M015635_00E

Technical Publication

Gas Engine 12 V 4000 L61 16 V 4000 L61 Operating Instructions M015635/00E

Printed in Germany 2004 Copyright MTU Friedrichshafen GmbH Diese Verffentlichung einschlielich aller ihrer Teile ist urheberrechtlich geschtzt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere fr Vervielfltigung, Verbreitung, Bearbeitung, bersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschlielich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Strungen oder Schden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfgung zu stellen. nderungen bleiben vorbehalten.

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Imprim en Allemagne 2004 Copyright MTU Friedrichshafen GmbH Tout droit rserv pour cet ouvrage dans son intgralit. Toute utilisation ou exploitation requiert au pralable laccord crit de MTU Friedrichshafen GmbH. Ceci sapplique notamment la reproduction, la diffusion, la modification, la traduction, larchivage sur microfiches, la mmorisation et / ou le traitement sur des systmes lectroniques, y compris les bases de donnes et les services en ligne. Le manuel devra tre observ en vue dviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous lexploitant de le mettre la disposition du personnel charg de lentretien et de la conduite. Modifications rserves.

Impreso en Alemania 2004 Copyright MTU Friedrichshafen GmbH Esta publicacin se encuentra protegida, en toda su extensin, por los derechos de autor. Cualquier utilizacin de la misma, as como su reproduccin, difusin, transformacin, traduccin, microfilmacin, grabacin y/o procesamiento en sistemas electrnicos, entre los que se incluyen bancos de datos y servicios en lnea, precisa de la autorizacin previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daos durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposicin del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania 2004 Copyright MTU Friedrichshafen GmbH Questa pubblicazione protetta dal diritto dautore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, allarchiviazione in microfilm e alla memorizzazione o allelaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH. II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dallutente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche.

Impresso na Alemanha 2004 Copyright MTU Friedrichshafen GmbH A presente publicao, inclusive todas as suas partes, est protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorizao prvia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular reproduo, divulgao, tratamento, traduo, microfilmagem, e a memorizao e/ou processamento em sistemas eletrnicos, inclusive bancos de dados e servios on-line. Para evitar falhas ou danos durante a operao, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve coloc-lo disposio do respetivo pessoal da conservao, e disposito dos operadores. Salvo alteraes.

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Safety

Safety, accident prevention and environmental protection instructions

Product Summary

Engine layout, technical data

Operation

Task descriptions

Maintenance and Servicing

Maintenance schedule

Troubleshooting

Malfunctions, causes, measures

Task Description

Inspection and maintenance tasks

Annex

Abbreviations

Index

Wichtig Important Importante

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Die Informationen der Inbetriebnahmemeldung sind Grundlage fr den vertraglich vereinbarten Logistik- Support (Gewhrleistung, Ersatzteile etc.).

Please complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH.

The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.).

Veuillez sparer la carte Signalisation de mise en service et la renvoyer la MTU Friedrichshafen GmbH.

Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en exploitation contractuelle (garantie, rechanges, etc.).

Rogamos separen la tarjeta Aviso de puesta en servicio y la devuelvan rellenada a MTU Friedrichshafen GmbH.

Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logstico contractual (garanta, piezas de repuesto, etc.).

Ritagliare Avviso di messa in servizio e rispedirlo debitamente compilato alla MTU Friedrichshafen GmbH.

Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).

gentileza cortar o carto "Participao da colocao em servio", preench-lo e devolv-lo a MTU Friedrichshafen.

Os dados referentes colocao em servio representam a base para o suporte logstico (garantia, peas sobressalentes, etc.) estabelecido contratualmente.

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MTU Friedrichshafen GmbH

Department SCSD

88040 Friedrichshafen

GERMANY

Inbetriebnahmemeldung Commissioning Note Notice de mise en service Aviso de puesta en servicio Avviso di messa in servizio Participao da colocao em servio

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Bemerkung: Remarks: Remarques: Observaciones: Commento: Observaes:

Motornr.: Engine No.: No du moteur: No de motor: Motore N.: No. do motor:

Motortyp: Engine model: Type du moteur: Tipo de motor: Motore tipo: Tipo do motor:

Eingebaut in: Installation site: Lieu de montage: Lugar de montaje: Installato: Incorporado em:

Auftragsnr.:MTU works order No.: N de commande: N de pedido: N. commessa: No. do pedido:

Inbetriebnahmedatum:Date put into operation: Mise en service le: Fecha de puesta en servicio: Messa in servizio il: Data da colocao em servio:

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GERMANY

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Table of Contents 1 I

1 Safety1.1 General conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 01

1.2 Personnel and organizational requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 02

1.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 03

1.4 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 04

1.5 Auxiliary materials, fire prevention and environmental protection . . . . . . . . . . . . . . . . 1 07

1.6 Standards for warning notices in the publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 09

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1 II Table of Contents

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Safety 1 01

1.1 General conditionsGeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other compulsoryregulations regarding accident prevention must be observed. This engine is a state-of-the art product and conformswith all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:

Incorrect use Operation, maintenance and repair by unqualified personnel Modifications or conversions Non-compliance with the Safety Instructions

Correct useThe engine is intended exclusively for the application specified in the contract or defined at the timeof delivery. Any other use is considered improper use. The manufacturer will accept no liability forany resultant damage. The responsibility is borne by the user alone.Correct use also includes observation of and compliance with the maintenance specifications.

Modifications or ConversionsModifications made by the customer to the engine may affect safety.MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.

Spare partsOnly genuine MTU spare parts must be used to replace components or assemblies. In theevent of any damage caused by the use of other spare parts, no liability nor warranty claimsvis--vis the engine manufacturer will be accepted.

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1 02 Safety

1.2 Personnel and organizational requirementsPersonnelWork on the engine must only be carried out by properly qualified and instructed personnel.The specified legal minimum age must be observed.Responsibilities of the operating, maintenance and repair personnel must be specified.

OrganizationThis publication must be issued to all personnel involved in operation, maintenance, repair or transportation.It must be kept at hand near the engine and accessible at any time to all personnel involvedin operation, maintenance, repair or transportation.The personnel must be instructed on engine operation and repair by means of this publication,and in particular the safety instructions must be explained.This is especially important for personnel who work on the engine only on an occasional basis.Such personnel must be given instructions repeatedly.

Working clothes and protective equipmentWear proper work clothing for all work.Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.Work clothing must be tight fitting so that it does not catch on rotating or projecting components.Do not wear jewelry (e.g. rings, chains etc.).

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Safety 1 03

1.3 TransportTransportLift the engine only with the lifting eyes provided.Use only the transport and lifting equipment approved by MTU.Take note of the engine center of gravity.The engine must only be transported in installation position, max. permissible diagonal pull 10.In the case of special packaging with aluminium foil, suspend the engine on the lifting eyes of thetransport pallet or transport with equipment for heavy loads (forklift truck).Prior to transporting the engine, it is imperative to install transport locking devices for crankshaft and engine mounts.Secure the engine against tilting during transportation. The engine must be especially securedagainst slipping or tilting when going up or down inclines and ramps.

Setting the engine down after transportPlace the engine only on an even, firm surface.Ensure appropriate consistency and load-bearing capacity of the ground or support surface.Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

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1.4 Safety precautions when working on the engineEngine operationWhen the engine is running, always wear ear protectors.Ensure that the engine room is well ventilated.Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable bonding agent.Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a healthhazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.Do not touch any battery terminals, generator terminals, cables or ignition system components (ignitioncoils, ignition cables, ignition cable connectors) during engine operation!Inadequate protection of electrical components can lead to electric shocks and serious injuries.When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.When the engine is running, beware of hot components. Risk of burns!When the engine is running, beware of rotating parts. Risk of injury!Maintenance and repairStrict adherence to the maintenance and repair schedule is an essential safety factor.Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical startersare fitted. Close the main valve on the compressed-air system and vent the compressed air line whenair starters are fitted. Shut off the gas supply to the engine. Activate the emergency stop at the engineinterface switchgear cabinet (MIS) or by turning the key switch, if fitted. Post the "Do Not Start" sign in theoperating room or affix it to the control device! Persons not involved must keep clear.Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special toolsrequired. Have maintenance and repair work carried out by qualified and authorized personnel only.All work on gas-carrying components must be carried out by authorized, specialized companies.Installation and connection of the gas supply must only be carried out by a specialized companywith staff that has been trained and authorized for this task.Use only proper, calibrated tools.Do not work on engines or components which are only held by lifting equipment or crane. Always support bysuitable means which conform with the applicable regulations before commencing maintenance or repair work.Before barring the engine, make sure that nobody is standing in the danger zone. After completingwork on the engine, check that all protective devices/safety guards have been installed and thatall tools and loose parts have been removed from the engine.Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Beforestarting work, relieve pressure in systems and H.P. lines which are to be opened.Never rework fuel lines or fuel system components and do not install lines or components that havebeen reworked or that have not been approved for the application in question. Keep fuel lines andconnections clean. Cap all removed or opened lines and check for leaks.During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections wheninstalling the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.Ensure that all fuel lines and pressurized oil lines have sufficient distance to other components to avoid contact withthem. Do not place fuel or oil lines near hot components, except when necessary for design reasons during installation.Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposeswhen exposed to fire or temperatures exceeding 300 C. Hydrogen fluoride vapors are released in thiscase. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric sealsif they have carbonized or resinous appearance. Wear protective gloves!Beware of hot fluids and gas in lines, pipes and chambers Risk of burns!Note cooling period for components which are heated for installation or removal Risk of injury!Never touch hot parts of the compressor and exhaust system Risk of burning!Take special care when removing ventilation or plug screws from engine. In order to avoid dischargeof highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if theengine has recently been shut down, as the liquids can still be hot.Take special care when draining hot fluids. Risk of injury!

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Safety 1 05

When draining, collect fluids in a suitable container, mop up any spilled fluids or wipe orsoak them with a suitable bonding agent.When changing engine oil or carrying out work on the fuel system, ensure sufficient ventilationof the machine room and shut off the main gas supply!When working high on the engine, always use suitable ladders and work platforms. Makesure components are placed on stable surfaces.In order to prevent back injuries when lifting heavy components adults, depending on age and sex,should only lift weights between max. 10 kg and 30 kg, therefore:

Use lifting gear or seek assistance. Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that

hooks are correctly positioned. Lifting eyes must not be unevenly loaded.

Welding workNever carry out welding work on the engine or engine-mounted units.Never use the engine as a ground connection. This prevents the welding current passing throughthe engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which maylead to bearing seizure and/or other material damage.Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwiseinduce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.The welding unit ground connection must not be more than 60 cm from the weld point.If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.It is not necessary to remove the connector and the connections when carrying out welding operationon MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wireis disconnected from the negative and positive poles on the battery.

Hydraulic installation and removalOnly the hydraulic installation and removal equipment specified in the work schedule andin the assembly instructions must be used.The max. permissible push-on pressure specified for the equipment must not be exceeded.The H.P. lines for hydraulic installation and removal are tested with 3800 bar.Do not attempt to bend or apply force to lines.Before starting work, pay attention to the following:

Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system tobe used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).

For hydraulic installation, screw on the tool with the piston retracted. For hydraulic removal, screw on the tool with the piston extended.

For a hydraulic installation/removal tool with central expansion pressure supply, screw spindleinto shaft end until correct sealing is achieved.During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of thecomponent to be installed/removed. As long as the system is under pressure, there is the risk that thecomponent to be installed/removed may be suddenly released from the pressure connection.Before use, the tools must be checked at regular intervals (crack test).Working on electrical/electronic assembliesAlways obtain the permission of the person in charge before commencing maintenance and repairwork or switching off any part of the electronic system required to do so.De-energize the appropriate areas prior to working on assemblies. Any measures requiring a powersupply are expressly defined as such at the appropriate place in the manual.Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow batteryacids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on thebattery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may leadto injury through the sudden discharge of acid or bursting of the battery body.Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it isnot damaged by contact with sharp objects, by rubbing against other component or by a hot surface.Do not secure wiring to fluid-carrying lines.On completion of the maintenance and repair work, any cables which have become loosemust be correctly connected and secured.

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1 06 Safety

On completion of all repair work, the component and system must be subjected to a function check.Separate testing of the repaired component without system integration is insufficient.If wires are installed beside mechanical components and there is a risk of chafing, usecable clamps to properly support the wires.For this purpose, no cable binders must be used as, during maintenance and / or repair work,the binders can be removed but not installed a second time.Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defectiveelectronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularlyprotected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipmentWhen working with laser equipment, always wear special laser-protection goggles.Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emissionin the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal andoptomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.Laser equipment must be fitted with the protective devices necessary for safeoperation according to type and application.For conducting light-beam procedures and measurement work, only the following laser devices must be used:

Laser devices of classes 1, 2 or 3A, Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a

maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

Operation of electrical equipmentWhen operating electrical equipment, certain components of this equipment are live.Noncompliance with the warning instructions given for this equipment may result inserious injury or damage to property.

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Safety 1 07

1.5 Auxiliary materials, fire prevention and environmentalprotection

Fire preventionRectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricantslying around on the engine. Do not store combustible materials near the engine.Do not carry out welding work on pipes and components carrying oil or fuel. Beforewelding, clean with a non-combustible fluid.When starting the engine with a foreign power source, connect the ground lead last and remove it first.To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power sourceto the ground lead of the engine or to the ground terminal of the starter.Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.NoiseNoise can lead to an increased risk of accident if acoustic signals, warning shouts orsounds indicating danger are drowned.At all workplaces with a sound pressure level over 85 dB (A), always wear ear protectors(protective wadding, plugs or capsules).Environmental protectionDispose of used fluids, lubricants, materials and filters in accordance with local regulations.Manipulation of the injection control system can influence the engine performance and exhaust emissions.As a result, compliance with environmental regulations may no longer be guaranteed.Only fuels of the specified quality required to achieve emission limits must be used (MTUFluids and Lubricants Specifications A001061/...).In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable,which means work must only be carried out by authorized specialist companies (MTU is such a company).Auxiliary materialsUse only fluids and lubricants that have been tested and approved by MTU.Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants andother chemical substances, follow the safety instructions applicable to the product. Take care when handling hot,chilled or caustic materials. When using flammable materials, avoid sparks and flames and do not smoke.

Natural gasNote 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 combustible gas:

Close off point of gas escape! Remove ignition sources! Close off danger zone. Ensure sufficient ventilation! Do not enter danger zone before measurements have confirmed that gas concentration is not hazardous.

Lead When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors. Adopt suitable measures to avoid the formation of lead dust! Switch on fume extraction system. After coming into contact with lead or lead-containing materials, wash hands!

Acids and alkaline solutions When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing. Immediately remove clothing wetted by acids and alkalis! Rinse injuries with plenty of water!

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1 08 Safety

Rinse eyes immediately with eyedrops or clean tap water.

Paints When painting anywhere other than in spray booths equipped with extractors, ensure good

ventilation. Make sure that adjacent work areas are not affected. No naked flames! No smoking. Observe fire prevention regulations! Wear masks providing protection against paint and solvent fumes.

Liquid oxygen Liquid oxygen is highly combustible. Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals)! Do not bring liquid oxygen in contact with the body (hands), as this causes frostbite and possibly the loss of tissue. No smoking, no naked flames, risk of explosion! Excessive oxygen in the air leads to explosive combustion. Do not store combustible substances, e.g. oils and greases, within 5 m of the working area! Under no circumstances should clothing be oily or greasy. Do not allow vapors to penetrate clothing! Oxygen enrichment in fabric can cause

working clothes to ignite suddenly! After working with liquid oxygen, do not smoke until clothing is free of vapors! Avoid all hard knocks and impacts when working with liquid oxygen.

Liquid nitrogen Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and the loss of tissue. Wear protective clothing, including gloves, closed shoes and protective goggles! Ensure that the room is well ventilated. Nitrogen concentration exceeding 88% of

breathing air leads to suffocation. Avoid all knocks and jars to the containers, fixtures or workpieces.

Compressed airCompressed air is air compressed at excess pressure and is stored in vessels from which it can be extracted.The pressure at which the air is kept can be read off at pressure gauges which must be connectedto the compressed air vessels and the compressed air lines.When working with compressed air, safety precautions must be constantly observed:

Pay special attention to the pressure level in the compressed air network and pressure vessel! Devices and equipment connected must either be designed for this pressure or, if the permitted

pressure for the connected elements is lower than the pressure required, a pressure reducingvalve and safety valve (set to permitted pressure) must form an intermediate connection. Hosecoupling and connections must be securely attached!

Always wear protective goggles when blowing off tools or chips! The snout of the air nozzle should be provided with a protective disc (e.g. rubber disc), which prevents

air-borne particles being deflected and thereby prevents injury to eyes. First shut off compressed air lines before compressed air equipment is disconnected from the

supply line or before equipment or tools are exchanged! Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII

and B) out of containers, carries the risk of explosion! Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)

for drying purposes or to check for leaks, results in a risk of shattering! Do not use compressed air to clean contaminated clothing whilst it is being worn. Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back,

the air can enter the anal cavity and fatally rupture the intestines!

Used oilUsed oil may contain health-threatening combustion residues.Rub barrier cream into hands!Wash hands after contact with used oil.

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Safety 1 09

1.6 Standards for warning notices in the publication

DANGER

In the event of immediate danger.Consequences: Death or serious injury.

Preventive measures

WARNING

In the event of possibly dangerous situations.Consequences: Death or serious injury.

Preventive measures

CAUTION

In the event of dangerous situations.Consequences: Slight injury or material damage.

Preventive measures

Note: This Publication contains especially emphasized safety instructions in accordance with the Americanstandard ANSI Z535, which begin with one of the above signal words according to the degree of danger:

Warning notices1. Read and become acquainted with all cautions and symbols before operating or repairing this product.2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

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1 10 Safety

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2 Product Summary2.1 Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 01

2.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 01

2.2 Engine Side and Cylinder Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 032.2.1 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 03

2.3 Main Engine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 042.3.1 Main engine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 04

2.4 Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 052.4.1 Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 05

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Engine Layout 2 01

2.1 Engine Layout

2.1.1 Engine layoutIllustration is also valid for 8V/16V 4000 L61

1 Blower/crankcase breather2 Exhaust outlet connection3 Gas dozing and mixing

unit (Tecjet)4 Gas inlet connection5 Intercooler6 Air filter / combustion air inlet7 Mixture coolant outlet to

cooler (LT circuit)

8 Mixture coolant inlet fromcooler (LT circuit)

9 Ignition coil10 Spark plug11 Cylinder head cover12 Starter13 Oil dipstick14 Cylinder head

15 Engine oil filter16 Oil level switch17 Coolant distribution housing18 Mixture coolant inlet from

cooler (HT circuit)19 Mixture coolant outlet to

cooler (HT circuit)20 Exhaust turbocharger

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2 02 Engine Layout

Engine model designationKey to the engine model designations 8/12/16V 4000 L61

8/12/16 Number of cylinders

V Cylinder configuration: V-engine

4000 Series

L Application: L = Gas engine

6 Application segment 50 Hz

1 Design index

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Engine Side and Cylinder Designations 2 03

2.2 Engine Side and Cylinder Designations

2.2.1 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.The numbering of engine components is also from the driving end, starting with No. 1.

1 KGS = Free end2 Right side

3 KS = Driving end4 Left side

M015635/00E 04-12 MTU

2 04 Main Engine Dimensions

2.3 Main Engine Dimensions

2.3.1 Main engine dimensions

Main engine dimensions

Length (A) approx. 2830 mmWidth (B) approx. 1550 mmHeight (C) approx. 2260 mmCrankshaft center to oil pan (D) approx. 636 mmCrankshaft center to engine mount (E) approx. 280 mm

M015635/00E 04-12 MTU

Firing Order 2 05

2.4 Firing Order

2.4.1 Firing order

Firing order

8 V A1-B4-A4-A2-B3-A3-B2-B1

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

M015635/00E 04-12 MTU

2 06 Firing Order

M015635/00E 04-12 MTU


3 Operation3.1 SIAM 4000 Operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 01

3.2 Putting the engine into operation after extended out-of-service periods (>3months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 03

3.3 Putting the engine into operation after scheduled out-of-service-period . . . . . . . . . . . 3 04

3.4 Starting the engine in manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 05

3.5 Starting the engine in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 06

3.6 Operational checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 07

3.7 Stopping the engine in manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 08

3.8 Stopping the engine in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 09

3.9 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 10

3.10 After stopping the engine Engine remains ready for operation . . . . . . . . . . . . . . . . . 3 11

3.11 After stopping the engine Putting the engine out of operation . . . . . . . . . . . . . . . . . . 3 12

M015635/00E 04-12 MTU


M015635/00E 04-12 MTU

Operation 3 01

3.1 SIAM 4000 Operating panel

SIAM 4000 Operating panel

LEDs Pushbuttons

1 "U1" Voltage L1 12 "Message" Route message

2 "U2" Voltage L2 12 "Select" Confirm selection

3 "U3" Voltage L3 13 "Display U" Switch display4 "Stop" "STOP" mode selected 13 "Digit" Increase digit5 -2.8 0 Hz +2.8

HzSynchronoscope 14 "Setpoint" Activate setpoint value

6 "Auto" "AUTOMATIC" mode selected 14 "Cursor" Move cursor one position tothe right

7 "Man." "MANUAL" mode selected 15 "Setpoint" Increase setpoint8 "Monitoring on" Monitoring function active 16 "Setpoint" Decrease setpoint9 "Error" Fault alarm present 17 "GCB ON" Close generator circuit

breaker manually

10 "GCB ON" Feedback GCB closed 18 "GCB OFF" Open generator circuitbreaker manually

11 "MCB ON" Feedback MCB closed 19 "MCB ON" Close mains circuit breakermanually

M015635/00E 04-12 MTU

3 02 Operation

20 "MCB OFF" Open mains circuit breakermanually

21 "AUTO" Activate AUTOMATIC mode

22 "MANUAL" Activate MANUAL mode

23 "START" Start genset manually

24 "STOP" Stop genset manually

26 "TEST" Activate TEST mode

LC Display 26 "STOP" Stop genset automatically

28 "LC Display" LC Display 27 "QUIT" Acknowledge fault alarms

M015635/00E 04-12 MTU

Operation 3 03

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

Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specification (A001061/..) is available.

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

Item Task

Engine Depreserve ( MTU Fluids and Lubricants Specifications A001061/.. ).Engine Bar engine manually ( Page 5 01).Valve Gear Lubricate valve gear ( Page 5 08).Lube oil system Check engine oil level ( Page 5 17), check oil level in oil storage tank

( Page 5 17).Coolant system If engine is out of service for more than one year, change engine coolant

( Page 5 23);change mixture coolant ( Page 5 27).

Coolant system Check engine coolant level ( Page 5 24);check mixture coolant level ( Page 5 28).

Coolant system Preheat coolant with preheating unit.

Engine wiring Check plug-in connections.

Gas supply Open gas shut-off valve.

Engine management system Check for fault messages.

Battery Check, top up with acid / alkaline solution ( Page 6 01).Engine/generator control system Select operating mode, e.g. HAND, MANUAL, AUTO, AUTOMATIC.

M015635/00E 04-12 MTU

3 04 Operation

3.3 Putting the engine into operation after scheduledout-of-service-period

Preconditions Engine is stopped and starting disabled.

Putting into operation

Item Task

Lube oil system Check engine oil level ( Page 5 17), check oil level in oil storage tank( Page 5 17).

Coolant system Check engine coolant level ( Page 5 24);check mixture coolant level ( Page 5 28).

Coolant system Preheat coolant with preheating unit.

Engine management system Check for fault messages.

Engine/generator control system Select operating mode, e.g. HAND, MANUAL, AUTO, AUTOMATIC

M015635/00E 04-12 MTU

Operation 3 05

3.4 Starting the engine in manual modePreconditions

Generator is not connected to network. Start interlock is not active.

DANGER

Unguarded rotating and moving engine components.Risk of serious injury danger to life!

Before barring or starting the engine, ensure that nobody is in the danger zone.

WARNING

Engine noise above 85 dB (A).Risk of damage to hearing!

Wear ear protectors.

Preparation

Item Task

Operating mode selector switch Set e.g. to manual operation, MANUAL.

Coolant preheating unit Preheat engine. System is usually autonomous and thermostat-controlled and preheated

automatically after applying supply voltage (fuse).

Starting the engine

Item Task

Switchgear cabinet, operatingpanel

1. Press MANUAL button. LED "Man." is lit.

2. Press START button until the engine is running.3. Synchronize after nominal speed has been reached, press GCB ON button.4. Increase power until desired value is reached. Increase power by pressingarrow-up button , reduce power by pressing arrow-down button .

M015635/00E 04-12 MTU

3 06 Operation

3.5 Starting the engine in automatic modePreconditions

Generator is not connected to network. Start interlock not active.

DANGER



WARNING



Preparation

Item Task

Operating mode selector switch Set e.g. to AUTO, automatic operation.

Coolant preheating unit Preheat engine. System is usually autonomous and thermostat-controlled and preheated

automatically after applying supply voltage (fuse).

Starting the engine

Item Task


Press AUTO button. LED "Auto" is lit; Automatic starting procedure is performed; Power is increased until setpoint value is reached.

M015635/00E 04-12 MTU

Operation 3 07

3.6 Operational checks

DANGER


Take special care when working on a running engine.

WARNING



Operational checks

Item Task

Machine room Check machine room for smell of gas ( Page 5 02).GECON, SIAM Check for fault messages and warnings;

In case of fault messages or warnings: Determine the cause, rectify the fault.Acknowledge fault message with the acknowledgement button.

Control and display panels Check indicated operating parameters (speed, temperatures, pressures) .Engine log Document operating parameters.

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

Engine under loadEngine at nominal speed

Check engine/plant and pipework for leaks, rectify any leaks with the enginestopped;Check for abnormal running noises and vibration.

M015635/00E 04-12 MTU

3 08 Operation

3.7 Stopping the engine in manual modePreconditions

Generator is not connected to network. Engine is running in manual mode.

CAUTION

Stopping the engine when it is running at full load causes extreme stress to the engine.Risk of overheating, damage to components!

Before stopping the engine, operate it at idle speed until operating temperatures decreaseand stable values are indicated.

Stopping the engine

Item Task


LED "Man." is lit.1. Press arrow-down button to decrease power to 0 kW.2. Open circuit breaker by pressing GCB OFF button.3. Press STOP button.

M015635/00E 04-12 MTU

Operation 3 09

3.8 Stopping the engine in automatic modePreconditions

Generator is not connected to network. Engine is running in automatic mode.

CAUTION

Stopping the engine when it is running at full load causes extreme stress to the engine.Risk of overheating, damage to components!

Before stopping the engine, operate it at idle speed until operating temperatures decreaseand stable values are indicated.

Stopping the engine

Item Task


Press STOP button or turn key switch for automatic start (if fitted) to 0.

M015635/00E 04-12 MTU

3 10 Operation

3.9 Emergency stop

CAUTION

An emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!

Initiate emergency stop only in emergency situations.

Emergency stop

Item Task

EMERGENCY STOP button Press. Engine is stopped

Safety measures

Item Task

Key switch Lock engine to prevent starting.

EMERGENCY STOP button Remove key.

Rectifying cause

Item Task

Engine Determine cause for emergency stop and take remedial action;if the fault cannot be corrected, contact Service.

Electronics/engine controlsystem

Determine cause for emergency stop and take remedial action;if the fault cannot be corrected, contact Service.

Prior to re-starting the engine

Item Task

Engine control system LED "Error" is lit.Acknowledge emergency stop message

EMERGENCY STOP button LED "Error" is dark and LED "Stop" is lit.Unlock.

Key switch Deactivate starting interlock.

M015635/00E 04-12 MTU

Operation 3 11

3.10 After stopping the engine Engine remainsready for operation

After stopping the engine

Item Task

Engine/generator control system Engine is in stop mode; LED "Stop" is lit.

Re-start by pressing the corresponding operating mode button, e.g. HAND,MANUAL, AUTO, AUTOMATIC

M015635/00E 04-12 MTU

3 12 Operation

3.11 After stopping the engine Putting the engineout of operation

Preconditions MTU Fluids and Lubricants Specification (A001061/..) is available.

After stopping the engine

Item Task

Coolant system Drain engine coolant ( Page 5 21);Drain mixture coolant ( Page 5 26)if:

freezing temperatures are expected and the engine is to remain out ofservice for an extended period, but engine coolant has no antifreezeadditive;

the engine room is not heated; the 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.

Engine/generator control system Switch OFF.

Gas supply Close gas shutoff valve.

Air intake and exhaust system If the engine is to remain out of service for more than 1 week, seal the enginesair and exhaust sides. If the engine is to remain out of operation for morethan 1 month, preserve engine (MTU Fluids and Lubricants SpecificationsA001061/..).

Starter battery (batteries) Charge regularly (trickle charge).Control-voltage battery(batteries)

If fitted: Charge regularly (trickle charge).

M015635/00E 04-12 MTU


4 Maintenance4.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 01

4.2 Maintenance schedule matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 03

4.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 08

M015635/00E 04-12 MTU


M015635/00E 04-12 MTU

Maintenance 4 01

4.1 Preface

GeneralLow operating and maintenance costs as well as operational reliability and availability depend onmaintenance and servicing being carried out in compliance with MTUs specifications and instructions.The overall system, of which the engine is an integral part, must be maintained in such a way as toensure trouble-free engine operation. For this purpose always ensure:

that sufficient fuel of specified quality is available that the combustion air is dry and clean that sufficient coolant and heating water of specified quality is available

Preventive maintenance instructions: Special care should be taken to keep the machinery plant in a clean and serviceable condition at all

times to facilitate detection of possible leaks and prevent subsequent damage. Protect rubber and synthetic parts from oil and fuel, never treat with organic detergents, only wipe with dry cloth. Always replace all seals and gaskets.

Our Service partner will always be available should assistance be required.

MTU maintenance conceptThe MTU maintenance concept is a preventive maintenance concept. Preventive maintenancepermits advance operational planning and increases availability.The maintenance schedule refers to the load profile/load factor specified below. The time intervalsat which the maintenance work is to be carried out, and the relevant checks and tasks involved, areaverage results based on operational experience and therefore represent guidelines only. Specificoperating conditions may require modifications to the Maintenance Schedule.

NoteThe maintenance task matrix covers all tasks up to extended component maintenance. After extended componentmaintenance, the maintenance tasks must continue to be performed in accordance with the specified schedule.The task number quoted in the task list also appears on the spare parts tag and servesas a cross-reference to the parts required.The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a list ofapproved fluids and lubricants are provided in the MTU Fluids and Lubricants Specification A001061 and thecomponent manufacturers fluids and lubricants specifications. Use only fluids and lubricants which comply with theMTU Fluids and Lubricants Specifications / are approved by the relevant component manufacturer.The user/customer must perform the following additional maintenance tasks:

Gas filter:Maintenance depends on gas quality (purity). Gas filters upstream of the engine mustbe regularly cleaned and renewed if necessary.

Battery:Maintenance depends on load and ambient conditions of the batteries. The specificationsof the battery manufacturer are binding.

Out-of-service periodsIf the engine is to remain out of service for more than 1 month, carry out engine preservation proceduresaccording to the Fluids and Lubricants Specifications, MTU Publication No. A001061.

Application group

3A Unrestricted continuous operation, load factor: 100%

M015635/00E 04-12 MTU

4 02 Maintenance

Load profileLoad-profile table

Continuous power ICFN

Speed 1500 min-1

Application Generator drive

Fuel gas Natural gas, methane number 70

M015635/00E 04-12 MTU

Maintenance 4 03

4.2 Maintenance schedule matrix

0 - 10,500 operating hours

Operating hours [h]Item

Lim

it,ye

ars

Dai

ly50

01,

000

1,50

02,

000

2,50

03,

000

3,50

04,

000

4,50

05,

000

5,50

06,

000

6,50

07,

000

7,50

08,

000

8,50

09,

000

9,50

010

,000

10,5

00

Engine oil filter 2

Engine operation - X

Ignition system - X X X X X X X X X X X X X X X X X X X X X

Valve gear - X X X X X X X X X X

Ignition system - X X X X X

Gas supply - X X

Air filter 3 X X

Component maintenance -

Cylinder head -

Pistons -

Camshaft -

Conrod bearings -

Gear train -

Cylinder liners -

Extended component maintenance 18

M015635/00E 04-12 MTU

4 04 Maintenance

11,000 - 21,500 operating hours


Lim

it,ye

ars

11,0

0011

,500

12,0

0012

,500

13,0

0013

,500

14,0

0014

,500

15,0

0015

,500

16,0

0016

,500

17,0

0017

,500

18,0

0018

,500

19,0

0019

,500

20,0

0020

,500

21,0

0021

,500

Engine oil filter 2

Engine operation -

Ignition system - X X X X X X X X X X X X X X X X X X X X X X

Valve gear - X X X X X X X X X X X


Gas supply - X X X

Air filter 3 X X X

Component maintenance - X

Cylinder head - X

Pistons -

Camshaft -

Conrod bearings -

Gear train -

Cylinder liners -


M015635/00E 04-12 MTU

Maintenance 4 05



Lim

it,ye

ars

22,0

0022

,500

23,0

0023

,500

24,0

0024

,500

25,0

0025

,500

26,0

0026

,500

27,0

0027

,500

28,0

0028

,500

29,0

0029

,500

30,0

0030

,500

31,0

0031

,500

32,0

0032

,500

Engine oil filter 2

Engine operation -



Ignition system - X X X X X X

Gas supply - X X X

Air filter 3 X X X


Cylinder head - X

Pistons - X

Camshaft - X

Conrod bearings - X

Gear train - X

Cylinder liners - X


M015635/00E 04-12 MTU

4 06 Maintenance



Lim

it,ye

ars

33,0

0033

,500

34,0

0034

,500

35,0

0035

,500

36,0

0036

,500

37,0

0037

,500

38,0

0038

,500

39,0

0039

,500

40,0

0040

,500

41,0

0041

,500

42,0

0042

,500

43,0

0043

,500

Engine oil filter 2

Engine operation -




Gas supply - X X

Air filter 3 X X

Component maintenance -

Cylinder head -

Pistons -

Camshaft -

Conrod bearings -

Gear train -

Cylinder liners -


M015635/00E 04-12 MTU

Maintenance 4 07



Lim

it,ye

ars

44,0

0044

,500

45,0

0045

,500

46,0

0046

,500

47,0

0047

,500

48,0

00

Engine oil filter 2

Engine operation -

Ignition system - X X X X X X X X X

Valve gear - X X X X X

Ignition system - X X X

Gas supply - X X

Air filter 3 X X


Cylinder head - X

Pistons - X

Camshaft - X

Conrod bearings - X

Gear train - X

Cylinder liners - X

Extended component maintenance 18 X

M015635/00E 04-12 MTU

4 08 Maintenance

4.3 Maintenance tasks

IntervalQual-ifica-tion [hours] [years]

Item Maintenance tasks TaskCode

QL1 - 2 Engine oil filter Replace when changing the oil or when theinterval/years is reached, at the latest ( Page 5 19).

W1008

QL1 Daily - Engine operation Check oil level ( Page 5 17). W0500Check engine visually for leaks and general condition. W0501

Check machine room for smell of gas ( Page 5 02). W0509Check for abnormal running noises and vibrations. W0515

QL1 500 - Ignition system Check ignition voltage in secondary circuit with theengine running ( Page 5 03).

W1167

QL1 1,000 - Valve gear Check valve clearance ( Page 5 09). W1002QL1 2,000 - Ignition system Replace spark plugs ( Page 5 06). W1168QL1 4,000 - Gas supply Check gas lines for leaks, repair if required

( Page 5 13).W1089

QL1 4,000 3 Air filter Replace air filter ( Page 5 14). W1005QL3 16,000 - Component

maintenanceBefore starting maintenance work, drain coolant andflush coolant circuits (Workshop Manual).

W2000

Check cylinder liner running pattern (WorkshopManual ).

W2022

Check piston crowns (visual check) (WorkshopManual ).

W2087

Check rocker arm and valve bridge for wear(Workshop Manual);Visually inspect swing follower and camshaftrunning faces with endoscope through pushrod bore(Workshop Manual).

W2001

Clean exhaust turbocharger and fit new sealing(Workshop Manual).

W2093

Gas train: Check diaphragms and springs ofgas pressure regulating units (manufacturersdocumentation).

W2107

QL3 16,000 - Cylinder head Replace cylinder heads (Workshop Manual). W1125QL3 24,000 - Pistons Check pistons, fit new piston rings if necessary

(Workshop Manual ).W1169

QL3 24,000 - Camshaft Check camshaft (visual check) (Workshop Manual ). W1085QL3 24,000 - Conrod bearing Replace conrod bearings (big eye) (Workshop

Manual ).W1171

QL3 24,000 - Gear train Check gears while installed (visual check) (WorkshopManual).

W1086

M015635/00E 04-12 MTU

Maintenance 4 09

IntervalQual-ifica-tion [hours] [years]

Item Maintenance tasks TaskCode

QL3 24,000 - Cylinder liners Rehone cylinder liners, replace if necessary(Workshop Manual ).

W1166

QL4 48,000 18 Extended componentmaintenance

Perform complete engine disassembly. Inspect enginecomponents acc. to assembly instructions; repair orreplace as necessary (Workshop Manual).

W3000

Replace all elastomer components and seals. W3001

Replace cylinder liners (Workshop Manual). W3005Replace pistons (Workshop Manual). W3040

M015635/00E 04-12 MTU

4 10 Maintenance

M015635/00E 04-12 MTU


5 Task Description5.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 01

5.1.1 Engine Barring manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 015.1.2 Checking machine room for smell of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 02

5.2 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 035.2.1 Ignition system Checking ignition voltage in secondary circuit with the engine

running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 035.2.2 Spark plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 065.2.3 Spark plug Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 07

5.3 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 085.3.1 Valve gear Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 085.3.2 Valve clearance Check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 095.3.3 Cylinder head cover Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5 12

5.4 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 135.4.1 Gas supply Checking gas lines for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 13

5.5 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 145.5.1 Air filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 145.5.2 Air filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 15

5.6 Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 165.6.1 Engine oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 165.6.2 Engine oil Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 175.6.3 Engine-oil Sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 18

5.7 Oil Filtration / Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 195.7.1 Engine oil filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 19

5.8 Cooling System, General, HT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 205.8.1 Engine coolant Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 205.8.2 Engine coolant Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 215.8.3 Engine coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 235.8.4 Engine coolant Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 24

5.9 Cooling System, LT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 255.9.1 Mixture coolant Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 255.9.2 Mixture coolant Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 265.9.3 Mixture coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 275.9.4 Mixture coolant Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 28

5.10 General Wiring, Engine / Gearbox / Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 295.10.1 Engine wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 29

M015635/00E 04-12 MTU


M015635/00E 04-12 MTU

Engine 5 01

5.1 Engine

5.1.1 Engine Barring manually


Special toolsDesignation / Use Part No. Qty.Barring tool F6555766 1Ratchet

DANGER


Before barring the engine, ensure that nobody is in the danger zone.

Engine Barring manually1. Remove protective plate.2. Install barring tool (2).3. Set ratchet (1) onto barring tool (2).4. Rotate crankshaft in engine direction of rotation.

Apart from the normal compression resistance,there should be no abnormal resistance.

5. For barring-tool removal follow reverse sequenceof working steps.

M015635/00E 04-12 MTU

5 02 Engine

5.1.2 Checking machine room for smell of gas

Special toolsDesignation / Use Part No. Qty.Gas detection and alarm unit

WARNING

Natural gas is combustible.Risk of fire and explosion!

Avoid naked flames, electrical sparks and ignition sources. Do not smoke.

Checking machine room for smell of gas1. Check machine room for smell of gas or localize gas supply leaks using gas detection and alarm unit.2. If smell of gas is detected or the gas detection and alarm unit is triggered:

Avoid naked flames! Avoid sparks! Do not use electrical appliances (including switches, connectors/sockets, telephone, bell). Do not smoke! Close main gas shutoff device! Open windows and doors! Warn residents and leave building! Call gas supplier from outside the building!

M015635/00E 04-12 MTU

Ignition System 5 03

5.2 Ignition System

5.2.1 Ignition system Checking ignition voltage in secondarycircuit with the engine running

Preconditions Operating voltage of genset control equipment is present. Genset is not connected to the network.

Special toolsDesignation / Use Part No. Qty.Scopemeter (oscilloscope) 1High-voltage terminal 1

Spare partsDesignation / Use Part No. Qty.Spark plug 1Sealing ring 1

DANGER



DANGER

Voltage frequencies.Risk of serious injury - danger to life!

Persons with cardiac pacemaker must not carry out this work!

DANGER

Live components, flash-over.Risk of serious injury - danger to life!

During operation, touch ignition cable only with high-voltage terminal!

WARNING



M015635/00E 04-12 MTU

5 04 Ignition System

Ignition system Checking ignition voltage insecondary circuit with the engine running

1. Start the engine ( Page 3 05).2. Connect cable of high-voltage terminal (3)

to scopemeter (1).3. Connect high-voltage terminal (3) to ignition

cable (2), touching the ignition cable only with thehigh-voltage terminal.

4. Perform measurement.

1 No spark duration2 No inductive postoscillation

5. Evaluate measured values indicated on thescopemeter. Illustrated: Graph of a faulty sparkplug.

6. Fit new spark plug ( Page 5 06).

M015635/00E 04-12 MTU


1 Spark duration approx. 200 sek2 Ignition voltage approx. 13 kV

7. Evaluate measured values indicated on thescopemeter. Illustrated: Graph of a properlyfunctioning spark plug.

8. Disconnect high-voltage terminal.

M015635/00E 04-12 MTU

5 06 Ignition System

5.2.2 Spark plug Replacement

Spare partsDesignation / Use Part No. Qty.Spark plug

Remove spark plug and install new one ( Page 5 07).

M015635/00E 04-12 MTU


5.2.3 Spark plug Removal and installation


Special toolsDesignation / Use Part No. Qty.Box wrench F30038494 1Torque wrench F30510423 1

Spare partsDesignation / Use Part No. Qty.Spark plugSealing ring

WARNING

Component is hot.Risk of burning!

Wear protective goggles.

Removing spark plug1. Remove protective cap from ignition coil.2. Remove screw, take off spring washer and

ignition cable.3. Unscrew spark plug and remove.

Installing spark plug1. Screw spark plug with new sealing ring into cylinder head and tighten to specified torque of 50 Nm using

a torque wrench.2. Connect ignition cable to ignition coil.3. Fit protective cap.

M015635/00E 04-12 MTU

5 08 Valve Gear

5.3 Valve Gear

5.3.1 Valve gear Lubrication


MaterialDesignation / Use Part No. Qty.Engine oil

Valve gear Lubrication1. Remove cylinder head covers ( Page 5 12).2. Fill oil chambers of rocker arms and adjusting

screws with oil.3. Install cylinder head covers ( Page 5 12).

M015635/00E 04-12 MTU

Valve Gear 5 09

5.3.2 Valve clearance Check and adjustmentPreconditions

Engine is stopped and starting disabled. Engine coolant temperature is max. 40 C. Valves are closed.

Special toolsDesignation / Use Part No. Qty.Feeler gauge Y20010128 1Allen key F30002817 1Torque wrench F30047446 1OJ Adapter F30029815 1

Preparatory steps1. Remove cylinder head cover ( Page 5 12).2. Install barring tool ( Page 5 01).3. Rotate crankshaft with barring tool in engine

direction of rotation until marking "OT-A1" andpointer are aligned.

Diagram Two crankshaft positions Applicable to 8V engines

M015635/00E 04-12 MTU

5 10 Valve Gear


1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCI Inlet valve

X Exhaust valve


Checking valve clearance at two crankshaft positions1. Check TDC position of piston in cylinder A1:

If the rocker arms are not under load on cylinder A1, the piston is in firing TDC. If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.

2. Check valve clearance with cold engine: Inlet valves (long rocker arm) = 0.2 mm Exhaust valves (short rocker arm) = 0.5 mm

3. Check all valve clearances in two crankshaft positions (firing and overlap TDC for cylinder A1) as per diagram.4. Use feeler gauge to determine the distance between valve bridge and rocker arm.5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

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Valve Gear 5 11

Adjusting valve clearance1. Release locknut (1).2. Insert feeler gauge between valve bridge and

rocker arm.3. Using Allen key, set adjusting screw (2) so that

the specified valve clearance is provided.4. Feeler gauge must just pass through the gap.5. Tighten locknut (1) to 90 +9 Nm, holding adjusting

screw (2) firm.6. Replace or rectify adjusting screws and/or

locknuts which do not move freely.7. Check valve clearance

Final steps1. Remove barring tool ( Page 5 01).2. Install cylinder head cover ( Page 5 12).

M015635/00E 04-12 MTU

5 12 Valve Gear

5.3.3 Cylinder head cover Removal and installation


Special toolsDesignation / Use Part No. Qty.Torque wrench F30026582 1Ratchet adapter F30027340 1

Spare partsDesignation / Use Part No. Qty.Gasket

Removing cylinder head cover1. Clean very dirty cylinder head covers prior to

removal.2. Remove protective cap from ignition coil.3. Remove screw, take off spring washer and

ignition cable.4. Remove protective cap from ignition cable.5. Remove screws.6. Remove cylinder head cover with gasket from

cylinder head.

Installing cylinder head cover1. Clean mating faces.2. Check condition of gasket, replace if damaged.3. Place gasket and cylinder head cover on cylinder head.4. Position cylinder head cover and tighten screws to specified torque of 42 Nm using a torque wrench.5. Fit protective cap on ignition cable.6. Connect ignition cable to ignition coil.7. Fit protective cap on ignition coil.

M015635/00E 04-12 MTU

Gas System 5 13

5.4 Gas System

5.4.1 Gas supply Checking gas lines for leaks


MaterialDesignation / Use Part No. Qty.Leakage detection spraySoap solution

WARNING

Natural gas is combustible.Risk of fire and explosion!

Avoid naked flames, electrical sparks and ignition sources. Do not smoke.

Gas supply Checking gas lines for leaks1. Coat all connections of the gas supply line with soap solution or spray with leakage detection spray from a

distance of 30 to 50 cm. Leaks are indicated by the formation of bubbles or foam.

2. Replace leaking parts.

M015635/00E 04-12 MTU

5 14 Air Filter

5.5 Air Filter

5.5.1 Air filter Replacement

Spare partsDesignation / Use Part No. Qty.Air filter

Remove air filter and install new one ( Page 5 15).

M015635/00E 04-12 MTU

Air Filter 5 15

5.5.2 Air filter removal and installation


Air filter removal and installation1. Loosen clamp (2).2. Remove air filter (3) and clamp (2) from flange of

intake housing (1).3. Verify that there are no objects in the flange of

the intake housing (1) and clean it.4. Place new air filter (3) with clamp (2) onto

intake housing (1).5. Tighten clamp (2).

M015635/00E 04-12 MTU

5 16 Lube Oil System

5.6 Lube Oil System

5.6.1 Engine oil Change

Preconditions Engine is stopped and starting disabled. Engine is at operating temperature. MTU Fluids and Lubricants Specification (A001061/..) is available.


WARNING

Hot oil.Oil can contain combustion residues which are harmful to health.Risk of injury and poisoning!

Wear protective clothing, gloves, and goggles / safety mask. Avoid contact with skin. Do not inhale oil vapor.

Oil extraction1. Open shut-off valve(s) in extraction line from engine and waste-oil tank.2. Extract all oil from oil pan using the electric pump.3. Close shut-off valve(s).

Filling with new oil1. Determine amount of engine oil required for oil change ( Product Summary - Technical Data).2. Use electric pump to fill engine with oil from new-oil tank until the "max." mark on the oil dipstick is reached.3. Check engine oil level ( Page 5 17).

M015635/00E 04-12 MTU

Lube Oil System 5 17

5.6.2 Engine oil Level check


Checking oil level prior to engine start1. Withdraw dipstick from guide tube and wipe it.2. Insert dipstick into guide tube up to the stop,

withdraw after approx. 10 seconds and checkoil level.

Note: After extended standstill, the oil levelmay exceed the mark (1) by up to 2 cm.This can be caused by oil flowing frome.g. oil filter or heat exchanger backto the oil pan.

3. The oil level must reach the mark (1) or exceedthe mark (1) by up to 2 cm.

4. If necessary, top up to mark (1) ( Page 5 16).5. Insert dipstick into guide tube up to the stop.

Checking oil level after the engine is stopped1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.3. Oil level must be between marks (1) and (2).4. If necessary, top up to mark (1) ( Page 5 16).5. Insert dipstick into guide tube up to the stop.

Checking oil level in oil storage tank1. Check oil level.2. Oil level must be between "min." and "max." marks.3. If necessary, top up to "max." mark ( Page 5 16).

M015635/00E 04-12 MTU

5 18 Lube Oil System

5.6.3 Engine-oil Sample extraction and analysis

Preconditions MTU Fluids and Lubricants Specification (A001061/..) is available.

Special toolsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1

DANGER


Take special care when working on a running engine.

WARNING



WARNING



Engine-oil Sample extraction and analysis1. With the engine running at operating temperature,

open screw on flange by 1 to 2 rotations.2. Drain approx. 2 liters engine oil to flush out

the oil sludge.3. Drain approx. 1 liter engine oil into a clean

container.4. Close screw.5. Using the equipment and chemicals of the MTU

test kit, examine the engine oil for: Dispersion capability (spot test); Water content.

M015635/00E 04-12 MTU

Oil Filtration / Cooling 5 19

5.7 Oil Filtration / Cooling

5.7.1 Engine oil filter Replacement


Special toolsDesignation / Use Part No. Qty.Oil filter wrench F30379104 1


Spare partsDesignation / Use Part No. Qty.Oil filter

WARNING



Engine oil filter Replacement1. Remove oil filter using the oil filter wrench.2. Clean the sealing surface of the filter head.3. Check condition of the new sealing ring and

coat it with oil.4. Screw on and tighten new oil filter by hand.5. Replace further oil filters in the same way.6. Check oil level ( Page 5 17).

M015635/00E 04-12 MTU

5 20 Cooling System, General, HT Circuit

5.8 Cooling System, General, HT Circuit

5.8.1 Engine coolant Filling


MaterialDesignation / Use Part No. Qty.Engine coolant

WARNING

Coolant is hot and under pressure.Risk of injury and scalding!

Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask.

CAUTION

Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!

Fill / top up coolant only into cold engine.

Filling with coolant1. Fill with treated coolant until the specified system pressure ( Product Summary - Technical Data) is provided.2. Start the engine and operate it at idle speed for some minutes.3. Check coolant level ( Page 5 24) and top up if required.

M015635/00E 04-12 MTU

Cooling System, General, HT Circuit 5 21

5.8.2 Engine coolant Draining


Spare partsDesignation / Use Part No. Qty.Sealing ring

WARNING



Preparatory steps1. Provide an appropriate container to drain the coolant into.2. Switch off preheating unit if installed.

M015635/00E 04-12 MTU


Engine coolant Draining1. Open drain valves and drain coolant at the

following points: At the crankcase free end, LHS and RHS

2. Draining of residual coolant: At coolant distribution housing.

3. Close all open drain points.

M015635/00E 04-12 MTU

Cooling System, General, HT Circuit 5 23

5.8.3 Engine coolant Change

MaterialDesignation / Use Part No. Qty.Engine coolant

Drain engine coolant ( Page 5 21).Fill engine coolant system ( Page 5 20).

M015635/00E 04-12 MTU


5.8.4 Engine coolant Level check


WARNING



Engine coolant Level check1. Read off system pressure at pressure gauge, for system pressure ( Product Summary - Technical Data).2. If required, top up with treated coolant ( Page 5 20).

M015635/00E 04-12 MTU

Cooling System, LT Circuit 5 25

5.9 Cooling System, LT Circuit

5.9.1 Mixture coolant Filling


MaterialDesignation / Use Part No. Qty.Mixture coolant

WARNING



CAUTION

Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!

Fill / top up coolant only into cold engine.

Filling with coolant1. Fill with treated coolant until the specified system pressure ( Product Summary - Technical Data) is provided.2. Start the engine and operate it at idle speed for some minutes.3. Check coolant level ( Page 5 24) and top up if required.

M015635/00E 04-12 MTU

5 26 Cooling System, LT Circuit

5.9.2 Mixture coolant Draining


WARNING



Mixture coolant Draining1. Provide an appropriate container to drain the coolant into.2. Open drain valve and drain coolant at the following drain point:

At coolant line.

M015635/00E 04-12 MTU

Cooling System, LT Circuit 5 27

5.9.3 Mixture coolant Change

MaterialDesignation / Use Part No. Qty.Mixture coolant

Drain mixture coolant ( Page 5 26).Fill mixture coolant ( Page 5 25).

M015635/00E 04-12 MTU

5 28 Cooling System, LT Circuit

5.9.4 Mixture coolant Level check


WARNING



Mixture coolant Level check1. Read off system pressure at pressure gauge, for system pressure ( Product Summary - Technical Data).2. If required, top up with treated coolant ( Page 5 25).

M015635/00E 04-12 MTU

General Wiring, Engine / Gearbox / Plant 5 29

5.10 General Wiring, Engine / Gearbox / Plant

5.10.1 Engine wiring check


MaterialDesignation / Use Part No. Qty.Isopropyl alcohol

Engine wiring check1. Check securing screws of cable clamps on the engine and tighten loose screw connections.2. Make certain that cables are securely seated in clamps and cannot move freely.3. Check cable binders for secure seating, tighten loose cable binders.4. Replace defective cable binders.5. Inspect electrical components visually for damage:

connector housings; contacts; connector sockets; cables and terminals; plug-in contacts.

6. If conductors are damaged, contact Service.7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.

M015635/00E 04-12 MTU

5 30 General Wiring, Engine / Gearbox / Plant

M015635/00E 04-12 MTU


6 Annex6.1 Manufacturers documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 01

6.2 MTU contact person/service partner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 02

6.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 03

M015635/00E 04-12 MTU


M015635/00E 04-12 MTU

Annex 6 01

6.1 Manufacturers documentationSee Manufacturers documentation.

M015635/00E 04-12 MTU

6 02 Annex

6.2 MTU contact person/service partnerYou will find the MTU contact person/service partner for your region at www.mtu-online.com,worldwide, in the left-hand navigation margin.

M015635/00E 04-12 MTU

Index 6 03

6.3 Index

AAfter stopping the engine Engine remainsready for operation . . . . . . . . . . . . . . . . . . . . . 3 11After stopping the engine Putting the engineout of operation . . . . . . . . . . . . . . . . . . . . . . . . 3 12Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 14

Air filter Replacement . . . . . . . . . . . . 5 14Air filter removal and installation . . . . . . 5 15

Air filter Replacement . . . . . . . . . . . . . . . . . . 5 14Air filter removal and installation . . . . . . . . . . . 5 15Auxiliary materials, fire prevention andenvironmental protection . . . . . . . . . . . . . . . . . 1 07

CChecking machine room for smell of gas . . . . 5 02Cooling System, General, HT Circuit . . . . . . . 5 20

Engine coolant Change . . . . . . . . . . . 5 23Engine coolant Draining . . . . . . . . . . . 5 21Engine coolant Filling . . . . . . . . . . . . . 5 20Engine coolant Level check . . . . . . . . 5 24

Cooling System, LT Circuit . . . . . . . . . . . . . . . 5 25Mixture coolant Change . . . . . . . . . . . 5 27Mixture coolant Draining . . . . . . . . . . 5 26Mixture coolant Filling . . . . . . . . . . . . 5 25Mixture coolant Level check . . . . . . . . 5 28

Cylinder head cover Removal andinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 12

EEmergency stop . . . . . . . . . . . . . . . . . . . . . . . 3 10Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 01

Checking machine room for smell ofgas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 02Engine Barring manually . . . . . . . . . . 5 01

Engine Barring manually . . . . . . . . . . . . . . . 5 01Engine coolant Change . . . . . . . . . . . . . . . . 5 23Engine coolant Draining . . . . . . . . . . . . . . . . 5 21Engine coolant Filling . . . . . . . . . . . . . . . . . . 5 20Engine coolant Level check . . . . . . . . . . . . . 5 24Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . 2 01Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . . 2 01

Engine layout . . . . . . . . . . . . . . . . . . . . 2 01Engine oil Change . . . . . . . . . . . . . . . . . . . . 5 16Engine oil Level check . . . . . . . . . . . . . . . . . 5 17Engine oil filter Replacement . . . . . . . . . . . . 5 19Engine side and cylinder designations . . . . . . 2 03Engine Side and Cylinder Designations . . . . . 2 03

Engine side and cylinderdesignations . . . . . . . . . . . . . . . . . . . . . 2 03

Engine wiring check . . . . . . . . . . . . . . . . . . . . 5 29

Engine-oil Sample extraction andanalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 18

FFiring order . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 05Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 05

Firing order . . . . . . . . . . . . . . . . . . . . . . 2 05

GGas supply Checking gas lines for leaks . . . 5 13Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . 5 13

Gas supply Checking gas lines forleaks . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 13

General conditions . . . . . . . . . . . . . . . . . . . . . 1 01General Wiring, Engine / Gearbox / Plant . . . . 5 29

Engine wiring check . . . . . . . . . . . . . . . 5 29

IIgnition System . . . . . . . . . . . . . . . . . . . . . . . . 5 03

Ignition system Checking ignitionvoltage in secondary circuit with theengine running . . . . . . . . . . . . . . . . . . . 5 03Spark plug Removal andinstallation . . . . . . . . . . . . . . . . . . . . . . . 5 07Spark plug Replacement . . . . . . . . . . 5 06

Ignition system Checking ignition voltage insecondary circuit with the engine running . . . . 5 03Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0

M015635_00E

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