MTU 12V4000L32FB User manual
Operating Instructions
Gas engine
12 V 4000 Lx2 xx
16 V 4000 Lx2 xx
MS150115/00E
Engine model kW/cyl. Application group
12V4000L32FB 100 kW/cyl. 3A, continuous operation, unrestricted
16V4000L32FB 100 kW/cyl. 3A, continuous operation, unrestricted
Table 1: Applicability
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 Transport 7
1.4 Safety regulations for startup and operation 8
1.5 Safety regulations for startup and operation,
special instructions for applications with
gaseous fuel 9
1.6 Safety regulations for maintenance and
repair work 10
1.7 Safety regulations for maintenance and
repair work, special instructions for
applications with gaseous fuel 13
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 14
1.9 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel 16
1.10 Standards for safety notices in the text 17
2 Product Summary
2.1 Engine layout 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 L32FB, 16 V 4000 L32FB engine
data, fuel optimized (TA-Luft) 23
2.5.2 12 V 4000 L32FB, 16 V 4000 L32FB engine
data, tropical applications (TA-Luft) 28
2.6 Monitoring, Control and Regulation
Equipment 33
2.6.1 Gas engine phase 3 system – Overview 33
2.6.2 Purpose of the units 35
3 Operation
3.1 Runtimes at partial load 37
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 38
3.3 Putting the engine into operation after
scheduled out-of-service-period 39
3.4 Control, starting and stopping sequences 40
3.5 Engine – Start 42
3.6 Operational checks 43
3.7 Emission values – Check 44
3.8 Engine – Shutdown 45
3.9 Emergency engine shutdown 46
3.10 After stopping the engine – Engine remains
ready for operation 48
3.11 After stopping the engine – Putting the
engine out of operation 49
4 Maintenance
4.1 50-hours check 50
4.2 Maintenance task reference table [QL1] 51
5 Troubleshooting
5.1 Fault messages - Key 52
5.2 Fault messages in communication protocol
to genset control system 54
5.3 Fault messages of the engine governor 96
6 Task Description
6.1 Engine 130
6.1.1 Engine – Barring manually 130
6.1.2 Checking machine room for smell of gas 131
6.2 Crankcase Breather 132
6.2.1 Oil separator – Filter replacement 132
6.3 Ignition System 134
6.3.1 Spark plug – Replacement 134
6.3.2 Spark plug – Removal 135
6.3.3 Spark plug – Installation 136
6.3.4 Spark plug connector – Replacement 138
6.3.5 Spark plug connector – Removal 139
6.3.6 Spark plug connector – Installing 140
6.3.7 Ignition system – Ignition timing check 143
6.4 Valve Drive 144
6.4.1 Valve depth – Measurement 144
6.4.2 Valve clearance – Check and adjustment 147
6.4.3 Valve gear – Lubrication 150
6.4.4 Cylinder head cover – Removal 151
6.4.5 Cylinder head cover – Installation 152
6.5 Gas System 153
6.5.1 Gas supply - Checking gas lines for leaks 153
6.6 Air Filter 154
6.6.1 Air filter – Replacement 154
6.6.2 Air filter – Removal and installation 155
6.7 Lube Oil System, Lube Oil Circuit 156
6.7.1 Engine oil – Level check 156
6.7.2 Engine oil – Change 157
6.7.3 Engine oil – Sample extraction and analysis 158
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6.8 Oil Filtration / Cooling 159
6.8.1 Engine oil filter – Replacement 159
6.9 Coolant Circuit, General, High-Temperature
Circuit 160
6.9.1 Engine coolant – Level check 160
6.9.2 Engine coolant – Change 161
6.9.3 Engine coolant – Draining 162
6.9.4 Engine coolant – Filling 164
6.9.5 Vent line of engine coolant circuit –
Replacement 165
6.10 Low-Temperature Circuit 166
6.10.1 Mixture coolant – Level check 166
6.10.2 Mixture coolant – Change 167
6.10.3 Mixture coolant – Draining 168
6.10.4 Mixture coolant – Filling 169
6.11 Wiring (General) for Engine/Gearbox/Unit 170
6.11.1 Engine wiring – Check 170
6.11.2 Sensors – Overview 171
7 Appendix A
7.1 Abbreviations 175
7.2 MTU Onsite Energy contacts / service
partners 177
8 Appendix B
8.1 Special Tools 178
8.2 Index 182
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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 Transport
Transport
Only use the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear-
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport
Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
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1.4 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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1.5 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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1.6 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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