MTU 12 V 4000 Lx4 User manual
Operating Instructions
Gas engine
12 V 4000 Lx4
16 V 4000 Lx4
MS15027/00E
Engine model kW/cyl. Application group
12V4000L64 130 kW/cyl. 3A, continuous operation, unrestricted
16V4000L64 130 kW/cyl. 3A, continuous operation, unrestricted
Table 1: Validity overview
Printed in Germany
© 2013 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, mi-
crofilming 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.
Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Personnel and organizational requirements 6
1.3 Safety regulations for startup and operation 7
1.4 Safety regulations for startup and operation,
special instructions for applications with
gaseous fuel 8
1.5 Safety regulations for maintenance and
repair work 9
1.6 Safety regulations for maintenance and
repair work, special instructions for
applications with gaseous fuel 12
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel 15
1.9 Standards for safety notices in the text 16
1.10 Transport 17
2 Product Summary
2.1 Engine overview 18
2.2 Engine side and cylinder designations 20
2.3 Main engine dimensions 21
2.4 Ignition order 22
2.5 Technical Data 23
2.5.1 12 V 4000 L64, 16 V 4000 L64 engine data,
fuel optimized ("TA-Luft") 23
2.5.2 12V 4000 L64, 16V 4000 L64 engine data,
emissions-optimized (1/2 "TA-Luft") 27
2.6 Monitoring, Control and Regulation
Equipment 31
2.6.1 Gas engine phase 4 system – Overview 31
2.6.2 Purpose of the units 33
3 Operation
3.1 Runtimes at partial load 35
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 36
3.3 Putting the engine into operation after
scheduled out-of-service-period 37
3.4 Control, starting and stopping sequences 38
3.5 Engine – Start 40
3.6 Operational checks 41
3.7 Emission values – Check 42
3.8 Engine – Shutdown 43
3.9 Emergency engine shutdown 44
3.10 After stopping the engine – Engine remains
ready for operation 46
3.11 After stopping the engine – Putting the
engine out of operation 47
4 Maintenance
4.1 50-hours check 48
4.2 Maintenance schedule reference table [QL1] 49
5 Troubleshooting
5.1 Fault messages - Key 50
5.2 Fault messages on log for genset control 52
5.3 Engine governor – Fault messages 110
6 Task Description
6.1 Engine 147
6.1.1 Engine – Barring manually 147
6.1.2 Machine room – Check for smell of gas 148
6.2 Crankcase Breather 149
6.2.1 Oil separator – Filter replacement 149
6.3 Ignition System 151
6.3.1 Spark plug – Replacement 151
6.3.2 Spark plug – Removal 152
6.3.3 Spark plug – Installation 153
6.3.4 Spark plug connector – Replacement 155
6.3.5 Spark plug connector – Removal 156
6.3.6 Spark plug connector – Installing 157
6.3.7 Ignition system – Ignition timing check 160
6.4 Valve Drive 161
6.4.1 Valve depth – Measurement 161
6.4.2 Valve gear – Lubrication 164
6.4.3 Valve clearance – Check and adjustment 165
6.4.4 Cylinder head cover – Removal 168
6.4.5 Cylinder head cover – Installation 169
6.5 Gas System 170
6.5.1 Gas supply - Checking gas lines for leaks 170
6.6 Air Filter 171
6.6.1 Air filter – Replacement 171
6.6.2 Air filter – Removal and installation 172
6.7 Lube Oil System, Lube Oil Circuit 173
6.7.1 Engine oil – Level check 173
6.7.2 Engine oil – Change 174
6.7.3 Engine oil – Sample extraction and analysis 175
6.8 Oil Filtration / Cooling 176
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6.8.1 Engine oil filter – Replacement 176
6.9 Coolant Circuit, General, High-Temperature
Circuit 177
6.9.1 Engine coolant – Level check 177
6.9.2 Engine coolant – Change 178
6.9.3 Engine coolant – Draining 179
6.9.4 Engine coolant – Filling 181
6.10 Low-Temperature Circuit 182
6.10.1 Mixture coolant level – Check 182
6.10.2 Mixture coolant – Change 183
6.10.3 Mixture coolant – Draining 184
6.10.4 Mixture coolant – Filling 185
6.11 Wiring (General) for Engine/Gearbox/Unit 186
6.11.1 Engine wiring – Check 186
6.11.2 Sensors – Overview 187
7 Appendix A
7.1 Abbreviations 191
7.2 MTU Onsite Energy contacts / service
partners 193
8 Appendix B
8.1 Special Tools 194
8.2 Index 198
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
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1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
•Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment
Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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1.3 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance the manufacturer's specifications
before putting the product into service.
Before the product is put into operation for the first time, all official authorizations must be available
and commissioning preconditions met.
When putting the product into operation, always ensure that
•All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All personnel is clear of the danger zone surrounding moving parts of the machine.
• The service room is adequately ventilated.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems work properly.
Safety regulations for equipment operation
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re-
gard to present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
The procedures for cases of emergency, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is recognized or reported by the sys-
tem:
• Inform supervisor(s) in charge.
• Analyze the message.
• If required, carry out emergency operations e.g. emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely neces-
sary.
Keep a safe distance away from the product if at all possible. Do not touch the product unless expressly
instructed to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder
agent.
Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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1.4 Safety regulations for startup and operation, special
instructions for applications with gaseous fuel
Gas system
Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device. This
must be designed by the plant designer according to site conditions.
The connection to the gas supply network is made by the plant designer in accordance with regulations
of the DVGW (DVGW490, G490/I). The plant designer must use certified gas trains for the fuel supply
to the product and connection to the gas supply network. The connection conditions and dimensions
must be coordinated with the manufacturer.
In flow direction, gas trains have:
•a manual shutoff fitting
• a gas filter
• two gas shutoff valves
• a pressure regulating device
The gas train must be fitted with an automatic leak check.
The gas shutoff valves are activated via two different paths from the control system, whereby one gas
shutoff valve respectively is activated via one of the paths.
Gas trains must be monitored to detect minimum pressure.
The plant designer must ensure that the gas train is positioned directly in front of the engine, however a
maximum of three meters before the interface of the engine. The interface is the flange in front of the
gas volume regulator of the product.
In the case of network supply pressures higher than 120 mbar, additional equipment is required on the
gas train.
The gas pressure regulator must be equipped with an approved safety shut-off valve and a safety dis-
charge valve to ensure safety in case of excessive outlet pressure at the pressure regulator.Gas dis-
charge must be routed to a safe area (to atmosphere).
If the gas supply is connected to a vessel or if gases containing oxygen are used, the gas train must be
equipped with a temperature-monitored flame arrester.
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1.5 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion
of oil vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
•Expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Secure the product against unintentional starting, e.g. with start interlock.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock contactors.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following applies to starters with copper-beryllium alloy pinions:
• Wear breathing protection of filter class P3 during maintenance work. Do not blow out the interior of
the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a
class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work
Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
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Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths
and cable ties).
Safety regulations after completion of maintenance and repair work
Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding
in its vicinity.
Before starting welding work:
•Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Hydraulic installation and removal
Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal jig, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries
Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear goggles and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
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