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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.
Printed in Germany
2004 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.
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.

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


Bitte die Karte Inbetriebnahmemeldung abtrennen und ausgefllt an MTU Friedrichshafen GmbH
zurcksenden.
Die Informationen der Inbetriebnahmemeldung sind Grundlage fr den vertraglich vereinbarten LogistikSupport (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.

Postcard
MTU Friedrichshafen GmbH
Department SCSD
88040 Friedrichshafen
GERMANY

Bitte in Blockschrift ausfllen!


Please use block capitals!
Prire de remplir en lettres capitales!
A rellenar en letras de imprenta!
Scrivere in stampatello!
Favor preencher com letras de forma!

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

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

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

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

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

Schiffstyp / Schiffshersteller:
Vessel/type/class / Shipyard:
Type du bateau / Constructeur:
Tipo de buque / Constructor:
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End user`s address:
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Remarks:
Remarques:
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Commento:
Observaes:

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

Amendment Service!
Any changes in contents will be sent to you in the form of an updated publication,
provided you complete the reverse of this receipt card and return it to us.

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MTU Friedrichshafen GmbH


Department SCT
88040 Friedrichshafen
GERMANY

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M015635/00E

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Table of Contents

1I

Safety
1.1

General conditions

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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Safety

1.1

1 01

General conditions

General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with 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 use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions
Modifications 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 parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis--vis the engine manufacturer will be accepted.

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1.2

Safety

Personnel and organizational requirements

Personnel
Work 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.
Organization
This 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 involved
in 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 equipment
Wear 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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Transport

Transport
Lift 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 the
transport 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 secured
against slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place 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

Safety precautions when working on the engine

Engine operation
When 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 health
hazard. 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 (ignition
coils, 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 repair
Strict 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 starters
are fitted. Close the main valve on the compressed-air system and vent the compressed air line when
air starters are fitted. Shut off the gas supply to the engine. Activate the emergency stop at the engine
interface switchgear cabinet (MIS) or by turning the key switch, if fitted. Post the "Do Not Start" sign in the
operating 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 tools
required. 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 company
with 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 by
suitable 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 completing
work on the engine, check that all protective devices/safety guards have been installed and that
all 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. Before
starting 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 have
been reworked or that have not been approved for the application in question. Keep fuel lines and
connections 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 when
installing 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 with
them. 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 decomposes
when exposed to fire or temperatures exceeding 300 C. Hydrogen fluoride vapors are released in this
case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals
if 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 discharge
of highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine 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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When draining, collect fluids in a suitable container, mop up any spilled fluids or wipe or
soak them with a suitable bonding agent.
When changing engine oil or carrying out work on the fuel system, ensure sufficient ventilation
of the machine room and shut off the main gas supply!
When working high on the engine, always use suitable ladders and work platforms. Make
sure 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 work
Never 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 through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead 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 otherwise
induce 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 operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in 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 to
be 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 spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component 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 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. Any measures requiring a power
supply 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 battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to 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 is
not 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 loose
must be correctly connected and secured.

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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, use
cable 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. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical 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 safe
operation 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 equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.

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Safety

1.5

1 07

Auxiliary materials, fire prevention and environmental


protection

Fire prevention
Rectify 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 lubricants
lying 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. Before
welding, 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 source
to 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.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
sounds indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB (A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose 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 (MTU
Fluids 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 materials
Use 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 and
other 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 gas
Note 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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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 air
Compressed 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 connected
to 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 reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling 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 oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.

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1 09

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 American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Warning notices
1. 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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Table of Contents

2I

Product Summary
2.1

Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1
Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 01
2 01

2.2

Engine Side and Cylinder Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


2.2.1
Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 03
2 03

2.3

Main Engine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


2.3.1
Main engine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 04
2 04

2.4

Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 05
2 05

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Engine Layout

2 01

2.1

Engine Layout

2.1.1

Engine layout

Illustration is also valid for 8V/16V 4000 L61

1 Blower/crankcase breather
2 Exhaust outlet connection
3 Gas dozing and mixing
unit (Tecjet)
4 Gas inlet connection
5 Intercooler
6 Air filter / combustion air inlet
7 Mixture coolant outlet to
cooler (LT circuit)

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8 Mixture coolant inlet from


cooler (LT circuit)
9 Ignition coil
10 Spark plug
11 Cylinder head cover
12 Starter
13 Oil dipstick
14 Cylinder head

15
16
17
18

Engine oil filter


Oil level switch
Coolant distribution housing
Mixture coolant inlet from
cooler (HT circuit)
19 Mixture coolant outlet to
cooler (HT circuit)
20 Exhaust turbocharger

MTU

2 02

Engine Layout

Engine model designation


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

Number of cylinders

Cylinder configuration: V-engine

4000

Series

Application: L = Gas engine

Application segment 50 Hz

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 designations

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

1 KGS = Free end


2 Right side

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3 KS = Driving end
4 Left side

MTU

2 04

Main Engine Dimensions

2.3

Main Engine Dimensions

2.3.1

Main engine dimensions

Main engine dimensions

Length (A)

approx. 2830 mm

Width (B)

approx. 1550 mm

Height (C)

approx. 2260 mm

Crankshaft center to oil pan (D)

approx. 636 mm

Crankshaft center to engine mount (E)

approx. 280 mm

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Firing Order

2 05

2.4

Firing Order

2.4.1

Firing order

Firing order
8V

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

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2 06

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Firing Order

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Table of Contents

3I

Operation
3.1

SIAM 4000 Operating panel

..............................................

3 01

3.2

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

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

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Operation

3.1

3 01

SIAM 4000 Operating panel

SIAM 4000 Operating panel

LEDs

Pushbuttons

"U1"

Voltage L1

12

"Message"

Route message

"U2"

Voltage L2

12

"Select"

Confirm selection

"U3"

Voltage L3

13

"Display U"

Switch display

"Stop"

"STOP" mode selected

13

"Digit"

Increase digit

-2.8 0 Hz +2.8
Hz

Synchronoscope

14

"Setpoint"

Activate setpoint value

"Auto"

"AUTOMATIC" mode selected

14

"Cursor"

Move cursor one position to


the right

"Man."

"MANUAL" mode selected

15

"Setpoint"

Increase setpoint

"Monitoring on"

Monitoring function active

16

"Setpoint"

Decrease setpoint

"Error"

Fault alarm present

17

"GCB ON"

Close generator circuit


breaker manually

10

"GCB ON"

Feedback GCB closed

18

"GCB OFF"

Open generator circuit


breaker manually

11

"MCB ON"

Feedback MCB closed

19

"MCB ON"

Close mains circuit breaker


manually

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3 02

Operation

LC Display
28

"LC Display"

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LC Display

20

"MCB OFF"

Open mains circuit breaker


manually

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

26

"STOP"

Stop genset automatically

27

"QUIT"

Acknowledge fault alarms

MTU

Operation

3.2

3 03

Putting the engine into operation after extended


out-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.

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3 04

3.3

Operation

Putting the engine into operation after scheduled


out-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

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Operation

3.4

3 05

Starting the engine in manual mode

Preconditions
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, operating


panel

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 pressing
arrow-up button , reduce power by pressing arrow-down button .

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3 06

3.5

Operation

Starting the engine in automatic mode

Preconditions
Generator is not connected to network.
Start interlock 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 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

Switchgear cabinet, operating


panel

Press AUTO button.


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

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Operation

3.6

3 07

Operational checks
DANGER

Unguarded rotating and moving engine components.


Risk of serious injury danger to life!
Take special care when working on a running engine.

WARNING

Engine noise above 85 dB (A).


Risk of damage to hearing!
Wear ear protectors.

Operational checks
Item

Task

Machine room

Check machine room for smell of gas ( Page 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 load


Engine at nominal speed

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

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3 08

3.7

Operation

Stopping the engine in manual mode

Preconditions
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 decrease
and stable values are indicated.

Stopping the engine


Item

Task

Switchgear cabinet, operating


panel

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.

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Operation

3.8

3 09

Stopping the engine in automatic mode

Preconditions
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 decrease
and stable values are indicated.

Stopping the engine


Item

Task

Switchgear cabinet, operating


panel

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

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3 10

3.9

Operation

Emergency stop
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
Initiate emergency stop only in emergency situations.

CAUTION
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 control
system

Determine cause for emergency stop and take remedial action;


if the fault cannot be corrected, contact Service.

Prior to re-starting the engine


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.

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Operation

3.10

3 11

After stopping the engine Engine remains


ready 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

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3 12

3.11

Operation

After stopping the engine Putting the engine


out 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 of
service for an extended period, but engine coolant has no antifreeze
additive;
the engine room is not heated;
the coolant is not maintained at a suitable temperature;
the antifreeze concentration is insufficient for the engine-room
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 engines
air and exhaust sides. If the engine is to remain out of operation for more
than 1 month, preserve engine (MTU Fluids and Lubricants Specifications
A001061/..).

Starter battery (batteries)

Charge regularly (trickle charge).

Control-voltage battery
(batteries)

If fitted: Charge regularly (trickle charge).

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Table of Contents

4I

Maintenance
4.1

Preface

4.2

Maintenance schedule matrix

4.3

Maintenance tasks

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4 01

..............................................

4 03

.......................................................

4 08

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4 II

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Maintenance

4.1

4 01

Preface

General
Low operating and maintenance costs as well as operational reliability and availability depend on
maintenance 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 to
ensure 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 concept


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

Note
The maintenance task matrix covers all tasks up to extended component maintenance. After extended component
maintenance, 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 serves
as a cross-reference to the parts required.
The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a list of
approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specification A001061 and the
component manufacturers fluids and lubricants specifications. Use only fluids and lubricants which comply with the
MTU 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 must
be regularly cleaned and renewed if necessary.
Battery:
Maintenance depends on load and ambient conditions of the batteries. The specifications
of the battery manufacturer are binding.

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

Application group
Unrestricted continuous operation, load factor: 100%

3A

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4 02

Maintenance

Load profile
Load-profile table
Continuous power

ICFN

Speed

1500 min-1

Application

Generator drive

Fuel gas

Natural gas, methane number 70

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Maintenance

4.2

4 03

Maintenance schedule matrix

Item

Operating hours [h]

Daily
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
10,000
10,500

Limit, years

0 - 10,500 operating hours

Engine oil filter

Engine operation

Ignition system

Valve gear

Ignition system

Gas supply

Air filter

Component maintenance

Cylinder head

Pistons

Camshaft

Conrod bearings

Gear train

Cylinder liners

Extended component maintenance

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X
X X X X X X X X X X X X X X X X X X X X X
X

X
X

X
X

X
X

X
X

X
X

18

MTU

4 04

Maintenance

Item

Operating hours [h]

11,000
11,500
12,000
12,500
13,000
13,500
14,000
14,500
15,000
15,500
16,000
16,500
17,000
17,500
18,000
18,500
19,000
19,500
20,000
20,500
21,000
21,500

Limit, years

11,000 - 21,500 operating hours

Engine oil filter

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

Ignition system

Gas supply

Air filter

Component maintenance

Cylinder head

Pistons

Camshaft

Conrod bearings

Gear train

Cylinder liners

Extended component maintenance

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X
X

X
X

X
X

18

MTU

Maintenance

4 05

Item

Operating hours [h]

22,000
22,500
23,000
23,500
24,000
24,500
25,000
25,500
26,000
26,500
27,000
27,500
28,000
28,500
29,000
29,500
30,000
30,500
31,000
31,500
32,000
32,500

Limit, years

22,000 - 32,500 operating hours

Engine oil filter

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

Ignition system

Gas supply

Air filter

Component maintenance

Cylinder head

Pistons

Camshaft

Conrod bearings

Gear train

Cylinder liners

Extended component maintenance

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X
X

X
X

X
X

X
X

X
X

18

MTU

4 06

Maintenance

Item

Operating hours [h]

33,000
33,500
34,000
34,500
35,000
35,500
36,000
36,500
37,000
37,500
38,000
38,500
39,000
39,500
40,000
40,500
41,000
41,500
42,000
42,500
43,000
43,500

Limit, years

33,000 - 43,500 operating hours

Engine oil filter

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

Ignition system

Gas supply

Air filter

Component maintenance

Cylinder head

Pistons

Camshaft

Conrod bearings

Gear train

Cylinder liners

Extended component maintenance

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X
X

X
X

X
X

X
X

18

MTU

Maintenance

4 07

Item

Operating hours [h]

44,000
44,500
45,000
45,500
46,000
46,500
47,000
47,500
48,000

Limit, years

44,000 - 48,000 operating hours

Engine oil filter

Engine operation

Ignition system

X X X X X X X X X

Valve gear

Ignition system

Gas supply

Air filter

Component maintenance

Cylinder head

Pistons

Camshaft

Conrod bearings

Gear train

Cylinder liners

18

Extended component maintenance

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X
X

X
X

MTU

4 08

Maintenance

4.3

Maintenance tasks

Qualification

Interval

QL1

QL1

Daily

Item

Maintenance tasks

Task
Code

Engine oil filter

Replace when changing the oil or when the


interval/years is reached, at the latest ( Page 5 19).

W1008

Engine operation

Check oil level ( Page 5 17).

W0500

Check engine visually for leaks and general condition.

W0501

Check machine room for smell of gas ( Page 5 02).

W0509

Check for abnormal running noises and vibrations.

W0515

[hours] [years]

QL1

500

Ignition system

Check ignition voltage in secondary circuit with the


engine running ( Page 5 03).

W1167

QL1

1,000

Valve gear

Check valve clearance ( Page 5 09).

W1002

QL1

2,000

Ignition system

Replace spark plugs ( Page 5 06).

W1168

QL1

4,000

Gas supply

Check gas lines for leaks, repair if required


( Page 5 13).

W1089

QL1

4,000

Air filter

Replace air filter ( Page 5 14).

W1005

QL3

16,000 -

Component
maintenance

Before starting maintenance work, drain coolant and


flush coolant circuits (Workshop Manual).

W2000

Check cylinder liner running pattern (Workshop


Manual ).

W2022

Check piston crowns (visual check) (Workshop


Manual ).

W2087

Check rocker arm and valve bridge for wear


(Workshop Manual);
Visually inspect swing follower and camshaft
running 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 of


gas pressure regulating units (manufacturers
documentation).

W2107

QL3

16,000 -

Cylinder head

Replace cylinder heads (Workshop Manual).

W1125

QL3

24,000 -

Pistons

Check pistons, fit new piston rings if necessary


(Workshop Manual ).

W1169

QL3

24,000 -

Camshaft

Check camshaft (visual check) (Workshop Manual ).

W1085

QL3

24,000 -

Conrod bearing

Replace conrod bearings (big eye) (Workshop


Manual ).

W1171

QL3

24,000 -

Gear train

Check gears while installed (visual check) (Workshop


Manual).

W1086

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Maintenance

4 09

Qualification

Interval

Item

Maintenance tasks

Task
Code

QL3

24,000 -

Cylinder liners

Rehone cylinder liners, replace if necessary


(Workshop Manual ).

W1166

QL4

48,000 18

Extended component
maintenance

Perform complete engine disassembly. Inspect engine


components acc. to assembly instructions; repair or
replace as necessary (Workshop Manual).

W3000

Replace all elastomer components and seals.

W3001

Replace cylinder liners (Workshop Manual).

W3005

Replace pistons (Workshop Manual).

W3040

[hours] [years]

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4 10

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Maintenance

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Table of Contents

5I

Task Description
5.1

Engine
5.1.1
5.1.2

.................................................................
Engine Barring manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking machine room for smell of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 01
5 01
5 02

5.2

Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1
Ignition system Checking ignition voltage in secondary circuit with the engine
running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2
Spark plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3
Spark plug Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 03
5 03
5 06
5 07

5.3

Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1
Valve gear Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2
Valve clearance Check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.3
Cylinder head cover Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . .

5 08
5 08
5 09
5 12

5.4

Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1
Gas supply Checking gas lines for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 13
5 13

5.5

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.1
Air filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.2
Air filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 14
5 14
5 15

5.6

Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.6.1
Engine oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.2
Engine oil Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.3
Engine-oil Sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 16
5 16
5 17
5 18

5.7

Oil Filtration / Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.7.1
Engine oil filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 19
5 19

5.8

Cooling System, General, HT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.8.1
Engine coolant Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8.2
Engine coolant Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8.3
Engine coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8.4
Engine coolant Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 20
5 20
5 21
5 23
5 24

5.9

Cooling System, LT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.9.1
Mixture coolant Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.2
Mixture coolant Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.3
Mixture coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.4
Mixture coolant Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 25
5 25
5 26
5 27
5 28

5.10

General Wiring, Engine / Gearbox / Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.10.1
Engine wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 29
5 29

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5 II

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Table of Contents

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Engine

5 01

5.1

Engine

5.1.1

Engine Barring manually

Preconditions
Engine is stopped and starting disabled.

Special tools
Designation / Use

Part No.

Qty.

Barring tool

F6555766

Ratchet

DANGER

Unguarded rotating and moving engine components.


Risk of serious injury danger to life!
Before barring the engine, ensure that nobody is in the danger zone.
Engine Barring manually
1. 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 sequence
of working steps.

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5 02

5.1.2

Engine

Checking machine room for smell of gas

Special tools
Designation / 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 gas


1. 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!

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Ignition System

5 03

5.2

Ignition System

5.2.1

Ignition system Checking ignition voltage in secondary


circuit with the engine running

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

Special tools
Designation / Use

Part No.

Qty.

Scopemeter (oscilloscope)

High-voltage terminal

Spare parts
Designation / Use

Part No.

Qty.

Spark plug

Sealing ring

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.

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

Engine noise above 85 dB (A).


Risk of damage to hearing!
Wear ear protectors.

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5 04

Ignition System

Ignition system Checking ignition voltage in


secondary 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 the
high-voltage terminal.
4. Perform measurement.

5. Evaluate measured values indicated on the


scopemeter. Illustrated: Graph of a faulty spark
plug.
6. Fit new spark plug ( Page 5 06).

1 No spark duration
2 No inductive postoscillation

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Ignition System

5 05

7. Evaluate measured values indicated on the


scopemeter. Illustrated: Graph of a properly
functioning spark plug.
8. Disconnect high-voltage terminal.

1 Spark duration approx. 200 sek


2 Ignition voltage approx. 13 kV

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5 06

5.2.2

Ignition System

Spark plug Replacement

Spare parts
Designation / Use

Part No.

Qty.

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

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Ignition System

5.2.3

5 07

Spark plug Removal and installation

Preconditions
Engine is stopped and starting disabled.

Special tools
Designation / Use

Part No.

Qty.

Box wrench
Torque wrench

F30038494
F30510423

1
1

Part No.

Qty.

Spare parts
Designation / Use
Spark plug
Sealing ring

WARNING

Component is hot.
Risk of burning!
Wear protective goggles.
Removing spark plug
1. Remove protective cap from ignition coil.
2. Remove screw, take off spring washer and
ignition cable.
3. Unscrew spark plug and remove.

Installing spark plug


1. 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.

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5 08

Valve Gear

5.3

Valve Gear

5.3.1

Valve gear Lubrication

Preconditions
Engine is stopped and starting disabled.

Material
Designation / Use

Part No.

Qty.

Engine oil
Valve gear Lubrication
1. 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).

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Valve Gear

5.3.2

5 09

Valve clearance Check and adjustment

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

Special tools
Designation / Use

Part No.

Qty.

Feeler gauge

Y20010128

Allen key

F30002817

Torque wrench

F30047446

OJ Adapter

F30029815

Preparatory steps
1. 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" and
pointer are aligned.

Diagram
Two crankshaft positions
Applicable to 8V engines

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Valve Gear

Diagram
Two crankshaft positions
Applicable to 12V engines

Diagram
Two crankshaft positions
Applicable to 16V engines

1
2
I
X

Cylinder A1 is in firing TDC


Cylinder A1 is in overlap TDC
Inlet valve
Exhaust valve

Checking valve clearance at two crankshaft positions


1. 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 clearance


1. 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 steps
1. Remove barring tool ( Page 5 01).
2. Install cylinder head cover ( Page 5 12).

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5 12

5.3.3

Valve Gear

Cylinder head cover Removal and installation

Preconditions
Engine is stopped and starting disabled.

Special tools
Designation / Use

Part No.

Qty.

Torque wrench

F30026582

Ratchet adapter

F30027340

Part No.

Qty.

Spare parts
Designation / Use
Gasket
Removing cylinder head cover
1. 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 cover


1. 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.

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Gas System

5 13

5.4

Gas System

5.4.1

Gas supply Checking gas lines for leaks

Preconditions
Engine is stopped and starting disabled.

Material
Designation / Use

Part No.

Qty.

Leakage detection spray


Soap 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 leaks


1. Coat all connections of the gas supply line with soap solution or spray with leakage detection spray from a
distance of 30 to 50 cm.
Leaks are indicated by the formation of bubbles or foam.
2. Replace leaking parts.

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5 14

Air Filter

5.5

Air Filter

5.5.1

Air filter Replacement

Spare parts
Designation / Use

Part No.

Qty.

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

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Air Filter

5.5.2

5 15

Air filter removal and installation

Preconditions
Engine is stopped and starting disabled.
Air filter removal and installation
1. 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).

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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.

Material
Designation / Use

Part No.

Qty.

Engine oil

WARNING

Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.

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

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Lube Oil System

5.6.2

5 17

Engine oil Level check

Preconditions
Engine is stopped and starting disabled.
Checking oil level prior to engine start
1. Withdraw dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop,
withdraw after approx. 10 seconds and check
oil level.
Note: After extended standstill, the oil level
may exceed the mark (1) by up to 2 cm.
This can be caused by oil flowing from
e.g. oil filter or heat exchanger back
to the oil pan.
3. The oil level must reach the mark (1) or exceed
the 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 stopped


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

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5 18

5.6.3

Lube Oil System

Engine-oil Sample extraction and analysis

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

Special tools
Designation / Use

Part No.

Qty.

MTU test kit

5605892099/00

DANGER

WARNING

WARNING

Unguarded rotating and moving engine components.


Risk of serious injury danger to life!
Take special care when working on a running engine.
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Engine noise above 85 dB (A).
Risk of damage to hearing!
Wear ear protectors.
Engine-oil Sample extraction and analysis
1. 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.

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Oil Filtration / Cooling

5.7

Oil Filtration / Cooling

5.7.1

Engine oil filter Replacement

5 19

Preconditions
Engine is stopped and starting disabled.

Special tools
Designation / Use

Part No.

Qty.

Oil filter wrench

F30379104

Part No.

Qty.

Part No.

Qty.

Material
Designation / Use
Engine oil

Spare parts
Designation / Use
Oil filter

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.
Engine oil filter Replacement
1. 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).

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5 20

Cooling System, General, HT Circuit

5.8

Cooling System, General, HT Circuit

5.8.1

Engine coolant Filling

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

Material
Designation / Use

Part No.

Qty.

Engine coolant

WARNING

CAUTION

Coolant is hot and under pressure.


Risk of injury and scalding!
Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
Fill / top up coolant only into cold engine.

Filling with coolant


1. 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.

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Cooling System, General, HT Circuit

5.8.2

5 21

Engine coolant Draining

Preconditions
Engine is stopped and starting disabled.

Spare parts
Designation / Use

Part No.

Qty.

Sealing ring

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.

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

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5 22

Cooling System, General, HT Circuit

Engine coolant Draining


1. 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.

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Cooling System, General, HT Circuit

5.8.3

5 23

Engine coolant Change

Material
Designation / Use

Part No.

Qty.

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

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5 24

5.8.4

Cooling System, General, HT Circuit

Engine coolant Level check

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

WARNING

Coolant is hot and under pressure.


Risk of injury and scalding!
Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.

Engine coolant Level check


1. 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).

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Cooling System, LT Circuit

5.9

Cooling System, LT Circuit

5.9.1

Mixture coolant Filling

5 25

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

Material
Designation / Use

Part No.

Qty.

Mixture coolant

WARNING

CAUTION

Coolant is hot and under pressure.


Risk of injury and scalding!
Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
Fill / top up coolant only into cold engine.

Filling with coolant


1. 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.

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5 26

5.9.2

Cooling System, LT Circuit

Mixture coolant Draining

Preconditions
Engine is stopped and starting disabled.

WARNING

Coolant is hot and under pressure.


Risk of injury and scalding!
Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.

Mixture coolant Draining


1. Provide an appropriate container to drain the coolant into.
2. Open drain valve and drain coolant at the following drain point:
At coolant line.

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Cooling System, LT Circuit

5.9.3

5 27

Mixture coolant Change

Material
Designation / Use

Part No.

Qty.

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

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5 28

5.9.4

Cooling System, LT Circuit

Mixture coolant Level check

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

WARNING

Coolant is hot and under pressure.


Risk of injury and scalding!
Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.

Mixture coolant Level check


1. 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).

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General Wiring, Engine / Gearbox / Plant

5 29

5.10

General Wiring, Engine / Gearbox / Plant

5.10.1

Engine wiring check

Preconditions
Engine is stopped and starting disabled.

Material
Designation / Use

Part No.

Qty.

Isopropyl alcohol
Engine wiring check
1. 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.

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5 30

M015635/00E

General Wiring, Engine / Gearbox / Plant

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Table of Contents

6I

Annex
6.1

Manufacturers documentation

.............................................

6 01

6.2

MTU contact person/service partner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 02

6.3

Index

6 03

M015635/00E

04-12

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MTU

6 II

M015635/00E

Table of Contents

04-12

MTU

Annex

6.1

6 01

Manufacturers documentation

See Manufacturers documentation.

M015635/00E

04-12

MTU

6 02

6.2

Annex

MTU contact person/service partner

You 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

6.3

6 03

Index
A

After stopping the engine Engine remains


ready for operation . . . . . . . . . . . . . . . . . . . . .
After stopping the engine Putting the engine
out of operation . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter Replacement . . . . . . . . . . . .
Air filter removal and installation . . . . . .
Air filter Replacement . . . . . . . . . . . . . . . . . .
Air filter removal and installation . . . . . . . . . . .
Auxiliary materials, fire prevention and
environmental protection . . . . . . . . . . . . . . . . .

Engine-oil Sample extraction and


analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 18
3 11

F
3 12
5 14
5 14
5 15
5 14
5 15
1 07

C
Checking machine room for smell of gas . . . .
Cooling System, General, HT Circuit . . . . . . .
Engine coolant Change . . . . . . . . . . .
Engine coolant Draining . . . . . . . . . . .
Engine coolant Filling . . . . . . . . . . . . .
Engine coolant Level check . . . . . . . .
Cooling System, LT Circuit . . . . . . . . . . . . . . .
Mixture coolant Change . . . . . . . . . . .
Mixture coolant Draining . . . . . . . . . .
Mixture coolant Filling . . . . . . . . . . . .
Mixture coolant Level check . . . . . . . .
Cylinder head cover Removal and
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 02
5 20
5 23
5 21
5 20
5 24
5 25
5 27
5 26
5 25
5 28
5 12

E
Emergency stop . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking machine room for smell of
gas . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Barring manually . . . . . . . . . .
Engine Barring manually . . . . . . . . . . . . . . .
Engine coolant Change . . . . . . . . . . . . . . . .
Engine coolant Draining . . . . . . . . . . . . . . . .
Engine coolant Filling . . . . . . . . . . . . . . . . . .
Engine coolant Level check . . . . . . . . . . . . .
Engine layout . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . .
Engine layout . . . . . . . . . . . . . . . . . . . .
Engine oil Change . . . . . . . . . . . . . . . . . . . .
Engine oil Level check . . . . . . . . . . . . . . . . .
Engine oil filter Replacement . . . . . . . . . . . .
Engine side and cylinder designations . . . . . .
Engine Side and Cylinder Designations . . . . .
Engine side and cylinder
designations . . . . . . . . . . . . . . . . . . . . .
Engine wiring check . . . . . . . . . . . . . . . . . . . .

M015635/00E

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3 10
5 01
5 02
5 01
5 01
5 23
5 21
5 20
5 24
2 01
2 01
2 01
5 16
5 17
5 19
2 03
2 03
2 03
5 29

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

G
Gas supply Checking gas lines for leaks . . .
Gas System . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas supply Checking gas lines for
leaks . . . . . . . . . . . . . . . . . . . . . . . . . . .
General conditions . . . . . . . . . . . . . . . . . . . . .
General Wiring, Engine / Gearbox / Plant . . . .
Engine wiring check . . . . . . . . . . . . . . .

5 13
5 13
5 13
1 01
5 29
5 29

I
Ignition System . . . . . . . . . . . . . . . . . . . . . . . .
Ignition system Checking ignition
voltage in secondary circuit with the
engine running . . . . . . . . . . . . . . . . . . .
Spark plug Removal and
installation . . . . . . . . . . . . . . . . . . . . . . .
Spark plug Replacement . . . . . . . . . .
Ignition system Checking ignition voltage in
secondary circuit with the engine running . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 03

5 03
5 07
5 06
5 03
6 03

L
Lube Oil System . . . . . . . . . . . . . . . . . . . . . . .
Engine oil Change . . . . . . . . . . . . . . .
Engine oil Level check . . . . . . . . . . . .
Engine-oil Sample extraction and
analysis . . . . . . . . . . . . . . . . . . . . . . . . .

5 16
5 16
5 17
5 18

M
Main engine dimensions . . . . . . . . . . . . . . . . .
Main Engine Dimensions . . . . . . . . . . . . . . . .
Main engine dimensions . . . . . . . . . . . .
Maintenance schedule matrix . . . . . . . . . . . . .
Maintenance tasks . . . . . . . . . . . . . . . . . . . . .
Manufacturers documentation . . . . . . . . . . . .
Mixture coolant Change . . . . . . . . . . . . . . . .
Mixture coolant Draining . . . . . . . . . . . . . . .
Mixture coolant Filling . . . . . . . . . . . . . . . . .
Mixture coolant Level check . . . . . . . . . . . . .
MTU contact person/service partner . . . . . . . .

2 04
2 04
2 04
4 03
4 08
6 01
5 27
5 26
5 25
5 28
6 02

MTU

6 04

Index

O
Oil Filtration / Cooling . . . . . . . . . . . . . . . . . . . 5 19
Engine oil filter Replacement . . . . . . . 5 19
Operational checks . . . . . . . . . . . . . . . . . . . . . 3 07

P
Personnel and organizational requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 02
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 01
Putting the engine into operation after extended
out-of-service periods (>3 months) . . . . . . . . . 3 03
Putting the engine into operation after scheduled
out-of-service-period . . . . . . . . . . . . . . . . . . . . 3 04

S
Safety precautions when working on the
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIAM 4000 Operating panel . . . . . . . . . . . . .
Spark plug Removal and installation . . . . . .
Spark plug Replacement . . . . . . . . . . . . . . .

M015635/00E

04-12

1 04
3 01
5 07
5 06

Standards for warning notices in the


publication . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the engine in automatic mode . . . . . .
Starting the engine in manual mode . . . . . . . .
Stopping the engine in automatic mode . . . . .
Stopping the engine in manual mode . . . . . . .

1 09
3 06
3 05
3 09
3 08

T
Transport

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 03

V
Valve clearance Check and adjustment . . . .
Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head cover Removal and
installation . . . . . . . . . . . . . . . . . . . . . . .
Valve clearance Check and
adjustment . . . . . . . . . . . . . . . . . . . . . .
Valve gear Lubrication . . . . . . . . . . . .
Valve gear Lubrication . . . . . . . . . . . . . . . . .

5 09
5 08
5 12
5 09
5 08
5 08

MTU