MTU 12V 4000 L64 User manual

Operating Instructions
Gas engine
12V 4000 L64
16V 4000 L64
MS15027/04E

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
© 2017 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Correct use of all products 6
1.3 Personnel and organizational requirements 7
1.4 Safety regulations for initial start-up and
operation 8
1.5 Safety regulations for startup and operation,
specific information for gaseous fuel or dual
fuel supply applications 10
1.6 Safety regulations for assembly,
maintenance, and repair work 12
1.7 Safety regulations for assembly,
maintenance and repair work, specific
information for gaseous fuel and dual fuel
supply or applications 16
1.8 Fire prevention and environmental
protection, fluids and lubricants, indirect
materials 17
1.9 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, specific information for gaseous
fuel supply in gaseous-fuel or dual-fuel
applications 19
1.10 Standards for warning notices in the text
and highlighted information 20
2 Transport
2.1 Transport 21
3 Product Summary
3.1 Engine overview 22
3.2 Engine side and cylinder designations 24
3.3 Main engine dimensions 25
3.4 Firing order 26
3.5 Technical Data 27
3.5.1 12V4000L64, 16V4000L64 engine data, fuel-
optimized (TA-Luft) 27
3.5.2 12V4000L64, 16V4000L64 engine data,
emissions optimized (1/2 TA-Luft) 31
3.6 Monitoring, Control and Regulation
Equipment 35
3.6.1 Gas engine system – Overview 35
3.6.2 Purpose of the units 37
4 Operation
4.1 Runtimes at partial load 39
4.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 40
4.3 Putting the engine into operation after
scheduled out-of-service-period 41
4.4 Control, starting and stopping sequences 42
4.5 Engine – Start 44
4.6 Operational checks 45
4.7 Emission values – Check 46
4.8 Engine – Shutdown 48
4.9 Engine – Emergency shutdown 49
4.10 After stopping the engine – Engine remains
ready for operation 51
4.11 After stopping the engine – Putting the
engine out of operation 52
5 Maintenance
5.1 50-hours check 53
5.2 Maintenance task reference table [QL1] 54
6 Troubleshooting
6.1 Fault messages - Key 55
6.2 Fault messages in genset control system log 57
6.3 Engine governor – Fault messages 123
7 Task Description
7.1 Engine 163
7.1.1 Engine – Barring manually 163
7.1.2 Machine room – Check for smell of gas 164
7.1.3 Engine – Test run 165
7.2 Crankcase Breather 166
7.2.1 Oil separator – Filter replacement 166
7.2.2 Crankcase breather – Pressure control check
and adjustment 168
7.3 Ignition System 169
7.3.1 Spark plug – Replacement 169
7.3.2 Spark plug – Removal 170
7.3.3 Spark plug – Installation 171
7.3.4 Spark plug connector – Replacement 173
7.3.5 Spark plug connector – Removal 174
7.3.6 Spark plug connector – Cleaning and check 175
7.3.7 Spark plug connector – Installation 176
7.3.8 Ignition system – Ignition timing check 178
7.4 Valve Drive 179
7.4.1 Valve protrusion – Measurement 179
7.4.2 Valve gear – Lubrication 182
7.4.3 Valve clearance – Check and adjustment 183
7.4.4 Cylinder head cover ‒ Removal 185
7.4.5 Cylinder head cover ‒ Installation 186
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7.5 Gas System 187
7.5.1 Gas supply - Checking gas lines for leaks 187
7.6 Air Filter 188
7.6.1 Air filter – Replacement 188
7.6.2 Air filter – Removal and installation 189
7.7 Lube Oil System, Lube Oil Circuit 190
7.7.1 Engine oil level – Check 190
7.7.2 Engine oil – Change 191
7.7.3 Engine oil – Sample extraction and analysis 192
7.8 Oil Filtration / Cooling 193
7.8.1 Engine oil filter – Replacement 193
7.9 Coolant Circuit, General, High-Temperature
Circuit 194
7.9.1 Engine coolant – Level check 194
7.9.2 Engine coolant – Change 195
7.9.3 Engine coolant – Draining 196
7.9.4 Engine coolant – Filling 198
7.9.5 Vent line of engine coolant circuit –
Replacement 199
7.10 Low-Temperature Circuit 200
7.10.1 Mixture coolant level – Check 200
7.10.2 Mixture coolant – Change 201
7.10.3 Mixture coolant – Draining 202
7.10.4 Mixture coolant – Filling 203
7.11 Wiring (General) for Engine/Gearbox/Unit 204
7.11.1 Engine cabling – Check 204
7.11.2 Sensors – Overview 205
8 Appendix A
8.1 Abbreviations 209
8.2 MTU Onsite Energy contact person / service
partner 211
9 Appendix B
9.1 Special Tools 212
9.2 Index 216
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1 Safety
1.1 Important provisions for all products
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
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 6).
Replacing components with emission labels
On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Emission labels shall not be transferred from the replaced part to the spare part.
• The emission labels must be removed from the replaced part and destroyed.
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1.2 Correct use of all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment
Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorisation and restriction of CHemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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1.4 Safety regulations for initial start-up and operation
Safety regulations for initial start-up
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• The product must be free of any damage, this applies in particular to lines and cabling.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/urea solution line, sup-
ply/return.
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.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• inform supervisor(s) in charge,
• analyze the message,
• respond by taking any necessary emergency action, e.g. emergency stop.
Contact Service if the root cause of the malfunction cannot be clearly identified.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
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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 binding agent.
Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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1.5 Safety regulations for startup and operation, specific
information for gaseous fuel or dual fuel supply applications
General safety regulations
Important information
The fuel supplied to the gas engine is exclusively fuel gas.
The fuel supply for dual fuel application is diesel with different shares of fuel gas.
Requirement for the user: Check the gas train every time the product is started.
The temperature of the gas during operation must not fall below 5 °C in any section.
Gas system, general requirements
The plant manufacturer/user shall establish the connection to the gas supply in accordance with the applica-
ble statutory requirements, e.g. DVGW, G490/I, G491/I, DIN EN 12186, NFPA37.
Gas supply shutoff: The plant manufacturer/user shall ensure that the gas shutoff device complies with local
regulations.
The pressure regulator shall be equipped with an approved safety shutoff valve and a safety exhaust valve to
handle the situation where the pressure at the outlet of the gas pressure regulator is too high. The gas must
be vented to a hazard-free zone (atmosphere).
The gas train shall be equipped with a temperature-monitored flame arrester if the gas supply system is con-
nected to a vessel or if oxygen-containing gases are used.
The gas shutoff valves are activated via two different paths from the control system, with one path assigned
to each of the gas shutoff valves.
The gas train shall feature minimum pressure monitoring.
Additional equipment may be necessary in the gas train, e.g. maximum pressure monitoring, if
• gas supply pressure exceeds 100 mbar
• gas volume flow exceeds 200 m³/h
• fuel efficiency exceeds 600 KW
Safety regulations for initial startup in gas mixture/dual fuel applications
Whenever the product is put into service, ensure that:
• Mobile application: The product shall only be used outdoors.
• Stationary application: The product shall only be used with adequate ventilation.
Gas system, requirements for gas operation
The plant manufacturer/user shall use tested gas trains for the fuel supply of the product and connection to
the gas supply network. The manufacturer shall be consulted on matters related to connection conditions
and dimensions.
Gas trains have the following components fitted in the flow direction:
• a manual shutoff valve
• a gas filter
• two gas shutoff valves
• a pressure regulating device
The gas train shall feature automatic leak monitoring.
The plant manufacturer/user shall ensure that the gas train is positioned directly in front of the engine, but
no more than 3 meters upstream of the engine interface. The interface is the flange of the gas flow controller
or the connection of the gas/air mixer of the engine.
Series 400: The gas train must be positioned directly before the engine but no more than 2 meters upstream
of the engine interface.
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Freedom of movement of the flexible line connection must be guaranteed in accordance with the installation
instructions.
Gas system, requirements for dual fuel applications
Gas trains feature the following components in the direction of flow (plant manufacturer/user scope of sup-
ply):
• a manual shutoff valve
• a gas filter
Gas trains feature the following components in the direction of flow (MTU scope of supply):
• two gas shutoff valves (automatic)
• a pressure regulating device
• a manual shutoff valve
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1.6 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch of the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Before working on the exhaust gas treatment system close the shut-off valve on the urea solution tank. Take
into consideration that the urea solution pumps continue to run for a certain period when the engine was
stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work
Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Setting down, lifting and climbing
Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down.
Ensure safe stand when performing assembly work.
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Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Removing, installing and cleanliness
Pay particular attention to cleanliness at all times.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all retainers and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Keep gaseous/liquid fuel injection lines, lines for urea solution and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
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.
Miscellaneous
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P2) when work-
ing on exhaust components. Wear protective gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations after performing assembly, maintenance, and repair work
Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
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Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
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 can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• 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 device 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 manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing assembly, 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.
ESD: Work on electrostatically endangered components which could be damaged by electrostatic discharge
(ESD) must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically con-
ductive work surfaces or antistatic wristbands.
Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
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Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)
Working with laser equipment
Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to type
and application.
Measuring component dimensions
Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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1.7 Safety regulations for assembly, maintenance and repair
work, specific information for gaseous fuel and dual fuel
supply or applications
Safety regulations for work prior to assembly, maintenance, and repair
Assembly work shall be performed by specially trained/qualified and authorized personnel only.
The gas supply shall be connected by trained/qualified and authorized personnel only.
Work on the gas-bearing parts of the product shall be performed by specially trained/qualified and author-
ized personnel only.
Ensure adequate – possibly increased – ventilation before opening the gas system.
Shut down the gas supply to the product by closing the manual shutoff valve.
Lock-out / tag-out the drive unit to prevent starting.
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1.8 Fire prevention and environmental protection, fluids and
lubricants, indirect materials
Fire prevention and safety
Flames, naked light and smoking are prohibited.
Ensure the area is well ventilated when working with combustible fluids and lubricants (e.g. cleaning agents).
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires so keep the product
clean at all times. Do not leave rags saturated with fluids and lubricants on the product. Do not store com-
bustible materials near the product.
Clean welding points with a non-flammable fluid before welding. Do not carry out welding work on pipes and
components carrying oil or fuel.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Ensure that suitable extinguishing agents (fire extinguisher) are always available and that personnel are famil-
iar with their correct handling.
Toxic substances may be present following a fire. Always wear protective gloves and other appropriate per-
sonal protective equipment when handling components.
Noise
Wear ear protectors in work areas with a sound pressure level in excess of 85dB (A).
Noise can lead to an increased risk of accident if audible signals, warning shouts or noises indicating danger
are drowned.
Environmental protection and disposal
Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Indirect materials, fluids and lubricants
Indirect materials, fluids and lubricants may be hazardous or contain toxic substances. Observe the informa-
tion provided in the safety data sheet for the product when using indirect materials and other chemical sub-
stances. The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Only use fluids and lubricants which have been approved by the manufacture and are specified in the Fluids
and Lubricants Specifications. Request the latest version from the manufacturer.
Contamination of fluids and lubricants with aqueous urea solution (e.g. AdBlue®, DEF): Store fluids and lubri-
cants in separate containers and use different drip trays. Even tiny amounts of aqueous urea solution can
contaminate sensors and other components leading to malfunction.
Used oil contains harmful combustion residue.
Always wear protective gloves when handling used oil.
Wash relevant areas after contact with used oil.
REACH regulation (Registration, Evaluation, Authorisation and restriction of
CHemicals)
Any Substances of Very High Concern used in our products are listed under:
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http://www.mtu-online.com/mtu/technical-info → SVHC acc. REACH in MTU products
Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing off workpieces or blowing away chips.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure level in the compressed air network or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Relieve residual pressure before removing compressed-air equipment from the supply line. To depressu-
rize compressed-air lines, shut off the lines first, then release the residual pressure.
• Perform leak testing in accordance with instructions.
Paints and lacquers
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray booths provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• Avoid open flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids/alkaline solutions/urea (e.g. AdBlue®, DEF)
• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and protec-
tive clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• Wash affected body areas with plenty of water after skin contact.
• Rinse eyes immediately with eyedrops or clean tap water after eye contact. Seek medical attention as
soon as possible.
Contamination of aqueous urea solution with other fluids and lubricants: Store aqueous urea solution in
separate containers and use different drip trays. Even the slightest contamination may cause the exhaust
gas aftertreatment system to malfunction.
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1.9 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials, specific information for
gaseous fuel supply in gaseous-fuel or dual-fuel applications
General notes on gas
Observe the information contained in the safety data sheet of the gas used. Consult with gas supplier/utility.
The gas used must comply with the (→ Fluids and Lubricants Specifications of the manufacturer).
Risk of poisoning due to hazardous impurities. The ingestion of even small quantities of hydrogen sulfide or
ammonia can be fatal.
Inhaling certain gases can be dangerous to life depending on concentration. Furthermore some gases can no
longer be detected by smell in higher concentrations.
Conduct in case of escaping gases:
• If safe to do so: Shut off main gas supply.
• If safe to do so: Execute an emergency stop.
• Cordon off danger zone.
• Ensure sufficient ventilation.
• Do not enter the hazard zone until it has been established (via measurement of the gas concentration with
a suitable gas detector) that the atmosphere is no longer hazardous.
Check all gas conveying lines for tightness prior to initial operation and at regular intervals during operation.
Natural gas (pipeline quality)
Highly flammable gas; forms an explosive mixture with air/oxygen.
Weakly narcotic gas; risk of suffocation at high concentrations.
Biogenic gases from fermentation processes
Highly flammable gas; forms an explosive mixture with air/oxygen.
Risk of poisoning due to hydrogen sulfide from the fermentation process. The ingestion of even small quanti-
ties of hydrogen sulfide can be fatal.
Weakly narcotic gas; risk of suffocation at high concentrations.
Biogenic gases have a tendency to segregate. In low-lying areas of the plant, carbon dioxide enrichment is
possible.
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1.10 Standards for warning notices in the text and highlighted
information
DANGER In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
CAUTION In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.
NOTICE In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.
Warning notices
1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.
Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
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