 553
9.7.3 Valve leak control – Function check 528
9.10.8 Control cabinet – Checking cooling louvers on
9.7.4 Shut-off device – Check 530
cooling unit 554
9.7.5 Gas supply - Checking gas lines for leaks 531
9.10.9 Control cabinet – Cleaning cooling louvers on
9.8 Exhaust System 532 cooling unit 555
9.8.1 Exhaust gas heat exchanger – Check 532
9.8.2 Exhaust temperature before/after exhaust gas
heat exchanger – Check 533
10 Appendix A
9.8.3 Exhaust back pressure before/after exhaust
10.1 Abbreviations 556
gas heat exchanger – Check 535
10.2 Conversion tables 558
9.8.4 Exhaust back pressure before/after catalytic
converter – Check 537
10.3 Tightening specifications for screws, nuts
9.8.5 Emission values – Check 538 and bolts 562
9.8.6 Condensate and neutralization system – Check 540 10.4 Contact person/Service partner 575
9.8.7 Exhaust flap – Check 541
9.8.8 Coolant flow rate – Check 542 11 Appendix B
9.9 Cooling System and Heating Water System 543 11.1 Special Tools 576
9.9.1 Rubber bellows and hoses – Check 543
11.2 Consumables 582
9.9.2 Coolant pump – Engine mount lubrication 544
11.3 Index 584
DCL-ID: 0000048557 - 009
SS180152/04E 2020-06 | Table of Contents | 5

1 Preface
1.1 Preface
These Operating Instructions contain general instructions for the proper operation of your engine-generator
set from the manufacturer MTU.It is vitally important that all persons working on or with the engine-genera-
tor set are familiar with all the contents of this manual and follow the instructions provided carefully at all
times.
In some cases, it may prove necessary to depart from the guidelines specified in this manual in response to
extraneous circumstances. Any such departure must comply with locally applicable directives and standards.
All relevant safety directives and safety precautions shall be duly considered and respected.
Following these Operating Instructions will ensure that the plant operates efficiently and reliably.
All procedural instructions and safety precautions shall be followed closely to ensure that the plant operates
as intended and to avoid injury or harm. Read and follow the instructions in the “Safety” section at the begin-
ning of this manual.
All the instructions and diagrams have been checked to ensure accuracy and user-friendliness, however the
skills and qualification of the operating personnel remain the most significant factor nevertheless. MTU can-
not give any assurances for the actual results of any work performed according to the descriptions provided
in this manual, nor shall MTU be held liable for any resultant personal injury or material damage. Personnel
charged with running and operating the plant do so entirely at their own risk.
Other documents included in the scope of supply shall also be given due consideration in addition to these
Operating Instructions.
All documents required by Machinery Directive 2006/42/EC are included in the standard scope of docu-
mentation for the engine-generator set. The following documents are supplied in addition:
• Test records
• Spare parts catalog
• Wiring diagrams
Definition of MTU
MTU refers to Rolls-Royce Power Systems AG and MTU Friedrichshafen GmbH or an affiliated company pur-
suant to Section §15 AktG (German Stock Corporation Act) or a controlled company (joint venture).
TIM-ID: 0000058778 - 004
6 | Preface | SS180152/04E 2020-06

2 Safety
2.1 Important provisions for all products
General
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number. This data must match the speci-
fications in these instructions.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv-
ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system
is not visible without the removal of components, the system integrator must install the second nameplate in
a clearly visible area on the vehicle/system.
Emissions regulations and emissions label

Responsibility for compliance with emissions 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 emissions characteristics of the
product are prohibited by emissions regulations. Emissions-related components must only be serviced, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these specifications will invalidate the design type approval or certification issued by
the emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emissions regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 9).
Emissions certification applicable to engines with EPA Nonroad Tier 4 emissions

certification in accordance with 40 CFR 1039 and with EPA Locomotive emissions
certification in accordance with 40 CFR 1033
Extract from the standard:
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
TIM-ID: 0000040530 - 016
Extract from the standard:

If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.
When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This
paragraph describes the process for requesting and fitting the label, the documentation obligations and stor-
age obligations for the required documents.
SS180152/04E 2020-06 | Safety | 7

Replacing components with emissions labels
On all engines from MTU fitted with emissions labels, these labels must remain on the engine throughout its
operational life.
Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emissions labels:
• The relevant emissions labels must be affixed to the spare part.
• Emissions labels shall not be transferred from the replaced part to the spare part.
• The emissions labels must be removed from the replaced part and destroyed.
TIM-ID: 0000040530 - 016
8 | Safety | SS180152/04E 2020-06

2.2 Gas systems – Intended use
Intended use
The machine is intended to be used exclusively for electrical power generation and waste heat utilization in
stationary operation, either in sufficiently ventilated rooms or in container solutions.
A gas/air mixture is fed to the internal combustion reciprocating piston engine. This is converted into me-
chanical work in the individual cylinders through combustion. The flywheel of the engine drives the synchro-
nous generator connected via an elastic coupling, resulting in a conversion to electric energy. The engine and
the generator are joined to the base frame with resilient, vibration-damped elements. For mains frequency
60 Hz, depending on the series either a gearbox is used between the engine and generator (Series 4000) or
the engine speed is increased accordingly (Series 400). The waste heat generated during the combustion
process is dissipated to the surroundings via coolers (power generator) and/or made available to the cus-
tomer via heat exchangers (combined heat and power plant).
Area of application Applicable Comment
Industry Yes –
Business/Service Yes In some individual cases, however,
such as with swimming pool facili-
ties, schools, heating stations for
apartment buildings and the like,
no end user in the classic sense is
involved
Household No Operation is excluded
Potentially explosive area No Operation is not permitted in po-
tentially explosive areas
Underground No Operation is excluded
Mobile use No Operation is excluded
Table 1: Area of application of machine

There are 3 operating modes of the machine:
• Mains parallel operation
• Mains failure operation
• Isolated operation
Foreseeable misuse
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 use.
Operation
Operation is not permissible if the physical conditions specified on the technical data sheet or on/in other
documents (concerning temperature, pressure, site altitude, etc.) are not complied with. Operation is not
TIM-ID: 0000065674 - 005
permissible without protective equipment, usage of approved spare parts, exclusion of conversions, warning
of foreseeable misuse.
Operation is only permissible with the use of fluids and lubricants (natural gas, biogas, quality-compliant gas,
quality-compliant water, lubricants) in accordance with the (→ Fluids and Lubricants Specifications).
Operation is only permissible with preservation agents approved by MTU in accordance with the (→ Preserva-
tion and Represervation Specifications).
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version of these are adopted. The latest version can be found at:
• http://www.mtu-solutions.com
SS180152/04E 2020-06 | Safety | 9

Surroundings, climate, temperature
The weather plays no role with regard to the intended use of the engine-generator set/module provided that
operation takes place inside an installation room. For container applications, however, the permissible out-
door temperatures at the installation site play a decisive role. The product-specific ambient conditions such
as climate and temperature are indicated in the technical description.
Prerequisite for proper use

Fulfillment of all the requirements set out in the “Installation conditions” document.
Any use that does not fall within the described limits for use is regarded as improper.
Work which requires communication with the control units must only be carried out with a diagnosis soft-
ware or with tools approved by the manufacturer.
Modifications or conversions
Unauthorized changes to the product breach the conditions concerning its intended use and compromise
safety.
Only modifications or conversions expressly authorized by the manufacturer are regarded as compliant in
this sense. The manufacturer shall not be held liable for any damage resulting from unauthorized modifica-
tions or conversions.
TIM-ID: 0000065674 - 005
10 | Safety | SS180152/04E 2020-06

2.3 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 repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such 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
and also for work with live parts
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 respective
descriptions of the individual activities or the manufacturer's documentation included in the delivery.
When working on live components, in particular on electrical switchgear or on high-voltage component, wear
special protective clothing according to IEC 61482.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorization and restriction of CHemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
TIM-ID: 0000040531 - 013
SS180152/04E 2020-06 | Safety | 11

2.4 Safety regulations for initial start-up and operation
Safety regulations for initial start-up
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 safeguards are in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• Adequate ventilation of the operating room must be ensured for any operating status.
• 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.
• The product must be free of any damage, this applies in particular to lines and cabling.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/reduction agent line,
supply/return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems work properly.
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.
Take the following steps if any system malfunctions are detected or signaled by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
TIM-ID: 0000040533 - 021
After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-
ed.
Contact Service if the root cause of the malfunction cannot be clearly identified.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
12 | Safety | SS180152/04E 2020-06

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

When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
TIM-ID: 0000040533 - 021
SS180152/04E 2020-06 | Safety | 13

2.5 Safety regulations for commissioning and operation, specific
information for gaseous fuel supply or and dual fuel
applications
Gas system, general requirements
Operating company requirements: When putting the product into operation, always check the gas control
units.
The temperature of the gas during operation must not fall below 5 °C in any section.
The plant manufacturer / operating company must make the connection to the gas supply according to the
respectively applicable official regulations, e.g. DVGW, G490/I, G491/I, DIN EN 12186, NFPA37.
Shut-off for the gas supply: The plant manufacturer / operating company must design the gas shut-off device
according to local regulations.
Work on lines and components carrying fuel gas must only be carried out gas specialist companies with spe-
cially qualified personnel.
In case pressure is exceeded, the gas pressure regulator must be equipped at the pressure regulator outlet
with a certified safety shut-off valve (SAV) and a safety blow-off valve (SBV). The gas must be directed into a
ventilated safe zone (to the atmosphere).
Gas engine (Loose engine)

The fuel supplied to the gas engine is exclusively fuel gas.
For the gas supply to the product and connection to a gas supply network, the plant manufacturer/operating
company must use inspected gas control units. The connection conditions and dimensions must be coordi-
nated with the manufacturer.
Depending on the country of use and usage conditions, further control and/or safety devices may be de-
manded and required.
If the gas supply is connected to a vessel or if gases containing oxygen are used, the gas control unit must
be equipped with a temperature-monitored flame arrestor.
The gas shut-off valves are activated via two different paths from the engine control system, whereby one
gas shut-off valve respectively is activated via one of the paths.
The gas control unit must be equipped with a minimum pressure monitor.
In flow direction, gas control units have:
• One manual shut-off fitting
• One gas filter
• Two gas shut-off valves
• One pressure regulating device
The gas control unit must be equipped with an automatic leak monitor.
Additional equipment for the gas control unit, e.g. a maximum pressure monitor, may be necessary
• at a pressure in the gas supply above 100 mbar
TIM-ID: 0000040550 - 013
• at a gas volume flow higher than 200 m³/h

• a fuel output higher than 600 KW
The plant manufacturer/operating company is responsible for positioning the gas control unit directly before
the engine, but a maximum of 3 meter line length before the engine interface. The interface is the flange of
the gas volume controller or the connection of the gas-air mixer of the engine.
Series 400: The gas control unit must be positioned directly before the engine, but a maximum of 2 meter
line length before the engine interface.
Freedom of movement of the flexible line connection must be guaranteed in accordance with the installation
instructions.
14 | Safety | SS180152/04E 2020-06

Gas engine-generator set
The fuel supplied to the gas engine is exclusively fuel gas.
The gas engine-generator set is delivered with a gas control path fitted in the factory. The gas control path is
equipped in the factory with the necessary control and safety devices.
For connection of the gas train to the gas engine-generator set, the installation conditions and the assembly
instructions for the gas engine-generator sets must be observed.
The connection line must have a manual shut-off valve outside the installation room. This must be easy to
reach in the event of danger.
Apart from the main shut-off cock, local authorities may also demand further safety devices, e.g.:
• Safety shut-off valve with integrated temperature monitoring (SAV)
• Thermal shut-off device (TAE)
and more.
Dual fuel application/bi-fuel operation

The fuel supply for dual fuel application is diesel mixed with different shares of fuel gas.
When putting the product into operation, always ensure that:
• Mobile application: The product is only used outdoors.
• Stationary application: The product must only be used with sufficient ventilation.
In flow direction, gas control units (provision by plant manufacturer/operating company) have:
• One gas filter
In flow direction, gas control units (MTU scope of supply) have:
• Two gas shut-off valves (automatic)
• One pressure regulating device
TIM-ID: 0000040550 - 013
SS180152/04E 2020-06 | Safety | 15

2.6 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, 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 from 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 containers of adequate capacity to catch fluids and lubricants.
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.
Work must only be carried out on lines when they are free of fluids and lubricants.
Ensure adequate ventilation of the operating room when conducting an oil change, working on the gaseous/
liquid fuel system or working with consumables (e.g. adhesive, cleaner).
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
• Close the main valve on the compressed-air system and vent the compressed-air line when air starters are
fitted.
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 circuit breakers.
Before starting work on CaPoS, if used:
• Switch off the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent
tank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
TIM-ID: 0000040535 - 023
Setting down, lifting and climbing

Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never stand beneath a suspended load.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces and secured against tilting over or roll-
ing away. Adopt suitable measures to prevent components/tools from falling down.
16 | Safety | SS180152/04E 2020-06

Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.
Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
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.
Miscellaneous
Sufficient ventilation must be guaranteed during the work.
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-
ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protective
gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters 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.
TIM-ID: 0000040535 - 023
Safety regulations after performing assembly, maintenance, and repair work

Before barring the engine, make sure no one is in the danger zone of the engine.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
All safety devices must be installed and all tools and loose parts must be removed (especially the barring
tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
SS180152/04E 2020-06 | Safety | 17

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 assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end
until correct sealing is established.
During hydraulic installation and removal of components, ensure that nobody is standing in the immediate
vicinity of the component to be installed/removed.
Working with batteries

Observe the safety instructions of the manufacturer when working on 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. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
TIM-ID: 0000040535 - 023
Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work or switching off any part of the electronic system required to do so.
De-energize the relevant areas prior to working on assemblies.
ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge
must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive
work surfaces or antistatic wristbands.
18 | Safety | SS180152/04E 2020-06

Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing 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 ties to secure lines.
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. The emergen-
cy stop function must be tested in particular. The functional check of the emergency stop, during which the
voltage supply of the engine governor is switched off, must only be carried out when the product is cold.
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 (as necessary)
Working with laser equipment

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 equipment must be fitted with the protective devices necessary for safe operation according to type
and application.
Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
TIM-ID: 0000040535 - 023
SS180152/04E 2020-06 | Safety | 19

2.7 Safety regulations for assembly, maintenance and servicing
work, specific information for gaseous fuel and dual fuel
supply or applications
Safety regulations for work prior to assembly, maintenance, and repair
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 shutoff valve.
Lock-out / tag-out the drive unit to prevent starting.
Additional safety regulations for marine application engines, engines with

multipoint gas injection
Depressurize the gas system and purge with nitrogen.
Depressurize the nitrogen overpressure leak monitoring system if applicable.
Purge the crankcase with nitrogen before opening the crankcase or oil separator.
TIM-ID: 0000040549 - 010
20 | Safety | SS180152/04E 2020-06

2.8 Fire and environmental protection, indirect materials
Fire prevention and fire
Flames, naked light and smoking are prohibited.
In the event of a fire, stop the fuel supply if this is possible without endangering personnel.
The product has hot surfaces that can ignite combustible gases and other substances in the surrounding
area. The operating company must ensure that the product is installed and operated a sufficient distance
away from danger sources and any existing safety instructions or recommendations must be observed. Prod-
ucts that comply with the SOLAS convention do not constitute such a danger.
Depending on the operating and ambient conditions, fuel temperatures above the flash point temperature
are possible in the tank. This can lead to the creation of a dangerous potentially explosive atmosphere in the
tank and makes suitable explosion protection measures necessary.
After working with combustible indirect materials (e.g. cleaning agents), ensure that the area is well ventilat-
ed. The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmos-
phere.
Immediately eliminate any leaks of indirect materials. Splashes of indirect materials on hot components can
cause fires, therefore keep the product clean at all times. Do not leave rags saturated with fluids and lubri-
cants on the product. Do not store combustible materials near the product.
Incorrect refueling of the reducing agent system with fuel can lead to fires.
Before welding, clean the areas to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
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.
A risk of fire due to human error or a technical defect cannot be excluded completely. Always have suitable
extinguishing agents (fire extinguishers) on hand and familiarize yourself fully with their handling.
For safety-critical environments, check whether further fire prevention measures are necessary.
Toxic substances may be created during a fire. Always wear protective gloves and any other personal protec-
tive equipment that may be necessary when touching any components.
Noise
Wear hearing protection in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.
Environmental protection and disposal

Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
TIM-ID: 0000040536 - 023
cled.
Indirect materials
Indirect materials may also be hazardous or toxic. When handling indirect materials as well as other chemical
substances, observe the information contained in the associated safety data sheet. The safety data sheet
may be obtained from the relevant manufacturer or from MTU.
Only fluids and lubricants approved by the manufacturer must be used in accordance with the Fluids and
Lubricants Specifications. Request the most recent edition from the manufacturer.
SS180152/04E 2020-06 | Safety | 21

Contamination of indirect materials with reducing agent (e.g. AdBlue®, DEF): Store indirect materials in sepa-
rate containers and use separate drip trays. Even very slight contamination with reducing agent can lead to
malfunctions in sensors and other components.
Used oil contains combustion residues that are harmful to health.
When handling used oil, protective gloves must be worn.
Wash relevant areas after contact with used oil.
Registration, evaluation, authorization and restriction of chemicals (REACH

ordinance)
Particularly hazardous substances in our products are compiled in a list:
• http://www.mtu-solutions.com → SVHC in accordance with REACH in MTU products
Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard rating 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 a compressed air device from the supply line. To depressurize
compressed-air lines, shut off the lines first, then release the residual pressure.
• Carrying out a leakage test as specified.
Paints
• 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 the working area is well ventilated.
TIM-ID: 0000040536 - 023
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
22 | Safety | SS180152/04E 2020-06

Acids/alkaline solutions/reducing agents (e.g. AdBlue®, DEF)
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If reducing agent is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After skin contact, wash body areas with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Consult a doctor as soon as possible.
Contamination of reducing agent with other indirect materials: Store reducing agent in separate contain-
ers and use separate drip trays. Even very slight contamination can result in malfunctions to the exhaust
gas aftertreatment system.
Incorrect refueling of the reducing agent system with fuel can cause leakages at the gaskets and in the
hoses.
TIM-ID: 0000040536 - 023
SS180152/04E 2020-06 | Safety | 23

2.9 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).
Inhaling certain gases can be dangerous to life depending on concentration. Furthermore some gases can no
longer be detected by smell in higher concentrations.
Risk of poisoning due to hazardous impurities.
The fuel gases
• Natural gas (pipeline quality or treated Compressed Natural Gas (CNG) or Liquified Natural Gas (LNG))
• Biogenic gases from fermentation processes
are highly flammable and form an explosive mixture with air/oxygen. Weakly narcotic gas; risk of suffocation
at high concentrations.
Check all gas conveying lines for tightness prior to initial operation and at regular intervals during operation.
Biogenic gases from fermentation processes

Risk of poisoning due to hydrogen sulfide from the fermentation process. The ingestion of even small quanti-
ties of hydrogen sulfide can be fatal.
Biogenic gases have a tendency to segregate. In low-lying areas of the plant, carbon dioxide enrichment is
possible.
Conduct in case of escaping gases

• If safe to do so: Shut off main gas supply.
• If safe to do so: Execute an emergency stop.
• Cordon off danger zone.
• Ensure sufficient ventilation.
• Do not enter the hazard zone until it has been established (via measurement of the gas concentration with
a suitable gas detector) that the atmosphere is no longer hazardous.
TIM-ID: 0000040537 - 007
24 | Safety | SS180152/04E 2020-06

2.10 Standards for warning notices in the text and highlighted
information
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 warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.
Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
TIM-ID: 0000040578 - 006
SS180152/04E 2020-06 | Safety | 25

2.11 Conventions for warning notices on safety signs on the
engine-generator set
Warning notices on safety signs
The safety sign shown here serves as an example for the safety signs affixed to the engine-generator set.
Figure 1: Safety sign layout

1 Colored field with signal 4 Safety text in local language 7 Safety symbol
word (optional) 8 Item number (sticker set)
2 3-figure number 5 Safety text in English 9 Safety text in German
3 Sticker at the danger spot (standard) (standard)
6 Language abbreviations
The safety text in local language (4) is only created for countries in which the Machinery Directive
2006/42/EC applies.
Hazard levels:
Danger
Safety sign with signal word DANGER
Indicates an immediate danger
TIM-ID: 0000069399 - 003
Consequences: Fatal, serious or permanent injuries!

Warning
Safety sign with signal word WARNING
Indicates a potential danger
Consequences: Fatal, serious or permanent injuries!
Caution
Safety sign with signal word CAUTION
Indicates a potential danger
Consequences: Minor injuries!
26 | Safety | SS180152/04E 2020-06

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: 0000069399 - 003
SS180152/04E 2020-06 | Safety | 27

2.12 Safety signs on engine-generator set – Overview
Figure 2: Warning notices on the engine-generator set – Engine end

1 CAUTION – Observe the 3 Attach here 5 DANGER – Flying parts /
safety regulations 4 CAUTION – Attachment and hot gas
2 DANGER – Electric voltage lifting at designated points 6 DANGER – High voltage
only
TIM-ID: 0000079884 - 001
28 | Safety | SS180152/04E 2020-06

Figure 3: Warning notices on the engine-generator set – Generator end
1 CAUTION – Observe the 3 DANGER – Electric voltage 5 Attach here
safety regulations 4 CAUTION – Attachment and 6 DANGER – Flying parts /
2 DANGER – High voltage lifting at designated points hot gas
only
TIM-ID: 0000079884 - 001
SS180152/04E 2020-06 | Safety | 29

2.13 Overview of protective devices on the engine-generator set
Figure 4: Guards on the engine-generator set 50 Hz

1 Damping (exhaust turbo- 4 Guard plate (flywheel hous- 7 Protective grill (Leroy-Som-
charger) ing) er generator)
2 Heat shield (mixture line) 5 Accidental-contact guard
3 Pole caps (starter, battery) (coupling)
6 Contact protection (Leroy-
Somer generator)
TIM-ID: 0000079851 - 001
30 | Safety | SS180152/04E 2020-06

Figure 5: Guards on the engine-generator set 60 Hz
1 Damping (exhaust turbo- 4 Guard plate (flywheel hous- 7 Contact protection (Leroy-
charger) ing) Somer generator)
2 Heat shield (mixture line) 5 Contact protection (engine 8 Protective grill (Leroy-Som-
3 Pole caps (starter, battery) – gearbox) er generator)
6 Contact protection (genera-
tor – gearbox)
The engine-generator set may only be operated when all safeguards are intact and in place.
The engine-generator set with circuit breaker may only be operated when the circuit breaker is closed and
the covers are installed. The center bearing must be intact if the circuit breaker is installed on the base
frame.
The engine-generator set with exhaust gas heat exchanger may only be operated with all covers fitted and
the exhaust gas heat exchanger properly insulated.
TIM-ID: 0000079851 - 001
SS180152/04E 2020-06 | Safety | 31

3 Transport
3.1 Transport
Lifting specifications
DANGER
Suspended load.
Danger to life!
• Use suitable equipment and lifting devices.
• Never stand beneath a suspended load and keep a safe distance.
• Wear personal protective equipment (e.g. protective helmet, safety shoes).
The figures show the lifting specifications for the engine-generator set and the heat module:
• Engine-generator set (→ Figure 6)
• Split engine-generator set:
– Engine section (→ Figure 8)
– Generator section (→ Figure 9)
• Heat module (→ Figure 10)
• Heat module with connections to exhaust gas heat exchanger (→ Figure 11)
• Heat module without plate-core heat exchanger (→ Figure 12)
Lifting specifications for engine-generator set
TIM-ID: 0000070905 - 006
Figure 6: Lifting specifications

1 Load chain 3 Lifting eye on engine
2 Stabilizer chain 4 Lifting eye on base frame
The engine-generator set must be lifted with a crane only.
The engine-generator set must not be lifted with a forklift truck.
32 | Transport | SS180152/04E 2020-06

Engine-generator sets for 50 Hz applications must always be lifted with an unilaterally adjustable H cross-
beam, which is capable of balancing changes in the center of gravity, or with an I crossbeam, see
(→ Figure 6).
Engine-generator sets for 60 Hz applications (with gearbox) must only be lifted with an I crossbeam (H cross-
beam is not permitted).
Other forms of lifting are not permitted, see (→ Figure 7).
Ensure for either lifting procedure that the load is evenly distributed to all lifting eyes.
The engine-generator set must be lifted by the marked lifting eyes (4) on the base frame only. Do not use the
lifting eyes on the engine or generator to lift the whole engine-generator set.
Note the center of gravity of the engine-generator set.
Use only appropriate lifting gear and equipment.
Observe the mass specifications on the nameplate.
Increase tilt resistance with additional stabilizer chains (2) on the engine lifting eyes (3). The stabilizer chains
must be load-free.
Remove any loose parts on the engine-generator set.
Remove emergency stop button at control cabinet.
Raise the engine-generator set slowly. Do not allow lifting ropes or chains to contact the engine-generator
set.
Only use suitable means of transport and lifting gear to lift and transport components which were delivered
loosely. Observe the mass specifications for these components.
TIM-ID: 0000070905 - 006
Figure 7: Lifting specifications for engine-generator set

A Lifting admissible B Lifting prohibited
Figures serve as examples.
SS180152/04E 2020-06 | Transport | 33

Lifting specifications for split engine-generator set, engine section
Figure 8: Lifting specifications for split engine-generator set, engine section

1 Load chain 2 Lifting eye on engine
The engine section must be lifted with a crane only.
The engine section must not be lifted with a forklift truck.
The figures illustrate lifting with diagonal pull using a crossbeam.
The engine section must be lifted by the marked lifting eyes on the engine (2) only.
Remove any loose parts on the engine section.
Raise the engine section slowly. Do not allow lifting ropes or chains to contact the engine section.
TIM-ID: 0000070905 - 006
34 | Transport | SS180152/04E 2020-06

Lifting specifications for split engine-generator set, generator section
Figure 9: Lifting specifications for split engine-generator set, generator section

1 Load chains 2 Stabilizer chain 3 Lifting eye on base frame
The generator section must be lifted with a crane only.
The generator section must not be lifted with a forklift truck.
The figures illustrate lifting with diagonal pull using a crossbeam.
The generator section set must be lifted by the marked lifting eyes on the base frame (3) only.
Remove any loose parts on the generator section.
Increase tilt resistance with additional stabilizer chains (2) on the engine lifting eyes of the generator. The
stabilizer chains must be load-free.
Raise the generator section slowly. Do not allow lifting ropes or chains to contact the generator section.
TIM-ID: 0000070905 - 006
SS180152/04E 2020-06 | Transport | 35

Lifting specifications for heat module
Figure 10: Lifting specifications for heat module

1 Load chains 2 Lifting eye
TIM-ID: 0000070905 - 006
Figure 11: Lifting specifications for heat module with connections to exhaust gas heat exchanger
36 | Transport | SS180152/04E 2020-06

Figure 12: Lifting specifications for heat module without plate-core heat exchanger
The heat module must be lifted with a crane only.
The chain lengths must be adapted so that the heat module is suspended horizontally from the crane.
The heat module must not be lifted with a forklift truck.
The heat module must be lifted by the marked lifting eyes (2) only. The heat module must not be lifted on the
pipes.
Remove any loose parts on the heat module.
Raise the heat module slowly. Do not allow lifting ropes or chains to contact the heat module.
Transport locking device

Always fit transport locking devices on the resilient engine and generator mounts prior to transport
(→ Page 39), (→ Page 40). The engine-generator set must be marked as “locked for shipment”.
TIM-ID: 0000070905 - 006
Always install the crankshaft transport locking device to avoid damaging the engine by undesired movement
of the crankshaft (→ Page 42).
Remove all transport locking devices before putting into operation.
Transport
The engine-generator set may be shipped by truck, train (in combined service) and by ship.
Transport by train in shunting service is prohibited.
The regulations, standards and codes for cargo lashing and transport security applicable at the time of the
transport must be complied with in the relevant country of transport.
SS180152/04E 2020-06 | Transport | 37

Load securing
Secure the engine-generator set and heat module such as to eliminate any risk of slipping and tilting during
transport.
The engine-generator set must be secured in accordance with the tie-down instructions to exclude the risk of
slipping and tilting during transport (→ Page 44).
TIM-ID: 0000070905 - 006
38 | Transport | SS180152/04E 2020-06

3.2 Transport locking device for engine mounting
Preconditions
☑ Engine coolant and engine oil must be filled.

Note: The transport locking device protects the engine mount from damage resulting from shock and vibration dur-
ing engine transport.
General notes on removing and installing transport locking devices:

1. Remove the transport locking devices on all resilient mounts before starting the engine-generator set.
2. Always install the transport locking devices on all resilient mounts before transporting.
Removing engine mount trans-

port locking devices
1. Slacken nuts (2).
2. Undo nut (3) and unscrew and remove screw
(1) together with washers and nuts (2 on
each mount).
3. Store the removed parts of the transport
locking device in a safe place for later use.
Figure 13: Engine mount transport locking device
Installing transport locking devi-

ces
1. Insert screws (1) together with washers and
nuts (2) (2 on each mount).
2. Screw on and tighten nut (3).
3. Tighten nuts (2) evenly in stages against en-
gine mount and base mount.
4. Mark the engine as “locked for shipment”.
TIM-ID: 0000048695 - 002
Figure 14: Engine mount transport locking device
SS180152/04E 2020-06 | Transport | 39

3.3 Transport locking device of generator mounting
Note: • The locking device protects the generator mounts from shocks and vibration damage during generator
transport.
• Remove the transport locking device from all mounts before putting the engine-generator set into opera-
tion.
• The transport locking device must be installed on all mounts according to the instructions before trans-
porting.
Removing transport locking de-
vice – Variant A
1. Loosen nuts (2).
2. Remove screw (1) together with washers and
nuts and remove (2x per mounting element).
locking device carefully for possible reuse.
Figure 15: Transport locking device of generator mounting –

Cummins
Note: Always use the screws supplied with or installed in the transport locking device to secure it.
Installing transport locking device – Variant A

1. Install in reverse order to removal.
2. Screw nuts (2) on evenly in stages.
3. Mark the generator as “locked for shipment”.

vice – Variant B
1. Loosen nuts (2).
TIM-ID: 0000079852 - 003

Cummins
40 | Transport | SS180152/04E 2020-06

Installing transport locking device – Variant B
1. Screw in screw (1) until the mounting element is locked at the base of the mount.
2. Tighten nuts (2) to secure screw (1).

vice – Variant C
1. Loosen nut (2).

Leroy-Somer
Installing transport locking device – Variant C

1. Screw in screw (1) until the mounting element is locked at the base of the mount.
2. Tighten nut (2) to secure the screw (1).
TIM-ID: 0000079852 - 003
SS180152/04E 2020-06 | Transport | 41

3.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10–60 Nm F30452769 1
Ratchet adapter F30027340 1
Engine oil

Note: The locking device on both ends protects the crankshaft bearings from shocks and vibration damage during
engine transport.
Observe the following instructions for removal and installation of the trans-
port locking device:
1. When installing the engine-generator set on site, leave the transport locking device installed on both sides as
long as possible.
2. Remove the transport locking device on both sides before putting the engine-generator set into operation.
3. Prior to every transport of the engine-generator set, reinstall the transport locking device on both sides ac-
cording to the instructions.
4. When the transport locking device is removed, install the guard plate on both sides of the flywheel housing.
Note: Always use the screws supplied with or installed in the transport locking device to secure it.
Fitting the transport locking de-
vice on driving end (KS)
Figure 18: Crankshaft transport locking device

TIM-ID: 0000049855 - 004
Note: Attach plate (6) only to the upper part of the openings.
1. Secure the plates (6) with screws (4) and washers (5) at the bores on both sides of the flywheel housing and
tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
42 | Transport | SS180152/04E 2020-06

2. Screw locknut (2) onto screw (1) up to the end of the thread.
3. The long end of holder (3) must face downwards. Insert holder (3) through openings in plate (6).
Note: The holder (3) must lock the flywheel only, not the ring gear.
4. Install screw (1) into the bore of holder (3) until the holder (3) is locked in position.
Note: The screw (1) must be tightened alternately on both sides of the flywheel housing.
5. Tighten screw (1) to specified tightening torque.
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Fit locknut (2) of screw (1) on plate (6) and secure.
Removing the transport locking

device from driving end (KS)
1. Release the locknut (2) on both sides of the
flywheel housing, remove screw (1) and take
off holder (3).
2. Remove screws (4) and take off with wash-
ers (5) and plate (6).
locking device carefully for possible reuse.
Figure 19: Crankshaft transport locking device

TIM-ID: 0000049855 - 004
SS180152/04E 2020-06 | Transport | 43

3.5 Tie-down instructions
DANGER
The load can slip or tip over.
Danger of crushing limbs and body parts!
• Secure the load.
• When securing the load, only used the permitted fastening points and fastening equipment.
Installation Instructions (M060775/..) available.
Attachment points on the 8V and 12V engine-generator set with Cummins

generator
Figure 20: Attachment points on 8V engine-generator set with Cummins generator

1 Attachment point on Leroy- 2 Attachment point on base 3 Attachment point on engine
Somer generator frame * *
* The attachment points shown in the figure are provided on both sides of the engine-generator set.
TIM-ID: 0000083746 - 002
44 | Transport | SS180152/04E 2020-06

Attachment points on the 16V and 20V engine-generator set with Cummins
generator
Figure 21: Attachment points on 16V engine-generator set with Cummins generator
1 Attachment point on Cum- 2 Attachment point on base 3 Attachment point on engine
mins generator* frame * *
TIM-ID: 0000083746 - 002
SS180152/04E 2020-06 | Transport | 45

Attachment points on 8V, 12V, 16V and 20V engine-generator sets with Leroy-
Somer generator
Figure 22: Attachment points on 16V engine-generator set with Leroy-Somer generator
1 Attachment point on Leroy- 2 Attachment point on base 3 Attachment point on engine
Somer generator frame * *
These instructions only apply to transportation of an engine-generator set by the following means of trans-
portation:
• Truck
• Ship
• Train in combined service
Transport by train in shunting service is prohibited.
Always fit transport locking devices on the resilient engine and generator mounts prior to transportation
(→ Page 39), (→ Page 40).
The transport locking device for the crankshaft must always be installed prior to transport (→ Page 42).
The base frame of the engine-generator set shall be placed on non-slip mats.
Before transportation, the base frame must be secured non-positively and/or positively using the attachment
TIM-ID: 0000083746 - 002
points provided.
In addition, the generator and engine need to be tied down non-positively with lashing straps using the at-
tachment points provided.
A sufficient number of lashing straps in accordance with EN 12195-2 must be used to secure the load.
Make sure the lashing straps on the engine-generator set are not laid across edges. Otherwise, parts of the
engine-generator set could be damaged.
The engine-generator set must not be overtensioned with the lashing straps.
46 | Transport | SS180152/04E 2020-06

The regulations, standards and codes for cargo lashing and transport security applicable at the time of the
transport must be complied with in the relevant country of transport.
TIM-ID: 0000083746 - 002
SS180152/04E 2020-06 | Transport | 47

4 Functional Description
4.1 Chapter overview
This chapter provides general information about the generating set and its component parts including a func-
tional description, technical data and details of benefits.
Engine-generator sets can be delivered with a range of standard and optional components.
Note: This publication describes all available engine-generator set components. Please disregard any compo-
nents which are not included in the scope of delivery of your particular engine-generator set.
For more technical data see (→ Page 124).
Please consult your local distributor or dealer should you require more detailed information about a specific
component.
TIM-ID: 0000034939 - 005
48 | Functional Description | SS180152/04E 2020-06

4.2 Engine-Generator Set
4.2.1 General description
The engine-generator set comprises the following main assemblies:
• Engine
• Generator and coupling
• Gearbox and coupling (60-Hz gensets)
• Gas train
• Base frame
• Heat extraction (with versions GR and GC)
• MMC (MTU Module Control) for plant control, closed-loop control, diagnostics (optional)
• MIP (MTU Interface Panel) for engine control, closed-loop control, diagnostics
• Damping plates under base frame
In the combustion engine, the energy contained in the fuel is converted into mechanical work and heat.
The generator is flange-mounted on the engine via a resilient coupling. The generator is installed on two slide
rails, which allow the generator to be shifted when the coupling element is being replaced. The engine and
generator are connected to the base frame via resilient, vibration-damped elements. Damping plates located
between foundation and base frame compensate for irregularities in the foundation and reduce the introduc-
tion of oscillations and vibrations to the foundation.
All closed-loop controls, control systems and monitoring systems, including communication options to and
from the system, are implemented in the hardware and software.
TIM-ID: 0000077769 - 002
SS180152/04E 2020-06 | Engine-Generator Set | 49

4.2.2 Engine-generator set – Application group
The engine-generator set consists of a gas engine and a generator mounted on a common base frame. Upon
demand, the engine will start and drives the generator to produce electrical power.
Application group 3A – Continuous operation, unrestricted (Continuous Power)

Engine-generator sets for unlimited continuous power supply are used for:
• Base load generation
• Part of a power supply or the public grid
Continuous operation Application group 3A
Operating mode Continuous operation, unrestricted
Rating definition 10% overload capacity (ICXN)
Load factor < 100 %
Operating hours Unlimited
TIM-ID: 0000064957 - 002
50 | Engine-Generator Set | SS180152/04E 2020-06

4.2.3 Engine-generator set – Nameplate and designation
Nameplates on engine-generator set
The engine-generator set has the following nameplates:
• Nameplate of engine-generator set
• Nameplate of engine
• Nameplate of generator
Figure 23: Installation position of nameplates (generator and engine-generator set)

1 Nameplate of engine 2 Nameplate of generator 3 Nameplate of engine-gener-
ator set
Key to product name

Example:MTU 12V4000 GS
MTU Brand
12 Number of cylinders of the engine
V Cylinder arrangement of the engine: Vee arrangement
4000 Series 4000
TIM-ID: 0000079789 - 004
GS Gas System
Key to model number

Example:GG12V4000A1
GG Product type: Gasgenset
12 Number of cylinders of the engine
V Cylinder arrangement

Example:GG12V4000A1
4000 Series 4000
A1 (A2) 50 Hz (60 Hz)
Overview of application groups on nameplate

Specification on the nameplate Application group
CONTINUOUS POWER 3A – Continuous operation, unrestricted
PRIME POWER 3B – Continuous operation, variable load, ICXN
LTP GRID STABILITY 3G – Prime power, time-limited, ICXN
DATA CENTER CONTINUOUS 3F – Mains backup mode, unlimited, ICXN
MISSION CRITICAL STANDBY 3H – Mains backup mode, special qualifications
Engine-generator set – Nameplate and designation
Figure 24: Nameplate of engine-generator set

Item Designation
1 Power ratings as per ISO standard power ISO 3046-1 no overload capability
TIM-ID: 0000079789 - 004
Air pressure (total pressure) pr = 100 kPa (100 above sea level)
Air temperature (at air filter inlet) Tr = 298 K (tr = 25 °C)
Relative air humidity ɸ = 30%
2 Heat recovery as per DIN 6280
3 Address field of manufacturer
4 Model
5 Module / genset no.
6 Project no.
7 Year of manufacture

Item Designation
8 Weight with / without fluids and lubricants [kg]
9 Electrical output COP [KW]
10 Performance class of generator
11 Rated voltage [V]
12 Rated frequency [Hz]
13 Max. outside temperature [°C]
14 Rated power factor cos ɸ inductive / capacitive
15 Max. site altitude [m above sea level]
16 Thermal rated power [kW]
17 Perm. heating water temperature [°C]
18 Perm. operating pressure in heating water circuit
TIM-ID: 0000079789 - 004

4.2.4 Engine-generator set – Standard scope of supply
Engine-generator sets for 50 Hz applications – Overview
Engine-generator set 20V4000Lxy
Figure 25: Engine-generator set with 20V engine, engine side

1 Exhaust outlet 4 Control cabinet 7 Lube oil pump
2 Gas train 5 Generator
3 Generator terminal box 6 Engine
TIM-ID: 0000079790 - 005

Figure 26: Engine-generator set with 20V engine, generator side
1 Air filter 3 Engine mounting 5 Damping plate
2 Base frame 4 Coupling 6 Generator mounting
TIM-ID: 0000079790 - 005

Engine-generator set 12V4000Lxy

1 Exhaust outlet 4 Control cabinet 7 Lube oil pump
2 Gas train 5 Generator
3 Generator terminal box 6 Engine
The figure (→ Figure 27) shows an engine-generator set with engine model 12V4000Lxy. The illustration also
applies in principle to engine-generator sets with engines models 8V4000Lxy and 16V4000Lxy
TIM-ID: 0000079790 - 005

1 Air filter 3 Engine mounting 5 Damping plate
2 Base frame 4 Coupling 6 Generator mounting
applies in principle to engine-generator sets with engines models 8V4000Lxy and 16V4000Lxy
TIM-ID: 0000079790 - 005

Engine-generator sets for 60 Hz applications – Overview
Engine-generator set 20V4000Lxy with 60-Hz gearbox

1 Exhaust outlet 4 Generator 7 Engine
2 Gas train 5 Control cabinet 8 Damping plate
3 Generator terminal box 6 Connection for gearbox 9 Lube oil pump
cooling
applies in principle to engine-generator sets with engines of Series 8V4000Lxy 12V4000Lxy and
16V4000Lxy.
TIM-ID: 0000079790 - 005

1 Air filter 4 Coupling (engine – gearbox) 7 Generator mount
2 Engine mount 5 Gearbox
3 Base frame 6 Coupling (generator – gear-
box)
16V4000Lxy.
TIM-ID: 0000079790 - 005

Overview of connections on engine-generator set
Figure 31: Engine-generator set 12V4000Lxy – connections

a Gas inlet d Mixture coolant outlet g Lube oil drain
b Exhaust outlet e Engine coolant inlet h Oil bleed system
c Mixture coolant inlet f Engine coolant outlet i Lube oil supply
The figure (→ Figure 31) shows an engine-generator set with a Series engine model 12V4000Lxy. The illustra-
tion also applies in principle to engine-generator sets with engines of Series 8V4000Lxy 16V4000Lxy and
20V4000Lxy.
TIM-ID: 0000079790 - 005

Figure 32: Engine-generator set 12V4000Lxy – optional connections
a Gas inlet d Mixture coolant inlet g Lube oil drain
b Exhaust outlet e Engine coolant inlet h Oil bleed system
c Mixture coolant outlet f Engine coolant outlet i Lube oil supply
20V4000Lxy.
TIM-ID: 0000079790 - 005

Standard scope of delivery Genset Basis (GB)
• Series 4000 gas engines:
– Rated speed 1,500 rpm
– Electronic engine management system (ECU)
– Electric starters
• 50 Hz generator:
– Voltage 400 V, 6300 V, 10500 V, 11000 V
– 2 bearings
– Digital voltage regulator
– Measuring current transformers
– Protective converters
– Winding temperature sensors
– 1 bearing temperature sensor for each bearing
– Space heater
– Degree of protection IP23
– Speed 1,800 rpm
– Voltage 480 V, 600 V, 4160 V, 12470 V, 13200 V, 13800 V
– 2 bearings
– Digital voltage regulator
– Winding temperature sensors
– Space heater
– Degree of protection IP23
• Exhaust silencer
• Gearbox for 60 Hz generator
• Coupling
• Gas train with connecting hoses to engine-generator set
• Oil system with oil pump for priming and for draining the oil pan
• MIP control system: Control cabinet without control function (interface between engine-generator set and
customer control system)
• Air filter, intake air housing for 20V engines
• Accessories (exhaust pipe bellows, hose, pole caps etc.)
• Coolant hoses
• Guards over all rotating parts
• Base frame with:
– Resilient engine and generator mounts
– Oil collecting trough with leak sensor
– Damping plates
TIM-ID: 0000079790 - 005

Standard scope of delivery Genset Reduced (GR)
Figure 33: Engine-generator set with 12V engine and heat module, generator side
1 Engine-generator set 2 Heat module
The scope of delivery for Genset Reduced (engine-generator set with heat recovery from engine coolant) in-
cludes the scope of delivery Genset Basic (engine-generator set) plus the following components:
• Heat module as frame structure with:
– Coolant pumps
– Plate-core heat exchanger
– Pipelines
– Measuring equipment
– Safety equipment
– Diaphragm type expansion tanks for mixture coolant circuit and engine coolant circuit
• Coolant pipework between heat module and engine-generator set
Standard scope of delivery Genset Combined (GC)

The scope of delivery for Genset Combined (module) includes the scope of delivery Genset Reduced (engine-
generator set with heat recovery from engine coolant) plus the following component:
• Exhaust gas heat exchanger for the utilization of the thermal energy of the exhaust gas in the heating wa-
ter system
TIM-ID: 0000079790 - 005

4.2.5 Engine-generator set – Optional scope of supply
Optional scope of delivery for Genset Basic, Genset Reduced and Genset
Combined
Not all optional subsystems can be combined with one another. The technical dimensioning of the subsys-
tem may vary according to the combination of the options and the requirements.
– Voltage 415 V
– Generator with next design size (oversized)
– Measuring current transformer for differential protection
• Generator circuit breaker panel (GCB panel):
– Generator circuit breaker
– Connection system, generator and customer
– Supply for auxiliary drives and/or MMC
• MMC controller (MTU Modul Control):
– MIP controller
– Control cabinet with battery charger
– Connection to machine EMERGENCY STOP and manual EMERGENCY STOP buttons
– Remote display
• Oil system extension:
– Fresh oil pump for automatic replenishment
– Oil bleed system for extending the oil service life
– Interchangeable tanks with monitoring of fresh and used oil
– Control of oil system with MMC control system
– Hose system for filling and draining
– Lube oil pump with higher capacity for energy balancing mode
• Exhaust system:
– Connection to engine-generator set
– Exhaust system
– Catalytic converter
– Exhaust gas heat exchanger (for GB and GR)
• Air intake extension
• Auxiliary drives panel (AUX)
• Gas alarm system
• Fire detector
• Emergency cooler
• Mixture cooling circuit cooler
• Coolant pipework (Genset Basic)
• Starter batteries with retainer and cable kit
• Container:
– Container covering
– Stack
– Ventilation system
– Neutralization of exhaust gas condensate
• Optional separate package:
– Resilient connections
TIM-ID: 0000077771 - 004
– Pipe pieces
– Bellows
– Screws and gaskets

4.2.6 Engine-generator set – Operating modes
Continuous operation (standard)
Gas engine-generator sets are designed for continuous operation in the defined power range, see
(→ Page 50).
Balancing energy (optional)

Balancing energy is required to balance out frequency variations.
Gas engine-generator sets in balancing mode are connected to the mains for 5 to 7 minutes.
Gas engine-generator sets in balancing energy mode with the option "quick-start capability" are connected to
the mains in 2 minutes at the latest.
Calorific value variations from the setting can occur. For higher values, please contact Service.
Important
Balancing energy requires the use of other engine data records.
TIM-ID: 0000085353 - 005

4.3 Engine
4.3.1 Engine – Overview
Engine overview 8V4000Lxy
Figure 34: Engine 8V4000Lxy – driving end

1 Air filter/air inlet 6 Heat shield 11 Starter
2 Mixture cooler 7 Engine mounting bracket, 12 Flywheel
3 Connection, exhaust gas free end KS Driving end
outlet 8 Engine lifting eye
4 Exhaust turbocharger 9 Engine mounting bracket,
5 Ignition system / capacitor driving end
10 Oil pan
TIM-ID: 0000079791 - 003
66 | Engine | SS180152/04E 2020-06

Figure 35: Engine 8V4000Lxy – free end
1 Crankcase breather, oil sep- 7 Ignition coil 13 Oil level switch
arator 8 Igniter 14 Engine coolant inlet connec-
2 Gas control valve 9 Cylinder head cover tion
3 Gas inlet connection 10 Cylinder head 15 Engine oil heat exchanger
4 Bypass line 11 Engine oil sampling neck 16 Engine coolant outlet con-
5 Engine governor/engine 12 Engine oil filter nection
monitoring unit KGS Free end
6 Throttle
TIM-ID: 0000079791 - 003
SS180152/04E 2020-06 | Engine | 67

Engine overview 12/16V4000Lxy

1 Air filter/air inlet 6 Heat shield 11 Starter
2 Bypass line 7 Engine mounting bracket, 12 Throttle
3 Mixture cooler free end 13 Flywheel
4 Exhaust turbocharger 8 Engine lifting eye KS Driving end
5 Ignition system / capacitor 9 Oil pan
10 Engine mounting bracket,
driving end
The illustration (→ Figure 36) applies similarly to Series 16V4000Lxy engines.
TIM-ID: 0000079791 - 003
68 | Engine | SS180152/04E 2020-06

1 Crankcase breather, oil sep- 7 Ignition coil 13 Oil level switch
arator 8 Igniter 14 Engine coolant inlet connec-
2 Connection, exhaust gas 9 Cylinder head cover tion
outlet 10 Cylinder head 15 Engine oil heat exchanger
3 Gas mixer 11 Engine oil filter 16 Engine coolant outlet con-
4 Gas control valve 12 Engine oil sampling neck nection
5 Gas inlet connection KGS Free end
6 Engine governor/engine
monitoring unit
The illustration (→ Figure 37) applies similarly to Series 16V4000Lxy engines.
TIM-ID: 0000079791 - 003
SS180152/04E 2020-06 | Engine | 69

Engine overview 20V4000Lxy

1 Air filter/air inlet 7 Engine oil heat exchanger 13 Cylinder head
2 Intake housing 8 Coolant distribution housing 14 Flywheel
3 Gas inlet connection 9 Ignition system / capacitor 15 Engine governor/engine
4 Bypass line 10 Cylinder head cover monitoring unit
5 Gas control valve 11 Igniter KS Driving end
6 Exhaust system 12 Ignition coil
TIM-ID: 0000079791 - 003
70 | Engine | SS180152/04E 2020-06

1 Engine coolant inlet connec- 6 Engine lifting eye 11 Engine oil filter
tion from cooler 7 Engine mounting bracket, 12 Engine oil sampling neck
2 Crankcase breather / oil driving end 13 Oil level switch
separator 8 Oil pan KGS Free end
3 Exhaust turbocharger 9 Heat shield
4 Gas mixer 10 Engine mounting bracket,
5 Throttle free end
Series 4000 engines are compact, powerful, reliable, maintenance-friendly and extremely economical.
Lean-burn technology, a state-of-the-art electronic ignition system featuring individual timing and automatic
energy regulation, anti-knock control and a rapid-response mixture/load control ensure safe, economical op-
eration and optimum power harnessing.
Technical data
• Four-stroke cycle spark ignition gas engines
• 8V, 12V, 16V and 20V cylinder versions
• 90° Vee angle
• Output (kWmech):
TIM-ID: 0000079791 - 003
Number of cyl- L32 FN* L32 FB* L32 FNER* L33 FN* L64 FN*
inders of the
engine
8 800 800 800 880 1040
12 1200 1200 1200 1320 1560
16 1600 1600 1600 1760 2080
20 2000 2000 2000 2200 2600
*
FN = natural gas, FB = biogas, FNER = epsilon-reduced
• Displacement (l):
SS180152/04E 2020-06 | Engine | 71

inders of the
engine
8 38.16 38.16 38.16 38.16 38.16
12 57.24 57.24 57.24 57.24 57.24
16 76.32 76.32 76.32 76.32 76.32
20 95.4 95.4 95.4 95.4 95.4
*
• Compression ratio (λ):
inders of the
engine
8 12.1 13.9 10.5 12.8 14.0
12 12.1 13.9 10.5 12.8 14.0
16 12.1 13.9 10.5 12.8 14.0
20 12.1 13.9 10.5 12.8 14.0
*
• Counterclockwise rotation
• Liquid-cooled
• Lean mixture, turbocharged
• Two-stage mixture cooling
• Open combustion chamber
• Microprocessor-controlled high-voltage ignition system
• Exhaust turbocharging
• Two cooling system circuits
• Piston cooling
• Electric starter
• Resilient engine mounting
TIM-ID: 0000079791 - 003
72 | Engine | SS180152/04E 2020-06

4.3.2 Engine side and cylinder designations
Figure 40: 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).
TIM-ID: 0000002185 - 014
SS180152/04E 2020-06 | Engine | 73

4.3.3 Sensors – Overview
Sensors – B-side
Illustration also applicable to 16V engines.
Figure 41: Sensors – B-side

Item Name Monitoring of
1 B90 Humidity/temperature sensor, intake air
2 B81.2 Intake air pressure after filter
3 B16.1 Coolant pressure after engine
4 B4.X Exhaust temperature after cylinder
5 B79.22 Mixture pressure before cylinder, B-side
6 B73 Mixture temperature before cylinder
7 B80.X Knock sensors (installed in each station near com-
bustion chamber)
Table 2: Sensors – B-side

TIM-ID: 0000038398 - 007
74 | Engine | SS180152/04E 2020-06

Sensors – Driving end
Figure 42: Sensors – Driving end

1 B88 Exhaust emission (NOx)
2 B79.23 Mixture pressure before throttle
3 B75 Crankshaft speed, reset, ignition system
4 B13.2 Crankshaft speed, ignition
Table 3: Sensors – Driving end

TIM-ID: 0000038398 - 007
SS180152/04E 2020-06 | Engine | 75

Sensors – A-side
Figure 43: Sensors – A-side

1 B44.1 (optional) Turbocharger speed sensor
2 B5.1 Engine oil pressure after filter
3 B7 Engine oil temperature after engine oil heat exchang-
er
4 B5.3 Engine oil pressure before filter
5 B50 Crankcase pressure
6 B79.21 Mixture pressure before cylinder, A side
Table 4: Sensors – A-side

TIM-ID: 0000038398 - 007
76 | Engine | SS180152/04E 2020-06

Sensors – Free end
Figure 44: Sensors – Free end

1 B6.1 Coolant temperature after engine
2 B4.21 Exhaust temperature after turbocharger
3 B16.3 Coolant pressure before engine
4 B1.3 Camshaft speed for knock monitoring
5 B1.1 Camshaft speed for engine governor
6 B24 Engine oil level
7 B1.2 Camshaft speed for ignition system
8 B6.3 Coolant temperature before engine
Table 5: Sensors – Free end

TIM-ID: 0000038398 - 007
SS180152/04E 2020-06 | Engine | 77

4.3.4 Mixture formation, turbocharging and exhaust system
Mixture formation, supercharging system and exhaust system for engines with
8, 12 and 16 cylinders
Figure 45: Mixture formation, turbocharging and exhaust system: 12V

1 Gas mixer 5 Restrictor flap, left side 9 Exhaust pipework with ex-
2 Gas control valve 6 Mixture line, left side haust pipe bellows
3 Air filter 7 Heat shield, left side 10 Exhaust turbocharger
4 Mixture cooler 8 Exhaust manifold, left side KGS Free end
The illustration (→ Figure 45) applies similarly to engines with 8 and 16 cylinders.
TIM-ID: 0000079793 - 002
78 | Engine | SS180152/04E 2020-06

Mixture formation, supercharging system and exhaust system for engines with
20 cylinders
Figure 46: Mixture formation, turbocharging and exhaust system: 20V

1 Exhaust pipework, right side 5 Gas control valve 9 Mixture line, left side
2 Exhaust turbocharger, right 6 Intake housing 10 Heat shield, left side
side 7 Air filter, left side 11 Exhaust manifold, left side
3 Gas mixer, right side 8 Restrictor flap, left side KGS Free end
4 Mixture cooler
Mixture formation
• Air intake via dry-type air filter, two dry-type air filters on the 20V engine
• Prefilter made of fleece
• Gas supply via electronically-controlled gas control valve
• Mixture formation in gas mixer
Turbocharging system
• Mixture compression in exhaust turbocharger
• Two-stage mixture cooling
• Restrictor flaps between mixture cooler and mixture lines
TIM-ID: 0000079793 - 002
• Shielding of mixture lines
Exhaust system
• Uncooled, insulated exhaust manifolds in V engine
• 8V/12V/16V engine: Common exhaust outlet
• 20V engine :Two exhaust turbochargers and two exhaust pipes
SS180152/04E 2020-06 | Engine | 79

Benefits
• Significant emission reduction at low engine speeds
• Good acceleration characteristics
• No mechanical adjustment required
• Easy maintenance
• High degree of reliability
• Exemplary smooth running
TIM-ID: 0000079793 - 002
80 | Engine | SS180152/04E 2020-06

4.3.5 Lube oil system
Figure 47: Lube oil system

1 Exhaust turbocharger 10 Supply connection for auto- 19 Crankshaft main bearing
2 Engine oil heat exchanger matic oil replenishment 20 Camshaft thrust bearings
3 Connection: lube oil pres- 11 Oil suction basket 21 Oil pan
sure sensor before filter 12 Engine oil pump 22 Crankshaft support bearing,
4 Oil sampling 13 Connection: oil priming inlet driving end
5 Engine oil filter 14 Engine oil pump pressure 23 Camshaft bearing
6 Bypass valve for engine oil relief valve 24 Main oil gallery
filter 15 Pressure limiting valve be- 25 Cylinder head
7 Connection: lube oil pres- fore engine 26 Spray nozzles for piston
sure sensor after filter 16 Vibration damper (optional cooling
8 Connection: engine oil tem- with 12V)
perature sensor after en- 17 Crankshaft support bearing,
gine oil heat exchanger free end (optional with 12V)
9 Drain plug on oil pan 18 Conrod bearings
Technical data
• Engine oil pump with safety valve
TIM-ID: 0000045081 - 002
• Two engine oil heat exchangers

• Engine oil filter with four replaceable filter cartridges
• Engine oil level monitoring
• Automatic oil replenishment
Benefits
• Long oil-change intervals
SS180152/04E 2020-06 | Engine | 81

Function
Engine oil pump (12) draws the oil from oil pan (21) via oil suction basket (11) and supplies it to oil heat
exchanger (2) and engine oil filter (5).
The cleaned oil flows directly to the lubrication points on the engine as well as to the main oil gallery.
The following components / assemblies are supplied directly:
• Piston cooling spray nozzles (26)
• Vibration damper (16)
• Crankshaft support bearing, free end (17)
• Exhaust turbocharger bearings (1)
The following components / assemblies are supplied from the main oil gallery (24):
• Main crankshaft bearings (19)
• Camshaft thrust bearings (20)
• Cylinder heads (25)
• Conrod bearing (18)
• Camshaft bearings (23)
• Crankshaft support bearing, driving end (22)
• Crankshaft axial bearings
The engine oil pump is a gear pump. It is driven by the crankshaft via an idler gear. A pressure relief valve
protects it from excessive oil pressure.
The pressure limiting valve provides oil-pressure control independent of engine speed.
Pressure maintaining valves supply the spray nozzles for piston cooling only when a minimum oil pressure is
provided. They thus ensure lubrication of the engine at lower speeds.
TIM-ID: 0000045081 - 002
82 | Engine | SS180152/04E 2020-06

4.3.6 Cooling system
Cooling system 8V, 12V, 16V without heat extraction from HT circuit
Figure 48: Cooling system 8V, 12V, 16V without heat extraction from HT circuit
1 Connection, mixture coolant 8 Connection, engine coolant 15 Connection, engine coolant
outlet to LT circuit cooler outlet to HT circuit cooler circuit ventilation
2 Connection, mixture coolant 9 Crankcase P = Pressure measuring point
inlet from LT circuit cooler 10 Engine coolant drain on T = Temperature measuring
3 Mixture cooler crankcase point
4 Connection, LT circuit vent 11 Engine coolant drain cock HT = high temperature
line 12 Exhaust turbocharger LT = low temperature
5 Connection, engine coolant 13 Connection, coolant inlet
inlet from HT cooler from standby pump
6 Lube oil heat exchanger 14 Throttle to bypass cool-
7 Connection, coolant outlet er (12/16 V only)
to standby pump
TIM-ID: 0000072931 - 002
SS180152/04E 2020-06 | Engine | 83

Cooling system 8V, 12V, 16V with heat extraction from HT circuit
Figure 49: Cooling system 8V, 12V, 16V with heat extraction from HT circuit
1 Connection, mixture coolant 8 Lube oil heat exchanger 15 Engine coolant drain cock
outlet to LT circuit cooler 9 Connection, coolant outlet 16 Connection, coolant inlet
2 Connection, mixture coolant to standby pump from standby pump
inlet from LT circuit cooler 10 Connection, engine coolant 17 Connection, charge-air cool-
3 Mixture cooler outlet to HT circuit cooler ant vent line
4 Connection, LT circuit vent 11 Crankcase P = Pressure measuring point
line 12 Engine coolant drain on T = Temperature measuring
5 Connection, inlet from crankcase point
charge-air coolant circuit 13 Connection, engine coolant HT = high temperature
cooler circuit ventilation LT = low temperature
6 Connection, outlet from 14 Exhaust turbocharger
charge-air coolant circuit
cooler
7 Connection, engine coolant
inlet from HT cooler
Technical data
• Two separate cooling circuits:
TIM-ID: 0000072931 - 002
– Engine coolant HT (high-temperature)

– Charge-air coolant LT (low-temperature)
• High-temperature circuit with integrated oil cooling, first stage of charge air cooling and cylinder cooling
• Rubber bellows for connection to external cooling circuits
• Integrated electric coolant preheating
84 | Engine | SS180152/04E 2020-06

Cooling system 20V without heat extraction from HT circuit
Figure 50: Cooling system: 20V

1 Connection, mixture coolant 7 Engine coolant outlet to HT P = Pressure measuring point
outlet to LT circuit cooler circuit cooler T = Temperature measuring
2 Connection, mixture coolant 8 Crankcase point
inlet from LT circuit cooler 9 Engine coolant drain on HT = high temperature
3 Mixture cooler crankcase LT = low temperature
4 Connection, engine coolant 10 Engine coolant drain cock
circuit vent line 11 Exhaust turbocharger
5 Connection, engine coolant 12 Connection, engine coolant
inlet from HT cooler circuit ventilation
6 Lube oil heat exchanger
TIM-ID: 0000072931 - 002
SS180152/04E 2020-06 | Engine | 85

Cooling system 20V with heat extraction from HT circuit
Figure 51: Cooling system 20V with heat extraction from HT circuit
1 Connection, mixture coolant 8 Throttle for cooler bypass 15 Engine coolant drain cock
outlet to LT circuit cooler 9 Lube oil heat exchanger 13 Connection: charge-air cool-
2 Connection, mixture coolant 10 Connection, engine coolant ant vent line
inlet from LT circuit cooler outlet from HT cooler P = Pressure measuring point
3 Mixture cooler 11 Crankcase T = Temperature measuring
4 Connection, LT circuit vent 12 Engine coolant drain on point
line crankcase HT = high temperature
5 Connection, inlet from 13 Connection, engine coolant LT = low temperature
charge-air coolant cooler circuit ventilation
6 Connection, outlet to 14 Exhaust turbocharger
charge-air coolant cooler
7 Connection, engine coolant
inlet from HT cooler
Benefits
• Engine, oil and charge-air reach optimum operating temperature very quickly
• Charge-air cooling in load operation
TIM-ID: 0000072931 - 002
Function
Engine coolant circuit (HT circuit)
Following the start of the engine, the engine coolant pump pumps the engine coolant through the lube oil
heat exchanger and then through the mixture cooler (only with HT heat extraction) and into the coolant
chambers of the crankcase. The coolant flows around the cylinder liners and into the cylinder heads.
Here, the coolant flows through the coolant chambers and bores of the cylinder heads. The coolant is then
returned to the HT cooler by means of the left and right-hand coolant manifolds.
The exhaust turbochargers are integrated in the coolant circuit by means of a bypass line.
86 | Engine | SS180152/04E 2020-06

Drain plugs and a drain cock are provided at the lowest points of the engine coolant circuit.
Mixture coolant circuit (low-temperature, LT)

After engine start, the mixture coolant pump pumps the mixture coolant through the mixture cooler. The
coolant flows back to the cooler of the LT circuit.
TIM-ID: 0000072931 - 002
SS180152/04E 2020-06 | Engine | 87

4.4 Gearbox / Transmission
4.4.1 Gearbox
Figure 52: Gearbox, engine side

1 Pressure switch 4 Connection for coolant sup- 7 Gearbox mounting
2 Oil cooler ply line
3 Connection for coolant re- 5 Oil drain
turn line 6 Drive shaft
TIM-ID: 0000075138 - 004
88 | Gearbox / Transmission | SS180152/04E 2020-06

Figure 53: Gearbox, generator side
1 Dry-bulb thermometer 4 Oil pump 7 Pressure gauge
2 Inspection opening cover 5 Oil filter
3 Oil sight glass 6 Output shaft
Function
With 60-Hz engine-generator sets, a gearbox is connected between engine and generator. The engine speed
remains at 1500 rpm. The gearbox increases the speed to the required generator speed of 1800 rpm to en-
sure compatibility with the mains frequency of 60 Hz. The gearbox is bolted on rigidly between engine and
generator on the base frame. In the first step, the torque generated by the engine is transmitted via a highly
resilient flange coupling to a step-up gear unit. The torque is then transferred to the generator from the gear-
box via a torsionally rigid multiple-disk clutch.
Description
• Single-stage spur gear
• Gearbox cooling integrated in the engine coolant circuit
• Lubrication via forced-feed lubrication
• Non-contact labyrinth seals
TIM-ID: 0000075138 - 004
SS180152/04E 2020-06 | Gearbox / Transmission | 89

4.5 Generator
4.5.1 Generator – General information
The generator serves to convert the mechanical power of the combustion engine into electrical power.
Self-regulating, brushless internal-pole synchronous generators with installed voltage regulator are used ex-
clusively.
Synchronous generators must only be connected to the main power grid if they have identical voltage, fre-
quency and phasing. A corresponding synchronizer is used for this purpose.
The cut-in command is calculated taking the parameterized phase angle (dalpha) and the switch response time
into account and is set in advance so that the main contacts of the circuit breaker are closed in the point of
synchronicity.
NOTE: See (→ operating instructions of the manufacturer).
TIM-ID: 0000065334 - 002
90 | Generator | SS180152/04E 2020-06

4.5.2 Coupling
Figure 54: Overview of coupling

1 Engine 3 Flange coupling
2 Flange bell (sectional view) 4 Generator
The flange coupling (3) can be operated under high thermal loads and its development took a maximum serv-
ice life into consideration. Replacement of the coupling element is possible by shifting the generator unit on
the base frame.
The flange bell (2) provides a torsionally rigid connection between generator (4) and engine (1). The lateral
openings guarantee the circulation of air and thus ensure optimum cooling of the flange coupling (3) during
operation. To protect against rotating parts, the openings are covered with perforated plates which, as acci-
dental-contact protection, represent a mechanical restraint device on the engine-generator set.
TIM-ID: 0000079792 - 002
SS180152/04E 2020-06 | Generator | 91

4.6 Monitoring and Control
4.6.1 MIP and MMC control system
Engine-specific control components and the generator protection are integrated in the MIP software (MTU
Interface Panel). Engine-generators set without module/engine-generator set controller MMC (MTU Modul
Control) are delivered only with the MIP-Standalone (standard scope of delivery). The MIP control cabinet is
permanently installed on the base frame. The MMC control cabinet is secured at the plant separately on the
floor.
MIP functions
The MIP has the following functions:
• Communication with engine governor ECU and engine monitoring unit EMU
• Synchronization and connecting the generator to the grid
• Activation of the auxiliary drives at the engine-generator set
• Generator and grid protective functions
MMC functions
The MMC has the following functions:
• Operation and visualization
• Activation of external auxiliary drives
TIM-ID: 0000065665 - 003
Figure 55: MIP control system

1 MIP control cabinet 2 Emergency stop button 3 MIP cooling device (option)
92 | Monitoring and Control | SS180152/04E 2020-06

4.7 Charge-air System and Gas System
4.7.1 Gas train
The gas system consists of the gas train and the connecting hoses to the engine-generator set.
The fuel gas must comply with the (→ Fluids and Lubricants Specifications (A001072/...)).
Gas train for natural gas
Figure 56: Gas train for natural gas

1 Gas filter 4 Max. pressure monitor max. 7 End contact
2 Pressure gauge with push- 5 Gas pressure regulator 8 Min. pressure monitor
button valve 6 Valve testing system
3 Double solenoid valve
Function
The gas supply to the gas engine is regulated via the gas train. The gas train acts as a shutoff device for the
customer’s gas supply and contains important safety devices.
The gas filter filters the fuel gas and thus protects shutoff organs, regulators and the engine against contami-
TIM-ID: 0000080358 - 003
nation. The min. pressure monitor monitors the minimum required gas pressure and guards against insuffi-
cient gas. Pressures can be read off at the pressure gauges.
The leak test is conducted each time before the engine is started. If a leak is detected, the genset can not be
started. The closing of the twin solenoid valves results in the supply of gas being safely blocked. The position
of the twin solenoid valve is monitored by limit switches. The gas pressure regulator adjusts the inlet pres-
sure to the operating pressure. The max. pressure monitor monitors the maximum permissible gas pressure.
If one of the pressure monitors, the twin solenoid valves close. The gas supply is safely locked and operation
of the engine-generator set is stopped.
SS180152/04E 2020-06 | Charge-air System and Gas System | 93

Engine-generator sets in balancing energy mode (optional)
If the engine-generator set is operated in the balancing energy mode with the optional quick-start feature, a
gas leak test must be performed when the engine-generator set is put out of operation.
TIM-ID: 0000080358 - 003
94 | Charge-air System and Gas System | SS180152/04E 2020-06

4.7.2 Air filter
Figure 57: Air filter 12V

1 Air filter
The illustration (→ Figure 57) applies similarly to 8V and 16V engine-generator sets.
TIM-ID: 0000079794 - 003
SS180152/04E 2020-06 | Charge-air System and Gas System | 95

Figure 58: Air filter 20V
1 Air filter 2 Intake housing
Function
The air filter cleans the drawn-in air to prevent damage to important components in the engine.
The drawn-in air passes the filter media in the air filter (1) from the outside to the inside and then flows via
the gas mixer to the engine. The dust particles are retained by the filter media.
With the 20V engine-generator set, the intake housing (2) connects both intake pipes for cylinder banks A
and B with one another and thus guarantees a uniform air flow and a compensating pressure regulation over
the two intake pipes.
TIM-ID: 0000079794 - 003
96 | Charge-air System and Gas System | SS180152/04E 2020-06

4.8 Exhaust System
4.8.1 Exhaust gas heat exchanger
Illustrations apply similarly to other configurations.
Figure 59: Exhaust gas heat exchanger

1 Exhaust gas inlet/outlet 3 Measurement connections 5 Condensate drain
2 Heating water inlet/outlet for pressure/temperature
4 Condensate drain
TIM-ID: 0000077344 - 003
SS180152/04E 2020-06 | Exhaust System | 97

Figure 60: Exhaust gas heat exchanger with integrated oxidation catalyst and technical safety equipment
1 Safety valve 4 Pressure measurement bar 7 Resistance thermometer
2 Safety temperature limiter 5 Resistance thermometer 8 Condensate drain
3 Pressure measurement bar 6 Vent 9 Oxidation catalyst with tem-
perature sensors
Function
With an exhaust gas heat exchanger, thermal energy is removed from the exhaust gas and, depending on the
project-specific usage or integration, is supplied to the coolant circuits (heating water or engine coolant). The
exhaust gas heat exchanger is provided with insulation to reduce the radiated heat of the heat-carrying com-
ponents. The insulation consists of glass fiber with stainless steel jacketing.
In addition, safety-related components such as safety temperature limiter, safety valve, etc. are installed.
Further connection options are available for:
• Vent
• Condensate drain
• Sensor system for pressure and temperature measurement
The exhaust gas heat exchanger can be combined with a custom-designed heat module, see (→ Page 108).
A catalytic converter can be integrated in the front head of the exhaust gas heat exchanger to guarantee a
compact design and positioning of the catalytic converter close to the gas engine, see (→ Page 99).
TIM-ID: 0000077344 - 003
An optional exhaust silencer can be installed downstream of the exhaust gas heat exchanger (→ Page 100).
The exhaust gas heat exchanger is delivered as a loose component and can be integrated on the plant side in
the customer-provided exhaust system
98 | Exhaust System | SS180152/04E 2020-06

4.8.2 Catalytic converter
Figure 61: Oxidation catalyst

1 Catalytic converter housing 2 Temperature sensor
Function
The exhaust gas flows from the exhaust turbochargers into the catalytic converter. In the catalytic converter,
carbon monoxide (CO) and unburned hydrocarbons (HC) are oxidized. This further reduces the emissions
from the combustion process.
The oxidation catalyst can be integrated in the exhaust system (→ Figure 61) near the engine or in the front
head of the exhaust gas heat exchanger, see (→ Page 97).
TIM-ID: 0000078948 - 003

4.8.3 Exhaust silencer
The illustration shows a silencer with horizontal inlet and outlet. The illustration applies also to other ver-
sions.
Figure 62: Exhaust silencer

1 Housing 3 Attachment point 5 Outlet with flange
2 Direction of exhaust gas 4 Inlet with flange a Exhaust gas
flow
Function
An exhaust silencer reduces the noise level created during operation of the gas engine in the exhaust gas.
The method of operation of the exhaust silencer is based on the reflection and absorption process. The de-
sign is based on VDI 2263 Sheet 3 (explosion pressure shock resistant design in the exhaust line).
Different versions of the exhaust silencer are available based on the required residual sound pressure level,
the inlet and outlet nominal widths and the type of gas used. Fastening kits can also be supplied, which con-
tain, e.g. weld-in flanges, screws and gaskets.
Depending on the project-specific usage or integration, connection options are provided on the exhaust si-
lencer for the condensate trap.
TIM-ID: 0000077345 - 002
The exhaust silencer is delivered as a loose component and can be integrated in the customer-provided ex-
haust system horizontally, vertically or can be suspended. The specified direction of flow must be taken into
consideration. Fastening is by means of the mounts prepared on the exhaust silencer.

4.9 Lube Oil System
4.9.1 Lube oil system – Engine-generator set
Figure 63: Lube oil system

1 Engine-generator set 7 Engine-generator set 19 Overfill protection
2 Bleed-oil system line 8 Customer-side 20 Tank vehicle connector
3 Lube oil 9 to 15 Ball valve DN25 21 Steel tank, jacketed, 2-
4 Used oil 16 Vacuum leak indicator chamber design
5 Oil priming 17 Level indicator 22 Steel tank, jacketed, 2-
6 Retention bund with leak 18 Mounting bracket with over- chamber design
monitoring fill protection and tank vehi- 23 Preassembled tank system
cle connector
Technology
• Solenoid valve for fresh-oil replenishment
• Oil tray with leak monitoring
• Oil priming pump assembly with 3-way solenoid valve
• Automatic oil bleed system
TIM-ID: 0000085036 - 002
Function
A fresh-oil pump supplies fresh oil from the active circulation tank to the engine-generator set.
The automatic oil bleed system allows longer oil change intervals. This system regularly transfers a small
amount of the circulating lube oil from the engine oil pan to the circulation tank. This reduces the fill level in
the engine oil pan. The drop in fill level is compensated for by short-term operation intervals of the fresh-oil
pump. As a result, there is a continuous exchange of the circulating oil volume. The increased total volume
results in longer oil change intervals.
When the lube oil needs to be changed, the lube oil pump supplies the used oil to the circulation tank. After
draining, the engine will be filled with the fresh lube oil from the second tank.
SS180152/04E 2020-06 | Lube Oil System | 101

Engine oil system preheating
When the engine was stopped, the oil priming pump continues running for a predefined period of time to
provide post lubrication of the engine.
The lube oil must be preheated. This may be provided by maintaining a constant engine room temperature.
The recommended engine room temperature is at least 20 °C to ensure that the lube oil is adequately pre-
heated. At engine room temperatures < 10 °C the lube oil system must be preheated.
Post-lubrication function
For engine-generator sets in energy balancing mode with or without optional quick-start feature, a bigger oil
priming pump with a higher capacity must be installed (→ Page 103). When the engine was stopped, the oil
priming pump continues running for a predefined period of time to provide post lubrication of the engine.
TIM-ID: 0000085036 - 002
102 | Lube Oil System | SS180152/04E 2020-06

4.9.2 Oil priming pump
Oil priming is used for temperature control of the lube oil and ensures that the bearings are lubricated before
the engine starts.
The oil system mounted on the base frame contains the following components:
• Oil pump for priming and draining the oil pan
• Solenoid valves and shutoffs
Figure 64: Oil priming pump

1 2/2-directional control 4 Oil priming pump 7 Oil bleed line lube oil outlet
valve 5 Oil drip pan 8 Lube oil outlet
2 3/2-way valve 6 Lube oil inlet
3 Nozzle of oil bleed system
Oil priming pump for engine-generator sets in balancing energy mode

(optional)
The oil priming pump for engine-generator sets in energy balancing mode with or without optional quick-start
feature is designed for the more challenging requirements in the energy-balancing mode. A lube oil pump
with higher capacity provides higher oil pressure and lubricates the bearings more quickly. This reduces wear
in the energy balancing mode.
TIM-ID: 0000085035 - 001
When the engine was stopped, the temperature in the engine room must be maintained at > 20 °C. This will
ensure adequate oil temperature. Should coolant preheating with an inlet temperature of 65 °C not be suffi-
cient to maintain an engine room temperature of 20 °C, additional heaters must be installed in the engine
room.
SS180152/04E 2020-06 | Lube Oil System | 103

4.10 Cooling System and Heating Water System
4.10.1 Cooling system – Engine-generator set
The cooling system consists of two separated cooling circuits:
• Mixture coolant circuit (LT)
Accumulated heat from the 2nd stage of the mixture cooler is dissipated.
• Engine coolant circuit (HT)
Accumulated heat from the 1st stage of the mixture cooler is dissipated.
The cooling systems are run with a mixture of water, antifreeze and corrosion inhibitor in accordance with
the Fluids and Lubricants Specifications.
The required temperature control for the cooling systems is implemented mechanically or by electrically-driv-
en mixing valves.
Heat dissipation can be implemented as follows:
• Heat dissipation via cooler: no heat utilization
• Heat recovery (optional): with heat utilization
Mixture coolant circuit (LT)

The coolant circuit is designed as a closed system. Temperature-related volume fluctuations are compensat-
ed through the provided diaphragm-type expansion tanks, which allow constant pressure conditions. To
avoid an impermissible temperature or pressure increase, corresponding measuring devices are provided in
the coolant circuit which then shut down the plant when tripped. Coolant is conveyed during operation by an
electrically driven centrifugal pump.
To guarantee the necessary inlet temperature at the engine, an electrically activated three-way valve is in-
stalled. This valve has the task of compensating for fluctuations during heat consumption or recooling and of
ensuring that the operating temperature is quickly reached after the starting phase.
The heat contained in the mixture coolant circuit is dissipated to the environment via a customer-provided
cooler.
TIM-ID: 0000085032 - 003
104 | Cooling System and Heating Water System | SS180152/04E 2020-06

Engine coolant circuit (HT) without heat utilization
Figure 65: Engine coolant circuit without heat utilization - Schematic diagram
1 Mixture cooler, HT circuit 9 Mixture cooler, LT circuit 17 Plate-core heat exchanger
2 Oil cooler 10 Safety valve 18 Emergency pump
3 Safety valve (engine coolant 11 3-way valve with limit 19 Customer
circuit) switch 20 Optional
4 Throttle (engine coolant cir- 12 Breather 21 Exhaust gas heat exchanger
cuit) 13 Cooler (mixture coolant cir- G Engine-generator set
5 Cooler cuit)
6 Warmup thermostat 14 Expansion tank (mixture
7 Expansion tank (engine coolant circuit)
coolant circuit) 15 Circulating pump (mixture
8 Circulating pump (engine coolant circuit)
coolant circuit) 16 Throttle (mixture coolant
circuit)
The coolant circuit is designed as a closed system. Pressure is maintained by the installed diaphragm expan-
sion tank. To avoid an impermissible temperature or pressure increase, corresponding protective devices are
provided in the coolant circuit which then shut down the plant when tripped. Coolant is conveyed during op-
eration by an electrically driven centrifugal pump.
To guarantee the necessary inlet temperature at the engine, an electrically activated three-way valve is in-
TIM-ID: 0000085032 - 003
stalled. This valve has the task of compensating for fluctuations during heat consumption or recooling and of
ensuring that the operating temperature is quickly reached after the starting phase. The heat is transferred
via a sandwich cooler integrated in the container to the environment.
SS180152/04E 2020-06 | Cooling System and Heating Water System | 105

Engine coolant circuit (HT) with heat utilization
Figure 66: Engine coolant circuit (HT) with heat utilization - Schematic diagram
1 Mixture cooler, HT circuit 9 Mixture cooler, LT circuit 17 Plate-core heat exchanger
2 Oil cooler 10 Safety valve 18 Emergency pump
3 Safety valve (engine coolant 11 3-way valve with limit 19 Heating water (customer-
circuit) switch provided)
4 Throttle (engine coolant cir- 12 Breather 20 Exhaust gas heat exchanger
cuit) 13 Cooler (mixture coolant cir- (optional)
5 Cooler cuit) 21 Exhaust
6 Warmup thermostat 14 Expansion tank (mixture G Engine-generator set
7 Expansion tank (engine coolant circuit)
coolant circuit) 15 Circulating pump (mixture
8 Circulating pump (engine coolant circuit)
coolant circuit) 16 Throttle (mixture coolant
circuit)
The following heat utilization options are available:
• Heat utilization from engine coolant
• Heat utilization from engine coolant and exhaust gas
Engine coolant circuit (HT) with heat utilization from engine coolant (GR)
TIM-ID: 0000085032 - 003
The heat absorbed by the coolant is transferred in the heat module (→ Page 108) to a plate-core heat ex-
changer. The plate-core heat exchanger represents the interface between the coolant system of the engine-
generator set and the customer-provided heating system.
Engine coolant circuit (HT) with heat utilization from engine coolant and exhaust
gas (GC)
With complete heat recovery (engine coolant and exhaust gas), the heat from the exhaust gas is supplied via
exhaust gas heat exchangers through the engine coolant circuit to the heating water. The plate-core heat
exchanger is built in the heat module (→ Page 108) and represents the interface between the coolant system
of the engine-generator set and the customer-provided heating system.

In balancing energy mode with optional quick-start feature, the engine coolant (HT) and the mixture coolant
(LT) must be preheated.
Engine coolant is preheated by means of the heating elements installed on the gas engine.
To preheat the mixture coolant circuit it is sufficient to switch on the mixture coolant pump at certain inter-
vals. This allows mixture coolant circulation. The mixture cooler installed on the gas engine ensures heat
transfer from the preheated engine coolant circuit to the mixture coolant circuit.
When the engine was stopped, the engine coolant pump must continue to run for a certain period of time to
provide continued cooling for components, e.g. exhaust turbocharger, crankcase etc.
TIM-ID: 0000085032 - 003

4.10.2 Heat module
Overview
The heat module is a preassembled unit compactly installed on a frame construction. It contains all compo-
nents required for cooling the gas engine. Furthermore, the thermal energy created in the gas engine can be
transferred via a plate-core heat exchanger to the customer-provided heating water system.
All heat modules are delivered loosely and are installed on-site. The heat module can be lifted using the three
integrated lifting eyes. By means of the four adjustable feet on the frame construction, the heat module can
be aligned to the engine-generator set.
The heat module is available in different versions depending on which application is desired. Customer-spe-
cific designs are required for the options.
The (standard) heat module contains the following components:
• Plate-core heat exchanger
• Coolant pumps
• Control valves
• Throttle and shut-off valves
• Diaphragm-type expansion tank
• Pipelines
• Technical safety equipment of the genset mixture coolant circuit and engine coolant circuit
• Sensors
TIM-ID: 0000084387 - 002
Figure 67: Overview of heat module

1 Terminal box 5 Diaphragm-type expansion 9 Diaphragm-type expansion
2 Pump for mixture cooling tank, mixture cooling circuit tank, engine coolant circuit
circuit 6 Plate-core heat exchanger 10 Base frame
3 Control valve 7 Adjustable foot
4 Lifting eye 8 Pump for engine coolant cir-
cuit

Function
The coolant circuit s are run with a mixture of water, antifreeze and corrosion inhibitor in accordance with
the Fluids and Lubricants Specifications. The temperature control for the coolant circuits is implemented by
electromechanically-driven mixing valves, FC-controlled pumps or thermostat valves.
The heat transfer to the customer-provided heating water circuit is implemented via a plate-core heat ex-
changer. The thermal energy created during gas engine operation is absorbed by the coolant. The customer
receives the thermal energy for further use (heating circuit, process heat, etc.) via the plate-core heat ex-
changer. The plate-core heat exchanger represents the hydraulic separation of the systems. The thermal en-
ergy from the mixture coolant circuit is transferred via a customer-provided installed cooler to the environ-
ment.
The diaphragm-type expansion tanks ensure that the minimum pressure is not undershot to prevent vacuum,
cavitation and evaporation and also compensate for volume fluctuations of the engine coolant as a result of
temperature changes.
Heat module connections – example
Figure 68: Connections for heat module with plate-core heat exchanger
a Mixture coolant inlet (from d Mixture coolant outlet (to g Engine coolant inlet (from
engine) cooler) engine)
b Mixture coolant outlet (to e Heating water outlet h Engine coolant outlet (to en-
TIM-ID: 0000084387 - 002
engine) f Heating water inlet gine)

c Mixture coolant inlet (from
cooler)

Figure 69: Connections for heat module with connections to exhaust gas heat exchanger
a Mixture coolant inlet (from e Mixture coolant inlet (from i Engine coolant inlet (from
engine) cooler) emergency cooler)
b Mixture coolant outlet (to f Mixture coolant outlet (to j Heating water inlet
engine) cooler) k Engine coolant inlet (from
c Engine coolant inlet (from g Engine coolant outlet (to ex- engine)
exhaust gas heat exchang- haust gas heat exchanger) l Engine coolant outlet (to en-
er) h Engine coolant outlet (to gine)
d Heating water outlet emergency cooler)
TIM-ID: 0000084387 - 002

Figure 70: Connections for heat module without plate-core heat exchanger
a Mixture coolant inlet (from d Mixture coolant outlet (to g Engine coolant inlet (from
engine) cooler) engine)
b Mixture coolant outlet (to e Engine coolant outlet (to h Engine coolant outlet (to en-
engine) customer-provided cooler) gine)
c Mixture coolant inlet (from f Engine coolant outlet (from
cooler) customer-provided cooler)
Depending on the expansion stage, the following coolant circuits are an element of the heat module.
Engine coolant circuit – high temperature (HT)

The engine coolant circuit is used to cool the components installed in the gas engine: Oil heat exchanger,
engine block including cylinder heads and the first stage in the mixture cooler. The thermal energy thus re-
moved from the gas engine is transferred via a heat exchanger to the customer-provided heating water cir-
cuit.
The engine coolant circuit represents a closed circuit, whereby all necessary components are installed in the
heat module including the safety-related equipment. It contains the following main component:
• Coolant pump
• Plate-core heat exchanger
TIM-ID: 0000084387 - 002
• Safety-related equipment
• Sensors
• Pipelines
The connections on the heat module are shown in the illustrations (→ Figure 68), (→ Figure 69) and
(→ Figure 70) and can be obtained from the arrangement drawings included in the delivery.

Engine coolant circuit - medium temperature (MT) (optional)
As an option, the first stage of the mixture cooler integrated in the engine coolant circuit as standard can be
decoupled and integrated in the customer-provided heating water circuit. Depending on how this integration
in the customer-provided heating water circuit is carried out, this can result in an increase in thermal effi-
ciency or the supply line temperature.
In case of a plant-side integration, further customer-provided add-on components may be required,
e.g. pipes, coolant pumps, shut-off valves, 3-way valves, etc. The connections for this option are not located
in the heat module, but rather directly on the gas engine.
Mixture coolant circuit – low temperature (NT)

The mixture coolant circuit is used to cool the second stage of the mixture cooler installed in the gas engine.
The thermal energy removed from the gas engine is dissipated via a cooler to the environment. The cooler is
not an element of the heat module and is installed separately in the customer-provided system.
The mixture coolant circuit represents a closed circuit and consists of the following main components:
• Coolant pump
• 3-way valve with actuator
• Heat exchanger
• Sensors
• Pipelines
In case of a plant-side assembly of the cooler, further customer-provided add-on components may be re-
quired, e.g. pipes, coolant pumps, shut-off valves, 3-way valves, etc.
The connections on the heat module are shown in the illustrations (→ Figure 68), (→ Figure 69) and
(→ Figure 70) and can be obtained from the arrangement drawings included in the delivery.
Emergency cooling circuit (optional)

An emergency coolant circuit can be integrated in the engine coolant circuit. In this case, the thermal energy
removed from the gas engine is dissipated optionally via a cooler to the environment if the thermal energy is
not required in the customer-provided heating water circuit and/or is dissipated. Cooling independent of the
customer-provided heating water circuit and thus operation of the gas engine thus continues to be guaran-
teed.
The emergency cooling circuit represents a closed circuit and consists of the following main components:
• Control valve with actuator
• Non-return flap
• Sensors
• Pipelines
In case of a plant-side assembly of the cooler, further customer-provided add-on components may be re-
quired, e.g. pipes, coolant pumps, shut-off valves, 3-way valves, etc.
The connections on the heat module are shown in the illustration (→ Figure 69) figure and can be obtained
from the arrangement drawings included in the delivery.
TIM-ID: 0000084387 - 002

4.11 Base Frame
4.11.1 Mounting
The base frame accommodates all components of the engine-generator set.
The illustration shows an example of a base frame for engine-generator sets.
Figure 71: Base frame for engine-generator sets – engine side

1 Engine foot 4 Oil pan 7 Resilient generator mount-
2 Base frame 5 Lifting eye ing element
3 Resilient engine mounting 6 Slide rail
element
The base frame (2) is a rigid welded construction with a slide rail for the generator (6). Four engine feet (1)
are welded onto the base frame, which are screwed onto the resilient mounting elements (3). The mounting
elements of the generator (7) are bolted onto the slide rails. The resilient bearing elements reduce vibrations
generated by the engine and generator during operation. An oil pan (4) is welded onto the base frame. The
base frame is provided with four lifting eyes (5), which are welded with longitudinal and crossbeams.
Technical data
TIM-ID: 0000079796 - 002
• Welded steel construction

• Resilient bearing elements for engine and generator
SS180152/04E 2020-06 | Base Frame | 113

Benefits
• Light weight of base frame
• Easier transport of engine-generator set thanks to common underframe
• Easy access to all main components
• Optimization of vibration properties
• Fast coupling replacement thanks to slide rail
• The oil pan is leaktight and welded with suitable materials. It therefore complies with the requirements of
the Water Resources Act
TIM-ID: 0000079796 - 002
114 | Base Frame | SS180152/04E 2020-06

4.12 Monitoring, Control and Regulation Equipment
4.12.1 Gas engine phase 4 system – Overview
General overview
Figure 72: General overview

1 Unit system 5 Engine monitoring 9 Knock module
2 Engine system 6 Empty 10 Ignition
3 System 7 Throttles 11 Compressor bypass
4 Engine governor 8 Gas dosing unit 12 NOx sensor (optional)
Governing/control/monitoring
Engine Control Unit ECU-9
• Controls engine starting, stopping and emergency stop
• Monitors engine operating parameters
• Controls throttles and sets gas mixture for requested speed/power
• Monitors first gas solenoid in gas train to engine
TIM-ID: 0000043155 - 003
Engine Monitoring Unit EMU 8

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

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

• Adjusts ignition timing for cylinders
SS180152/04E 2020-06 | Monitoring, Control and Regulation Equipment | 115

Anti-knock control 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 TecJet52

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

• The mixture throttles in the mixture lines which are controlled by the engine governor
TIM-ID: 0000043155 - 003
116 | Monitoring, Control and Regulation Equipment | SS180152/04E 2020-06

4.12.2 Purpose of the units
ECU 9 engine governor
Figure 73: ECU9

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
TIM-ID: 0000040818 - 002
• One data record for genset software
SS180152/04E 2020-06 | Monitoring, Control and Regulation Equipment | 117

Engine Monitoring Unit EMU 8
Figure 74: Engine Monitoring Unit EMU 8

EMU = Engine Monitoring Unit
Monitoring unit for the engine
• Acquisition and processing of cylinder exhaust temperatures
Self-monitoring
TIM-ID: 0000040818 - 002
118 | Monitoring, Control and Regulation Equipment | SS180152/04E 2020-06

4.13 Electrical System
4.13.1 Starter battery
Starter batteries are necessary to start the engine. A combination of four 12 V batteries is used to provide
the necessary 24 V system voltage and the required capacity. The batteries are series-connected in pairs and
these are then connected in parallel.
Technical data
• Set of four 12 V batteries
• Sealed gel batteries
Benefits
• Immediate start of the engine-generator set due to high quality batteries
• Large tolerance for low ambient temperatures
• Automatic recharge by the battery charger
• Easy installation and maintenance
• Rechargeable
• Very low self-discharge
Function
The batteries are connected to the engine starter. When an engine-generator set start request command is
received, the control system commands the starter to operate. The engagement relay of the starter closes
the starting circuit to provide DC current for the start of the engine-generator set. Once the engine is run-
ning, the power supply from the batteries stops.
Number of starters:
• One starter with 8- and 12-cylinder engines
• Two starters with 16- and 20-cylinder engines
The battery charger monitors the charging condition of the batteries and recharges them.
All starter batteries of an engine-generator set must be the same size.
The leads of the two parallel-connected batteries must be the same length.
Safety
When handling the battery, observe the safety regulations .
NOTE: Fit terminal caps on battery and starter to protect against short circuits.
TIM-ID: 0000077256 - 001
SS180152/04E 2020-06 | Electrical System | 119

4.13.2 Battery charger
• Battery charger for providing the control voltage
The control cabinet is equipped with a battery charger. This device charges the controller batteries for the
supply of the 24 VDC consumers (e.g. display, PLC, switch).
TIM-ID: 0000070036 - 001
120 | Electrical System | SS180152/04E 2020-06

4.14 Gas Alarm and Fire Alarm
4.14.1 Gas alarm system
The gas alarm system can only be integrated as a safety function in the controller in conjunction with an
MTU Module Control (MMC).
The illustration is an example.
Figure 75: Gas alarm system – example

1 Gas warning sensor 3 Exhaust air
2 Engine-generator set 4 Supply air
Function
The gas detector consists of a transmitter and an evaluation unit. The sensors for the gas detector are deliv-
ered in the MMC control cabinet.
The gas alarm system serves as an additional protective measure against the risk of explosion. If gas leaks
occur, the gas detector responds at a proportion of 15% of the lower explosion limit in the installation room.
When the gas alarm system trips, the engine-generator set is shut down safely and locked against powering
up again.
TIM-ID: 0000065679 - 006
The transmitter is installed such that its sensors face vertically downwards and gas can also reach the sen-
sor even in unfavorable ventilation conditions. At least one gas warning sensor is positioned above the plant
in the area between the gas train and the engine in the exhaust air area. Additional gas sensors must be
installed if there are any areas in the installation room with a poor air flow.
SS180152/04E 2020-06 | Gas Alarm and Fire Alarm | 121

4.14.2 Fire detector
The fire detector can only be integrated as a safety function in the controller in conjunction with an MTU
Module Control (MMC).
Illustrations serve as examples.
Figure 76: Fire detector – negative example

1 Fire detector 3 Engine-generator set 5 Exhaust air
2 Obstruction 4 Supply air
TIM-ID: 0000065518 - 007
122 | Gas Alarm and Fire Alarm | SS180152/04E 2020-06

Figure 77: Fire detector – example
1 Fire detector 3 Engine-generator set 5 Exhaust air
2 Obstruction 4 Supply air
Function
The fire detector comprises an installation base and a fire detector. The use of a fire detector allows early
detection of fires and smoldering.
The fire detector responds in the event of smoke development and a temperature increase to + 65 °C.
When the fire detector trips, the engine-generator set is shut down safely and locked against powering up
again.
It is installed in the area of the exhaust air flow. Otherwise there is no guarantee that the fire detector can
recognize smoke development. If the distance between ceiling and exhaust air flow is too great, a longer
base is used for the fire detector. Depending on local conditions, it may be necessary to use several fire
detectors.
TIM-ID: 0000065518 - 007
SS180152/04E 2020-06 | Gas Alarm and Fire Alarm | 123

5 Technical Data
5.1 Technical data
Detailed technical data for the engine-generator set is provided in the as-delivered documentation, (→ see
chapter “Technical data”).
TIM-ID: 0000069327 - 002
124 | Technical Data | SS180152/04E 2020-06

6 Operation
This section contains instructions for operating the engine-generator set.
nents which are not included in the scope of supply of your particular engine-generator set.
Before starting work
• Ensure that the prerequisites listed in the descriptions have been fulfilled.
Contact Service if a task cannot be successfully completed.
TIM-ID: 0000070223 - 001
SS180152/04E 2020-06 | Operation | 125

6.2 Conduct in case of activated gas alarm
WARNING
Ignitable or potentially explosive gas-air mixture emerges at gas outlet.
Explosion hazard!
• Do not enter the installation room.
• Stop the escape of gas and close the main cock outside the building.
WARNING
High concentration of gas in the air through the gas outlet.
Danger of suffocation!
• Do not enter the installation room.
• Stop the escape of gas and close the main cock outside the building.
Note: In case of a gas alarm, the ventilation system powers up automatically to 100% and vents the room.
Conduct in case of activated gas alarm

1. Call the fire department.
2. Cordon off danger zone.
3. Do not enter the danger zone until it has been established (by measuring the gas concentration) that the
atmosphere is no longer hazardous.
Note: • The acknowledgment button provides an option for shutting down the horn signal.
• When the acknowledgment button for the horn is actuated, the flashing light and plant start interlock re-
main unchanged.
Acknowledging flashing horn

Note: The horn can be acknowledged under the following conditions:
• Unauthorized persons are shielded from the danger area.
• The operator does not enter the danger area.
u Acknowledge the flashing horn via the acknowledgment button at the controller. Actuate acknowledgment
button, see Operating Instructions for MMC400 and/or MMC4000 controller.
TIM-ID: 0000076935 - 003
126 | Operation | SS180152/04E 2020-06

6.3 Conduct in case of activated fire alarm
DANGER
Firefighting on components carrying high voltages.
Danger of fatal electric shocks when firefighting with water!
• Never use water to extinguish fires.
• Ensure that only suitable fire extinguishers are used.
Note: In case of a fire alarm, the ventilation shuts down and the ventilation flaps close automatically.
Conduct in case of activated fire alarm:

1. Keep calm.
2. Close the main cock and shut off the gas supply outside the building.
3. Close the door of the installation room if it is safe to do so.
4. Call the fire department.
Note: • The acknowledgment button provides an option for shutting down the horn signal.
• When the acknowledgment button for the horn is actuated, the flashing light and plant start interlock re-
main unchanged.
Acknowledging flashing horn

Note: The horn can be acknowledged under the following conditions:
• Unauthorized persons are shielded from the danger area.
• The operator does not enter the danger area.
u Acknowledge the flashing horn via the acknowledgment button at the controller. Actuate acknowledgment
button, see Operating Instructions for MMC400 and/or MMC4000 controller.
TIM-ID: 0000076936 - 003
SS180152/04E 2020-06 | Operation | 127

6.4 Conduct in case of activation of safety functions
WARNING
Incorrect correction of causes of malfunctions.
Risk of injury!
• Causes of malfunctions must only be correct by authorized persons. These persons must have the
necessary technical expertise and be instructed in plant operation.
• When eliminating the causes of malfunctions, all warnings and safety instructions in the correspond-
ing system and plant documentation must be observed.
WARNING
Hot components/surfaces
Risk of burns!
• Wear suitable protective equipment/heat protective gloves.
• Avoid unprotected contact with hot surfaces.
Conduct in case of activation of safety functions

Note: The activation of a safety function is displayed in the MMC controller as a red alarm.
1. Check and, if possible, eliminate the cause.
2. If the cause can not be eliminated, consult Service personnel.
TIM-ID: 0000077071 - 004
128 | Operation | SS180152/04E 2020-06

6.5 Operating room – Check 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 operating room for smell of gas

1. Check operating room for smell of gas or localize gas supply leaks using gas detection and alarm unit.
2. If smell of gas is detected or the gas detection and alarm unit is triggered:
• Avoid naked flames!
• Avoid sparks! Do not use electrical appliances (including switches, connectors/sockets, telephone, bell).
• Do not smoke!
• Close main gas shutoff device!
• Open windows and doors!
• Warn residents and leave building!
• Call gas supplier from outside the building!
TIM-ID: 0000002533 - 005
SS180152/04E 2020-06 | Operation | 129

6.6 Lockout/tagout procedure
Preconditions
☑ Engine-generator set is shut down and controller is switched off.
☑ Engine starting current deactivated.
DANGER
Unqualified personnel, failure to comply with safety regulations when working on electrical systems.
Danger of fatal electric shock and burns from flashover!
• De-energize the electrical system supplying live components.
• Follow lockout/tagout procedures conscientiously to preclude accidental energization.
• Verify absence of voltage with appropriate measuring/testing equipment, e.g. voltage tester.
• Connect conductors and ground with a short-circuiting device, e.g. grounding rod.
• Safely cover any live components in the vicinity. Prevent unauthorized access.
DANGER
Manipulation of safety interlocks on live components and connections.
Danger of burns or potentially fatal electric shock!
• Do not manipulate safety interlocks on the product.
DANGER
Electrical voltage at exposed terminals and components.
Risk of serious injury - danger to life!
• Work must be carried out by trained, qualified and approved according to the regional regulations
personnel only!
• Ensure that no other persons have access to exposed terminals and/or components!
• Close terminal boxes and/or components immediately after completion of work!
• Act with extreme caution!
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.
WARNING
Batteries are live parts.
Danger of burns and electric shock.
• Be careful when disconnecting battery cables.
• Disconnect the cable on the negative battery terminal first.
WARNING
The lead-acid battery contains highly corrosive sulfuric acid.
The batter/lead-acid battery may produce flammable gases, particularly when being charged.
Short circuit when jumping battery terminals with metal objects.
TIM-ID: 0000083361 - 004
Danger of chemical burns, explosion and short circuit!

• Wear personal protective equipment e.g. face mask, safety clothing and protective gloves.
• Avoid sparks resulting from short circuit and other sources of ignition.
• Never place metal objects on the battery.
• If case of contact with electrolyte, wash the skin and eyes immediately with water and seek medical
attention without delay.
• Follow manufacturer's safety instructions.
Note: The instructions provided in this section are general in nature and do not necessarily cover all possible con-
figurations (controller, circuit breakers etc.).
130 | Operation | SS180152/04E 2020-06

General recommendations
• The manufacturer urgently recommends documenting the starting process during commissioning of the
installation concerned.
• All co-workers involved in commissioning must have completed the commissioning training course for op-
erators. This training course is conducted by the authorized training center in your region.
Battery
1. Disconnect negative lead from battery terminal.
2. Provide sign with inscription "DO NOT OPERATE" or similar warning.
Circuit breakers
Note: DANGER, busbar may still be live when circuit breaker is open.
u Open circuit breaker according to manufacturer's specifications and secure against reactivation.
Auxiliary drives
u Switch off main switch of the auxiliary drives and lock it.
Engine-generator set controller

Note: Switching off the engine-generator set, switches of the engine coolant pump at the same time. Wait until the
engine has cooled down.
1. Press the emergency stop pushbutton to lockout the engine-generator set.
2. Padlock the door and affix a warning sign indicating lockout (if this is not already the case).
Mains circuit breaker

1. Switch the handle of the circuit breaker to the OPEN position.
2. Provide sign with inscription "DO NOT OPERATE" or similar warning.
3. For multiple circuit breakers, repeat the two previous steps.
TIM-ID: 0000083361 - 004
SS180152/04E 2020-06 | Operation | 131

6.7 Unlocking procedure
Preconditions
☑ Engine is stopped and control system is in "OFF" position.
☑ Engine starting circuit is disabled.
DANGER
High voltage. Live components and connections.
Risk of burns or death from electric shock!
• Disable the engine start contact leads from the engine-generator set control panel.
• Do not disconnect the engine start contact leads from the transfer switch enclosure.
DANGER
Circuit breakers are live components.
Risk of fatal electric shock or burns!
• Make sure that all circuit breakers are in the OPEN position before starting and when conducting
maintenance work.
DANGER
The battery charger contains live electrical components.
• Before starting maintenance and repair work, wait at least 30 seconds following disconnection of the
voltage source from the battery charger.
WARNING
Rotating and moving parts and high level of engine noise in the event of unexpected engine-generator
set start during service.
Risk of crushing, danger of parts of the body being caught or pulled in!
Risk of damage to hearing!
• Ensure the engine-generator set has been stopped.
• Ensure the control panel is in "OFF" position to disable starting during service.
• Disconnect the battery charger prior to service.
WARNING
Rotating and moving parts and high level of engine noise in the event of unexpected engine-generator
set start after service.
• Ensure the control panel is in "OFF" position prior to reconnecting the negative terminal of the bat-
tery.
WARNING
Batteries are live parts.
Danger of burns and electric shock.
• Be careful when disconnecting battery cables.
• Disconnect the cable on the negative battery terminal first.
TIM-ID: 0000092640 - 001
NOTICE
Surge when using insufficient fuses.
Damage to engine-generator set!
• Make notes from where each fuse is removed, and keep these notes until reinstallation.
• Ensure to install the correct fuses in each slot of the control panel and the battery charger.
Note: The instructions in this section are general and cannot reflect all possible control and electrical configura-
tions (control panel, circuit breaker, etc.).
132 | Operation | SS180152/04E 2020-06

General recommendations
• The manufacturer urgently recommends documenting the starting process during commissioning of the
installation concerned.
• All co-workers involved in commissioning must have completed the commissioning training course for op-
erators. This course is offered by the authorized training center responsible for your region.
Automatic transfer switch (if fitted)

1. Remove lockout tag and lock.
2. Open engine-generator set control cabinet .
3. Remove protective cover to exposed lead ends.
4. Reinstall start leads of automatic transfer switch.
5. Reinstall fuses.
6. Close control cabinet.
Engine-generator set controller

1. Turn and pull EMERGENCY STOP button to reset.
2. Remove lock and tag.
3. Select operating mode.
Battery
1. Remove lock and lockout tag.
2. Remove lead cap from negative lead.
3. Connect negative lead to negative battery terminal.
Result: This starts the panel boot process which causes the alarm to sound.
Note: There is a button which functions to silence the alarm. Depending on your configuration, this button will be
called ALARM SILENCE, ACK, etc.
4. Press this button to silence the alarm.
Facility battery charger

1. Close circuit breaker supplying AC power to battery charger.
2. Reinstall battery charger fuses.
3. Reinstall AC power source to battery charger.
Main circuit breaker(s)

1. Remove tag "DO NOT OPERATE" or similar warning label.
2. Set circuit breaker according to the configuration used, see "General recommendations".
Final step
u Test engine-generator set through normal test run procedure (→ Page 439).
TIM-ID: 0000092640 - 001
SS180152/04E 2020-06 | Operation | 133

6.8 Control, starting and stopping sequences
DANGER
Electromagnetic field present when generator is running.
Danger to life due to interference with pacemakers or other active medical implants!
• Access to the generator area is prohibited for personnel wearing pacemakers or implanted defibrilla-
tors.
DANGER
Rotating, moving parts during operation.
Risk of crushing, danger of limbs being caught up or drawn in!
• Personnel must only stay in the operating room of the engine/engine-generator set as long as neces-
sary and only if on-site attendance is expressly required in the descriptions.
• Keep away from the danger zone of the engine/engine-generator set.
DANGER
Live components and connections.
personnel only.
• Proceed with extreme caution during operational checks.
WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.
WARNING
A high level of noise is produced when the engine is running.
Risk of hearing loss!
• Wear suitable hearing protection.
WARNING
The exhaust system is highly pressurized downstream of the exhaust turbocharger during a hot start of
the engine.
Danger of deflagration in the exhaust system during an engine hot start!
• During an engine hot start, leave the installation room if possible. Otherwise restrict your stay in the
engine room to a minimum.
NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.
NOTICE
The start interlock of the engine-generator set is enabled when a programmed number of starting at-
TIM-ID: 0000085392 - 005
tempts have failed. Repeated acknowledgement of the fault and re-starting without eliminating the
cause of the failures leads to inadmissibly high temperatures of the electric starter and of the cabling.
Risk of serious damage to starter and cabling!
• Before acknowledging the fault and re-starting the engine-generator set, make sure that the cause of
the fault has been eliminated.
134 | Operation | SS180152/04E 2020-06

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.
Starting and stopping sequences

The starting sequence is software-controlled and depends on the place of start command input.
With a gas engine, you must ensure, e.g. when switching the ignition on and off, that there is no mixture in
the engine. A special routine for starting and stopping the engine is provided for this purpose.
The maximum starting speed is limited:
• Three starts in succession with engine-generator sets in continuous operation (standard)
• One start for model type L64 FNER
After this, an extended flushing phase is initiated with the gas shut-off valves closed and the ignition off in
order to purge the intake duct, engine cylinders and exhaust duct (up to the exhaust turbine outlet elbow)
with air. The operator must introduce on-site measures to ensure that flammable gases or vapors do not de-
velop in hazardous quantities or concentrations in the areas surrounding the plant (gas pipework up to gas
control valve and exhaust gas system after turbine). Contact to MTU is available to initiate such safety meas-
ures.
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. Oil priming (optional)
3. Leak test of the gas solenoids (this is omitted in the starting sequence with the optional fast-start
capability and secondary balancing energy and is integrated in the stopping sequence)
4. Activating starter
5. Waiting for starting speed
6. Flushing engine
7. Activating ignition function
8. Opening gas 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. If a start was terminated, the maximum number of successive starts is limited according to the oper-
ating mode.
2. Following this, an alarm is output
3. Requesting external ventilation by contact
TIM-ID: 0000085392 - 005
4. Engine start is disabled as long as the fault is not acknowledged

5. In order that a subsequent fast start can be carried out, a flushing phase must be initiated before-
hand. Otherwise the ramp-up with a subsequent fast start is lengthened by the flushing phase.
SS180152/04E 2020-06 | Operation | 135

Stopping sequence
The following steps are performed automatically when a stop command is activated:
1. Closing gas solenoid valves
2. Opening mixture throttles, purging of residual gas
3. Engine running down to standstill
4. Deactivating ignition
5. Closing mixture throttles
6. Leak test of gas solenoid valves (with fast-start capability option)
Emergency stopping sequence

If an emergency stop takes place, the following steps are carried out automatically:
1. Closing gas solenoid valves
2. Closing mixture throttles
3. Engine running down to standstill
4. Deactivating ignition
5. Requesting external ventilation by contact
Start after emergency stop

A flushing phase and a request for external ventilation by contact take place following a start request after
emergency shutdown.
In order that fast start can be carried out after an emergency stop, a flushing phase must be initiated before-
hand. Otherwise the ramp-up with a subsequent fast start is lengthened by the flushing phase.
1. Activating request for external ventilation via contact
2. Activating starter
3. Waiting for starting speed
4. Flushing engine
5. Disengaging starter
6. Engine coasting down to standstill
7. Resetting start counter
8. Waiting for start request
Topping up oil
1. Waiting for engine running
2. Engine running for a minimum (programmed) time period
3. Enabling oil refilling
4. When oil refill request is received
5. Refilling oil (automatically)
6. Oil refill request is canceled
7. Stopping oil refilling (automatically)
TIM-ID: 0000085392 - 005
136 | Operation | SS180152/04E 2020-06

6.9 Runtimes at partial load
Gas engines were designed and optimized for continuous operation at 100% load.
The following restrictions apply to ensure maximum operational availability of the engine plant and to reduce
maintenance to a minimum:
Operation with natural gas

Power relative to rated load Recommended maximum run- Recommended minimum run-
time time
at this load in subsequent operation
at load > 50%
5 % to 20 % 30 minutes 120 minutes
Max. 25 hours per annum
20 % to 35 % 5 hours 120 minutes
35 % to 100 % No restriction No restriction
Operation with biogas

Power relative to rated load Recommended maximum run- Recommended minimum run-
time time
at this load in subsequent operation
at load > 50%
5 % to 20 % 30 minutes 120 minutes
20 % to 50 % 5 hours 120 minutes
50 % to 100 % No restriction No restriction
A minimum operating time of 5 hours per start is recommended to counteract increased engine loading re-
sulting from temperature changes (cold start to engine operating temperature).
TIM-ID: 0000077342 - 001
SS180152/04E 2020-06 | Operation | 137

6.10 Automatic start and shutdown
Preconditions
☑ Operating instructions for MMC4000 controller available.
Automatic start
u Refer to the operating instructions for the MMC4000 controller for details of the procedure for starting the
engine-generator set automatically.
Automatic shutdown
u Refer to the operating instructions for the MMC4000 controller for details of the procedure to stop the en-
gine-generator set down automatically.
TIM-ID: 0000071926 - 002
138 | Operation | SS180152/04E 2020-06

6.11 Engine-generator set – Starting in Manual mode
Preconditions
☑ Engine-generator set is ready for operation.
☑ Engine-generator set is not in Automatic mode.
DANGER
tors.
DANGER
DANGER
personnel only.
WARNING
WARNING
WARNING
the engine.
NOTICE
TIM-ID: 0000071927 - 004

SS180152/04E 2020-06 | Operation | 139

NOTICE
The start interlock of the engine-generator set is enabled when a programmed number of starting at-
tempts have failed. Repeated acknowledgement of the fault and re-starting without eliminating the
cause of the failures leads to inadmissibly high temperatures of the electric starter and of the cabling.
Risk of serious damage to starter and cabling!
• Before acknowledging the fault and re-starting the engine-generator set, make sure that the cause of
the fault has been eliminated.
Preparation
u Prepare switch settings:
Key switch / pushbutton Position
on control cabinet
Enable engine-generator set 1
Control: Local / Remote Local
Operating mode: Manual / Manual
Automatic
Enable standby operation 0
Power outage test 0
Reset Not actuated
Start request 0
EMERGENCY STOP switch Unlocked
Result: The operating message "Module ready for operation” must appear on the display.
Starting engine-generator set

1. Initiating start:
Key switch / pushbutton Position
on control cabinet
Start request 1
Actuate Start pushbutton, see Operating Instructions for MMC4000 control-
ler.
2. Check idle speed. TIM-ID: 0000071927 - 004
140 | Operation | SS180152/04E 2020-06

6.12 Status signals
No. Designation Description
1 No Release module The “Enable module” key-operated switch is
set to Off.
2 Module enable The “Enable module” key-operated switch is
set to On.
3 Manual mode The “Manual/Automatic” key-operated switch
is set to Manual.
4 Automatic mode The “Manual/Automatic” key-operated switch
is set to Automatic.
5 Local control The “Local/Remote” key-operated switch is
set to Local. All of the operations can be per-
formed locally.
6 Remote control The “Local/Remote” key-operated switch is
set to Remote. All of the operations can be
performed remotely. This operating mode is al-
so required for operation via the interface.
7 Control via interface Enable via interface is activated. The “Local/
Remote” key-operated switch must be set to
Remote.
8 Machine available This message is active if the “Enable” key-op-
erated switch is set to On and the module/
genset is at standstill. Furthermore, no fault
which could cause a shutdown may be active.
9 Engine stopped If the engine speed is below 50 rpm.
10 Gas type A active The gas train for gas type A is active.
11 Gas type B active The gas train for gas type B is active. Only rel-
evant to dual gas operation.
12 Gas exchange active Only for dual gas operation! This message is
active when changing over from gas type A to
gas type B and vice versa.
TIM-ID: 0000073985 - 002
SS180152/04E 2020-06 | Operation | 141

13 Start demand active A distinction is made between three variants
in the case of this message:
1. Location
The start demand is applied when:
• The “Enable” key-operated switch is set to
On
• The “Local/Remote” key-operated switch is
set to Local
• The key-operated switch “Start demand lo-
cal” is set to On
• Optional conditions have been met, such as
sufficient fill level with the gas tank fill level
option.
2. Remote
On
• The “Local/Remote” key-operated switch
must be set to Remote
• Digital input “Remote Start/Stop” is set to
High
• The “Manual/Automatic” key-operated
switch is set to Automatic
• The interface must not be enabled
option.
3. Interface
On
• The “Local/Remote” key-operated switch
must be set to Remote
• The interface must be enabled
• Starting is initiated via interface
• The “Manual/Automatic” key-operated
switch is set to Automatic
option.
14 Start active Is active when the module is starting.
15 Stop active Is active when the module is being stopped.
16 Leakage test gas line A active Gas leak testing for gas type A is in progress.
Testing is carried out automatically, but can al-
so be performed in Manual mode.
TIM-ID: 0000073985 - 002
17 Leakage test gas line A OK This message is active after receiving feed-
back of successful completion of gas leak test
for gas type A.
18 Leakage test gas line B active Gas leak testing for gas type B is in progress.
Testing is carried out automatically, but can al-
so be performed in Manual mode.
19 Leakage test gas line B OK This message is active after receiving feed-
back of successful completion of gas leak test
for gas type B.
142 | Operation | SS180152/04E 2020-06

20 Auxiliary drives on This message is active as soon as the auxiliary
drives have been set.
21 Cooling water pump 1 on This message indicates that cooling water
pump 1 is active.
22 Used oil / oil priming pump active This message indicates that the priming pump
is actively draining.
23 Waste/Prelube oil pump manual This message indicates that the priming pump
is actively draining in Manual mode.
24 Gas valve 1 for gas type A open Gas valve 1 for gas train A is open.
25 Gas valve 1 for gas type B open Gas valve 1 for gas train B is open.
26 Release island operation (key switch) Enable island operation is activated via the
key-operated switch.
27 Mains ok A stabilization timer lapses after a grid failure.
This message is indicated after the time has
lapsed and no further grid failure has occur-
red.
28 Gas valve 2 for gas type B open Gas valve 2 for gas train B is open.
29 Synchronization – generator c.b. If the EMM was enabled for synchronization of
the generator circuit breaker. The generator
circuit breaker must not be closed yet and no
stop procedure must be in progress.
30 Synchronization – mains c.b. If the EMM was enabled for synchronization of
the power tie breaker. The power tie breaker
must not be closed yet.
31 Generator c.b. is off “Off” feedback from generator circuit breaker.
32 Generator c.b. is on “On” feedback from generator circuit breaker.
33 Mains c.b. is off “Off” feedback from power tie breaker, if
present. Is selected via Option.
34 Mains c.b. is on “On” feedback from power tie breaker, if
present. Is selected via Option. Unless a pow-
er tie breaker is present, this signal will always
be active.
35 Surge current active The “peak current” operating mode is active.
36 Mains parallel mode is active This message is active as soon as the genera-
tor circuit breaker and power tie breaker are
on. If no power tie breaker is present, only the
generator circuit breaker must be “on”.
37 Island operation active As soon as the generator circuit breaker is
“on” and the power tie breaker is open.
TIM-ID: 0000073985 - 002
38 Mains failure test active The key-operated switch for the power outage
test has been actuated.
39 Cooling water preheating blocked Coolant preheating can be disabled via the vis-
ualization system.
40 Start condition for automatic mode OK When the “Enable” key-operated switch is set
to On and optional conditions have been met,
such as sufficient fill level with the gas tank fill
level option.
SS180152/04E 2020-06 | Operation | 143

41 Generator heater on The generator anti-condensation heater has
been activated. The engine must be stopped.
42 Hardware signal “Request GCU check” from The engine has set the hardware signal “Re-
Engine quest GCU check”.
43 Hardware signal “Request gas solenoid valve The engine has set the hardware signal “Re-
1” from Engine quest gas valve solenoid 1”.
44 Hardware signal “Request gas solenoid valve The engine has set the hardware signal “Re-
2” from Engine quest gas solenoid valve 2”.
45 Signal “Request synchronization” from Engine The engine has set the “Request synchroniza-
tion” signal.
46 Gas compressor on This message is active when the gas compres-
sor has been activated.
47 Heating water pump 1 on As soon as heating water pump 1 is active.
48 Planned maintenance This status signal is indicated 200 hours be-
fore reaching the set operating hours.
49 Power controller – constant value active This message is active if one of the following
cases applies:
• The fixed value is selected via the visualiza-
tion program, whereby the “Local/Remote”
key-operated switch must be set to “Local”.
• The fixed value is activated via hardware
contact signal, whereby the “Local/
Remote” key-operated switch must be set
to “Remote”.
• The fixed value is activated via interface,
whereby enabling via interface must be ac-
tivated and the “Local/Remote” key-operat-
ed switch must be set to “Remote”.
50 No-feed controller active This message is active if one of the following
cases applies:
• The grid feed-in control is selected via the
visualization program, whereby the “Local/
to “Local”.
• The grid feed-in control is activated via
hardware contact signal, whereby the “Lo-
cal/Remote” key-operated switch must be
set to “Remote”.
• The grid feed-in control is activated via the
interface, whereby enabling via the inter-
face must be activated and the “Local/
TIM-ID: 0000073985 - 002
to “Remote”.
51 Lube oil refill active As soon as oil replenishment is requested.
This message is also indicated in manual oil
refill mode.
52 Warming up is active As soon as MTU engine management requests
coolant preheating.
144 | Operation | SS180152/04E 2020-06

53 Water temperature control active The water temperature control is enabled
when the engine speed exceeds 50 rpm. As
soon as the engine stops, an adjustable over-
run time is activated for the water cooling con-
trol. The water controller is deactivated once
the overrun time has lapsed.
54 Emergency cooler fan active This signal is active as soon as one of the 8
possible emergency cooler fan levels has been
put into service.
55 Emergency water cooling control active The emergency water cooling control is ena-
bled by request of the auxiliary drives. As soon
as the engine stops, an adjustable overrun
time is activated for the emergency cooler
cooling control. The emergency water cooling
control is deactivated once the overrun time
has lapsed.
56 Air fans active This signal is active as soon as one of the 4
possible fresh-air fans or extractor fans has
been put into service.
57 Room temperature control active The room temperature controller is enabled
with activation of one of the fresh-air fans or
extractor fans. As soon as all fresh-air fans or
extractor fans are switched off, an adjustable
overrun time is activated for the room temper-
ature controller. The room temperature con-
troller is deactivated once the overrun time
has lapsed.
58 Mixture water control active The mixture water controller is enabled once
the rated speed has been reached during the
start procedure. As soon as the engine stops,
an adjustable overrun time is activated for the
mixture water control. The mixture water con-
troller is deactivated once the overrun time
has lapsed.
59 Gas valve 2 for gas type A open Gas valve 2 for gas train A is open.
60 Exhaust air flap open This message is active as soon as the exhaust
flaps are opened. These valves can also be
opened and closed in Manual mode.
TIM-ID: 0000073985 - 002
SS180152/04E 2020-06 | Operation | 145

61 Bypass flap 1 open This message is active as soon as bypass flap
1 is opened.
To this end, the following procedure is carried
out:
First, bypass mode must be activated or deac-
tivated. Bypass mode is activated if one of the
following conditions is fulfilled:
• The heating water temperature exceeds an
adjustable value
• Bypass mode is selected in Manual mode
• Remote bypass mode is selected via digital
input
Bypass flap 2 opens first when bypass mode is
activated. If this flap is open, bypass flap 1 is
closed.
deactivated. If this flap is open, bypass flap 2
is closed.
Bypass flap 1 can also be opened/closed in
Manual mode.
62 Bypass flap 2 open This message is active as soon as bypass flap
2 is opened.
To this end, the following procedure is carried
out:
First, bypass mode must be activated or deac-
tivated. Bypass mode is activated if one of the
following conditions is fulfilled:
• The heating water temperature exceeds an
adjustable value
• Bypass mode is selected in Manual mode
• Remote bypass mode is selected via digital
input
activated. If this flap is open, bypass flap 1 is
closed.
deactivated. If this flap is open, bypass flap 2
is closed.
Bypass flap 2 can also be opened/closed in
Manual mode.
63 Stop command from operator This message is active when a start request is
no longer present. Start request see also sta-
tus signal 13.
64 Protocol – testing plant active This message is active when logging via visual-
ization has been selected.
TIM-ID: 0000073985 - 002
65 Pump emergency cooler active This message is active as soon as the emer-
gency cooler pump has been activated.
66 Lube oil pump active The external lube oil pump is activated when
the refill contact has been tripped. The lube oil
pump can also be activated in Manual mode.
67 Load rejection ready Is active if the load was successfully shed dur-
ing initiation of island operation. The feedback
signal is analyzed via digital input.
146 | Operation | SS180152/04E 2020-06

68 Start demand from timer If a start request was received from the timer
in Automatic mode. Automatic mode must be
activated.
69 Start demand from gas tank (level/pressure) If a start request was received from the gas
tank fill level contact in Automatic mode. Au-
tomatic mode must be activated.
70 Load shedding active Is active if the load is successfully shed during
initiation of island operation and once the load
has been reconnected in sequence after the
generator circuit breaker is closed.
71 Start demand from CH4 proportion If a start request was received from the CH4
controller in Automatic mode.
72 Start demand from feed-in controller If a start request was received from the grid
feed-in controller in Automatic mode.
73 Start demand from heat mode If a start request was received from the heat-
ing mode controller in Automatic mode.
74 Start demand heating water reservoir If a start request was received from the buffer
store analyzer in Automatic mode.
75 Heating operation – temp. lowering active If “reduction” is active during heating mode.
76 Heating operation – release boiler If the boiler is enabled in heating mode.
77 Heating water reservoir is full This message is active if the PT7 temperature
sensor value for the buffer store is greater
than the set limit value.
78 Heating water reservoir is empty This message is active if the PT4 temperature
sensor value for the buffer store is lower than
the set limit value.
79 Heating water reservoir is refilled This message is active as long as the buffer
store is being filled.
80 Heating water reservoir is emptied This message is active as long as the buffer
store is being drained.
81 Machine for remote control available The module is available for the selection of the
external master control unit. The following
conditions must be met:
• Release module
• Automatic mode
• Control via interface
• No active stop signal
82 Release emergency power supply operation The system receives the enable signal from
from remote controller the master control unit to enable initiation of
island operation.
TIM-ID: 0000073985 - 002
83 Short interruption A brief grid failure has occurred. Due to the

brief interruption, either the grid circuit break-
er or the generator circuit breaker is opened
by the EMM or the optional grid protection sta-
tion.
If the grid circuit breaker was disconnected
from the power supply, it will be reverse
synchronized.
If the generator circuit breaker was discon-
nected from the power supply, it will be re-
verse synchronized.
SS180152/04E 2020-06 | Operation | 147

84 Heating water pump 2 on As soon as heating water pump 2 is active.
85 Heating water pump 2 Manual mode Indicates that Manual mode is activated for
heating water pump 2.
86 MMC board heater on The control cabinet heater is activated. The re-
quest is signaled by a hydrostat installed in
the control cabinet.
87 Request pre lubrication active The controller requests oil priming. The lube
oil pump is activated.
88 Circulation pump turbo charger active The turbocharger bypass pump is active. This
is a standard response to failure of the supply
voltage for the auxiliary drives.
89 Cooling water pump 2 on As soon as coolant pump 2 is active.
90 Cooling water pump 2 manual mode Indicates that Manual mode is activated for
coolant pump 2.
91 Enable generator c.b missing (external control If there is no enable signal received from the
system) master control unit for the GCB. The following
conditions must be met:
• The remote control unit must be activated
• A remote start request was received via the
digital input
• There is no enable signal from the master
control unit for the GCB
92 Gastorch is on This message is active when the gas flare has
been activated.
93 Gastorch – manual mode This message is active when Manual mode has
been activated for the gas flare.
94 Release synchronization GCB Conditions for enabling synchronization of the
generator circuit breaker GCB are fulfilled.
95 Biogas active This signal indicates that the biogas line is cur-
rently active.
96 Reserve #
97 Fault acknowledgment The reset button was activated in the control
cabinet door, at the IPC, or via interface.
98 Mixture cooler pump 1 active Indicates that the mixture cooler pump is ac-
tive.
99 Mixture cooler pump 1 manual mode Manual mode for the mixture cooler pump is
active.
100 Warm up phase in island parallel operation ac- A waiting period applies during the warm-up
tive phase in island/standby operation to allow the
TIM-ID: 0000073985 - 002
coolant to reach the required temperature.

During this period power is limited and other
modules have to cover any additional demand
for power.
101 Black start interlock generator breaker in is- The generator circuit breaker is disabled by
land/standby operation other modules/gensets in island/standby op-
eration.
102 Room fans manual mode Manual mode for room fans is active.
148 | Operation | SS180152/04E 2020-06

103 Backup protection active If the generator c.b./contactor cannot be
opened due to a failure which leads to a shut-
down, reverse operation will be activated. The
grid c.b. or CHP transfer switch will be
opened, if available, and this message will be
displayed.
104 Island power supply operation step 1 Emergency generation stage 1 is active when
a grid failure is detected. Emergency genera-
tion mode is initiated.
105 Island power supply operation step 2 A specific action is executed in emergency
generation stage 2 depending on the emergen-
cy generation operating mode.
• Operating mode 1 (MCB isolates supply (no
interruption in the event of grid failure), in-
terruption on grid system recovery (open
GCB) -> close MCB -> synchronize GCB):
The EMM opens the MCB, the GCB is
“closed”. Standby mode was successfully
initiated.
interruption in the event of grid failure), au-
tomatic reverse synchronization on grid
system recovery (synchronize MCB)):
The EMM opens the MCB, the GCB is
“closed”. Standby mode was successfully
initiated.
• Operating mode 3 (interruption in the event
of grid failure (open GCB -> open MCB ->
close GCB) + interruption on grid system re-
covery (open GCB) -> close MCB -> syn-
chronize GCB):
The EMM opens the GCB, the MCB is
“closed”.
close GCB) + automatic reverse synchroni-
zation on grid system recovery (synchronize
MCB)):
The EMM opens the GCB, the MCB is
“closed”.
TIM-ID: 0000073985 - 002
SS180152/04E 2020-06 | Operation | 149

The GCB is “Closed” and the MCB is
“Open”, the grid has settled -> the GCB is
opened.
interruption in the event of grid failure), au-
tomatic reverse synchronization on grid
system recovery (synchronize MCB)):
The GCB is “Closed” and the MCB is
“Open”, the grid has settled -> the MCB is
reverse synchronized. The GCB is opened
when a start request is no longer applied.
chronize GCB):
The MCB is “Open” the GCB is “Open”, load
shedding is activated.
MCB)):
The MCB is “Open” the GCB is “Open”, load
shedding is activated.
TIM-ID: 0000073985 - 002
150 | Operation | SS180152/04E 2020-06

The GCB is “OPEN”, a switching interval
starts.
chronize GCB):
A waiting period applies until successful
load shedding is confirmed whereupon the
GCB is closed.
MCB)):
A waiting period applies until successful
load shedding is confirmed whereupon the
GCB is closed.
The switching phase has lapsed, the MCB is
“OPEN”, the GCB is “OPEN”, the MCB is
closed, the GCB is reverse synchronized if a
start request is made.
chronize GCB):
Standby mode was successfully initiated.
TIM-ID: 0000073985 - 002
MCB)):
Standby mode was successfully initiated.
SS180152/04E 2020-06 | Operation | 151

Island operation is completed.
chronize GCB):
The GCB is “Closed”, the MCB is “Open”,
the grid has settled, the GCB is opened.
MCB)):
The GCB is “Closed”, the MCB is “Open”,
the grid has settled, the MCB is reverse
synchronized. The GCB is opened when a
start request is no longer applied.
of mains failure (open GCB -> open MCB ->
close GCB) + interruption on mains system
recovery (open GCB) -> close MCB -> syn-
chronize GCB):
The GCB was opened, a switching interval is
started, the MCB is closed when the switch-
ing interval has lapsed.
of mains failure (open GCB -> open MCB ->
close GCB) + interruption on mains system
recovery (open GCB) -> close MCB -> syn-
chronize GCB):
Emergency generation mode stops when
the MCB is “closed”. The GCB is reverse
TIM-ID: 0000073985 - 002
synchronized if a start request is made.

112 Island power supply operation step 9 Not assigned at present.
113 Island power supply operation step 10 Not assigned at present.
114 Reserve #
115 Gas mixer water cooler fan active This message is active when the gas mixer wa-
ter cooler fan is running.
116 Gas mixer water cooler fan manual mode Indicates activated manual operation of the
gas mixer water cooler fan.
152 | Operation | SS180152/04E 2020-06

117 Fan emergency cooler manual mode Indicates activated manual operation of the
emergency cooler fan.
118 Heating water pump 1 manual mode Indicates that Manual mode is activated for
heating water pump 1.
119 Cooling water pump 1 manual mode Indicates that Manual mode is activated for
cooling water pump 1.
120 Auxiliary drives manual mode Indicates activated manual operation of the
auxiliary drives.
121 Gas compressor manual mode Indicates activated manual operation of the
gas compressor.
122 Pump emergency cooler manual mode Indicates activated manual operation of the
emergency cooler pump.
123 Lube oil pump manual mode Indicates manual operation of the lube-oil
pump for replenishment.
124 Reserve #
125 Generator de-excitation active Generator de-excitation is activated when:
• Manual EMERGENCY STOP is tripped
• Generator protection is tripped
• Differential protection is tripped
• Ground-fault protection is tripped
126 Diesel: GCB closed “On” feedback from generator circuit breaker
from diesel genset.
127 Generator protection enabled The generator protection monitors for under-
voltage/underfrequency are enabled.
128 Level Lube Oil Min Message from MTU engine management via
CAN bus. Signal contact for auto lube system
(<Min) has responded.
129 Level Lube Oil MinMax Message from MTU engine management via
CAN bus. Signal contact for auto lube system
(MinMax) has responded. Oil must be replen-
ished.
130 Level Lube Oil Max Message from MTU engine management via
CAN bus. Signal contact of auto lube system
(>Max) has responded.
131 Stop Activated Message from MTU engine management via
CAN bus. A Stop command is output to MTU
engine management.
132 Engine running Message from MTU engine management via
CAN bus. Activated when engine speed ex-
ceeds 300 rpm.
TIM-ID: 0000073985 - 002
133 Generator active Message from MTU engine management via

CAN bus. The engine has set the “Request
synchronization” signal.
134 Waste oil solenoid valve is on This message is active when the used oil sole-
noid valve has been activated.
135 Circulation air fan active This message is active when the circulation
fan has been activated.
SS180152/04E 2020-06 | Operation | 153

136 Go / NoGo Message from MTU engine management via
CAN bus. The IC92x ignition system has been
activated. Not used at present.
137 Wait for 0 RPM Message from MTU engine management via
CAN bus. Message from IC92x ignition sys-
tem. Not used at present.
138 Starter ON Message from MTU engine management via
CAN bus. The starter has been activated.
139 Mixture throttle position maximum Message from MTU engine management via
CAN bus. The throttles have reached the maxi-
mum variable.
140 Limitation active Message from MTU engine management via
CAN bus. The engine is operating at its limits,
power may not be increased.
141 Reserve #
142 Reserve #
143 Reserve #
144 Mixture cooler pump 2 active Indicates that mixture cooler pump 2 is active.
145 Mixture cooler pump 2 manual mode Manual mode for mixture cooler pump 2 is ac-
tive.
146 Back synchronization MCB from MCS/external Reverse synchronization of MCB is requested.
control technology or other module active Generator frequency is adjusted to grid fre-
quency and generator voltage is adjusted to
grid voltage.
147 Mains disconnection via MCB from external When the supply is isolated by the MCB the
mains circuit breaker is opened in case of grid
failure when grid parallel operation is active.
148 Waste oil solenoid valve manual mode Indicates activated manual operation of the
used oil solenoid valve.
149 Reserve #
150 Safety shut-off valve close - Manual mode The safety shut-off valve is closed in Manual
mode.
151 Safety shut-off valve opened Safety shut-off valve Open limit position has
been tripped.
152 Safety shut-off valve closed Safety shut-off valve Closed limit position has
been tripped.
153 Safety shut-off manual mode active Safety shut-off valve Manual mode is active.
154 Exhaust turbocharger after lubrication active The engine has shut down the turbocharger is
relubricated with oil: -> cooling of turbocharg-
TIM-ID: 0000073985 - 002
er
154 | Operation | SS180152/04E 2020-06

6.13 Operational monitoring
DANGER
tors.
DANGER
personnel only.
DANGER
WARNING
Gases suitable for engine combustion are combustible/explosive.
• On-site room ventilation should be provided to ensure that escaping residual gas quantities are safely
discharged and that a potentially explosive atmosphere is not created.
• Do not smoke.
WARNING
WARNING
WARNING
Risk of burns!
TIM-ID: 0000065974 - 006
WARNING
Overpressure in the coolant system is released by the pressure relief valve.
Risk of burns due to escaping pressurized coolant!
• Install a coolant blow-off line that safely diverts the coolant (operating company/integrator).
• Assure the correct seating and operation of the coolant blow-off line.
• During engine operation, stay clear of the area around the pressure relief valve.
• Always wear protective gloves and protective goggles/safety mask.
SS180152/04E 2020-06 | Operation | 155

Daily check
Item Action
Engine-generator set / en- Smooth running of engine
gine Check for leaks and damage (bellows, hoses etc.)
Exhaust system Check exhaust pipework for escaping condensate (visual inspection for
leaks)
Check condensate collecting tank after condensate drain (if applicable)
Gas supply / gas system Check for damage (visual inspection)
Controller Check that indicated operating values are within limits:
• Electrical power, battery voltage, lambda sensor voltage (if applicable)
• Lube oil pressure, lube oil level
• Coolant pressure, coolant temperature
• Exhaust temperature
• Heating water supply and return temperature (if applicable)
• Check operation of oil bleed system (if applicable)
Additional daily checks with 60-Hz engine-generator sets:

Item Action
Gearbox Checking bearing temperatures
Check oil pressure, oil level, oil temperature
Check oil filter contamination display
Check for leaks, noises and vibrations
u Enter daily checks in the separate checklist and save it in the log. If required, the checklist can then be sent
to a contact of MTU or handed over to the mechanic on site.
Weekly check
Item Action
Machine room Check temperature
Engine-generator set / en- General visual inspection
gine Check stability of engine speed governor and linkage (if applicable)
Controller Check:
• Operating hours
• Number of starts
Lube oil system Check lube oil consumption / content of fresh-oil tank
Additional weekly checks with 60-Hz engine-generator sets:

Item Action
Gearbox Check gearbox mounting
Check external condition of gearbox (contamination, oil deposits, etc.)
TIM-ID: 0000065974 - 006
Check condition of gear oil (visual check)
u Enter daily checks in the separate checklist and save it in the log. If required, the checklist can then be sent
to a contact of MTU or handed over to the mechanic on site.
156 | Operation | SS180152/04E 2020-06

6.14 Engine-generator set – Shutdown in Manual mode
Preconditions
☑ Generator is not connected to network
☑ Engine-generator set is not in Automatic mode.
☑ Operating instructions for MMC4000 controller available.
DANGER
tors.
DANGER
DANGER
personnel only.
WARNING
WARNING
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.
TIM-ID: 0000071921 - 004
Preparation
Item Action
Engine-generator set Allow to cool down by running idle for approx. 5 minutes.
Shutting down the engine-generator set

Item Action
Controller Actuate Stop pushbutton, see Operating Instructions for MMC4000 control-
ler.
SS180152/04E 2020-06 | Operation | 157

6.15 Emergency shutdown
Preconditions
☑ Engine-generator set running
DANGER
tors.
DANGER
WARNING
Exhaust gas is harmful to health.
Risk of poisoning!
• Repair leaking exhaust pipes prior to starting and operating the engine.
• Do not modify or tamper with the exhaust or emission control system.
• Always start and operate the engine in a well-ventilated area.
• If operating the engine in an enclosed area, properly vent the exhaust to the atmosphere.
WARNING
NOTICE
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to engine-generator set!
• Stop the engine according to the instructions in this manual.
• Initiate emergency stop only in emergency situations.
Emergency shutdown
Item Measure
Emergency stop pushbutton Press pushbutton.
on control cabinet • Engine is stopped
• Signaling (e.g. horn, flashing light) is triggered, see customer controller
documentation.
TIM-ID: 0000065976 - 002
After emergency shutdown

Item Measure
Customer controller Press Alarm acknowledgment pushbutton, see customer controller documen-
tation.
• Audible and visual alarm output stops
158 | Operation | SS180152/04E 2020-06

6.16 After shutdown
Preconditions
☑ Preservation and Represervation Specifications (A001070/..) are available.
After stopping the engine – engine remains ready for operation

Item Measure
Engine/generator controller select operating mode, e.g. MANUAL, AUTOMATIC.
(manufacturer-specific)
After shutdown – Putting engine-generator set out of operation

Item Measure
Engine-generator set Perform lockout/tagout procedure.
Controller Switch off.
Cooling system Drain engine coolant (→ Page 478);
Drain charge-air coolant (→ Page 484)in the following cases:
• freezing temperatures are expected, the genset is to remain out of service
for an extended period and no antifreeze additive has been mixed into the
engine coolant;
• the genset room is not heated;
• coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the room temperature;
• antifreeze concentration is 50 % and room temperature is below -40 °C.
Air inlet and exhaust system If the engine is to remain out of operation for more than 1 week, seal the
engine's air inlet and exhaust outlet.
Engine-generator set Preserve the engine-generator set (→ Preservation and Represervation Speci-
fications) if the engine is to remain out of service for more than 1 month.
TIM-ID: 0000065977 - 002
SS180152/04E 2020-06 | Operation | 159

6.17 Re-starting the engine following an automatic safety
shutdown
NOTICE
Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault
has been identified and eliminated.
Procedure following an automatic safety shutdown

1. Eliminate fault.
2. If the root cause cannot be identified or eliminated, contact Service.
Important
The function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-
ed.
TIM-ID: 0000081383 - 001
160 | Operation | SS180152/04E 2020-06

6.18 Putting the engine-generator set into operation after extended
out-of-service-period
Preconditions
☑ Engine-generator set is stopped and starting disabled.
☑ Engine-generator set is not in automatic mode.
☑ Generator is not connected to mains.
☑ Preservation and Represervation Specifications are available.
DANGER
• Prior to maintenance work, disconnect the engine-generator set from all voltage sources (mains, bat-
teries, other external voltage supplies).
DANGER
tors.
WARNING
Batteries develop explosive gases during charging.
Risk of serious injury from explosion and burning!
• Work in a well-ventilated area.
• Avoid open flames, electrical sparks and ignition sources near the battery.
• Do not smoke.
• Ensure only the negative lead is removed from the battery.
• Ensure correct polarity of battery connections.
WARNING
Batteries contain very caustic acid.
Risk of serious injury from chemical burn!
• Wear protective clothing, gloves and goggles/safety mask.
• If contact with battery acid occurs, flush skin with water, apply baking soda or lime to neutralize the
acid, flush eyes with water and get medical attention immediately.
Additional work following out-of-service periods exceeding 3 months

Item Measure
Engine-generator set Depreserve (→ Preservation and Represervation Specifications).
Engine Bar engine manually (→ Page 444).
Valve drive Standstill ≥ 6 months: Lubricate valve gear (→ Page 461).
TIM-ID: 0000071928 - 004
Lube oil system Check engine oil level (→ Page 470);

Check oil level in oil storage tank (→ Page 470).
Coolant circuit Standstill > 1 year: Change engine coolant (→ Page 477).
Change mixture coolant (→ Page 483).
Check engine coolant level (→ Page 476).
Check mixture coolant level (→ Page 482).
Engine wiring Check plug-in connections (→ Page 488).
Engine management system Check for fault messages.
Starting system Check power supply to electric starter.
SS180152/04E 2020-06 | Operation | 161

Preparations before putting the engine into operation
Item Measure
Engine-generator set room Ensure that the location is free of debris and flammable or combustible ma-
terials.
Engine-generator set Check for contamination and leakage; clean and repair as necessary.
Check that cable connections are properly secured; tighten as required.
Ensure that inlets and outlets, strainers and protective devices are clean and
unobstructed.
Ensure all required fuel and cooling line valves are open, and drain valves are
closed.
Engine Check engine cabling (→ Page 488).
Check plug connections of engine governor.
Charge-air system Check air filter for contamination and damage .
Exhaust system Check for leaks.
Check for missing securing components.
Check heat shield for damage (if applicable).
Exhaust silencers, if applica- Check for leaks.
ble Check for corrosion.
Check rain cap for damage and proper fit.
Lube oil system Check oil level in oil storage tank (→ Page 470).
Cooling system Check engine coolant level (→ Page 476);
Check mixture coolant level (→ Page 482).
Starter batteries Check and clean battery terminals.
Check battery acid level, note battery type.
Check state of battery charge (perform charge test), charge as necessary.
Battery charger Check cabling.
Controller Perform functional check, see Operating Instructions for MMC4000 control-
ler.
Check cabling.
Circuit breaker, if applicable Check function of circuit breaker and trigger mechanisms.
Check terminal lugs and load cabling.
Generator space heater, if Check heating elements cabling.
applicable Leave the heating elements on for between 24 and 48 hours before starting
the engine-generator set if it has been out of operation for a longer period.
Rotating rectifier / main ro- Check diodes.
tor assembly Check cabling of rotating exciter and shaft for damage.
Check stator winding and field wiring F1/F2.
Check insulating coating of main stator and rotor winding.
Check generator tap box for contamination, clean as necessary.
Check generator terminals
Phase rails / insulators Check rail terminal connections and insulators.
Check insulators for loose seating and cracking.
TIM-ID: 0000071928 - 004
Voltage regulator Check measuring and field lines for damage or loose connections.
Check PMG or AREP cabling for damage or loose connections.
Engine governor Check for fault messages.
Putting into operation

Element Measure
Engine-generator set Perform unlocking procedure (→ Page 132).
Engine-generator set room Ensure that room ventilation is operating correctly.
162 | Operation | SS180152/04E 2020-06

Element Measure
Cooling system Warm up coolant with preheater (if applicable).
Controller Set operating mode, e.g. MANUAL, AUTOMATIC MODE, see Operating In-
structions for MMC4000 controller.
Check for outstanding service bulletins and take appropriate measures as
necessary.
TIM-ID: 0000071928 - 004
SS180152/04E 2020-06 | Operation | 163

7 Troubleshooting
This chapter provides information on how to recognize and rectify engine-generator set malfunctions:
• Fault messages on log for genset control, with possible causes and corrective action (→ Page 166).
• Fault messages of the controller including possible causes and corrective action (→ Page 231).
• Engine governor fault messages displayed on the controller including possible causes and corrective ac-
tion (→ Page 393).
Important
This chapter is intended for technical personnel who are qualified and trained to perform maintenance work
on engines and machines. Qualifications for performing these tasks can also be obtained in the training
center at MTU.
Work on the gas system must only be carried out by a specialist gas company.
Work on plant electrical components must only be carried out by specialist personnel with electrotechnical
training.
Corrective action may involve performing any number of work steps. In some cases, reference may also be
made to a separate task within a given step. In this case, complete this task first. Then return to the original
task and continue with the next step.
Contact Service if these troubleshooting activities do not successfully eliminate the fault, or if the same mal-
function occurs frequently.
TIM-ID: 0000080397 - 004
164 | Troubleshooting | SS180152/04E 2020-06

7.2 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 been undershot
LOLO Low Low: The second limit value has been undershot
MG Message: General message
SE System Error: Warning due to node failure on the default field bus
PB Pushbutton: Status indication due to activation of certain control keys.
AKR Anti Knock Control GET
Important information about fault messages from the Engine Control Unit /
Engine Monitoring Unit
Fault messages from the Engine Control Unit are shown in the fault code list (→ Page 393).
Information pertaining to alarm colors and automatic engine shutdown in the fault code list refer to the (de-
fault) factory settings of the Engine Control Unit on delivery. Different system responses may be possible due
to changes to the engine-generator set controller made by the OEM (see documentation of the genset manu-
facturer).
Appropriate qualifications/training at MTU are a requirement for performing troubleshooting activities.
Contact Service if troubleshooting according to the fault code list proves unsuccessful.
Recommended action in case of alarm

TIM-ID: 0000027852 - 005
Yellow alarm:
The engine can still be operated temporarily providing that automatic engine shutdown to protect the engine
has not been configured or tripped. Contact Service immediately/start fault rectification.
Red alarm:
Caution, the engine is operating at its limits. Shut down manually without further delay if the engine does not
shut itself down immediately after a red alarm is signaled.
Procedure following an automatic safety shutdown (→ Page 160)
SS180152/04E 2020-06 | Troubleshooting | 165

7.3 Fault messages in genset control system log
Possible engine responses to yellow alarm:
Warning, power limitation/reduction, speed limitation, engine stop
Possible engine responses to red alarm:

Engine stop, power limitation/reduction, speed limitation, warning
112222 – HI T-Exhaust Mean

Yellow alarm. Initiated by EMU.
Cause Corrective action
Weighted average of all cylinder 1. Check emission values (→ Page 538).
exhaust gas temperatures is too 2. Check ignition timing (→ Page 457).
high. 3. Check valve drive (exhaust valves do not close).
112223 – HIHI T-Exhaust Mean

Red alarm. Initiated by EMU.
Weighted average of all cylinder 1. Check emission values (→ Page 538).
exhaust gas temperatures is too 2. Check ignition timing (→ Page 457).
high. 3. Check valve drive (exhaust valves do not close).
112301 – HI T-Exhaust A1
Exhaust gas temperature of this 1. Check emission values (→ Page 538).
cylinder is too high in comparison 2. Check ignition timing (→ Page 457).
with weighted average. 3. Check valve drive (exhaust valves do not close).
TIM-ID: 0000038611 - 007

TIM-ID: 0000038611 - 007


Yellow alarm.
112311 – HI T-Exhaust B1
TIM-ID: 0000038611 - 007



112401 – LO T-Exhaust A1
TIM-ID: 0000038611 - 007

Exhaust gas temperature of this 1. Check igniter.
cylinder is too low in comparison 2. Check emission values (→ Page 538).
with weighted average. 3. Check ignition timing (→ Page 457).
4. Check valve drive.
5. Check wiring on the ignition rail/ignition coil for thermal and
mechanical damage.

mechanical damage.
mechanical damage.
mechanical damage.
mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.
mechanical damage.
mechanical damage.
mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.
112411 – LO T-Exhaust B1
mechanical damage.
mechanical damage.
mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.
mechanical damage.
mechanical damage.
mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.
mechanical damage.

mechanical damage.
112501 – HIHI T-Exhaust A1


TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007



112511 – HIHI T-Exhaust B1




TIM-ID: 0000038611 - 007



Exhaust gas temperature of this 1. Check emission values(→ Page 538).




TIM-ID: 0000038611 - 007


112601 – LOLO T-Exhaust A1
mechanical damage.

mechanical damage.

mechanical damage.

mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.

cylinder is too low in comparison 2. Check emission values(→ Page 538).
mechanical damage.

mechanical damage.

mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.

4. Check valve drive (→ Page 457).
mechanical damage.
112611 – LOLO T-Exhaust B1

mechanical damage.

mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.

mechanical damage.

mechanical damage.

mechanical damage.
TIM-ID: 0000038611 - 007

mechanical damage.

mechanical damage.

mechanical damage.

mechanical damage.
TIM-ID: 0000038611 - 007
112701 – HIHI T-Exhaust A1 (abs)

cylinder is too high. 2. Check ignition timing (→ Page 457).
3. Check valve drive (exhaust valves do not close).


cylinder is too high. 2. Check ignition timing(→ Page 457).




TIM-ID: 0000038611 - 007




Exhaust gas temperature of this 1. Check emission values(→ Page 538).
112711 – HIHI T-Exhaust B1 (abs)



TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007


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

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 488).
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 488).
113603 – AL Gas Valve feedback (internal)

TIM-ID: 0000038611 - 007
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 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

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 488).
for anti-knock control. 2. Check sensor B 1.3, replace as necessary (→ Page 74).
1.4510.192 – Knock Sensor Error A1

TIM-ID: 0000038611 - 007
No signal from this knock sensor. 1. Check cabling (→ Page 488).

2. Check sensor (tightening torque, damage), replace as necessary
(→ Page 74).

(→ Page 74).

(→ Page 74).

(→ Page 74).

(→ Page 74).

(→ Page 74).

TIM-ID: 0000038611 - 007

(→ Page 74).

(→ Page 74).

(→ Page 74).

(→ Page 74).
1.4510.202 – Knock Sensor Error B1

(→ Page 74).

(→ Page 74).

TIM-ID: 0000038611 - 007

(→ Page 74).

(→ Page 74).

(→ Page 74).

(→ Page 74).

(→ Page 74).

(→ Page 74).

TIM-ID: 0000038611 - 007

(→ Page 74).

(→ Page 74).
1.4520.232 – Error Missing Ring Gear Signal

Red alarm. Initiated by IC922.
Crankshaft speed signal 182 teeth u Check sensor B13.2, check sensor clearance and cabling, replace
is missing. as necessary (→ Page 74) (→ Page 488).
1.4520.233 – Error Missing Reset Signal

Reset signal from crankshaft is u Check sensor B75, check sensor clearance and cabling, replace as
missing. necessary (→ Page 74) (→ Page 488).
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 74) (→ Page 488).
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 74).
1.4520.236 – Unknown Engine Appl. Code

Ignition setting is not correct. u Check settings at ignition system.
TIM-ID: 0000038611 - 007
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.
1.4520.240 – Unknown Timing or Energy Level

No global ignition timing and u Check cabling and setting (→ Page 488).
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 488).
TIM-ID: 0000038611 - 007
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 488).
discharged. 2. Check ignition coils.






TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007






1.4520.270 – Warn. Missing Ring Gear Signal

Crankshaft speed signal 182 teeth u Sensor B 13.3, check sensor, sensor gap and cabling, replace as
is missing. necessary (→ Page 74) (→ Page 488).
TIM-ID: 0000038611 - 007
1.4520.271 – Warning Missing Reset Signal

Reset signal from crankshaft is u Sensor B 75, check sensor, sensor gap and cabling, replace as
missing. necessary (→ Page 74) (→ Page 488).

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 74) (→ Page 488).
1.4520.273 – SCR Fault Odd

2. Check cabling to ignition coil (→ Page 488).
1.4520.274 – SCR Fault Even

2. Check cabling to ignition coil (→ Page 488).
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.
TIM-ID: 0000038611 - 007
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.
3. Check igniters.
1.4520.522 – MIC5 Stat W: invalid coil data

The ignition 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

TIM-ID: 0000038611 - 007
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.
3. Replace ignition control unit.
1.4520.529 – MIC5 Stat Trigger supply volt. fail

Malfunction in the auxiliary supply 1. Check wiring to sensor B1.2 (→ Page 488).
voltage for the pulse sensor. 2. Check B1.2 sensor (→ Page 74).
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 488).
1.4520.541 – MIC5 E1 Overspeed

TIM-ID: 0000038611 - 007

The overspeed limit was reached. 1. Check Engine Control Unit settings.
2. Check the speed sensors of the ignition system (→ Page 74).

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

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.
TIM-ID: 0000038611 - 007
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.
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 74) (→ Page 488)
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 74) (→ Page 488)
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 74) (→ Page 488)
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 74) (→ Page 488)
1.4520.554 – MIC5 E1 Tr1 wrong polarity

TIM-ID: 0000038611 - 007

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 74) (→ Page 488)

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
pulse sensor 1 (B1.2). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
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 74) (→ Page 488)
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 74) (→ Page 488)
1.4520.559 – MIC5 E1 Tr1 index mark not detected

pulse sensor 1 (B1.2) in wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
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
TIM-ID: 0000038611 - 007
(B1.2) detected too early or faulty. wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
1.4520.561 – MIC5 E1 Tr1 index to late / missing

(B1.2) detected too late or wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
missing.

1.4520.570 – MIC5 IPE Primary Open Cylinder 1
Disruption in primary circuit of 1. Check cabling to ignition coil (→ Page 488).
cylinder 1 in ignition sequence. 2. Check ignition coil.





TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007
1.4520.590 – MIC5 IPE Prim Short Circuit Cyl 1

Short circuit in primary circuit of 1. Check cabling to ignition coil (→ Page 488).






TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007






1.4520.610 – MIC5 ISE Secondary Open Cylinder 1

Disruption in secondary circuit of 1. Check ignition lead, connector and igniter.
TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007







TIM-ID: 0000038611 - 007





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 - 007







TIM-ID: 0000038611 - 007

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

sequence.

sequence.

sequence.

sequence.

sequence.

TIM-ID: 0000038611 - 007

sequence.

sequence.

sequence.

sequence.

sequence.

from pulse sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

TIM-ID: 0000038611 - 007

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 74) (→ Page 488)

(B75). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

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 74) (→ Page 488)

pulse sensor 2 (B75). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

2 (B75) is missing. wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
TIM-ID: 0000038611 - 007

sensor 2 (B75) detected. wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

pulse sensor 2 (B75) in operation. wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

(B75) detected too early or faulty. wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

(B75) detected too late or wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
missing.

from pulse sensor 3 (B13.2). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

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 74) (→ Page 488)

TIM-ID: 0000038611 - 007
(B13.2). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

sensor 3 (B13.2). wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

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 74) (→ Page 488)

sensor 3 (B13.2) detected. wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)

pulse sensor 3 (B13.2) in wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
TIM-ID: 0000038611 - 007
operation.

(B13.2) detected too early or wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
faulty.

(B13.2) detected too late or wheel. Replace sensor as necessary. (→ Page 74) (→ Page 488)
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 flap setting.
correct.
1.4530.011 – PWM Input Low Duty Cycle Error

TIM-ID: 0000038611 - 007

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 488).
1.4530.015 – Input Supply Voltage Low Error

minimum limit value. 2. Check cabling (→ Page 488).
1.4530.016 – Electronics Temperature High Error

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

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

TIM-ID: 0000038611 - 007

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 488).
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 - 007
1.4540.011 – Flow Not Reached

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
Red alarm. Initiated by TecJet.
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 - 007
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 - 007
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 488).
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 - 007
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 488).
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 488).
TIM-ID: 0000038611 - 007
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 488).
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 - 007
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 488).
TIM-ID: 0000038611 - 007
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 of cylinder bank A.
Hardware not ready for operation. 1. Restart throttle.
2. Replace throttle.
1.4550.032 – A - Stop commanded (Run/Stop)

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

maximum or minimum limit value. 2. Check cabling (→ Page 488).
1.4550.034 – A - Position Error

feedback signal do not match . 2. Restart throttle.
TIM-ID: 0000038611 - 007
1.4550.035 – A - Temperature Sensor Fault

Red alarm. Initiated by ProAct of cylinder bank A.
Internal temperature sensor 1. Restart throttle.
faulty. 2. Replace throttle.

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

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

Position setpoint is missing or out 1. Check throttle settings.
of range. 2. Check cabling (→ Page 488).
1.4550.039 – A - Demand Tracking Fault

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

1.4550.041 – A - PWM Position Demand Failed

1.4550.042 – A - CAN Position Demand Failed

TIM-ID: 0000038611 - 007

Position setpoint not received or 1. Check throttle settings.

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

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

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

Yellow alarm. Initiated by throttle of cylinder bank B.
1.4550.133 – B - Input (Supply) Voltage Fault

maximum or minimum limit value. 2. Check cabling (→ Page 488).
1.4550.134 – B - Position Error

feedback signal do not match . 2. Restart throttle.
TIM-ID: 0000038611 - 007
1.4550.135 – B - Temperature Sensor Fault

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

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

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

Position setpoint is missing or out 1. Check throttle settings.
of range. 2. Check cabling (→ Page 488).
1.4550.139 – B - Demand Tracking Fault

1.4550.140 – B - Analog Position Demand Failed

1.4550.141 – B - PWM Position Demand Failed

1.4550.142 – B - CAN Position Demand Failed

TIM-ID: 0000038611 - 007

Position setpoint not received or 1. Check throttle settings.

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

“Stop” input signal received via u Check throttle settings.
CAN bus.
TIM-ID: 0000038611 - 007

7.4 MMC controller – Fault messages
No. Designation Description Enable Fault rectification
1 Message Emergency This message is a This message is active Eliminate all active
stop group signal compris- with each occurring faults coded with
ing all other “emergen- fault coded with "Emer- "Emergency stop" as
cy stop signals”. When gency stop" as reac- reaction -> This must
this fault signal is acti- tion, or if the "ma- be done first to be able
vated, the “machine” chine" or "manual to acknowledge this
safety circuit is trip- emergency stop" safe- fault signal via the
ped, and the machine ty circuit was tripped. manual "Reset" button.
is immediately shut Check the "machine"
down. The safety cir- or "manual emergency
cuit can only be ac- stop" safety circuit
knowledged by press- (possibly broken wire
ing the “Reset” button or open circuit) then
(control cabinet door). acknowledge using the
manual "Reset" button.
2 Message Stop This message is a This message is active Eliminate all active
group signal compris- with each occurring faults coded with
ing all other “stop sig- fault coded with “Stop” “Stop” as reaction and
nals”. The machine is as reaction. not as “auto acknowl-
shut down. edge”. With active
faults coded with
“Stop” as reaction and
“auto acknowledge”,
this message is auto
acknowledged when
the corresponding con-
ditions exist.
3 Group Message Alarm This message is a This message is active Eliminate all active
group signal of all oth- with each occurring faults coded with
er “alarm signals”. The fault coded with “alarm” as reaction
machine will not be “alarm” as reaction. and not as “auto ac-
shut down. knowledge”. With ac-
tive faults coded with
“alarm” as reaction
and as “auto acknowl-
edge”, this message is
auto acknowledged
when the correspond-
ing conditions exist.
4 Reserve # # #
TIM-ID: 0000073956 - 007

5 Manual emergency Activation of the man- The manual emergen- Unlock the manual
stop – safety circuit ual emergency-stop cy-stop button in the emergency-stop but-
tripped button is detected with control cabinet door tons(s) and acknowl-
this fault. If this is the was pressed, or acti- edge using the manual
case, the safety relay vated externally at the “Reset” button. Should
of the “manual emer- customer's site (if it not be possible to
gency stop” safety cir- available). subsequently acknowl-
cuit is released and edge the safety circuit,
sends a low signal to a wire may be broken
the controller. The ma- within the circuit.
chine is immediately
shut down. The safety
circuit can only be ac-
knowledged by press-
ing the “Reset” button
(control cabinet door).
6 Machine Emergency If a machine safety cri- A machine safety crite- • Fix tripped machine
stop – safety circuit terion trips (e.g. safety rion was tripped, if: safety criterion (see
tripped temperature limiter), • The safety pressure detailed message in
the “machine” safety limiters min. for IPC) and acknowl-
circuit will be immedi- coolant or mixture edge via manual
ately tripped and a low coolant have tripped “Reset” button.
signal sent to the con- or • Eliminate all active
troller. The machine is • other optional limit- faults coded with
immediately shut ers / monitoring "Emergency stop"
down. A detailed mes- systems were trip- as reaction -> This
sage also indicates ped within the safe- must be done first
which criterion was ty circuit to be able to ac-
tripped. The auxiliary knowledge this fault
drives continue to run. signal via the man-
The safety circuit can ual "Reset" button.
only be acknowledged • Check “machine”
by pressing the “Re- safety circuit for
set” button (control possible broken
cabinet door). wire.
• If no detailed mes-
sage is indicated on
the IPC, there may
be no feedback
from the tripped lim-
iter, or a broken
wire may be indicat-
ed.
TIM-ID: 0000073956 - 007

7 Coolant pump 1 failure This fault indicates This message is active • Coolant pump mo-
whether there is a if the motor protection tor protection
coolant pump fault. If switch has been trip- switch defective
there is a fault, a high ped, or if the coolant • Check motor pro-
signal is sent to the pump motor was not tection switch-soft
controller from the activated following ac- starter for "Coolant
coolant pump motor tivation of start phase pump on" for incor-
protection switch. 1. rect setting/opera-
tion
• Check coolant
pump connection
(coolant pump is
possibly only run-
ning on 2 phases)
8 Automatic circuit- This group signal is A low signal is used to • Switch on circuit
breaker 400 VAC for sent if an automatic indicate tripping of a breaker or motor
auxiliary drives panel circuit-breaker or mo- circuit breaker or mo- protection switch
tripped tor protection switch tor protection switch • Pinpoint the cause if
for 400 VAC in the aux- it has tripped during
iliary drives panel trips. operation (short cir-
cuit, overcurrent....)
breaker 230 VAC for sent if an automatic indicate tripping of a breaker or motor
auxiliary drives panel circuit-breaker or mo- circuit breaker or mo- protection switch
tripped tor protection switch tor protection switch • Pinpoint the cause if
for 230 VAC in the aux- it has tripped during
iliary drives panel trips. operation (short cir-
10 Mixture coolant tem- This fault is activated if This temperature ex- Check water system in-
perature at inlet < limit this temperature exceeds a limit value cluding water tempera-
value ceeds the set limit val- ture control
ue. This is used to sig-
nal alarms.
11 Status X20 – module If a digital or analog in- Monitoring is always • Switch off supply
faulty put/output module is active voltage to the RPS
not functioning cor- and X2X link, then
rectly or was not cor- reset circuit break-
rectly initialized, this er.
message does not be- • A flashing green “r”
come active. indicates modules
which are not func-
tioning properly.
Check that the mod-
ule concerned is
TIM-ID: 0000073956 - 007
properly connected.
Replace module if
necessary; the
equipment must be
de-energized prior
to replacement.
12 Heating water temper- This fault is activated if This temperature ex- Check water system in-
ature at inlet > limit this temperature exceeds a limit value cluding water tempera-
value 1 ceeds the set limit val- ture control
nal alarms.

ature at inlet > limit this temperature exceeds a limit value cluding water tempera-
ue. The engine is im-
mediately stopped.
14 Heating water inlet With an AT4222 mod- In case of wire break/ • Check sensor
temperature (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
ware) or 3-wire), the follow- AT4222 module. adapter module
ing values occur: wire
break/short circuit: -
3276.7 or 3274.7. The
engine is immediately
stopped.
15 Mixture coolant tem- This fault is activated if This temperature ex- Check mixture coolant
perature at inlet > limit this temperature exceeds a limit value system including mix-
value 1 ceeds the set limit val- ture coolant tempera-
ue. This is used to sig- ture control
nal alarms.
perature at inlet > limit this temperature exceeds a limit value system including mix-
value 2 ceeds the set limit val- ture coolant tempera-
ue. The engine is im- ture control
mediately stopped.
17 Mixture coolant inlet With an AT4222 mod- In case of wire break/ • Check sensor
temperature (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.
ature at outlet > limit this temperature exceeds a limit value cluding water tempera-
nal alarms.
ature at outlet > limit this temperature exceeds a limit value cluding water tempera-
ue. The engine is im-
mediately stopped.
20 Heating water temper- With an AT4222 mod- In case of wire break/ • Check sensor
ature at outlet (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
TIM-ID: 0000073956 - 007

3276.7 or 3274.7. The
stopped.

breaker 400 VAC mod- sent if an automatic indicate tripping of a breaker or motor
ule control tripped circuit-breaker or mo- circuit breaker or mo- protection switch
tor protection switch tor protection switch • Pinpoint the cause if
for 400 VAC in the it has tripped during
module control trips. operation (short cir-
breaker 230 VAC mod- sent if an automatic indicate tripping of a breaker or motor
ule control tripped circuit-breaker or mo- circuit breaker or mo- protection switch
tor protection switch tor protection switch • Pinpoint the cause if
for 230 VAC in the it has tripped during
module control trips. operation (short cir-
23 Automatic circuit- This group signal is A low signal is used to • Switch on automatic
breaker 24 VDC / 24 sent if an automatic indicate tripping of a circuit-breaker
VAC module control circuit-breaker or mo- circuit breaker • Pinpoint the cause if
tripped tor protection switch it has tripped during
for 24 VDC / 24 VAC operation (short cir-
in the module control cuit, overcurrent....)
trips.
24 Circuit breaker tripped This group signal is A low signal is used to • Switch on circuit
(MIP) sent if a circuit breaker indicate tripping of a breaker or motor
or motor protection circuit breaker or mo- protection switch
switch trips. tor protection switch • Pinpoint the cause if
it has tripped during
operation (short cir-
25 Mixture coolant tem- With an AT4222 mod- In case of wire break/ • Check sensor
perature after cooler ule (4*PT100/1000, 2 short circuit or faulty • Check controller
(hardware) or 3-wire), the follow- AT4222 module. adapter module
3276.7 or 3274.7. The
stopped.
26 Remote machine emer- A high signal is sent to The sensor for external • Check sensor set-
gency stop 1 the controller if the machine emergency ting
sensor of the external stop has tripped. • Sensor defective
machine emergency
stop is tripped. The en-
gine stops immediate-
ly.
27 Engine coolant, insuffi- A low signal is sent to The sensor for insuffi- • Check water system
TIM-ID: 0000073956 - 007
cient water the controller if the cient water in the en- • Check sensor set-
sensor for insufficient gine coolant has been ting
water in the engine tripped. • Sensor wire break
coolant is tripped. The • Sensor defective
engine stops immedi-
ately.

28 Mixture coolant insuffi- A low signal is sent to The sensor for mixture • Check water system
cient water the controller if the coolant deficiency has • Check sensor set-
sensor for insufficient been tripped. ting
water in the mixture • Sensor wire break
coolant is tripped. The • Sensor defective
ately.
29 Engine coolant - safety If this limiter responds, The engine coolant SPL • Check water system
pressure limiter min a high signal is sent to min has been tripped. • Check limiter set-
(SPL min) the controller and the ting
“machine” safety cir- • Defective limiter
cuit is tripped. The en-
ly.
30 Mixture coolant - safe- If this limiter responds, The mixture coolant • Check water system
ty pressure limiter min a high signal is sent to SPL min has been trip- • Check limiter set-
(SPL min) the controller and the ped. ting
ly.
31 Gas pressure > max. This message is issued This fault message is • Check gas supply
(gas line A) if the gas pressure active when gas type A (shut-off devices,
max. switch for gas is selected (active), or etc.)!
line A (located on gas in case of dual gas op- • Check gas pressure
line) is tripped. If this eration with one gas max. switch (cabling
switch responds, a line; also with gas type for possible broken
high signal is sent to B (only one gas line is wire)
the controller and the available), and the gas • With biogas, check
“machine” safety cir- pressure max. switch the gas compressor
cuit is tripped. The en- has tripped. • Check setting of gas
gine stops immediate- pressure switch
ly.
32 Gas pressure < Min. This message is issued • This fault message • Check gas supply
(gas line A) if the gas pressure is active when gas (shut-off devices,
min. switch for gas line type A is selected etc.)!
A (located on gas line) (active), or in case • Check gas pressure
is tripped. If this switch of dual gas opera- min. switch (cabling
responds, a high signal tion with one gas for possible broken
is sent to the controller line; also with gas wire)
and the “machine” type B (only one gas • With biogas, check
safety circuit is trip- line is available), the gas compressor;
ped. The engine stops and the gas pres- the on-delay or off-
immediately. sure min. switch has delay of the gas
TIM-ID: 0000073956 - 007
tripped. compressor may

• If this gas line is need to be adjusted
currently being op- • Check setting of gas
erated with biogas, pressure switch
this message will
only be active from
start phase 2.

33 Gas pressure < Min. This message is issued • The fault message is • Check gas supply
(gas line B) if the gas pressure active if, in dual-gas (shut-off devices,
min. switch for gas line operation, gas type etc.)!
A (located on gas line) B is selected (ac- • Check gas pressure
is tripped. If this switch tive) and the gas min. switch (cabling
responds, a high signal pressure min. for possible broken
is sent to the controller switch has tripped wire)
and the “machine” • If this gas line is • With biogas, check
safety circuit is trip- currently being op- the gas compressor;
ped. The engine stops erated with biogas, the on-delay or off-
immediately. this message will delay of the gas
only be active from compressor may
start phase 2. need to be adjusted
• Check setting of gas
pressure switch
34 Gas leak-tightness If, after activation of This fault message is • Check whether sup-
check failure (gas line the gas test (gas type active when gas type A ply voltage is availa-
A) A), the "OK" message is selected (active), or ble for the “leak
does not appear within in case of dual gas op- test”
a certain time. An eration with one gas • Check gas supply
alarm message without line; also with gas type • Check cabling of
automatic acknowledg- B (only one gas line is feedback signal con-
ment is issued. available), and no feed- tact for possible
back that the gas leak- broken wire
tightness test was OK • Possibly defective
is received. gas leak tester
35 Gas leak-tightness If, after activation of This fault message is • Check gas supply
check faulty (gas line the gas test (gas type active if, in dual-gas • Check whether sup-
B) B), the "OK" message operation, gas type B is ply voltage is availa-
does not appear within selected (active) and ble for the “leak
a certain time. An no feedback that gas test”
alarm message without leak-tightness was OK • Check cabling of
automatic acknowledg- is received. feedback signal con-
ment is issued. tact for possible
broken wire
• Possibly defective
gas leak tester
perature at outlet > this temperature exceeds a limit value. system including mix-
limit value 1 ceeds the set limit val- ture coolant tempera-
ue. This is used to sig- ture control
nal alarms.
perature at outlet > this temperature exceeds a limit value. system including mix-
TIM-ID: 0000073956 - 007
limit value 2 ceeds the set limit val- ture coolant tempera-
ue. The engine is im- ture control
mediately stopped.
38 Mixture coolant tem- With an AT4222 mod- In case of wire break/ • Check sensor
perature at outlet ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.

39 Cabinet temperature This fault is activated if Control cabinet tem- • Check control cabi-
EIP > limit 1 the control cabinet perature exceeds limit net fans for correct
temperature exceeds value functioning
the set limit value. This • Clean air outlet filter
is used to signal mats
alarms. • Ambient tempera-
ture is too high for
the control cabinet
EIP > limit 2 the control cabinet perature exceeds limit net fans for correct
temperature exceeds value functioning
the set limit value. The • Clean air outlet filter
engine is stopped in a mats
controlled manner. • Ambient tempera-
the control cabinet
41 Cabinet temperature With an AT4222 mod- In case of wire break/ • Check sensor
EIP (hardware failure) ule (4*PT100/1000, 2 short circuit or faulty • Check controller
or 3-wire), the follow- AT4222 module. adapter module
3276.7 or 3274.7.
module control > limit the control cabinet perature exceeds limit net fans for correct
1 temperature exceeds value functioning
the set limit value. This • Clean air outlet filter
is used to signal mats
alarms. • Ambient tempera-
the control cabinet
module control > limit the control cabinet perature exceeds limit net fans for correct
2 temperature exceeds value functioning
the set limit value. The • Clean air outlet filter
engine is stopped in a mats
controlled manner. • Ambient tempera-
the control cabinet
44 Cabinet temperature With an AT4222 mod- In case of wire break/ • Check sensor
sensor module control ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7.
TIM-ID: 0000073956 - 007

45 Coolant pump 2 failure This fault indicates This message is active • Coolant pump 2 mo-
whether there is a if the motor protection tor protection
coolant 2 pump fault. If switch has been trip- switch defective
there is a fault, a high ped, or if the coolant • Incorrect setting of
signal is sent to the pump 2 motor was not motor protection
controller from the activated following ac- switch
coolant pump motor tivation of start phase • Check soft starter
protection switch. 1. for “coolant pump
on” for correct func-
tioning
• Check coolant
pump connection
(coolant pump is
possibly only run-
ning on 2 phases)
46 Oil-leakage engine A low signal is sent to The sensor for oil leak- Check oil system for
base frame the controller if the oil age monitoring in the leaks
leakage monitor for the engine drip pan has
engine drip pan is trip- been tripped.
ped.
47 Engine cooling circuit < This alarm message is The temperature re- Check engine cooling
limit value alarm activated if this tem- mains below a limit val- circuit including engine
perature remains be- ue - the generator cir- coolant temperature
low the set limit value. cuit breaker is closed. control
48 Engine cooling circuit < This alarm message is The temperature re- Check engine cooling
limit value shutdown activated if this tem- mains below a limit val- circuit including engine
perature remains be- ue - the generator cir- coolant temperature
low the set limit value. cuit breaker is closed. control
The engine is stopped
in a controlled manner.
49 Lube oil refill: oil bleed This signal is used for Should the lube oil re- Check lube oil system
system faulty monitoring the lube oil fill system not be acti-
refill system. Should vated within a fixed
the lube oil refill sys- time (default: 8 hours).
tem not be activated Engine must be in op-
within a fixed time (de- eration.
fault: 8 hours), this
message is activated.
50 Voltage monitoring of The phase monitoring The phase sequence / • Check whether sup-
auxiliary drives MIP system is used for phase failure monitor- ply voltage is availa-
monitoring the supply ing system or the re- ble for auxiliary
voltage of the auxiliary verse voltage detection drives
drives. This message is system (via unbalance • Check supply volt-
active should the analysis) of the phase age of auxiliary
TIM-ID: 0000073956 - 007
phase sequence / monitoring system has drives for correct

phase failure monitor- been tripped. phase sequence and
ing system or the re- phase failure
verse voltage detection • Broken wire of sig-
system (via unbalance nal contact connec-
analysis) of the phase tion between con-
monitoring system be troller and phase
tripped. monitoring system

51 Remote machine emer- A high signal is sent to The sensor of the ex- • Check sensor set-
gency stop 2 the controller if the ternal machine emer- ting
sensor of the external gency stop has tripped. • Sensor defective
machine emergency
stop is tripped. The en-
ly.
52 Heating water - safety A high signal is sent to The sensor of heating • Check heating water
pressure limiter min the controller if the water - safety pressure system
(SPL min.) sensor of heating wa- limiter min has tripped. • Check sensor set-
ter safety pressure lim- ting
iter min. is tripped. The • Sensor defective
ately.
53 Generator winding This fault is activated if This temperature ex- Check generator
temperature U1 > limit this temperature exceeds a limit value
value 1 ceeds the set limit val-
nal alarms.
temperature U1 > limit this temperature exceeds a limit value
ue. The engine is stop-
ped in a controlled
manner.
55 Generator winding With an AT4222 mod- In case of wire break/ • Check sensor
temperature U1 (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
engine is stopped im-
mediately.
temperature V1 > limit this temperature exceeds a limit value
nal alarms.
temperature V1 > limit this temperature exceeds a limit value
ped in a controlled
manner.
TIM-ID: 0000073956 - 007
temperature V1 (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.

temperature W1 > limit this temperature exceeds a limit value
nal alarms.
temperature W1 > limit this temperature exceeds a limit value
ped in a controlled
manner.
temperature W1 (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.
breaker 24 DC for aux- sent if an automatic indicate tripping of a breaker or motor
iliary drives panel trip- circuit-breaker or mo- circuit breaker or mo- protection switch
ped tor protection switch tor protection switch • Pinpoint the cause if
for 24VDC in the auxili- it has tripped during
ary drives panel trips. operation (short cir-
63 Cooling unit fault (aux- The cooler in the con- • Cooler available op- Check cooler
iliary drives panel) trol cabinet indicates a tion selected in op-
fault. This is used to tions list
signal alarms. • The signal contact
of the cooling unit in
the control cabinet
indicates a fault
64 Gas flare faulty The feedback signal Always • Check wiring of gas
(digital input) of the flare
gas flare signals a • Check function of
"fault" gas flare
65 Engine stop This message is only This fault message is Eliminate the fault at
activated when the always enabled. the engine, see de-
MTU engine manage- scription for MTU en-
ment signal an engine gine management
stop to the MIP. This
message results in an
immediate engine
TIM-ID: 0000073956 - 007
stop.
66 Red alarm, engine This message is acti- This fault message is Eliminate the fault at
vated when the MTU always enabled. the engine, see de-
engine management scription for MTU en-
signals a red alarm to gine management
the MIP. This message
results in an engine
stop.

67 Yellow alarm, engine This message is acti- This fault message is Eliminate the fault at
vated when the MTU always enabled. the engine, see de-
engine management scription for MTU en-
signals a yellow alarm gine management
to the MIP. The engine
is not stopped.
68 Generator underspeed If, in mains failure op- Mains failure operation Check PV 2.1060.313
eration, the engine is active and the gener-
control system re- ator circuit breaker is
quests opening of the on.
GCB.
69 Mains protection - V Monitoring of the line Always released. • Wait until the mains
>>> voltage is imperative if failure has been re-
the generator is utility- solved
connected. In case of a • If there is no actual
power outage mains failure, it may
(e.g. brief interruption be due to one of the
of service), the utility- following reasons:
connected generator – Open circuit in
must be automatically line voltage ca-
disconnected from the bling to the EMM
mains. The mains line- – Check setting of
to-line voltages are line voltage moni-
monitored for exceed- toring in EMM
ing of the set response
value. If the response
value is exceeded the
system will be discon-
nected from the mains.
All of the mains protec-
tion signals must only
be parameterized as an
alarm. The remaining
reactions (e.g. initiate
mains backup mode,
open generator circuit
breaker, ...) are linked
to the program de-
pending on the op-
tions. Typically, it is
faster to configure this
value than the mains
protection - V > fault.
TIM-ID: 0000073956 - 007

70 Mains protection - U Monitoring of the line Always released. • Wait until the mains
<<< voltage is imperative if failure has been re-
monitored for dropping toring in EMM
below the set response
value is not reached,
the system will be dis-
connected from the
mains. All of the mains
protection signals
must only be parame-
terized as an alarm.
The remaining reac-
tions (e.g. initiate
mains backup mode,
to the program de-
pending on the op-
protection - U < fault.
71 Bearing temperature This fault is activated if This temperature ex- Check generator
on driving end > limit this temperature exceeds a limit value
nal alarms.
on driving end > limit this temperature exceeds a limit value
ped in a controlled
manner.
73 Bearing temperature With an AT4222 mod- In case of wire break/ • Check sensor
TIM-ID: 0000073956 - 007
on driving end (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.

pressure limiter max. the controller if the water - safety pressure system
(SPL max 1) sensor of heating wa- limiter max 1 has trip- • Check sensor set-
ter - safety pressure ped. ting
limiter max. 1 is trip- • Sensor defective
ped. The engine stops
immediately.
temperature limiter the controller if the water - safety tempera- system
max. (STL max 1) sensor of heating wa- ture limiter max 1 has • Check sensor set-
ter - safety tempera- tripped. ting
ture limiter max. 1 is • Sensor defective
tripped. The engine
stops immediately.
76 Gas valve 1 faulty (gas This fault signal is used This fault is active if • Check gas valve for
line B) for monitoring the acti- • the gas valve is acti- correct functioning
vation of the gas valve. vated but the valve • Check cabling of the
The machine is imme- is not opened gas valve
diately shut down, the • the gas valve is not
machine emergency activated but the
stop circuit is tripped. valve is opened
line B) for monitoring the acti- • the gas valve is acti- correct functioning
78 Load controller – nomi- There has been a set- Is activated when the Eliminate the cause of
nal/target value differ- point/actual value de- power controller is en- the value violation (e.g.
ence viation in the power abled reduce intake air tem-
controller for a long perature)
period of time. The per-
missible deviation
range (dead band) is
set in the power con-
troller.
79 Differential pressure of A high signal is sent to The sensor for the • Check heating water
heating water tripped the controller if the heating water differen- system
sensor for heating wa- tial pressure has trip- • Check sensor set-
ter differential pres- ped. ting
sure is tripped. The en- • Sensor defective
ly.
TIM-ID: 0000073956 - 007

80 Enable speed for gas With the gas valves This fault is active if, • Check setting for
valves not reached opened, the speed with the gas valves mixture control/
(1000-1100 rpm) must opened, the speed speed control
be reached within the (1000-1100 rpm) is not • Check gas valve for
set time. This fault sig- reached within the set correct functioning
nal is also used for time. • Check cabling of the
monitoring the activa- gas valve
tion of the gas valve.
The machine is imme-
diately shut down, the
machine emergency
stop circuit is tripped.
81 Gas valve 2 faulty (gas This fault signal is used This fault is active if: • Check gas valve for
line A) for monitoring the acti- • the gas valve is acti- correct functioning
line A) for monitoring the acti- • the gas valve is acti- correct functioning
83 Heating water - insuffi- A low signal is sent to The sensor for insuffi- • Check heating water
cient water the controller if the cient heating water has system
sensor for insufficient tripped. • Check sensor set-
heating water is trip- ting
ped. The engine stops • Sensor defective
immediately.
84 Phasing generator c.b. The monitoring time • Generator circuit Connection require-
failure starts once “Enable breaker has not yet ments can not be met
Synchronization” has closed within the set time.
been activated. The • Automatic mode This may be due to one
fault is only enabled in must be activated of the following rea-
automatic mode. A • Energy measure- sons:
stop is initiated if the ment module is ena- • The idle speed is set
“generator circuit bled for synchroni- too high or too low
breaker is on” signal is zation • The idle speed is set
not received before the too precisely
set time has lapsed. • Generator voltage is
too low/too high,
TIM-ID: 0000073956 - 007
check voltage regu-

lator setting.

85 Phasing mains c.b. fail- The monitoring time • Mains tie circuit Connection require-
ure starts once “Enable breaker is not on ments can not be met
Synchronization of • Automatic mode within the set time.
Mains Circuit Breaker” must be activated This may be due to one
has been activated. • Energy measure- of the following rea-
The fault is only ena- ment module is ena- sons:
bled in automatic bled for synchroniz- • Generator voltage is
mode and with the op- ing the mains tie cir- too low/too high,
tion “Mains Backup cuit breaker check voltage regu-
Mode”. An alarm is ini- lator setting.
tiated if the “Mains Cir-
cuit Breaker is On” sig-
nal is not received be-
fore the set time has
lapsed. Reverse syn-
chronization is can-
celed and the machine
remains in mains fail-
ure mode. Reverse
synchronization is only
re-initiated after the
fault has been ac-
knowledged.
86 GCB - Feedback (On/ The machine is imme- This fault is active if • Check generator cir-
Off) incorrect diately stopped if this generator circuit cuit breaker
fault signal is indicat- breaker feedback sig- • Check cabling of
ed. This signal is used nals “Open” and “Open” and
for monitoring correct “Closed” are active si- “Closed” feedback
functioning of the gen- multaneously signal contacts and
erator circuit breaker. check for possible
broken wire
• Defective relays of
“Open” and
“Closed” feedback
signal contacts
TIM-ID: 0000073956 - 007

87 Generator c.b. could The following functions There is an extended • Check generator cir-
not be opened are carried out when “Off” pulse and the cuit breaker
this fault is picked up: generator circuit • Check cabling for
The module should breaker is still closed. “Off” command of
continue to run at a generator circuit
power of 5% until a ter- breaker
minating fault occurs.
The higher-level switch
(mains circuit breaker)
is opened when this
fault occurs. This is on-
ly possible, however, if
this switch can be ac-
cessed (mains circuit
breaker exists and/or
designed as backup). If
this is not the case, the
module continues to
run in trailing mode
(switch off module,
open exhaust flaps,
switch on auxiliary
drives). If mains failure
mode is in operation
and this fault signal is
indicated, the mains
circuit breaker will be
opened and the mod-
ule shut down.
88 Generator c.b. could The module is shut A stop is pending and • Check generator cir-
not be opened – re- down (gas valves the generator circuit cuit breaker
verse operation closed) if the “Genera- breaker will not open. • Check cabling for
tor circuit breaker will “Off” command of
not open – trailing generator circuit
mode” fault (e.g. over- breaker
temperature) is pend-
ing and if the mains tie
circuit breaker can not
be accessed. The auxil-
iary drives remain acti-
vated.
89 Generator c.b. could This fault is indicated • Automatic mode • Turn-on command is
not be closed (only in automatic must be activated disabled at the cus-
mode) when the ex- • Generator circuit tomer's site, or
tended turn-on pulse is breaker has not yet there is a wiring er-
TIM-ID: 0000073956 - 007
sent and there is no closed ror

“Generator circuit • The EMM issues the • No “Generator cir-
breaker is on” feed- turn-on pulse, but cuit breaker on”
back signal after the the generator circuit feedback signal
time set above has breaker will not • Check generator cir-
elapsed. This fault is close cuit breaker
suppressed in manual
mode so that activa-
tion can be tested.

90 Mains c.b. failure This signal is used for This warning is active • Check mains tie cir-
monitoring the mains if: cuit breaker
tie circuit breaker for • the feedback signals • Check cabling for
correct functioning. “MCB is open” and “faulty mains tie cir-
“MCB is closed” are cuit breaker” feed-
received simultane- back signal contact
ously and check for possi-
• the optional fault in- ble broken wire
put of the MCB has • Check cabling of
responded (low sig- “Open” and
nal) “Closed” feedback
signal contacts and
check for possible
broken wire
• Defective relays of
“Open” and
“Closed” feedback
signal contacts
91 Mains tie circuit break- Is not enabled unless • Mains CB (MCB) will • Check mains tie cir-
er could not be opened “Mains failure opera- not open after 10 cuit breaker
tion” was selected and turn-off pulses • Check wiring for
automatic mode is ac- • Mains failure opera- MCB activation; the
tive. This fault is acti- tion option turn-off command
vated after the turn-off • Single module sys- may be disabled at
pulse was sent 10 tem selected in op- the customer's site
times and the “is off” tions list or there is a fault in
feedback signal was • Automatic mode the cabling
not received. A stop is must be activated
initiated when this fault
is indicated.
92 Mains tie circuit break- Is not enabled unless • MCB will not close • Check mains tie cir-
er could not be closed “Mains failure opera- after 10 turn-off cuit breaker
tion” was selected and pulses • Check wiring for
automatic mode is ac- • Mains failure opera- MCB activation; the
tive. This fault is acti- tion option – single turn-on command
vated after the turn-off module system se- may be disabled at
pulse was sent 10 lected in options list the customer's site
times and the “is on” • Automatic mode or there is a fault in
feedback signal was must be activated the cabling
not received. The fault
is also activated at en-
gine standstill. This is
necessary if both cir-
cuit breakers (genera-
tor, mains) are open
TIM-ID: 0000073956 - 007
and the energy meas-

urement module at-
tempts to close the
MCB automatically.
The turn-off pulse is
disabled when this
fault is indicated.

93 Failure changing gas Maximum time limit If the “dual gas opera- There are separate
type max. time (= 700 s) exceeded for tion” option was se- fault signals during a
gas change. Gas lected and the maxi- gas change for level 1
change is canceled. mum time limit for the (check gas control
gas change (= 700 sec) valve) and level 2 (gas
was exceeded. leak test); the maxi-
mum time during a gas
change can therefore
be caused by level 3
(power reduction). This
is the case when the
set power reduction
value is not reached.
94 Generator protection – The generator frequen- The EMM signals over- • Check setting for
overfrequency cy is monitored for ex- frequency-trailing overfrequency in the
ceeding of the set re- mode must not be ac- EMM
sponse value. The set- tive • Engine speed is too
ting is made in the high
EMM. If the response
value is exceeded, the
generator will be dis-
connected from power
through tripping of the
“Command: Open
GCB” relay. The ma-
shut down.
95 Generator protection – The generator frequen- EMM signals underfre- • Check setting for
underfrequency cy is monitored for quency underfrequency in
dropping below the set the EMM
response value. The • Engine speed is too
setting is made in the low
EMM. If the pickup val-
ue is not reached, the
“Command: Open
shut down.
96 Generator protection – The generator voltages The EMM signals over- • Check the EMM set-
overvoltage are monitored for ex- voltage ting
ceeding of the set pick- • Check voltage regu-
up value. The setting is lator setting
TIM-ID: 0000073956 - 007
made in the EMM. If

the response value is
exceeded, the genera-
tor will be disconnect-
ed from power through
tripping of the “Com-
mand: Open GCB” re-
lay. The machine is im-
mediately shut down.

97 Generator protection – The generator voltages • EMM signals under- • Check the EMM set-
undervoltage are monitored for ex- frequency ting
ceeding of the set pick- • Trailing mode must • Check voltage regu-
up value. The setting is not be active lator setting
made in the EMM. If
the pickup value is not
reached, the generator
will be disconnected
from power through
98 Generator protection – The effective power of EMM signals overload Check EMM setting
overload the generator is moni-
tored for exceeding of
the set pickup value.
The setting is made in
the EMM. If the pickup
threshold is exceeded,
the generator will be
disconnected from
power through tripping
of the “ Command:
Open GCB” relay. The
machine is immediate-
ly shut down.
99 Generator protection – The effective power of EMM signals reverse • Check EMM setting
reverse load the generator is moni- power • Check gas supply,
tored for dropping be- little gas
low the set response • Poor quality of gas
value. The setting is in biogas systems
made in the EMM. If
the pickup value is not
from power through
TIM-ID: 0000073956 - 007

100 Generator protection – The individual genera- EMM signals overcur- • Check EMM setting
overcurrent limit 1 tor currents are moni- rent level 1 • Check generator
tored for exceeding of
the limit value. The rat-
ed generator current is
used as the reference
value. The overcurrent
monitoring relay has
two trip levels and thus
offers the possibility of
setting trip level 1 at a
lower trip value with a
relatively longer delay,
and trip level 2 at a
higher trip value with a
shorter delay (fast trip-
ping relay). The setting
is made in the EMM. If
the exceeding of a limit
value is detected, the
“Command: Open
shut down.
101 Generator protection – The individual genera- EMM signals overcur- • Check the EMM set-
overcurrent limit 2 tor currents are moni- rent level 2 ting
tored for exceeding of • Check generator
the limit value. The rat-
ed generator current is
used as the reference
value. The overcurrent
monitoring relay has
two trip levels and thus
offers the possibility of
setting trip level 1 at a
lower trip value with a
relatively longer delay,
and trip level 2 at a
higher trip value with a
shorter delay (fast trip-
ping relay). The setting
is made in the EMM. If
the exceeding of a limit
TIM-ID: 0000073956 - 007
value is detected, the

“Command: Open
shut down.

102 Oil-leakage pump The corresponding Via digital input to the • Check connection
group leakage sensor has PLC positions for possi-
been tripped. An alarm ble leaks
is output. • Check wiring and
logic of sensor
103 Generator protection - Currently not used. # • Check EMM setting
load unbalance • Check generator
104 Generator protection – This signal is used for • Capacitive power • Check setting for
cosphi controller fail- monitoring the power factor out of range power factor con-
ure (capacitive check) factor controller. The • Mains parallel oper- troller
maximum permissible ation or mains fail- • Check generator
capacitive power factor ure operation is ac-
is evaluated. tive
This signal is the result
of meeting the follow-
ing criteria: (Actual
power factor (Cosphi)
> minimum limit for ca-
pacitive power factor)
& (current actual value
of each phase > mod-
ule parameter 79/80)
& delay time elapsed.
The minimum limit for
the capacitive power
factor is set under
module parameter 77.
105 Generator protection - This signal is used for • Inductive power fac- • Check setting for
cosphi controller fail- monitoring the power tor out of range power factor con-
ure (inductive check) factor controller. The • Mains parallel oper- troller
minimum permissible ation active • Check generator
inductive power factor
is evaluated.
The following criteria
form the basis of the
message: (Actual pow-
er factor (Cosphi) >
minimum limit for in-
ductive power factor) &
(current actual value of
each phase > module
parameter 79/80) &
delay time elapsed.
The minimum limit for
the inductive power
TIM-ID: 0000073956 - 007
factor is set under

module parameter 78.

106 Generator protection – The difference in cur- • Difference in cur- • Check setting in
max. difference current rents exceeds the per- rent L1 / L2 ex- fault signal parame-
L1 / L2 missible limit value. ceeds limit ters
This fault is sup- • Mains parallel mode • Check generator
pressed in mains fail- is active
ure operation. The limit
value is set in the fault
signal parameters. The
ly shut down.
ly shut down.
ly shut down.
109 Generator protection – The machine is imme- • Phase L1 fails Check connection of
phase failure L1 diately shut down • Generator circuit phase L1 (open cir-
should the current breaker must be cuit...)
drop below the set lim- closed
it value in mains paral-
lel operation. This fault
is considered an alarm
only in mains failure
operation or in manual
mode (regardless of
how it was parameter-
ized here). In the worst
case scenario, a phase
may not be loaded and
this fault could inter-
TIM-ID: 0000073956 - 007
rupt isolated operation.

110 Generator protection – In mains parallel opera- • Phase L2 fails Check connection of
phase failure L2 tion, the machine is • Generator circuit phase L2 (open cir-
shut down immediate- breaker must be cuit...)
ly. Special feature: This closed
fault is considered an
alarm only in mains
failure operation or in
manual mode (regard-
less of how it was par-
ameterized here). In
the worst case scenar-
io, a phase may not be
loaded and this fault
could interrupt isolated
operation.
111 Generator protection – In mains parallel opera- • Phase L3 fails Check connection of
phase failure L3 tion, the machine is • Generator circuit phase L3 (open cir-
shut down immediate- breaker must be cuit...)
ly. Special feature: This closed
alarm only in mains
ameterized here). In
the worst case scenar-
io, a phase may not be
loaded and this fault
could interrupt isolated
operation.
TIM-ID: 0000073956 - 007

112 Mains protection – fail- A mains failure is ana- This fault message is • Wait until the mains
ure lyzed by the energy always enabled. failure has been re-
measurement module solved
(EMM) or via an exter- • If there is no actual
nal mains protection mains failure, it may
device. The following be due to one of the
monitoring systems of following reasons:
the EMM cause a – Open circuit in
mains failure: line voltage ca-
• Line frequency mon- bling to the EMM
itoring – Check setting for
• Line voltage moni- mains protection
toring monitoring in
• Unbalance monitor- EMM or from ex-
ing ternal mains pro-
• Phase shift monitor- tection device
ing
• Frequency change
df/dt
• FRT curve
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

113 Mains protection – f > Monitoring of the line • The EMM signals • Wait until the mains
frequency is imperative overfrequency (f>) failure has been re-
if the generator is utili- from grid solved
ty-connected. In case • This signal is not an- • If there is no actual
of a power outage alyzed in mains fail- mains failure, it may
(e.g. brief interruption ure operation be due to one of the
mains. The line fre- – Check setting of
quency is monitored line frequency
for exceeding of the monitoring in
set response value. EMM
the EMM. If the re-
sponse value is ex-
ceeded the system will
be disconnected from
the mains. All of the
mains protection sig-
nals must only be para-
meterized as an alarm.
The remaining reac-
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

114 Mains protection – f < Monitoring of the line • The EMM signals • Wait until the mains
frequency is imperative underfrequency (f <) failure has been re-
if the generator is utili- from grid solved
ty-connected. In case • This signal is not an- • If there is no actual
of a power outage alyzed in mains fail- mains failure, it may
mains. The line fre- – Check setting of
quency is monitored line frequency
for dropping below the monitoring in
set response value. If EMM
not reached, the sys-
tem will be disconnect-
ed from the mains. All
of the mains protection
signals must only be
parameterized as an
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

115 Mains protection – V > Monitoring of the line • The EMM signals • Wait until the mains
voltage is imperative if overvoltage (U>) failure has been re-
the generator is utility- from grid solved
connected. In case of a • This signal is not an- • If there is no actual
power outage alyzed in mains fail- mains failure, it may
value. The setting is
made in the EMM. If
the pickup limit value
is exceeded, the sys-
tem will be disconnect-
ed from the grid. All of
the mains protection
parameterized as an
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

116 Mains protection - V < Monitoring of the line • The EMM signals • Wait until the mains
voltage is imperative if undervoltage (U <) failure has been re-
the generator is utility- from grid solved
connected. In case of a • This signal is not an- • If there is no actual
power outage alyzed in mains fail- mains failure, it may
connected from the
protection signals
The remaining reac-
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

117 Mains protection – The EMM determines a • EMM signals df_dt • Wait until the mains
df_dt measured value for from grid failure has been re-
changing the frequen- • This signal is not an- solved
cy. In order to enable a alyzed in mains fail- • If there is no actual
conclusive differentia- ure operation mains failure, it may
tion between phase be due to one of the
shift and df/dt, the following reasons:
measurement is taken – Open circuit in
over 10 cycles. This re- line voltage ca-
sults in a minimum trip bling to the EMM
time of approx. – Check setting of
220 ms. If the re- df/dt monitoring
sponse value is ex- in EMM
the mains. The setting
is made in the EMM.
mains backup mode,
to the program de-
pending on the op-
tions.
118 Mains protection – The grid line-to-line vol- • The EMM signals • Wait until the mains
asymmetry tages are monitored asymmetry from the failure has been re-
for balance. Unbalance grid solved
is assumed to exist • This signal is not an- • If there is no actual
when the difference alyzed in mains fail- mains failure, it may
between two given ure operation be due to one of the
line-to-line voltages is following reasons:
greater than the set – Open circuit in
pickup value. The set- line voltage ca-
ting is made in the bling to the EMM
EMM. – Check setting of
unbalance moni-
toring in EMM
TIM-ID: 0000073956 - 007

119 Mains protection – The term “phase shift” • Check setting of un- • Wait until the mains
phase shift refers to a sudden balance monitoring failure has been re-
change in the voltage in EMM solved
curve, which may be • This signal is not an- • If there is no actual
caused by a major alyzed in mains fail- mains failure, it may
change in load. In this ure operation be due to one of the
case the device recog- following reasons:
nizes a change in peri- 1. Open circuit in line
od length once. This voltage cabling to
change in period the EMM
length is compared to 2. Check setting of
the arithmetic mean of phase shift moni-
the sum of all previous- toring in EMM
ly taken measure-
ments. Monitoring is
performed on three-
phase or, optionally, on
single-phase systems.
the EMM.
120 Heating water – Flow < A high signal is sent to The sensor for heating • Check heating water
Min. the controller if the water flow has tripped. system
sensor for heating wa- • Check sensor set-
ter flow min. is tripped. ting
The engine stops im- • Sensor defective
mediately.
121 Battery undervoltage, The 24VDC supply volt- Supply voltage under- Weak control batteries,
module control age is continuous shoots limit value check whether the
monitored. control batteries are
being charged
122 Battery charging cur- The battery charge cur- Always active • Check control bat-
rent, module control > rent is measured via an teries
limit value 1 analog input and moni- • Check setting
tored by the MMC.
123 Exhaust gas tempera- In case of wire break In case of wire break/ • Check sensor
ture before Ox Cat. or faulty AT2402 mod- short circuit or faulty • Check controller
(hardware) ule. AT2402 module. adapter module
124 Exhaust flaps – limit This signal indicates an • Both end position • Check activation of
position error error with the end posi- signals are pending exhaust flaps
tion of the exhaust simultaneously • Check end positions
flaps. Both end posi- • With the machine and exhaust flaps
tion signals are pend- running, the “open for broken wire
ing simultaneously or, end position” of the
when the engine is run- exhaust flap is no
TIM-ID: 0000073956 - 007
ning, a sudden drop- longer pending

out of the “open end
position” of the ex-
haust flap.
125 Exhaust flaps - End po- The end position If the end position • Check activation of
sition closed not closed is not reached. closed is not reached exhaust flaps
reached within a certain time. • Check end positions
The time is set in the and exhaust flaps
fault message parame- for broken wire
ters.

126 Exhaust flaps - End po- The end position open If the end position • Check activation of
sition open not is not reached. open is not reached exhaust flaps
reached within a certain time. • Check end positions
The time is set in the and exhaust flaps
fault message parame- for broken wire
ters.
127 Bypass flaps – limit po- This signal indicates an • Both end position • Check activation of
sition error error with the end posi- signals are pending bypass flaps
tion of the bypass simultaneously • Check end positions
flaps. Both end posi- • With the machine and exhaust flaps
tion signals are pend- running, the open for broken wire
ing simultaneously or, end position of a by-
when the engine is run- pass flap is no lon-
ning, a sudden drop- ger pending
out of the “open end
position” of a bypass
flap.
128 Wrong operation mode Digital inputs are used This message is active Check activation of
from remote for remote and project- if digital inputs for the digital inputs for oper-
specific selection of operating mode selec- ating mode selection.
operating modes. The tion are set so that
operating mode assign- there is no correspond-
ment to digital inputs ing operating mode as-
can be found in the cir- signed (e.g. several in-
cuit diagram. This mes- puts simultaneously).
sage is active if digital
inputs are set so that
there is no correspond-
ing operating mode
(e.g. several digital in-
puts simultaneously).
129 Mixture coolant pump This fault indicates This message is active • Mixture coolant
1 faulty whether there is a mix- if the motor protection pump motor protec-
ture coolant pump switch drops out. tion switch defec-
fault. If there is a fault, tive
a high signal is sent to • Incorrect setting of
the controller from the motor protection
mixture coolant pump switch
motor protection • Check mixture cool-
switch. ant pump connec-
tion (mixture cool-
ant pump is possibly
only running on 2
phases)
TIM-ID: 0000073956 - 007
130 Coolant preheating This fault indicates This message is active • Engine coolant pre-
faulty whether there is an en- if one of the motor pro- heating motor pro-
gine coolant preheat- tection switches drops tection switch de-
ing fault. If there is a out. fective
fault, a high signal is • Incorrect setting of
sent to the controller motor protection
from the motor protec- switch
tion switch of the pre- • Check connection of
heating cartridges. This engine coolant pre-
message is used for heating
alarm signaling.

131 Used oil/oil priming This fault indicates This message is active • Motor protection
pump whether there is a fault if the motor protection switch of the used
in the used oil pump. If switch drops out. oil pump defective
there is a fault, a high • Incorrect setting of
signal is sent to the motor protection
controller from the mo- switch
tor protection switch of • Check connection of
the used oil pump. This used oil pump (used
is used to signal oil pump is possibly
alarms. only running on 2
phases)
132 Load step controller – An overload is indicat- Option for load stage Consumer load too
overload ed in mains failure op- control available se- high on one load stage;
eration. The required lected in options list clarify with customer
load stages are shed. If
the current module
power actual value is >
(power value (of the
stages currently cut in)
+ overload limit value),
a time delay starts run-
ning. At the end of this
time, a fault message
is output and a stage is
shed. Load application
is only performed after
the fault has been ac-
knowledged.
133 Generator rated fre- The generator frequen- If the generator fre- Check set target idling
quency not reached cy is monitored from quency is not reached speed
start phase 3 onward. from start phase 3 on-
This is used to signal ward
alarms. This message
is active if the genera-
tor frequency lies out-
side the set band
range during this start
phase.
134 Communication to ex- Communication to ex- Interface faults at fol- • Check interface ca-
ternal common control ternal common control lowing interfaces: bling of MTU and
system disrupted system can take place • CAN customer controller
via different interfaces: • Profibus DP • Check interface pa-
• CAN • RK 3964 rameter settings
• Profibus DP • RK 512
• RK 3964 • Modbus RTU
TIM-ID: 0000073956 - 007
• RK 512 • Modbus TCP

• Modbus RTU • UDP
• Modbus TCP • PVI
• UDP
• PVI
If one of these interfa-
ces is faulty, this mes-
sage is generated.

135 Generator diode fault If the digital voltage Always • Check the diode
regulator (AVR) detects plates of the gener-
a diode fault, this mes- ator
sage is tripped • Contact the genera-
tor manufacturer
136 Connection PLC <-> Termination of commu- The IPC sets a variable Check Ethernet con-
Visualization disrupted nication between PLC every 10 sec. nection cable between
and IPC. PLC and IPC for open
This is used to signal circuit
alarms. The PLC and
IPC are connected via
Ethernet.
137 PLC - battery weak The status of the PLC • No buffer battery is • Check whether the
buffer battery is indi- present buffer battery was
cated here. The buffer • Buffer battery too correctly inserted
battery is inserted di- low • Replace battery if
rectly in the CP (e.g. • Buffer battery was low! Battery replace-
CP1484). incorrectly inserted ment is not per-
formed with the PLC
de-energized
• The battery must be
changed every 4
years
138 PLC - forcing value ac- This message is indi- An analog value is si- If desired, deactivate
tive cated if an analog val- mulated. the Input/Output sig-
ue is simulated on the nal in the Service
“Analog Parameter” menu under Analog
visualization screen. value parameters
139 Emergency stop relay This signal is used for • No emergency stop Check emergency stop
defective monitoring the safety has been activated, relay from RPS (wire
relays (activated by the but there is a high break, defect,...)
RPS). signal at the input
• An emergency stop
was activated, but
there is a low signal
at the input
140 Connection PLC <-> If the connection be- Every 2 s a live cycle is Check CAN connection
Visualization disrupted tween MMC controller expected from the en- between engine and
and MTU engine man- gine. If it is not re- MMC controller for dis-
agement is disrupted. ceived, this message is ruption and correct ca-
This is used to signal issued bling.
alarms.
141 Battery charger faulty Message is issued by Always Check battery charger
the battery charger. supply voltage
TIM-ID: 0000073956 - 007

142 Mains failure operation This message is active • Power failure de- • Pinpoint cause of
due to power failure if mains failure opera- tected by EMM mains failure
tion is active as a re- • Mains failure opera- • Check MCB
sult of a power outage tion must be ena- • Wait until the grid
(detection by EMM). bled and automatic has stabilized again
Automatic reverse syn- mode must be ac-
chronization can be ini- tive using the key
tiated after the grid switches in the con-
power has been re- trol cabinet door
stored. This is used to
signal alarms.
143 Emergency power sup- This message is acti- • Failed mains circuit Pinpoint cause of failed
ply operation due to vated if mains failure breaker mains circuit breaker
MCB failure operation is active as a • Mains failure opera-
result of a failed mains tion must be ena-
circuit breaker. If can bled and automatic
only be switched back mode must be ac-
if the message has tive using the key
been acknowledged. switches in the con-
trol cabinet door
144 GCB and MCB open => When both circuit • Feedback signal A circuit-breaker (MCB
No auxiliary drive sup- breakers are opened, that the generator or GCB) must be
ply the auxiliary drives are circuit breaker and closed within a speci-
not supplied with pow- mains circuit break- fied time window. The
er. er are open supply of the auxiliary
• Automatic mode drives is thus guaran-
must be activated teed. Check cut-in con-
• Rated speed has ditions for the corre-
been reached sponding circuit-break-
er, e.g. enable signal
for GCB etc.
145 Exhaust gas tempera- In case of wire break In case of wire break/ • Check controller
ture after Ox Cat. or faulty AT2402 mod- short circuit or faulty adapter module
(hardware) ule. AT2402 module. • Check sensor
146 Generator rated volt- The generator voltage From start phase 3 on- Check generator volt-
age not reached is monitored from start ward, the rated voltage age setting via voltage
phase 3 onward. This of the generator is not regulator. To do so, the
is used to signal reached generator must be run-
alarms. This message ning at rated frequen-
is active if the genera- cy.
tor voltage lies outside
the set band range
from this start phase
onward.
TIM-ID: 0000073956 - 007
147 Start condition for au- One requirement has • Start request must Check start conditions
tomatic mode missing not been met (e.g. gas be received for corresponding op-
tank fill level) => auto- • Automatic mode is erating mode. The fol-
matic mode is disa- active lowing operating
bled. Important: The modes require the
grid stabilization time start conditions:
must have lapsed be- • Gas tank or CH4
fore the machine is • Grid feed-in control
started after a mains • Peak current mode
failure (default: 60s)! • Heating mode
• Timer

pressure limiter max. a high signal is sent to max 1 has been trip- • Check limiter set-
(SPL max 1) the controller and the ped. ting
ly.
149 Reserve # # #
150 Alarm gas detector – This fault message is • Optional external • Determine why the
shut down machine output by a gas detec- gas warning 1-stage external gas detec-
tor. If it responds this selected in options tor responded
message is active. The list • If the gas detector
module is shut down. • Via low signal from did not respond, but
The room fans are acti- connected gas de- this message is indi-
vated. tector cated, check the ca-
bling of the feed-
back signal contact
of the gas detector
to the controller
(e.g. wire break,......)
151 Mixture cooler faulty This fault indicates This message is active • Motor protection
whether there is a fault if the motor protection switch of the mix-
in the mixture cooler. If switch or another sen- ture cooler is defec-
there is a fault, a high sor has tripped. tive
signal is sent to the • Incorrect setting of
controller from the mo- motor protection
tor protection switch switch
or another sensor.
152 Lube oil tank 2 fill level The transmitter for This message is acti- • Check filling level in
< min. “Filling level < min. in vated when the trans- lube oil tank 2
lube oil tank 2” has mitter “Filling level < • The feedback con-
tripped. An alarm is min. in lube oil tank 2” tact may have suf-
output. transmits a low signal fered a wire break if
to the controller. the transmitter “Fill-
ing level < min. in
lube oil tank 2” did
not respond.
153 CH4 proportion < min If the CH4 content has CH4 content drops be- • Check gas quality
dropped below a fixed low lower limit value or • for sufficiently high
limit value or the “CH4 “CH4 start enable” dig- CH4 content
start enable” digital in- ital input drops out.
put has dropped out.
This is used to signal
alarms.
TIM-ID: 0000073956 - 007
154 Engine cooling water - If this limiter responds, The engine coolant STL • Check water system
safety temperature lim- a high signal is sent to max 1 has been trip- • Check limiter set-
iter max (STL max 1) the controller and the ped. ting
ly.

155 Mixture coolant – safe- If this limiter responds, The mixture coolant • Check water system
ty pressure limiter max a high signal is sent to SPL min has been trip- • Check limiter set-
(SPL max.) the controller and the ped. ting
ly.
156 Failure external plant A digital input (custom- The customer-provided Rectify fault in external
er-supplied signal) is digital input signals a system
used for signaling a “low” signal.
fault of the external
system. As standard
practice, a “low” signal
(wire break monitoring)
should be used for sig-
naling the fault. The
engine is stopped in a
controlled manner.
157 Start canceled (false This message appears • Start demand active Rectify the shutdown
start) when the starting se- • Abort during start fault that terminated
quence is interrupted phase after a shut- the starting sequence
by shutdown faults. down fault
158 Fire alarm The fire alarm system • Fire alarm option • Determine why the
signals a fire. If this available fire alarm system re-
message is issued, the • Via low signal responded
engine is immediately ceived from the con- • If the fire alarm did
stopped. The room nected fire alarm not trip, but this
fans are deactivated. system message is still
pending, check the
cabling of the feed-
back signal contact
from the fire alarm
to the controller
159 Emergency cooler 2 The emergency cooler Faulty digital input for Check emergency
faulty signals a fault. emergency cooler sig- cooler
naled via high signal
160 Mixture coolant - safe- If this limiter responds, The mixture coolant • Check water system
ty temperature limiter a high signal is sent to safety temperature lim- • Check limiter set-
max (STL max) the controller and the iter max has tripped. ting
ly.
TIM-ID: 0000073956 - 007
161 Generator c.b. opened This fault is indicated if • Automatic mode • Circuit breaker was
no opening command must be activated opened externally
was sent to the gener- • Generator circuit • Faulty feedback sig-
ator circuit breaker, breaker was on (still nal (e.g. wire break)
but the generator cir- receives activation • Defective generator
cuit breaker opens re- signals) and sudden- circuit breaker
gardless. ly there is no “On”
feedback signal
from the generator
circuit breaker

162 Mains c.b. opened This fault is indicated if • Automatic mode • Circuit breaker was
no opening command must be activated opened externally
was sent to the mains • Mains circuit break- • Faulty feedback sig-
circuit breaker, but the er was on (still re- nal (e.g. wire break)-
mains circuit breaker ceives activation defective MCB
opens regardless. signals) and sudden-
ly there is no “On”
feedback signal
from the mains cir-
cuit breaker
163 Cooling unit fault (MIP) The cooler in the con- • Cooler available op- Check cooler
trol cabinet indicates a tion selected in op-
the control cabinet
indicates a fault
164 External heating water If the external heating Contact tripped for • Check motor pro-
pump 1 faulty water pump has sig- group fault signal. This tection switch
naled a fault (e.g. trip- may be due to the • Check cabling
ped motor protection feedback signal con-
switch). tact of the motor pro-
tection switch for the
heating water pump, or
other customer-provid-
ed feedback.
165 External heating water If the external heating Contact tripped for • Check motor pro-
pump 2 faulty water pump has sig- group fault signal. This tection switch
naled a fault (e.g. trip- may be due to the • Check cabling
ped motor protection feedback signal con-
switch). tact of the motor pro-
tection switch for the
heating water pump, or
other customer-provid-
ed feedback.
166 Gas pressure < min When changing gas • When switching to • Check gas supply
(gas type changing) from the active gas the inactive gas (shut-off devices,
type to the inactive gas type during the gas etc.)!
type involving two gas change, gas pres- • Check gas pressure
lines, a check is per- sure < min is deter- min. switch (cabling
formed to ensure that mined for possible broken
the gas pressure of the • Dual gas operation wire)
inactive gas type is OK. option activated in • Check gas compres-
This is used to signal options list sor if available
TIM-ID: 0000073956 - 007
alarms. The started gas • Check gas pressure

change is aborted. setting of gas pres-
sure switch
167 Emergency cooler wa- If this limiter responds, The emergency cooler • Check water system
ter - safety pressure a high signal is sent to water SPL max has • Check limiter set-
limiter max (SPL max) the controller and the tripped. ting
ly.

168 Emergency cooler 1 The emergency cooler Faulty digital input for Check emergency
faulty signals a fault. emergency cooler sig- cooler
naled via high signal
169 Failure room air inlet The room fan signals a Faulty digital input for • Check room fan
fan fault. This may be a room fan signaled via • Check motor pro-
signal contact or feed- high signal tection switch set-
back from a motor pro- ting (if applicable)
tection switch. • Defective motor
protection switch (if
applicable)
170 Starter battery under- The supply voltage is The voltage of the • Low starter batter-
voltage continuously moni- starter battery under- ies, check whether
tored. Continuous un- shoots a set value the starter batteries
dershooting of the set are being charged
limit value for at least • Check setting of
2 minutes results in fault message
the alarm message be- • This message may
ing issued. The evalua- be indicated in case
tion is issued as an of successive start
alarm. attempts
171 Communication to The connection be- The connection be- • Check Ethernet con-
MTU control technolo- tween the module con- tween the module connection for open cir-
gy out of order troller and communica- troller and communica- cuit. All RJ45 plugs
tion to MTU control in- tion to MTU control in- must be connected
strumentation signals a strumentation signals a • Faulty Ethernet ca-
fault. The connection is fault. ble (open circuit,
made via Ethernet. short-circuit, etc.)
• Check whether the
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules and com-
mon control system
are supplied with
power (check at the
LEDs, the “RUN”
LED must light up
green)
172 Lube oil tank 2 overfil- The transmitter for This message is acti- • Check filling level in
led “Overfilling lube oil vated when the trans- lube oil tank 2
tank 2” has been trip- mitter “Overfilling lube • The feedback con-
TIM-ID: 0000073956 - 007
ped. An alarm is out- oil tank 2” transmits a tact may have suf-
put. low signal to the con- fered a wire break if
troller. the transmitter
“Overfilling lube oil
tank 2” did not re-
spond

> max. “Filling level > max. in vated when the trans- lube oil tank 2
lube oil tank 2” has mitter “Filling level > • The feedback con-
been tripped. An alarm max. in lube oil tank 2” tact may have suf-
is output. transmits a low signal fered a wire break if
ing level > max. in
not respond.
174 Module stationary due This message is active The engine must be Group signal: Deter-
to fault (self-acknowl- if auto acknowledging stopped and fault sig- mine original fault
edging fault active) => fault signals queue for nals coded as auto ac- message
delayed notification an adjustable period. knowledging are
This delay is config- queued for the set de-
ured in the fault sig- lay of this fault signal.
nals. The purpose of
this signal is to send
auto acknowledging
fault signals to a dialer
(via floating contact) or
via text message or
email client in a time
delayed manner.
175 Failure Pump emergen- The emergency cooler Faulty digital input of • Check emergency
cy cooler pump signals a fault. emergency cooler cooler pump
pump signaled via low • Broken wire be-
signal tween signal con-
tact of emergency
cooler pump and
controller
< min. “Filling level < min. in vated when the trans- lube-oil tank 1
lube oil tank 1” has mitter “Filling level < • The feedback con-
tripped. An alarm is min. in lube oil tank 1” tact may have suf-
output. transmits a low signal fered a wire break if
ing level < min. in
not respond.
> max. “Filling level > max. in vated when the trans- lube oil tank 1
lube oil tank 1” has mitter “Filling level > • The feedback con-
been tripped. An alarm max. in lube oil tank 1” tact may have suf-
is output. transmits a low signal fered a wire break if
TIM-ID: 0000073956 - 007

ing level > max. in
not respond.
ter - safety pressure a high signal is sent to water SPL min has • Check limiter set-
limiter min (SPL min) the controller and the been tripped. ting
ly.

on output side > limit this temperature exceeds a limit value
nal alarms.
on output side > limit this temperature exceeds a limit value
ped in a controlled
manner.
181 Bearing temperature With an AT4222 mod- In case of wire break/ • Check sensor.
on output side (hard- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.
182 Testbed program is ac- This signal indicates The key switches in the Deactivate MTU test
tive that the automatic control cabinet door program for the engine
break-in program or must be positioned as test stand
logging has been acti- follows:
vated. The run-in pro- • Enable module local
gram is used for run- control
ning in the engine over • Automatic mode
various output stages start request at 0
(standard: If you go to the “Serv-
25%-50%-75%-100%). ice” menu press the
“Run in” button on the
“Test stand” screen, it
then appears.
183 Generator circuit The machine is imme- This fault is activated if • Check generator cir-
breaker tripped/faulty diately stopped if this the generator circuit cuit breaker
fault signal is indicat- breaker is tripped/ • Check cabling of
ed. This signal is used signals a fault. feedback signal con-
for monitoring correct tact (tripped/faulty)
functioning of the gen- for generator circuit
erator circuit breaker. breaker and check
for possible broken
wire
184 Lube oil tank 1 overfil- The transmitter for This message is acti- • Check filling level in
led “Overfilling lube oil vated when the trans- lube oil tank 1
tank 1” has been trip- mitter “Overfilling lube • The feedback con-
TIM-ID: 0000073956 - 007
ped. An alarm is out- oil tank 1” transmits a tact may have suf-
put. low signal to the con- fered a wire break if
troller. the transmitter
“Overfilling lube oil
tank 1” did not re-
spond

185 Lube oil tank 2 leakage The transmitter for This message is acti- Check lube oil tank 2
“Leakage monitoring vated when the trans-
lube oil tank 2” has mitter “Leakage moni-
been tripped. An alarm toring lube oil tank 2”
is output. transmits a low signal
to the controller.
186 Lube oil tank 1 leakage The transmitter for This message is acti- Check lube oil tank 1
“Leakage monitoring vated when the trans-
lube oil tank 1” has mitter “Leakage moni-
been tripped. An alarm toring lube oil tank 1”
is output. transmits a low signal
to the controller.
187 Sensor emergency With an AT4222 mod- In case of wire break/ • Check sensor
cooler (hardware fail- ule (4*PT100/1000, 2 short circuit or faulty • Check controller
ure) or 3-wire), the follow- AT4222 module. adapter module
3276.7 or 3274.7. This
is used to signal
alarms.
188 Gas tank vacuum This message is option- • Biogas must be ac- If you suspect that this
al. The engine is stop- tive signal was sent in error
ped immediately if the • The “Gas tank un- (gas tank signals un-
“Gas tank underpres- derpressure” sensor derpressure, but pres-
sure” sensor sends a sends a low signal sure is OK), check the
low signal to the con- to the controller following items:
troller. • Broken wire be-
tween sensor and
controller
• Check “Gas tank un-
derpressure” sensor
189 Voltage control auxili- The phase monitoring The phase sequence / • Check whether sup-
ary drives MMC system is used for phase failure monitor- ply voltage is availa-
monitoring the supply ing system or the re- ble for auxiliary
active if the phase se- analysis) of the phase age of auxiliary
quence / phase failure monitoring system has drives for correct
monitoring system or been tripped. phase sequence and
the reverse voltage de- phase failure
tection system (via un- • Broken wire of sig-
balance analysis) of nal contact connec-
the phase monitoring tion between con-
system is tripped. troller and phase
TIM-ID: 0000073956 - 007
monitoring system
190 Failure energy meas- If the energy measure- • The energy meas- Disconnect 24VDC
urement module ment module is not urement module supply to energy meas-
ready for operation, was not correctly in- urement module and
then this message is stalled connect again
active. • The energy meas-
urement module is
overloaded
• The 24VDC supply
signals undervoltage

module 1 failed tween module control tween module control nection for open cir-
and module 1 for com- and module 1 for com- cuit. All RJ45 plugs
munication signals a munication signals a must be connected
fault. The connection is fault. • Faulty Ethernet ca-
made via Ethernet. ble (open circuit,
short-circuit, etc.)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
the “RUN” LED must
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
and module 10 for and module 10 for cuit. All RJ45 plugs
communication signals communication signals must be connected
a fault. The connection a fault. • Faulty Ethernet ca-
is made via Ethernet. ble (open circuit,
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
201 Communication faulty This message is acti- Number of modules is Check Ethernet con-
in isolated/mains par- vated if communication ≥ 2. nection
allel mode with over 50% of the
modules/engine-gen-
erator sets is disrupted
in isolated / mains
parallel operation. The
TIM-ID: 0000073956 - 007

ately.
202 External heating water If external heating wa- Fault message 164 and • Check motor pro-
pump 1+2 faulty ter pump 1 and exter- fault message 165 ac- tection switch
nal heating water tive. • Check cabling
pump 2 signal a fault
(e.g. tripped motor pro-
tection switch).

203 Coolant pump 1+2 If coolant pump 1 and Fault message 7 and • Motor protection
faulty coolant pump 2 signal fault message 45 ac- switch of coolant
a fault (e.g. tripped tive. pump defective
motor protection • Incorrect setting of
switch). motor protecting
switches
• Check connection of
coolant pumps
(coolant pump pos-
sibly only running on
2 phases)
204 2nd energy measure- If the energy measure- • The energy meas- Disconnect 24VDC
ment module faulty ment module is not urement module supply to energy meas-
ready for operation, was not correctly in- urement module and
then this message is stalled connect again
active. • The 24VDC supply
signals undervoltage
205 Mixture coolant pump This fault indicates This message is active • Mixture coolant
2 faulty whether there is a mix- if the motor protection pump motor protec-
ture coolant pump switch drops out. tion switch defec-
fault. If there is a fault, tive
a high signal is sent to • Incorrect setting of
the controller from the motor protection
mixture coolant pump switch
motor protection • Check mixture cool-
switch and the ma- ant pump connec-
chine is shut down in a tion (mixture cool-
controlled manner. ant pump is possibly
only running on 2
phases)
pressure limiter max a high signal is sent to max 2 has been trip- Check limiter set-
(SPL max 2) the controller and the ped. ting
ly.
207 Engine cooling water - If this limiter responds, The engine coolant STL • Check water system
safety temperature lim- a high signal is sent to max 2 has been trip- • Check limiter set-
iter max (STL max 2) the controller and the ped. ting
ly.
TIM-ID: 0000073956 - 007
208 Exhaust gas tempera- This fault is activated if This temperature ex- Allow oxidation cata-
ture before Ox Cat. > this temperature exceeds a limit value lyst to cool down, no
limit value 1 ceeds the set limit val- further starting at-
ue. This is used to sig- tempts
nal alarms.
ture before Ox Cat. this temperature exceeds a limit value lyst to cool down, no
ceeds the set limit val- further starting at-
ue. The engine is stop- tempts
ped.

ture after Ox Cat. > this temperature exceeds a limit value lyst to cool down, no
ue. This is used to sig- tempts
nal alarms.
ture after Ox Cat. > this temperature exceeds a limit value lyst to cool down, no
ue. The engine is stop- tempts
ped.
212 Cylinder exhaust gas Used for controlled In isolated parallel op- • Check igniter
temperature engine shutdown of the ma- eration, the enable is • Emission values –
too high/low chine in isolated (is- issued if more than 2 Check
land) parallel operation engines share the load • Ignition timing
because, with a high- distribution. check
er/lower cylinder ex- • Check valve lift
haust gas temperature
limit value 2 comes in-
to effect which results
in an immediate stop.
The island could thus
be overloaded.
213 Failure room air outlet The room fan signals a Faulty digital input for • Check room fan
fan fault. This may be a room fan signaled via • Check motor pro-
applicable)
214 Gas compressor out of The gas compressor Faulty digital input for • Check gas compres-
order signals a fault. This gas compressor sig- sor
may be a signal con- naled via high signal • Check motor pro-
tact or feedback from tection switch set-
a motor protection ting (if applicable)
switch. • Defective motor
applicable)
215 Cooling unit faulty The cooler in the con- • Cooler available op- Check cooler
(MMC) trol cabinet indicates a tion selected in op-
the control cabinet
indicates a fault
TIM-ID: 0000073956 - 007

216 Mixture coolant pump If mixture coolant Fault message 129 and • Mixture coolant
1 +2 faulty pump 1 and mixture fault message 205 ac- pump motor protec-
coolant pump 2 signal tive. tion switch defec-
a fault (e.g. tripped tive
motor protection • Incorrect setting of
switch). motor protecting
switches
• Check soft starter
for "mixture coolant
pump 1 on" and
"mixture coolant
pump 2 on" for cor-
rect functioning
• Check connection of
mixture coolant
pump (mixture cool-
ant pump possibly
only running on 2
phases)
217 Exhaust heat exchang- If this limiter responds, Exhaust gas heat ex- • Check water system
er - flow < min. a high signal is sent to changer – Flow < Min. • Check limiter set-
the controller and the has been tripped. ting
ly.
218 Exhaust gas heat ex- If this limiter responds, Exhaust gas heat ex- • Check water system
changer - safety pres- a high signal is sent to changer - safety pres- • Check limiter set-
sure limiter min (SPL the controller and the sure limiter min (SPL ting
min) “machine” safety cir- min) has tripped. • Defective limiter
ly.
sure limiter max (SPL the controller and the sure limiter max (SPL ting
max 1) “machine” safety cir- max 1) has tripped. • Defective limiter
ly.
sure limiter max (SPL the controller and the sure limiter max (SPL ting
max 2) “machine” safety cir- max 2) has tripped. • Defective limiter
TIM-ID: 0000073956 - 007

ly.
er - safety temperature a high signal is sent to changer - safety tem- • Check limiter set-
limiter max the controller and the perature limiter max ting
(STL max 1) “machine” safety cir- (STL max 1) has trip- • Defective limiter
cuit is tripped. The en- ped.
ly.

er - safety temperature a high signal is sent to changer - safety tem- • Check limiter set-
limiter max the controller and the perature limiter max ting
(STL max 2) “machine” safety cir- (STL max 2) has trip- • Defective limiter
cuit is tripped. The en- ped.
ly.
223 Heating water - safety If this limiter responds, Heating water - safety • Check heating water
pressure limiter max. a high signal is sent to pressure limiter max system
(SPL max 2) the controller and the (SPL max 2) has trip- • Check limiter set-
“machine” safety cir- ped. ting
cuit is tripped. The en- • Defective limiter
ly.
224 Heating water - safety If this limiter responds, Heating water - safety • Check heating water
temperature limiter a high signal is sent to temperature limiter system
max. (STL max 2) the controller and the max (STL max 2) has • Check limiter set-
“machine” safety cir- tripped. ting
cuit is tripped. The en- • Defective limiter
ly.
ter - safety tempera- a high signal is sent to water safety tempera- • Check limiter set-
ture limiter max (STL the controller and the ture limiter max has ting
max) “machine” safety cir- tripped. • Defective limiter
ly.
226 Reserve # # #
227 Reserve # # #
228 Reserve # # #
229 Fault in the configura- The X20 analog input Always active • Check the analog
tion of analog input/ and output modules value parameters
output boards (e.g. AT4222, AI4622, and change if nec-
AO4622) can be para- essary.
meterized via the HMI. • Install correct X20
In the Service menu analog module.
under "Analog value
parameters", the indi-
vidual analog values
are listed. The hard-
ware assignment or
hardware configuration
TIM-ID: 0000073956 - 007
are also saved here.

Valid values for "Scal-
ing", "Model number"
and "Channel" must be
entered.

230 Generator protection – The generator line-to- EMM signals voltage Check generator
voltage asymmetry line voltages are moni- unbalance
tored for balance. Un-
balance is assumed to
exist when the differ-
ence between two giv-
en line-to-line voltages
is greater than the set
pickup value. The set-
ting is made in the
EMM. If the response
value exceeded or not
from power through
231 Generator protection – The unbalanced load The present unbal- • Check setting of un-
current asymmetry monitoring system is anced load current ex- balanced load moni-
used for continuously ceeds the permissible toring system
monitoring the alter- limit value. • Check generator
nating currents inject- • Ensure a balanced
ed by the generator load distribution
current transformers during mains failure
and for continuously operation
computing the present
unbalanced load cur-
rent. Analysis is per-
formed in the EMM.
The GCB will be
opened if the permissi-
ble limit value is ex-
ceeded. The engine
stops immediately.
232 Generator protection – The monitoring device The neutral conductor • Check setting of
neutral conductor cur- is tripped should the current exceeds the monitoring system
rent max. pickup limit value for set pickup limit value. for neutral conduc-
the neutral conductor tor current
current be exceeded • Ensure a balanced
for a given period of load distribution
time. Analysis is per- during mains failure
formed in the EMM. operation (the reac-
The percentage pickup tive power should
TIM-ID: 0000073956 - 007
value refers to the rat- also be balanced)

ed generator current.
The GCB will be
opened if the permissi-
ble limit value is ex-
ceeded. The engine
stops immediately.

233 Generator protection – The monitoring device The capacitive reactive • Check setting of
capacitive reactive is tripped should the power exceeds the set monitoring system
power monitoring pickup value for the ca- pickup limit value. for capacitive reac-
pacitive reactive power tive power
be exceeded for a giv- • Check generator
en period of time. Anal- (possible excitation
ysis is performed in the failure)
EMM. The engine stops
immediately.
234 – Reserved for customer # # #
243 configuration
244 Feed-in reduction: Not Message from ripple • “Feed-in reduction Check whether a re-
approved control receiver. available” option is lease was signaled by
activated in options the ripple control. If so,
list resolve the problem
• Signal contact of with the responsible
ripple control receiv- utility company. If not,
er reports “no re- check the wiring.
lease”
245 Feed-in reduction: Message from ripple • “Feed-in reduction Check the ripple con-
Power reduction < min- control receiver. available” option is trol receiver. If the rip-
imum power activated in options ple control receiver in-
list dicates a power reduc-
• Signaling contact of tion under 50% then re-
ripple control receiv- solve the problem with
er reports power re- the responsible power
duction under 50%. supply company. If
This can be more there is no power re-
than one contact. duction, check the wir-
ing.
246 Feed-in reduction: 60% Message from ripple • “Feed-in reduction Check the ripple con-
power reduction control receiver. available” option is trol receiver. If the rip-
activated in options ple control receiver in-
• Signaling contact of tion under 60% then re-
duction 60%. supply company. If
there is no power re-
duction, check the wir-
ing.
247 Feed-in reduction: 30% Message from ripple • “Feed-in reduction Check the ripple con-
power reduction control receiver. available” option is trol receiver. If the rip-
activated in options ple control receiver in-
TIM-ID: 0000073956 - 007

• Signaling contact of tion of 30% then re-
duction 30%. supply company. If
there is no power re-
duction, check the wir-
ing.

248 Phase failure L1 - 2nd The machine is imme- • Phase L1 fails Check connection of
energy measurement diately shut down if the • Generator circuit phase L1 (open cir-
module current drops below breaker must be cuit...)
the set limit value in closed
mains parallel opera-
tion.
Special feature: This
alarm only in mains
ameterized here).
In the worst case sce-
nario, a phase may not
be loaded and this
fault could interrupt
isolated operation.
energy measurement diately shut down in • Generator circuit phase L2 (open cir-
module mains parallel opera- breaker must be cuit...)
tion. closed
alarm only in mains
ameterized here).
be loaded and this
isolated operation.
energy measurement diately shut down in • Generator circuit phase L3 (open cir-
module mains parallel opera- breaker must be cuit...)
tion. closed
alarm only in mains
ameterized here).
TIM-ID: 0000073956 - 007

be loaded and this
isolated operation.

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
TIM-ID: 0000073956 - 007

switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
switch for Ethernet
connection is sup-
plied with power
(check at the LEDs)
controllers in the
modules are sup-
plied with power
(check at the LEDs,
light up green)
271 Wrong setting of CPU The node switches at Always released. Check setting of node
node switch the RPS (e.g. CP1484) switches at the RPS.
must be correctly set.
The setting is hexadec-
imal via two node
switches. Setting of
node switch for mod-
TIM-ID: 0000073956 - 007
ule 1 = 11 (Hex 0B),

module 2 = 12 (Hex
0C) etc.

272 Auxiliary drive voltage The phase monitoring The phase sequence / • Check whether sup-
monitor (auxiliary system is used for phase failure monitor- ply voltage is availa-
drives panel) monitoring the supply ing system or the re- ble for auxiliary
active should the analysis) of the phase age of auxiliary
phase sequence / monitoring system has drives for correct
phase failure monitor- been tripped. phase sequence and
ing system or the re- phase failure
verse voltage detection • Broken wire of sig-
system (via unbalance nal contact connec-
analysis) of the phase tion between con-
monitoring system be troller and phase
tripped. monitoring system
273 Reserve # # #
274 Mains protection – U > Monitoring of the line Always released. • Wait until the mains
(average) voltage is imperative if failure has been re-
mains. The mean value – Check setting of
of the mains measure- line voltage moni-
ment voltage is ex- toring in EMM
ceeded during a set
period of time (default
setting: 600 s)
TIM-ID: 0000073956 - 007

275 Mains protection – V Monitoring of the line Always released. • Wait until the mains
>> voltage is imperative if failure has been re-
mains backup mode,
to the program de-
pending on the op-
protection - V > fault.
TIM-ID: 0000073956 - 007

276 Mains protection – U Monitoring of the line Always released. • Wait until the mains
<< voltage is imperative if failure has been re-
connected from the
protection signals
The remaining reac-
mains backup mode,
to the program de-
pending on the op-
protection - U < fault.
277 GridCode – Frequency- The grid code function • The corresponding This fault is resolved as
dependent effective of frequency-depend- option for this con- soon as the line fre-
power active ent power reduction trol type must be quency drops below a
has been activated. set configured limit value
The effective power is • Mains frequency again.
reduced by a fixed gra- must increase be-
dient if the line fre- yond one of the limit
quency limit is exceed- values
ed.
278 GridCode – Generator- The effective power is • The corresponding Adjust power factor
dependent effective reduced if the config- option for this con- specification. Check
power active (depend- ured generator voltage trol type must be grid code parameters.
TIM-ID: 0000073956 - 007
ing on power factor or power factor is not set

and line voltage) reached. • Mains voltage and
power factor must
increase beyond the
set limit value

279 GridCode - no enable The engine is shut Module is in automatic Wait until the connec-
from mains operator down if the connection mode, mains failure tion conditions are
(connection require- requirements for line operation not enabled within the configured
ments are not met) frequency and line volt- range. Check parame-
age have not been met ters
according to the grid
code
280 Control energy: Com- Is used in combination When the E-Box from • Check wiring on E-
munication failure with an Enernoc E-Box. Enernoc is used, this Box
message is always re- • Contact Enernoc
leased Service
281 Gradient after mains After a mains failure, After a mains failure Wait until a power
failure re-powering may only and first-time grid syn- ramp is no longer re-
be performed using chronization quired after a mains
configured gradients in failure. (Default: after
accordance with grid 10 min)
code guidelines.
282 Engine room tempera- This sensor monitors This temperature ex- Check room ventila-
ture > limit 1 the ambient tempera- ceeds a limit value tion.
ture around the ma-
chine. This fault is acti-
vated if this tempera-
ture exceeds the set
limit value. This is used
to signal alarms.
283 Engine room tempera- This sensor monitors This temperature ex- Check room ventila-
ture > limit 2 the ambient tempera- ceeds a limit value tion.
ture around the ma-
chine. This fault is acti-
vated if this tempera-
ture exceeds the set
limit value. The engine
is stopped.
284 Engine room tempera- With an AT4222 mod- In case of wire break/ • Check sensor
ture (hardware) ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.
285 Mixture coolant inlet With an AT4222 mod- In case of wire break/ • Check sensor
temperature (dew ule (4*PT100/1000, 2 short circuit or faulty • Check controller
point monitoring) or 3-wire), the follow- AT4222 module. adapter module
TIM-ID: 0000073956 - 007
(hardware) ing values occur: wire

3276.7 or 3274.7. The
stopped.

286 Level monitor in con- If this limiter responds, Level monitor in con- • Check limiter set-
densate trap a high signal is sent to densate trap has been ting
the controller and the tripped. • Defective limiter
“machine” safety cir-
ly.
287 Gas pressure in digest- If this limiter responds, Gas pressure monitor • Check limiter set-
er a high signal is sent to in digester has been ting
the controller and the tripped. • Defective limiter
ly.
288 Gas pressure monitor If this limiter responds, Gas pressure monitor • Check limiter set-
before compressor a high signal is sent to before compressor has ting
the controller and the been tripped. • Defective limiter
ly.
289 – Reserve # # #
315
316 Lube oil pump out of This fault indicates This message is active • Defective pump mo-
order whether there is a if the motor protection tor protection
pump fault. If there is a switch drops out. switch
fault, a high signal is • Incorrect setting of
sent to the controller motor protection
from the motor protec- switch
tion switch of the • Check pump con-
pump. This is used to nection (pump may
signal alarms. only run on 2 phas-
es)
317 Emergency cooler in- A low signal is sent to The sensor for insuffi- • Check water system
sufficient water the controller if the cient emergency cool- • Check sensor set-
sensor for insufficient er water has been trip- ting
emergency cooler wa- ped. • Sensor wire break
ter is tripped. The en- • Sensor defective
ly.
318 Safety sensor re- If this limiter responds, Safety sensor re- • Check limiter set-
serve 1 a high signal is sent to serve 1 has tripped. ting
the controller and the • Defective limiter
TIM-ID: 0000073956 - 007

ly.
ly.

ly.
ly.
ly.
ly.
ly.
ly.
326 Reserve # # #
TIM-ID: 0000073956 - 007
327 Mains protection from An external mains pro- If the external mains • Check digital input
external tection system is used protection has been signal and/or ca-
for monitoring the grid. tripped. bling
This fault signal is acti- • Check setting for
vated if this system mains protection
has been tripped and monitoring by the
the GCB or the MCB (in external mains pro-
case of mains isolation tection device
by the MCB) will open.

328 Differential protection/ The generator is moni- If the external differen- • Check digital input
ground-fault protec- tored by an external tial protection/ground- signal and/or ca-
tion, external, tripped differential protection/ fault protection has bling
ground-fault protection been tripped. • Check the setting of
system. If it is tripped, the external differ-
the GCB is opened and ential protection/
this fault message is ground-fault protec-
activated. The engine tion
stops immediately.
329 Battery charging cur- The battery charge cur- Always active • Check control bat-
rent, module control > rent is measured via an teries
limit value 2 analog input and moni- • Check setting
tored by the MMC. • This message may
be indicated in case
of successive start
attempts
330 Generator AVR: Error Generator fault Enabled after reaching • Check digital input
(e.g. overexcitation, rated speed. signal and/or ca-
underexcitation, etc.) bling
from digital voltage • Check generator
regulator by low signal. and voltage regula-
The GCB is opened and tor
the engine is shut
down immediately.
331 Ground-fault protection Internal ground-fault In case of warning • Check digital input
warning protection relay signals from internal ground- signal and/or ca-
warning. The machine fault protection relay. bling
will not be shut down. • Check mains con-
nection for ground
fault
• Check setting of the
internal ground-fault
protection relay
332 Differential protection Internal differential If the internal differen- • Check digital input
tripped protection relay has tial protection has signal and/or ca-
tripped. The machine is been tripped. bling
shut down. • Check protection
area for short circuit
or ground fault
internal differential
protection relay
333 Ground-fault protection Internal ground-fault If the internal ground- • Check digital input
is tripped protection relay has fault protection relay signal and/or ca-
TIM-ID: 0000073956 - 007
tripped. The machine is has been tripped. bling

shut down. • Check mains con-
nection for ground
fault
internal ground-fault
protection relay

334 Exciter failure detec- The exciter failure de- Enabled after reaching • Check wiring for
tion has tripped tection system moni- rated and generator voltage regulator
tors the generator volt- circuit breaker is on. and exciting field
age regulator output • Check voltage regu-
for excitation failure. lator
335 Grid code – Force An offset may be Always released. Deactivate grid code
mode is active specified for checking testing.
grid code functions. If
the offset is active, the
fault message will also
be active.
336 Grid code – power The module is shut If the corresponding Check grid code pa-
specification below down if, based on grid function was activated rameters.
minimum load code functions, an out- once, this message is
put value is specified always enabled and is
that lies below the par- activated externally by
ameterized threshold digital inputs.
337 Reserve # # #
338 Reserve # # #
339 IPC – write protection Write protection of par- Always Activate the write pro-
disabled tition C: of the IPC is tection via script on
not active. This must the admin account or
be activated for safety via HMI in the system
reasons related to the overview
operating system.
340 Power factor / reactive The upper or lower lim- Invalid signal value or • Check sensor
power default from it of the analog module defect of the analog • Check cabling
ESC (hardware) was reached. module. • Check analog input
module of controller
341 Gas alarm fault (gas This fault message is • Optional external • Check gas detector
detector failure) output by a gas detec- gas warning 1-stage • If the gas detector
tor. If it responds this selected in options did not respond, but
message is active. The list this message is indi-
module is shut down. • Via low signal from cated, check the ca-
The room fans are acti- connected gas de- bling of the feed-
vated. tector back signal contact
of the gas detector
to the controller
342 Incorrect position of In order that an exter- Always with active use Check the key switch
“Local/Remote” key nal genset controller of a genset controller at MIP/MMC for the
switch can control the engine, correct position
the “Local/Remote”
TIM-ID: 0000073956 - 007
key switch must be set

to Remote
343 Incorrect position of In order that an exter- Always with active use Check the key switch
key switch for Manual/ nal genset controller of a genset controller at MIP/MMC for the
Automatic mode can control the engine, correct position
the “Manual mode/
Automatic mode” key
switch must be set to
Automatic

344 Gear oil temperature > This sensor is used to This temperature ex- Check gearbox or sen-
limit value 1 monitor the gearbox on ceeds a limit value sor.
60 Hz applications.
This fault is activated if
this temperature ex-
ceeds the set limit val-
nal alarms.
345 Gear oil temperature > This sensor is used to This temperature ex- Check gearbox or sen-
limit value 2 monitor the gearbox on ceeds a limit value sor.
60 Hz applications.
This fault is activated if
this temperature ex-
ceeds the set limit val-
ped.
346 Gear oil pressure < This transmitter is Enabled after reaching Check gearbox or
Min. used to monitor the rated speed. transmitter.
gearbox on 60 Hz ap-
plications. A low signal
is sent to the controller
if the transmitter is
tripped. The engine
stops immediately.
347 Gear oil temperature < This transmitter is This temperature ex- Increase temperature
limit value used to monitor the ceeds a limit value in engine room.
gearbox on 60 Hz ap-
plications. This fault is
activated if this tem-
perature falls below
the set limit value. The
engine can not be
started.
348 Gear oil temperature With an AT4222 mod- In case of wire break/ • Check sensor
(hardware) ule (4*PT100/1000, 2 short circuit or faulty • Check controller
3276.7 or 3274.7. The
stopped.
349 Inappropriate start/ Monitoring of the oper- Enable from 500 oper- Contact Service.
stop ratio: Please con- ating hours per GCB ating hours (500 = de-
tact your Service connection. The default value).
TIM-ID: 0000073956 - 007
fault limit value is de-

fined at 5 Bh/GCB.
This value is deter-
mined continuously by
average determination
of the last 1000Bh. If
this limit value is un-
dershot, an alarm is is-
sued.

350 Failure room circula- The room fan signals a Faulty digital input for • Check room fan
tion air fan fault. This may be a room fan signaled via • Check motor pro-
applicable)
351 Speed adjustment set- The speed signal for If an external controller • Check wiring to ex-
point value external the engine (external controls the speed ternal controller
controller (hardware) controller) is faulty. • Restart the external
controller
• Check settings of
the controller and
the MMC
352 Scavenging active dur- Engine was stopped Engine was stopped Start engine so that
ing next engine start with emergency stop with emergency stop the additional scaveng-
or did not finish start- or did not finish starting phase is carried out
ing successfully on ing successfully on to save the additional
several occasions. An several occasions. An time for the starting
additional scavenging additional scavenging sequence with a bal-
phase is initiated dur- phase is initiated dur- ancing energy/Fast-
ing the next engine ing the next engine Gas request.
start. start.
353 Mains protection de- Faulty communication Activated by the op- Check cabling
vice: Communication to external, optional tional Deif mains pro-
DEIF GPU3 disrupted mains protection detection device or by
vice the EMM.
354 Generator protection – The generator frequen- Activated by the op- • Check setting for
overfrequency 2 cy is monitored for ex- tional Deif mains pro- overfrequency in
ceeding of the set re- tection device or by HMI
sponse value. The set- the EMM. • Engine speed is too
ting is made in an ex- high, check speed
ternal, optional mains governor
protection device. If
TIM-ID: 0000073956 - 007

overfrequency 3 cy is monitored for ex- tional Deif mains pro- overfrequency in
ceeding of the set re- tection device or by HMI
sponse value. The set- the EMM. • Engine speed is too
ting is made in an ex- high, check speed
ternal, optional mains governor
underfrequency 2 cy is monitored for tional Deif mains pro- underfrequency in
dropping below the set tection device or by HMI
response value. The the EMM. • Engine speed is too
setting is made in an high, check speed
external, optional governor
mains protection de-
vice. If the response
disconnected from
of the “Command:
ly shut down.
underfrequency 3 cy is monitored for tional Deif mains pro- underfrequency in
dropping below the set tection device or by HMI
response value. The the EMM. • Engine speed is too
setting is made in an high, check speed
external, optional governor
disconnected from
of the “Command:
TIM-ID: 0000073956 - 007
ly shut down.

358 Generator protection – The generator voltage Activated by the op- • Check setting for
overvoltage 2 is monitored for ex- tional Deif mains pro- overvoltage in HMI
ceeding of the set re- tection device or by • Check the voltage
sponse value. The set- the EMM. regulator settings in
ting is made in an ex- the generator
ternal, optional mains
undervoltage 2 is monitored for drop- tional Deif mains pro- undervoltage in HMI
ping below the set re- tection device or by • Check the voltage
not reached, the gener-
ator will be disconnect-
undervoltage 3 is monitored for drop- tional Deif mains pro- undervoltage in HMI
ping below the set re- tection device or by • Check the voltage
not reached, the gener-
ator will be disconnect-
TIM-ID: 0000073956 - 007

361 Generator protection - The generator output is Activated by the op- Check setting for over-
overload 2 monitored for exceed- tional Deif mains pro- load in HMI
ing of the set response tection device or by
value. The setting is the EMM.
made in an external,
optional mains protec-
tion device. If the re-
sponse value is ex-
ceeded, the generator
from power through
sponse value is ex-
from power through
sponse value is ex-
from power through
TIM-ID: 0000073956 - 007

sponse value is ex-
from power through
365 Generator protection – The effective power of Activated by the op- Check setting for re-
reverse load 2 the generator is moni- tional Deif mains pro- verse load in HMI
tored for dropping be- tection device or by
low the set response the EMM.
sponse value is not
from power through
366 Generator protection - The individual genera- Activated by the op- Check setting for over-
overcurrent stage 3 tor currents are moni- tional Deif mains pro- current at the HMI or
tored for exceeding of tection device or by at the 2nd EMM for
the limit value. The rat- the EMM. plants with step-up
ed transformer current transformer.
is used as the refer-
ence value. The setting
is made in an external,
tion device or, on
plants with a step-up
transformer, by an ad-
ditional energy meas-
uring module for gen-
TIM-ID: 0000073956 - 007
erator (2nd EMM avail-

able). If the response
“Command: Open
shut down.

overcurrent stage 4 tor currents are moni- tional Deif mains pro- current at the HMI or
tored for exceeding of tection device or by at the 2nd EMM for
the limit value. The rat- the EMM. plants with step-up
ed transformer current transformer.
tion device or, on
plants with a step-up
transformer, by an ad-
ditional energy meas-
uring module for gen-
erator (2nd EMM avail-
able). If the response
“Command: Open
shut down.
368 Generator protection – The individual genera- Activated by the op- Check setting for over-
overcurrent fast limit1 tor currents are moni- tional Deif mains pro- current in HMI
tored for exceeding of tection device or by
the limit value. The rat- the EMM.
ed transformer current
sponse value is ex-
from power through
TIM-ID: 0000073956 - 007

overcurrent fast level2 tor currents are moni- tional Deif mains pro- current in HMI
tored for exceeding of tection device or by
sponse value is ex-
from power through
overcurrent voltage-de- tor currents are moni- tional Deif mains pro- current in HMI
pendent tored for exceeding of tection device or by
tion device.
If the response value is
TIM-ID: 0000073956 - 007

371 Mains protection – f >> Monitoring of the line EMM signals overfre- Wait until the mains
frequency is imperative quency from mains. failure has been re-
if the generator is utili- This signal is not ana- solved. If there is no
ty-connected. In case lyzed in mains failure actual mains failure, it
of a power outage operation may be due to one of
(e.g. brief interruption the following reasons:
of service), the utility- • Open circuit in line
connected generator voltage cabling to
must be automatically the external, option-
disconnected from the al mains protection
mains. The line fre- device
quency is monitored • Check setting of line
for exceeding of the frequency monitor-
set response value. ing in HMI
an external, optional
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

372 Mains protection – Monitoring of the line EMM signals overfre- Wait until the mains
overfrequency 3 frequency is imperative quency from mains. failure has been re-
for exceeding of the frequency monitor-
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

373 Mains protection – f << Monitoring of the line EMM signals overfre- Wait until the mains
frequency is imperative quency from mains. failure has been re-
for dropping below the frequency monitor-
connected from the
protection signals
The remaining reac-
mains backup mode,
to the program de-
pending on the op-
tions.
374 Mains protection facili- Monitoring of the reac- This is tripped by the Wait until the mains
ty - Q & V protection 1 tive power as a func- optional Deif mains failure has been re-
tion of the line voltage protection device. solved. If there is no
Q(V) is optional and is actual mains failure, it
categorized as plant may be due to one of
protection. the following reasons:
1. Open circuit in line
voltage cabling to
the external, op-
tional mains pro-
tection device
2. Check setting of
mains reactive
TIM-ID: 0000073956 - 007
power monitoring
in HMI

375 Mains protection facili- Monitoring of the reac- This is tripped by the Wait until the mains
ty - Q & V protection 2 tive power as a func- optional Deif mains failure has been re-
tion of the line voltage protection device. solved. If there is no
Q(V) is optional and is actual mains failure, it
categorized as plant may be due to one of
protection. the following reasons:
1. Open circuit in line
voltage cabling to
the external, op-
tional mains pro-
tection device
2. Check setting of
mains reactive
power monitoring
in HMI
376 Mains protection facili- Monitoring of the line This is tripped by the Wait until the mains
ty - overvoltage 1 voltage is imperative if optional Deif mains failure has been re-
the generator is utility- protection device. solved. If there is no
connected. In case of a actual mains failure, it
power outage may be due to one of
mains. The mains line- device
to-line voltages are • Check setting of line
monitored for exceed- voltage monitoring
ing of the set response in HMI
sponse value is ex-
The remaining reac-
mains backup mode,
to the program de-
TIM-ID: 0000073956 - 007
pending on the op-

tions.

ty - overvoltage 2 voltage is imperative if optional Deif mains failure has been re-
monitored for exceed- voltage monitoring
ing of the set response in HMI
sponse value is ex-
The remaining reac-
mains backup mode,
to the program de-
pending on the op-
tions.
TIM-ID: 0000073956 - 007

ty - undervoltage 1 voltage is imperative if optional Deif mains failure has been re-
monitored for dropping voltage monitoring
below the set response in HMI
sponse value is not
reached, the system
from the mains. All of
the mains protection
parameterized as an
mains backup mode,
to the program de-
pending on the op-
tions.
379 Mains protection – The time-dependent Always released. Wait until the mains
time-dependent under- voltages of the fixed failure has been re-
voltage 1-3 FRT curve were not solved. If there is no
reached for points 1-3. actual mains failure, it
If the response value is may be due to one of
not reached, the sys- the following reasons:
tem will be disconnect- • Open circuit in line
ed from the mains. The voltage cabling to
remaining reactions the external, option-
(e.g. initiate mains al mains protection
backup mode, open device
generator circuit • Check setting of line
breaker, ...) are linked voltage monitoring
TIM-ID: 0000073956 - 007
to the program de- in HMI

pending on the op-
tions.

380 Mains protection – The time-dependent Always released. Wait until the mains
voltage 4-6 FRT curve were not solved. If there is no
reached for points 4-6. actual mains failure, it
If the response value is may be due to one of
not reached, the sys- the following reasons:
tem will be disconnect- • Open circuit in line
ed from the mains. The voltage cabling to
remaining reactions the external, option-
pending on the op-
tions.
381 Mains protection - acti- FRT was detected Always released. Wait until the mains
vation of time-depend- failure has been re-
ent undervoltage 1 solved. If there is no
actual mains failure, it
may be due to one of
the following reasons:
• Open circuit in line
voltage cabling to
the external, option-
al mains protection
device
• Check setting of line
voltage monitoring
in HMI
382 Mains protection - The time-dependent Always released. Wait until the mains
voltage 1 FRT curve were not solved. If there is no
reached. If the re- actual mains failure, it
sponse value is not may be due to one of
reached, the system the following reasons:
will be disconnected • Open circuit in line
from the mains. The re- voltage cabling to
maining reactions the external, option-
pending on the op-
TIM-ID: 0000073956 - 007
tions.
383 Mains protection de- Parameter configura- If the external mains parameterize the de-
vice: Parameters not tion of the external protection device (DE- vice once again
identical mains protection de- IF) is available, always
vice was not success-
ful

384 Mains protection - The mains protection Optional, in mains par- Check mains connec-
FRT1 has detected an FRT allel operation tion
(Fault Ride Through). Contact power supply
Due to the dynamic company
mains support, the
plant remained on the
mains and rode
through the fault (volt-
age dip).
385 Mains protection - The mains protection Optional, in mains par- Check mains connec-
FRT2 has detected an FRT allel operation tion
(Fault Ride Through). Contact power supply
Due to the dynamic company
mains support, the
plant remained on the
mains and rode
through the fault (volt-
age dip).
386 External power factor The corresponding ex- If analog value 52 is Check wiring and ex-
(CosPhi) for the power ternal signal is not reused, this message is ternal source
factor control - (hard- ceived enabled
ware fault)
387 REL-Feed in manage- The upper or lower lim- Invalid signal value or • Check sensor
ment setpoint active it of the analog module defect of the analog • Check cabling
power generator (hard- was reached. module. • Check analog input
ware) module of controller
388 Q-U-protection on GCB The Q-V protection (ra- Optional, in mains par- • Check reactive pow-
tripped tio between reactive allel operation er control and set-
power and voltage) has tings
tripped and the GCB • Waiting until the line
was opened voltage has normal-
ized again
• Contact power sup-
ply company
389 Q-U-protection on MCB The Q-V protection (ra- Optional, in mains par- • Check reactive pow-
tripped tio between reactive allel operation er control and set-
power and voltage) has tings
tripped and MCB was • Waiting until the line
opened voltage has normal-
ized again
• Contact power sup-
ply company
390 Main switch auxiliaries The main switch on the Always Find out who turned it
MMC/AUX open door of the control off.
TIM-ID: 0000073956 - 007
cabinet was set man- Turn the main switch

ually to "Off" back on (front door of
control cabinet) after
consultation with all in-
volved personnel

391 Main switch auxiliaries The main switch on the Always Find out who turned it
MIP open door of the control off.
cabinet was set man- Turn the main switch
ually to "Off" back on (front door of
control cabinet) after
consultation with all in-
volved personnel
392 Generator voltage of The energy measure- Released at rated • Check generator
2nd energy measurement module has de- speed wiring
ment module failure tected a failure of the • Check wiring to 2nd
generator voltage. energy measure-
ment module
393 Load controller – auto- This message is only a If the above-mentioned Determine and analyze
matic load reduction warning. conditions are met and cause of power reduc-
Several factors may if the power controller tion. For example, the
trigger the automatic has been enabled and power reduction could
reduction in power: is in “power control- have been tripped by
1.) Reduction by en- ling” state. an increased coolant
gine (knocking) temperature. In this
2.) Gas exchange case, the coolant tem-
3.) Generator perature must be re-
4.) Mixture coolant in- duced to end the pow-
let temperature er reduction.
5.) Mixture coolant
temperature at outlet
6.) Heating water inlet
temperature
7.) Heating water tem-
perature at outlet
394 Minimum load After rated speed has Rated speed reached. Check specified power
been reached, monitor- + actual power for en-
ing of engine operation gine.
at minimum power
takes place. The mini-
mum power and the
delay are parameter-
ized in this fault mes-
sage.
395 Minimum load in auto- After rated speed has Rated speed reached + Check specified power
matic mode been reached in auto- automatic mode, fault + actual power for en-
matic mode, monitor- message 394 active. gine
ing of engine operation
at minimum power
takes place. The mini-
TIM-ID: 0000073956 - 007
mum power and the

delay are parameter-
ized in fault message
394. In manual mode,
this message is deacti-
vated.

396 Mixture coolant tem- Dew point monitoring Always Check mixture coolant
perature < limit value is enabled when the system including mix-
(dew point undershot) engine is running. If P4 ture coolant tempera-
is > P4 target and the ture control
delay time has
elapsed, this fault mes-
sage is active. (P4 = P-
mixture before throt-
tle).
397 Start/stop sequence - Unloading takes place This monitoring is • Check throttle.
maximum relief time down a power ramp if started if: • Check generator cir-
exceeded stopping is initiated by • The Start command cuit breaker.
cancellation of the is reset
Start command or on • Fault messages con-
receiving fault messag- figured to respond
es configured to re- with controlled shut-
spond with controlled down are active
shutdown. The ma-
chine must be unload-
ed and the generator
circuit breaker opened
within a configurable
time window.
398 Lube oil refill – time ex- This message is acti- Lube oil refilling is • Check oil level and
ceeded vated if lube oil refilling pending for the set oil replenishment
was not successful af- time of the fault mes- status.
ter a specific time. The sage. • Check solenoid
engine is shut down in valve and/or lube
a controlled manner. oil pump for refill-
The time to be set de- ing.
pends on the custom- • Check lube oil sys-
er-specific configura- tem.
tion (e.g. with/without • Check connector of
pump). auto lube system.
399 Start termination From start phase 2 on- • Synchronization is If the cause is the devi-
ward, whether syn- not initiated from ation of the generator
chronization has been start phase 2 on- frequency or generator
initiated is monitored. ward in automatic voltage, then refer to
If this is not the case, mode the corresponding fault
from this start phase • The engine runs in message
onward this message manual mode in idle
becomes active in au- (from start phase 2
tomatic mode after a onward)
delay time. The engine
is then shut down. If
TIM-ID: 0000073956 - 007
the engine is started in

manual mode and ini-
tiation of the synchro-
nization is overlooked,
this message becomes
active after 1 hour. The
engine is then also
shut down.

400 Check whether all pa- This message is used Always Check connection of
rameters for fault mes- for internal testing pur- IPC and PLC
sages have been read poses (to check that all
in fault message parame-
ters are read-in).
401 LO P-Lube oil (FC 015) Engine oil pressure too Engine oil pressure too 1. Check oil system,
low (limit value 1). No low (limit value 1). No oil heat exchanger.
oil in engine, engine oil in engine, engine 2. Replace oil filter.
speed too low, oil lines, speed too low, oil lines, 3. Take oil sample
oil heat exchanger oil heat exchanger and analyze.
clogged, oil pump faul- clogged, oil pump faul-
ty. ty.
402 SS P-Lube oil (FC 016) Engine oil pressure too Engine oil pressure too 1. Check oil system,
low (limit value 2). No low (limit value 2). No oil heat exchanger.
oil in engine, engine oil in engine, engine 2. Replace oil filter.
speed too low, oil lines, speed too low, oil lines, 3. Take oil sample
oil heat exchanger oil heat exchanger and analyze.
clogged, oil pump faul- clogged, oil pump faul-
ty. ty.
403 HI T-Exhaust A (FC Exhaust gas tempera- Exhaust gas tempera- 1. Check exhaust tur-
019) ture (A side) after tur- ture (A side) after turbocharger.
bine too high (limit val- bine too high (limit val- 2. Check ignition tim-
ue 1). Incorrect ignition ue 1). Incorrect ignition ing.
timing, mixture too timing, mixture too 3. Check mixture set-
lean or too rich, dam- lean or too rich, dam- ting.
age to turbine. age to turbine. 4. Check igniters.
404 SS T-Exhaust A (FC Exhaust gas tempera- Exhaust gas tempera- 1. Check exhaust tur-
020) ture (A side) after tur- ture (A side) after turbocharger.
405 HI T-Exhaust B (FC Exhaust gas tempera- Exhaust gas tempera- 1. Check exhaust tur-
021) ture (B side) after tur- ture (B side) after turbocharger.
406 SSI T-Exhaust B (FC Exhaust gas tempera- Exhaust gas tempera- 1. Check exhaust tur-
022) ture (B side) after tur- ture (B side) after turbocharger.
TIM-ID: 0000073956 - 007


407 HI P-Diff-Lube oil (FC Pressure loss via oil fil- Pressure loss via oil fil- 1. Replace oil filter.
025) ter too high (limit val- ter too high (limit val- 2. If this fault mes-
ue 1). ue 1). sage occurs again
after unexpectedly
short filter run-
time, check oil fil-
ter for deposits,
change oil as nec-
essary.
408 SS P-Diff-Lube oil (FC Pressure loss via oil fil- Pressure loss via oil fil- 1. Replace oil filter.
026) ter too high (limit value ter too high (limit value 2. If this fault mes-
2). 2). sage occurs again
after unexpectedly
short filter run-
time, check oil fil-
ter for deposits,
change oil as nec-
essary.
409 SS Engine Overspeed Overspeed detected by Overspeed detected by 1. Check speed gov-
(FC 030) ECU. This fault mes- ECU. This fault mes- ernor.
sage usually follows sage usually follows 2. Check throttle
other fault messages. other fault messages. closing position.
Check speed governor, Check speed governor,
throttle closing posi- throttle closing posi-
tion. tion.
410 HI ETC1 Overspeed (FC Speed of turbocharger Speed of turbocharger 1. Check intake air
031) 1 too high (limit value 1 too high (limit value temperature.
1). 1). 2. Check emissions.
3. If the sensor is not
obstructed, check
the conditions for
activating this
monitoring feature
in the ECU param-
eter record.
411 SS ETC1 Overspeed Speed of turbocharger Speed of turbocharger 1. Check intake air
(FC 032) 1 too high (limit value 1 too high (limit value temperature.
obstructed, check
the conditions for
activating this
monitoring feature
in the ECU param-
TIM-ID: 0000073956 - 007
eter record.
412 HI ETC2 Overspeed (FC Speed of turbocharger Speed of turbocharger 1. Check intake air
036) 2 too high (limit value 2 too high (limit value temperature.
obstructed, check
the conditions for
activating this
monitoring feature
in the ECU param-
eter record.

413 SS ETC2 Overspeed Speed of turbocharger Speed of turbocharger 1. Check intake air
(FC 037) 2 too high (limit value 2 too high (limit value temperature.
obstructed, check
the conditions for
activating this
monitoring feature
in the ECU param-
eter record.
414 HI T-Lube oil (FC 051) Engine oil temperature Engine oil temperature 1. Check engine cool-
after oil heat exchang- after oil heat exchang- ant circuit.
er too high (limit value er too high (limit value 2. Check oil heat ex-
1). Oil heat exchanger 1). Oil heat exchanger changer.
contaminated, coolant contaminated, coolant 3. Check oil level.
temperature is too temperature is too
high. Insufficient oil high. Insufficient oil
volume flow rate. volume flow rate.
415 SS T-Lube oil (FC 052) Engine oil temperature Engine oil temperature 1. Check engine cool-
after oil heat exchang- after oil heat exchang- ant circuit.
er too high (limit value er too high (limit value 2. Check oil heat ex-
2). Oil heat exchanger 2). Oil heat exchanger changer.
contaminated, coolant contaminated, coolant 3. Check oil level.
temperature is too temperature is too
high. Insufficient oil high. Insufficient oil
volume flow rate. volume flow rate.
416 HI T-Intake air (FC 053) Intake air temperature Intake air temperature Check ventilation sys-
too high (limit value 2). too high (limit value 2). tem.
417 HIHI T-Intake air (FC Intake air temperature Intake air temperature 1. Check ventilation
054) too high (limit value 2). too high (limit value 2). system.
2. Reduce power.
418 LO P-Coolant (FC 057) Coolant pressure after Coolant pressure after Check engine coolant
engine too low (limit engine too low (limit circuit (pressure and
value 1). Insufficient value 1). Insufficient flow).
volume flow, static volume flow, static
pressure too low. pressure too low.
419 SS P-Coolant (FC 058) Coolant pressure after Coolant pressure after Check engine coolant
engine too low (limit engine too low (limit circuit (pressure and
value 2). Insufficient value 1). Insufficient flow).
volume flow, static volume flow, static
pressure too low. pressure too low.
TIM-ID: 0000073956 - 007

420 HI P-Crankcase (FC Crankcase pressure Crankcase pressure 1. Check crank drive:
063) too high (limit 1). too high (limit 1). • Engine turning
Throttle in crankcase Throttle in crankcase • Endoscope
breather is closed too breather is closed too combustion
far, air filter is faulty, far, air filter is faulty, chambers from
oil separator is clog- oil separator is clog- bottom dead
ged, piston rings are ged, piston rings are center to top
seized, other damage seized, other damage dead center.
to crank drive. to crank drive. 2. Check air filter for
contamination, re-
place if contamina-
tion is visible.
3. Check setting of
blow-by throttle.
4. Check oil separa-
tor condition, re-
place as necessa-
ry.
421 SS P-Crankcase (FC Crankcase pressure Crankcase pressure 1. Check crank drive:
064) too high (limit value 2). too high (limit value 2). • Engine turning
Throttle in crankcase Throttle in crankcase • Endoscope
breather is closed too breather is closed too combustion
far, air filter is faulty, far, air filter is faulty, chambers from
oil separator is clog- oil separator is clog- bottom dead
ged, piston rings are ged, piston rings are center to top
seized, other damage seized, other damage dead center.
to crank drive. to crank drive. 2. Check air filter for
contamination, re-
place if contamina-
tion is visible.
3. Check setting of
blow-by throttle.
4. Check oil separa-
tor condition, re-
place as necessa-
ry.
422 HI T-Coolant (FC 067) Coolant temperature Coolant temperature Check engine coolant
after engine too high after engine too high circuit.
(limit value 1). Engine (limit value 1). Engine
coolant pump failure, coolant pump failure,
volumetric flow too volumetric flow too
low, air in engine cool- low, air in engine cool-
ant circuit. ant circuit.
423 SS T-Coolant (FC 068) Coolant temperature Coolant temperature Check engine coolant
after engine too high after engine too high circuit.
TIM-ID: 0000073956 - 007
(limit value 2). Engine (limit value 2). Engine


424 SS Engine speed too Engine is being stalled. Engine is being stalled. 1. In mains parallel
low (FC 089) The engine speed of The engine speed of operation:
the normally operating the normally operating • Check mains for
engine dropped below engine dropped below frequency drop.
the limit from parame- the limit from parame- • Check genera-
ter 2.2500.027 Limit ter 2.2500.027 Limit tor and coupling
Engine Speed Low Engine Speed Low for damage.
without any stop re- without any stop re- 2. In isolated opera-
quest. The engine is quest. The engine is tion:
shut down for safety shut down for safety • Check throttle
reasons. reasons. position.
• Check throttles
for implausible
closing. If throt-
tles are fully
open:
– Check if load
step values
are admissi-
ble.
• Check bypass
position.
• Check air filter
for contamina-
tion, replace if
contamination
is visible.
• Check exhaust
back pressure.
• Check differen-
tial pressure
over mixture
cooler.
• Check emis-
sions and injec-
tion timing.
• Check oil sepa-
rator efficiency
(oil in compres-
sor intake el-
bow), clean
compressor as
necessary.
• Check valve
clearance.
• Check gasket
TIM-ID: 0000073956 - 007
between mix-
ture line and
cylinder head
for correct fit-
ting position.
425 SS Idle Speed Not Idle speed not Idle speed not 1. Check ignition.
Reached (FC 090) reached. reached. 2. Check gas supply.
3. Check mixture set-
ting.

426 SS Release Speed Not The speed (starter DIS- The speed (starter DIS- 1. Check ignition.
Reached (FC 091) ENGAGE) was not at- ENGAGE) was not at- 2. Check gas supply.
tained, ignition not tained, ignition not 3. Check mixture set-
working or no gas working or no gas ting.
available. available.
427 SS Starter Speed Not Minimum speed for Minimum speed for Check starter system.
Reached (FC 092) scavenging process scavenging process
and ignition release and ignition release
was not attained. was not attained.
428 SS T-Preheat (FC 093) Preheating tempera- Preheating tempera- 1. Check preheating.
ture too low (limit val- ture too low (limit val- 2. Check differential
ue 2). Coolant temper- ue 2). Coolant temper- coolant pressure.
ature too low for en- ature too low for en- 3. Check heating ele-
gine start. gine start. ments.
4. Check cabling.
429 LO T-Preheat (FC 094) Preheating tempera- Preheating tempera- 1. Check preheating.
ture too low (limit val- ture too low (limit val- 2. Check differential
ue 1). Coolant temper- ue 1). Coolant temper- coolant pressure.
ature too low for en- ature too low for en- 3. Check heating ele-
gine start. gine start. ments.
4. Check cabling.
430 AL Prelubrication Fault Oil priming fault. Oil priming fault. 1. Check oil pressure,
(FC 095) oil temperature, oil
level.
2. Replace oil priming
pump.
431 AL Eng Hours Counter Operating hours meter Operating hours meter Replace Engine Control
Defect (FC 104) faulty. Internal Engine faulty. Internal Engine Unit.
Control Unit fault. Control Unit fault.
432 LO ECU Power Supply Supply voltage too low Supply voltage too low 1. Check supply volt-
Voltage (FC 118) (limit value 1). (limit value 1). age.
2. Check cabling.
433 LOLO ECU Power Sup- Supply voltage too low Supply voltage too low 1. Check supply volt-
ply Voltage (FC 119) (limit value 2). (limit value 2). age.
2. Check cabling.
434 HI ECU Power Supply Supply voltage too high Supply voltage too high 1. Check supply volt-
Voltage (FC 120) (limit value 1). (limit value). age.
2. Check cabling.
435 HIHI ECU Power Sup- Supply voltage too high Supply voltage too high 1. Check supply volt-
ply Voltage (FC 121) (limit value 2). (limit value 2). age.
2. Check cabling.
436 HI T-ECU (FC 122) Temperature of elec- Temperature of elec- 1. Ensure better cool-
TIM-ID: 0000073956 - 007
tronics too high (limit tronics too high (limit ing of the ECU. Re-
value 1). value 1). duce room temper-
ature, check air
flow to ECU.
2. Compare device
temperature with
temperature gauge
in DiaSys®.

437 AL LifeData not availa- Message from MTU en- Message from MTU en- #
ble (FC 176) gine management via gine management via
CAN bus. CAN bus.
438 AL LifeData restore in- Message from MTU en- Message from MTU en- #
complete (FC 177) gine management via gine management via
CAN bus. CAN bus.
439 AL CAN1 Node Lost Bus user (EMU) no lon- Bus user (EMU) no lon- Check operation of no-
(FC 180) ger present on CAN ger present on CAN des and cabling. Buses
bus 2. bus 2. (CAN bus 1 and CAN
bus 2) are redundant.
440 AL CAN2 Node Lost Bus user (EMU) no lon- Bus user (EMU) no lon- Check operation of no-
(FC 181) ger present on CAN ger present on CAN des and cabling. Buses
bus 2. bus 2. (CAN bus 1 and CAN
bus 2) are redundant.
441 AL CAN Wrong Param- Wrong parameter value Wrong parameter value Contact Service (con-
eters (FC 182) entered in data record. entered in data record. figuration error)
442 AL CAN No PU Data A CAN mode has been A CAN mode has been Contact Service (con-
(FC 183) selected that initiates selected that initiates figuration error)
communication with communication with
the help of the PU data the help of the PU data
module. However, the module. However, the
necessary PU data necessary PU data
module is not present module is not present
or is invalid. or is invalid.
443 AL CAN PU-Data Flash A program error occur- A program error occur- Contact Service (con-
Error (FC 184) red while trying to copy red while trying to copy figuration error)
a received PU data a received PU data
module to the flash module to the flash
module. module.
444 AL CAN1 Bus Off (FC CAN controller 1 is in CAN controller 1 is in Check operation of no-
186) “Bus-Off” status. Auto- “Bus-Off” status. Auto- des and cabling.
matic switching to CAN matic switching to CAN
bus 2. Bus devices bus 2. Bus devices
(ECU or EMU) faulty. (ECU or EMU) faulty.
445 AL CAN1 Error Passive CAN Controller 1 has CAN Controller 1 has Check operation of no-
(FC 187) signaled a warning. signaled a warning. des and cabling.
Possible causes may Possible causes may
be, e.g. missing associ- be, e.g. missing associ-
ated nodes, minor mal- ated nodes, minor mal-
functions or temporary functions or temporary
bus overload. bus overload.
TIM-ID: 0000073956 - 007
188) “Bus-Off” status. Auto- “Bus-Off” status. Auto- des and cabling.
matic switching to CAN matic switching to CAN
bus 1. Bus devices bus 1. Bus devices
(ECU or EMU) faulty. (ECU or EMU) faulty.
447 AL CAN2 Error Passive CAN controller 2 has CAN controller 2 has Check operation of no-
(FC 189) indicated a warning. indicated a warning. des and cabling.
Possible causes may Possible causes may
be, e.g. missing associ- be, e.g. missing associ-
ated nodes, minor mal- ated nodes, minor mal-
functions or temporary functions or temporary
bus overload. bus overload.

448 AL EMU Parameter Not EMU parameters are EMU parameters are Contact Service (con-
Supported (FC 190) not supported. not supported. figuration error)
449 SD T-Coolant (FC 201) Coolant temperature Coolant temperature Check sensor and ca-
sensor at engine outlet sensor at engine outlet bling (B6.1), replace as
faulty, short circuit or faulty, short circuit or necessary. Error
wire break. wire break. cleared after restarting
the engine.
450 SD Level Lube Oil (FC Engine oil level sensor Engine oil level sensor Check sensor and ca-
204) faulty, short circuit or faulty, short circuit or bling (B24), replace as
wire break. wire break. necessary. Error
cleared after restarting
the engine.
451 SD T-Exhaust A (FC Exhaust temperature Exhaust temperature Check sensor and ca-
206) sensor on A side faulty, sensor on A side faulty, bling (B4.21), replace
short circuit or wire short circuit or wire as necessary. Error
break. break. cleared after restarting
the engine.
452 SD T-Exhaust B (FC Exhaust temperature Exhaust temperature Check sensor and ca-
207) sensor on B side faulty, sensor on B side faulty, bling (B4.22), replace
the engine.
453 SD P-Lube Oil (FC 211) Engine oil pressure Engine oil pressure Check sensor and ca-
sensor after filter faul- sensor after filter faul- bling (B5.1), replace as
ty, short circuit or wire ty, short circuit or wire necessary. Error
the engine.
454 SD P-Coolant (FC 212) Coolant pressure sen- Coolant pressure sen- Check sensor and ca-
sor after engine faulty, sor after engine faulty, bling (B16.1), replace
the engine.
455 SD P-Crankcase (FC Crankcase pressure Crankcase pressure Check sensor and ca-
214) sensor faulty, short cir- sensor faulty, short cir- bling (B50), replace as
cuit or wire break. cuit or wire break. necessary. Error
the engine.
456 SD T-Lube Oil (FC 216) Engine oil temperature Engine oil temperature Check sensor and ca-
sensor after oil heat sensor after oil heat bling (B7), replace as
exchanger faulty, short exchanger faulty, short necessary. Error
circuit or wire break. circuit or wire break. cleared after restarting
the engine.
TIM-ID: 0000073956 - 007
457 SD T-Intake Air (FC Intake air temperature Intake air temperature Check sensor and ca-
219) sensor faulty, short cir- sensor faulty, short cir- bling (B49.1 / B90), re-
cuit or wire break. cuit or wire break. place as necessary. Er-
ror cleared after re-
starting the engine.

458 SD P-Diff Lube Oil (FC Engine oil pressure Engine oil pressure Check sensor and ca-
221) sensor faulty, short cir- sensor faulty, short cir- bling before fil-
cuit or wire break. cuit or wire break. ter (B5.3) and after fil-
ter (B5.1), replace as
necessary. Error
the engine.
459 SD Oil Pressure before Engine oil pressure Engine oil pressure Check sensor and ca-
Filter (FC 227) sensor before filter sensor before filter bling (B5.3), replace as
faulty, short circuit or faulty, short circuit or necessary. Error
wire break. wire break. cleared after restarting
the engine.
460 AL Stop Camshaft Sen- Engine stop due to Engine stop due to Check sensor and ca-
sor Defect (FC 229) camshaft sensor fail- camshaft sensor fail- bling (B1.1), replace as
ure. ure. necessary. Error
the engine.
461 SD Camshaft Speed Camshaft sensor faul- Camshaft sensor faul- Check sensor and ca-
(FC 231) ty, short circuit or wire ty, short circuit or wire bling (B1.1), replace as
break. break. necessary. Error
the engine.
462 SD Charger 1 Speed Speed sensor of turbo- Speed sensor of turbo- 1. Check sensor and
(FC 232) charger 1 faulty, short charger 1 faulty, short cabling (B44.1), re-
circuit or wire break. circuit or wire break. place as necessa-
ry. Error cleared
after restarting the
engine.
obstructed, check
the conditions for
activating this
monitoring feature
in the ECU param-
eter record.
463 SD Charger 2 Speed Speed sensor of turbo- Speed sensor of turbo- 1. Check sensor and
(FC 233) charger 2 faulty, short charger 2 faulty, short cabling (B44.2), re-
circuit or wire break. circuit or wire break. place as necessa-
ry. Error cleared
after restarting the
engine.
obstructed, check
the conditions for
TIM-ID: 0000073956 - 007
activating this
monitoring feature
in the ECU param-
eter record.
464 SD ECU Power Supply Internal Engine Control Internal Engine Control Replace ECU.
Voltage (FC 245) Unit fault. Unit fault.

465 SD Speed Demand (FC Speed setting signal Speed setting signal 1. Check Engine Con-
266) can no longer be trans- can no longer be trans- trol Unit setting
mitted from plant. mitted from plant. (default setting is
speed demand via
CAN bus).
2. Check signal and
cabling between
plant and ECU.
466 AL Wiring TOP 1 (FC Short circuit or wire Short circuit or wire Check cabling.
381) break at transistor out- break at transistor out-
put 1 plant side (TOP put 1 plant side (TOP
1). Activation of yellow 1). Activation of yellow
summary alarm faulty. summary alarm faulty.
2). Activation of red 2). Activation of red
summary alarm faulty. summary alarm faulty.
3). Activation of gas 3). Activation of gas
supply solenoid valve supply solenoid valve
No.1 faulty. No.1 faulty.
4). Activation of gas 4). Activation of gas
supply solenoid valve supply solenoid valve
No. 2 faulty. No. 2 faulty.
470 SD T-Intake Air B (FC Intake air temperature Intake air temperature Check sensor and ca-
418) sensor faulty, short cir- sensor faulty, short cir- bling (B49.2), replace
cuit or wire break. cuit or wire break. as necessary.
471 SD T-Coolant before Coolant temperature Coolant temperature Check sensor and ca-
Engine (FC 419) sensor at engine inlet sensor at engine inlet bling (B6.3), replace as
faulty, short circuit or faulty, short circuit or necessary.
wire break. wire break.
472 LO P-Coolant Differ- Coolant differential Coolant differential Check engine coolant
ence (FC 423) pressure too low (limit pressure too low (limit circuit (pressure and
value 1). Insufficient value 1). Insufficient volume flow).
volume flow. volume flow.
473 HI P-Coolant (FC 429) Coolant pressure after Coolant pressure after Check engine coolant
engine too high (limit engine too high (limit circuit (pressure and
TIM-ID: 0000073956 - 007
value 3). value 3). volume flow).

474 LO P-Coolant before Coolant pressure be- Coolant pressure be- Check engine coolant
Engine (FC 430) fore engine too low fore engine too low circuit (pressure and
(limit value 1). Insuffi- (limit value 1). Insuffi- volume flow).
cient volume flow, stat- cient volume flow, stat-
ic pressure too low. ic pressure too low.

475 SS P-Coolant before Coolant pressure be- Coolant pressure be- Check engine coolant
Engine (FC 431) fore engine too low fore engine too low circuit (pressure and
(limit value 2). Insuffi- (limit value 2). Insuffi- volume flow).
cient volume flow, stat- cient volume flow, stat-
ic pressure too low. ic pressure too low.
476 HI T-Coolant before En- Coolant temperature Coolant temperature Check engine coolant
gine (FC 434) before engine too high before engine too high circuit (pressure and
(limit value 1). Engine (limit value 1). Engine volume flow).
477 SS T-Coolant before Coolant temperature Coolant temperature Check engine coolant
Engine (FC 435) before engine too high before engine too high circuit (pressure and
(limit value 2). Engine (limit value 2). Engine volume flow).
478 HI P-Charge Mix Diff Difference in mixture Difference in mixture 1. Check throttles for
(FC 443) pressures sensed on A pressures sensed on A varying positions
and B side is too high and B side is too high and malfunction.
(limit value 1). (limit value 1). 2. Check mixture line
for leakage.
3. Check sensors and
wiring (B79.22,
B79.21).
479 HIHI P-Charge Mix Diff Difference in mixture Difference in mixture 1. Check throttles for
(FC 447) pressures sensed on A pressures sensed on A varying positions
and B side is too high and B side is too high and malfunction.
(limit value 2). (limit value 2). 2. Check mixture line
for leakage.
3. Check sensors and
wiring (B79.22,
B79.21).
480 HI T-Charge Mix (FC Mixture temperature Mixture temperature 1. Check mixture
451) too high (limit value 2). too high (limit value 2). cooling circuit.
Mixture coolant pump Mixture coolant pump 2. Check mixture
failure, volumetric flow failure, volumetric flow cooler for dirt.
too low, cooling sys- too low, cooling sys-
tem inlet temperature tem inlet temperature
too high, mixture cool- too high, mixture cool-
er clogged. er clogged.
481 HIHI T-Charge Mix (FC Mixture temperature Mixture temperature 1. Check mixture
TIM-ID: 0000073956 - 007
452) too high (limit value 2). too high (limit value 2). cooling circuit.
Mixture coolant pump Mixture coolant pump 2. Check mixture
failure, volumetric flow failure, volumetric flow cooler for dirt.
too low, cooling sys- too low, cooling sys-
tem inlet temperature tem inlet temperature
too high, mixture cool- too high, mixture cool-
er clogged. er clogged.

482 LO T-Charge Mix (FC Mixture temperature is Mixture temperature is 1. Check intake air
453) too low (limit value 3). too low (limit value 3). temperature.
2. Check mixture
cooling circuit.
483 SS Power Reduction Power reduction acti- Power reduction acti- 1. Rectify limit value
Active (FC 454) vated. vated. violation of the
source alarm (e.g.
reduce intake air
temperature).
2. Check exhaust
system compo-
nents for leaks/
cracks.
484 LO T-Intake Air (FC Intake air temperature Intake air temperature Check ventilation sys-
457) is too low (limit value is too low (limit value tem.
3). 3).
485 LOLO T-Intake Air (FC Intake air temperature Intake air temperature Check ventilation sys-
458) is too low (limit value is too low (limit value tem.
4). 4).
486 SD P-Coolant b. Engine Coolant pressure sen- Coolant pressure sen- Check sensor and ca-
(FC 459) sor faulty, short circuit sor faulty, short circuit bling (B16.3), replace
or wire break. or wire break. as necessary. Error
the engine.
487 SD T-ECU (FC 470) Temperature sensor in Temperature sensor in Replace ECU.
Engine Control Unit Engine Control Unit
faulty. faulty.
488 AL Stop SD (FC 472) Engine stop since all Engine stop since all Summary alarm (for
shutdown channels shutdown channels details, refer to the
signal “sensor failure”. signal “sensor failure”. source alarm).
489 AL Wiring PWM_CM2 Message from MTU en- Message from MTU en- #
(FC 473) gine management via gine management via
CAN bus. CAN bus.
490 AL Comb. Alarm Yel Summary alarm YEL- Summary alarm YEL- Summary alarm (for
(Plant) (FC 478) LOW from system. LOW from system. details, refer to the
source alarm).
491 AL Comb. Alarm Red Summary alarm RED Summary alarm RED Summary alarm (for
(Plant) (FC 479) from system. from system. details, refer to the
source alarm).
492 SD P-Charge Mix A (FC Mixture pressure sen- Mixture pressure sen- Check sensor and ca-
496) sor on A side faulty, sor on A side faulty, bling (B79.21), replace
TIM-ID: 0000073956 - 007

the engine.
493 SD P-Charge Mix B (FC Mixture pressure sen- Mixture pressure sen- Check sensor and ca-
497) sor on B side faulty, sor on B side faulty, bling (B79.22), replace
the engine.

494 SD P-Charge Mix Diff Mixture differential Mixture differential Check sensor and wir-
(FC 498) pressure sensor on A pressure sensor on A ing (B79.21, B79.22),
or B side faulty, short or B side faulty, short replace if necessary.
circuit or wire break. circuit or wire break. Error cleared after re-
495 SD T-Charge Mix (FC Mixture temperature Mixture temperature Check sensor and ca-
499) sensor faulty, short cir- sensor faulty, short cir- bling (B73), replace as
cuit or wire break. cuit or wire break. necessary. Error
the engine.
496 HIHI P-Charge Mix A Mixture pressure on A Mixture pressure on A 1. Check emissions.
(FC 511) side too high (limit val- side too high (limit val- 2. Check ignition tim-
ue 2). ue 2). ing.
3. Check exhaust
back pressure.
4. Check valve clear-
ance.
5. Check throttle.
6. Check mixture
coolant system.
497 HIHI P-Charge Mix B Mixture pressure on B Mixture pressure on B 1. Check emissions.
(FC 512) side too high (limit val- side too high (limit val- 2. Check ignition tim-
ue 2). ue 2). ing.
3. Check exhaust
back pressure.
4. Check valve clear-
ance.
5. Check throttle.
6. Check mixture
coolant system.
498 SD P-Coolant Diff (FC Coolant pressure sen- Coolant pressure sen- Check sensor and wir-
513) sor faulty, short circuit sor faulty, short circuit ing (B16.1, B16.3), re-
or wire break. or wire break. place if necessary. Er-
ror cleared after re-
499 AL Starter Not Engag- Starter not engaged. Starter not engaged. 1. Check starter.
ed (FC 515) ECU does not detect ECU does not detect 2. Check cabling.
engine speed during engine speed during 3. Check speed sen-
starting sequence. starting sequence. sor B1.1 if speed is
not indicated al-
though engine is
turning.
500 SD P-Charge Mix be- Mixture pressure sen- Mixture pressure sen- Check sensor and ca-
fore Throttle (FC 517) sor before throttle faul- sor before throttle faul- bling (B79.23), replace
TIM-ID: 0000073956 - 007
ty, short circuit or wire ty, short circuit or wire as necessary. Error
the engine.
501 SD P-Intake Air after Intake air pressure Intake air pressure Check sensor and ca-
Filter A (FC 520) sensor after filter on A sensor after filter on A bling (B81.1), replace
side faulty, short cir- side faulty, short cir- as necessary. Error
cuit or wire break. cuit or wire break. cleared after restarting
the engine.

502 SD P-Intake Air after Intake air pressure Intake air pressure Check sensor and ca-
Filter B (FC 522) sensor after filter on B sensor after filter on B bling (B81.2), replace
side faulty, short cir- side faulty, short cir- as necessary. Error
cuit or wire break. cuit or wire break. cleared after restarting
the engine.
503 AL Wiring PWM_CM1 Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
504 AL Wiring PWM1 (FC Message from MTU en- Message from MTU en- #
532) gine management via gine management via
CAN bus. CAN bus.
505 AL Wiring PWM2 (FC Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
506 AL Multiple FDH Slaves Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
507 AL Configuration Message from MTU en- Message from MTU en- #
Changed (FC 544) gine management via gine management via
CAN bus. CAN bus.
508 AL GasControlCheck Gas regulating unit test Gas regulating unit test 1. Gas regulating
Fault (FC 552) was not successful. was not successful. unit.
Alarm is activated if Alarm is activated if 2. Check cabling.
the gas regulating unit the gas regulating unit
does not report OK does not report OK
within a specified time- within a specified time-
out period. Either the out period. Either the
gas regulating unit leak gas regulating unit leak
test was not success- test was not success-
ful, the timeout period ful, the timeout period
is set too short, or is set too short, or
communication is faul- communication is faul-
ty. ty.
509 AL Ignition Fault (FC Ignition failure. Alarm Ignition failure. Alarm 1. Check ignition sys-
554) is activated if the feed- is activated if the feed- tem.
back signal from igni- back signal from igni- 2. Check ignition sys-
tion system is not re- tion system is not re- tem speed sen-
ceived within a speci- ceived within a speci- sors.
fied timeout period. Ei- fied timeout period. Ei- 3. Check cabling.
ther the ignition could ther the ignition could
not be activated, the not be activated, the
timeout period is set timeout period is set
too short, or communi- too short, or communi-
TIM-ID: 0000073956 - 007
cation is faulty. cation is faulty.

510 AL GasValve Fault (FC Gas supply solenoid Gas supply solenoid 1. Gas regulating
556) valve faulty. Alarm is valve faulty. Alarm is unit.
activated when prob- activated when prob- 2. Check cabling.
lems with the gas sup- lems with the gas sup-
ply solenoid valves oc- ply solenoid valves oc-
cur. Either the gas sup- cur. Either the gas sup-
ply solenoid valves are ply solenoid valves are
faulty, the timeout pe- faulty, the timeout pe-
riod is set too short, or riod is set too short, or
communication is faul- communication is faul-
ty. ty.
511 AL EngineSpeedCol- Speed dip. Alarm is ac- Speed dip. Alarm is ac- Gas regulating unit.
lapse Fault (FC 557) tivated if engine speed tivated if engine speed
dips during starting se- dips during starting se-
quence. quence.
512 AL mixture throttle A A problem related to A problem related to Check mixture throttle
fault (FC 559) mixture throttle on A mixture throttle on A on A side and cabling.
side occurred. Possible side occurred. Possible Replace mixture throt-
causes: causes: tle on A side as neces-
• Mixture throttle faul- • Mixture throttle faul- sary.
ty. ty.
• Mixture throttle has • Mixture throttle has
no power supply. no power supply.
• There is a problem • There is a problem
with the wiring for with the wiring for
the feedback the feedback
and/or position sig- and/or position sig-
nal. nal.
513 AL mixture throttle B A problem related to A problem related to Check mixture throttle
fault (FC 560) mixture throttle on B mixture throttle on B on B side and cabling.
side occurred. Possible side occurred. Possible Replace mixture throt-
causes: causes: tle on B side as neces-
• Mixture throttle faul- • Mixture throttle faul- sary.
ty. ty.
• Mixture throttle has • Mixture throttle has
no power supply. no power supply.
• There is a problem • There is a problem
with the wiring for with the wiring for
the feedback the feedback
and/or position sig- and/or position sig-
nal. nal.
514 AL L1 P-Intake Air after Pressure loss over air Pressure loss over air Fit new air filters.
Filter A (FC 565) filter on A side is too filter on A side is too
high. high.
TIM-ID: 0000073956 - 007
Filter A (FC 566) filter on A side is too filter on A side is too
high. high.
Filter B (FC 567) filter on B side is too filter on B side is too
high. high.
Filter B (FC 568) filter on B side is too filter on B side is too
high. high.

518 AL SAM Missing Data This alarm is activated This alarm is activated Check the cabling/
Fault (FC 569) if the ECU does not re- if the ECU does not re- connectors of the devi-
ceive some messages ceive some messages ces connected to bus
to be transmitted from to be transmitted from users EMU and ECU.
EMU. Possible problem EMU. Possible problem Replace devices as
related to CAN bus, related to CAN bus, necessary.
EMU does not work EMU does not work
properly or a device properly or a device
connected to EMU connected to EMU
does not work properly does not work properly
so that EMU can not so that EMU can not
transmit the messages transmit the messages
from this device suc- from this device suc-
cessfully. cessfully.
519 L1 Al CAN Max. Re- Due to detected Due to detected 1. Check emissions.
tarded Timing (FC 570) knocking, the cylinder knocking, the cylinder 2. Check ignition tim-
set to maximum reset to maximum re- ing.
tarded timing has vio- tarded timing (ignition 3. Check combustion
lated the limit value. point) has exceeded chamber.
the limit value. 4. Check gas quality
if feasible (meth-
ane number).
tarded timing (ignition tarded timing (ignition 3. Check combustion
point) has exceeded point) has exceeded chamber.
the second limit value. the second limit value. 4. Check gas quality
Power reduction is ini- Power reduction is ini- if feasible (meth-
tiated. tiated. ane number).
tarded timing (ignition tarded timing (ignition 3. Check combustion
point) has exceeded point) has exceeded chamber.
the third limit value. the third limit value. 4. Check gas quality
if feasible (meth-
ane number).
522 AL Circuit Breaker Generator load switch Generator load switch 1. Check generator
Closed (FC 583) does not open when does not open when load switch.
engine stops. Engine is engine stops. Engine is 2. Disconnect gener-
motoring. motoring. ator switch man-
ually.
3. Open mains circuit
TIM-ID: 0000073956 - 007
breaker if availa-
ble.
4. Do not actuate
manual emergency
off if possible.
523 AL Hut Changespeed Excessively rapid Excessively rapid Check gas system.
max. (FC 604) change in gas quality. change in gas quality.
524 LO Current Value Hu Fuel calorific value has Fuel calorific value has Check gas quality if
(FC 617) fallen below the first fallen below the first feasible.
limit value. limit value.

525 LOLO Current Value Hu Fuel calorific value has Fuel calorific value has Check gas quality if
(FC 618) exceeded the second exceeded the second feasible.
526 HI Current Value Hu Fuel calorific value has Fuel calorific value has Check gas quality if
(FC 619) exceeded the first limit exceeded the first limit feasible.
value. value.
527 HIHI Current Value Hu Fuel calorific value has Fuel calorific value has Check gas quality if
(FC 620) exceeded the second exceeded the second feasible.
528 LO Nox Value (FC 621) NOx emissions have NOx emissions have 1. Check gas quality
undershot the first lim- undershot the first lim- if feasible.
it value. it value. 2. Check gas pres-
sure.
3. Check NOx sensor.
4. Check emissions.
529 LOLO Nox Value (FC NOx emissions have NOx emissions have 1. Determine gas
622) undershot the second undershot the second quality if possible.
limit value. limit value. 2. Check gas pres-
sure.
3. Check NOx sensor.
4. Check emissions.
530 HI NOx Value (FC 623) NOx emissions have NOx emissions have 1. Determine gas
exceeded the first limit exceeded the first limit quality if possible.
value. value. 2. Check NOx sensor.
3. Check emissions.
531 HIHI NOx Value (FC NOx emissions have NOx emissions have 1. Determine gas
624) exceeded the second exceeded the second quality if possible.
limit value. limit value. 2. Check NOx sensor.
3. Check emissions.
532 AL Knock Intensity (FC Knock intensity ex- Knock intensity ex- 1. Determine gas
646) ceeded (extreme ceeded (extreme quality if possible
knocking detected). knocking detected). (methane number).
2. Check emissions.
3. Check combustion
chamber.
533 AL Deviation Throttle A Opening angle of throt- Opening angle of throt- 1. Check charge
(FC 649) tles A exceeded. tles A exceeded. pressure reserve.
2. Intake air tempera-
ture outside TVU
Data
3. Check compressor
for contamination.
4. Check exhaust
TIM-ID: 0000073956 - 007
system on engine
side for leakage.
5. Reduce power.

534 AL Deviation Throttle B Opening angle of throt- Opening angle of throt- 1. Check charge
(FC 650) tles B exceeded. tles B exceeded. pressure reserve.
2. Intake air tempera-
ture outside TVU
Data
3. Check compressor
for contamination.
4. Check exhaust
system on engine
side for leakage.
5. Reduce power.
535 AL Preheating Error Engine preheating faul- Engine preheating faul- 1. Low coolant.
(FC 651) ty. ty. 2. Missing differential
pressure in coolant
system.
3. Coolant pump
does not start/is
faulty.
536 AL GET Comm Lost (FC CAN bus communica- CAN bus communica- 1. Check cabling.
652) tion to knock control tion to knock control 2. Check power sup-
faulty. faulty. ply.
3. Carry out restart of
ECU, AMU and
knock control.
4. Check settings us-
ing device-specific
dialog software
(XD10).
537 AL IC92x Comm Lost CAN bus communica- CAN bus communica- 1. Check cabling.
(FC 653) tion to ignition system tion to ignition system 2. Check power sup-
ECU, AMU and ig-
nition system.
ing device-specific
dialog software.
538 AL FSeries Comm Lost CAN bus communica- CAN bus communica- 1. Check cabling.
(FC 654) tion to bypass flap faul- tion to bypass flap faul- 2. Check power sup-
ty. ty. ply.
ECU, AMU and by-
pass flap.
TIM-ID: 0000073956 - 007
ing device-specific
dialog software
(XD50.3).

539 AL TecJet Comm Lost CAN bus communica- CAN bus communica- 1. Check cabling.
(FC 655) tion to gas control tion to gas control 2. Check power sup-
valve faulty (alterna- valve faulty (alterna- ply.
tively a stepper motor tively a stepper motor 3. Carry out restart of
with gas mixer can be with gas mixer can be ECU, AMU and gas
installed). installed). control valve.
ing device-specific
dialog software
(XD11).
540 AL ProActA Comm Lost CAN bus communica- CAN bus communica- 1. Check cabling.
(FC 656) tion to throttle B faulty. tion to throttle B faulty. 2. Check power sup-
ply.
ECU, AMU and
throttle A.
ing device-specific
dialog software
(XD50.1).
541 AL ProActB Comm Lost CAN bus communica- CAN bus communica- 1. Check cabling.
(FC 657) tion to throttle B faulty. tion to throttle B faulty. 2. Check power sup-
ply.
ECU, AMU and
throttle B.
ing device-specific
dialog software
(XD50.2).
542 AL NOxA Comm Lost CAN bus communica- CAN bus communica- 1. Check cabling.
(FC 658) tion to NOx sensor is tion to NOx sensor is 2. Check power sup-
3. Restart ECU.
4. Replace sensor.
543 AL NOxB Comm Lost CAN bus communica- CAN bus communica- 1. Check cabling.
(FC 659) tion to NOx sensor B is tion to NOx sensor is 2. Check power sup-
3. Restart ECU.
4. Replace sensor.
544 AL PhytronA Comm Message from MTU en- Message from MTU en- #
Lost (FC 660) gine management via gine management via
CAN bus. CAN bus.
545 AL PhytronB Comm Message from MTU en- Message from MTU en- #
TIM-ID: 0000073956 - 007
Lost (FC 661) gine management via gine management via

CAN bus. CAN bus.
546 AL Oil Refill (FC 664) Summary alarm for au- Summary alarm for au- A programmable time
tomatic oil replenish- tomatic oil replenish- period starts after sig-
ment. ment. naling of the alarms
"HI Oil Refill" and
"HI LUBE LEVEL refill".
The engine is stopped
when this time expires.

547 AL GET Yellow (FC An internal summary An internal summary Precise error name is
665) alarm in knock control alarm in knock control transmitted via the
was detected. was detected. CAN bus to the genset
controller.
548 AL IC92x Yellow (FC An internal summary An internal summary Precise error name is
666) alarm in the ignition alarm in the ignition transmitted via the
system was detected. system was detected. CAN bus to the genset
controller.
549 AL FSeries Yellow (FC An internal summary An internal summary Precise error name is
667) alarm in the bypass alarm in the bypass transmitted via the
flap was detected. flap was detected. CAN bus to the genset
controller.
550 AL TecJet Yellow (FC An internal summary An internal summary Precise error name is
668) alarm in the gas con- alarm in the gas con- transmitted via the
trol valve was detect- trol valve was detect- CAN bus to the genset
ed. ed. controller.
551 AL ProActA Yellow (FC An internal summary An internal summary Precise error name is
669) alarm in throttle A was alarm in throttle A was transmitted via the
detected. detected. CAN bus to the genset
controller.
552 AL ProActB Yellow (FC An internal summary An internal summary Precise error name is
670) alarm in throttle B was alarm in throttle B was transmitted via the
controller.
553 AL NOxA Yellow (FC An internal summary An internal summary Precise error name is
671) alarm at NOx sensor A alarm at NOx sensor A transmitted via the
controller.
554 AL NOxB Yellow (FC An internal summary An internal summary Precise error name is
672) alarm at NOx sensor B alarm at the NOx sen- transmitted via the
was detected. sor was detected. CAN bus to the genset
controller.
555 AL PhyA Yellow (FC Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
556 AL PhyB Yellow (FC Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
557 AL GET Red (FC 675) An internal summary An internal summary Precise error name is
alarm in knock control alarm in knock control transmitted via the
controller.
TIM-ID: 0000073956 - 007
558 AL IC92x Red (FC 676) An internal summary An internal summary Precise error name is
alarm in the ignition alarm in the ignition transmitted via the
controller.
559 AL FSeries Red (FC An internal summary An internal alarm in the Precise error name is
677) alarm in the bypass bypass flap was de- transmitted via the
flap was detected. tected. CAN bus to the genset
controller.

560 AL TecJet Red (FC 678) An internal summary An internal summary Precise error name is
alarm in the gas con- alarm in the gas con- transmitted via the
trol valve was detect- trol valve was detect- CAN bus to the genset
ed. ed. controller.
561 AL ProActA Red (FC An internal summary An internal summary Precise error name is
679) alarm in throttle A was alarm in throttle A was transmitted via the
controller.
562 AL ProActB Red (FC An internal summary An internal summary Precise error name is
680) alarm in throttle B was alarm in throttle B was transmitted via the
controller.
563 AL NOxA Red (FC 681) An internal summary An internal summary Precise error name is
alarm at NOx sensor A alarm at NOx sensor A transmitted via the
controller.
564 AL NOxB Red (FC 682) An internal summary An internal summary Precise error name is
alarm at NOx sensor B alarm at NOx sensor B transmitted via the
controller.
565 AL PhyA Red (FC 683) Message from MTU en- Message from MTU en- #
gine management via gine management via
CAN bus. CAN bus.
566 AL PhyB Red (FC 684) Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
567 AL Lube Oil Min (FC Minimum engine oil fill- Minimum engine oil fill- 1. Check engine oil
685) ing level detected. ing level detected. level.
2. Check replenish-
ment system.
3. Top up oil.
568 AL Lube Oil Max (FC Maximum engine oil Maximum engine oil 1. Check engine oil
686) filling level detected. filling level detected. level.
2. Check replenish-
ment system.
3. Drain oil.
569 LO Oil Refill (FC 688) No oil replenishment No oil replenishment Check oil replenish-
within a programmable within a programmable ment system.
time. time.
570 HI Oil Refill (FC 689) Engine oil was refilled Engine oil was refilled Check engine oil level.
too often within a cer- too often within a cer- Check oil supply.
tain time interval. tain time interval.
TIM-ID: 0000073956 - 007
571 HI Lube Oil Level refill Engine oil was refilled Engine oil was refilled Check engine oil level.
(FC 691) too often within a cer- too often within a cer- Check oil supply.
tain time interval. tain time interval.
572 SD T-Gas (FC 694) Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
573 AL T-Gas L1 (FC 719) 1st lower limit value 1st lower limit value Check gas supply.
violated. violated.

574 AL T-Gas L2 (FC 720) 2nd lower limit value 2nd lower limit value Check gas supply.
violated. violated.
575 SD P-Ambient Air (FC Ambient air pressure Ambient air pressure Replace ECU.
445) sensor on ECU defec- sensor on ECU defec-
tive. tive.
576 AL Crash Rec. Init. Er- Crash recorder initiali- Crash recorder initiali- Contact Service
ror (FC 476) zation error. zation error.
577 AL Wiring PWM_CM1 Open load or short cir- Open load or short cir- Check cabling to igni-
(FC 536) cuit on channel cuit on channel tion.
PWM_CM1. PWM_CM1.
578 AL Wiring PWM_CM7 Open load or short cir- Open load or short cir- Check cabling to NOx
(FC 609) cuit on channel cuit on channel sensor on A side.
PWM_CM7. PWM_CM7.
579 SD P-Ambient Air Message from MTU en- Message from MTU en- #
(HDT2800) (FC 633) gine management via gine management via
CAN bus. CAN bus.
580 SD T0-Ambient Air Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
581 SD Air Humidity Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
582 SD electr. engine pow- Motor power sensor Motor power sensor 1. Effective generator
er AI2 (FC 642) defect (analog input 2). defect (analog input 2). power not trans-
mitted correctly.
2. Effective generator
power can option-
ally be transmitted
via the CAN bus.
3. Check plant con-
trol application en-
gineering.
583 AL ActFuelValvePos L1 TecJet throttle position TecJet throttle position Check gas supply.
(FC 842) has exceeded limit val- has exceeded limit val-
ue 1. ue 1.
584 AL Rel. Humidity L1 Calculated air humidity Calculated air humidity Check air humidity.
(FC 848) has exceeded limit val- has exceeded limit val-
ue 1. ue 1.
585 AL turning activated Engine was stopped Engine was stopped 1. Await end of scav-
(FC 891) with emergency stop with emergency stop enging phase.
or did not finish start- or did not finish start- 2. Check engine
TIM-ID: 0000073956 - 007
ing successfully on ing successfully on speed. A speed of

several occasions. several occasions. at least 80 rpm
must be reached.
586 AL MIC5 Yellow (FC An internal summary An internal summary Precise error name is
932) alarm in the ignition alarm in the ignition transmitted via the
controller.

587 AL MIC5 Red (FC 933) An internal summary An internal summary Precise error name is
alarm in the ignition alarm in the ignition transmitted via the
controller.
588 AL MIC5 Comm Lost CAN bus communica- CAN bus communica- Check cabling.
(FC 934) tion to ignition system tion to ignition system
faulty. faulty.
589 AL ESI activated (FC Emergency stop input Emergency stop input 1. Rectify cause of
948) has been activated. has been activated. alarm.
2. Check cabling.
590 AL MIC5 Signature dif- The ignition system The ignition system 1. Restart ECU.
ference (FC 972) has not accepted the has not accepted the 2. Check setting at
configuration from the configuration from the Engine Control
Engine Control Unit. Engine Control Unit. Unit.
974) “Bus-Off” status. Bus “Bus-Off” status. Bus des and cabling.
nodes (ignition, knock nodes (ignition, knock
module, throttles or module, throttles or
gas mixture) malfunc- gas mixture) malfunc-
tioning. tioning.
592 AL CAN3 Error Passive CAN controller 3 has CAN controller 3 has Check operation of no-
(FC 975) indicated a warning. indicated a warning. des and cabling.
Bus nodes (ignition, Bus nodes (ignition,
knock module, throt- knock module, throt-
tles or gas mixture) tles or gas mixture)
malfunctioning. malfunctioning.
976) “Bus-Off” status. Bus “Bus-Off” status. Bus des and cabling.
nodes (ignition, knock nodes (ignition, knock
module, throttles or module, throttles or
gas mixture) malfunc- gas mixture) malfunc-
tioning. tioning.
594 AL CAN4 Error Passive CAN controller 4 has CAN controller 4 has None.
(FC 977) indicated a warning. indicated a warning.
595 AL Develop PR Set (FC The ECU parameter re- The ECU parameter re- Load series parameter
596) cord in use is a test cord in use is a test record on ECU.
version. version.
596 SD Air Humidity (FC Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
597 AL MIC5 parameter Parameter download Parameter download Wait until parameter
download active (FC from ECU to ignition from ECU to ignition downloading has been
TIM-ID: 0000073956 - 007
1012) system is active. system is active. completed. Max. time

is approx. 2 min.
598 HI Delta NOx (A-B) (FC NOx values measured NOx values measured 1. Check emissions.
1013) for banks A and B are for banks A and B are 2. Check NOx sen-
too far apart (limit val- too far apart (limit val- sors.
ue 1). ue 1). 3. Check ignition tim-
ing.

599 HIHI Delta NOx (A-B) NOx values measured NOx values measured 1. Check emissions.
(FC 1014) for banks A and B are for banks A and B are 2. Check NOx sen-
too far apart (limit val- too far apart (limit val- sors.
ue 2). ue 2). 3. Check ignition tim-
ing.
600 HI T-Exhaust A1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check emission
112301) ture of this cylinder is values.
too high in comparison 2. Check ignition tim-
with weighted average. ing.
3. Check valve drive
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
TIM-ID: 0000073956 - 007

(exhaust valves do
not close).
(exhaust valves do
not close).

(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
610 HIHI T-Exhaust A1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check emission
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
TIM-ID: 0000073956 - 007

(exhaust valves do
not close).

(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
620 HIHI T-Exhaust A1 Exhaust gas tempera- Initiated by EMU. 1. Check emission
(abs) (FC 112701) ture of this cylinder is values.
TIM-ID: 0000073956 - 007
too high. 2. Check ignition tim-

ing.
(exhaust valves do
not close).

ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
TIM-ID: 0000073956 - 007

ing.
(exhaust valves do
not close).

ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
630 HI T-Exhaust B1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check emission
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
TIM-ID: 0000073956 - 007

(exhaust valves do
not close).

(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
640 HIHI T-Exhaust B1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check emission
(exhaust valves do
not close).
TIM-ID: 0000073956 - 007

(exhaust valves do
not close).

(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
(exhaust valves do
not close).
TIM-ID: 0000073956 - 007

(exhaust valves do
not close).

(exhaust valves do
not close).
650 HIHI T-Exhaust B1 Exhaust gas tempera- Initiated by EMU. 1. Check emission
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
TIM-ID: 0000073956 - 007

ing.
(exhaust valves do
not close).

ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
ing.
(exhaust valves do
not close).
660 LO T-Exhaust A1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check igniter.
112401) ture of this cylinder is 2. Check emission
too low in comparison values.
with weighted average. 3. Check ignition tim-
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
TIM-ID: 0000073956 - 007

5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
TIM-ID: 0000073956 - 007
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
670 LOLO T-Exhaust A1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check igniter.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
TIM-ID: 0000073956 - 007
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
TIM-ID: 0000073956 - 007
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
679 LOLO T-Exhaust A10 Exhaust gas tempera- Initiated by EMU. 1. Check igniter.
(FC 112610) ture of this cylinder is 2. Check emission
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
680 LO T-Exhaust B1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check igniter.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
TIM-ID: 0000073956 - 007
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
TIM-ID: 0000073956 - 007
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
690 LOLO T-Exhaust B1 (FC Exhaust gas tempera- Initiated by EMU. 1. Check igniter.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
TIM-ID: 0000073956 - 007
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
TIM-ID: 0000073956 - 007
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.

ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
699 LOLO T-Exhaust B10 Exhaust gas tempera- Initiated by EMU. 1. Check igniter.
(FC 112620) ture of this cylinder is 2. Check emission
ing.
5. Check ignition
rail/ignition coil
for thermal and
mechanical dam-
age.
700 HI T-Exhaust Mean (FC Weighted average of all Initiated by EMU. 1. Check emission
112222) cylinder exhaust gas values.
temperatures is too 2. Check ignition tim-
high. ing.
(exhaust valves do
not close).
701 HIHI T-Exhaust Mean Weighted average of all Initiated by EMU. 1. Check emission
(FC 112223) cylinder exhaust gas values.
temperatures is too 2. Check ignition tim-
high. ing.
TIM-ID: 0000073956 - 007

(exhaust valves do
not close).
702 MD / SD T-Exhaust (FC Summary alarm (for Initiated by EMU. Summary alarm (for
112923) details, refer to the details, refer to the
source alarm). source alarm).
703 ECU Comm Lost (FC No communication Initiated by EMU. 1. Check ECU supply
113200) with ECU on CAN. voltage.
2. Check CAN con-
necting line.

704 AL Gas Valve 1 feed- Summary alarm, gas Initiated by EMU. 1. Check valve 1 and
back (FC 113601) solenoid valve 1 feed- cabling.
back does not corre- 2. Rectify cause of
spond with setpoint alarm.
signal.
705 AL GValve Status (in- Wire break or short cir- Initiated by EMU. Check cabling and ex-
ternal) (FC 113602) cuit at channel TO1- ternal diode and resis-
OUT or TO2-OUT. tor circuitry.
706 AL GVal Feedback (in- Gas solenoid valve log- Initiated by EMU. Check valve 1.
ternal) (FC 113603) ic feedback does not
correspond with set-
point signal.
707 SS Local Initiated Emergency stop de- Initiated by EMU. 1. Emergency stop
Emerg. Stop (FC tected. Emergency enabled.
113902) stop was released 2. Check speed gov-
manually (button), or ernor.
ignition system report- 3. Check throttle
ed overspeed. closing position.
708 – Reserve # # #
749
750 Zero Pressure Detect- No gas pressure/gas Initiated by TecJet. Check gas pressure.
ed - TecJet (FC flow detected.
1.4540.009)
751 Zero Flow Detected - No gas pressure/gas Initiated by TecJet. Check gas pressure.
TecJet (FC 1.4540.010) flow detected.
752 Flow not Reached - No gas flow detected. Initiated by TecJet. 1. Check inlet and
TecJet (FC 1.4540.011) outlet.
2. Check gas pres-
sure, gas quality,
gas filter, gas line
for obstruction.
3. Check engine for
overloading.
753 Valve Position Error - Unable to set the re- Initiated by TecJet. 1. Restart TecJet.
TecJet (FC 1.4540.012) quested flap control. 2. Check mechanical
system.
3. Replace TecJet.
754 High Electric Tempera- Ambient temperature Initiated by TecJet. 1. Restart TecJet.
ture - TecJet (FC too high. 2. Replace TecJet.
1.4540.013)
755 Electric Temperature Internal temperature Initiated by TecJet. 1. Restart TecJet.
Fail High - TecJet (FC sensor faulty. 2. Replace TecJet.
TIM-ID: 0000073956 - 007
1.4540.014)
756 FGT Fail High - TecJet Internal gas tempera- Initiated by TecJet. 1. Restart TecJet.
(FC 1.4540.015) ture sensor faulty. 2. Replace TecJet.
757 Delta P Fail High - Tec- Internal differential gas Initiated by TecJet. 1. Restart TecJet.
Jet (FC 1.4540.016) pressure sensor faulty. 2. Replace TecJet.
758 FGT Fail High - TecJet Internal gas pressure Initiated by TecJet. 1. Restart TecJet.
(FC 1.4540.017) sensor faulty. 2. Replace TecJet.

759 Coil Current Fail High - Actuator current limit Initiated by TecJet. 1. Restart TecJet.
TecJet (FC 1.4540.018) reached. 2. Check mechanical
system.
3. Replace TecJet.
760 Position Fail High - Internal position sen- Initiated by TecJet. 1. Restart TecJet.
TecJet (FC 1.4540.019) sor faulty. 2. Replace TecJet.
761 Electric Temperature Internal temperature Initiated by TecJet. 1. Restart TecJet.
Fail Low - TecJet (FC sensor faulty. 2. Replace TecJet.
1.4540.020)
762 FGT Fail Low - TecJet Internal gas tempera- Initiated by TecJet. 1. Restart TecJet.
(FC 1.4540.021) ture sensor faulty. 2. Replace TecJet.
763 Delta P Fail Low - Tec- Internal gas differential Initiated by TecJet. 1. Restart TecJet.
Jet (FC 1.4540.022) pressure sensor faulty. 2. Replace TecJet.
764 FGP Fail Low - TecJet Internal gas pressure Initiated by TecJet. 1. Restart TecJet.
(FC 1.4540.023) sensor faulty. 2. Replace TecJet.
765 Coil Current Fail Low - Actuator current limit Initiated by TecJet. 1. Restart TecJet.
TecJet (FC 1.4540.024) reached. 2. Check mechanical
system.
3. Replace TecJet.
766 Position Fail Low - Tec- Internal Position Sen- Initiated by TecJet. 1. Restart TecJet.
Jet (FC 1.4540.025) sor Defect. 2. Replace TecJet.
767 Analog Input Low Er- TecJet setting is not Initiated by TecJet. Check TecJet settings.
ror- TecJet (FC correct.
1.4540.026)
768 Analog Input High Error TecJet setting is not Initiated by TecJet. Check TecJet settings.
- TecJet (FC correct.
1.4540.027)
769 PWM Duty cycle Low TecJet setting is not Initiated by TecJet. Check TecJet settings.
Error - TecJet (FC correct.
1.4540.028)
770 PWM Duty Cycle High TecJet setting is not Initiated by TecJet. Check TecJet settings.
Error - TecJet (FC correct.
1.4540.056)
771 Battery Volt Low Error- Supply voltage has Initiated by TecJet. 1. Check supply volt-
TecJet (FC 1.4540.029) reached minimum limit age.
value. 2. Check cabling.
772 FGT Low Limit Error- Gas temperature be- Initiated by TecJet. 1. Check TecJet set-
TecJet (FC 1.4540.030) fore TecJet is below tings.
the preset limit value. 2. Check gas temper-
ature.
TIM-ID: 0000073956 - 007
773 Delta P Low Limit Error Pressure difference Initiated by TecJet. 1. Check TecJet set-
- TecJet (FC through TecJet below tings.
1.4540.031) the preset limit value. 2. Check TecJet in-
stallation direc-
tion.
774 FGP Low Limit Error - Gas pressure before Initiated by TecJet. 1. Check TecJet set-
TecJet (FC 1.4540.032) TecJet is below the tings.
preset limit value. 2. Check gas pres-
sure.

775 Battery Volt High Error Supply voltage has Initiated by TecJet. 1. Check supply volt-
- TecJet (FC reached maximum limit age.
1.4540.033) value. 2. Check cabling.
776 FGT High Limit Error- Gas temperature be- Initiated by TecJet. 1. Check TecJet set-
TecJet (FC 1.4540.034) fore TecJet is above tings.
the preset limit value. 2. Check gas temper-
ature.
777 Delta P High Limit Er- Pressure difference Initiated by TecJet. 1. Check TecJet set-
ror- TecJet (FC through TecJet above tings.
1.4540.035) the preset limit value. 2. Check gas pres-
sure.
778 FGP High Limit Error - Gas pressure before Initiated by TecJet. 1. Check TecJet set-
TecJet (FC 1.4540.036) TecJet is above the tings.
preset limit value. 2. Check gas pres-
sure.
779 Watchdog Reset - Tec- Hardware not ready for Initiated by TecJet. Restart TecJet.
Jet (FC 1.4540.037) operation.
780 CAN Flow Demand Position setpoint not Initiated by TecJet. 1. Check supply volt-
Failed - TecJet (FC received or received age.
1.4540.038) too late. 2. Check cabling.
781 TecJet Shutdown (FC Summary alarm (for Initiated by TecJet. Rectify cause of alarm.
1.4540.040) details, refer to the
source alarm).
782 TecJet Internal Fault Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
(FC 1.4540.041) operation. 2. Replace TecJet.
783 Keyswitch state - Tec- Secondary alarm fol- Initiated by TecJet. 1. Rectify cause of
Jet (FC 1.4540.042) lowing emergency en- alarm.
gine stop. 2. Check cabling.
784 Parameter Error - Tec- Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
Jet (FC 1.4540.043) operation. 2. Replace TecJet.
785 Parameter Version Er- Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
ror - TecJet operation. 2. Replace TecJet.
(1.4540.044)
786 Main EEP Read Fail - Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
TecJet (FC 1.4540.045) operation. 2. Replace TecJet.
787 Main EEP Write Fail - Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
788 Reading Parameters - Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
789 SPI ADC Error - TecJet Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
TIM-ID: 0000073956 - 007

790 Sense 5V Error - TecJet Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
791 Sense Neg 9V Error - Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
792 Sense 12V Error - Tec- Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
793 ADC Test Error - TecJet Hardware not ready for Initiated by TecJet. 1. Restart TecJet.

794 CAN Timing Changed - CAN baud rate change Initiated by TecJet. 1. Check TecJet set-
TecJet (FC 1.4540.053) detected. tings.
2. Check cabling.
795 Exception Error - Tec- Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
796 Factory Cal Error - Tec- Hardware not ready for Initiated by TecJet. 1. Restart TecJet.
797 Reserve # # #
798 Reserve # # #
799 Reserve # # #
800 Primary Open Cylinder Disruption in primary Initiated by MIC5. 1. Check cabling to
1 - MIC5 (FC circuit of cylinder 1 in ignition coil.
1.4520.570) ignition sequence. 2. Check ignition coil.
TIM-ID: 0000073956 - 007

820 Primary Short Circuit Short circuit in primary Initiated by MIC5. 1. Check cabling to
Cylinder 1 - MIC5 (FC circuit of cylinder 1 in ignition coil.
TIM-ID: 0000073956 - 007


840 – Reserve # # #
849
850 Error Missing Ring Crankshaft signal 182 Initiated by IC922. Check sensor B13.2,
Gear Signal - IC92x (FC teeth is missing. sensor distance and
1.4520.232) wiring. Replace as nec-
essary.
851 Error Missing Reset Reset signal from Initiated by IC922. Check sensor B75,
Signal - IC92x (FC crankshaft is missing. sensor distance and
TIM-ID: 0000073956 - 007

essary.
852 Error Missing Camshaft Missing camshaft sig- Initiated by IC922. Check sensor B1.2,
Signal - IC92x (FC nal for ignition system. sensor distance and
essary.
853 Error Number of Gear Incorrect number of Initiated by IC922. 1. Check settings at
Teeth - IC92x (FC teeth detected on tim- ignition system.
1.4520.235) ing wheel. 2. Check sensor and
sensor gaps.

854 Unknown Engine Appli- Ignition setting is not Initiated by IC922. Check settings at igni-
cation Code - IC92x correct. tion system.
(FC 1.4520.236)
855 Overspeed Shutdown - Genset has exceeded Initiated by IC922. Restart ignition.
IC92x (FC 1.4520.237) admissible speed.
856 E2PROM Checksum Er- Hardware not ready for Initiated by IC922. 1. Restart ignition.
ror - IC92x (FC operation. 2. Replace ignition.
1.4520.238)
857 Global Timing out of Specified global igni- Initiated by IC922. 1. Adapt value in ECU
Range - IC92x (FC tion timing is beyond parameter set.
1.4520.239) the valid range. 2. Check settings at
ignition system.
858 Unknown Global Tim- No global ignition tim- Initiated by IC922. Check wiring and set-
ing or Energy Level - ing and power level re- tings.
IC92x (FC 1.4520.240) ceived, CAN bus con-
nection is faulty.
859 Individual Timing out of Specified individual ig- Initiated by IC922. 1. Adapt value in ECU
Range - IC92x (FC nition timing is beyond parameter set.
1.4520.241) the valid range. 2. Check settings at
ignition system.
860 Selftest Shutdown - Self-test is active with Initiated by IC922. Restart ignition.
IC92x (FC 1.4520.242) the engine rotating.
861 Open Primary Rate Ex- Admissible summation Initiated by IC922. 1. Check associated
ceeded - IC92x (FC of discharge faults is cabling.
1.4520.243) reached. 2. Check ignition coil.
862 Open Primary Channel Ignition energy was not Initiated by IC922. 1. Check cabling to
1 - IC92x (FC discharged. ignition coil.
1.4520.245) 2. Check ignition coil.
TIM-ID: 0000073956 - 007


882 Open Primary Channel Reserve Reserve Reserve
21 - IC92x (FC
1.4520.266)
22 - IC92x (FC
TIM-ID: 0000073956 - 007
1.4520.267)
23 - IC92x (FC
1.4520.268)
24 - IC92x (FC
1.4520.269)

886 Warning Missing Ring Crankshaft speed sig- Initiated by IC922. Check sensor B13.3,
Gear Signal - IC92x (FC nal 182 teeth is miss- sensor distance and
1.4520.270) ing. wiring. Replace as nec-
essary.
887 Warning Missing Reset Reset signal from Initiated by IC922. Check sensor B75,
Signal - IC92x (FC crankshaft is missing. sensor distance and
essary.
888 Warning Missing Cam- Missing camshaft sig- Initiated by IC922. Check sensor B1.2,
shaft Signal - IC92x nal for ignition system. sensor distance and
(FC 1.4520.272) wiring. Replace as nec-
essary.
889 SCR Fault Odd - IC92x Hardware not ready for Initiated by IC922. 1. Restart ignition.
(FC 1.4520.273) operation. 2. Check cabling to
ignition coil.
890 SCR Fault Even - IC92x Hardware not ready for Initiated by IC922. 1. Restart ignition.
(FC 1.4520.274) operation. 2. Check cabling to
ignition coil.
891 Odd Energy Level out Specified energy level Initiated by IC922. Adapt value in ECU pa-
of Range - IC92x (FC is beyond the valid rameter set.
1.4520.275) range.
892 Even Energy Level out Specified energy level Initiated by IC922. Adapt value in ECU pa-
of Range - IC92x (FC is beyond the valid rameter set.
1.4520.276) range.
893 – Reserve # # #
899
900 Secondary Open Cylin- Disruption in secon- Initiated by MIC5. 1. Check ignition
der 1 - MIC5 (FC dary current circuit of lead, connector
1.4520.610) cylinder 1 in ignition and igniter.
sequence. 2. Check ignition coil.
TIM-ID: 0000073956 - 007


TIM-ID: 0000073956 - 007


920 Secondary Short Cir- Short circuit in secon- Initiated by MIC5. 1. Check ignition
cuit Cylinder 1 - MIC5 dary current circuit of lead, connector
(FC 1.4520.630) cylinder 1 in ignition and igniter.
TIM-ID: 0000073956 - 007


940 – Reserve # # #
949
950 Knock Sensor Error A1 No signal from this Initiated by anti-knock 1. Check cabling.
- GET (FC 1.4510.192) knock sensor. control. 2. Check sensor
(tightening torque,
damage), replace
as necessary.
951 Knock Sensor Error B1 No signal from this Initiated by anti-knock 1. Check cabling.
(tightening torque,
TIM-ID: 0000073956 - 007
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.

(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
TIM-ID: 0000073956 - 007
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.

(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
(tightening torque,
damage), replace
as necessary.
968 Knock Sensor Error No signal from this Initiated by anti-knock 1. Check cabling.
A10 - GET (FC knock sensor. control. 2. Check sensor
1.4510.201) (tightening torque,
damage), replace
as necessary.
969 Knock Sensor Error No signal from this Initiated by anti-knock 1. Check cabling.
B10 - GET (FC knock sensor. control. 2. Check sensor
1.4510.211) (tightening torque,
damage), replace
as necessary.
970 Reserve # # #
971 Error Status - GET (FC Summary alarm (for Initiated by anti-knock 1. Rectify cause of
1.4510.186) details, refer to the control. alarm
source alarm). 2. Restart knock
module.
972 Combined Error - GET Summary alarm (for Initiated by anti-knock Rectify cause of alarm.
(FC 1.4510.187) details, refer to the control.
TIM-ID: 0000073956 - 007
source alarm).
973 Internal Error - GET (FC Hardware not ready for Initiated by anti-knock 1. Restart knock
1.4510.188) operation. control. module.
2. Replace knock
module.
974 Error Camshaft - GET No signal from cam- Initiated by anti-knock 1. Check cabling.
(FC 1.4510.189) shaft sensor for anti- control. 2. Check sensor
knock control. B1.3, replace as
necessary.

975 – Reserve # # #
999
1000 A - Internal Fault - Pro- Hardware not ready for Initiated by throttle of 1. Restart throttle.
Act (FC 1.4550.031) operation. cylinder bank A. 2. Replace throttle.
1001 A - Stop Command Throttle setting is not Initiated by throttle of Check throttle setting.
(Run/Stop) - ProAct correct. cylinder bank A.
(FC 1.4550.032)
1002 A - Input (Supply) Volt- Upper or lower limit of Initiated by throttle of 1. Check supply volt-
age Fault - ProAct (FC supply voltage cylinder bank A. age.
1.4550.033) reached. 2. Check cabling.
1003 A - Position Error - Pro- Position specification Initiated by throttle of 1. Check mechanical
Act (FC 1.4550.034) and feedback signal do cylinder bank A. system.
not match. 2. Restart throttle.
1004 A - Temperature Sen- Internal temperature Initiated by throttle of 1. Restart throttle.
sor Fault - ProAct (FC sensor faulty. cylinder bank A. 2. Replace throttle.
1.4550.035)
1005 A - Temperature Derat- Internal Temperature Initiated by throttle of 1. Check room tem-
ing Active - ProAct (FC above 100 °C. Adjust- cylinder bank A. perature and venti-
1.4550.036) ment speed is re- lation.
duced. 2. Restart throttle.
1006 A - Temperature above Internal temperature Initiated by throttle of 1. Check room tem-
120 °C - ProAct (FC above 120 °C. cylinder bank A. perature and venti-
1.4550.037) lation.
2. Restart throttle.
1007 A - Loss of Position De- Position setpoint is Initiated by throttle of 1. Check throttle set-
mand - ProAct (FC missing or out of cylinder bank A. tings.
1.4550.038) range. 2. Check cabling.
1008 A - Demand Tracking Throttle setting is not Initiated by throttle of Check throttle setting.
Fault - ProAct (FC correct. cylinder bank A.
1.4550.039)
1009 A - Analog Position De- Throttle setting is not Initiated by throttle of Check throttle setting.
mand Failed - ProAct correct. cylinder bank A.
(FC 1.4550.040)
1010 A - PWM Position De- Throttle setting is not Initiated by throttle of Check throttle setting.
mand Failed - ProAct correct. cylinder bank A.
(FC 1.4550.041)
1011 A - CAN Position De- Position setpoint not Initiated by throttle of 1. Check throttle set-
mand Failed - ProAct received or received cylinder bank A. tings.
(FC 1.4550.042) too late. 2. Check cabling.
1012 A - CAN Fault (CAN CAN bus connection Initiated by throttle of 1. Check cabling.
Bus Off, CAN Address faulty. cylinder bank A. 2. Check throttle set-
TIM-ID: 0000073956 - 007
Claim Error) - ProAct tings.

(FC 1.4550.043)
1013 A - CAN Stop Com- “Stop” input signal re- Initiated by throttle of Check throttle setting.
mand - ProAct (FC ceived via CAN bus. cylinder bank A.
1.4550.044)
1014 B - Internal Fault - Pro- Hardware not ready for Initiated by throttle of 1. Restart throttle.
Act (FC 1.4550.131) operation. cylinder bank B. 2. Replace throttle.

1015 B - Stop Commanded Throttle setting is not Initiated by throttle of Check throttle setting.
(Run/Stop) - ProAct correct. cylinder bank B.
(FC 1.4550.132)
1016 A - Input (Supply) Volt- Upper or lower limit of Initiated by throttle of 1. Check supply volt-
age Fault - ProAct (FC supply voltage cylinder bank B. age.
1.4550.133) reached. 2. Check cabling.
1017 B - Position Error - Pro- Position specification Initiated by throttle of 1. Check mechanical
Act (FC 1.4550.134) and feedback signal do cylinder bank B. system.
not match. 2. Restart throttle.
1018 B - Temperature Sen- Internal temperature Initiated by throttle of 1. Restart throttle.
sor Fault - ProAct (FC sensor faulty. cylinder bank B. 2. Replace throttle.
1.4550.135)
1019 B - Temperature Derat- Internal Temperature Initiated by throttle of 1. Check throttle set-
ing Active - ProAct (FC above 100 °C. Adjust- cylinder bank B. tings.
1.4550.136) ment speed is re- 2. Check cabling.
duced.
1020 B - Temperature above Internal temperature Initiated by throttle of 1. Check room tem-
120 °C - ProAct (FC above 120 °C. cylinder bank B. perature and venti-
1.4550.137) lation.
2. Restart throttle.
1021 B - Loss of Position De- Position setpoint is Initiated by throttle of 1. Check throttle set-
mand - ProAct (FC missing or out of cylinder bank B. tings.
1.4550.138) range. 2. Check cabling.
1022 B - Demand Tracking Throttle setting is not Initiated by throttle of Check throttle setting.
Fault - ProAct (FC correct. cylinder bank B.
1.4550.139)
1023 B - Analog Position De- Throttle setting is not Initiated by throttle of Check throttle setting.
mand Failed - ProAct correct. cylinder bank B.
(FC 1.4550.140)
1024 B - PWM Position De- Throttle setting is not Initiated by throttle of Check throttle setting.
mand Failed - ProAct correct. cylinder bank B.
(FC 1.4550.141)
1025 B - CAN Position De- Position setpoint not Initiated by throttle of 1. Check throttle set-
mand Failed - ProAct received or received cylinder bank B. tings.
(FC 1.4550.142) too late. 2. Check cabling.
1026 B - CAN Fault (CAN CAN bus connection Initiated by throttle of 1. Check cabling.
Bus Off, CAN Address faulty. cylinder bank B. 2. Check throttle set-
Claim Error) - ProAct tings.
(FC 1.4550.143)
1027 B - CAN Stop Com- “Stop” input signal re- Initiated by throttle of Check throttle setting.
mand - ProAct (FC ceived via CAN bus. cylinder bank B.
TIM-ID: 0000073956 - 007
1.4550.144)
1028 Reserve # # #
–
1049
1050 PWM Input High Duty Compressor bypass Initiated by compres- Check compressor by-
Cycle Error - TecJet (FC setting is not correct. sor bypass. pass flap setting.
1.4530.010)
1051 PWM Input Low Duty Compressor bypass Initiated by compres- Check compressor by-
Cycle Error - TecJet (FC setting is not correct. sor bypass. pass flap setting.
1.4530.011)

1052 Analog Input High Error Compressor bypass Initiated by compres- Check compressor by-
- FSeries (FC setting is not correct. sor bypass. pass flap setting.
1.4530.012)
1053 Analog Input Low Error Compressor bypass Initiated by compres- Check compressor by-
- FSeries (FC setting is not correct. sor bypass. pass flap setting.
1.4530.013)
1054 Input Supply Volt High Supply voltage has Initiated by compres- 1. Check supply volt-
Error - FSeries (FC reached maximum limit sor bypass. age.
1.4530.014) value. 2. Check cabling
1055 Input Supply Volt Low Supply voltage has Initiated by compres- 1. Check supply volt-
Error - FSeries (FC reached minimum limit sor bypass. age.
1.4530.015) value. 2. Check cabling
1056 Electronics Tempera- Temperature of the Initiated by compres- 1. Check room tem-
ture High Error - FSer- electronics above 145 sor bypass. perature and venti-
ies (FC 1.4530.016) ºC or internal tempera- lation.
ture sensor faulty. 2. Compare device
temperature with
temperature gauge
in Service tool.
3. Replace compres-
sor bypass flap.
1057 Electronics Tempera- Temperature of the Initiated by compres- 1. Check room tem-
ture Low Error - FSer- electronics below -45 sor bypass. perature and venti-
ies (FC 1.4530.017) ºC or internal tempera- lation.
ture sensor faulty. 2. Compare device
temperature with
temperature gauge
in Service tool.
3. Replace compres-
sor bypass flap.
1058 Position Error - FSeries Position specification Initiated by compres- 1. Check mechanical
(FC 1.4530.018) and feedback signal do sor bypass. system
not match. 2. Restart compres-
sor bypass flap.
1059 Run Enable not Active - Compressor bypass Initiated by compres- Check compressor by-
FSeries (FC setting is not correct. sor bypass. pass flap setting.
1.4530.019)
1060 Spring Check Failed - Compressor bypass Initiated by compres- Check compressor by-
FSeries (FC setting is not correct. sor bypass. pass flap setting.
1.4530.020)
1061 Internal Fault - FSeries Hardware not ready for Initiated by compres- 1. Restart compres-
(FC 1.4530.021) operation. sor bypass. sor bypass flap.
TIM-ID: 0000073956 - 007
2. Replace compres-
sor bypass flap.
1062 CAN Fault - FSeries CAN bus connection Initiated by compres- 1. Check cabling.
(FC 1.4530.022) faulty. sor bypass. 2. Check compressor
bypass flap set-
tings.
1063 Shutdown - FSeries (FC Hardware not ready for Initiated by compres- 1. Restart compres-
1.4530.007) operation. sor bypass. sor bypass flap.
2. Replace compres-
sor bypass flap.

1064 Alarm - FSeries (FC Summary alarm (for Initiated by compres- Rectify cause of alarm.
1.4530.008) details, refer to the sor bypass.
source alarm).
1065 Derating Active - FSer- Internal temperature Initiated by compres- 1. Check room tem-
ies (FC 1.4530.009) too high. Adjustment sor bypass. perature and venti-
rate is reduced. lation.
2. Check mechanical
system.
3. Restart compres-
sor bypass flap.
1066 Reserve # # #
–
1099
1100 A - Position Error - Phy- Message from MTU en- Message from MTU en- #
tron (FC 1.4570.026) gine management via gine management via
CAN bus. CAN bus.
1101 A - Alarm Low Voltage - Message from MTU en- Message from MTU en- #
Phytron (FC gine management via gine management via
1.4570.025) CAN bus. CAN bus.
1102 A - Error Temperature - Message from MTU en- Message from MTU en- #
1103 A - Alarm Temperature Message from MTU en- Message from MTU en- #
- Phytron (FC gine management via gine management via
1104 A - Circuit - Phytron Message from MTU en- Message from MTU en- #
(FC 1.4570.022) gine management via gine management via
CAN bus. CAN bus.
1105 A - Watchdog - Phytron Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
1106 B - Position Error - Phy- Message from MTU en- Message from MTU en- #
tron (FC 1.4570.126) gine management via gine management via
CAN bus. CAN bus.
1107 B - Alarm Low Voltage - Message from MTU en- Message from MTU en- #
1108 B - Error temperature - Message from MTU en- Message from MTU en- #
1109 B - Alarm Temperature Message from MTU en- Message from MTU en- #
TIM-ID: 0000073956 - 007
- Phytron (FC gine management via gine management via

1110 A - Circuit - Phytron Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.
1111 A - Watchdog - Phytron Message from MTU en- Message from MTU en- #
CAN bus. CAN bus.

1112 HI Delta p5 for NOx NOx values measured NOx values measured 1. Check emissions.
(FC 1017) for banks A and B are for banks A and B are 2. Check NOx sen-
too far away from the too far away from the sors.
assumed NOx value assumed NOx value 3. Check ignition tim-
(limit value 1). (limit value 1). ing.
1113 LO P-Crank Case (FC Crankcase pressure Crankcase pressure 1. Check air filter for
1030) too low (limit value 1). too low (limit value 1). damage, replace if
Throttle in crankcase Throttle in crankcase damage is visible.
breather open too breather open too 2. Check setting of
wide; defective air fil- wide; defective air fil- blow-by throttle.
ter. ter.
1114 LOLO P-Crank Case Crankcase pressure Crankcase pressure 1. Check air filter for
(FC 1031) too low (limit value 2). too low (limit value 2). damage, replace if
Throttle in crankcase Throttle in crankcase damage is visible.
breather open too breather open too 2. Check setting of
wide; defective air fil- wide; defective air fil- blow-by throttle.
ter. ter.
1115 HIHI Power Difference SET and ACTUAL pow- SET and ACTUAL pow- 1. Check converter.
(FC 534) er deviate excessively er deviate excessively 2. Check fuel set-
from each other. from each other. tings.
3. Check emissions.
1116 LOLO Power Difference SET and ACTUAL pow- SET and ACTUAL pow- 1. Check converter.
(FC 535) er deviate excessively er deviate excessively 2. Check fuel set-
from each other. from each other. tings.
3. Check emissions.
1117 AL EIL Protection (FC Response to faulty or Response to faulty or Check EIL.
615) manipulated EIL. manipulated EIL.
1118 AL EIL Alarm (FC 616) Faulty or manipulated Faulty or manipulated Check EIL.
EIL. EIL.
1119 AL EIL Different Engine Engine number in EIL Engine number in EIL 1. Check the engine
Number (FC 832) differs from engine differs from engine number in the
number in ECU. Two number in ECU. Two ECU. Check that
further attempts at en- further attempts at en- the ECU parameter
gine starting remain af- gine starting remain af- record matches
ter the first occurrence ter the first occurrence this engine.
before engine starting before engine starting 2. Check EIL.
is disabled. is disabled.
1120 AL P-Charge Mix Mean Mixture pressure too Mixture pressure too Check power measur-
to Electr. Engine Power high compared to high compared to ing chain.
HIHI (FC 992) measured electrical measured electrical
power. power.
1121 AL P-Charge Mix Mean Mixture pressure too Mixture pressure too Check power measur-
TIM-ID: 0000073956 - 007
to Electr. Engine Power low compared to meas- low compared to meas- ing chain.
LOLO (FC 993) ured electrical power. ured electrical power.
1122 HI P-Coolant before En- Coolant pressure be- Coolant pressure be- Check coolant pres-
gine (FC 995) fore engine too high fore engine too high sure before engine and
(limit value 3). (limit value 3). set to value below per-
missible limit value.

1123 L4 Al CAN Max. Re- One or several ignition One or several ignition 1. Check mixture
tarded Timing FG (FC times have been dis- times have been dis- temperature.
996) placed further than placed further than 2. Check emissions
permitted as limit for permitted as limit for in the entire load
FastGas mode. This FastGas mode. This range.
temporarily blocks temporarily blocks 3. Check gas quality
FastGas mode. FastGas mode. and gas quality
settings in the
ECU.
1124 AL FastGas Max Acti- FastGas mode was ac- FastGas mode was ac- 1. Check ambient
vation Time (FC 997) tivated for too long and tivated for too long and conditions for fast
is now blocked until is now blocked until start.
the next engine start. the next engine start. 2. Check charge
pressure reserve.
1125 AL LO p LubeOil after FastGas mode is FastGas mode is Check lube oil pres-
Filt. FastGas (FC 998) blocked due to insuffi- blocked due to insuffi- sure after oil filter with
cient lube oil pressure cient lube oil pressure start request.
after filter. To enable after filter. To enable
the mode, the engine the mode, the engine
must be restarted. must be restarted.
1126 AL HI T Exhaust mean The exhaust gas tem- The exhaust gas tem- 1. Check mixture
FastGas (FC 999) perature mean value perature mean value temperature
exceeded the limit for exceeded the limit for 2. Check emissions
FastGas mode, where- FastGas mode, where- in the entire load
by FastGas mode was by FastGas mode was range.
blocked. Blocking is blocked. Blocking is 3. Check gas quality
canceled as soon as canceled as soon as and gas quality
the temperature under- the temperature under- settings in the
shoots the limit value shoots the limit value ECU.
minus hysteresis. minus hysteresis.
1127 AL Wiring PWM_CM8 Wire break or short cir- Wire break or short cir- Check cabling to NOx
(FC 626) cuit on channel cuit on channel sensor on B side.
PWM_CM8. PWM_CM8.
1128 Reserve # # #
–
1149
1150 A - Gas Sensor Power Message from MTU en- Message from MTU en- #
not in Range (FC gine management via gine management via
1151 A - Gas Sensor not at Message from MTU en- Message from MTU en- #
Temperature (FC gine management via gine management via
1152 A - NOx Reading not Message from MTU en- Message from MTU en- #
TIM-ID: 0000073956 - 007
Stable (FC gine management via gine management via

1153 A - Wide Range O2 Message from MTU en- Message from MTU en- #
Reading not Stable (FC gine management via gine management via
1154 B - Gas Sensor Power Message from MTU en- Message from MTU en- #
not in Range (FC gine management via gine management via

1155 B - Gas Sensor not at Message from MTU en- Message from MTU en- #
Temperature (FC gine management via gine management via
1156 B - NOx Reading not Message from MTU en- Message from MTU en- #
Stable (FC gine management via gine management via
1157 B - Wide Range O2 Message from MTU en- Message from MTU en- #
Reading not Stable (FC gine management via gine management via
1158 Reserve # # #
1159 Reserve # # #
1160 Reserve # # #
1161 Reserve # # #
1162 Reserve # # #
1163 Reserve # # #
1164 Trigger 3: Synchroniza- Unable to synchronize Initiated by MIC5 Check sensor, sensor
tion Fault - MIC5 (FC with signal from pulse gap, cabling, data re-
1.4520.670) sensor 3 (B13.2). cord settings and tim-
ing wheel. Replace
sensor as necessary.
1165 Trigger 3: Operational Pulse sensor 3 (B13.2) Initiated by MIC5 1. Check sensor, sen-
Error - MIC5 (FC has tripped an opera- sor gap, cabling,
1.4520.671) tional error. data record set-
tings and timing
wheel. Replace
sensor as necessa-
ry.
2. Restart ignition
control unit.
1166 Trigger 3: no signal de- No signal from pulse Initiated by MIC5 Check sensor, sensor
tected - MIC5 (FC sensor 3 (B13.2). gap, cabling, data re-
1.4520.672) cord settings and tim-
ing wheel. Replace
1167 Trigger 3: polarity de- Unable to detect polar- Initiated by MIC5 Check sensor, sensor
tection failed - MIC5 ity of pulse sensor 3 gap, cabling, data re-
(FC 1.4520.673) (B13.2). cord settings and tim-
ing wheel. Replace
1168 Trigger 3: wrong polari- Pulse sensor 3 (B13.2) Initiated by MIC5 Check sensor, sensor
ty - MIC5 (FC has wrong polarity. gap, cabling, data re-
TIM-ID: 0000073956 - 007

ing wheel. Replace
1169 Trigger 3: no index Unable to detect index Initiated by MIC5 Check sensor, sensor
mark detected - MIC5 mark of pulse sensor 3 gap, cabling, data re-
(FC 1.4520.675) (B13.2) cord settings and tim-
ing wheel. Replace

1170 Trigger 3: wrong num- Incorrect number of Initiated by MIC5 Check sensor, sensor
ber of trigger events - events from pulse sen- gap, cabling, data re-
MIC5 (FC 1.4520.676) sor 3 (B13.2). cord settings and tim-
ing wheel. Replace
1171 Trigger 3: signal miss- Expected signal from Initiated by MIC5 Check sensor, sensor
ing - MIC5 (FC pulse sensor 3 (B13.2) gap, cabling, data re-
1.4520.677) is missing. cord settings and tim-
ing wheel. Replace
1172 Trigger 3: signal faulty - Unexpected signal Initiated by MIC5 Check sensor, sensor
MIC5 (FC 1.4520.678) from pulse sensor 3 gap, cabling, data re-
(B13.2) detected. cord settings and tim-
ing wheel. Replace
1173 Trigger 3: index mark Unable to detect index Initiated by MIC5 Check sensor, sensor
not detected - MIC5 mark of pulse sensor 3 gap, cabling, data re-
(FC 1.4520.679) (B13.2) in operation. cord settings and tim-
ing wheel. Replace
1174 Trigger 3: index too Index mark of pulse Initiated by MIC5 Check sensor, sensor
early / faulty - MIC5 sensor 3 (B13.2) de- gap, cabling, data re-
(FC 1.4520.680) tected too early or faul- cord settings and tim-
ty. ing wheel. Replace
late / missing - MIC5 sensor 3 (B13.2) de- gap, cabling, data re-
(FC 1.4520.681) tected too late or miss- cord settings and tim-
ing. ing wheel. Replace
1176 Operational Error - An operational error Initiated by MIC5 1. Rectify cause of
MIC5 (FC 1.4520.508) has occurred. alarm.
2. Restart ignition
control unit.
1177 System Error - MIC5 A system error has oc- Initiated by MIC5 1. Rectify cause of
(FC 1.4520.509) curred. alarm.
2. Restart ignition
control unit.
1178 Temperature limit The device tempera- Initiated by MIC5 Ensure that the genset
reached - MIC5 (FC ture is too high room is adequately
1.4520.520) ventilated.
1179 Power output limit Power output is too Initiated by MIC5 1. Check ignition sys-
TIM-ID: 0000073956 - 007
reached - MIC5 (FC high. tem settings in the

1.4520.521) Engine Control
Unit.
2. Check ignition
coils.
3. Check igniters.

1180 Invalid coil data - MIC5 The ignition system Initiated by MIC5 1. Check ignition sys-
(FC 1.4520.522) settings are invalid. tem settings in the
Engine Control
Unit.
2. Restart ignition
control unit.
1181 Invalid configuration - The ignition system Initiated by MIC5 1. Check ignition sys-
MIC5 (FC 1.4520.523) settings are invalid. tem settings in the
Engine Control
Unit.
2. Restart ignition
control unit.
1182 Invalid trigger configu- The ignition system Initiated by MIC5 1. Check ignition sys-
ration - MIC5 (FC settings are invalid. tem settings in the
1.4520.524) Engine Control
Unit.
2. Restart ignition
control unit.
1183 Configuration data The ignition system Initiated by MIC5 1. Check ignition sys-
checksum error - MIC5 settings are invalid. tem settings in the
(FC 1.4520.525) Engine Control
Unit.
2. Restart ignition
control unit.
1184 Analog Current Signal Failure of the current Initiated by MIC5 Check settings in igni-
Failure - MIC5 (FC signal to adjust the ig- tion control unit.
1.4520.526) nition point.
1185 Analog Voltage Signal Failure of the current Initiated by MIC5 Check settings in igni-
Failure - MIC5 (FC signal to adjust the ig- tion control unit.
1.4520.527) nition point.
1186 Auxiliary inputs supply Malfunction in the aux- Initiated by MIC5 1. Check settings.
voltage failure - MIC5 iliary supply voltage for 2. Restart ignition
(FC 1.4520.528) the analog inputs. control unit.
3. Replace ignition
control unit.
1187 Trigger supply voltage Malfunction in the aux- Initiated by MIC5 1. Check wiring to
failure - MIC5 (FC iliary supply voltage for sensor B1.2.
1.4520.529) the pulse sensor. 2. Check sensor
B1.2.
3. Restart ignition
control unit.
4. Replace ignition
control unit.
TIM-ID: 0000073956 - 007
1188 Global timing limited - The global ignition Initiated by MIC5 Check Engine Control
MIC5 (FC 1.4520.530) point is beyond the val- Unit settings.
id range.
1189 General fault - MIC5 A general fault has oc- Initiated by MIC5 1. Check Engine Con-
(FC 1.4520.540) curred. trol Unit settings.
2. Check cabling.
3. Restart ignition
control unit.
4. Replace ignition
control unit.

1190 Overspeed - MIC5 (FC The overspeed limit Initiated by MIC5 1. Check Engine Con-
1.4520.541) was reached. trol Unit settings.
2. Check speed sen-
sor of ignition sys-
tem.
3. Restart ignition
control unit.
1191 Speed signal detected Pulse sensor signals Initiated by MIC5 Restart ignition control
during selftest - MIC5 were detected during unit.
(FC 1.4520.542) the self-test.
1192 Shutdown Due to Shutdown due to Initiated by MIC5 1. Rectify cause of
Alarm - MIC5 (FC alarm. alarm.
1.4520.543) 2. Restart ignition
control unit.
1193 Identification of output The characteristic data Initiated by MIC5 1. Restart ignition
board failed - MIC5 (FC of the output board is control unit.
1.4520.544) illegible or corrupt. 2. Replace ignition
control unit.
1194 Failure high-voltage The high voltage power Initiated by MIC5 1. Rectify cause of
power supply - MIC5 supply unit is faulty. alarm.
(FC 1.4520.545) 2. Restart ignition
control unit.
1195 Failure temperature The temperature sen- Initiated by MIC5 1. Rectify cause of
sensor - MIC5 (FC sor is faulty. alarm.
1.4520.546) 2. Restart ignition
control unit.
1196 Failure current sensor - The current sensor is Initiated by MIC5 1. Rectify cause of
MIC5 (FC 1.4520.547) faulty. alarm.
2. Restart ignition
control unit.
1197 Temperature limit The device tempera- Initiated by MIC5 1. Ensure that the
reached - MIC5 (FC ture has exceeded the genset room is ad-
1.4520.548) admissible value. equately ventilat-
ed.
2. Restart ignition
control unit.
1198 Power output limit The power output has Initiated by MIC5 1. Check ignition sys-
reached - MIC5 (FC exceeded the admissi- tem settings in the
1.4520.549) ble value. Engine Control
Unit.
2. Check ignition
coils.
3. Check igniters.
TIM-ID: 0000073956 - 007
4. Restart ignition
control unit.
1199 Trigger 1: synchroniza- Unable to synchronize Initiated by MIC5 Check sensor, sensor
tion fault - MIC5 (FC with signals from pulse gap, cabling, data re-
1.4520.550) sensor 1 (B1.2). cord settings and tim-
ing wheel. Replace

1200 Trigger 1: operational Pulse sensor 1 (B1.2) Initiated by MIC5 1. Check sensor, sen-
error - MIC5 (FC has tripped an opera- sor gap, cabling,
tings and timing
wheel. Replace
sensor as necessa-
ry.
2. Restart ignition
control unit.
tected - MIC5 (FC sensor 1 (B1.2) gap, cabling, data re-
ing wheel. Replace
ing wheel. Replace
1203 Trigger 1: wrong polari- Pulse sensor 1 (B1.2) Initiated by MIC5 Check sensor, sensor
ing wheel. Replace
ing wheel. Replace
MIC5 (FC 1.4520.556) sor 1 (B1.2). cord settings and tim-
ing wheel. Replace
ing - MIC5 (FC pulse sensor 1 (B1.2) gap, cabling, data re-
1.4520.557) is missing. cord settings and tim-
ing wheel. Replace
(b1.2) detected cord settings and tim-
ing wheel. Replace
TIM-ID: 0000073956 - 007
1208 Trigger 1: index mark ## Message from MTU Initiated by MIC5 Check sensor, sensor
not detected - MIC5 engine management gap, cabling, data re-
(FC 1.4520.559) via CAN bus. See docu- cord settings and tim-
mentation of MTU En- ing wheel. Replace
gine Management. ## sensor as necessary.

early / faulty - MIC5 sensor 1 (B1.2) detect- gap, cabling, data re-
(FC 1.4520.560) ed too early or missing. cord settings and tim-
ing wheel. Replace
late / missing - MIC5 sensor 1 (B1.2) detect- gap, cabling, data re-
(FC 1.4520.561) ed too late or missing. cord settings and tim-
ing wheel. Replace
1211 Trigger 2: synchroniza- Unable to synchronize Initiated by MIC5 Check sensor, sensor
tion fault - MIC5 (FC with signal from pulse gap, cabling, data re-
1.4520.658) sensor 2 (B75). cord settings and tim-
ing wheel. Replace
1212 Trigger 2: operational Pulse sensor 2 (B75) Initiated by MIC5 1. Check sensor, sen-
error - MIC5 (FC has tripped an opera- sor gap, cabling,
tings and timing
wheel. Replace
sensor as necessa-
ry.
2. Restart ignition
control unit.
tected - MIC5 (FC sensor 2 (B75). gap, cabling, data re-
ing wheel. Replace
(FC 1.4520.661) (B75). cord settings and tim-
ing wheel. Replace
1215 Trigger 2: wrong polari- Pulse sensor 2 (B75) Initiated by MIC5 Check sensor, sensor
ing wheel. Replace
(FC 1.4520.663) (B75). cord settings and tim-
ing wheel. Replace
TIM-ID: 0000073956 - 007
MIC5 (FC 1.4520.664) sor 2 (B75). cord settings and tim-
ing wheel. Replace

ing - MIC5 (FC pulse sensor 2 (B75) is gap, cabling, data re-
1.4520.665) missing. cord settings and tim-
ing wheel. Replace
(B75) detected. cord settings and tim-
ing wheel. Replace
1220 Trigger 2: index mark Unable to detect index Initiated by MIC5 Check sensor, sensor
not detected - MIC5 mark of pulse sensor 2 gap, cabling, data re-
(FC 1.4520.667) (B75) in operation. cord settings and tim-
ing wheel. Replace
early / faulty - MIC5 sensor 2 (B75) detect- gap, cabling, data re-
(FC 1.4520.668) ed too early or faulty. cord settings and tim-
ing wheel. Replace
late / missing - MIC5 sensor 2 (B75) detect- gap, cabling, data re-
(FC 1.4520.669) ed too late or faulty. cord settings and tim-
ing wheel. Replace
1223 Reserve # # #
–
2099
2100 Hardware Fault of the With an AT4222 mod- In case of wire break/ • Check sensor.
custom analog value ule (4*PT100/1000, 2 short circuit or faulty • Check controller
220 or 3-wire), the follow- AT4222 module. adapter module.
ing values occur (wire
break/short circuit):
• -3276.7
• 3274.7
The engine is immedi-
ately stopped.
• -3276.7
TIM-ID: 0000073956 - 007
• 3274.7
ately stopped.

• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
TIM-ID: 0000073956 - 007
ately stopped.
• -3276.7
• 3274.7
ately stopped.

• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
TIM-ID: 0000073956 - 007
ately stopped.
• -3276.7
• 3274.7
ately stopped.

• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
2116 Hardware Fault of the With an AT4222 mod- In case of wire break/ • Check sensor
236 or 3-wire), the follow- AT4222 module. adapter module
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
2118 Hardware Fault of the The following values In case of wire break/ • Check sensor.
custom analog value apply to an AT4222 short circuit or faulty • Check controller
238 module (4 * AT4222 module. adapter module.
PT100/1000, 2 or 3-
wire):
• -3276.7
• 3274.7
TIM-ID: 0000073956 - 007
ately stopped.
• -3276.7
• 3274.7
ately stopped.

• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
PT100/1000, 2 or 3-
wire):
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
TIM-ID: 0000073956 - 007
ately stopped.
• -3276.7
• 3274.7
ately stopped.

PT100/1000, 2 or 3-
wire):
• -3276.7
• 3274.7
ately stopped.
PT100/1000, 2 or 3-
wire):
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
ately stopped.
• -3276.7
• 3274.7
TIM-ID: 0000073956 - 007
ately stopped.
2131 Reserve # # #
–
2200
2201 Reserved for customer # # #
–2400 configuration

7.5 Engine Control Unit – Fault messages
Possible engine responses to yellow alarm:
Warning, power limitation/reduction, speed limitation, engine stop
Possible engine responses to red alarm:

Engine stop, power limitation/reduction, speed limitation, warning
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 474).
speed too low, oil lines, oil heat 3. Take oil sample and analyze (→ Page 472).
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 474).
speed too low, oil lines, oil heat 3. Take oil sample and analyze (→ Page 472).
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 457).
1). Incorrect ignition timing, 3. Check mixture setting.
TIM-ID: 0000038612 - 005
mixture too lean or too rich,

damage to turbine.

020 – SS T-Exhaust A
Yellow alarm.
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 474).
(limit value 1). 2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil as necessary
TIM-ID: 0000038612 - 005
(→ Page 471).

026 – SS P-Diff-Lube Oil
Pressure loss via oil filter too high 1. Replace oil filter (→ Page 474).
(limit value 2). 2. If this fault message occurs again after unexpectedly short filter
runtime, check oil filter for deposits, change oil as necessary
(→ Page 471).
030 – SS Engine Overspeed

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

Yellow alarm. Power reduction.
Speed of turbocharger 1 too high 1. Check intake air temperature.
(limit value 1). 2. Check emissions (→ Page 538).
3. If the sensor is not obstructed, check the conditions for activating
this monitoring feature in the ECU parameter record.
032 – SS ETC1 Overspeed

TIM-ID: 0000038612 - 005
036 – HI ETC2 Overspeed


037 – SS ETC2 Overspeed
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 470).
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 470).
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).
TIM-ID: 0000038612 - 005
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
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-Crank Case

Yellow alarm.
Crankcase pressure too high (limit 1. Check crank drive:
value 1). Restrictor valve in • Bar engine (→ Page 444).
crankcase breather is closed too • Endoscope combustion chambers from bottom dead center to
far, air filter is faulty, oil separator top dead center.
is clogged, piston rings are seized, 2. Check air filter for contamination, replace if contamination is
other damage to crank drive. visible (→ Page 522).
3. Check setting of blow-by restrictor valve.
4. Check oil separator condition, replace as necessary (→ Page 445).
064 – SS P-Crank Case

Crankcase pressure too high (limit 1. Check crank drive: Bar engine (→ Page 444), endoscope
value 2). Restrictor valve in combustion chambers from bottom dead center to top dead
TIM-ID: 0000038612 - 005
crankcase breather is closed too center.

far, air filter is faulty, oil separator 2. Check air filter for contamination, replace if contamination is
is clogged, piston rings are seized, visible (→ Page 522).
other damage to crank drive. 3. Check setting of blow-by restrictor valve.
4. Check oil separator condition, replace as necessary (→ Page 445).

067 – HI T-Coolant
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 mains parallel operation:
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) and no 2. In isolated operation:
engine stop is applied. The engine • Check restrictor flap position.
is shutdown for safety reasons. • Check restrictor flaps for implausible closing. If restrictor flaps
are fully open: Check if load step values are admissible.
• Check bypass position.
• Check air filter for contamination, replace if contamination is
visible (→ Page 522).
• Check exhaust back pressure.
• Check differential pressure over mixture cooler.
• Check emissions and injection timing (→ Page 538)
(→ Page 457).
• Check oil separator efficiency (oil in compressor intake elbow),
clean compressor as necessary.
TIM-ID: 0000038612 - 005
• Check valve clearance (→ Page 462).

• Check gasket between mixture line and cylinder head for
correct installation position.

090 – SS Idle Speed Not Reached
Red alarm. Start is terminated.
Idle speed not reached. 1. Check ignition.
2. Check gas supply.
3. Check mixture setting.
091 – SS Release Speed Not Reached

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 Starter Speed Not Reached

Minimum speed for flushing u Check starter system.
process and ignition release was
not attained.
093 – SS T-Preheat
Preheating temperature too low 1. Check preheating.
(limit value 2). Coolant 2. Check differential coolant pressure.
temperature too low for engine 3. Check heating elements.
start. 4. Check cabling (→ Page 488).
094 – LO T-Preheat
Yellow alarm.
TIM-ID: 0000038612 - 005

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 488).

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

Yellow alarm.
Operating hours meter faulty. u Replace Engine Control Unit.
Internal Engine Control Unit fault.
118 – LO ECU Power Supply Voltage

Yellow alarm.
Supply voltage too low (limit value 1. Check supply voltage.
1). 2. Check cabling (→ Page 488).
119 – LOLO ECU Power Supply Voltage

Red alarm.
Supply voltage too low (limit value 1. Check supply voltage.
2). 2. Check cabling (→ Page 488).
120 – HI ECU Power Supply Voltage

Yellow alarm.
Supply voltage too high (limit 1. Check supply voltage.
value 1). 2. Check cabling (→ Page 488).
TIM-ID: 0000038612 - 005
121 – HIHI ECU Power Supply Voltage

Red alarm.
Supply voltage too high (limit 1. Check supply voltage.
value 2). 2. Check cabling (→ Page 488).

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.
2. Compare device temperature with temperature gauge 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.
Wrong parameter value entered in u Contact Service (configuration error).
data record.
183 – AL CAN No PU-Data

Red alarm.
A CAN mode has been selected u Contact Service (configuration error).
TIM-ID: 0000038612 - 005
that initiates communications

with the 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.
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.

TIM-ID: 0000038612 - 005
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
Coolant temperature sensor at u Check sensor and cabling (B6.1), replace as necessary (→ Page 74)
engine outlet faulty, short circuit (→ Page 488). Error cleared after restarting the engine.
or wire break.
204 – SD Level Lube Oil

Engine oil level sensor faulty, u Check sensor and cabling (B24), replace as necessary (→ Page 74)
short circuit or wire break. (→ Page 488). Error cleared after restarting the engine.
206 – SD T-Exhaust A
Yellow alarm.
Exhaust temperature sensor on A u Check sensor and wiring (B4.21), replace as necessary (→ Page 74)
side faulty, short circuit or wire (→ Page 488). Error cleared after restarting the engine.
break.
207 – SD T-Exhaust B
Yellow alarm.
TIM-ID: 0000038612 - 005
Exhaust temperature sensor on B u Check sensor and wiring (B4.22), replace as necessary (→ Page 74)
side faulty, short circuit or wire (→ Page 488). Error cleared after restarting the engine.
break.

211 – SD P-Lube Oil
Engine oil pressure sensor after u Check sensor and cabling (B5.1), replace as necessary (→ Page 74)
filter faulty, short circuit or wire (→ Page 488). Error cleared after restarting the engine.
break.
212 – SD P-Coolant
Red alarm.
Coolant pressure sensor after u Check sensor and cabling (B16.1), replace as necessary
engine faulty, short circuit or wire (→ Page 74) (→ Page 488). Error cleared after restarting the engine.
break.
214 – SD P-Crankcase
Red alarm.
Crankcase pressure sensor faulty, u Check sensor and wiring (B50), replace as necessary (→ Page 74)
short circuit or wire break. (→ Page 488). Error cleared after restarting the engine.
216 – SD T-Lube Oil

Engine oil temperature sensor u Check sensor and wiring (B7), replace as necessary (→ Page 74)
after oil heat exchanger faulty, (→ Page 488). Error cleared after restarting the engine.
short circuit or wire break.
219 – SD T-Intake Air

Yellow alarm.
TIM-ID: 0000038612 - 005
Intake air temperature sensor u Check sensor and cabling (B49.1 / B90), replace as necessary
faulty, short circuit or wire break. (→ Page 74) (→ Page 488). 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 74) (→ Page 488). Error cleared after
restarting the engine.
227 – SD P-Lube Oil before Filter

Yellow alarm.
Engine oil pressure sensor before u Check sensor and wiring (B5.3), replace as necessary (→ Page 74)
filter faulty, short circuit or wire (→ Page 488). Error cleared after restarting the engine.
break.
229 – AL Stop Camshaft Sensor Defect

Engine stop due to camshaft u Check sensor and cabling (B1.1), replace as necessary (→ Page 74)
sensor failure. (→ Page 488). Error cleared after restarting the engine.
231 – SD Camshaft Speed

Camshaft sensor faulty, short u Check sensor and cabling (B1.1), replace as necessary (→ Page 74)
circuit or wire break. (→ Page 488). Error cleared after restarting the engine.
232 – SD Charger 1 Speed

Red alarm.
TIM-ID: 0000038612 - 005
Speed sensor of turbocharger 1 1. Check sensor and wiring (B44.1), replace as necessary (→ Page 74)
faulty, short circuit or wire break. (→ Page 488). Error cleared after restarting the engine.

233 – SD Charger 2 Speed
Red alarm.
Speed sensor of turbocharger 2 1. Check sensor and wiring (B44.2), replace as necessary (→ Page 74)
245 – SD ECU Power Supply Voltage

Red alarm.
Internal Engine Control Unit fault. u Replace 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 wire break at u Check cabling (→ Page 488).
transistor output 1 plant side (TOP
1). Activation of yellow summary
alarm faulty.

Red alarm.
TIM-ID: 0000038612 - 005

2). Activation of red summary
alarm faulty.

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

Red alarm.
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 74) (→ Page 488).
419 – SD T-Coolant before Engine

Red alarm.
Coolant temperature sensor at u Check sensor and cabling (B6.3), replace as necessary (→ Page 74)
engine inlet faulty, short circuit or (→ Page 488).
wire break.
423 – LO P-Coolant Diff.

TIM-ID: 0000038612 - 005

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.
Coolant pressure before engine u Check engine coolant circuit (pressure and flow).
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

TIM-ID: 0000038612 - 005

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 restrictor 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 74)
(→ Page 488).
445 – SD P-Ambient Air

Yellow alarm.
Ambient air pressure sensor on u Replace ECU.
ECU faulty.
447 – HIHI P-Charge Mix Diff.

Difference in mixture pressures 1. Check restrictor 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 74)
(→ Page 488).
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.
TIM-ID: 0000038612 - 005

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.
454 – SS Power Reduction Active

Yellow alarm.
Power reduction activated. 1. Rectify limit value violation of the source alarm (e.g. reduce intake
temperature).
2. Check exhaust system components for leaks/cracks
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

TIM-ID: 0000038612 - 005

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 wiring (B16.3), replace as necessary (→ Page 74)
engine faulty, short circuit or wire (→ Page 488). Error cleared after restarting the engine.
break.
470 – SD T-ECU
Red alarm.
Temperature sensor in Engine u Replace ECU.
Control Unit faulty.
472 – AL Stop SD
Engine stop, since all shutdown u Summary alarm (for details, refer to the source alarm).
channels have “sensor failure”.
476 – AL Crash Rec.Init Fault

Red alarm.
Crash recorder initialization error. u Contact Service.
478 – AL Comb. Alarm Yel (Plant)

Yellow alarm.
Summary alarm YELLOW from u Summary alarm (for details, refer to the source alarm).
system.
TIM-ID: 0000038612 - 005
479 – AL Comb. Alarm Red (Plant)

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
497 – SD P-Charge Mix B

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

Red alarm.
Mixture differential pressure u Check sensors and cabling (B79.21, B79.22), replace as necessary
sensor on A or B side faulty, short (→ Page 74) (→ Page 488). Error cleared after restarting the engine.
circuit or wire break.
499 – SD T-Charge Mix

Red alarm.
Mixture temperature sensor u Check sensor and cabling (B73), replace as necessary (→ Page 74)
511 – HIHI P-Charge Mix A

Mixture pressure on A side too 1. Check emissions (→ Page 538).
TIM-ID: 0000038612 - 005
high (limit value 2). 2. Check ignition timing (→ Page 457).

3. Check exhaust back pressure.
4. Check valve clearance (→ Page 462).
5. Check restrictor flap.
6. Check mixture coolant system.

512 – HIHI P-Charge Mix B
Mixture pressure on B-side too 1. Check emissions (→ Page 538).
high (limit value 2). 2. Check ignition timing (→ Page 457).
3. Check exhaust back pressure.
4. Check valve clearance (→ Page 462).
5. Check restrictor 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 74) (→ Page 488). Error cleared after restarting the engine.
break.
515 – AL Starter Not Engaged

Yellow alarm.
Starter not engaged. ECU does 1. Check starter.
not detect engine speed during 2. Check cabling (→ Page 488).
starting sequence. 3. Check speed sensor B1.1 if speed is not indicated although engine
is turning (→ Page 74).
517 – SD P-Charge Mix before Throttle

Red alarm.
Mixture pressure sensor before u Check sensor and wiring (B79.23), replace as necessary
restrictor flap faulty, short circuit (→ Page 74) (→ Page 488). Error cleared after restarting the engine.
or wire break.
520 – SD P-Intake Air after Filter A

TIM-ID: 0000038612 - 005
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 74) (→ Page 488). Error cleared after restarting the engine.
or wire break.

522 – SD P-Intake Air after Filter B
Yellow alarm.
Intake air pressure sensor after u Check sensor and wiring (B81.2), replace as necessary (→ Page 74)
filter on B-side faulty, short circuit (→ Page 488). Error cleared after restarting the engine.
or wire break.
534 – HIHI Power Difference

Set and actual power deviate 1. Check converter.
excessively from each other. 2. Check fuel settings.
3. Check emissions (→ Page 538).
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.
TIM-ID: 0000038612 - 005
Gas train test was not successful. 1. Check gas train.

Alarm is activated if the gas train 2. Check cabling (→ Page 488).
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 74).
ignition system is not received 3. Check cabling (→ Page 488).
within a specified time-out period.
Either the ignition could not be
activated, the timeout period is
set too short, or communication is
faulty.
556 – AL GasValve Fault

Red alarm.
Gas supply solenoid valve faulty. 1. Check gas train.
Alarm is active if there are 2. Check cabling (→ Page 488).
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 EngineSpeedCollapse Fault

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

Red alarm.
TIM-ID: 0000038612 - 005
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 restrictor flap on A-side and cabling. Replace
restrictor flap on A-side occurred. mixture restrictor flap on A-side as necessary.
Possible causes: Mixture
restrictor flap faulty, no power
supply to restrictor flap, cabling of
feedback and/or position signal
faulty.
560 – AL mixture throttle B fault

A problem related to mixture u Check mixture restrictor flap on B-side and cabling. Replace
restrictor flap on B-side occurred. mixture restrictor flap on B-side as necessary.
Possible causes: Mixture
restrictor flap faulty, no power
supply to restrictor 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 522).
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 522).
side is too high.
TIM-ID: 0000038612 - 005
567 – AL L1 P-Intake Air after Filter B

Yellow alarm.
Pressure loss over air filter on B- u Replace air filter (→ Page 522).
side is too high.

568 – AL L2 P-Intake Air after Filter B
Yellow alarm.
Pressure loss over air filter on B- u Replace air filter (→ Page 522).
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.
Due to detected knocking, the 1. Check emissions (→ Page 538).
cylinder set to maximum retarded 2. Check ignition timing (→ Page 457).
timing has violated the limit value. 3. Check combustion chamber.
4. Check gas quality if feasible (methane number).

TIM-ID: 0000038612 - 005
timing has violated the second 3. Check combustion chamber.

limit value. Power reduction is 4. Check gas quality if feasible (methane number).
initiated.

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

Red alarm.
channel PWM_CM3.
583 – AL Circuit Breaker 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

Yellow alarm.
TIM-ID: 0000038612 - 005

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

Red alarm.
channel PWM_CM5.
603 – SD Air Humidity

Yellow alarm.
Air humidity sensor faulty. Short u Check cabling and sensor (→ Page 488).
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 488).
1 and 2.

Red alarm.
channel PWM_CM6.
TIM-ID: 0000038612 - 005

Red alarm.
Wire break or short circuit on u Check cabling to NOx sensor on A side (→ Page 488).
channel PWM_CM7.

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

Red alarm.
Faulty or manipulated EIL. u Check EIL.
617 – LO Actual Value Hu

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

Yellow alarm.
Fuel calorific value has undershot u Check gas quality if feasible.
the second limit value.
619 – HI Actual Value Hu

Yellow alarm.
Fuel calorific value has exceeded u Check gas quality if feasible.
the first limit value.
TIM-ID: 0000038612 - 005
620 – HIHI Actual Value Hu

Yellow alarm.
Fuel calorific value has exceeded u Check gas quality if feasible.
the second limit value.

621 – LO NOx Value
Yellow alarm.
NOx emissions have undershot 1. Check gas quality if feasible.
the first limit value. 2. Check gas pressure.
3. Check NOx sensor (→ Page 74).
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 74).
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 74).
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 74).

Red alarm.
TIM-ID: 0000038612 - 005

Wire break or short circuit on u Check cabling to NOx sensor on B side (→ Page 488).
channel PWM_CM8.

Red alarm.
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 538).
3. Check combustion chamber.
649 – Al Req Angle Throttle A

TIM-ID: 0000038612 - 005
Opening angle of restrictor flaps A 1. Check charge-air pressure reserve.

exceeded. 2. Intake air temperature not as per TVU data.
3. Check compressor for contamination.
4. Check exhaust system on engine side for leakage.
5. Reduce power.

650 – Al Req Angle Throttle B
Opening angle of restrictor flaps B 1. Check charge-air pressure reserve.
exceeded. 2. Intake air temperature not as per TVU data.
3. Check compressor for contamination.
4. Check exhaust system on engine side for leakage.
5. 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 488).
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

TIM-ID: 0000038612 - 005
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
Red alarm.
CAN bus communication for gas 1. Check cabling (→ Page 488).
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.
restrictor flap A faulty. 2. Check power supply.
3. Carry out restart of ECU, EMU and restrictor flap A.
657 – AL ProActB Comm Lost

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

Red alarm.
CAN bus communication for NOx 1. Check cabling (→ Page 488).
sensor A faulty. 2. Check power supply.
3. Restart ECU.
4. Replace sensor (→ Page 74).
659 – AL NOxB Comm Lost

TIM-ID: 0000038612 - 005
Red alarm.
CAN bus communication for NOx 1. Check cabling (→ Page 488).
sensor B faulty. 2. Check power supply.
3. Restart ECU.
4. Replace sensor (→ Page 74).

664 – AL Oil Refill Error
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.
TIM-ID: 0000038612 - 005
gas control valve was detected. control system.
669 – AL ProActA Yellow

Yellow alarm.
restrictor flap A was detected. control system.

670 – AL ProActB Yellow
Yellow alarm.
restrictor 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.
TIM-ID: 0000038612 - 005
677 – AL FSeries Red

Red alarm.
bypass flap was detected. control system.

678 – AL TecJet Red
Red alarm.
gas control valve was detected. control system.
679 – AL ProActA Red

Red alarm.
restrictor flap A was detected. control system.
680 – AL ProActB Red

Red alarm.
restrictor 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.
TIM-ID: 0000038612 - 005
685 – AL Lube Oil Min

Red alarm.
Minimum engine oil filling level 1. Check engine oil level (→ Page 470).
detected. 2. Check replenishment system.
3. Fill oil.

686 – AL Lube Oil Max
Red alarm.
Maximum engine oil filling level 1. Check engine oil level (→ Page 470).
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 470). 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.
TIM-ID: 0000038612 - 005
720 – AL T-Gas L2
Red alarm.
2nd lower limit value violated. u Check gas supply.

832 – AL EIL Different Engine Number
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 ActFuelValvePos L1
TecJet restrictor 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.
TIM-ID: 0000038612 - 005


933 – AL MIC5 Red
Red alarm.
934 – AL MIC5 Comm Lost

Red alarm.
CAN bus communication for u Check cabling (→ Page 488).
ignition system faulty.
948 – AL ESI activated

Red alarm.
Emergency stop input has been 1. Rectify fault at source.
activated. 2. Check cabling (→ Page 488).
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.
TIM-ID: 0000038612 - 005
status. Bus nodes (ignition, knock

module, restrictor 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, restrictor flaps or
gas mixture) malfunctioning.

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

Yellow alarm.
CAN controller 4 has indicated a u None
warning.
992 – AL HIHI P-Charge Mix Mean for el. Power

Mixture pressure too high in u Check power measurement chain.
comparison to measured
electrical power.
993 – AL LOLO P-Charge Mix Mean for el. Power

TIM-ID: 0000038612 - 005

Mixture pressure too low in u Check power measurement chain.
comparison to measured
electrical power.

995 – Hi P-Coolant b.Engine
Coolant pressure before engine u Check coolant pressure before engine and set to value below the
too high (limit value 3). permissible limit value.

Yellow alarm.
One or several ignition times are 1. Check mixture temperature.
displaced further than the limit 2. Check emissions in complete load range (→ Page 538).
permitted for FastGas mode. This 3. Check gas quality and gas quality settings in the ECU.
temporarily blocks FastGas mode.
997 – AL FastGas Max Activation Time

Yellow alarm.
FastGas mode was activated for 1. Check ambient conditions for FastStart.
too long and is now blocked until 2. Check charge-air pressure reserve.
the next engine start.
998 – AL LO p Lube Oil after Filt. FastGas

Yellow alarm.
FastGas mode is blocked because u Check lube oil pressure after oil filter with start request.
of insufficient lube oil pressure
after filter. To enable the mode,
the engine must be restarted.
999 – AL HI T-Exhaust Mean FastGas

Yellow alarm.
TIM-ID: 0000038612 - 005

The exhaust gas temperature 1. Check mixture temperature.
mean value has exceeded the 2. Check emissions in complete load range (→ Page 538).
limit for FastGas mode, which 3. Check gas quality and gas quality settings in the ECU.
results in FastGas mode being
blocked. The blocking is canceled
as soon as the temperature drops
below the limit value minus the
hysteresis.

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 538).
and B are too far apart (limit value 2. Check NOx sensors (→ Page 74).
1). 3. Check ignition points. (→ Page 457)
1014 – HIHI Delta NOx (A-B)

Red alarm.
and B are too far apart (limit value 2. Check NOx sensors (→ Page 74).
2). 3. Check ignition points. (→ Page 457)
1017 – HI Delta p5 for NOx

Yellow alarm.
and B are too far away from the 2. Check NOx sensors (→ Page 74).
assumed NOx value (limit value 3. Check ignition points. (→ Page 457)
1).
1030 – LO P-Crank Case

Yellow alarm.
TIM-ID: 0000038612 - 005

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 too widely
open, faulty air filter.

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 too widely
open, faulty air filter.
TIM-ID: 0000038612 - 005

8 Maintenance
8.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals required for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
Task Maintenance tasks
WM00050 Check general condition of resilient mount (visual inspec- (→ Page 486)
tion)
WM00067 Replace engine oil filter when changing engine oil, or when (→ Page 474)
the interval (years) is reached, at the latest.
WM00094 Check valve clearance, adjust as necessary. ATTENTION! (→ Page 462)
First adjustment after 1,000 operating hours on a new en-
gine and after 1,000 operating hours following each cylin-
der head overhaul.
WM00098 Measure valve protrusion. (→ Page 458)
WM00136 Check securing screws for secure seating. (→ Page 487)
WM00150 Replace NOx sensor. (→ Page 489)
WM00286 Visually inspect engine for leaks and general condition. (→ Page 155)
WM00338 Carry out test run, minimum duration: until steady-state (→ Page 439)
temperature is reached, no less than 1/3 load (monthly).
WM00426 Check operating room for smell of gas. (→ Page 129)
WM00427 Check for abnormal running noises and vibrations. (→ Page 155)
WM00428 Check engine oil level in storage tank. (→ Page 470)
WM00431 Replace starter. (→ Page 467)
WM00433 Check gas lines for leaks, seal as necessary. (→ Page 531)
WM00434 Check ignition timing, adjust if required. (→ Page 457)
WM00442 Clean exhaust turbocharger. (→ Page 443)
WM00447 Replace coarse filter (coalescer filter). (→ Page 445)
WM00453 X Check exhaust flap for operation and leaks. (→ Page 541)
WM00454 X Check exhaust temperature and exhaust back pressure (→ Page 533)
before and after exhaust gas heat exchanger. (→ Page 535)
WM00456 X Check exhaust gas heat exchanger, clean as necessary. (→ Page 532)
TIM-ID: 0000073292 - 005
(→ Page 443)
WM00457 Check shutdown criteria in peripheral equipment. (→ Page 442)
WM00462 Check filter fan for contamination. (→ Page 549)
WM00463 Check noise generation of filter fans. (→ Page 551)
WM00465 Check mixture temperature. (→ Page 440)
WM00467 Cummins generator: Clean generator intake grill. (→ Page 505)
Leroy-Somer generator: Clean generator intake grill. (→ Page 515)
SS180152/04E 2020-06 | Maintenance | 435

Option
WM00468 Check generator power and generator operating data. (→ Page 440)
WM00469 Check generator voltage in idle mode. (→ Page 440)
WM00470 X Check noise generation of compressor and fans. (→ Page 552)
WM00471 X Check gearbox housing temperature and bearing tempera- (→ Page 503)
ture.
WM00472 Check heating water supply and return temperature. (→ Page 440)
WM00473 X Check internal condition and function of gearbox and oil (→ Page 491)
circulation system.
WM00476 X Check condensate neutralization system and flush conden- (→ Page 540)
sate line with condensate collecting tank.
WM00477 X Check cooling function of cooling unit. (→ Page 553)
WM00478 X Check cooling fins for contamination, clean if required. (→ Page 554)
WM00480 Check stability of coolant temperature in high-temperature (→ Page 440)
and low-temperature circuit.
WM00482 Cummins generator: Check coupling element element. (→ Page 512)
Leroy-Somer generator: Check coupling element element. (→ Page 519)
WM00483 Cummins generator: Lubricate bearings according to in- (→ Page 507)
struction plate, check bearing temperature and winding (→ Page 504)
temperature.
Leroy-Somer generator: Lubricate bearings according to (→ Page 514)
instruction plate, check bearing temperature and winding (→ Page 517)
temperature.
WM00484 X Cummins generator: Replace air filter if necessary. (→ Page 506)
WM00485 Lubricate motor bearings as per manufacturer's specifica- (→ Page 544)
tions.
WM00486 Check supply voltage. (→ Page 440)
WM00488 Check oil pressure and oil level. (→ Page 440)
WM00489 Check oil temperature. (→ Page 440)
WM00490 X Oil change. ATTENTION! First change after 500 operating (→ Page 497)
hours.
WM00491 X Replace buffer battery in central processing unit (CPU) of (→ Page 547)
the PC.
WM00492 Cooling water: Check supply and return temperature. (→ Page 440)
WM00495 Visually inspect rubber bellows, hoses and coolant pump. (→ Page 543)
WM00496 Check starter batteries. (→ Page 548)
TIM-ID: 0000073292 - 005
Check back-up batteries. (→ Page 547)

WM00499 Check function of valve-leak control and check shut-off (→ Page 528)
equipment. (→ Page 530)
WM00500 X Check gear oil and take oil sample. (→ Page 495)
WM00501 X Check exhaust gas heat exchanger, clean or replace if nec- (→ Page 532)
essary.
WM00506 X Replace safety switching device. (→ Page 547)
WM00508 Replace flexible hose of coolant line (only 8V, 12V, and (→ Page 481)
16V).
436 | Maintenance | SS180152/04E 2020-06

Option
WM00509 If spark plug is replaced: Clean and check spark plug con- (→ Page 454)
nector, replace if necessary. (→ Page 452)
WM00510 Check crankcase pressure control and adjust if necessary. (→ Page 447)
WM00511 Check emissions values, adjust as necessary. Observe lo- (→ Page 538)
cal emissions regulations.
WM00512 X Replace oil filter. (→ Page 500)
WM00573 Replace fine filter. (→ Page 445)
WM00779 X Replace spark plugs in case of operation with 250 mg NOx (→ Page 448)
and replace seal in spark plug connector.
WM00780 X Replace spark plugs in case of operation with >250 mg (→ Page 448)
NOx and replace seal in spark plug connector.
WM00813 X Check exhaust back pressure before/after catalytic con- (→ Page 537)
verter.
WM00814 Check differential pressure at gas filter. (→ Page 524)
WM00816 Replace gas filter. (→ Page 526)
WM00817 Visually inspect coolant pumps. (→ Page 545)
WM00818 X Replace ring gear of gearbox oil pump. (→ Page 492)
WM00819 X Clean gearbox inside and clean oil circulation system. (→ Page 499)
WM00822 Check air filter and replace if necessary. (→ Page 522)
WM00825 X Clean oil filter, replace if necessary. After 500 operating (→ Page 502)
hours for the first time.
WM00919 Check screw connections on all exhaust gas components (→ Page 562)
after the engine, replace seals and screws if necessary.
WM00931 Replace prefilter. (→ Page 521)
Table 6: Maintenance task reference table [QL1]

TIM-ID: 0000073292 - 005
SS180152/04E 2020-06 | Maintenance | 437

9 Task Description
This chapter provides instructions on performing the necessary maintenance work on the engine-generator
set.
nents which are not included in the scope of supply of your particular engine-generator set.
Prior to commencing work
• Ensure that the prerequisites listed in the descriptions have been met.
• Ensure that all necessary special tools, consumables and spare parts are available.
• Ensure that fluids and lubricants used for work have been approved for the engine-generator set.
Important
This chapter is intended for technical personnel who are qualified and trained to perform maintenance work
on engines and machines. Qualifications for performing these tasks can also be obtained in the training
center at MTU.
Work on the gas system must only be carried out by a specialist gas company.
All work on sections and components in contact with gas must only be carried out by instructed technical
personnel with knowledge in the area of explosion protection:
• Close the main shut-off cock prior to working on the gas system and after a long out-of-service period of
the plant.
• Close the solenoid valve of the gas train before working on the gas system.
• Increase the additional air flow in the installation room to the maximum before opening the gas system
in the shut-off and secured section.
• Switching off or locking the supply air fans via the motor protecting switch in this situation is prohibited.
Work on plant electrical components must only be carried out by specialist personnel with electro-technical
training.
The designation of the spare part and required unit counts are listed in the Task Description.
Approved lubricants, coolants, fuels and cleaning agents are listed in the (→ Fluids and Lubricants Specifica-
tions).
If it was not possible to successfully complete a maintenance task, contact Service.
TIM-ID: 0000076214 - 004
438 | Task Description | SS180152/04E 2020-06

9.2 Engine-Generator Set
9.2.1 Performing test run
DANGER
tors.
DANGER
personnel only.
DANGER
Components are moving or rotating.
• Operate the engine at low load only. Keep clear of the danger zone of the engine.
WARNING
• Do not smoke.
WARNING
Risk of poisoning!
WARNING
Performing test run

1. Start engine-generator set (→ Page 139).
TIM-ID: 0000070068 - 004
2. Perform test run at not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 155).
4. Shut down engine-generator set (→ Page 157).

9.2.2 Operating data check after 3000 hours
Preconditions
☑ Operating Instructions for MMC4000 controller available
DANGER
tors.
DANGER
personnel only.
DANGER
WARNING
• Do not smoke.
WARNING
WARNING
WARNING
Risk of burns!
TIM-ID: 0000070404 - 003

Checking operating data after 3000 hours

u Check operating data after 20 minutes in operation at full load.

Item Measure after 20 minutes in operation under full load
MMC display Cooling system
• Check stability of coolant temperatures in high-temperature circuit
• Check stability of coolant temperatures in low-temperature circuit
• Heating water supply and return temperature
• Cooling water supply and return temperature
Check that indicated operating values are within limits. Enter operating val-
ues in checklist:
Lube oil system
• Oil pressure
• Oil level
• Oil temperature
Generator
• Generator power
• Generator operating data
• Check mains voltage
• Check generator voltage in idle mode
Air intake / mixture supply
• Mixture temperature
TIM-ID: 0000070404 - 003

9.2.3 Shutdown criteria – Check
DANGER
tors.
DANGER
personnel only.
DANGER
WARNING
Risk of poisoning!
WARNING
Activating EMERGENCY STOP circuit

1. Consult the circuit diagram.
2. Check all sensors incorporated in the safety circuit.
3. Adjust all sensors incorporated in the safety circuit.
4. Test function of all sensors incorporated in the safety circuit.
5. Simulate sensor tripping, e.g. by disconnecting sensor.
6. Check that the safety circuit responds by switching.
7. Check all external manual EMERGENCY STOP switches incorporated in the safety circuit and test their func-
tion.
8. Check feedback to the MMC controller.
9. Activate the safety circuit by temporarily bridging minimum gas pressure.
TIM-ID: 0000071931 - 002
10. Check minimum and maximum gas pressure.

11. Monitor differential pressure at exhaust gas heat exchanger:
1. Start pump in Manual mode.
2. Allow timeout to expire.
3. Slowly close the manual valve until the monitor is tripped.
12. Check that all safety-related components have been fully and correctly installed.
13. Check that plant components which are intentionally exposed in the installation room do not present any
danger.
14. Document results in the test record.

9.3 Engine
9.3.1 Work with special qualifications
Work with special qualifications

Note: Maintenance work may only be carried out by duly qualified personnel.
u Contact Service for the following tasks:
• WM00442 - Clean exhaust turbocharger.
• WM00456 - Clean exhaust gas heat exchanger.
TIM-ID: 0000087805 - 003
SS180152/04E 2020-06 | Engine | 443

9.3.2 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.

Barring gear F6555766 1
Ratchet head with extension F30006212 1
DANGER
Rotating and moving engine parts.
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
Barring engine manually

1. Remove guard plate.
2. Engage 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.
Figure 78: Barring engine manually

TIM-ID: 0000002531 - 002
444 | Engine | SS180152/04E 2020-06

9.3.3 Oil separator – Filter replacement
Preconditions

Filter element (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• 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

Important information
Incorrectly installed filters can cause malfunctions.
1. Unscrew locknut (2) on housing cover (1).

2. Remove housing cover (1) together with plas-
tic disk (3).
3. Unscrew locknut (4) on filter cover (6).
4. Remove filter cover (6) together with plastic
disk (5).
TIM-ID: 0000029127 - 010
Figure 79: Oil separator – Cover
SS180152/04E 2020-06 | Engine | 445

5. Carefully lift out fine filter (1).
6. Carefully lift out coalescer filter (2).
7. Clean sealing faces and inside of housing.
Note: Ensure that sealing faces are clean.
8. Check condition of gaskets on new fine filter
and new coalescer filter.
Note: The fine filter (1) must be installed in the cor-
rect position in the housing.
9. Place fine filter (1) in housing, ensuring it is
straight.
Note: The coalescer filter (2) must be installed in
the correct position in the housing.
10. Place coalescer filter (2) in housing, ensuring
it is straight.
Figure 80: Oil separator – Filter elements

11. Fit filter cover (6), ensuring it is positioned
correctly.
Figure 81: Oil separator – Cover

12. Screw on new plastic disk (5) with new locknut (4) and use torque wrench to tighten to specified tightening
torque.
Locknut Tightening torque ±8 Nm
13. Fit housing cover (1).

14. Screw on new plastic disk (3) with new locknut (2) and use torque wrench to tighten to specified tightening
TIM-ID: 0000029127 - 010
torque.
Locknut Tightening torque ±8 Nm
446 | Engine | SS180152/04E 2020-06

9.3.4 Crankcase breather – Pressure control check and adjustment
Preconditions
Checking and adjusting pres-

sure control on 8/12/16V en-
gines
1. Check crankcase pressure and adjust if nec-
essary.
2. Turn flow restrictor (1) for adjustment by
±90°.
Figure 82: Checking and adjusting pressure

Power at engine setting Setting value
100 % -10 mbar ±2 mbar
Table 7: Pressure control setting
Checking and adjusting pres-

sure control on 20V engines
1. Check crankcase pressure and adjust if nec-
essary.
2. To adjust pressure control, turn ball valve (1).
TIM-ID: 0000079772 - 001
Figure 83: Checking and adjusting pressure

Power at engine setting Setting value
100 % -10 mbar ±2 mbar
Table 8: Pressure control setting
SS180152/04E 2020-06 | Engine | 447

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

1. Remove spark plug (→ Page 449).
2. Install new spark plug (→ Page 450).
TIM-ID: 0000004224 - 002
448 | Engine | SS180152/04E 2020-06

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

Special wrench, 20.8 mm F30452574 1
WARNING
Risk of burns!
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 hearing protection.
Removing spark plug

1. Remove spark plug connector (1)
(→ Page 453).
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.
Figure 84: Removing spark plug

TIM-ID: 0000043424 - 004
SS180152/04E 2020-06 | Engine | 449

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

Special wrench, 20.8 mm F30452574 1
Spark plug (→ Spare Parts Catalog)
Spark plug connector with ignition line (→ Spare Parts Catalog)
DANGER
Live components, arcing due to flash-over.
Risk of serious injury – danger to life!
• Do not touch live components during operation.
• Wear suitable electrician gloves.
WARNING
Risk of burns!
WARNING
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
TIM-ID: 0000043425 - 006
450 | Engine | SS180152/04E 2020-06

Installing spark plug
1. Clean and dry the mating surfaces on spark
plug (1), sealing ring (2) and cylinder head.
2. Install new sealing ring (2) on spark plug (1)
with the flat side facing the insulator.
3. Remove dust and deposits from ignition line
on side facing spark plugs so that perfect
contact is achieved when reused.
4. Install a new lower seal in the ignition line
(→ Page 455)
Note: Ensure that tools and assembly aids are free
from grease.
5. Screw spark plug into cylinder head.
Figure 85: Installing spark plug

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 50 +5 Nm
7. Install spark plug connector (1) (→ Page 455).
Figure 86: Installing ignition line

TIM-ID: 0000043425 - 006
SS180152/04E 2020-06 | Engine | 451

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

1. Remove spark plug connector (→ Page 453).
2. Install spark plug connector (→ Page 455).
TIM-ID: 0000035897 - 004
452 | Engine | SS180152/04E 2020-06

9.3.9 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.
Figure 87: Removing spark plug connector

TIM-ID: 0000043225 - 004
SS180152/04E 2020-06 | Engine | 453

9.3.10 Spark plug connector – Cleaning and check
Multimeter, measuring range 20 kΩ (→ Spare Parts Catalog)
WARNING
Risk of burns!
WARNING
Cleaning and checking spark plug connector

2. Removing spark plug isolator sealing ring (→ Page 455).
3. Check spark plug connector (1) and ignition
line (2) visually for kinks, pinching points and
brittleness, replace if necessary.
4. Check connection between upper section of
insulation (3) and lower section of insula-
tion (4) for firm seating, tighten hand-tight if
required.
5. Blow out connection opening to spark plug
with compressed air.
6. Check connection to spark plug visually. The
connection spring (5) must be free of parti-
cles.
Note: Moving the test prod back and forth can re-
duce the risk of an intermittent contact.
7. Check the ohmic resistance of the ignition
line at both connection ends (5) and (6) using
a suitable test prod (e.g. clamp-type test
prod). The resistance value should be in the
range of 5 ± 1 kOhm. Figure 88:
TIM-ID: 0000070448 - 002
8. Installing spark plug isolator sealing ring

(→ Page 455)
454 | Engine | SS180152/04E 2020-06

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

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 456).
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
Figure 89: Installing spark plug connector

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.
SS180152/04E 2020-06 | Engine | 455

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).
Figure 90: Removing spark plug isolator sealing ring

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.
Figure 91: Installing spark plug isolator sealing ring

5. Carefully press sealing ring (1) into the
groove until it is flush with the bore in Teflon
sleeve (2).
TIM-ID: 0000043226 - 006
Figure 92: Checking spark plug isolator sealing ring position
456 | Engine | SS180152/04E 2020-06

9.3.12 Ignition system – Ignition timing check
Preconditions
☑ Operating voltage of engine-generator set controller is present.
☑ Engine-generator set is disconnected from the mains.

Stroboscope (not stocked in warehouse)
DANGER
Live components, arcing due to flash-over.
Risk of serious injury – danger to life!
• Do not touch live components during operation.
• Wear suitable electrician gloves.
DANGER
Rotating and moving engine parts.
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
Ignition system – Ignition timing

check
Note: Service tool DiaSys® and a 1A level dongle
(or higher) as well as the Woodward IC900
series service tool (for Woodward ignition
systems only) are required to determine the
ignition timing setting.
1. Stop engine (→ Page 157).
2. Install stroboscope clamp on cylinder A1 igni-
tion cable.
3. Start engine (→ Page 139).
4. Use stroboscope to check ignition timing on
flywheel mark and compare with engine-spe-
cific setpoint value.
5. If the ignition timing deviates from the speci-
TIM-ID: 0000043949 - 007
fication, it must be adjusted by correcting the

reset position in the ignition system. Correct
reset position with DiaSys® (for Motortech Figure 93: Ignition timing check
ignition systems only) or Woodward IC900
series service tool (for Woodward ignition
systems only).
6. Check ignition timing.
7. Disconnect stroboscope.
8. Stop engine (→ Page 157).
SS180152/04E 2020-06 | Engine | 457

9.3.13 Valve protrusion – Measurement
Preconditions

Sliding depth gage, 200 mm Y20000918 1
Preparatory steps
1. Remove igniters (→ Page 449).
2. Remove cylinder head covers (→ Page 465).
3. Remove sleeves (arrowed).
4. Install barring tool (→ Page 444).
Figure 94: Measuring valve stem end to cylinder head top

distance
5. Rotate crankshaft with barring tool in engine
direction of rotation until marking “OT” and
pointer are aligned. TIM-ID: 0000043220 - 003
Figure 95: Check valve clearance
458 | Engine | SS180152/04E 2020-06

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 462).
3. Release adjusting screw (1) and remove valve
bridge. Do not remove rocker arm (2)!
Figure 96: Measuring valve protrusion

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 462).
Figure 97: Depth gage
Final steps
TIM-ID: 0000043220 - 003
1. Remove barring tool (→ Page 444).

2. Check condition of O-rings at the sleeves, replace if damaged.
SS180152/04E 2020-06 | Engine | 459

3. Install sleeves (arrowed).
4. Install cylinder head covers (→ Page 466).
5. Install igniters with new sealing rings
(→ Page 450).
Figure 98: Measuring valve stem end to cylinder head top

distance
TIM-ID: 0000043220 - 003
460 | Engine | SS180152/04E 2020-06

9.3.14 Valve gear – Lubrication
Preconditions

Engine oil
Lubricating valve gear

1. Remove cylinder head covers (→ Page 465).
2. Fill oil chambers of rocker arms and adjusting
screws with oil.
3. Install cylinder head covers (→ Page 466).
Figure 99: Lubricating valve gear

TIM-ID: 0000043352 - 001
SS180152/04E 2020-06 | Engine | 461

9.3.15 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 465).
2. Install barring device (→ Page 444).
3. Rotate crankshaft with barring device in en-
gine direction of rotation until marking “OT”
and pointer are aligned.
Figure 100: Valve clearance check
Diagram – two crankshaft positions

Position Cylinder 1 2 3 4 5 6 7 8 9 10
TIM-ID: 0000077283 - 003
8V
Firing TDC in cylinder A1 Bank A IX –X IX –X
Bank B IX I– –– I–
Overlap TDC in cylinder A1 Bank A –– I– –– I–
Bank B –– –X IX –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
462 | Engine | SS180152/04E 2020-06

Position Cylinder 1 2 3 4 5 6 7 8 9 10
12 V
Firing TDC in cylinder A1 Bank A IX I– –X I– –X ––
Bank B –X IX I– –X –– I–
Overlap TDC in cylinder A1 Bank A –– –X I– –X I– IX
Bank B I– –– –X I– IX –X
16 V
Firing TDC in cylinder A1 Bank A IX –X I– –X I– I– IX ––
Bank B I– I– –– –X –– –X IX –X
Overlap TDC in cylinder A1 Bank A –– I– –X I– –X –X –– IX
Bank B –X –X IX I– IX I– –– I–
20 V
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
Overlap TDC in cylinder A1 Bank A –– I– IX –X I– –X I– –X IX
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 9: Valve clearance adjustment
Checking valve clearance at two crankshaft positions

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 adjustment 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 the distance between valve bridge and rocker arm.
5. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance.
TIM-ID: 0000077283 - 003
SS180152/04E 2020-06 | Engine | 463

Adjusting valve clearance
1. Loosen 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.
Figure 101: Valve clearance check

5. Use torque wrench to tighten locknut (1) to specified tightening torque, holding the adjusting screw (2) to
prevent it from turning.
Locknut M16 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 444).
2. Install cylinder head cover (→ Page 466).
TIM-ID: 0000077283 - 003
464 | Engine | SS180152/04E 2020-06

9.3.16 Cylinder head cover ‒ Removal
Preconditions
Cylinder head cover ‒ Removal

1. Clean very dirty cylinder head covers (1) prior
to removal.
3. Remove screws (2).
4. Remove cylinder head cover with gasket from
cylinder head.
Figure 102: Cylinder head cover ‒ Removal

TIM-ID: 0000042136 - 002
SS180152/04E 2020-06 | Engine | 465

9.3.17 Cylinder head cover ‒ Installation
Gasket (→ Spare Parts Catalog)
NOTICE
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.
Figure 103: Cylinder head cover ‒ Installation
TIM-ID: 0000042137 - 002
466 | Engine | SS180152/04E 2020-06

9.3.18 Starter – Replacement
Preconditions
☑ Operating voltage switched off.

Screwdriver bit F30378921 1
Socket screwdriver, 14 mm F30378499 1
Torque wrench, 0.5–5 Nm 0015384230 1
Ratchet bit F30027340 1
Lubricating grease (Molykote Longtherm 2 Plus NLGI 2) X00057299 1
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
DANGER
WARNING
Risk of burns!
WARNING
Heavy part, risk of falling or overturning due to lack of stability.
Risk of crushing body or limbs!
• Use appropriate lifting gear and appliances.
• Wear safety shoes.
TIM-ID: 0000079840 - 004
CAUTION
Low voltage short circuit.
Minor injuries due to fire or fusing material (e.g. injuries to the fingers)!
• De-energize components before commencing work.
• Ensure that connections do not come into contact with each other.
SS180152/04E 2020-06 | Engine | 467

Disconnecting and removing starter
1. Disconnect the charge voltage to the battery.
2. Disconnect cable from negative terminal of battery.
3. Disconnect cable from positive terminal of connected battery.
4. Prior to disconnecting, mark all cables with writable adhesive tape.
5. Disconnect all cables from starter.
6. Protect all cables from damage.
Note: Only one starter (right) with 8V and 12V.
7. Remove screws from starter as per overview
drawing.
8. Remove starter.
9. Protect starter against damage.
Figure 104: Starter overview
Installing new starter

1. Coat starter pinion with lubricating grease.
Note: Only one starter (right) with 8V and 12V.
2. Install starter as per overview drawing.
Connecting starter to the elec-

tric system
1. Connect cables to starter according to mark-
ing or wiring diagram. TIM-ID: 0000079840 - 004
Figure 105: Starter
468 | Engine | SS180152/04E 2020-06

2. Screw on nuts (1), (2), (3), (4) and (5) and use torque wrench to tighten to specified tightening torque.
a) Connection terminal 50 (3)
Nut M5 Tightening torque 2.5 Nm ±0.5 Nm
b) Connection terminal 30 (2), 30b (4), 31 (5) and connection terminal 45 (1)
Nut M12 Tightening torque 30 Nm ±3 Nm
3. Connect cable to positive terminal of battery.

4. Connect cable to negative terminal of battery to re-establish the charge voltage to the battery.
5. Connect the charge voltage to the battery.
6. Check that starter works properly.
TIM-ID: 0000079840 - 004
SS180152/04E 2020-06 | Engine | 469

9.3.19 Engine oil level – Check
Preconditions
WARNING
Oil is hot.
WARNING
• Do not smoke.
Checking oil level prior to en-

gine start
1. Pull out oil dipstick from guide tube and wipe
it.
2. Insert oil dipstick into guide tube up to the
stop, pull it out 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 Figure 106: Engine oil level
works properly.
4. Insert oil dipstick into guide tube up to the
stop.
Checking engine oil level after engine has stopped

1. 5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.
TIM-ID: 0000006169 - 008
2. Insert oil dipstick into guide tube up to the stop, pull it out 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.
470 | Engine | SS180152/04E 2020-06

9.3.20 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ Fluids and Lubricants Specifications (A001072/..) are available.

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

1. Open shutoff valve(s) in extraction line from engine and waste-oil tank.
2. Use electric pump to extract all oil from oil pan.
3. Close shutoff valve(s).
Filling with new engine oil

1. Determine the oil change quantity (→ Page 124).
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 470).
TIM-ID: 0000077367 - 002
SS180152/04E 2020-06 | Engine | 471

9.3.21 Engine oil – Sample extraction and analysis
Preconditions
DANGER
WARNING
Oil is hot.
• Wear protective clothing, protective gloves and safety goggles / safety mask.
WARNING
• Do not smoke.
WARNING
Extracting oil sample on 8V en-

gines
1. Connect sampling hose (unit manufacturer
scope of supply) to sampling neck (arrowed)
with engine running at operating tempera-
ture.
2. Rinse sampling neck and sampling hose by
draining approx. 300 ml engine oil in a suita-
ble container. Subsequently, dispose off en-
gine oil in accordance with the regulations
applicable.
3. Extract engine oil samples in accordance with
the Fluids and Lubricants Specifications
(A001072/..) and have them analyzed by a
certified laboratory.
TIM-ID: 0000079775 - 004
Figure 107: Oil sample extraction
472 | Engine | SS180152/04E 2020-06

Extracting oil sample on
12/16/20V engines
1. Connect sampling hose (unit manufacturer
scope of supply) to sampling neck (arrowed)
with engine running at operating tempera-
ture.
2. Rinse sampling neck and sampling hose by
draining approx. 300 ml engine oil in a suita-
ble container. Subsequently, dispose off en-
gine oil in accordance with the regulations
applicable.
3. Extract engine oil samples in accordance with
the Fluids and Lubricants Specifications
(A001072/..) and have them analyzed by a
certified laboratory.
Figure 108: Oil sample extraction

TIM-ID: 0000079775 - 004
SS180152/04E 2020-06 | Engine | 473

9.3.22 Engine oil filter – Replacement
Preconditions

Oil filter wrench F30379104 1
Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Oil is hot.
WARNING
• Do not smoke.
Replacing engine oil filter on 8V

engines
1. Unscrew oil filter using 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 470).
TIM-ID: 0000079776 - 001
Figure 109: Replacing engine oil filter
474 | Engine | SS180152/04E 2020-06

Replacing engine oil filter on
12/16/20V engines
1. Use oil filter wrench to unscrew oil filter.
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 470).
Figure 110: Replacing engine oil filter

TIM-ID: 0000079776 - 001
SS180152/04E 2020-06 | Engine | 475

9.3.23 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.
Checking engine coolant level

1. Read off system filling pressure (→ Page 124) on pressure gauge.
2. If required, top up with treated engine coolant (→ Page 480).
TIM-ID: 0000077368 - 002
476 | Engine | SS180152/04E 2020-06

9.3.24 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 478).
2. Fill with engine coolant (→ Page 480).
TIM-ID: 0000000036 - 031
SS180152/04E 2020-06 | Engine | 477

9.3.25 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
Figure 111: Engine coolant – Draining

TIM-ID: 0000006751 - 002
478 | Engine | SS180152/04E 2020-06

2. Draining of residual coolant:
• At coolant distribution housing.
3. Close all open drain points.
Figure 112: Engine coolant – Draining

TIM-ID: 0000006751 - 002
SS180152/04E 2020-06 | Engine | 479

9.3.26 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 engine coolant

1. Fill pre-mixed coolant with pressure pump until system filling pressure is reached (→ Page 124).
2. Vent engine coolant circuit at vent line.
3. Start engine and run at idle speed for some minutes.
4. Check coolant level (→ Page 476).
TIM-ID: 0000077369 - 002
480 | Engine | SS180152/04E 2020-06

9.3.27 Coolant vent line (engine coolant circuit) – Replacement
Preconditions
WARNING
Replacing coolant vent line

1. Drain engine coolant (→ Page 478).
2. Release union nuts (1) and (3).
3. Remove coolant vent line (2).
4. Install new coolant vent line (2) horizontally
on upper connection. An upward inclination is
not permitted.
5. Fill with engine coolant (→ Page 480).
Figure 113: Coolant vent line

TIM-ID: 0000029143 - 005
SS180152/04E 2020-06 | Engine | 481

9.3.28 Mixture coolant level – Check
Preconditions
WARNING
Checking mixture coolant level

1. Read off system filling pressure (→ Page 124) on pressure gauge.
2. If required, top up with treated engine coolant (→ Page 485).
TIM-ID: 0000077370 - 002
482 | Engine | SS180152/04E 2020-06

9.3.29 Mixture coolant – Change
Mixture coolant
Mixture coolant – Change

1. Drain mixture coolant (→ Page 484).
2. Fill with fresh mixture coolant (→ Page 485).
TIM-ID: 0000007027 - 004
SS180152/04E 2020-06 | Engine | 483

9.3.30 Mixture coolant – Draining
Preconditions
WARNING
Draining mixture coolant

1. Provide a suitable receptacle to catch the coolant.
2. Open drain valve at drain point in coolant line to mixture coolant cooler and drain coolant.
TIM-ID: 0000042774 - 001
484 | Engine | SS180152/04E 2020-06

9.3.31 Mixture coolant – Filling
Preconditions

Mixture coolant
Filling engine coolant

Note: The lowest point in the mixture coolant circuit may be on the plant side.
1. Fill mixture coolant at the lowest point in the mixture coolant circuit.
Note: The highest point in the mixture coolant circuit may be on the plant side.
2. Vent the mixture coolant circuit at the highest point.
3. Vent the other point several times during the filling procedure.
4. Fill with treated coolant until the system filling pressure (→ Page 124) has been reached.
5. Close shutoff cocks.
6. Start engine and operate it at idle speed for a few minutes to check the leak-tightness.
TIM-ID: 0000077371 - 005
SS180152/04E 2020-06 | Engine | 485

9.3.32 Еngine mounting ‒ Check
NOTICE
Contamination of engine mounts made of natural rubber with fuel or oil.
Engine mounts swell. Risk of shorter service life or destruction of the mounts!
• Cover engine mounts when working with fuel or oil.
• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.
Еngine mounting ‒ Check

Item Findings Measure
Visually inspect mounts. • Damage Replace, (→ contact Service.)
• Brittleness
• Deformation
• Crack formation
• Swelling
visible
TIM-ID: 0000027322 - 003
486 | Engine | SS180152/04E 2020-06

9.3.33 Engine mounting – Checking securing screws for secure seating
Preconditions
☑ Engine is stopped and starting disabled
Checking securing screws of engine mounting for secure seating

1. Check securing screws for secure seating.
2. If irregularities are detected at the engine mounting:
• Check engine mounting (→ Page 486).
• Contact Service.
3. Tighten loose screw connections.
TIM-ID: 0000087419 - 003
SS180152/04E 2020-06 | Engine | 487

9.3.34 Engine cabling – Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Checking engine cabling

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 that cable clamps are secure, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close off disconnected connectors with protective caps provided.
8. Use isopropyl alcohol to clean dirty connector housings, sockets and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
Important
Connecting connectors to sensors is only permitted when the engine is stopped.
TIM-ID: 0000000029 - 026
488 | Engine | SS180152/04E 2020-06

9.3.35 NOx sensor – Replacement
Preconditions
☑ Power supply to electronic engine management system is switched off.

Ratchet bit F30027340 1
Assembly compound (Molykote P 37) 50564 1
NOx sensor (→ Spare Parts Catalog) 1
WARNING
Risk of burns!
NOTICE
Incorrect measurement of the sensors are possible even with small amounts of contamination during
assembly and due to contaminated process materials.
Sensor damage resultant damage to components is possible!
• Prior to assembly, check sensors for particular cleanness and install with clean hands.
• Protect sensor against contamination with certain materials (e.g. thread grease, engine oil, silicone,
reducing agent and others).
• The process materials must meet the requirements of the Fluids and Lubricants Specifications.
NOTICE
High voltage.
Risk of damage to components!
• Switch off ignition before replacing components.
NOTICE
Ceramic cell breakage due to shock or impact.
Risk of damage to components!
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
TIM-ID: 0000079922 - 001
SS180152/04E 2020-06 | Engine | 489

Removing NOx sensor
Note: Observe arrangement and position of sensor
(→ Page 74).
1. Disconnect and remove male connector (2)
from control unit (1).
2. Unscrew control unit (1) at the eyelets.
3. Remove sensor (3).
Figure 114: Removing NOx sensor
Installing NOx sensor

Note: Note the following:
• If sensor (3) has suffered shock or impact
it is deemed as being defective and shall
not be used.
• Always replace NOx sensor (3) together
with control unit (1).
1. Screw on control unit (1) at the eyelets and
tighten screws.
2. Remove protective cap on thread of sen-
sor (3) only just before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
3. Coat sensor thread (3) thinly with specified
assembly compound as necessary.
4. Screw in sensor (3) by hand.
Figure 115: Installing NOx sensor

5. Tighten nut (3) to specified torque using a torque wrench.
Nut M20 Tightening torque (Assembly compound 40 Nm +4 Nm
(Molykote P 37))
6. Fit male connector (2) and latch it.

TIM-ID: 0000079922 - 001
490 | Engine | SS180152/04E 2020-06

9.4 Gearbox / Transmission
9.4.1 Gearbox and oil circulation system – Check
WARNING
Oil is hot.
WARNING
• Do not smoke.
Checking internal condition and operation of gearbox

Note: Engine-generator set is stopped and starting disabled.
1. Remove cover from inspection port.
2. Check gearbox interior for contamination.
3. Close cover on inspection port.
Checking operation of the oil circulation system

Note: Engine-generator set is ready for operation.
1. Start the plant.
2. Check oil pressure.
3. Check oil filter contamination display.
TIM-ID: 0000077777 - 002

9.4.2 Ring gear of transmission oil pump – Replacement
Preconditions

Open-end wrench, 40 A/F (→ Tools Catalog)
Torque wrench (→ Tools Catalog)
Socket, 13 A/F (→ Tools Catalog)
Gear oil
Surface sealant Loctite 50569
Ring gear 93223140007
WARNING
Oil is hot.
WARNING
• Do not smoke.
Preparatory steps
u Drain gear oil (→ Page 497)
Removing gear oil pump

1. Release union nuts (3) and (4).
2. Loosen and remove screws (1).
3. Remove gear oil pump (2).
4. Clean sealing faces between gear oil pump
(3) and bearing cap (5).
TIM-ID: 0000087406 - 001
Figure 116: Gear oil pump

Replacing ring gear
Note: • If the ring gear (1) is seriously damaged,
clean gear oil filter (→ Page 502)
• The coupling elements (3) and (4) must
not be disassembled.
1. Remove ring gear (1).
2. Clean coupling elements.
3. Install new ring gear (1).
Figure 117: Ring gear
Installing gear oil pump

1. Clean sealing faces (arrow) between bearing
cap (1) and gear oil pump flange (2) with
(Surface sealant Loctite).
Figure 118: Apply surface sealant

2. Install gear oil pump (2) with coupling ele-
ment.
TIM-ID: 0000087406 - 001
Figure 119: Installing gear oil pump

3. Insert screws (1) in bearing cap (5) and tighten.
Screw M8 Tightening torque 22.5 Nm
4. Screw in union nuts (3) and (4) and tighten.
TIM-ID: 0000087406 - 001

9.4.3 Gear oil – Sample extraction
Preconditions
☑ Engine-generator set is in operation.
☑ Gearbox at operating temperature.
DANGER
tors.
DANGER
WARNING
Risk of burns!
WARNING
Oil is hot.
WARNING
Medium is hot and highly pressurized.
WARNING
• Do not smoke.
WARNING
TIM-ID: 0000079193 - 002

Oil sample extraction
1. Remove safety cap from measuring connec-
tion (1) or (3) on oil cooler (2).
2. With the gearbox running and at operating
temperature, connect high-pressure hose
(engine-generator set manufacturer's scope
of supply) to measuring connection (1) or (3).
3. Drain approx. 250 ml oil into collecting con-
tainer.
Note: Following the instructions in the description
of the oil sample kit.
4. Fill sample oil into container included in the
delivery.
5. Remove high-pressure hose.
6. Fit safety cap on measuring connection (1) or
(3) and close it.
7. Fill out the enclosed data sheets as specified.
8. Have gear oil sample analyzed by a certified Figure 120: Oil sample extraction
test institute.
TIM-ID: 0000079193 - 002

9.4.4 Gear oil – Change
Preconditions
☑ Gearbox at operating temperature.
☑ Fluids and Lubricants Specifications are available

Gear oil
WARNING
Oil is hot.
WARNING
• Do not smoke.
Pumping off gear oil

1. Provide a suitable container in which to col-
lect the gear oil.
2. Unscrew screw plug (1) from semirotary hand
pump (3).
3. Open ball cock (2).
4. Use semirotary hand pump (3) to pump off oil
completely via the connection out of oil pan.
5. Close ball cock (2) and screw in screw plug
(1).
6. Clean existing permanent magnets (at oil
drain, oil dipstick, etc.) and contaminated oil
sight glasses.
7. Check interior of gearbox for deposits and
residue.
Result: If deposits/residue are found, clean gearbox
(→ Page 499)
TIM-ID: 0000077776 - 002
Figure 121: Semirotary hand pump
Cleaning oil filter

1. Remove and clean oil filter (→ Page 502).
2. Install new or cleaned oil filter.

Fill with new gearbox oil
1. Determine the oil change quantity (→ Page 124).
Note: To avoid contamination, pour the oil through a hair sieve or a filter.
3. Fill new gear oil through the inspection port.
4. Check filling level via the markings on the oil sight glass.
TIM-ID: 0000077776 - 002

9.4.5 Gearbox – Cleaning
Preconditions
☑ Gear oil is drained.
☑ Plant is switched off and starting disabled.

Gear oil
WARNING
Oil is hot.
WARNING
• Do not smoke.
WARNING
Note: Flush gearbox if necessary, e.g. initial operation, contamination, switch to different oil.
Flush gearbox
Note: Use operating oil for flushing.
1. Fill gearbox with the flushing oil up to the oil level marking in the oil sight glass.
Note: The flushing time is between 30 and 60 minutes and depends on the degree of contamination.
2. Run the gearbox without load.
3. Drain flushing oil.
Cleaning oil circulation system

TIM-ID: 0000078139 - 002
u Flushing oil lines and oil pumps and blow out with compressed air if necessary.

9.4.6 Oil filter – Removal and installation
Preconditions
☑ Plant is switched off and starting disabled.

Filter element (→ Spare Parts Catalog)
WARNING
Oil is hot.
WARNING
• Do not smoke.
Removing oil filter housing

1. Unscrew oil filter housing (1) at hexagon (2).
2. Remove oil filter housing (1).
Figure 122: Removing oil filter housing

TIM-ID: 0000087352 - 001
Oil filter element

u (Filter element)Remove and clean or replace.

Installing oil filter housing
1. Place oil filter housing (1) in position and
screw in.
2. Tighten oil filter housing (1) at hexagon (2).
Figure 123: Installing oil filter housing

TIM-ID: 0000087352 - 001

9.4.7 Oil filter – Cleaning
WARNING
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
Note: The described cleaning instructions apply to coarse filter elements from 40 μm onwards. For finer filter ele-
ments, cleaning in an ultrasonic bath is recommended.
Cleaning oil filter

1. Seal filter element for the clean side.
Note: Suitable cleaning fluids are petroleum spirit, diesel fuel or warm water.
2. Place filter element in a suitable container with cleaning fluid.
3. Allow filter element to soak for up to 30 minutes depending on degree of contamination.
4. Remove deposits with a soft brush or a paintbrush.
5. Rinse filter element in clean water.
6. Blow out filter element from the inside with compressed air or a steam jet.
7. Let filter element dry.
8. Visually check filter element.
Result: • If the filter pores are free of particles, the filter element can still be used.
• If there is still residue in the filter pores in spite of cleaning, use a new oil filter.
TIM-ID: 0000078141 - 001

9.4.8 Bearing and housing temperature – Check
WARNING
Checking housing and bearing temperatures

1. Check bearing temperature at both shaft ends directly on the bearing caps.
2. Compare measured temperature with the temperature of the installed thermometer.
3. Enter measured values in a continuous table.
4. If the bearing temperatures deviate from the previous measured values, contact Service.
TIM-ID: 0000077778 - 003

9.5 Generator
9.5.1 Cummins Generator
9.5.1.1 Bearing and winding temperature – Check

WARNING
Note: • The generator is factory-set for a max. ambient temperature of 40 °C on delivery.

• MMC alarm and immediate shutdown can be adjusted.
Checking bearing temperatures

1. Check driving end bearing temperature at the controller:
• MMC alarm at 85 °C
• MMC immediate shutdown at 90 °C
2. Check PTO end bearing temperature at the controller:
Checking winding temperature of stator

u Check winding temperature of stator at the controller:
TIM-ID: 0000070415 - 002
504 | Generator | SS180152/04E 2020-06

9.5.1.2 Intake grill – Cleaning
Preconditions
☑ Main switch actuated
☑ Circuit breaker locked (padlock inserted)
☑ Starter battery disconnected
☑ Auxiliary equipment (e.g. battery charger, coolant preheater) de-energized.
DANGER
DANGER
personnel only!
WARNING
Rotating and moving parts and high level of engine noise in the event of accidental engine-generator set
start during service.
• Ensure the engine-generator set has been stopped and starting is disabled during service.
WARNING
Risk of burns!
Cleaning air inlet and outlet

1. Check the air inlet and air outlet on the A and B sides of the generator for visible dirt and obstruction.
2. Remove any dirt with vacuum cleaner, brush or damp rag.
TIM-ID: 0000070418 - 002
3. Remove foreign material to keep the openings unobstructed.
SS180152/04E 2020-06 | Cummins Generator | 505

9.5.1.3 Air filter – Replacement
Preconditions
☑ Main switch actuated.
DANGER
DANGER
personnel only!
WARNING
WARNING
Risk of burns!
Preparatory steps
1. Clean intake grill (→ Page 505).
2. Remove intake grill.
TIM-ID: 0000070411 - 002
Replacing air filter

1. Remove air filter from frame at blower and junction box (if applicable).
2. Clean oil separator, if applicable (→ Page 510).
3. Wash air filter and seals and allow to dry.
4. Check air filter and seals for damage, replace as necessary.
5. Fit air filter and seals.
Final steps
u Install intake grill.
506 | Cummins Generator | SS180152/04E 2020-06

9.5.1.4 Antifriction bearings – Lubrication
Preconditions
☑ Engine-generator set is ready for operation.
DANGER
tors.
DANGER
WARNING
WARNING
the engine.
WARNING
Risk of burns!
Preparatory steps
1. Identify grease nipples, lubricating signs and bearing type of each bearing.
2. Wipe clean grease nipples, end covers and surrounding parts of the generator.
3. Remove any hardened grease from the drain holes. Use a piece of wire as necessary.
4. Clean oil separator, if applicable (→ Page 510).
Adding grease
1. Unscrew cap covering grease nipple.
2. Clean grease nipple and remove any encrusted lubricating grease.
TIM-ID: 0000070413 - 003
3. Clean grease gun coupler.

4. Start engine-generator set, see Starting sequences (→ Page 139).
Note: • Type and quantity of the lubricating grease are specified on the generator nameplate.
• Use right amount of grease. Too much or too little grease may damage the generator.
• Use fresh grease from clean, closed drums and avoid contamination.
• The temperature of the antifriction bearing temporarily increases just after relubricating .
5. Connect low-pressure grease gun to grease nipple and add grease as specified on the data plate with the
engine-generator set running.

Final steps
1. Run engine-generator set with and without load for at least 60 minutes to allow excess grease to emerge.
2. Shut down engine-generator set, see Shutdown sequences (→ Page 157).
3. Wipe away any emerging grease.
4. Compare emerging lubricant with new lubricant.
Result: If the color and consistency of emerging and new lubricant differ, replace the generator bearings
(→ Page 509).
5. Screw end cover onto grease nipple.
6. Install air filter.
TIM-ID: 0000070413 - 003

9.5.1.5 Antifriction bearings – Replacement
Replacing generator bearings

u Replace antifriction bearings, contact Service.
TIM-ID: 0000079194 - 001

9.5.1.6 Oil separator – Cleaning
Preconditions
DANGER
DANGER
personnel only!
WARNING
WARNING
Risk of burns!
Preparatory steps
1. Clean intake grill (→ Page 505).
2. Remove intake grill with air filter.
TIM-ID: 0000073398 - 002

Cleaning oil separator
1. Undo screws (3, 4) and washers.
2. Remove oil separator (2) from air intake grill
(1).
3. Clean oil separator (2).
4. Install oil separator and tighten screws.
Figure 124: Removing oil separator
Final steps
1. Insert air filter in intake grill.
2. Install intake grill.
TIM-ID: 0000073398 - 002

9.5.1.7 Coupling element – Check
Preconditions
DANGER
DANGER
personnel only!
WARNING
WARNING
Risk of burns!
TIM-ID: 0000070420 - 002

Note: Work on the generator must only be performed by a trained and instructed electrically qualified person; oth-
erwise contact Service!
Checking coupling element
1. Remove screws (2) with washers.
2. Remove protective screen (1).
3. Bar engine manually (→ Page 444).
4. Check coupling element (3) for wear and
cracking.
Result: Contact Service on noticing any wear and/or
cracking.
Figure 125: Cummins coupling element

TIM-ID: 0000070420 - 002

9.5.2 Leroy-Somer Generator
9.5.2.1 Bearing and winding temperature – Check

WARNING
Note: • The generator is factory-set for a max. ambient temperature of 40 °C on delivery.

• MMC alarm and immediate shutdown can be adjusted.
Checking bearing temperatures

1. Check driving end bearing temperature at the controller:
2. Check PTO end bearing temperature at the controller:
Checking winding temperature of stator

u Check winding temperature of stator at the controller:
TIM-ID: 0000070414 - 002
514 | Leroy-Somer Generator | SS180152/04E 2020-06

9.5.2.2 Intake grill – Cleaning
Preconditions
DANGER
DANGER
personnel only!
WARNING
WARNING
Risk of burns!
TIM-ID: 0000070417 - 002
SS180152/04E 2020-06 | Leroy-Somer Generator | 515

Cleaning air inlet and outlet
1. Check the air inlet (1) and air outlet on the A
and B sides (2) of the generator for visible
dirt and obstruction.
2. Remove any dirt with vacuum cleaner, brush
or damp rag.
3. Remove foreign material to keep the open-
ings unobstructed.
Figure 126: Cleaning intake grill
TIM-ID: 0000070417 - 002

9.5.2.3 Antifriction bearings – Lubrication
Preconditions
DANGER
DANGER
personnel only!
WARNING
WARNING
Risk of burns!
Preparatory steps
1. Clean grease nipples, end covers and surrounding parts on the B-side of the generator by wiping.
2. Remove any hardened grease from the drain holes. Use a piece of wire as necessary.
TIM-ID: 0000070412 - 002

Adding grease
1. Unscrew cap.
2. Clean grease nipple and remove any encrust-
ed lubricating grease.
Note: • Type and quantity of the lubricating grease
are specified on the generator nameplate.
• Use the right amount of grease. Too much
or too little grease may damage the gener-
ator.
• Use fresh grease from clean, closed drums
and avoid contamination.
• The temperature of the antifriction bearing
temporarily increases just after relubricat-
ing .
3. Add grease as specified on the data plate us-
ing a low-pressure grease gun.
Figure 127: Leroy-Somer generator grease nipples
Final steps
1. Start the engine-generator set, see Starting sequences (→ Page 139).
2. Run the engine-generator set for around 15 minutes to let excess grease escape.
3. Shut down engine-generator set, see Shutdown sequences (→ Page 157).
4. Wipe away any emerging grease.
5. Screw cap back on grease nipple.
TIM-ID: 0000070412 - 002

9.5.2.4 Coupling element – Check
Preconditions
DANGER
DANGER
personnel only!
WARNING
WARNING
Risk of burns!
TIM-ID: 0000070421 - 002

Note: Work on the generator must only be performed by a trained and instructed electrically qualified person; oth-
erwise contact Service!
Checking coupling element
1. Remove screws (2) with washers.
2. Remove protective screen (1).
3. Bar engine manually (→ Page 444).
4. Check coupling element (3) for wear and
cracking.
Result: Contact Service on noticing any wear and/or
cracking.
Figure 128: Coupling element Leroy-Somer
TIM-ID: 0000070421 - 002

9.6 Air Intake / Mixture Supply
9.6.1 Prefilter – Replacement
Prefilter made of fleece (→ Spare Parts Catalog)
WARNING
Risk of burns!
Replacing prefilter
Note: Prefilter is fastened by a Velcro fastener (3).
1. Remove prefilter (2) from air filter (1).
2. Install new prefilter (1) on air filter (2).
Figure 129: Replacing prefilter

TIM-ID: 0000087354 - 001
SS180152/04E 2020-06 | Air Intake / Mixture Supply | 521

9.6.2 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 523).
2. Install new air filter (→ Page 523).
TIM-ID: 0000013394 - 002
522 | Air Intake / Mixture Supply | SS180152/04E 2020-06

9.6.3 Air filter – Removal and installation
Preconditions

WARNING
Risk of burns!
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. Check connecting flange (1) of intake hous-
ing for obstruction.
4. Use suitable cleaning agent to clean contact
surfaces of intake housing and air filter.
Note: The contact surfaces must be dry and free
from grease.
5. Place new air filter (3) with clamp (2) onto in-
take housing (1).
Figure 130: Air filter – Removal and installation

6. Use torque wrench to tighten screw on clamp (2) to specified tightening torque.
Screw - Tightening torque 20 Nm +2 Nm
TIM-ID: 0000044568 - 003
SS180152/04E 2020-06 | Air Intake / Mixture Supply | 523

9.7 Gas System
9.7.1 Gas filter differential pressure – Check
Preconditions
☑ Genset is in operation.
DANGER
personnel only.
WARNING
• Do not smoke.
WARNING
For all described tasks at the genset:
Risk of injury!
• For all tasks, the respective required personal protective equipment (safety shoes, ear protection,
protective gloves, safety goggles, respiratory protection, etc.) is to be used.
WARNING
Rotating parts.
Risk of injury!
• Keep sufficiently clear off rotating parts.
WARNING
TIM-ID: 0000071615 - 002
524 | Gas System | SS180152/04E 2020-06

Checking differential pressure –
Variant A
1. Undo grub screws at test connections (1).
2. Connect U-tube pressure gauge and test con-
nections (1).
3. Measure while engine is running.
Result: • Differential pressure ∆p ≤ 20 mbar.
• If differential pressure is ∆p > 20 mbar, re-
place gas filter (→ Page 526).
4. Disconnect U-tube pressure gauge from test
connections.
5. Close grub screws at test connections (1).
6. Check leak-tightness of test connections us-
ing leak identification spray.
Figure 131: Measuring points on gas filter
Checking differential pressure –

Variant B
1. Undo grub screws at test connections (1).
2. Connect U-tube pressure gauge and test con-
nections (1).
3. Measure while engine is running.
Result: • Differential pressure ∆p ≤ 10 mbar.
• If differential pressure is ∆p > 10 mbar, re-
place gas filter (→ Page 526).
4. Disconnect U-tube pressure gauge from test
connections.
5. Close grub screws at test connections (1).
6. Check leak-tightness of test connections us-
ing leak identification spray.
Figure 132: Measuring points on gas filter

TIM-ID: 0000071615 - 002
SS180152/04E 2020-06 | Gas System | 525

9.7.2 Gas filter – Replacement
Preconditions
☑ Genset is stopped and starting disabled.

Leak detection spray
Soap suds
DANGER
personnel only.
WARNING
• Do not smoke.
WARNING
Risk of injury!
WARNING
Rotating parts.
Risk of injury!
WARNING
TIM-ID: 0000070424 - 003
526 | Gas System | SS180152/04E 2020-06

Note: Gas train design and arrangement may vary.
Replacing gas filter – Variant A
1. Shut off gas supply and close gas cock.
2. Undo screws (2) and remove cover (1) with
O-ring.
3. Remove gas filter.
4. Clean filter housing.
Note: Ensure that new gas filter is properly seated
in groove in housing and cover.
5. Insert new gas filter.
6. Fit cover (1) with O-ring and tighten
screws (2).
7. Open gas cock.
8. Check function and leak-tightness using leak
spray.
Figure 133: Replacing gas filter

Replacing gas filter – Variant B
1. Shut off gas supply and close gas cock (1).
2. Undo screws (3) and remove cover (2) with
O-ring.
3. Remove gas filter.
4. Clean filter housing.
Note: Ensure that new gas filter is properly seated
in groove in housing and cover.
5. Insert new gas filter.
6. Fit cover (2) with O-ring and tighten
screws (3).
7. Open gas cock (1).
8. Check function and leak-tightness using leak
spray.
Figure 134: Replacing gas filter

TIM-ID: 0000070424 - 003
SS180152/04E 2020-06 | Gas System | 527

9.7.3 Valve leak control – Function check
Preconditions
☑ Genset is ready for starting.
☑ Operating Instructions for MMC4000 controller (MS60024/..) available.

Foam forming agent
DANGER
personnel only.
WARNING
• Do not smoke.
WARNING
Risk of injury!
WARNING
Rotating parts.
Risk of injury!
WARNING
TIM-ID: 0000070423 - 003
528 | Gas System | SS180152/04E 2020-06

Checking valve leak control
1. Unscrew grub screw (1) in measuring adapter
on rear side of the double solenoid valve to
create a leak.
2. Start gas leak test manually via the MMC
controller. See also operating instructions for
MMC4000 controller (MS60024/..).
Result: Fault message at controller: "Gas leak test
faulty", see (→ Page 231).
3. Close grub screw (1) in measuring adapter.
4. Acknowledge fault at controller.
5. Start engine-generator set, check leak-tight-
ness of grub screw at operating pressure with
(Foam forming agent).
Figure 135: Solenoid valve with leak check

TIM-ID: 0000070423 - 003
SS180152/04E 2020-06 | Gas System | 529

9.7.4 Shut-off device – Check
Preconditions
☑ Genset is ready for starting.
DANGER
personnel only.
WARNING
• Do not smoke.
WARNING
Risk of injury!
WARNING
Rotating parts.
Risk of injury!
WARNING

Checking shut-off devices
u Check gas lever (1) for ease of movement.
Result: Contact Service if stiff or stuck.
TIM-ID: 0000070230 - 002
Figure 136: Gas cock
530 | Gas System | SS180152/04E 2020-06

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

Leak identification spray
Soap suds
WARNING
• Do not smoke.
Gas supply, checking gas lines for leaks

1. Coat all connections of the gas supply line with soap solution or spray with leakage detection spray from a
distance of 30 to 50 cm.
• Leaks are indicated by the formation of bubbles or foam.
2. Replace leaking parts.
TIM-ID: 0000029135 - 001
SS180152/04E 2020-06 | Gas System | 531

9.8 Exhaust System
9.8.1 Exhaust gas heat exchanger – Check
Preconditions
☑ Engine-generator set is operated at rated load.

Thermometer (→ Tools Catalog)
WARNING
WARNING
• Do not smoke.
WARNING
WARNING
Risk of injury!
Checking exhaust back pressure

1. Check exhaust back pressure at the following points:
• After exhaust turbocharger
• Before and after catalytic converter (if applicable) (→ Page 537)
• Before and after exhaust gas heat exchanger (→ Page 535)
2. Compare exhaust back pressure values with commissioning record.
3. If pressure values are very high, clean exhaust gas heat exchanger, contact Service.
TIM-ID: 0000070360 - 007
Checking heating water supply temperature

1. Check heating water supply temperature.
2. Compare heating water supply temperature with commissioning record.
3. If temperatures are too low, clean exhaust gas heat exchanger, contact Service.

9.8.2 Exhaust temperature before/after exhaust gas heat exchanger – Check
Preconditions
☑ Engine-generator set is run at rated load.

Dry-bulb thermometer (→ Tools Catalog)
WARNING
WARNING
• Do not smoke.
WARNING
WARNING
Risk of burns!
WARNING
Risk of injury!
TIM-ID: 0000070359 - 003

Checking exhaust temperature
Note: Test port is hot!
1. Insert thermometer into test ports (1, 2) up
to middle of exhaust flow. Average out hot-
test zone by moving thermometer in and out
(approx. 5 min).
Result: Specified value: 100 to 120 °C
2. Remove thermometer from test port (1, 2).
Figure 137: Checking exhaust temperature
TIM-ID: 0000070359 - 003

9.8.3 Exhaust back pressure before/after exhaust gas heat exchanger – Check
Preconditions

Digital pressure gauge (→ Tools Catalog)
WARNING
WARNING
• Do not smoke.
WARNING
WARNING
Risk of burns!
WARNING
Risk of injury!
TIM-ID: 0000070357 - 003

Checking exhaust back pres-
sure
Note: Test port is hot!
1. Connect pressure gauge to test ports (1, 2).
2. Measure differential pressure over exhaust
gas heat exchanger and enter value in check-
list.
3. Document measured values and the develop-
ment in comparison to commissioning.
Result: New condition setpoint value: 120 mmWS
4. Remove pressure gauge.
5. Close measuring points on exhaust gas heat
exchanger.
Figure 138: Checking exhaust back pressure
TIM-ID: 0000070357 - 003

9.8.4 Exhaust back pressure before/after catalytic converter – Check
Preconditions

Digital pressure gauge (→ Tools Catalog)
WARNING
WARNING
• Do not smoke.
WARNING
WARNING
Risk of burns!
WARNING
Risk of injury!
Preparatory steps
Note: Plugs are hot!
1. Open measuring points on catalytic converter.
2. Connect pressure gauge.
TIM-ID: 0000072120 - 003
Checking exhaust back pressure

1. Check differential pressure over catalytic converter and enter value in checklist.
2. Document measured values and the development in comparison to commissioning.
Result: New condition setpoint value: 120 mmWS
Final steps
1. Remove pressure gauge.
2. Close measuring points on catalytic converter.

9.8.5 Emission values – Check
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.
WARNING
WARNING
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.
TIM-ID: 0000088226 - 003

Checking emission values
Note: • Open exhaust gas measuring line and
install and remove measuring instru-
ment only when the engine is at stand-
still.
• Measure emissions at corresponding
measuring points after engine (2) and after
catalytic converter (2).
1. Apply exhaust probe (1) at measuring point.
2. Start engine.
3. Approach measuring point until a stable oper-
ating state has been reached.
4. Carry out measurement and read off meas-
ured value for NOx rel (ppm).
5. Compare measured values with delivery
specifications and country-specific limit value
and adjust exhaust emissions in case of devi-
ations. Figure 139: Checking emission values
TIM-ID: 0000088226 - 003

9.8.6 Condensate and neutralization system – Check
Preconditions
WARNING
Condensation contains acid.
Risk of chemical burns!
• Wear protective goggles.
• Wear protective gloves.
WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.
Checking condensate and neutralization system

1. Check condensate for smell of exhaust gas or exhaust gas discharge.
Result: If an exhaust gas odor or discharge is detected, contact Service.
2. Check neutralization system for correct amount of granulate.
3. Check container for damage and leaks.
Note: The system may be under pressure. Open the drain cock slowly to relieve such pressure.
Draining condensate
1. Place an acid-resistant vessel under the drain cock of the condensate collecting line.
2. Slowly open drain cock and drain condensate completely into acid-resistant vessel.
3. Close drain cock.
Flushing condensate line

u Flush the condensate line with water.
Disposing of condensate
1. Add small quantities of a suitable base to the condensate while stirring continuously.
2. Measure pH-value regularly.
3. As soon as a neutral pH-value is reached, dispose of the condensate in the wastewater system.
TIM-ID: 0000070367 - 002

9.8.7 Exhaust flap – Check
Preconditions
WARNING
Risk of burns!
Preparatory steps
u Remove spark plugs (→ Page 449).
Checking exhaust flap

1. Check exhaust flap setting at mark.
Result: The exhaust flap is closed when the genset is shut down.
2. Measure pressure with a U-tube pressure gage at the measuring point on the exhaust gas heat exchanger.
Result: No significant pressure can be detected
3. Check for the smell of exhaust gas at the open test connection or spark plug bores.
Final steps
u Install spark plugs (→ Page 449).
TIM-ID: 0000070370 - 001

9.8.8 Coolant flow rate – Check
Preconditions
☑ Engine-generator set is running.
WARNING
Risk of burns!
Checking coolant flow rate

Note: The coolant flow rate of the exhaust gas heat exchanger is measured at the safety fitting assembly.
u Read off volume flow rate at the flow monitor.
TIM-ID: 0000070426 - 001

9.9 Cooling System and Heating Water System
9.9.1 Rubber bellows and hoses – Check
Preconditions
☑ Power circuits are disconnected.
☑ Lock-out / tag-out procedure completed.
WARNING
WARNING
Risk of burns!
Checking rubber bellows and

hoses
1. Check rubber bellows (1) between engine-
generator set and heat module.
Result: Cracking or porosity visible. Contact Service.
2. Check engine and mixture coolant hoses.
Result: Leaking sealing surfaces, damaged hoses.
Contact Service.
Figure 140: Rubber bellows on heat module

TIM-ID: 0000070665 - 001

9.9.2 Coolant pump – Engine mount lubrication
Preconditions
☑ Coolant pumps are de-energized.

Grease gun (→ Tools Catalog) 1
Lubricating grease 1
WARNING
WARNING
Risk of burns!
WARNING
Components have sharp edges.
Risk of injury!
Note: Engines up to an including size 160 have maintenance-free, permanently lubricated bearings. Lubricate en-
gines from size 160 onward according to the following specifications:
Lubricating engine mount of
coolant pump
Note: Details of the type and volume of the lubri-
cant to be used are provided on the rating
plate. Excess grease can emerge from the
motor of the lube oil pump.
u Lubricate the engine mount of the coolant
pump with a grease gun via the grease nip-
ples (1, 2).
TIM-ID: 0000070341 - 002
Figure 141: Lubricating engine mount

9.9.3 Coolant pump – Check
Preconditions
☑ Coolant pumps are de-energized.

Coolant pump (→ Spare Parts Catalog)
Pump shaft (→ Spare Parts Catalog)
Impeller (→ Spare Parts Catalog)
Bearing housing (→ Spare Parts Catalog)
Rotary seal (→ Spare Parts Catalog)
WARNING
Heavy part, risk of falling or overturning due to lack of stability.
Risk of crushing body or limbs!
• Use appropriate lifting gear and appliances.
• Wear safety shoes.
WARNING
Components have sharp edges.
Risk of injury!
TIM-ID: 0000070317 - 001

Checking coolant pump
Item Findings Measure
Pump makes loud noises. • Low inlet pressure • Increase liquid level on intake
Pump runs unevenly and vibrates. • Air in intake line or pump side and maintain constant.
• Low back pressure Open shut-off valve in intake
• Pump draws air line.
• Impeller unbalanced • Vent and fill intake line or
• Internal components worn pump.
• Pipelines under tension • Adjust operating point as per
• Bearing faulty data sheet.
• Engine fan faulty • Increase liquid level on intake
• Foreign body in pump side and maintain constant.
• Clean and check impeller.
• Replace damaged parts.
• Install pump without tension.
Secure pipework.
• Replace bearing.
• Replace engine fan.
• Clean pump.
Contact Service.
Leakage at pump or connections. • Pipelines under tension • Install pump without tension.
• Seals on pump housing or con- Secure pipework.
nections faulty. • Replace seals on pump housing
Shaft surface worn or connections.
• Replace shaft.
Contact Service.
Leakage at rotary seal. • Rotary seal dirty or gummed up • Clean and check rotary seal.
• Rotary seal faulty • Replace rotary seal.
Contact Service.
TIM-ID: 0000070317 - 001

9.10 Electrical System
9.10.1 Working in the control cabinet
Working in the control cabinet

Note: Maintenance work may only be carried out by duly qualified personnel.
u For any work in the control cabinet, contact Service.
TIM-ID: 0000087347 - 005

9.10.2 Starter battery – Check
Preconditions
WARNING
The lead-acid battery contains highly corrosive sulfuric acid.
The batter/lead-acid battery may produce flammable gases, particularly when being charged.
Short circuit when jumping battery terminals with metal objects.
Danger of chemical burns, explosion and short circuit!
• Wear personal protective equipment e.g. face mask, safety clothing and protective gloves.
• Avoid sparks resulting from short circuit and other sources of ignition.
• Never place metal objects on the battery.
• If case of contact with electrolyte, wash the skin and eyes immediately with water and seek medical
attention without delay.
• Follow manufacturer's safety instructions.
CAUTION
Incorrect connection of batteries leads to explosion and escape of corrosive gases.
Risk of injury to skin, eyes and respiratory tract due to corrosive effects!
• Connect the batteries, making sure of the correct polarity.
• Do not cover battery outlet valves.
• Use personal protective equipment such as face mask, safety shoes and protective gloves.
• Comply with the safety information of the manufacturer.
Checking starter battery

1. Check battery voltage.
Note: The maximum permitted deviation between battery voltages is 0.5 V.
2. Check the float voltage of the batteries.
Result: Contact Service if cell/block voltages deviate from the mean float charge voltage by more than 0.5 from one
another.
3. Check surface temperature of all cells/blocks.
Result: Contact Service if the surface temperatures of different cells/blocks differ by more than 5 K.
4. Check battery compartment temperature.
Note: Contamination on batteries can promote leakage current.
5. Check the cleanness of the batteries.
6. Check battery terminals for oxidation and coat with terminal grease if necessary.
7. Check that battery terminal covers are present.
Visual inspection
1. Check that unsecured screw connections are tight, tighten as necessary.
2. Check ventilation in the battery cubicle.
3. Check for contamination and moisture.
• If contamination is present, the plastic parts of the battery must be cleaned with water or water-soaked
TIM-ID: 0000069406 - 004
cleaning cloths without additives.

• If moisture is present, dry the battery surface (e.g. with compressed air or water-moist, antistatic cleaning
cloths).

9.10.3 Control cabinet – Filter fan contamination check
Preconditions
☑ No operating voltage applied.
DANGER
Note: If a cooling unit is installed at the control cabinet, see (→ Page 554)
Checking filter fans for contamination

1. Check filter fan for contamination at louver grill and filter mat.
2. If necessary, clean louver grill and replace filter mat (→ Page 550).
TIM-ID: 0000078228 - 001

9.10.4 Control cabinet – Filter mat replacement
Preconditions

Filter mat (→ Spare Parts Catalog)
DANGER
WARNING
NOTICE
Replace filter mat

1. Unlock louver grill at filter fan and fold down.
2. Remove filter mat.
3. If necessary, clean louver grill with a vacuum cleaner or compressed air.
4. Insert new filter mat and close louver grill.
5. Repeat procedure to service any other filter mats.
TIM-ID: 0000078239 - 001

9.10.5 Control cabinet – Filter fan and noise generation check
Preconditions
DANGER
Note: If a cooling unit is installed at the control cabinet, see (→ Page 552).
Checking noise generation of filter fans

u Check filter fan at control cabinet for unusual running noises and noise generation.
Result: If unusual noises or changed noises as compared to normal operation are determined, contact Service.
TIM-ID: 0000078227 - 001

9.10.6 Control cabinet – Cooling unit noise generation check
Preconditions
DANGER
Checking noise generation of compressor and fans

u Check fans and compressor for unusual running noises.
Result: If unusual noises or changed noises as compared to normal operation are determined, contact Service.
TIM-ID: 0000078235 - 001

9.10.7 Control cabinet – Cooling unit cooling function check
Preconditions
DANGER
Check cooling function of cooling unit

1. Switch on power supply.
2. Activate test mode of cooling unit.
Result: Cooling unit starts operation and green LED at controller flashes.
TIM-ID: 0000078231 - 001

9.10.8 Control cabinet – Checking cooling louvers on cooling unit
Preconditions
DANGER
Check cooling louvers for contamination

1. Check cooling louvers for contamination.
2. Clean cooling louvers if necessary (→ Page 555)
TIM-ID: 0000078230 - 001

9.10.9 Control cabinet – Cleaning cooling louvers on cooling unit
Preconditions

Filter mat (→ Spare Parts Catalog) 1
DANGER
Cleaning cooling louvers

1. Remove upper louver grill.
2. Remove filter mat and check for contamination, replace as necessary.
3. Clean louvers with a vacuum cleaner or compressed air.
4. Remove stubborn, oily dirt with a non-flammable cleaner.
5. Insert filter mat.
6. Install upper louver grill.
TIM-ID: 0000078236 - 001

10 Appendix A
10.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ANSI American National Association of American standardization organizations
Standards Institute
AUX Auxilary-drives panel
BHKW Blockheizkraftwerk Cogeneration plant
CAN bus Controller Area Net- Serial field bus system
workbus
CSA Canadian Standards Certification for Canada
Association
DIN Deutsches Institut für German national standards institute, at the same time identifier of Ger-
Normung e.V. man standards (DIN = “Deutsche Industrie-Norm”)
DP Dezentrale Peripherie Communication record
ECU Engine Control Unit -
EEG Erneuerbare Energien Renewable Energy Sources Act
Gesetz
EMM Energiemessmodul Energy Measurement Module
EMU Engine Monitoring -
Unit
GCB Generator circuit -
breaker panel
GCB Generator circuit -
breaker
HTB Heat–recovery–mod- -
ule terminal – box
IEC International Electro- International standardization organization for all electrical, electronic
technical Committee and associated technologies
IPC Industrie PC Industrial PC
MCS MTU Control System -
MIP MTU Interface Panel -
MMC MTU Genset control MTU module / engine-generator set control cabinet
enclosure
NFPA National Fire Protec- US American fire-prevention association
tion Association
TIM-ID: 0000061969 - 008
SMS Short Messages Serv- -

ice
SPS Speicherprogram- Programmable Logic Controller (PLC)
mierbare Steuerung
TCP Transmission Control -
Protocol
556 | Appendix A | SS180152/04E 2020-06

Abbrevia- Meaning Explanation
tion
UDP User Datagram Proto- -
col
UL Underwriters Labora- Certification for USA
tories
TIM-ID: 0000061969 - 008
SS180152/04E 2020-06 | Appendix A | 557

10.2 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
Nm 1.852 = km
ft 3 = yd
in 36 = yd
Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Surface
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.59 = km2
Unit B multiplied by factor Unit A

mm 2 0.00155 = in2
m2 10.764 = ft2
m2 1.1960 = yd2
km2 0.3861 = stat. mile2
Volume
in 3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.785 = dm3
TIM-ID: 0000002173 - 019
gallon (brit.) 4.546 = dm3

cm 3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (U.S.)
dm3 0.22 = gallon (brit.)
558 | Appendix A | SS180152/04E 2020-06

Volumetric flow
gal/min (GPM, U.S.) 3.79 = l/min
gal/min (GPM, U.S.) 0.134 = ft3/min (cfm)
ft3/min (cfm) 1.70 = m3/h

l/min 0.264 = gal/min (U.S.)
3
ft /min (cfm) 7.48 = gal/min (U.S.)
m3/h 0.589 = ft3/min (cfm)
Velocity
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (brit.) 1.852 = km/h

m/s 3.281 = ft/s
km/h 0.6214 = stat. mile/h (mph)
km/h 0.54 = knot (brit.)
Mass
lb 0.4536 = kg
oz 28.35 =g
ton (imp.) 1.016 =t

g 0.03527 = oz
kg 2.205 = lb
t 0.9842 = ton (imp.)
Force
lbf 0.4536 = kp
lbf 4.4482 =N
TIM-ID: 0000002173 - 019
kp 9.80665 =N

kp 2.205 = lbf
N 0.10197 = kp
N 0.2248 = lbf
SS180152/04E 2020-06 | Appendix A | 559

Density
slug/ft 3 515.4 = kg/m3

kg/m 3 0.00194 = slug/ft3
Torque
lbf ft 1.3558 = Nm

Nm 0.7376 = lbf ft
Pressure
2
lbf/in (psi) 703.1 = kp/m2 (mmH2O)
lbf/in2 (psi) 0.06895 = bar
2
lbf/ft (psf) 47.88 = Pa
inHg 0.03386 = bar
inHg 345.3 = kp/m2 (mmH2O)

atm 760 = mmHg
atm 1.0133 = bar
atm 10332 = kp/m2 (mmH2O)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lbf/in2 (psi)
bar 14.504 = lbf/in2 (psi)
Pa 0.0209 = lbf/ft2 (psf)
2nd moment of mass

slug ft 2 1.3558 = kg m2

kg m 2 0.7376 = slug ft2
TIM-ID: 0000002173 - 019
Energy
lbf ft 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
560 | Appendix A | SS180152/04E 2020-06

J 0.7376 = lbf ft
J 0.0002388 = kcal
J 0.0009478 = BTU
J 0.00052656 = CHU
Power
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.054 = kW
kcal/h 1.163 =W
HP 550 = lbf ft/s

kW 1.36 = PS
kW 1.341 = HP
kW 0.9487 = BTU/s
W 0.8598 = kcal/h
lbf ft/s 0.0018 = HP
Temperature
Celsius Kelvin
x °C - = x + 273.15 K
xK = x − 273.15 °C -
x °F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 K
x °R = 5/4x °C = (5/4x) + 273.15 K
Fahrenheit Réaumur
x °C = 9/5x + 32 °F = (4/5x) °R
xK = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R
x °F - = 4/9 (x − 32) °R
x °R = (9/4x) + 32 °F -
Fuel consumption
mile/gal (US) 0.4251 = km/l
TIM-ID: 0000002173 - 019
gal/mile (US) 2.3527 = l/km

km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
SS180152/04E 2020-06 | Appendix A | 561

10.3 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and connections as per MTN 5008 standard
This standard applies to setscrews not subject to dynamic loads and the associated nuts according to:
• MMN 384
• ISO 4762 (DIN 912)
• ISO 4014 (DIN 931-1)
• ISO 4017 (DIN 933)
• DIN EN ISO 8765 (EN 28765; DIN 960)
• DIN EN ISO 8676 (EN 28676; DIN 961)
• DIN 6912
This standard applies to studs not subject to dynamic loads and the associated nuts according to:
• DIN 833
• DIN 835
• DIN EN ISO 5395 (DIN 836)
• DIN 938
• DIN 939
This standard applies to screws with hexalobular heads according to:
• DIN 34800
• DIN 34801
The standard does not apply to heat-resistant screws in the hot component zone.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bare, phosphatized or
galvanized) and 10.9 (surface condition bare or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
When hand-tightening (defined torque), an assembly tolerance of -5+15% of the figures in the table is permit-
ted.
When machine-tightening, the permissible assembly tolerance is ±15%.
Tightening torques for setscrews

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
TIM-ID: 0000002333 - 018
M12 x 1.25 80 110 75 105

M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
562 | Appendix A | SS180152/04E 2020-06

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M20 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = tightening torques
Tightening torques for studs

screwed into
Thread Steel M A Gray cast iron MA AI alloy MA
(Nm) (Nm) (Nm)
M6 9 6 6
M8 11 9 10
M10 17 13 13
M12 27 23 18
M14 37 33 33
M16 55 45 –
Tightening torques for setscrews and nuts made of stainless steel

The values in the table are based on a friction coefficient µtot = 0.12, lubricated with Molykote on the thread
and under the screw head.
Strength class
70 80
Basic size Material
MA MA
(Nm) (Nm)
M5 3.7 4.9 A2 / A4
M6 6.4 8.5 A2 / A4
M8 15.3 20.4 A2 / A4
TIM-ID: 0000002333 - 018
M10 31 41 A2 / A4
M12 52 70 A2 / A4
M16 126 167 A2 / A4
M20 254 326 A2 / A4
SS180152/04E 2020-06 | Appendix A | 563

Tightening torque for self-locking hex nuts
Thread MA (Nm) Lubricants
M6 7.5 +1 –
M8 17 +2 –
M10 35 +4 –
M12 59 +6 –
M14 100 +10 –
M16 140 +14 –
M20 290 +29 –
Tightening torque for stress bolt connections as per MTN 5007 standard
This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of
strength class 10.9 as well as to the associated nuts.
Shaft and transition dimensions as per MMN 209 standard and material and machining as per MMN 389
standard (bright surface or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
The values in the tables are for manual tightening using a torque wrench.
Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)

M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
TIM-ID: 0000002333 - 018
M20 350 450

M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
564 | Appendix A | SS180152/04E 2020-06

Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)
M30 1250 1575
*Protect screw shaft from torsion when tightening.
MA= tightening torques.
Tightening torques for plug screws as per MTN 5183-1 standard

This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852
Form A (sealed with sealing ring to DIN 7603-Cu).
Figure 142: Plug screw

TIM-ID: 0000002333 - 018
SS180152/04E 2020-06 | Appendix A | 565

Tightening torques MA are given for screw plugs made of steel (St) with surface protected by a phosphate
coating and oiled or galvanized.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
Tightening torques for plug screws to DIN 908, DIN 910 and DIN 7604A (with short threaded end).
screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 25 25
M14 x 1.5 35 30
M16 x 1.5 40 35
M18 x 1.5 50 40
M20 x 1.5 60 50
M22 x 1.5 70 70
M24 x 1.5 85 80
M26 x 1.5 100 100
M27 x 2 100 100
M30 x 1.5 110 110
M30 x 2 120 120
TIM-ID: 0000002333 - 018
M33 x 2 160 160

M36 x 1.5 190 180
M38 x 1.5 220 200
M42 x 1.5 260 240
M45 x 1.5 290 270
M48 x 1.5 310 300
M52 x 1.5 325 320
M56 x 2 380 360
566 | Appendix A | SS180152/04E 2020-06

screwed into
(Nm) (Nm)
M64 x 2 400 400
Tightening torque for plug screws DIN 7604C (with long screwed end)
screwed into
Thread Steel/gray cast iron M A AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
Tightening torque for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws to MMN 223 and N 15011 sealed with sealing ring to DIN 7603-Cu.
Figure 145: Banjo screw

TIM-ID: 0000002333 - 018
SS180152/04E 2020-06 | Appendix A | 567

Figure 146: Banjo screw
The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled or
galvanized and for copper-aluminum alloy.
Tightening torques for steel banjo screws

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
TIM-ID: 0000002333 - 018
Tightening torques for copper-aluminum alloy banjo screws

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M10 x 1 15
M16 x 1.5 30
568 | Appendix A | SS180152/04E 2020-06

Tightening torques for male connectors as per MTN 5183-3 standard
This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by
sealing ring to DIN 7603-Cu).
Figure 147: Male union
Tightening torques MA are given for male unions made of steel (St) with phosphatized surface coating and
oiled, or galvanized.
inserted in steel/gray cast iron MA
Thread
(Nm)
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 35
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
TIM-ID: 0000002333 - 018
SS180152/04E 2020-06 | Appendix A | 569

Tightening torques for union nuts as per DIN 3859-2
1 Union nut
2 Screw fixture
3 O-ring
4 Linear ball bearing
Figure 148: Threaded end
Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase
in force), it should be tightened another 1/4 turn (90°) past this point.
Tightening torques for spigot unions with O-ring to ISO 6149-2
Figure 149: MTN5185_5187

TIM-ID: 0000002333 - 018
Thread Torque (Nm) +10%

M8 x 1 10
M10 x 1 20
M12 x 1.5 35
M14 x 1.5 45
M16 x 1.5 55
M18 x 1.5 70
M20 x 1.5 1) 80
570 | Appendix A | SS180152/04E 2020-06

M22 x 1.5 100
M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)
Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789)
Tightening torques for screwed plugs with O-ring as per ISO 6149-3
Figure 150: MTN5186_5211

M8 x 1 8
M10 x 1 15
M12 x 1.5 25
M14 x 1.5 35
M16 x 1.5 40
M18 x 1.5 45
M22 x 1.5 60
M27 x 2 100
M33 x 2 160
TIM-ID: 0000002333 - 018
M42 x 2 210
M48 x 2 260
M60 x 2 315
SS180152/04E 2020-06 | Appendix A | 571

Tightening torques for plug screw joints as per MTN 5183-6
Figure 151: MTN5210
screwed into
(Nm) (Nm)
M10 x 1 20 10 +2
M12 x 1.5 35 14 +2
M14 x 1.5 45 15 +3
M16 x 1.5 55 18 +3
M18 x 1.5 70 23 +3
M22 x 1.5 100 33 +4
M27 x 2 170 57 +5
M33 x 2 310 103 +10
M42 x 2 330 110 +11
M48 x 2 420 140 +14
M60 x 2 – 200 +20
Assembly instructions and tightening torque for hose fittings with union nuts
These instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose fittings
with sealing heads and the matching adapters must be fitted and connected as follows.
TIM-ID: 0000002333 - 018
Hose fitting, metallic sealing with union nut: tighten union nut by hand then tighten a further max. 1/4 of a
turn with a wrench.
Hose fitting with O-ring and union nut: tighten union nut by hand then tighten a further max. 1/2 of a turn
with a wrench.
Hoses must be properly aligned before tightening the union nuts.
572 | Appendix A | SS180152/04E 2020-06

Sealing head/sealing cone with metric union nut
Metric thread Pipe outer dia. Torque (Nm)
M12 x 1.5 6 20
M14 x 1.5 8 38
M16 x 1.5 8 45
10
M18 x 1.5 10 51
12
M20 x 1.5 12 58
M22 x 1.5 14 74
15
M24 x 1.5 16 74
M26 x 1.5 18 105
M30 x 2 20 135
22
M36 x 2 25 166
28
M42 x 2 30 240
M45 x 2 35 290
M52 x 2 38 330
42
Sealing head with BSP union nut

BSPP thread Torque (Nm)
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
G1.1/4 210
G1.1/2 290
G2 400
SAE sealing cone with union nut JIC 37°

UNF thread Size Torque (Nm)
7/16–20 –4 15
1/2–20 –5 20
TIM-ID: 0000002333 - 018
9/16–18 –6 30
3/4–16 –8 50
7/8–14 –10 69
1.1/16–12 –12 98
1.3/16–12 –14 118
1.5/16–12 –16 140
1.5/8–12 –20 210
SS180152/04E 2020-06 | Appendix A | 573

SAE sealing cone with union nut JIC 37°
1.7/8–12 –24 290
2.1/2–12 –32 450
ORFS – flat sealing with union nut

9/16–18 –4 14 +2
11/16–16 –6 24 +3
13/16–16 –8 43 +4
1–14 –10 60 +8
1.3/16–12 –12 90 +5
1.3/16–12 –14 90 +5
1.7/16–12 –16 125 +10
1.11/16–12 –20 170 +20
2–12 –24 200 +25
2–1/2–20 –32 460 +30
TIM-ID: 0000002333 - 018
574 | Appendix A | SS180152/04E 2020-06

10.4 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 locally available support, go to the Internet site: http://www.mtu-solutions.com
24 h Hotline
With our 24 h hotline and high flexibility, we are your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: service.de@ps.rolls-royce.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 parts logistics system.
Your contact at Headquarters:
Germany:
• Tel: +49 821 74800
• Fax: +49 821 74802289
• E-mail: spareparts-oeg@ps.rolls-royce.com
Worldwide:
• Tel: +49 7541 9077777
• Fax: +49 7541 9077778
• E-mail: spareparts-oeg@ps.rolls-royce.com
TIM-ID: 0000002624 - 009
SS180152/04E 2020-06 | Appendix A | 575

11 Appendix B
11.1 Special Tools
Angular screw driver
Part No.: F30452765
Qty.: 1
Used in: 9.3.15 Valve clearance – Check and adjustment
(→ Page 462)
Barring gear
Part No.: F6555766
Qty.: 1
Used in: 9.3.2 Engine – Barring manually (→ Page 444)
Digital pressure gauge

Part No.:
Qty.:
Used in: 9.8.3 Exhaust back pressure before/after exhaust gas
heat exchanger – Check (→ Page 535)
Qty.:
Used in: 9.8.4 Exhaust back pressure before/after catalytic con-
verter – Check (→ Page 537)
Dry-bulb thermometer
Part No.:
DCL-ID: 0000048557 - 009
Qty.:
Used in: 9.8.2 Exhaust temperature before/after exhaust gas heat
exchanger – Check (→ Page 533)
576 | Appendix B | SS180152/04E 2020-06

Feeler gauge
Part No.: Y20098771
Qty.: 1
(→ Page 462)

Part No.:
Qty.:
Used in: 6.5 Operating room – Check for smell of gas (→ Page 129)
Qty.:
Used in: 9.8.5 Emission values – Check (→ Page 538)
Grease gun
Part No.:
Qty.: 1
Used in: 9.9.2 Coolant pump – Engine mount lubrication
(→ Page 544)
Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 9.3.22 Engine oil filter – Replacement (→ Page 474)
Open-end wrench, 13 A/F

Part No.:
Qty.:
DCL-ID: 0000048557 - 009
Used in: 9.4.2 Ring gear of transmission oil pump – Replacement

(→ Page 492)

Part No.:
Qty.:
Used in: 9.4.6 Oil filter – Removal and installation (→ Page 500)
SS180152/04E 2020-06 | Special Tools | 577

Part No.:
Qty.:
(→ Page 492)
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 3.4 Crankshaft transport locking device (→ Page 42)
Ratchet bit
Part No.: F30027340
Qty.: 1
Used in: 9.3.18 Starter – Replacement (→ Page 467)
Qty.: 1
Used in: 9.3.35 NOx sensor – Replacement (→ Page 489)
Ratchet head with extension

Part No.: F30006212
Qty.: 1
Used in: 9.3.2 Engine – Barring manually (→ Page 444) DCL-ID: 0000048557 - 009
578 | Special Tools | SS180152/04E 2020-06

Screwdriver bit
Part No.: F30378921
Qty.: 1
Sliding depth gage, 200 mm

Part No.: Y20000918
Qty.: 1
Used in: 9.3.13 Valve protrusion – Measurement (→ Page 458)
Socket screwdriver, 14 mm
Part No.: F30378499
Qty.: 1
Socket wrench, 24 mm
Part No.: F30029815
Qty.: 1
(→ Page 462)
DCL-ID: 0000048557 - 009

Socket, 13 A/F
Part No.:
Qty.:
(→ Page 492)
Special wrench, 20.8 mm

Part No.: F30452574
Qty.: 1
Used in: 9.3.6 Spark plug – Removal (→ Page 449)
Qty.: 1
Used in: 9.3.7 Spark plug – Installation (→ Page 450)
Stroboscope (not stocked in warehouse)

Part No.:
Qty.:
Used in: 9.3.12 Ignition system – Ignition timing check
(→ Page 457)
Thermometer
Part No.:
Qty.:
Used in: 9.8.1 Exhaust gas heat exchanger – Check (→ Page 532)
Torque wrench
Part No.:
Qty.:
(→ Page 492)
Torque wrench, 0.5–5 Nm

Part No.: 0015384230
Qty.: 1
DCL-ID: 0000048557 - 009
580 | Special Tools | SS180152/04E 2020-06

Torque wrench, 10–60 Nm
Part No.: F30452769
Qty.: 1
Qty.: 1
Used in: 9.3.7 Spark plug – Installation (→ Page 450)
Qty.: 1
Used in: 9.3.11 Spark plug connector – Installation (→ Page 455)
Qty.: 1

Part No.: F30026582
Qty.: 1

Part No.: F30452768
Qty.: 1
Qty.: 1
(→ Page 462)

Part No.: F30027336
Qty.: 1
Used in: 9.6.3 Air filter – Removal and installation (→ Page 523)
DCL-ID: 0000048557 - 009

11.2 Consumables
Assembly compound (Molykote P 37)
Part No.: 50564
Qty.: 1
Coolant
Part No.:
Qty.:
Used in: 9.3.24 Engine coolant – Change (→ Page 477)
Engine coolant
Part No.:
Qty.:
Used in: 9.3.26 Engine coolant – Filling (→ Page 480)
Engine oil
Part No.:
Qty.:
Qty.:
Used in: 9.3.14 Valve gear – Lubrication (→ Page 461)
Qty.:
Used in: 9.3.15 Valve clearance – Check and adjustment (→ Page 462)
Qty.:
Used in: 9.3.20 Engine oil – Change (→ Page 471)
Qty.:
Used in: 9.3.22 Engine oil filter – Replacement (→ Page 474)
Foam forming agent

Part No.:
Qty.:
Used in: 9.7.3 Valve leak control – Function check (→ Page 528)
Gear oil
Part No.:
DCL-ID: 0000048557 - 009
Qty.:
Used in: 9.4.2 Ring gear of transmission oil pump – Replacement (→ Page 492)
Qty.:
Used in: 9.4.4 Gear oil – Change (→ Page 497)
Qty.:
Used in: 9.4.5 Gearbox – Cleaning (→ Page 499)
582 | Consumables | SS180152/04E 2020-06

Leak detection spray
Part No.:
Qty.:
Used in: 9.7.2 Gas filter – Replacement (→ Page 526)
Leak identification spray

Part No.:
Qty.:
Used in: 9.7.5 Gas supply - Checking gas lines for leaks (→ Page 531)
Lubricating grease
Part No.:
Qty.: 1
Used in: 9.9.2 Coolant pump – Engine mount lubrication (→ Page 544)
Lubricating grease (Molykote Longtherm 2 Plus NLGI 2)

Part No.: X00057299
Qty.: 1
Mixture coolant
Part No.:
Qty.:
Used in: 9.3.29 Mixture coolant – Change (→ Page 483)
Qty.:
Used in: 9.3.31 Mixture coolant – Filling (→ Page 485)
Soap suds
Part No.:
Qty.:
Used in: 9.7.2 Gas filter – Replacement (→ Page 526)
Qty.:
Used in: 9.7.5 Gas supply - Checking gas lines for leaks (→ Page 531)
Solvent (isopropyl alcohol)

Part No.: X00058037
Qty.: 1
Used in: 9.3.34 Engine cabling – Check (→ Page 488)
DCL-ID: 0000048557 - 009
Surface sealant Loctite

Part No.: 50569
Qty.:
Used in: 9.4.2 Ring gear of transmission oil pump – Replacement (→ Page 492)
SS180152/04E 2020-06 | Consumables | 583

11.3 Index
A Control system
Abbreviations 556 – MIP 92
Air filter 95 Controller
– Installation 523 – MMC 92
– Removal 523 Conversion tables 558
– Replacement 522 Coolant
– Generator (Cummins) 506 – Change 477
Alarms Coolant flow rate
– Fire alarm 127 – Check 542
– Gas alarm 126 Coolant pump
Antifriction bearings – Engine mount
– Lubrication – Lubrication 544
– Generator (Leroy-Somer) 517 Coolant vent line (engine coolant circuit)
Antifriction bearings (Cummins) – Replacement 481
– Lubrication 507 Cooling circuit
– Replacement 509 – Pump
Application group 50 – Check 545
Cooling system
B – Engine 83
Balancing energy 65 – Engine-generator set 104
Base frame 113 Coupling
Battery charger 120 – Functional description 91
Bearing temperature Coupling element
– Check – Check
– Generator (Cummins) 504 – Generator (Cummins) 512
– Generator (Leroy-Somer) 514 – Generator (Leroy-Somer) 519
Crankcase breather
C – Adjustment
Cabling – Pressure control 447
– Check – Check
– On engine 488 – Pressure control 447
Catalytic converter 99 Cylinder
– Exhaust back pressure check 537 – Designation 73
Condensate Cylinder head cover
– Check 540 – Installation 466
Conduct – Removal 465
– Fire alarm 127
E
– Gas alarm 126
Connections Emergency
– Heat module 108 – Conduct 128
Contact person 575 Emergency shutdown 158
Continuous operation, unrestricted 65 Emission values
Control 134 – Check 538
Engine
DCL-ID: 0000048557 - 009
Control cabinet
– Cooling unit – Barring manually 444
– Cleaning cooling louvers 555 – Mounting check 486
– Cooling function check 553 – Nameplate 51
– Cooling louvers check 554 Engine cabling
– Noise generation check 552 – Check 488
– Filter fan Engine coolant
– Cleaning 550 – Change 477
– Contamination check 549 – Draining 478
– Noise generation check 551 – Filling 480
– Filter mat 550 – Pump
– Qualification 547 – Check 545
584 | Index | SS180152/04E 2020-06

Engine coolant level F
– Check 476 Fault messages
Engine driving end – Engine Control Unit 393
– Definition 73 – Genset control system log 166
Engine free end – Key 165
– Definition 73 – MMC controller 231
Engine mount Fire alarm
– Coolant pump – Conduct 127
– Lubrication 544 Fire detectors 122
Engine mounting Functional description 48
– Check 486
– Checking securing screws for secure seating 487 G
Engine oil Gas alarm
– Change 471 – Conduct 126
– Sample analysis 472 Gas alarm system 121
– Sampling 472 Gas engine phase 4 system
Engine oil filter – Overview 115
– Replacement 474 Gas filter
Engine oil level – Differential pressure check 524
– Check 470 – Replacement 526
Engine sides Gas supply
– Designation 73 – Checking gas lines for leaks 531
Engine – Overview 66 Gas train 93
Engine-generator set Gear oil
– Application group 50 – Change 497
– Designation 51 – Sample extraction 495
– General description 49 Gear oil pump
– Nameplate 51 – Ring gear replacement 492
– Options 64 Gearbox
– Protective devices 30 – Bearing temperature
– Safety signs 28 – Check 503
– Standard scope of supply 54 – Check 491
Exhaust back pressure – Cleaning 499
– After catalytic converter check 537 – Gear oil
– After exhaust gas heat exchanger check 535 – Change 497
– Before catalytic converter check 537 – Gear oil pump
– Before exhaust gas heat exchanger check 535 – Ring gear replacement 492
Exhaust flap – Housing temperature
– Check 541 – Check 503
Exhaust gas heat exchanger 97 – Take oil sample 495
– Check 532 General description
– Coolant flow rate, check 542 – Engine-generator set 49
– Exhaust back pressure check 535 Generator
– Exhaust temperature check 533 – Functional description 90
Exhaust gas system – Nameplate 51
– Catalytic converter 99
Exhaust silencer 100
DCL-ID: 0000048557 - 009
Exhaust system 78
– Exhaust flap check 541
– Exhaust gas heat exchanger 97
Exhaust temperature
– After exhaust gas heat exchanger check 533
– Before exhaust gas heat exchanger check 533
SS180152/04E 2020-06 | Index | 585

Generator (Cummins) M
– Air filter Maintenance Schedule
– Replacement 506 – Maintenance task reference table [QL1] 435
– Antifriction bearing replacement 509 Malfunctions
– Antifriction bearings, lubrication 507 – Conduct 128
– Bearing temperature MIP 92
– Check 504 Mixture coolant
– Coupling element – Change 483
– Check 512 – Draining 484
– Intake grill – Filling 485
– Cleaning 505 Mixture coolant level
– Oil separator – Check 482
– Cleaning 510 Mixture formation 78
– Winding temperature MMC 92
– Check 504 Mounting 113
Generator (Leroy-Somer)
– Antifriction bearings N
– Lubrication 517 Nameplate 51
– Bearing temperature Neutralization system
– Check 514 – Check 540
– Check NOx sensor
– Winding temperature 514 – Replacement 489
– Coupling element
– Check 519 O
– Intake grill Oil filter
– Cleaning 515 – Change 500
Genset – Cleaning 502
– Technical data 124 Oil priming pump 103
Oil separator
H
– Cleaning
Heat module – Generator (Cummins) 510
– Connections 108 – Filter replacement 445
– Emergency coolant circuit 108 Operating data check
– Engine coolant circuit (HT) 108 – After 3000 hours 440
– Engine coolant circuit (MT) 108 Operating modes 65
– Function 108 Operating room – Check for smell of gas 129
– Mixture coolant circuit (LT) 108 Operation 125
– Overview 108 Operational monitoring
– Rubber bellows and hoses – Daily check 155
– Check 543 – Weekly check 155
Hoses Overview
– Heat module – Sensors 74
– Check 543 Oxidation catalyst 99
Hotline 575
P
I
Prefilter
Ignition system – Replacement 521
DCL-ID: 0000048557 - 009
– Ignition timing check 457 Preparation for startup

Intake grill – After extended out-of-service periods 161
– Cleaning Pressure control
– Generator (Cummins) 505 – Adjustment
– Generator (Leroy-Somer) 515 – Crankcase breather 447
– Check
L
– Crankcase breather 447
Lifting specifications 32 Protective devices
Lockout/tagout 130 – Engine-generator set 30
Lockout/tagout procedure 130
Lube oil system 81
– Engine-generator set 101
586 | Index | SS180152/04E 2020-06

Pump S
– Cooling circuit Safety regulations
– Check 545 – Assembly work 16
– Engine coolant – Assembly work, specific information for dual fuel sup-
– Check 545 ply applications 20
Purpose of the units 117 – Auxiliary materials 21
Putting into operation 161 – Auxiliary materials, specific information for dual fuel
Putting out of operation 159 applications 24
– Auxiliary materials, specific information for gaseous
Q
fuel supply applications 24
Qualification – Commissioning, specific information for dual fuel ap-
– Special tasks 443 plications 14
– Commissioning, specific information for gaseous fuel
R
supply 14
Replacement 550 – Environmental protection 21
Rubber bellows – Environmental protection, specific information for dual
– Heat module fuel applications 24
– Check 543 – Environmental protection, specific information for gas-
Runtimes eous fuel supply applications 24
– At partial load 137 – Fire prevention, specific information for dual fuel ap-
plications 24
– Fire prevention, specific information for gaseous fuel
supply applications 24
– Fire protection 21
– Fluids and lubricants, specific information for dual fuel
applications 24
– Fluids and lubricants, specific information for gaseous
– Important provisions 7
– Indirect materials 21
– Initial start-up 12
– Intended use 9
– Maintenance work 16
– Maintenance work, specific information for dual fuel
– Maintenance work, specific information for gaseous
– Operation 12
– Operation, specific information for dual fuel applica-
tions 14
– Operation, specific information for gaseous fuel supply
14
– Organizational requirements 11
– Personnel requirements 11
– Repair work 16
– Safety signs on the engine-generator set 26
– Servicing work, specific information for dual fuel sup-
DCL-ID: 0000048557 - 009
ply applications 20
– Servicing work, specific information for gaseous fuel
Safety requirements
– Warning notices, standards 25
Safety signs
– Engine-generator set 28
Sensors
– Overview 74
– Replacement
– NOx 489
SS180152/04E 2020-06 | Index | 587

Service partner 575 V
Shutdown Valve clearance
– In Manual mode 157 – Adjustment 462
– Remote control 138 – Check 462
Shutdown criteria Valve gear
– Check 442 – Lubrication 461
Shut-off device Valve leak control
– Check 530 – Function check 528
Spare parts service 575 Valve protrusion
Spark plug – Measurement 458
– Installation 450
– Removal 449 W
– Replacement 448 Warning notices, conventions
Spark plug connector – On the engine-generator set 26
– Check 454 Warning notices, standards 25
– Cleaning 454 Winding temperature
– Installation 455 – Check
– Removal 453 – Generator (Cummins) 504
– Replacement 452 – Generator (Leroy-Somer) 514
Start
– Remote control 138
Starter
– Replacement 467
Starter battery 119
– Check 548
Starting
– In Manual mode 139
Starting sequence 134
Status signals 141
Stopping sequence 134
Supercharging 78
T
Task description 438
Technical data 124
Test run 439
Tie-down instructions 32, 44
Tightening specifications
– Nuts 562
– Screws and bolts 562
– Screws, nuts and bolts 562
Transport 44
– Lifting instructions 32
– Tie-down instructions 32
– Transport locking device 32
Transport locking device 32
– Crankshaft
DCL-ID: 0000048557 - 009
– Installation 42
– Removal 42
– Engine mount
– Installation 39
– Removal 39
– Generator mounting
– Installation 40
– Removal 40
Troubleshooting 164
U
Unlocking procedure 132
588 | Index | SS180152/04E 2020-06

L64FN & FNER Operation and Maintenance Manual - SS180152 - 04 - E

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

L64FN & FNER Operation and Maintenance Manual - SS180152 - 04 - E

Uploaded by

Copyright:

Available Formats

Operating Instructions

Gas engine-generator sets

© 2020 Copyright MTU

SS180152/04E 2020-06 | Table of Contents | 3

9 Task Description 9.5 Generator 504

4 | Table of Contents | SS180152/04E 2020-06

SS180152/04E 2020-06 | Table of Contents | 5

TIM-ID: 0000058778 - 004

6 | Preface | SS180152/04E 2020-06

Emissions regulations and emissions label

Emissions certification applicable to engines with EPA Nonroad Tier 4 emissions

Extract from the standard:

SS180152/04E 2020-06 | Safety | 7

TIM-ID: 0000040530 - 016

8 | Safety | SS180152/04E 2020-06

Table 1: Area of application of machine

SS180152/04E 2020-06 | Safety | 9

Prerequisite for proper use

TIM-ID: 0000065674 - 005

10 | Safety | SS180152/04E 2020-06

Clothing and personal protective equipment

SS180152/04E 2020-06 | Safety | 11

Safety regulations during operation

Malfunctions and emergency stop

12 | Safety | SS180152/04E 2020-06

Operation of electrical equipment

SS180152/04E 2020-06 | Safety | 13

Gas engine (Loose engine)

• at a gas volume flow higher than 200 m³/h

14 | Safety | SS180152/04E 2020-06

Dual fuel application/bi-fuel operation

SS180152/04E 2020-06 | Safety | 15

Safety regulations when performing assembly, maintenance, and repair work

Setting down, lifting and climbing

16 | Safety | SS180152/04E 2020-06

Removing, installing and cleanliness

Safety regulations after performing assembly, maintenance, and repair work

SS180152/04E 2020-06 | Safety | 17

Hydraulic installation and removal

Working with batteries

Working on electrical and electronic assemblies

18 | Safety | SS180152/04E 2020-06

Working with laser equipment

Measuring component dimensions

SS180152/04E 2020-06 | Safety | 19

Additional safety regulations for marine application engines, engines with

TIM-ID: 0000040549 - 010

20 | Safety | SS180152/04E 2020-06

Environmental protection and disposal

SS180152/04E 2020-06 | Safety | 21

Registration, evaluation, authorization and restriction of chemicals (REACH

22 | Safety | SS180152/04E 2020-06

SS180152/04E 2020-06 | Safety | 23

Biogenic gases from fermentation processes

Conduct in case of escaping gases

TIM-ID: 0000040537 - 007

24 | Safety | SS180152/04E 2020-06

SS180152/04E 2020-06 | Safety | 25

Figure 1: Safety sign layout

Consequences: Fatal, serious or permanent injuries!

26 | Safety | SS180152/04E 2020-06

SS180152/04E 2020-06 | Safety | 27