Мануал L33 - new - MS50199 - 01E
Мануал L33 - new - MS50199 - 01E
Мануал L33 - new - MS50199 - 01E
MS50228/00E
SLU Name Sales Name Engine model Application group
GG08V4000A1 MTU 8V4000 GS 8V4000L32 3A, continuous operation, unrestrict-
GG08V4000A2 8V4000L32ER ed
8V4000L33
8V4000L33 reduced power
8V4000L62
8V4000L63
GG12V4000A1 MTU 12V4000 GS 12V4000L32 3A, continuous operation, unrestrict-
GG12V4000A2 12V4000L32ER ed
12V4000L33
12V4000L33 reduced power
12V4000L62
12V4000L63
GG16V4000A1 MTU 16V4000 GS 16V4000L32 3A, continuous operation, unrestrict-
GG16V4000A2 16V4000L32ER ed
16V4000L33
16V4000L33 reduced power
16V4000L62
16V4000L63
GG20V4000A1 MTU 20V4000 GS 20V4000L32 3A, continuous operation, unrestrict-
GG20V4000A2 20V4000L32ER ed
20V4000L33
20V4000L33 reduced power
20V4000L62
20V4000L63
This Maintenance Schedule is valid for Series 4000Lxx gas engines as of the following engine serial numbers.
Engine model Engine serial number
8V4000Lxx 524101824
12V4000Lxx 526109166
16V4000Lxx 527112719
20V4000Lxx 528103970
Table 1: Applicability
The fluids and lubricants specification, the guidelines for maintenance and fluid and lubricant
change as well as a list of recommended fluids and lubricants are contained in the Fluids and
Lubricants Specifications of MTU Onsite Energy as well as in the fluids and lubricants specifica-
tions of the component manufacturers. They are therefore not included in the maintenance
schedule (exception: deviations from the Fluids and Lubricants Specifications). Use only fluids
and lubricants which comply with the Fluids and Lubricants Specifications of MTU Onsite Ener-
gy or which are approved by the relevant component manufacturer.
The following additional maintenance operations must be performed on direct responsibility of the opera-
tor / customer:
• Protect components made of rubber or synthetic material from oil. Never treat them with organic deter-
gents. Wipe with a dry cloth only.
• Gas filter:
The maintenance interval depends on gaseous fuel quality (purity). Fuel filters upstream of the engine
must be regularly cleaned and renewed if necessary.
• Battery:
Battery maintenance depends on duty and ambient conditions. The specifications of the battery manufac-
turer apply.
Items listed in this maintenance schedule but which are not included in the scope of delivery of MTU On-
site Energy may be disregarded.
Generator maintenance
Please refer to the Operating Instructions provided by the generator manufacturer for the intervals for these
maintenance tasks.
Please refer to the Operating Instructions provided by the relevant component manufacturer for the intervals
for these maintenance tasks.
Maintenance tasks
The respective maintenance tasks to be carried out are based on operating hours (see the following pages).
When using the unit supplied in a foreign country or in special regions, MTU Onsite Energy is
not responsible for the adherence to the legal or other regulations / standards at the place of
use.
Additional checks
The operator's gas installation (upstream of twin solenoid valve) must be inspected for leaks at the following
intervals:
• Every year for engines with turbocharger
• Every six months for aspirated engines
The following checks are to be carried out at appropriate intervals, depending on the degree of contamina-
tion:
• Check room air fan and fresh air filter for contamination
• Check filter or air-conditioning unit for control cabinet for contamination
• Check recooler for contamination
Electrical systems
Electrical systems and operating equipment must be checked prior to initial commissioning, after repairs,
prior to re-commissioning and at regular intervals. The intervals are to be so arranged that defects, which are
to be expected, are detected at an early stage.
Here, among others, the following requirements apply:
• Accident prevention regulations BGV A3 "Electrical Systems and Operating Equipment"
• Technical rules for operational safety TRBS 2131 "Electrical Hazards"
• Industrial Safety Directive (BetrSichV)
• DIN VDE 0701/0702 Repairs, modifications and testing of electrical equipment/repeat tests on electrical
units
• DIN EN 60204-1 Safety of machinery - Electrical equipment of machines
The operating company has the responsibility to see that these tests are carried out correctly. Electrical sys-
tems and fixed electrical operating equipment must be tested at appropriate intervals by a qualified electri-
cian for their correct condition. The test is to include the following:
• Visual inspection and testing of protective equipment
• Testing of protective conductor resistance, insulation resistance, leakage current replacement, protective
conductor current and differential current
• Carrying out fault diagnoses
• Preparation of test reports and inspection stickers
The industrial safety regulations, the technical rules for operational safety and the BGV A3 are fundamental
with regard to adherence to the protective measures for "Electric Plants and Operating Equipment". The op-
erating company is accordingly obligated to care for the safety of electrical systems and operating equip-
ment.
Designation
DIN Deutsches Institut für Normung (Federal German Standards Institute)
EN Europäische Normung (European Standards)
TIM-ID: 0000052185 - 001
10.500
12.000
15.000
18.000
21.000
24.000
27.000
30.000
31.500
33.000
36.000
39.000
42.000
45.000
48.000
51.000
52.500
54.000
57.000
60.000
63.000
1.000
3.000
6.000
9.000
Limit
Daily
Engine
W0501 - X
W0509 - X
W0523 - X
W0527 - X
W8660 1a X X X X X X X X X X X X X X X X X X X X X
W1008 2a X X X X X X X X X X X X X X X X X X X X X
W1005 3a X X X X X X X X X X X X X X X X X X X X X
W1525 6a X X X X X X X X X X X X X X X X X X X X X
W1616 18 a X X X X X X X X X X X X X X X X X X X X X
W4137 18 a X X X X X X X X X X X X X X X X X X X X X
W1207 18 a X X X X X X X X X X X X X X X X X X X X X X
W1091 18 a X X X X X X X X X X X X X X X X X X X X X
W1089 3a X X X X X X X X X X
W1689 18 a X X X X X X X
W1798 3a X X X X X X
W1799 3a X X X
W4138 4a X X X
W1690 18 a X X X X X X
W1691 18 a X X X
W1802 18 a X X X
W1084 18 a X X X
W1038 18 a X X X
W1082 18 a X X X
W1083 18 a X X X
W1755 18 a X X X
W2001 18 a X X X
W1520 18 a X X
W1134 18 a X
W1693 18 a X
W3000 18 a X
W3001 18 a X
W3004 18 a X
W3018 18 a X
W3083 18 a X
TIM-ID: 0000069135 - 001
W3103 18 a X
W3177 18 a X
W3182 18 a X
w = weeks
m = months
a = years
10,500
12,000
13,500
15,000
16,500
18,000
19,500
21,000
22,500
24,000
25,500
27,000
28,500
30,000
31,500
33,000
34,500
36,000
37,500
39,000
40,500
42,000
43,500
1,500
3,000
4,500
6,000
7,500
9,000
Limit
500
W0863 30
m
W0806 1a
W0889 10 a
W0854 - X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W0823 - X X X X X X X X X X X X X X
W0829 - X X X X X X X X X X X X X X
W0833 - X X X X X X X X X X X X X X
W0847 - X X X X X X X X X X X X X X
W0860 - X X X X X X X X X X X X X X
W0861 - X X X X X X X X X X X X X X
W0864 - X X X X X X X X X X X X X X
W0812 - X X X X X X X X X X X X X X
W0815 - X X X X X X X X X X X X X X
W0817 - X X X X X X X X X X X X X X
W0831 - X X X X X X X X X X X X X X
W0841 - X X X X X X X X X X X X X X
W0843 - X X X X X X X X X X X X X X
W0826 - X X X X X X X X X X X X X X
W0855 - X X X X X X X X X X X X X X
W0830 - X X X X X X X X X X X X X X
W0857 - X X X X X X X X X X X X X X
W0832 1a X X X X X X X X X X X X X X
W0835 1a X X X X X X X X X X X X X X
W0880 1a X X X X X X X X X X X X X X
W0851 - X X X X X X X
W0856 - X X X X X X X
W0878 1a X X X X X X X
W0862 2a X X X X X X X X
W0821 - X X X X
W0867 1a
W0859 1a X X X X X X X
TIM-ID: 0000069271 - 001
W0875 1a X X X X X X X
W0807 1a X X X X
W0848 - X X
W0874 - X X
W0825 - X
w = weeks
m = months
a = years
45,000
46,500
48,000
49,500
51,000
52,500
54,000
55,500
57,000
58,500
60,000
61,500
63,000
Limit
W0863 30
m
W0806 1a
W0889 10 a
W0854 - X X X X X X X X X X X X X
W0823 - X X X X X X X
W0829 - X X X X X X X
W0833 - X X X X X X X
W0847 - X X X X X X X
W0860 - X X X X X X X
W0861 - X X X X X X X
W0864 - X X X X X X X
W0812 - X X X X X X X
W0815 - X X X X X X X
W0817 - X X X X X X X
W0831 - X X X X X X X
W0841 - X X X X X X X
W0843 - X X X X X X X
W0826 - X X X X X X X
W0855 - X X X X X X X
W0830 - X X X X X X X
W0857 - X X X X X X X
W0832 1a X X X X X X X
W0835 1a X X X X X X X
W0880 1a X X X X X X X
W0851 - X X X
W0856 - X X X
W0878 1a X X X
W0862 2a X X X
W0821 - X X X
W0867 1a
W0859 1a X X X
W0875 1a X X X
W0807 1a X X X
W0848 - X
W0874 - X
W0825 - X
w = weeks
TIM-ID: 0000069271 - 001
m = months
a = years
W0801 - X X X X X X X X X X X X X X X X X X X X X
W0802 - X X X X X X X X X X X X X X X X X X X X X
W0803 - X X X X X X X X X X X X X X X X X X X X X
W0838 - X X X X X X X X X X X X X X X X X X X X X
W0873 - X X X X X X X X X X X X X X X X X X X X X
W0869 - X X X X X X X X X X
W0888 - X X X X X X X X X X
W0805 - X X X X X X
W0883 - X
W0813 1a
W0819 1a
W0837 - X X X X
w = weeks
m = months
a = years
Option
Task
cation [h]
Engine
QL1 Daily - Engine operation Visually inspect engine for leaks and general condition. W0501
Check machine room for smell of gas. W0509
Check for abnormal running noises and vibrations. W0523
Check engine oil level in storage tank. X W0527
QL1 3000 1a Emissions Check emission values; adjust if necessary. Observe local emissions W8660
regulations.
QL1 3000 2a Engine oil filter Replace engine oil filter when changing engine oil, or when the interval W1008
(years) is reached, at the latest.
QL1 3000 3a Air filter Replace air filter. W1005
QL1 3000 6a NOx sensor Replace sensor. X W1525
QL1 3000 18 a Spark plugs Replace spark plugs and spark plug connectors. W1616
QL1 3000 18 a Ignition system When replacing spark plug: Clean and check spark plug connector, re- W4137
place if required.
QL1 3000 18 a Valve gear Check valve clearance and adjust if necessary. IMPORTANT! First ad- W1207
justment after 1,000 operating hours on a new engine and after 1,000
operating hours following each cylinder head overhaul.
QL1 3000 18 a Ignition system Check ignition timing, readjust as necessary. W1091
QL1 6000 3a Gas supply Check gas lines for leaks, seal if required. W1089
QL1 9000 18 a Cylinder head Measuring valve protrusion. W1689
QL1 10500 3a Crankcase breather Replace fine filter. W1798
QL1 21000 3a Crankcase breather Replace coarse filter (coalescence filter). W1799
QL1 21000 4a Coolant vent line Replace flexible coolant hose line (only 8V, 12V, and 16V engines). W4138
QL3 10500 18 a Exhaust turbocharger Clean exhaust turbocharger. W1690
QL3 21000 18 a Mixture cooler Check for contamination and leaks, clean as necessary. W1691
QL3 21000 18 a Coolant distribution housing/ Replace O-rings in the plug connections between coolant distribution W1802
mixture cooler housing and mixture cooler.
QL3 21000 18 a Cylinder liners Replace cylinder liners. W1084
QL3 21000 18 a Exhaust turbocharger Overhaul turbocharger. W1038
QL3 21000 18 a Piston Replace pistons. W1082
QL3 21000 18 a Conrod bearing Replace conrod bearings. W1083
QL3 21000 18 a Flame arrester Check for contamination, clean as necessary. X W1755
QL3 21000 18 a Component maintenance Check rocker arm and valve bridge for wear. Visually inspect swing W2001
follower and camshaft running faces with endoscope through pushrod
bore.
QL3 31500 18 a Vibration damper Replace vibration damper. X W1520
QL3 63000 18 a Cylinder head Overhaul cylinder heads. W1134
QL3 63000 18 a Conrod Replace conrods. W1693
QL4 63000 18 a Extended component mainte- Disassemble engine completely. Inspect engine components acc. W3000
nance to assembly instructions; repair or replace as necessary.
TIM-ID: 0000069136 - 001
Option
Task
cation [h]
level
QL1 - 30 m Switchgear cabinet Replace buffer battery in central processing unit (CPU) of the PC. X W0863
QL1 - 1a Control system Check shutdown criteria in peripheral equipment. W0806
QL1 - 10 a Switchgear cabinet Replace safety switching device. X W0889
QL1 1500 - Generator Lubricate bearings according to instruction plate, check bearing tem- W0854
perature and winding temperature.
QL1 3000 - Operating data Check mixture temperature. W0823
Check generator power and generator operating data. W0829
Check heating water supply and return temperature. W0833
Check stability of coolent temperature in high-temperature and low- W0847
temperature circuit.
Check oil pressure and oil level. W0860
Check oil temperature. W0861
Check cooling water supply and return temperature. W0864
QL1 3000 - Gas supply Check differential pressure at gas filter. W0812
QL1 3000 - Switchgear cabinet Check filter fans for contamination and replace if required. W0815
Check noise level of filter fans. W0817
Check noise level of compressor and fans. X W0831
Check cooling function of cooling unit. X W0841
Check cooling fins for contamination, clean if required. X W0843
QL1 3000 - Generator Clean generator intake grill. W0826
Replace air filter if required. X W0855
QL1 3000 - Start sequence Check generator voltage in idle mode. W0830
Check grid voltage. W0857
QL1 3000 1a Transmission (60 Hz) Check transmission housing temperature and bearing temperature. X W0832
Check internal condition and function of transmission and oil circula- X W0835
tion system.
Check transmission oil level and take oil sample. X W0880
QL1 6000 - Generator Check coupling element and windings. W0851
QL1 6000 - Coolant pump Lubricate motor bearings acc. to the specifications of the manufac- W0856
ture.
QL1 6000 1a Gas supply Check function of valve-leak control and check shut-off equipment. W0878
QL1 6000 2a Transmission (60 Hz) Carry out oil change. First oil change after 500 operating hours. . X W0862
QL1 9000 - Gas supply Replace gas filter. W0821
QL3 - 1a Coolant and heating water sys- Check safety valve. W0867
tem
QL3 6000 1a Transmission (60 Hz) Check surface condition and contact pattern of tooth flanks. X W0859
Check shaft alignment. X W0875
QL3 9000 1a Generator Check power cable connections in terminal box, tighten if required. W0807
QL3 21000 - Coupling element Replace coupling element. W0848
TIM-ID: 0000069275 - 001
Option
Task
cation [h]
level
QL1 3000 - Exhaust system Check exhaust back pressure before / after catalyst. X W0801
Check function of exhaust flap and inspect for leaks. X W0802
Check exhaust temperature and exhaust back pressure before and af- X W0803
ter exhaust heat exchanger.
Check condensate neutralization system and flush condensate line X W0838
with condensate collecting tank.
QL1 3000 - Batteries Check starter and backup batteries. W0873
QL1 6000 - Coolant system Check rubber belows, hoses and coolant pump (visual inspection). W0869
Check coolant pumps. W0888
QL1 10500 - Exhaust system Check exhaust heat exchanger, clean if required. X W0805
QL1 63000 - Exhaust system Check exhaust heat exchanger, clean or replace if required. X W0883
QL3 - 1a Machine room Maintenance tasks / checks to be carried out by the qualified person. W0813
Check function of fire and smoke detectors. W0819
QL3 15750 - Exhaust system Check catalyst, replace if required. X W0837
w = weeks
m = months
a = years
TIM-ID: 0000069276 - 001
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
24-h Hotline
With our 24-h hotline and the flexibility of our service staff, we are always ready to assist you - either during
operation, for preventive maintenance, corrective work in case of malfunction or changed operating condi-
tions, or for spare parts supply.
For our locally available support, go to MTU's Internet site:
• http://www.mtuonsiteenergy.com/haendlersuche/index.de.html
Your contact at Headquarters:
• support-oeg@mtu-online.com