MTU 8V4000L63 User manual

Operating Instructions
Gas engine
8 V 4000 Lx3
MS150057/02E

Engine model kW/cyl. Application group
8V4000L63 110 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 Engine ‒ Main dimensions 21
2.4 Firing order 22
2.5 Technical Data 23
2.5.1 8V 4000 L63 engine data, fuel-optimized (TA-
Luft) 23
2.5.2 8V 4000 L63 engine data, emissions-optimized
(1/2 TA-Luft) 27
2.6 Monitoring, Control and Regulation
Equipment 31
2.6.1 Gas engine phase 3 system – Overview 31
2.6.2 Control cabinet MIS – Overview 33
2.6.3 Purpose of the units 34
3 Operation
3.1 Runtimes at partial load 38
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 39
3.3 Putting the engine into operation after
scheduled out-of-service-period 40
3.4 Control, starting and stopping sequences 41
3.5 Engine – Start 43
3.6 Operational checks 44
3.7 Emission values – Check 45
3.8 Engine – Shutdown 46
3.9 Emergency stop 47
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 indication on SAM display 52
5.2 SAM – Fault messages 56
5.3 Engine governor – Fault messages 106
6 Task Description
6.1 Engine 137
6.1.1 Engine – Barring manually 137
6.1.2 Machine room – Check for smell of gas 138
6.2 Crankcase Breather 139
6.2.1 Oil separator – Filter replacement 139
6.3 Ignition System 141
6.3.1 Spark plug – Replacement 141
6.3.2 Spark plug – Removal 142
6.3.3 Spark plug – Installation 143
6.3.4 Spark plug connector – Replacement 145
6.3.5 Spark plug connector – Removal 146
6.3.6 Spark plug connector – Installation 147
6.3.7 Ignition system – Ignition timing check 149
6.4 Valve Drive 150
6.4.1 Valve clearance – Check and adjustment 150
6.4.2 Valve projection – Measurement 153
6.4.3 Valve gear – Lubrication 156
6.4.4 Cylinder head cover – Removal 157
6.4.5 Cylinder head cover – Installation 158
6.5 Gas System 159
6.5.1 Gas supply – Checking gas lines for leaks 159
6.6 Air Filter 160
6.6.1 Air filter – Replacement 160
6.6.2 Air filter – Removal and installation 161
6.7 Lube Oil System, Lube Oil Circuit 162
6.7.1 Engine oil – Level check 162
6.7.2 Engine oil – Change 163
6.7.3 Engine oil – Sample extraction and analysis 164
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6.8 Oil Filtration / Cooling 165
6.8.1 Engine oil filter – Replacement 165
6.9 Coolant Circuit, General, High-Temperature
Circuit 166
6.9.1 Engine coolant – Level check 166
6.9.2 Engine coolant – Change 167
6.9.3 Engine coolant – Draining 168
6.9.4 Engine coolant – Filling 170
6.9.5 Vent line of engine coolant circuit –
Replacement 171
6.10 Low-Temperature Circuit 172
6.10.1 Mixture coolant level – Check 172
6.10.2 Mixture coolant – Change 173
6.10.3 Mixture coolant – Draining 174
6.10.4 Mixture coolant – Filling 175
6.11 Wiring (General) for Engine/Gearbox/Unit 176
6.11.1 Engine wiring – Check 176
6.11.2 Sensors ‒ Overview 177
7 Appendix A
7.1 Abbreviations 181
7.2 MTU Onsite Energy contacts / service
partners 183
8 Appendix B
8.1 Special Tools 184
8.2 Index 188
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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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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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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 reinstalling ensure that wiring is not damaged dur-
ing operation by contact with sharp objects, by rubbing against other components or by a hot surface.
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 function check on completion of all repair work. In partic-
ular, 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
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be equipped with the protective devices necessary for safe operation according
to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
•Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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1.7 Safety regulations for maintenance and repair work, special
instructions for applications with gaseous fuel
Safety regulations prior to maintenance and repair work
Installation and connection of the gas supply must only be carried out by a specialized company with
staff that has been trained and authorized for this task.
Have all work on gas-carrying components carried out by authorized, specialized companies.
Prior to starting maintenance work, shut off the gas supply to the product. Activate the emergency stop
at the interface switchgear cabinet or by turning the key switch (if fitted).
In case of scheduled shutdowns of the product, coolant pump operation must continue for a certain
time.
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1.8 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 lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal
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 guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
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.
Consumable fluids and 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 "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
coming into contact with ignition sources 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.
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Lead
•Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.
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 to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• 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.
Paints and varnishes
• Observe the relevant safety data sheet for all materials.
• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• 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.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• 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.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.
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1.9 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials, special instructions for
applications with gaseous fuel
Natural gas
Observe the safety data sheet.
Caution: Highly flammable gas, forms an explosive mixture with air/oxygen.
Caution: Weak narcotic gas, risk of suffocation at very high concentration.
All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during
operation.
Procedure in the case of accidental release of gaseous fuel:
•If safely feasible: Shut off main gas supply.
• If safely feasible: Carry out emergency stop.
• Cordon off danger zone.
• Ensure sufficient ventilation!
• Do not enter danger zone before measurements with a suitable gas detector have confirmed that gas
concentration is not hazardous.
Biogenic gases from fermentation processes
Observe the safety data sheet.
Caution: Highly flammable gas, forms an explosive mixture with air/oxygen.
Caution: Can be life threatening depending on concentration. Some gases can no longer be detected by
sense of smell in higher concentrations.
Caution: Risk of poisoning due to hazardous byproducts. The absorption of even small quantities of hy-
drogen sulfide or ammonium may be lethal.
Caution: Danger of suffocation. Due to the lack of oxygen, the absorption of methane can occasionally
lead to increased breathing frequency (hyperventilation) and heart rates, low blood pressure, numbness
of the extremities, drowsiness, mental confusion and loss of memory!
Biogenic gases tend to segregate. In low-lying areas of the plant, carbon dioxide enrichment is possible.
All gas-carrying lines must be checked for leaks prior to commissioning and at regular intervals during
operation.
Procedure in the case of accidental release of gaseous fuel:
• If safely feasible: Shut off main gas supply.
• If safely feasible: Carry out emergency stop.
• Cordon off danger zone.
• Ensure sufficient ventilation!
• Do not enter danger zone before measurements with a suitable gas detector have confirmed that gas
concentration is not hazardous.
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1.10 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
uThis manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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2 Product Summary
2.1 Engine layout
1 Engine governor/engine
monitoring
2Air filter/air inlet
3 Mixture cooler
4 Exhaust turbocharger
5 Engine lifting eye
6 Capacitor ignition system
7 Engine mounting bracket,
free end
8 Oil pan
9 Engine mounting bracket,
driving end
10 Starter
11 Flywheel
KS Driving end
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1 Crankcase breather, oil
separator
2Exhaust gas outlet connec-
tion
3 Gas control valve
4 Gas inlet connection
5 Throttle
6 Ignition coil
7 Spark plug
8 Cylinder head cover
9 Cylinder head
10 Engine oil sampling con-
nection
11 Engine oil filter
12 Oil level switch
13 Engine coolant inlet con-
nection
14 Engine oil heat exchanger
15 Engine coolant outlet con-
nection
KGS Free end
Engine model designation
Key to the engine model designations 8 V 4000 L63
8 Number of cylinders
V Cylinder arrangement: Vee engine
4000 Series
L Application: L = Gas engine
6 Load profile
3 Design index
Table 2: Key to the engine model designations 8 V 4000 L63
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2.2 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS) (4).
For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on
the left-hand side of the engine and the letter "B" (3) to refer to the cylinders on the right-hand side. The
cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of other engine components also starts with no. 1 at the driving end.
1 Left-hand side of engine
2Free end
3 Right-hand side of engine
4 Driving end
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