MTU MS15027/02E, 20 V 4000 Lx4 Operating Instuctions

Operating Instructions

Gas engine

12 V 4000 Lx4
16 V 4000 Lx4

MS15027/02E

Engine model kW/cyl.

Application group

12V4000L64 130 kW/cyl. 3A, continuous operation, unrestricted

16V4000L64 130 kW/cyl. 3A, continuous operation, unrestricted

Table 1: Validity overview

© 2015 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla­tion, microfilming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents

1 Safety

1.1 Important provisions for all products 5

1.2 Personnel and organizational requirements 7

1.3 Safety regulations for startup and operation 8

1.4 Safety requirements for startup and
operation, special instructions for
applications with gaseous fuel 9

1.5 Safety regulations for maintenance and
repair work 10

1.6 Safety requirements for maintenance and
repair work, special instructions for
applications with gaseous fuel 13

1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 14

1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel

16

1.9 Standards for safety notices in the text 17

1.10 Transport 18

2 Product Summary

2.1 Engine overview 19

2.2 Engine side and cylinder designations 21

2.3 Main engine dimensions 22

2.4 Firing order 23

2.5 Technical Data 24

2.5.1 12 V 4000 L64, 16 V 4000 L64 engine data,
fuel optimized ("TA-Luft") 24

2.5.2 12V 4000 L64, 16V 4000 L64 engine data,
emissions-optimized (1/2 "TA-Luft") 28

2.6 Monitoring, Control and Regulation
Equipment 32

2.6.1 Gas engine system – Overview 32

2.6.2 Purpose of the units 34

3 Operation

3.1 Runtimes at partial load 36

3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 37

3.3 Putting the engine into operation after
scheduled out-of-service-period 38

3.4 Control, starting and stopping sequences 39

3.5 Engine – Start 41

3.6 Operational checks 42

3.7 Emission values – Check 43

3.8 Engine – Shutdown 44

3.9 Emergency engine shutdown 45

3.10 After stopping the engine – Engine remains
ready for operation 47

3.11 After stopping the engine – Putting the
engine out of operation 48

4 Maintenance

4.1 50-hours check 49

4.2 Maintenance schedule reference table [QL1] 50

5 Troubleshooting

5.1 Fault messages - Key 51

5.2 Fault messages in log for genset controller 53

5.3 Engine Control Unit – Fault messages 111

6 Task Description

6.1 Engine 150

6.1.1 Engine – Barring manually 150

6.1.2 Machine room – Check for smell of gas 151

6.2 Crankcase Breather 152

6.2.1 Oil separator – Filter replacement 152

6.3 Ignition System 154

6.3.1 Spark plug – Replacement 154

6.3.2 Spark plug – Removal 155

6.3.3 Spark plug – Installation 156

6.3.4 Spark plug connector – Replacement 158

6.3.5 Spark plug connector – Removal 159

6.3.6 Spark plug connector – Installation 160

6.3.7 Ignition system – Ignition timing check 162

6.4 Valve Drive 163

6.4.1 Valve projection – Measurement 163

6.4.2 Valve gear – Lubrication 166

6.4.3 Valve clearance – Check and adjustment 167

6.4.4 Cylinder head cover ‒ Removal 169

6.4.5 Cylinder head cover ‒ Installation 170

6.5 Gas System 171

6.5.1 Gas supply - Checking gas lines for leaks 171

6.6 Air Filter 172

6.6.1 Air filter – Replacement 172

6.6.2 Air filter – Removal and installation 173

6.7 Lube Oil System, Lube Oil Circuit 174

6.7.1 Engine oil – Level check 174

6.7.2 Engine oil – Change 175

6.7.3 Engine oil – Sample extraction and analysis 176

6.8 Oil Filtration / Cooling 177

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6.8.1 Engine oil filter – Replacement 177

6.9 Coolant Circuit, General, High-Temperature
Circuit 178

6.9.1 Engine coolant – Level check 178

6.9.2 Engine coolant – Change 179

6.9.3 Engine coolant – Draining 180

6.9.4 Engine coolant – Filling 182

6.10 Low-Temperature Circuit 183

6.10.1 Mixture coolant level – Check 183

6.10.2 Mixture coolant – Change 184

6.10.3 Mixture coolant – Draining 185

6.10.4 Mixture coolant – Filling 186

6.11 Wiring (General) for Engine/Gearbox/Unit 187

6.11.1 Engine cabling – Check 187

6.11.2 Sensors – Overview 188

7 Appendix A

7.1 Abbreviations 192

7.2 MTU Onsite Energy contact person / service
partner 194

8 Appendix B

8.1 Special Tools 195

8.2 Index 199

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1 Safety

1.1 Important provisions for all products

Nameplate

The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.

Nameplate, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine
in the EU: The second nameplate must be affixed in a prominent position as described in the accompa­nying specifications.

General information

This product may pose a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Noncompliance with the safety instructions and warning notices

Correct use

The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.

Intended use entails operation:

• Within the permissible operating parameters in accordance with the (→ Technical data)

• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri­cants Specifications of the manufacturer)

• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)

• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ­ing (including engine control/parameters)

• In compliance with all safety regulations and in adherence with all warning notices in this manual

• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product

• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques

• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair

• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul

Any other use is considered improper use. Such improper use increases the risk of injury and damage
when working with the product. The manufacturer shall not be held liable for any damage resulting from
improper, non-intended use.

Modifications or conversions

Unauthorized changes to the product represent a contravention of its intended use and compromise
safety.

Changes or modifications shall only be considered to comply with the intended use when expressly au­thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.

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Emission regulations and emission labels

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional com­ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu­facturer.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions
regulation authorities. The manufacturer does not accept any liability for violations of the emission reg­ulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of
the product.

Replacing components with emission labels

Emission labels are attached to all MTU engines. These must remain on the engine throughout its op­erational life.

Engines used exclusively in land-based, military applications other than by US government agencies are
excepted from this proviso.

Please note the following when replacing components with emission labels:

• Appropriate emission labels must be affixed on spare parts.

• Emission labels may not be transferred from old components to new ones.

• Emission labels on old components must be removed and destroyed.

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1.2 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair or transporta­tion.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte­nance, repair and transport personnel at all times.

Personnel must receive instruction on product handling and maintenance on the basis of this manual
with a special emphasis on safety requirements and warnings.

This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.

Personnel requirements

All work on the product shall be carried out by trained and qualified personnel only:

• Training at the Training Center of the manufacturer

• Qualified personnel specialized in mechanical and plant engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, re­pair and transport.

Working clothes and personal protective equipment

Wear proper protective clothing for all work.

When working, always wear the necessary personal protective equipment (e.g. safety footwear, ear pro­tectors, protective gloves, goggles, breathing protection). Observe the information on personal protec­tive equipment in the respective activity description.

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1.3 Safety regulations for startup and operation

Safety requirements for startup

Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica­tions before putting the product into service. All necessary approvals must be granted by the relevant
authorities and all requirements for initial startup must be fulfilled.

When putting the product into operation, always 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 is switched on.

• All maintenance and repair work has been completed.

• All loose parts have been removed from rotating machine components.

• All safety equipment is in place.

• No persons wearing pacemakers or any other technical body aids are present.

• The service room is adequately ventilated.

• Keep clear of the service room during the first operating hours. Hazardous gases may occur as a re­sult of the combustion of paints or oils.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.

• Protect battery terminals, generator terminals or cables against accidental contact.

• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).

Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.

Safety requirements for operation

The operator must be familiar with the controls and displays.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with re­gard to present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

The procedures for emergencies, in particular, emergency stop, must be practiced regularly.

The following steps must be taken if a malfunction of the system is detected or reported by the system:

• Inform supervisor(s) in charge.

• Analyze the message.

• Respond to the emergency appropriately, e.g. execute an emergency stop.

Operation

Do not remain in the operating room when the product is running for any longer than absolutely neces­sary.

Keep a safe distance away from the product if possible. Do not touch the product unless expressly in­structed to do so following a written procedure.

Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:

• Wear ear protectors.

• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder
agent.

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.

Observe the safety instructions for these devices.

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1.4 Safety requirements for startup and operation, special
instructions for applications with gaseous fuel

Safety requirements for startup

Whenever the product is started, always ensure that:

• The operator has fulfilled the requirement to: Check the gas train.

Gas system, requirements

Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device. This
must be realized by the plant designer to suit site conditions.

The connection to the gas supply network is established by the plant designer in accordance with re­quirements of the DVGW (DVGW490, G490/I). The plant designer must use certified gas trains for the
fuel supply to the product and connection to the gas supply network. The connection conditions and
dimensions must be coordinated with the manufacturer.

In flow direction, gas trains have:

• a manual shutoff valve

• a gas filter

• two gas shutoff valves

• a pressure regulating device

The gas train must be fitted with an automatic leak check.

The gas shutoff valves are activated via two different paths from the control system, whereby one gas
shutoff valve respectively is activated via one of the paths.

Gas trains must be monitored to detect minimum pressure.

The plant designer must ensure that the gas train is positioned directly in front of the engine, yet a max­imum of 3 meters before the interface of the engine. The interface is the flange in front of the gas vol­ume regulator of the product.

In the case of network supply pressures higher than 100 mbar, additional equipment is required on the
gas train.

The gas pressure regulator must be equipped with an approved safety shut-off valve and a safety dis­charge valve to ensure safety in case of excessive outlet pressure at the pressure regulator. Gas dis­charge must be routed to a safe area (to atmosphere).

If the gas supply is connected to a vessel or if gases containing oxygen are used, the gas train must be
equipped with a temperature-monitored flame arrester.

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1.5 Safety regulations for maintenance and repair work

Safety regulations prior to maintenance and repair work

Have maintenance or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collecting vessels of adequate capacity to catch fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately venti­lated.

Never carry out maintenance and repair work with the product in operation, unless:

• It is expressly permitted to do so following a written procedure.

• The product is running in the low load range and only for as long as absolutely necessary.

Lock-out the product to preclude undesired starting, e.g.

• Start interlock

• With hydraulic starting system: shut off supply line.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery. Lock out circuit breakers.

Close the main valve on the compressed-air system and vent the compressed-air line when air starters
are fitted.

Disconnect the control equipment from the product.

Use special tools if they are specified for the relevant work.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be
painted. They may only be installed after painting the engine or must be covered before painting work is
carried out.

The following applies to starters with copper-beryllium alloy pinions:

• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the flywheel housing inside with a class H dust extraction device.

• Observe the safety data sheet.

Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.

Take care when draining hot fluids and lubricants (risk of burning).

Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis­assembly.

Carry out work only on assemblies or plants which are properly secured.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid
that components/tools fall down .Use the specified lifting equipment for all components.

Never use lines for climbing.

Keep fuel injection lines and connections clean.

Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Avoid damaging lines, particularly the fuel lines.

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Ensure that all retainers and dampers are installed correctly.

Ensure that O-rings are not installed ina slanted/twisted condition.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.

Note cooling time for components which are heated for installation or removal (risk of burning).

When working high on the engine, always use suitable ladders and work platforms.

Pay particular attention to cleanliness at all times.

Remove any condensate from components which were chilled before assembly.If necessary, coat the
components with a suitable corrosion inhibitor.

Safety regulations after completion of maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safety equipment has been installed and that all tools and loose parts have been re­moved (especially the barring gear).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Welding work

Welding operations on the product or mounted units are not permitted. Cover the product when welding
in its vicinity.

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery.

• Separate the electrical ground of electronic equipment from the ground of the unit.

No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable process materials.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.

Observe the max. permissible force-on pressure specified for the jig/fixture.

Do not attempt to bend or exert force on HP lines.

Before starting work, pay attention to the following:

• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.

• During the installation procedure, screw on jig with plunger extended.

• During the removal procedure, screw on jig with plunger retracted.

For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.

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

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Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow electrolyte to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.

Do not place tools on the battery.

Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.

De-energize the appropriate areas prior to working on assemblies.

Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be dam­aged during operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable straps to secure cables.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to a functional testing on completion of all repair work. In
particular, check the function of the engine emergency stop feature.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack­age faulty electronic components or assemblies properly before dispatching for repair:

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil if necessary.

Working with laser devices

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi­ly focused radiation).

Laser devices must be equipped with protective devices in accordance with their class and usage to
ensure safe operation.

For conducting light-beam procedures and measurement work, only the following laser devices may be
used:

• Laser devices of classes 1, 2 or 3A.

• Class 3B laser devices:
– which operate in the visible spectral range (400 nm to 700 nm) only
– which have a maximum output of 5 mW
– which are arranged such as to prevent the beam from harming eyesight.

Measuring component deviations

Workpieces, components and measuring equipment are within specified tolerances at a reference tem­perature of 20 °C.

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1.6 Safety requirements for maintenance and repair work, special
instructions for applications with gaseous fuel

Safety requirements before commencing maintenance and repair work

Installation and connection of the gas supply must only be carried out by a specialized company with
staff that has been trained and authorized for this task.

Have all work on gas-bearing components carried out by authorized, specialized companies.

Shut off the gas supply to the product and activate the emergency stop at the interface switchgear cab­inet or by turning the key switch (if applicable).

Close the manual shutoff valve for the gas supply.

The coolant pumps must keep running-on for a longer period in the case of scheduled shutdowns.

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1.7 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials

Fire prevention

Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al­ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.

Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.

When starting the engine with an external power source, connect the ground cable last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground cable from the external power
source to the ground cable of the engine or to the ground terminal of the starter.

Always have a suitable extinguishant (fire extinguisher) on hand and familiarize yourself fully with its
handling.

Noise

Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating
danger are drowned.

Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal

Dispose of used fluids, lubricants and filters in accordance with local regulations.

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.

Fluids and lubricants, auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera­tion, make sure that the latest version is used. The latest version can be found on the website on the
“Technical Info” or “Parts and Service” tabs at http://www.mtu-online.com.

Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as
well as other chemical substances, observe the information contained in the safety data sheet for the
product. The safety data sheet may be obtained from the relevant manufacturer or from MTU.

Take special care when using hot, chilled or caustic materials.

When using flammable materials, avoid all sparks and do not smoke.

Used oil

Used oil contains combustion residues that are harmful to health.

Rub barrier cream into hands.

Wash hands after contact with used oil.

Lead

• Adopt suitable measures to avoid the formation of lead dust.

• Switch on extraction system.

• When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale

lead vapors.

• Wash hands after contact with lead or lead-containing substances.

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Compressed air

Observe special safety precautions when working with compressed air:

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.

• Wear goggles when blowing dirt off workpieces or blowing away swarf.

• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.

• Pay special attention to the pressure in the compressed air system or pressure vessel.

• Assemblies or products 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).

• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.

• Carry out leak test in accordance with the specifications.

Painting

• Observe the relevant safety data sheet for all materials.

• When carrying out painting work outside the spray stands provided with fume extraction systems,
ensure that the area is well ventilated. Make sure that neighboring work areas are not adversely af­fected.

• There must be no naked flames in the vicinity.

• No smoking.

• Observe fire-prevention regulations.

• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen

• Observe the relevant safety data sheet for all materials.

• Work with liquid nitrogen may be carried out only by qualified personnel.

• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and safety goggles.

• Make sure that working area is well ventilated.

• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

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

• Observe the relevant safety data sheet for all materials.

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.

• Do not inhale vapors.

• If urea solution is swallowed, rinse out mouth and drink plenty of water.

• Remove any wet clothing immediately.

• After contact with skin, rinse affected parts of the body with plenty of water.

• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi­ble.

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1.8 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials, special instructions for
applications with gaseous fuel

Natural gas

Observe the safety data sheet.

Caution: Highly flammable gas, forms an explosive mixture with air/oxygen.

Caution: Weak narcotic gas, risk of suffocation at very high concentration.

All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during
operation.

Procedure in the case of accidental release of gaseous fuel:

• If safely feasible: Shut off main gas supply.

• If safely feasible: Carry out emergency stop.

• Cordon off danger zone.

• Ensure sufficient ventilation!

• Do not enter danger zone before measurements with a suitable gas detector have confirmed that gas

concentration is not hazardous.

Biogenic gases from fermentation processes

Observe the safety data sheet.

Caution: Highly flammable gas, forms an explosive mixture with air/oxygen.

Caution: Can be life threatening depending on concentration. Some gases can no longer be detected by
sense of smell in higher concentrations.

Caution: Risk of poisoning due to hazardous byproducts. The absorption of even small quantities of hy­drogen sulfide or ammonium may be lethal.

Caution: Danger of suffocation. Due to the lack of oxygen, the absorption of methane can occasionally
lead to increased breathing frequency (hyperventilation) and heart rates, low blood pressure, numbness
of the extremities, drowsiness, mental confusion and loss of memory!

Biogenic gases tend to segregate. In low-lying areas of the plant, carbon dioxide enrichment is possible.

All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during
operation.

Procedure in the case of accidental release of gaseous fuel:

• If safely feasible: Shut off main gas supply.

• If safely feasible: Carry out emergency stop.

• Cordon off danger zone.

• Ensure sufficient ventilation!

• Do not enter danger zone before measurements with a suitable gas detector have confirmed that gas

concentration is not hazardous.

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1.9 Standards for safety notices in the text

DANGER

In the event of immediate danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

WARNING

In the event of a situation involving potential danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!

• Remedial action.

NOTICE

In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!

• Remedial action.

• Additional product information.

Safety notices

1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.

2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.

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1.10 Transport

Taking the engine's center of gravity into account

For information regarding the center of gravity of the engine, refer to the installation/arrangement
drawing of the engine/genset/system.

Transport

• Lift the engine/genset/system only with the lifting eyes provided.

• Only use transport and lifting devices approved by MTU.

• The engine/genset/system must only be transported in installation position.

• Max. permissible diagonal pull 10°.

• If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes
of the trestle or use a means of transportation which is appropriate for the given weight (forklift
truck).

• Prior to transporting the engine/genset/system, it is imperative to install the transport locking de­vice for the crankshaft.

• Prior to transporting the engine/genset/system, it is imperative to install the transport locks for the
engine mounts.

• Secure the engine/genset/system such as to preclude tipping during transport.

• Secure the engine/system/genset as to preclude slipping and tipping when driving up or down in­clines and ramps.

Setting the engine down after transport

• Make sure that the consistency and load-bearing capacity of the ground or support surface is ade­quate.

• Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by
MTU on a case-to-case basis.

• Place the engine/genset/system on a firm, flat surface only.

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2 Product Summary

2.1 Engine overview

1 Engine Control Unit / En-

gine Monitoring Unit
2 Throttle
3 Mixture cooler
4 Exhaust turbocharger

5 Engine lifting equipment
6 Capacitor ignition system
7 Engine mounting bracket -

free end

8 Oil pan

9 Engine mounting bracket,

driving end
10 Flywheel
11 Air filter/air inlet
KS Driving end

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1 Crankcase breather, oil

separator
2 Exhaust outlet
3 Gas control valve
4 Gas inlet connection
5 Ignition coil

6 Spark plug
7 Cylinder head cover
8 Cylinder head
9 Oil filter

10 Engine oil sampling con-

nection

11 Oil level switch
12 Connection: engine cool-

ant inlet
13 Engine oil heat exchanger
14 Connection: engine cool-

ant outlet

KGS Free end

Engine model designation

Key to the engine model designation 12/16 V 4000 L64

12/16 Number of cylinders

V Cylinder arrangement: V engine

4000 Series

L Application: L = Gas engine

6 Load profile

4 Design index

Table 2: Key to the engine model designation

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2.2 Engine side and cylinder designations

1 Left engine side (A-side)
2 Engine free end in accord-

ance with DIN ISO 1204
(KGS = Kupplungsgegen­seite)

3 Right engine side (B-side)
4 Engine driving end in ac-

cordance with
DIN ISO 1204 (KS = Kup­plungsseite)

Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).

The numbering of other engine components also starts with 1 at driving end (4).

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2.3 Main engine dimensions

Main engine dimensions

Item Dimensions

Length 12 V (A) Approx. 2868 mm

Length 16 V (A) Approx. 3372 mm

Width 12 V (B) Approx. 1742 mm

Width 16 V (B) Approx. 1789 mm

Height 12 V (C) Approx. 2146 mm

Height 16 V (C) Approx. 2171 mm

Crankshaft center to
oil pan 12 V (D)

Approx. 636 mm

Crankshaft center to
oil pan 16 V (D)

Approx. 636 mm

Crankshaft center to
engine mount 12 V (E)

Approx. 280.5 mm

Crankshaft center to
engine mount 16 V (E)

Approx. 280.5 mm

Table 3: Main engine dimensions

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2.4 Firing order

Firing order

Number of cylinders

Firing order

12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6

16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7

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2.5 Technical Data

2.5.1 12 V 4000 L64, 16 V 4000 L64 engine data, fuel optimized ("TA-Luft")

Explanation:

DL Ref. value: Continuous power
BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value

- Not applicable

X Applicable

Reference conditions

Engine model 12 V 400

0

L64

16 V 400

0

L64

Application group 3A 3A

Intake air temperature °C 25 25

Mixture coolant temperature °C 43 43

Barometric pressure mbar 1000 1000

Site altitude above sea level m 100 100

Table 4: Reference conditions

Power-related data (power ratings are net brake power as per ISO 3046)

Number of cylinders 12

16

Rated engine speed A rpm 1500 1500

Mean piston speed m/s 10.5 10.5

Continuous power as per ISO 3046 A kW 1560 2080

Mean effective pressure (pme) (continuous power as per ISO

3046)

bar 21.8 21.8

Table 5: Power-related data (power ratings are net brake power as per ISO 3046)

General conditions (for maximum power)

Number of cylinders 12

16

Relative air humidity A % 30 30

Intake air temperature A °C 25 25

Intake air temperature, min. L °C 20 20

Intake air temperature, max. L °C 30 30

Mixture temperature after mixture cooler A °C 48 48

Ambient intake depression, max. L mbar 3 3

Pressure loss over air filter, max. L mbar 30 30

Exhaust back pressure, min. L mbar 30 30

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Number of cylinders 12

16

Exhaust back pressure, max. L mbar 60 60

Gas type: natural gas X X

Methane number, min. L 80 80

Table 6: General conditions (for maximum power)

Consumption

Number of cylinders 12

16

Lube oil consumption after 1000 h run time g/kWh 0.15 0.15

Table 7: Consumption

Model-related data (basic design)

Number of cylinders 12

16

Operating method: Four-stroke cycle, Otto engine, single-acting X X

Combustion method: Mixture charging, spark ignition X X

Number of cylinders 12 16

Cylinder arrangement: V-angle Degrees

(°)

90 90

Bore mm 170 170

Stroke mm 210 210

Displacement, cylinder Liters 4.77 4.77

Displacement, total Liters 57.24 76.32

Compression ratio 14:1 14:1

Standard housing connecting flange (engine main PTO) SAE 00 00

Table 8: Model-related data (basic design)

Coolant system (HT circuit)

Number of cylinders 12

16

Coolant temperature (at engine connection: outlet to cooling
equipment) (w/o antifreeze)

A °C 90 90

Coolant temperature (at engine connection: inlet from cooling
equipment) (w/o antifreeze)

A °C 78 78

Coolant temperature after engine, warning R °C 95 95

Coolant temperature after engine, shutdown L °C 98 98

Coolant temperature for load enable, max. 10% load L °C 40 40

Coolant outlet temperature for 100% load L °C 65 65

Coolant antifreeze content, max. L % 50 50

Coolant pump: Volumetric flow L m³/h 55 76

Filling pressure in cooling system (cold) R bar 0.5 0.5

Pressure in cooling system, max. L bar 6.0 6.0

Pressure loss over engine (at nominal flow rate 7.27) bar 1.8 3.1

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Number of cylinders 12

16

Thermostat: Starts to open R °C 68 68

Thermostat: Opening stops (thermostat fully open and bypass
closed)

A °C 78 78

Table 9: Coolant system (HT circuit)

Coolant system (LT circuit)

Number of cylinders 12

16

Coolant temperature before mixture cooler (at engine connection:
inlet from cooling equipment) (w/o antifreeze)

A °C 43 43

Coolant antifreeze content, max. L % 50 50

Coolant pump: Volumetric flow A m³/h 32 32

Pressure in cooling system, max. L bar 6.0 6.0

Pressure loss over LT mixture cooler (at nominal flow rate 8.56) bar 0.3 0.3

Table 10: Coolant system (LT circuit)

Lube oil system

Number of cylinders 12

16

Lube oil operating temperature after oil heat exchanger, from R °C 82 82

Lube oil operating temperature after oil heat exchanger, to R °C 90 90

Lube oil operating temperature after oil heat exchanger, warning R °C 93 93

Lube oil operating temperature after oil heat exchanger, shutdown L °C 97 97

Lube oil pressure after oil filter bar 5.5 5.5

Lube oil pressure after oil filter, warning R bar 5.0 5.0

Lube oil pressure after oil filter, shutdown L bar 4.5 4.5

Table 11: Lube oil system

Fuel system

Number of cylinders 12

16

Gas temperature before engine, min. L °C 10 10

Gas temperature before engine, max. L °C 50 50

Gas flow pressure before Tecjet, min. L mbar 80 80

Gas flow pressure before Tecjet, max. L mbar 200 200

Table 12: Fuel system

General operating data

Number of cylinders 12

16

Cold start capability: Air temperature (w/o starting aid, with pre­heating) - (case C)

R °C 15 15

General condition (to case C): Engine coolant temperature R °C 40 40

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Number of cylinders 12

16

Minimum idling speed A rpm 1500 1500

Limit speed for overspeed alarm/emergency shutdown L rpm 1900 1900

Table 13: General operating data

Starter (electric)

Number of cylinders 12

16

Starter, rated power (standard design) R kW 9 2 x 9

Rated starter voltage (standard design) R V 24 24

Starter, current consumption, max. (standard design) R A 2500 2 x 2500

Starting-attempt duration, max. L s 15 15

Number of teeth on starter ring gear 182 182

Table 14: Starter (electric)

Oil and coolant capacity

Number of cylinders 12

16

Engine coolant capacity, engine side (without cooling equipment) R Liters 200 270

Engine coolant, mixture side (without cooling equipment) R Liters 20 25

Total engine oil capacity for initial filling (standard oil system) R Liters 320 365

Oil change capacity, max. (standard oil system) R Liters 280 330

Table 15: Oil and coolant capacity

Weights / main dimensions

Number of cylinders 12

16

Dry engine weight (basic-configuration engine) R kg 6700 8300

Heaviest component to be lifted during extended component
maintenance (QL3)

R kg 450 450

Table 16: Weights / main dimensions

Exhaust emissions

Number of cylinders 12

16

Exhaust emission before catalytic converter at 100% DL nitric ox­ides (NOx) (in dry exhaust gas, 5% O2)

G

mg/m3n

500 500

Exhaust emission before catalytic converter at 100% DL nitric ox­ides (NOx) (in dry exhaust gas)

A ppm 165 165

Table 17: Exhaust emissions

Acoustics

Number of cylinders 12

16

Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) 116 113

Genset surface noise with attenuated intake noise (filter) - DL
(sound power level LW, ISO 8528-10)

R dB(A) 124 124

Table 18: Acoustics

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2.5.2 12V 4000 L64, 16V 4000 L64 engine data, emissions-optimized (1/2 "TA-Luft")

Explanation:

DL Ref. value: Continuous power
BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value

- Not applicable

X Applicable

Reference conditions

Engine model 12V 4000

L64

16V 4000

L64

Application group 3A 3A

Intake air temperature °C 25 25

Mixture coolant temperature °C 43 43

Barometric pressure mbar 1000 1000

Site altitude above sea level m 100 100

Table 19: Reference conditions

Power-related data (power ratings are net brake power as per ISO 3046)

Number of cylinders 12

16

Rated engine speed A rpm 1500 1500

Mean piston speed m/s 10.5 10.5

Continuous power as per ISO 3046 A kW 1560 2080

Mean effective pressure (pme) (continuous power as per ISO

3046)

bar 21.8 21.8

Table 20: Power-related data (power ratings are net brake power as per ISO 3046)

General conditions (for maximum power)

Number of cylinders 12

16

Relative air humidity A % 30 30

Intake air temperature A °C 25 25

Intake air temperature, min. L °C 20 20

Intake air temperature, max. L °C 30 30

Mixture temperature after mixture cooler A °C 48 48

Ambient intake depression, max. L mbar 3 3

Pressure loss over air filter, max. L mbar 30 30

Exhaust back pressure, min. L mbar 30 30

Exhaust back pressure, max. L mbar 60 60

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Number of cylinders 12

16

Gas type: natural gas X X

Methane number, min. L 80 80

Table 21: General conditions (for maximum power)

Consumption

Number of cylinders 12

16

Lube oil consumption after 1000 h run time g/kWh 0.15 0.15

Table 22: Consumption

Model-related data (basic design)

Number of cylinders 12

16

Operating method: Four-stroke cycle, Otto engine, single-acting X X

Combustion method: Mixture charging, spark ignition X X

Number of cylinders 12 16

Cylinder arrangement: V-angle Degrees

(°)

90 90

Bore mm 170 170

Stroke mm 210 210

Displacement, cylinder Liters 4.77 4.77

Displacement, total Liters 57.24 76.32

Compression ratio 14:1 14:1

Standard housing connecting flange (engine main PTO) SAE 00 00

Table 23: Model-related data (basic design)

Coolant system (HT circuit)

Number of cylinders 12

16

Coolant temperature (at engine connection: outlet to cooling
equipment) (w/o antifreeze)

A °C 90 90

Coolant temperature (at engine connection: inlet from cooling
equipment) (w/o antifreeze)

A °C 78 78

Coolant temperature after engine, warning R °C 95 95

Coolant temperature after engine, shutdown L °C 98 98

Coolant temperature for load enable, max. 10% load L °C 40 40

Coolant outlet temperature for 100% load L °C 65 65

Coolant antifreeze content, max. L % 50 50

Coolant pump: Volumetric flow L m³/h 57 80

Filling pressure in cooling system (cold) R bar 0.5 0.5

Pressure in cooling system, max. L bar 6.0 6.0

Pressure loss over engine (at nominal flow rate 7.27) bar 2.0 3.4

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Number of cylinders 12

16

Thermostat: Starts to open R °C 68 68

Thermostat: Opening stops (thermostat fully open and bypass
closed)

A °C 78 78

Table 24: Coolant system (HT circuit)

Coolant system (LT circuit)

Number of cylinders 12

16

Coolant temperature before mixture cooler (at engine connection:
inlet from cooling equipment) (w/o antifreeze)

A °C 43 43

Coolant antifreeze content, max. L % 50 50

Coolant pump: Volumetric flow A m³/h 32 32

Pressure in cooling system, max. L bar 6.0 6.0

Pressure loss over LT mixture cooler (at nominal flow rate 8.56) bar 0.3 0.3

Table 25: Coolant system (LT circuit)

Lube oil system

Number of cylinders 12

16

Lube oil operating temperature after oil heat exchanger, from R °C 82 82

Lube oil operating temperature after oil heat exchanger, to R °C 90 90

Lube oil operating temperature after oil heat exchanger, warning R °C 93 93

Lube oil operating temperature after oil heat exchanger, shutdown L °C 97 97

Lube oil pressure after oil filter bar 5.5 5.5

Lube oil pressure after oil filter, warning R bar 5.0 5.0

Lube oil pressure after oil filter, shutdown L bar 4.5 4.5

Table 26: Lube oil system

Fuel system

Number of cylinders 12

16

Gas temperature before engine, min. L °C 10 10

Gas temperature before engine, max. L °C 50 50

Gas flow pressure before Tecjet, min. L mbar 80 80

Gas flow pressure before Tecjet, max. L mbar 200 200

Table 27: Fuel system

General operating data

Number of cylinders 12

16

Cold start capability: Air temperature (w/o starting aid, with pre­heating) - (case C)

R °C 15 15

General condition (to case C): Engine coolant temperature R °C 40 40

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Number of cylinders 12

16

Minimum idling speed A rpm 1500 1500

Limit speed for overspeed alarm/emergency shutdown L rpm 1900 1900

Table 28: General operating data

Starter (electric)

Number of cylinders 12

16

Starter, rated power (standard design) R kW 9 2 x 9

Rated starter voltage (standard design) R V 24 24

Starter, current consumption, max. (standard design) R A 2500 2 x 2500

Starting-attempt duration, max. L s 15 15

Number of teeth on starter ring gear 182 182

Table 29: Starter (electric)

Oil and coolant capacity

Number of cylinders 12

16

Engine coolant capacity, engine side (without cooling equipment) R Liters 200 270

Engine coolant, mixture side (without cooling equipment) R Liters 20 25

Total engine oil capacity for initial filling (standard oil system) R Liters 320 365

Oil change capacity, max. (standard oil system) R Liters 280 330

Table 30: Oil and coolant capacity

Weights / main dimensions

Number of cylinders 12

16

Dry engine weight (basic-configuration engine) R kg 6700 8300

Heaviest component to be lifted during extended component
maintenance (QL3)

R kg 450 450

Table 31: Weights / main dimensions

Exhaust emissions

Number of cylinders 12

16

Exhaust emission before catalytic converter at 100% DL nitric ox­ides (NOx) (in dry exhaust gas, 5% O2)

G

mg/m3n

250 250

Exhaust emission before catalytic converter at 100% DL nitric ox­ides (NOx) (in dry exhaust gas)

A ppm 81 81

Table 32: Exhaust emissions

Acoustics

Number of cylinders 12

16

Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) 116 113

Genset surface noise with attenuated intake noise (filter) - DL
(sound power level LW, ISO 8528-10)

R dB(A) 124 124

Table 33: Acoustics

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2.6 Monitoring, Control and Regulation Equipment

2.6.1 Gas engine system – Overview

Overview

1 Unit system

2 Engine system

3 System

4 Engine Control Unit

5 Engine Monitoring Unit
6 Humidity sensor
7 Throttles
8 Gas control unit

9 Knock module
10 Ignition
11 Compressor bypass
12 NOx sensor (optional)

Closed-/open-loop control / monitoring

Engine Control Unit ECU-9

• Controls engine starting, stopping and emergency stop

• Monitors engine operating parameters

• Controls throttles and sets gas mixture for requested speed/power

• Monitors first gas solenoid in gas train to engine

Engine Monitoring Unit EMU8

• Evaluation unit for PT 1000 temperature sensor to determine and monitor exhaust temperatures of
individual cylinders

• Monitors second gas solenoid in gas train to engine

Compressor bypass (F-Series)

• Controls throttle reserve, prevents compressor pumping

Ignition system MIC5

• Adjusts ignition timing for cylinders

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Anti-Knock Regulation AKR

• Controls monitored cylinders in regard of knock characteristics. If knocking is detected, 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 / TecJet85

• Controls the required amount of gas

Mixture throttles (P-Series)

• The mixture throttles in the mixture lines which are controlled by the Engine Control Unit

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2.6.2 Purpose of the units

ECU 9 engine governor

Central control and monitoring unit for the engine

• Communication with other devices and higher-level systems via CAN bus

• Control of throttles (mixture and gas)

• Registration and analysis of engine operating states

• Limit value monitoring

• Self-monitoring and diagnostics
– Integral status/fault display
– Fault memory

• Extensive I/O features:

• Engine and genset-related parameter settings in flash memory

• In the event of inadmissible states and limit value violations: Initiation of power reduction, engine
stop or emergency engine stop (configurable)

• Diagnostic function via CAN interface (Default CAN1, connection for dialog unit provided)

Software structure:

• One data record for engine software

• One data record for genset software

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Engine Monitoring Unit EMU 8

EMU = Engine Monitoring Unit

Monitoring unit for the engine

• Acquisition and processing of cylinder exhaust temperatures

Self-monitoring

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3 Operation

3.1 Runtimes at partial load

Gas engines were designed and optimized for continuous operation at 100% load.

The following restrictions apply to ensure maximum operational availability of the engine plant and to
reduce maintenance to a minimum:

Power, referenced to nominal
load

Recommended maximum run­time
at this load

Recommended minimum run­time
in subsequent operation
at load > 50%

0% to 30% 30 minutes 120 minutes

30% to 50% 120 minutes 120 minutes

50% to 100% No restriction No restriction

To reduce increased engine load due to temperature change (cold start to engine at operating tempera­ture), a minimum runtime of 5h per start is recommended.

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3.2 Putting the engine into operation after extended out-of-service
periods (>3 months)

Preconditions

☑Engine is stopped and starting disabled.

☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Putting the engine into operation after extended out-of-service-periods (>3
months)

Item Measure

Engine Depreserve (→ MTU Preservation and Represervation Specifications

A001070/..).

Engine Bar engine manually (→ Page 150).

Valve gear Standstill ≥ 6 months: Lubricate valve gear (→ Page 166).

Lube oil system Check engine oil level (→ Page 174);

Check oil level in oil storage tank (→ Page 174).

Coolant circuit Standstill > 1 year: Change engine coolant (→ Page 179);

Change mixture coolant (→ Page 184)

Coolant circuit Check engine coolant level (→ Page 178);

Check mixture coolant level (→ Page 183)

Engine cabling Check plug-in connections (→ Page 187).

Gas supply The gas shut-off valves with control solenoids are not included in the scope

of supply of the engine. The components are controlled by the engine elec­tronics.

Engine management system Check for fault messages.

Starting system Check power supply to electric starter.

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3.3 Putting the engine into operation after scheduled out-of­service-period

Preconditions

☑Engine shut down and starting disabled.

Putting into operation

Item Measure

Lube oil system Check oil level in oil storage tank (→ Page 174).

Coolant circuit Check engine coolant level (→ Page 178);

Check mixture coolant level (→ Page 183)

Engine management system Check for fault messages.

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3.4 Control, starting and stopping sequences

NOTICE

Risk of engine damage due to incorrect action.

Risk of severe damage to property!

• Ensure engine is ready for operation before starting. See engine documentation.

Starting and stopping sequences

The starting sequence is software-controlled and depends on the place of start command input.

To ensure that no mixture is in the engine when ignition is switched on or off, which is a specific re­quirement for gas engines, special procedures for engine start / stop are specified.

The maximum number of attempted starts is limited to three. After this, an extended scavenging phase
is initiated with the gas shut-off valves closed and the ignition off in order to purge the intake duct,
engine cylinders and exhaust duct (up to the exhaust turbine outlet elbow) with air. The operator shall
ensure by means of structural safeguards that flammable gases or vapors do not arise in hazardous
quantities or concentrations in the surroundings of the installation (gas pipework up to gas control valve
and exhaust gas system after turbine). A contact is designated to initiate such safety measures.

Starting sequence

The following steps are performed automatically when a start command is activated with the engine at
standstill:

1. Setting start counter

2. Priming (optional)

3. Checking gas supply solenoid valves for leaks

4. Activating starter

5. Waiting for starting speed

6. Scavenging the engine

7. Ignition

8. Opening gas supply solenoid valves

9. Waiting for starter disengagement speed

10. Disengaging starter

11. Waiting for idling speed

12. Ramping-up to rated speed

Start termination

1. The maximum number of attempted starts is limited to three following start termination

2. An alarm is then signaled

3. Requesting external ventilation by contact

4. A new engine start request is only possible following fault acknowledgment

Stopping sequence

The following steps are performed automatically when a stop command is activated:

1. Closing gas supply solenoid valves

2. Opening mixture throttles, scavenging residual gas

3. Engine running down to standstill

4. Deactivating ignition

5. Closing mixture throttles

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Emergency stopping sequence

If an emergency stop command is activated, the following steps are carried out automatically:

1. Closing gas supply solenoid valves

2. Closing mixture throttles

3. Engine running down to standstill

4. Deactivating ignition

5. Requesting external ventilation by contact

Restarting after emergency stop

A scavenging phase and a request for external ventilation by contact ensue following a start request
after emergency shutdown.

1. Requesting external ventilation by contact

2. Activating starter

3. Waiting for starting speed

4. Scavenging the engine

5. Disengaging starter

6. Engine running down to standstill

7. Resetting start counter

8. Awaiting start request

Oil refill sequence

1. Waiting for engine running

2. Engine running for a minimum (programmed) time period

3. Oil refilling enabled

4. When oil refill request is received

5. Refilling oil (automatically)

6. When oil refill request is canceled

7. Stopping oil refilling (automatically)

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3.5 Engine – Start

Preconditions

☑Generator not connected to network.

☑Start interlock not active.

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before cranking the engine with starter system, make sure that there are no persons in the en­gine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Starting engine

u Start engine in accordance with starting sequence specifications (→ Page 39).

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3.6 Operational checks

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Operational checks

Item Action

Machine room Check machine room for smell of gas (→ Page 151).

ECU Check for fault messages;

if fault messages are displayed: Determine the cause, rectify the fault.

Check indicated operating parameters (speed, temperatures, pressures).

Operation log (if available) Document operating parameters

• This is especially useful for fault localization and fast remedial action.

Engine under load,
engine at rated speed

Visually inspect engine/plant and all pipework for leaks, rectify any leaks
with the engine stopped;
check for abnormal running noises and vibration.

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3.7 Emission values – Check

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Gas measuring and warning device (not stocked by MTU)

-

WARNING

Exhaust gases are hot and pressurized.

Risk of injury and burning!

• Wear protective clothing, gloves, and goggles / safety mask.

WARNING

Exhaust gases are harmful to health.

Risk of poisoning!

• Ensure that the engine room is well ventilated.

• Repair leaking exhaust pipework immediately.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Checking emission values

Note: Open the exhaust gas measuring line and

install the measuring instrument only when
the engine is at standstill.

1. Apply exhaust gas sensor (1) to measuring
point (2).

2. Start engine.

3. Approach measuring point until a stable
operating state has been reached.

4. Carry out measurement and read off meas­ured value for NO

x rel

(ppm).

5. Compare measured value with limit value
(tolerance = − 10 %), adjust exhaust gas
emissions in case of deviation.

• NOx limit value, fuel-optimized (“TA-

Luft”) (→ Page 24).

• NOx limit value, emissions-optimized

(“1/2 TA-Luft”) (→ Page 28).

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3.8 Engine – Shutdown

Preconditions

☑Generator is not connected to network.

NOTICE

Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.

Overheating of and, therefore, damage to components is possible!

• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.

Shutting down engine

u Shut down engine in accordance with stopping sequence specifications (→ Page 39).

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3.9 Emergency engine shutdown

WARNING

Escaping residual gas may create an explosive atmosphere in case of emergency stop.

Explosion hazard!

• Ensure that any escaping residual gas is routed out by means of appropriate facility ventilation
and use of an SBV (safety blow-off valve) to prevent any risk of explosive atmosphere.

• Install an SAV (safety shut-off valve) in the gas control system when using gas control systems
with inlet pressures in excess of 0.1 bar.

• Install an SAV (safety shut-off valve) and an SBV (safety blow-off valve) in the gas control system
when using single-stage gas control systems with inlet pressures in excess of 1 bar.

NOTICE

An emergency stop causes extreme stress to the engine plant.

Risk of overheating, damage to components!

• Initiate emergency stop only in emergency situations.

Emergency engine shutdown

Item Action

Gas shut-off solenoids Two contacts are provided for electrical connection. Close gas shut-off sole-

noids.

• Engine is stopped.

Ignition, ignition system In the case of an external EMERGENCY STOP, the ignition remains on until

the engine has run down to a standstill in order to safely burn off uncombust­ed fuel/air mixture.

• The ignition is only switched off in case of an overspeed violation or an
internal ignition fault.

Throttles The throttles are always closed in case of EMERGENCY STOP. Closing the

throttles impedes the scavenging of residual gas. External ventilation and in­erting systems must therefore be activated following an emergency engine
stop.

Room ventilation, facility
ventilation

Residual gas may escape from the fuel line in case of EMERGENCY STOP.

• A contact is provided to request room and facility ventilation.

Table 34: Emergency engine shutdown

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Remedy the cause, re-enable starting

Item Action

Engine Control System Determine cause of emergency stop and take remedial action; contact Serv-

ice if the fault cannot be corrected.
Fault acknowledgment is possible in engine stop mode only . Automatic se­lection and remote start immediately following an emergency engine stop is
not admissible.

Plant control system An extended scavenging phase with the ignition off precedes engine starting

when selected again following an emergency engine stop. Suitable exhaust
gas ventilation equipment must be provided in the facility to ensure that the
exhaust gas system downstream of the engine is safely purged.

• A contact is provided to request the ventilation system in the scavenging
phase.

Note:
Gas train

• The gas control system must be equipped with an SAV (safety shut-off
valve) when using gas control systems with inlet pressures in excess of

0.1 bar. If the SAV is tripped by an EMERGENCY STOP it must be reset
manually. SAV tripping is not indicated by the engine.

Table 35: Remedy the cause, re-enable starting

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3.10 After stopping the engine – Engine remains ready for
operation

After stopping the engine

Item Action

Engine/generator controller
(manufacturer-specific)

Select operating mode, e.g. MANUAL, AUTOMATIC.

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

Preconditions

☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

After stopping the engine

Item Action

Coolant circuit Drain engine coolant (→ Page 180)

Drain mixture coolant (→ Page 185) if:

• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but coolant has no antifreeze additive;

• the engine room is not heated;

• the engine coolant is not maintained at a suitable temperature;

• the antifreeze concentration is insufficient for the engine-room tempera­ture;

• antifreeze concentration is 50 % and engine-room temperature is below

-40 °C.

Operating voltage for engine
management

Switch off.

Gas supply Close manual gas shutoff valve.

Air intake and exhaust sys­tems

If the engine is to remain out of service for more than 1 week, seal the en­gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ MTU Preservation and Represerva­tion Specifications A001070/..).
The corrosion-inhibiting effect of the engine coolant may be used as an alter­native in case of out-of-service periods lasting for more than 1 month, by run­ning the engine for at least 2 hours at rated power once a month.

Starter battery (batteries) Charge regularly (trickle charge).

Control-voltage battery (bat­teries)

If fitted: Charge regularly (trickle charge).

Table 36: After stopping the engine

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4 Maintenance

4.1 50-hours check

50-hours check

One-time operations to be carried out after a test run or after the first 10 to 50 operating hours of the
cylinder head (with a new engine, after installation of new cylinder heads, after component mainte­nance or extended component maintenance).

When installing a cylinder head with run-in mating faces (e.g. after piston replacement), a repeated
check after the first 50 operating hours is not necessary.

Qualifi­cation

Interval Item Maintenance tasks Task

[h] [a]

QL1 - - Valve gear Check valve clearance (→ Page 167) -

Table 37: 50-hours check

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4.2 Maintenance schedule reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.

The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.

Task Maintenance tasks

W0501 Visually inspect engine for leaks and general condition. (→ Page 42)

W0509 Check machine room for smell of gas. (→ Page 151)

W0523 Check for abnormal running noises and vibrations. -

W0527 Check engine oil level in storage tank. (→ Page 174)

W1002 Check valve clearance, adjust if required. (→ Page 167)

W1005 Replace air filter. (→ Page 172)

W1008 Replace engine oil filter when changing engine oil, or when the

interval (years) is reached, at the latest.

(→ Page 177)

W1046 Replace filter or filter element. (→ Page 152)

W1089 Check gas lines for leaks, repair if required. (→ Page 171)

W1091 Check ignition timing, adjust if required. (→ Page 162)

W1168 Replace spark plugs. (→ Page 154)

W1341 Check emission values, adjust if required. (→ Page 43)

W1688 Replace spark plug connector. (→ Page 158)

W1689 Measure valve clearance. (→ Page 163)

Table 38: Maintenance task reference table [QL1]

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5 Troubleshooting

5.1 Fault messages - Key

The fault messages are applicable to 8V, 12V, 16V and 20V engines.

Explanation of the abbreviations used

The following abbreviations are used in the texts for the fault messages:

Abbreviation

Meaning

DL <number> Default Lost: The device with designation <number> has lost its connec-

tion to the default CAN bus.

RL <number> Redundant Lost: The device with designation <number> has lost its con-

nection to the redundant CAN bus.

SD <sensor designation> Sensor defect: The sensor with the designation <sensor designation> is

not sending an analyzable signal.

MD Missing Data: Data is missing from a measuring point.

AL Alarm: Alarm message

SS Safety System: The safety system has reacted in some way.

TD Transmitter Deviation: Two sensors that record the measured values for

the same medium are sending different measured values.

HI High: The first limit value has been exceeded.

HIHI High High: The second limit value has been exceeded.

LO Low: The first limit value has not been attained.

LOLO Low Low: The second limit value has not been attained.

MG Message: General message

SE System Error: Warning due to node failure on the default field bus.

PB Push Button: Status indication due to activation of certain control keys.

AKR Anti Knock Control GET

Important information about fault messages from the engine governor/engine
monitoring

Fault messages from the engine governor are represented in the fault code list (→ Page 111).

Information pertaining to alarm colors and automatic engine shutdown in the fault code list refer to the
(default) factory settings of the engine governor on delivery. Different system response may be possible
due to changes to the genset control system made by the OEM (see documentation of the genset man­ufacturer).

A prerequisite for performing the measures to rectify faults is corresponding qualification/training at
MTU.

Contact Service should troubleshooting as prescribed in the fault code list prove unsuccessful.

Recommended action in case of alarm

Yellow alarm:

The engine can still be operated providing that automatic engine shutdown to protect the engine has
not been configured or is not tripped. Contact Service immediately/start fault rectification.

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Red alarm:

Caution, the engine is running at its limits. Shut down manually without further delay if the engine does
not shut itself down immediately after a red alarm is signaled.

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5.2 Fault messages in log for genset controller

112222 – HI T-Exhaust Mean

Yellow alarm. Initiated by EMU.

Cause Corrective action

Weighted average of all
individual exhaust gas
temperatures is too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112223 – HIHI T-Exhaust Mean

Red alarm. Initiated by EMU.

Cause Corrective action

Weighted average of all
individual exhaust gas
temperatures is too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112301 – HI T-Exhaust A1

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112302 – HI T-Exhaust A2

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112303 – HI T-Exhaust A3

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112304 – HI T-Exhaust A4

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112305 – HI T-Exhaust A5

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112306 – HI T-Exhaust A6

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112307 – HI T-Exhaust A7

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112308 – HI T-Exhaust A8

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112309 – HI T-Exhaust A9

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112310 – HI T-Exhaust A10

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112311 – HI T-Exhaust B1

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112312 – HI T-Exhaust B2

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112313 – HI T-Exhaust B3

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112314 – HI T-Exhaust B4

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112315 – HI T-Exhaust B5

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112316 – HI T-Exhaust B6

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112317 – HI T-Exhaust B7

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112318 – HI T-Exhaust B8

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112319 – HI T-Exhaust B9

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112320 – HI T-Exhaust B10

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112401 – LO T-Exhaust A1

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112402 – LO T-Exhaust A2

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112403 – LO T-Exhaust A3

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112404 – LO T-Exhaust A4

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112405 – LO T-Exhaust A5

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112406 – LO T-Exhaust A6

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112407 – LO T-Exhaust A7

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112408 – LO T-Exhaust A8

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112409 – LO T-Exhaust A9

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112410 – LO T-Exhaust A10

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112411 – LO T-Exhaust B1

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112412 – LO T-Exhaust B2

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112413 – LO T-Exhaust B3

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112414 – LO T-Exhaust B4

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112415 – LO T-Exhaust B5

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112416 – LO T-Exhaust B6

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112417 – LO T-Exhaust B7

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112418 – LO T-Exhaust B8

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112419 – LO T-Exhaust B9

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112420 – LO T-Exhaust B10

Yellow alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112501 – HIHI T-Exhaust A1

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162)

3. Check valve gear (exhaust valves do not close).

112502 – HIHI T-Exhaust A2

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112503 – HIHI T-Exhaust A3

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112504 – HIHI T-Exhaust A4

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112505 – HIHI T-Exhaust A5

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112506 – HIHI T-Exhaust A6

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112507 – HIHI T-Exhaust A7

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112508 – HIHI T-Exhaust A8

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112509 – HIHI T-Exhaust A9

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112510 – HIHI T-Exhaust A10

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112511 – HIHI T-Exhaust B1

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112512 – HIHI T-Exhaust B2

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112513 – HIHI T-Exhaust B3

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112514 – HIHI T-Exhaust B4

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112515 – HIHI T-Exhaust B5

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112516 – HIHI T-Exhaust B6

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112517 – HIHI T-Exhaust B7

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112518 – HIHI T-Exhaust B8

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112519 – HIHI T-Exhaust B9

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112520 – HIHI T-Exhaust B10

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high in comparison with
weighted average.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112601 – LOLO T-Exhaust A1

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112602 – LOLO T-Exhaust A2

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112603 – LOLO T-Exhaust A3

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112604 – LOLO T-Exhaust A4

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112605 – LOLO T-Exhaust A5

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112606 – LOLO T-Exhaust A6

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112607 – LOLO T-Exhaust A7

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112608 – LOLO T-Exhaust A8

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112609 – LOLO T-Exhaust A9

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112610 – LOLO T-Exhaust A10

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing.

4. Check valve gear (→ Page 162).

112611 – LOLO T-Exhaust B1

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112612 – LOLO T-Exhaust B2

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112613 – LOLO T-Exhaust B3

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112614 – LOLO T-Exhaust B4

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112615 – LOLO T-Exhaust B5

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112616 – LOLO T-Exhaust B6

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112617 – LOLO T-Exhaust B7

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112618 – LOLO T-Exhaust B8

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

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112619 – LOLO T-Exhaust B9

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112620 – LOLO T-Exhaust B10

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too low in comparison with
weighted average.

1. Check spark plug.

2. Check emission values.

3. Check ignition timing (→ Page 162).

4. Check valve gear.

112701 – HIHI T-Exhaust A1 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112702 – HIHI T-Exhaust A2 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112703 – HIHI T-Exhaust A3 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing(→ Page 162).

3. Check valve gear (exhaust valves do not close).

112704 – HIHI T-Exhaust A4 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112705 – HIHI T-Exhaust A5 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112706 – HIHI T-Exhaust A6 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112707 – HIHI T-Exhaust A7 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112708 – HIHI T-Exhaust A8 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112709 – HIHI T-Exhaust A9 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112710 – HIHI T-Exhaust A10 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112711 – HIHI T-Exhaust B1 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112712 – HIHI T-Exhaust B2 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112713 – HIHI T-Exhaust B3 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112714 – HIHI T-Exhaust B4 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112715 – HIHI T-Exhaust B5 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112716 – HIHI T-Exhaust B6 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

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112717 – HIHI T-Exhaust B7 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112718 – HIHI T-Exhaust B8 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112719 – HIHI T-Exhaust B9 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112720 – HIHI T-Exhaust B10 (abs)

Red alarm. Initiated by EMU.

Cause Corrective action

Individual exhaust gas
temperature of this cylinder is
too high.

1. Check emission values.

2. Check ignition timing (→ Page 162).

3. Check valve gear (exhaust valves do not close).

112923 – MD/SD T-Exhaust

Red alarm. Initiated by EMU.

Cause Corrective action

Combined alarm (for details,
refer to the source alarm).

u Combined alarm (for details, refer to the source alarm).

113200 – Communication Lost ECU

Red alarm. Initiated by EMU.

Cause Corrective action

No communication with ECU
CAN.

1. Check supply voltage.

2. Check connecting line.

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113601 – AL Gas Valve 1 feedback

Red alarm. Initiated by EMU.

Cause Corrective action

Feedback signal from valve 1
does not correspond with
setpoint signal.

u Check valve 1 and cabling.

113902 – SS Local Initiated Emerg. Stop

Red alarm. Initiated by EMU.

Cause Corrective action

Emergency stop detected.
Emergency stop was released
manually (button), or ignition
system reported overspeed.

1. Enable emergency stop.

2. Check governor.

3. Check throttle closing position.

1.4510.186 – Error Status

Red alarm. Initiated by antiknock control.

Cause Corrective action

Transmission combined alarm.
At least one further transmission
alarm is present.

u Rectify cause of alarm.

1.4510.187 – Combined Error

Red alarm. Initiated by antiknock control.

Cause Corrective action

Combined alarm (for details,
refer to the source alarm).

u Combined alarm (for details, refer to the source alarm)

1.4510.188 – Internal Error

Red alarm. Initiated by antiknock control.

Cause Corrective action

Hardware not ready for
operation.

u Restart knock module.

1.4510.189 – Error Camshaft

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from camshaft sensor
for antiknock control.

u Check cabling. Check sensor B 1.3, replace if required.

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1.4510.192 – Knock Sensor Error A1

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.193 – Knock Sensor Error A2

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.194 – Knock Sensor Error A3

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.195 – Knock Sensor Error A4

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.196 – Knock Sensor Error A5

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.197 – Knock Sensor Error A6

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

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1.4510.198 – Knock Sensor Error A7

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.199 – Knock Sensor Error A8

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.200 – Knock Sensor Error A9

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.201 – Knock Sensor Error A10

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.202 – Knock Sensor Error B1

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.203 – Knock Sensor Error B2

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

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1.4510.204 – Knock Sensor Error B3

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.205 – Knock Sensor Error B4

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.206 – Knock Sensor Error B5

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.207 – Knock Sensor Error B6

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.208 – Knock Sensor Error B7

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.209 – Knock Sensor Error B8

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

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1.4510.210 – Knock Sensor Error B9

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4510.211 – Knock Sensor Error B10

Red alarm. Initiated by antiknock control.

Cause Corrective action

No signal from this knock
sensor.

1. Check cabling.

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

1.4520.508 – MIC5 Stat Operational error

Red alarm. Initiated by MIC5.

Cause Corrective action

An operational error has
occurred.

u Rectify cause of alarm.

1.4520.509 – MIC5 Stat System error

Red alarm. Initiated by MIC5.

Cause Corrective action

A system error has occurred. u Rectify cause of alarm.

1.4520.520 – MIC5 Stat W: temperat. limit reached

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The device temperature is too
high.

u Ensure sufficient ventilation in the genset room.

1.4520.521 – MIC5 Stat W: pow output lim reached

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The power output is too high. u Check settings in data record, ignition coils and spark plugs.

1.4520.522 – MIC5 Stat W: invalid coil data

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The ignition system settings are
invalid.

u Check settings. Restart ignition control unit.

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1.4520.523 – MIC5 Stat W: invalid configuration

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The ignition system settings are
invalid.

u Check settings. Restart ignition control unit.

1.4520.524 – MIC5 Stat W: invalid trigger config

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The ignition system settings are
invalid.

u Check settings. Restart ignition control unit.

1.4520.525 – MIC5 Stat W: conf data checksum err

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The ignition system settings are
invalid.

u Check settings. Restart ignition control unit.

1.4520.526 – MIC5 Stat Analogue current sig fail

Red alarm. Initiated by MIC5.

Cause Corrective action

Failure of current signal for
adjusting the ignition timing.

u Check settings.

1.4520.527 – MIC5 Stat Analogue voltage sig fail

Red alarm. Initiated by MIC5.

Cause Corrective action

Failure of voltage signal for
adjusting the ignition timing.

u Check settings.

1.4520.528 – MIC5 Stat Aux inp supply volt. fail

Red alarm. Initiated by MIC5.

Cause Corrective action

Analog input auxiliary supply
voltage failure.

u Check settings.

1.4520.529 – MIC5 Stat Trigger supply volt. fail

Red alarm. Initiated by MIC5.

Cause Corrective action

Trigger auxiliary supply voltage
failure.

1. Check wiring to sensor B1.2.

2. Check settings.

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1.4520.530 – MIC5 Stat Global timing limited

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The global timing is outside of
the valid range.

u Check settings.

1.4520.540 – MIC5 E1 General fault

Red alarm. Initiated by MIC5.

Cause Corrective action

A general fault occurred. 1. Check settings.

2. Check cabling.

3. Restart ignition control unit.

1.4520.541 – MIC5 E1 Overspeed

Red alarm. Initiated by MIC5.

Cause Corrective action

The overspeed limit was
reached.

u Check settings. Restart ignition control unit.

1.4520.542 – MIC5 E1 Speed sig during selftest

Red alarm. Initiated by MIC5.

Cause Corrective action

Pickup signals were detected
during self-test.

u Restart ignition control unit.

1.4520.543 – MIC5 E1 Shutdown due to alarm

Red alarm. Initiated by MIC5.

Cause Corrective action

Shutdown due to alarm. u Rectify cause of alarm.

1.4520.544 – MIC5 E1 Id of output board failed

Red alarm. Initiated by MIC5.

Cause Corrective action

The output board characteristics
were unreadable or are
incorrect.

u Restart ignition control unit.

1.4520.545 – MIC5 E1 Fail hi-voltage pow supply

Red alarm. Initiated by MIC5.

Cause Corrective action

The high-voltage power supply is
defective.

u Restart ignition control unit.

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1.4520.546 – MIC5 E1 Failure temperature sensor

Red alarm. Initiated by MIC5.

Cause Corrective action

The temperature sensor is
defective.

u Restart ignition control unit.

1.4520.547 – MIC5 E1 Failure current sensor

Red alarm. Initiated by MIC5.

Cause Corrective action

The current sensor is defective. u Restart ignition control unit.

1.4520.548 – MIC5 E1 Temperature limit reached

Red alarm. Initiated by MIC5.

Cause Corrective action

The device temperature has
exceeded the permissible value.

u Ensure sufficient ventilation in the genset room. Restart ignition

control unit.

1.4520.549 – MIC5 E1 Power output limit reached

Red alarm. Initiated by MIC5.

Cause Corrective action

The power output has exceeded
the permissible value.

u Check settings in data record, ignition coils and spark plugs.

Restart ignition control unit.

1.4520.550 – MIC5 E1 Tr1 synchronization fault

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Synchronization not possible on
signal from trigger 1 (B1.2).

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.551 – MIC5 E1 Tr1 operational error

Red alarm. Initiated by MIC5.

Cause Corrective action

Trigger 1 (B1.2) has triggered
operational error.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.552 – MIC5 E1 Tr1 no signal detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

No signal from trigger 1 (B1.2). u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

80 | Troubleshooting | MS15027/02E 2015-04

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1.4520.553 – MIC5 E1 Tr1 polarity detection fail

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Polarity of trigger 1 (B1.2) could
not be detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.554 – MIC5 E1 Tr1 wrong polarity

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Trigger 1 (B1.2) has wrong
polarity.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.555 – MIC5 E1 Tr1 no index mark detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Index mark of trigger 1 (B1.2)
was not detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.556 – MIC5 E1 Tr1 wrong n of trigg events

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The number of trigger 1 (B1.2)
events is not correct.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.557 – MIC5 E1 Tr1 signal missing

Yellow alarm. Initiated by MIC5.

Cause Corrective action

An expected signal from trigger
1 (B1.2) was missing

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.558 – MIC5 E1 Tr1 signal faulty

Yellow alarm. Initiated by MIC5.

Cause Corrective action

An unexpected signal from
trigger 1 (B1.2) was detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.559 – MIC5 E1 Tr1 index mark not detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 1
(B1.2) was not detected during
operation.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

MS15027/02E 2015-04 | Troubleshooting | 81

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1.4520.560 – MIC5 E1 Tr1 index too early / faulty

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 1
(B1.2) was detected too early or
was faulty.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.561 – MIC5 E1 Tr1 index too late / missing

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 1
(B1.2) was detected too late or
was missing.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.570 – MIC5 IPE Primary Open Cylinder 1

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 1 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.571 – MIC5 IPE Primary Open Cylinder 2

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 2 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.572 – MIC5 IPE Primary Open Cylinder 3

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 3 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.573 – MIC5 IPE Primary Open Cylinder 4

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 4 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.574 – MIC5 IPE Primary Open Cylinder 5

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 5 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

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1.4520.575 – MIC5 IPE Primary Open Cylinder 6

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 6 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.576 – MIC5 IPE Primary Open Cylinder 7

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 7 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.577 – MIC5 IPE Primary Open Cylinder 8

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 8 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.578 – MIC5 IPE Primary Open Cylinder 9

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 9 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.579 – MIC5 IPE Primary Open Cylinder 10

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 10 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.580 – MIC5 IPE Primary Open Cylinder 11

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 11 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.581 – MIC5 IPE Primary Open Cylinder 12

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 12 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

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1.4520.582 – MIC5 IPE Primary Open Cylinder 13

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 13 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.583 – MIC5 IPE Primary Open Cylinder 14

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 14 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.584 – MIC5 IPE Primary Open Cylinder 15

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 15 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.585 – MIC5 IPE Primary Open Cylinder 16

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 16 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.586 – MIC5 IPE Primary Open Cylinder 17

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 17 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.587 – MIC5 IPE Primary Open Cylinder 18

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 18 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.588 – MIC5 IPE Primary Open Cylinder 19

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 19 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

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1.4520.589 – MIC5 IPE Primary Open Cylinder 20

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in primary circuit of
cylinder 20 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.590 – MIC5 IPE Prim Short Circuit Cyl 1

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 1 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.591 – MIC5 IPE Prim Short Circuit Cyl 2

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 2 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.592 – MIC5 IPE Prim Short Circuit Cyl 3

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 3 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.593 – MIC5 IPE Prim Short Circuit Cyl 4

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 4 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.594 – MIC5 IPE Prim Short Circuit Cyl 5

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 5 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.595 – MIC5 IPE Prim Short Circuit Cyl 6

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 6 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

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1.4520.596 – MIC5 IPE Prim Short Circuit Cyl 7

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 7 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.597 – MIC5 IPE Prim Short Circuit Cyl 8

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 8 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.598 – MIC5 IPE Prim Short Circuit Cyl 9

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 9 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.599 – MIC5 IPE Prim Short Circuit Cyl 10

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 10 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.600 – MIC5 IPE Prim Short Circuit Cyl 11

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 11 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.601 – MIC5 IPE Prim Short Circuit Cyl 12

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 12 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.602 – MIC5 IPE Prim Short Circuit Cyl 13

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 13 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

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1.4520.603 – MIC5 IPE Prim Short Circuit Cyl 14

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 14 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.604 – MIC5 IPE Prim Short Circuit Cyl 15

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 15 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.605 – MIC5 IPE Prim Short Circuit Cyl 16

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 16 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.606 – MIC5 IPE Prim Short Circuit Cyl 17

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 17 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.607 – MIC5 IPE Prim Short Circuit Cyl 18

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 18 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.608 – MIC5 IPE Prim Short Circuit Cyl 19

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 19 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

1.4520.609 – MIC5 IPE Prim Short Circuit Cyl 20

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in primary circuit of
cylinder 20 in firing order.

1. Check cabling to ignition coil.

2. Check ignition coil.

MS15027/02E 2015-04 | Troubleshooting | 87

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1.4520.610 – MIC5 ISE Secondary Open Cylinder 1

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 1 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.611 – MIC5 ISE Secondary Open Cylinder 2

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 2 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.612 – MIC5 ISE Secondary Open Cylinder 3

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 3 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.613 – MIC5 ISE Secondary Open Cylinder 4

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 4 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.614 – MIC5 ISE Secondary Open Cylinder 5

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 5 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.615 – MIC5 ISE Secondary Open Cylinder 6

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 6 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.616 – MIC5 ISE Secondary Open Cylinder 7

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 7 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

88 | Troubleshooting | MS15027/02E 2015-04

TIM-ID: 0000044566 - 002

1.4520.617 – MIC5 ISE Secondary Open Cylinder 8

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 8 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.618 – MIC5 ISE Secondary Open Cylinder 9

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 9 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.619 – MIC5 ISE Secondary Open Cylinder 10

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 10 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.620 – MIC5 ISE Secondary Open Cylinder 11

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 11 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.621 – MIC5 ISE Secondary Open Cylinder 12

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 12 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.622 – MIC5 ISE Secondary Open Cylinder 13

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 13 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.623 – MIC5 ISE Secondary Open Cylinder 14

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 14 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

MS15027/02E 2015-04 | Troubleshooting | 89

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1.4520.624 – MIC5 ISE Secondary Open Cylinder 15

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 15 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.625 – MIC5 ISE Secondary Open Cylinder 16

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 16 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.626 – MIC5 ISE Secondary Open Cylinder 17

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 17 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.627 – MIC5 ISE Secondary Open Cylinder 18

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 18 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.628 – MIC5 ISE Secondary Open Cylinder 19

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 19 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.629 – MIC5 ISE Secondary Open Cylinder 20

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Disruption in secondary circuit
of cylinder 20 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.630 – MIC5 ISE Secon Short Circuit Cyl 1

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 1 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

90 | Troubleshooting | MS15027/02E 2015-04

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1.4520.631 – MIC5 ISE Secon Short Circuit Cyl 2

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 2 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.632 – MIC5 ISE Secon Short Circuit Cyl 3

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 3 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.633 – MIC5 ISE Secon Short Circuit Cyl 4

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 4 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.634 – MIC5 ISE Secon Short Circuit Cyl 5

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 5 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.635 – MIC5 ISE Secon Short Circuit Cyl 6

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 6 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.636 – MIC5 ISE Secon Short Circuit Cyl 7

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 7 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.637 – MIC5 ISE Secon Short Circuit Cyl 8

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 8 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

MS15027/02E 2015-04 | Troubleshooting | 91

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1.4520.638 – MIC5 ISE Secon Short Circuit Cyl 9

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 9 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.639 – MIC5 ISE Secon Short Circuit Cyl 10

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 10 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.640 – MIC5 ISE Secon Short Circuit Cyl 11

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 11 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.641 – MIC5 ISE Secon Short Circuit Cyl 12

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 12 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.642 – MIC5 ISE Secon Short Circuit Cyl 13

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 13 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.643 – MIC5 ISE Secon Short Circuit Cyl 14

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 14 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.644 – MIC5 ISE Secon Short Circuit Cyl 15

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 15 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

92 | Troubleshooting | MS15027/02E 2015-04

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1.4520.645 – MIC5 ISE Secon Short Circuit Cyl 16

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 16 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.646 – MIC5 ISE Secon Short Circuit Cyl 17

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 17 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.647 – MIC5 ISE Secon Short Circuit Cyl 18

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 18 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.648 – MIC5 ISE Secon Short Circuit Cyl 19

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 19 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.649 – MIC5 ISE Secon Short Circuit Cyl 20

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Short circuit in secondary circuit
of cylinder 20 in firing order.

1. Check ignition line, spark plug connector and spark plug.

2. Check ignition coil.

1.4520.658 – MIC5 E2 Tr2 synchronization fault

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Synchronization not possible on
signal from trigger 2 (B75).

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.659 – MIC5 E2 Tr2 operational error

Red alarm. Initiated by MIC5.

Cause Corrective action

Trigger 2 (B75) has triggered
operational error.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

MS15027/02E 2015-04 | Troubleshooting | 93

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1.4520.660 – MIC5 E2 Tr2 no signal detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

No signal from trigger 2 (B75). u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.661 – MIC5 E2 Tr2 polarity detection fail

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Polarity of trigger 2 (B75) could
not be detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.662 – MIC5 E2 Tr2 wrong polarity

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Trigger 2 (B75) has wrong
polarity.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.663 – MIC5 E2 Tr2 no index mark detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Index mark of trigger 2 (B75)
was not detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.664 – MIC5 E2 Tr2 wrong n of trigg events

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The number of trigger 2 (B75)
events is not correct.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.665 – MIC5 E2 Tr2 signal missing

Yellow alarm. Initiated by MIC5.

Cause Corrective action

An expected signal from trigger
2 (B75) was missing

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.666 – MIC5 E2 Tr2 signal faulty

Yellow alarm. Initiated by MIC5.

Cause Corrective action

An unexpected signal from
trigger 2 (B75) was detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

94 | Troubleshooting | MS15027/02E 2015-04

TIM-ID: 0000044566 - 002

1.4520.667 – MIC5 E2 Tr2 index mark not detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 2
(B75) was not detected during
operation.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.668 – MIC5 E2 Tr2 index too early / faulty

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 2
(B75) was detected too early or
was faulty.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.669 – MIC5 E2 Tr2 index too late / missing

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 2
(B75) was detected too late or
was missing.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.670 – MIC5 E2 Tr3 synchronization fault

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Synchronization not possible on
signal from trigger 3 (B13.2).

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.671 – MIC5 E2 Tr3 operational error

Red alarm. Initiated by MIC5.

Cause Corrective action

Trigger 3 (B13.2) has triggered
operational error.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.672 – MIC5 E2 Tr3 no signal detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

No signal from trigger 3 (B13.2). u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

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1.4520.673 – MIC5 E2 Tr3 polarity detection fail

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Polarity of trigger 3 (B13.2)
could not be detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.674 – MIC5 E2 Tr3 wrong polarity

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Trigger 3 (B13.2) has wrong
polarity.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.675 – MIC5 E2 Tr3 no index mark detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

Index mark of trigger 3 (B13.2)
was not detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.676 – MIC5 E2 Tr3 wrong n of trigg events

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The number of trigger 3 (B13.2)
events is not correct.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.677 – MIC5 E2 Tr3 signal missing

Yellow alarm. Initiated by MIC5.

Cause Corrective action

An expected signal from trigger
3 (B13.2) was missing

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.678 – MIC5 E2 Tr3 signal faulty

Yellow alarm. Initiated by MIC5.

Cause Corrective action

An unexpected signal from
trigger 3 (B13.2) was detected.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.679 – MIC5 E2 Tr3 index mark not detected

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 3
(B13.2) was not detected during
operation.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

96 | Troubleshooting | MS15027/02E 2015-04

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1.4520.680 – MIC5 E2 Tr3 index too early / faulty

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 3
(B13.2) was detected too early
or was faulty.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4520.681 – MIC5 E2 Tr3 index too late / missing

Yellow alarm. Initiated by MIC5.

Cause Corrective action

The index mark of trigger 3
(B13.2) was detected too late or
was missing.

u Check sensor, sensor clearance, cabling, settings in data record

and timing wheel. Replace sensor if required.

1.4530.007 – Shutdown

Red alarm. Initiated by F-Series.

Cause Corrective action

Hardware not ready for
operation.

u Restart F-Series.

1.4530.008 – Alarm

Yellow alarm. Initiated by F-Series.

Cause Corrective action

Combined alarm (for details,
refer to the source alarm).

u Combined alarm (for details, refer to the source alarm)

1.4530.009 – Derating Active

Yellow alarm. Initiated by F-Series.

Cause Corrective action

Combined alarm (for details,
refer to the source alarm).

u Combined alarm (for details, refer to the source alarm)

1.4530.010 – PWM Input High Duty Cycle Error

Yellow alarm. Initiated by F-Series.

Cause Corrective action

F-Series setting is not correct. u Check setting.

1.4530.011 – PWM Input Low Duty Cycle Error

Yellow alarm. Initiated by F-Series.

Cause Corrective action

F-Series setting is not correct. u Check setting.

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1.4530.012 – Analog Input High Error

Yellow alarm. Initiated by F-Series.

Cause Corrective action

F-Series setting is not correct. u Check setting.

1.4530.013 – Analog Input Low Error

Yellow alarm. Initiated by F-Series.

Cause Corrective action

F-Series setting is not correct. u Check setting.

1.4530.014 – Input Supply Voltage High Error

Yellow alarm. Initiated by F-Series.

Cause Corrective action

Supply voltage has reached
maximum limit value.

1. Check supply voltage.

2. Check cabling.

1.4530.015 – Input Supply Voltage Low Error

Yellow alarm. Initiated by F-Series.

Cause Corrective action

Supply voltage has reached
minimum limit value.

1. Check supply voltage.

2. Check cabling.

1.4530.016 – Electronics Temperature High Error

Red alarm. Initiated by F-Series.

Cause Corrective action

Hardware not ready for
operation.

u Restart F-Series.

1.4530.017 – Electronics Temperature Low Error

Red alarm. Initiated by F-Series.

Cause Corrective action

Hardware not ready for
operation.

u Restart F-Series.

1.4530.018 – Position Error

Red alarm. Initiated by F-Series.

Cause Corrective action

Position demand and feedback
do not match

1. Check mechanical system.

2. Restart F-Series.

98 | Troubleshooting | MS15027/02E 2015-04

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1.4530.019 – Run Enable not active

Yellow alarm. Initiated by F-Series.

Cause Corrective action

F-Series setting is not correct. u Check setting.

1.4530.020 – Spring Check Failed

Yellow alarm. Initiated by F-Series.

Cause Corrective action

F-Series setting is not correct. u Check setting.

1.4530.021 – Internal Fault

Yellow alarm. Initiated by F-Series.

Cause Corrective action

Hardware not ready for
operation.

u Restart F-Series.

1.4530.022 – CAN Fault

Red alarm. Initiated by F-Series.

Cause Corrective action

CAN bus connection faulty. u Check cabling and setting.

1.4540.009 – Zero Pressure Detected

Yellow alarm. Initiated by TecJet.

Cause Corrective action

No gas pressure/gas flow
detected.

u Check gas pressure.

1.4540.010 – Zero Flow Detected

Yellow alarm. Initiated by TecJet.

Cause Corrective action

No gas pressure/gas flow
detected.

u Check gas pressure.

1.4540.011 – Flow Not Reached

Red alarm. Initiated by TecJet.

Cause Corrective action

No gas flow detected. 1. Check inlet and outlet.

2. Check gas pressure, gas quality, gas filter, gas line for
obstruction.

3. Check engine for overloading.

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1.4540.012 – Valve Position Error

Red alarm. Initiated by TecJet.

Cause Corrective action

Hardware not ready for
operation.

u Restart TecJet.

1.4540.013 – High Elec Temp

Red alarm. Initiated by TecJet.

Cause Corrective action

Hardware not ready for
operation.

u Restart TecJet.

1.4540.014 – Elec Temp Fail High

Red alarm. Initiated by TecJet.

Cause Corrective action

Hardware not ready for
operation.

u Restart TecJet.

1.4540.015 – FGT Fail High

Red alarm. Initiated by TecJet.

Cause Corrective action

Hardware not ready for
operation.

u Restart TecJet.

1.4540.016 – Delta P Fail High

Red alarm. Initiated by TecJet.

Cause Corrective action

Differential pressure at TecJet
too high.

1. Check gas pressure.

2. Check TecJet for dirt.

1.4540.017 – FGP Fail High

Red alarm. Initiated by TecJet.

Cause Corrective action

Hardware not ready for
operation.

u Restart TecJet.

1.4540.018 – Coil Current Fail High

Red alarm. Initiated by TecJet.

Cause Corrective action

Hardware not ready for
operation.

u Restart TecJet.

100 | Troubleshooting | MS15027/02E 2015-04

TIM-ID: 0000044566 - 002