MTU Gas engine8 V 4000 L62 User manual

Operating Instructions
Gas engine
8 V 4000 L62
MS150032/02E

Printed in Germany
© 2012 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, micro‐
filming 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 General conditions 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety regulations for startup and operation 8
1.5 Safety requirements for maintenance and
repair work 9
1.6 Fluids and lubricants, fire prevention and
environmental protection 12
1.7 Conventions for safety instructions in the
text 15
2 Product Summary
2.1 Engine – Overview 16
2.2 Engine side and cylinder designations 18
2.3 Engine – Main dimensions 19
2.4 Firing order 20
2.5 Technical Data 21
2.5.1 Runtimes at partial load 21
2.5.2 8V 4000 L62 engine data, fuel-optimized (TA-
Luft) 22
2.5.3 8V 4000 L62 engine data, emissions-
optimized (1/2 TA-Luft) 26
2.6 Monitoring, Control and Regulation
Equipment 30
2.6.1 Gas engine phase 3 system – Overview 30
2.6.2 Control cabinet MIS – Overview 32
2.6.3 Purpose of the units 33
3 Operation
3.1 Putting the engine into operation after
extended out-of-service-periods (>3
months) 37
3.2 Putting the engine into operation after
scheduled out-of-service-period 38
3.3 Control, starting and stopping sequences 39
3.4 Starting the engine 40
3.5 Operational checks 41
3.6 Stopping the engine 42
3.7 Emergency stop 43
3.8 After stopping the engine – Engine remains
ready for operation 44
3.9 After stopping the engine – Putting the
engine out of operation 45
4 Maintenance
4.1 50-hours check 46
4.2 Maintenance task reference table [QL1] 47
5 Task Description
5.1 Engine 48
5.1.1 Engine – Barring manually 48
5.1.2 Checking machine room for smell of gas 49
5.2 Crankcase Breather 50
5.2.1 Oil separator – Filter replacement 50
5.3 Ignition System 52
5.3.1 Ignition system – Ignition timing check 52
5.3.2 Spark plug connector – Replacement 53
5.3.3 Spark plug connector – Removal and
installation 54
5.3.4 Spark plug – Replacement 56
5.3.5 Spark plug – Removal and installation 57
5.4 Valve Drive 59
5.4.1 Valve gear - Overview 59
5.4.2 Valve clearance – Check and adjustment 60
5.4.3 Valve depth – Measurement 62
5.4.4 Valve gear – Lubrication 65
5.4.5 Cylinder head cover – Removal and
installation 66
5.5 Gas System 67
5.5.1 Gas supply – Checking gas lines for leaks 67
5.6 Air Filter 68
5.6.1 Air filter – Replacement 68
5.6.2 Air filter – Removal and installation 69
5.7 Lube Oil System, Lube Oil Circuit 70
5.7.1 Engine oil level – Check 70
5.7.2 Engine oil – Change 71
5.7.3 Engine oil – Sample extraction and analysis 72
5.8 Oil Filtration / Cooling 73
5.8.1 Engine oil filter – Replacement 73
5.9 Coolant Circuit, General, High-
Temperature Circuit 74
5.9.1 Engine coolant – Level check 74
5.9.2 Engine coolant – Change 75
5.9.3 Engine coolant – Draining 76
5.9.4 Engine coolant – Filling 78
5.9.5 Vent line of engine coolant circuit –
Replacement 79
5.10 Low-Temperature Circuit 80
5.10.1 Mixture coolant level - Check 80
MS150032/02E 2012-07 | Table of Contents | 3
DCL-ID: 0000016354 - 003

5.10.2 Mixture coolant - Change 81
5.10.3 Mixture coolant - Draining 82
5.10.4 Mixture coolant - Filling 83
5.11 Wiring (General) for Engine/Gearbox/Unit 84
5.11.1 Engine wiring – Check 84
5.11.2 Sensors – Overview 85
6 Troubleshooting
6.1 Fault indication on SAM display 89
6.2 SAM – Fault messages 93
6.3 Engine governor – Fault messages 143
7 Appendix A
7.1 Abbreviations 174
7.2 MTU Onsite Energy contact / service
partner 176
8 Appendix B
8.1 Special Tools 177
8.2 Consumables 181
8.3 Spare Parts 182
8.4 Index 184
4 | Table of Contents | MS150032/02E 2012-07
DCL-ID: 0000016354 - 003

1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present 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
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the operating instructions and mainte‐
nance and repair specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
MS150032/02E 2012-07 | Safety | 5
TIM-ID: 0000000860 - 016

1.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.
6 | Safety | MS150032/02E 2012-07
TIM-ID: 0000000874 - 016

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.
MS150032/02E 2012-07 | Safety | 7
TIM-ID: 0000002614 - 003

1.4 Safety regulations for startup and operation
Safety precautions when putting the equipment into operation
Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐
tions and check the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems are working properly.
Safety regulations for equipment operation
Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of all operations to be 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.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
8 | Safety | MS150032/02E 2012-07
TIM-ID: 0000023743 - 010

1.5 Safety requirements for maintenance and repair work
Safety requirements for maintenance and repair work
Maintenance and repair work may only be carried out by authorized, qualified personnel.
All work on gas-carrying components must be carried out by authorized, specialized companies.
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.
Before starting maintenance work, allow the engine to cool down (danger of explosion due to vapors),
shut off the gas supply to the engine and activate the emergency stop at the engine interface switch cabi‐
net (MIS) or by turning the keyswitch, if fitted.
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from engine. Cover the screw or plug with a
rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ risk of burning.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Prior to all work, allow the engine / genset to cool down.
Observe maintenance and repair instructions.
Never perform care or maintenance work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting.
With electric starter, disconnect the battery.
Close the main valve on the compressed-air system and vent the compressed-air line when air starters
are fitted.
Disconnect the control device from the assembly or plant.
Only use adequate, calibrated tools. During assembly and disassembly, observe the specified tightening
torques.
Carry out work only on assemblies or plants that are secured as specified.
Do not use lines as climbing aids.
Only use fuel lines or fuel system components that have been approved for the application in question.
Keep fuel lines and connections clean.
Always fit caps/covers to close off any openings exposed by removing or opening lines.
Take care to avoid damaging fuel lines in the course of care and maintenance work.
Ensure that all mounts and dampers are correctly installed.
Ensure that all fuel lines and pressurized oil lines have sufficient distance to other components to avoid
contact with them. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) if they have carbonized or resinous appearance.
Note cooling period 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. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness during maintenance and repair work on the assembly or plant. After comple‐
tion of maintenance and repair work, make sure that no loose objects are in/on the assembly or plant.
Ensure that all personnel is clear of danger zones before turning the engine. Check that all guards have
been reinstalled and that all tools and loose parts have been removed after working on the engine.
MS150032/02E 2012-07 | Safety | 9
TIM-ID: 0000002818 - 004

If starters with beryllium copper pinions are installed, the following also applies:
• To avoid health risks with the pinion containing beryllium, breathing protection of filter class P2 must
be worn during maintenance work. Do not blow out the interior of the flywheel housing and the starter
with compressed air. The interior of the flywheel housing must be additionally cleaned with a dust-
removal machine of class H.
Welding work
Never carry out welding work on the assembly or engine plant or mounted units. Cover the engine when
welding in its vicinity.
Observe the following before starting welding work on the MTU electronic system:
• Switch the main power switch to "OFF".
• Disconnect the cables and the negative and positive poles of the battery.
Do not use the assembly or plant as a ground terminal.
Never place the welding cable across or near wiring harnesses of MTU plants. The welding current may
otherwise induce an interference voltage in the wiring harnesses which could damage the electrical sys‐
tem.
If welding has to be carried out on components (e.g. exhaust manifold), these components must first be
removed from the engine.
Hydraulic installation and removal
Check the tools and devices to be used for perfect operation and safe condition. Only use the specified
devices for force-fitting/removing parts.
Observe the maximum press-on pressure for the device for force-fitting/removing parts.
Do not attempt to bend or exert force on H.P. lines.
Observe the following before starting the pressing procedure:
• Bleed air from the device for force-fitting/removing parts, pumps and piping at the points provided for
the system concerned (e.g. open threaded vent plugs, pump until no bubbles can be discerned in the
oil, close threaded vent plugs).
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal tool 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.
Working on electrical/electronic assemblies
Before starting any maintenance or repair work, or before switching off any electronic components nec‐
essary to carry out the work, permission must first be obtained from the relevant manager or supervisor.
Before work is carried out on the assemblies, the power supply to the relevant areas must be switched
off.
Do not damage wiring during the removal work. When reinstalling, ensure that the wiring cannot be dam‐
aged during engine operation through contact with sharp edges, rubbing against a component or through
contact with a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable clamps to secure the lines.
Observe the following when working with batteries:
• Avoid sparks and naked flames.
• Keep electrolyte away from the skin and clothing. Wear protective goggles.
• Do not place tools on the battery.
• Before connecting the cable to the battery, check the battery polarity.
10 | Safety | MS150032/02E 2012-07
TIM-ID: 0000002818 - 004