MTU 8V4000Lx4 Manuale utente
Operating Instructions
Gas engine
8V4000Lx4
MS15026/00E
Engine model kW/cyl. Application group
8V4000L64 130 kW/cyl. 3A, continuous operation, unrestricted
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 Safety regulations for startup and operation 8
1.4 Safety requirements for startup and
operation, special instructions for
applications with gaseous fuel 10
1.5 Safety regulations for maintenance and
repair work 11
1.6 Safety requirements for maintenance and
repair work, special instructions for
applications with gaseous fuel 14
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 15
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel 17
1.9 Standards for safety notices in the text 18
1.10 Transport 19
2 Product Summary
2.1 Engine – Overview 20
2.2 Engine side and cylinder designations 22
2.3 Engine – Main dimensions 23
2.4 Firing order 24
2.5 Technical Data 25
2.5.1 8V4000L64 engine data, fuel-optimized (TA-
Luft) 25
2.5.2 8V4000L64 engine data, emissions optimized
(1/2 TA-Luft) 29
2.6 Monitoring, Control and Regulation
Equipment 33
2.6.1 Gas engine system – Overview 33
2.6.2 Purpose of the units 35
3 Operation
3.1 Runtimes at partial load 37
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 38
3.3 Putting the engine into operation after
scheduled out-of-service-period 39
3.4 Control, starting and stopping sequences 40
3.5 Engine – Start 42
3.6 Operational checks 43
3.7 Emission values – Check 44
3.8 Engine – Shutdown 45
3.9 Emergency engine shutdown 46
3.10 After stopping the engine – Engine remains
ready for operation 48
3.11 After stopping the engine – Putting the
engine out of operation 49
4 Maintenance
4.1 50-hours check 50
4.2 Maintenance schedule reference table [QL1] 51
5 Troubleshooting
5.1 Fault messages - Key 52
5.2 Fault messages in log for genset controller 54
5.3 Engine Control Unit – Fault messages 112
6 Task Description
6.1 Engine 151
6.1.1 Engine – Barring manually 151
6.1.2 Machine room – Check for smell of gas 152
6.2 Crankcase Breather 153
6.2.1 Oil separator – Filter replacement 153
6.3 Ignition System 155
6.3.1 Spark plug – Replacement 155
6.3.2 Spark plug – Removal 156
6.3.3 Spark plug – Installation 157
6.3.4 Spark plug connector – Replacement 159
6.3.5 Spark plug connector – Removal 160
6.3.6 Spark plug connector – Installation 161
6.3.7 Ignition system – Ignition timing check 163
6.4 Valve Drive 164
6.4.1 Valve projection – Measurement 164
6.4.2 Valve gear – Lubrication 167
6.4.3 Valve clearance – Check and adjustment 168
6.4.4 Cylinder head cover ‒ Removal 170
6.4.5 Cylinder head cover ‒ Installation 171
6.5 Gas System 172
6.5.1 Gas supply - Checking gas lines for leaks 172
6.6 Air Filter 173
6.6.1 Air filter – Replacement 173
6.6.2 Air filter – Removal and installation 174
6.7 Lube Oil System, Lube Oil Circuit 175
6.7.1 Engine oil – Level check 175
6.7.2 Engine oil – Change 176
6.7.3 Engine oil – Sample extraction and analysis 177
6.8 Oil Filtration / Cooling 178
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6.8.1 Engine oil filter – Replacement 178
6.9 Coolant Circuit, General, High-Temperature
Circuit 179
6.9.1 Engine coolant – Level check 179
6.9.2 Engine coolant – Change 180
6.9.3 Engine coolant – Draining 181
6.9.4 Engine coolant – Filling 183
6.10 Low-Temperature Circuit 184
6.10.1 Mixture coolant level – Check 184
6.10.2 Mixture coolant – Change 185
6.10.3 Mixture coolant – Draining 186
6.10.4 Mixture coolant – Filling 187
6.11 Wiring (General) for Engine/Gearbox/Unit 188
6.11.1 Engine cabling – Check 188
6.11.2 Sensors – Overview 189
7 Appendix A
7.1 Abbreviations 193
7.2 MTU Onsite Energy contact person / service
partner 195
8 Appendix B
8.1 Special Tools 196
8.2 Index 200
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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
• Technical personnel from the areas mechanical engineering, plant construction and electrical engi-
neering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Personnel must not be under the influence of alcohol, drugs or strong medication.
Work clothing and personal protective equipment
When working, always wear the necessary personal protective equipment (e.g. safety shoes, ear protec-
tors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
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1.3 Safety regulations for startup and operation
Safety regulations 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 (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.
• 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.
Smoking is prohibited in the area of the product.
Safety regulations during 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
During operation of electrical devices, certain elements of these devices are live/under high voltage.
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Observe the warning information applicable to the devices.
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1.4 Safety requirements for startup and operation, special
instructions for applications with gaseous fuel
Safety requirements for startup
Whenever the product is started, always ensure that:
• The operator has fulfilled the requirement to: Check the gas train.
• The temperature in the area of the product must not fall below 5 °C at any point.
Gas system, requirements
Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff device. This
must be realized by the plant designer to suit site conditions.
The connection to the gas supply network is established by the plant designer in accordance with re-
quirements 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 valve
• 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, yet a max-
imum of 3 meters before the interface of the engine. The interface is the flange in front of the gas vol-
ume regulator of the product.
In the case of network supply pressures higher than 100 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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