MTU 12V4000T94 User manual

Operating Instructions
Diesel engine
12 V 4000 T94x
MS150096/03E

Engine model kW/cyl. Application group
12V4000T94 140 kW/cylinder 4D, Frac operation (continuous operation at low load)
12V4000T94L 155,4 kW/cylinder 4D, Frac operation (continuous operation at low load)
Table 1: Applicability
© 2015 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 consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming 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 Personnel and organizational requirements 7
1.3 Transport 8
1.4 Crankshaft transport locking device 9
1.5 Safety regulations for startup and operation 13
1.6 Safety regulations for maintenance and
repair work 14
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 17
1.8 Standards for safety notices in the text 19
2 General Information
2.1 Engine side and cylinder designations 20
2.2 Engine – Overview 21
2.3 Back Pack – Overview 22
2.4 Sensors, actuators and injectors – Overview 23
3 Technical Data
3.1 12 V 4000 T94/T94L engine data 27
3.2 Firing order 31
3.3 Engine – Main dimensions 32
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 33
4.2 Putting the engine into operation after
scheduled out-of-service-period 34
4.3 Operational checks 35
4.4 Starting the engine in manual mode 36
4.5 Stopping the engine in manual mode 37
4.6 After stopping the engine – Putting the
engine out of operation 38
4.7 Plant – Cleaning 39
5 Maintenance
5.1 Maintenance task reference table [QL1] 40
6 Troubleshooting
6.1 Troubleshooting 42
6.2 Engine governor ECU9 – Fault messages 45
7 Task Description
7.1 Engine 73
7.1.1 Engine – Barring manually 73
7.1.2 Barring engine with starting system 75
7.1.3 Engine – Test run 76
7.2 Cylinder Liner 77
7.2.1 Cylinder liner – Endoscopic examination 77
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 79
7.3 Crankcase Breather 81
7.3.1 Oil mist fine separator – Replacement 81
7.4 Valve Drive 82
7.4.1 Valve gear – Lubrication 82
7.4.2 Valve clearance – Check and adjustment 83
7.4.3 Cylinder head cover ‒ Removal and
installation 86
7.5 Injection Pump / HP Pump 87
7.5.1 HP pump – Filling with engine oil 87
7.6 Injection Valve / Injector 89
7.6.1 Injector – Replacement 89
7.6.2 Injector – Removal and installation 90
7.7 Fuel System 95
7.7.1 Fuel system – Venting 95
7.8 Fuel Filter 96
7.8.1 Fuel filter – Replacement 96
7.8.2 Additional fuel filter – Replacement 97
7.8.3 Fuel prefilter – Draining 98
7.8.4 Fuel prefilter – Filter element replacement 99
7.9 Exhaust Turbocharger 100
7.9.1 Exhaust turbocharger – Turbine housing
check 100
7.9.2 Exhaust turbocharger (LP) – Turbine housing
check 101
7.9.3 Exhaust turbocharger (HP) – Turbine housing
check 109
7.10 Charge-Air Cooling 115
7.10.1 Intercooler – Leak check 115
7.11 Air Filter 116
7.11.1 Air filter – Replacement 116
7.12 Air Intake 117
7.12.1 Service indicator – Signal ring position check 117
7.12.2 Emergency-air shutoff flaps – Functional
check with electric actuation 118
7.13 Exhaust Gas Recirculation 120
7.13.1 Exhaust flaps – Overview 120
7.13.2 Exhaust flaps – Checking operation of
actuators 122
7.13.3 Exhaust flaps – Checking coupling rods
operability and play 123
7.13.4 Exhaust flaps – Coupling rod replacement 125
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7.14 Starting Equipment 128
7.14.1 Starter – Condition check 128
7.15 Lube Oil System, Lube Oil Circuit 129
7.15.1 Engine oil level – Check at sight glass 129
7.15.2 Engine oil – Level check with oil dipstick 130
7.15.3 Engine oil – Change 131
7.15.4 Engine oil – Sample extraction and analysis 133
7.16 Oil Filtration / Cooling 134
7.16.1 Engine oil filter – Replacement 134
7.16.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 136
7.17 High-Temperature Circuit 138
7.17.1 Engine coolant – Level check 138
7.17.2 Engine coolant – Change 139
7.17.3 Engine coolant – Draining 140
7.17.4 Engine coolant – Filling 142
7.17.5 Engine coolant pump – Relief bore check 145
7.18 Low-Temperature Circuit 146
7.18.1 Charge-air coolant – Level check 146
7.18.2 Charge-air coolant – Change 147
7.18.3 Charge-air coolant – Draining 148
7.18.4 Charge-air coolant – Filling 151
7.18.5 Checking charge-air coolant pump pressure
relief port 154
7.19 Belt Drive 155
7.19.1 Drive belt – Condition check 155
7.20 Battery-Charging Generator 156
7.20.1 Checking battery-charging generator 156
7.20.2 Battery-charging generator drive – Drive belt
tension adjustment 157
7.20.3 Battery-charging generator drive – Drive belt
replacement 158
7.21 Engine Mounting / Support 159
7.21.1 Engine mounting – Check 159
7.22 Wiring (General) for Engine/Gearbox/Unit 160
7.22.1 Engine cabling – Check 160
7.23 Accessories for (Electronic) Engine
Governor / Control System 161
7.23.1 Resetting CDC parameter and entering IIG
with DiaSys® 161
7.23.2 Actuators – Visual inspection and test 162
7.23.3 Engine governor and connector – Cleaning 164
7.23.4 Engine governor plug connections – Check 165
7.23.5 NOx sensor – Replacement 166
7.23.6 Lambda sensor – Replacement 168
7.24 Exhaust System 170
7.24.1 Exhaust silencer – Condensate drain check 170
7.24.2 Back Pack – Visual inspection of securing
screws 171
7.24.3 Back Pack – Checking securing screws for
firm seating 172
8 Appendix A
8.1 Abbreviations 174
8.2 MTU contact persons/service partners 177
9 Appendix B
9.1 Special Tools 178
9.2 Index 187
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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.
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 accompa-
nying specifications.
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 for use in accordance with its contractually-defined purpose as described in the
relevant 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 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
• With maintenance work performed in accordance with 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
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use. 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.
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 au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
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Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents 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, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions
regulation authorities. The manufacturer does not accept any liability for violations of the emission reg-
ulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of
the product.
Replacing components with emission labels
Emission labels are attached to all MTU engines. These must remain on the engine throughout its op-
erational life.
Engines used exclusively in land-based, military applications other than by US government agencies are
excepted from this proviso.
Please note the following when replacing components with emission labels:
• Appropriate emission labels must be affixed on spare parts.
• Emission labels may not be transferred from old components to new ones.
• Emission labels on old components must be removed and destroyed.
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1.2 Personnel and organizational requirements
Organizational measures of the user/manufacturer
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.
Personnel must receive instruction on product handling and maintenance on the basis of this manual
with a special emphasis on safety requirements and warnings.
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. safety footwear, ear pro-
tectors, protective gloves, goggles, breathing protection). Observe the information on personal protec-
tive equipment in the respective activity description.
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1.3 Transport
Taking the engine's center of gravity into account
For information regarding the center of gravity of the engine, refer to the installation/arrangement
drawing of the engine/genset/system.
Transport
• Lift the engine/genset/system only with the lifting eyes provided.
• Only use transport and lifting devices approved by MTU.
• The engine/genset/system must only be transported in installation position.
• Max. permissible diagonal pull 10°.
• If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes
of the trestle or use a means of transportation which is appropriate for the given weight (forklift
truck).
• Prior to transporting the engine/genset/system, it is imperative to install the transport locking de-
vice for the crankshaft.
• Prior to transporting the engine/genset/system, it is imperative to install the transport locks for the
engine mounts.
• Secure the engine/genset/system such as to preclude tipping during transport.
• Secure the engine/system/genset as to preclude slipping and tipping when driving up or down in-
clines and ramps.
Setting the engine down after transport
• Make sure that the consistency and load-bearing capacity of the ground or support surface is ade-
quate.
• Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by
MTU on a case-to-case basis.
• Place the engine/genset/system on a firm, flat surface only.
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1.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Torque wrench, 60-320 Nm F30452768 1
Engine oil
Transport locking device
Note: The locking device protects the crankshaft bearings from possible shocks and vibration damage during
engine transport.
For installation and removal of the transport locking device, observe the following instructions:
• The transport locking device must remain installed as long as possible during engine installation in
order to avoid damage.
• Starting or barring the engine is allowed only with the transport locking device removed. If the gener-
ator/gearbox is flanged on, make sure that the transport locking device of the generator/gearbox is
removed as well.
• The transport locking device must be reinstalled according to the instructions prior to every engine
transport.
• If the generator/gearbox is flanged on and is also going to be moved, install the transport locking
device of the generator/gearbox as well.
Removing the transport locking
device from driving end (KS),
version A
1. Remove parts (1) to (8) from engine.
Spacer sleeves (5) are optional.
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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Installing the transport locking
device on driving end (KS), ver-
sion A
1. Screw holder (4) with spacer sleeves (5)
and screws (6) onto crankshaft. Spacer
sleeves (5) are optional.
2. Tighten screws (6) with torque wrench to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 160 Nm +16 Nm
3. Screw nut (3) with washer (2) onto holder (4).
4. Fit carrier (1) with washer (7) and nut (8) and tighten to the specified tightening torque using the torque
wrench.
Name Size Type Lubricant Value/Standard
Nut M24 Tightening torque (Engine oil) 100 Nm +10 Nm
5. Lock with nut (3).
6. Mark the engine as "Fitted with transportation locking device".
Removing the transport locking
device from driving end (KS),
version B
1. Release locknuts (3) on both sides of the
flywheel housing, remove screws (4) and
take off the two holders (1).
2. Remove screws (6) with washers (5), la-
bel (7) and plates (2).
3. Store the removed parts carefully for possi-
ble reuse.
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Note: Use only the screws supplied with or re-
moved from the guard plates to secure the
guard plates.
4. Install guard plates (3), washers (2) and
screws (1) on both sides.
5. Tighten screws (1).
Fitting the transport locking de-
vice on driving end (KS), version
B
1. Remove screws (1) with washers (2) and
take off guard plates (3).
2. Store the removed parts carefully for possi-
ble reuse.
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Note: Only screw on the transport locking device with the screws supplied with or removed from the transport
locking device.
3. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
4. Screw nut (3) onto screws (4) up to the end of the thread.
5. Fit the holders (1) through the openings of plates (2) and fasten with the screws (4).
6. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
7. Screw on nuts (3) of both screws (4) at plates (2) and secure.
8. Fit label (7) to mark the engine as "Fitted with transport locking device".
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1.5 Safety regulations for startup and operation
Safety requirements for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica-
tions 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.
When putting the product into operation, always 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 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.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• Keep clear of the service room during the first operating hours. Hazardous gases may occur as a re-
sult of the combustion of paints or oils.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.
Safety requirements for 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 emergencies, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond to the emergency appropriately, e.g. execute an 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 possible. Do not touch the product unless expressly in-
structed 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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1.6 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 (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
suitable collecting vessels 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:
• It is 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.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when air starters
are fitted.
Disconnect the control equipment from the product.
Use special tools if they are specified for the relevant work.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be
painted. They may only be installed after painting the engine or must be covered before painting work is
carried out.
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 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.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid
that components/tools fall down .Use the specified lifting equipment for all components.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
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Ensure that all retainers and dampers are installed correctly.
Ensure that O-rings are not installed ina slanted/twisted condition.
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 (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the engine, always use suitable ladders and work platforms.
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly.If necessary, coat the
components with a suitable corrosion inhibitor.
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 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 re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
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 process materials.
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 components (e.g. exhaust pipe) from the product before performing necessary welding work .
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 exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on jig with plunger extended.
• During the removal procedure, screw on jig with plunger retracted.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of
the component being pressed.
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Working with batteries
Observe the safety instructions of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not 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.
Working on electrical and 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.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be dam-
aged during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a functional testing on completion of all repair work. In
particular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Working with laser devices
When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser devices must be equipped with protective devices in accordance with their class and usage to
ensure safe operation.
For conducting light-beam procedures and measurement work, only the following laser devices may be
used:
• Laser devices of classes 1, 2 or 3A.
• Class 3B laser devices:
– which operate in the visible spectral range (400 nm to 700 nm) only
– which have a maximum output of 5 mW
– which are arranged such as to prevent the beam from harming eyesight.
Measuring component deviations
Workpieces, components and measuring equipment are within specified tolerances at a reference tem-
perature of 20 °C.
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1.7 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground cable 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.
Always have a suitable extinguishant (fire extinguisher) on hand and familiarize yourself fully with its
handling.
Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating
danger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Fluids and lubricants, auxiliary materials
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
“Technical Info” or “Parts and Service” tabs at http://www.mtu-online.com.
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as
well as other chemical substances, observe the information contained in the safety data sheet for the
product. The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.
When using flammable materials, avoid all sparks and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.
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Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• 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 in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. In-
stall 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).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems,
ensure that the area is well ventilated. Make sure that neighboring work areas are not adversely af-
fected.
• There must be no naked 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 specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)
• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.
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1.8 Standards for safety notices in the text
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.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
MS150096/03E 2015-04 | Safety | 19
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2 General Information
2.1 Engine side and cylinder designations
1 Left engine side (A-side)
2 Engine free end in accord-
ance with DIN ISO 1204
(KGS = Kupplungsgegen-
seite)
3 Right engine side (B-side)
4 Engine driving end in ac-
cordance with
DIN ISO 1204 (KS = Kup-
plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
20 | General Information | MS150096/03E 2015-04
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