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Instructions
Diesel Engine
12V2000Gx6x
16V2000Gx6x
18V2000Gx6x
12V2000Bx6x
16V2000Bx6x
18V2000Bx6x
Application groups 3A, 3B, 3D,3E, 3F, 3G, 3H
MS65026/01E
Applicability
See: ( Page 6)
Table 1: Applicability
14 Electronic Controls
11 Lube Oil System
14.1 Electronic controls Safety notes and
11.1 Lube oil system Safety and general
general information 166
information 124
14.2 Engine governing 167
11.2 Closed crankcase ventilation system 126
14.3 Engine diagnostics 168
11.3 Oil lines 127
14.4 Engine Control Unit (ECU) 169
11.4 Auxiliary equipment for lube oil preheating 128
14.5 Sensors 170
11.5 Oil filter configuration 129
14.6 Wiring 172
11.6 Oil Level Measurement 130
14.7 Networking 173
11.6.1 Oil level measuring 130
11.6.2 Oil dipstick 131
14.8 ADEC Functional checks prior to initial
start-up 174
11.7 Inclined operation 132
11.8 Oil priming 133 15 Generator
11.9 Recommended and approved fluids and
lubricants 134 15.1 Generators and couplings 175
15.2 Recommendations to Avoid Electric Erosion 176
12 Cooling System 15.2.1 General information 176
15.2.2 Insulated generator bearings and insulated
12.1 Cooling system Safety notes and general auxiliary drive 177
15.2.3 Additional installation instructions for
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information 135
12.2 Cooling system Description 137 generators 178
15.2.4 General grounding recommendations 179
12.3 Coolant 138
12.4 Cooling System Component Design Criteria 139 15.3 Single bearing 180
12.4.1 Cooler core 139 15.4 Installation requirements for single bearing
12.4.2 Expansion tank 140 generators 181
12.4.3 Pressure seal cap with pressure limiting valve 143 15.5 Double bearing generators 182
12.5 Flexible connections 145 15.6 Installation requirements for double bearing
12.6 Coolant pump 146 generators 183
IFN
16V2000G76S 68.6 kW/cyl. 1800 3D, standby operation, fuel stop power,
IFN
16V2000G86F 68.8 kW/cyl. 1500 3D, standby operation, fuel stop power,
IFN
16V2000G86S 85.7 kW/cyl. 1800 3D, standby operation, fuel stop power,
IFN
18V2000B26F 49.3 kW/cyl. 1500 3A, continuous operation, unrestricted
18V2000B26S 61 kW/cyl. 1800 3A, continuous operation, unrestricted
Table 2: Applicability
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Initial operation is the procedure by which MTU conclusively checks engine installation. A series of functional
checks are performed in the course of initial operation. The results are documented and retained for future
reference. Unless otherwise agreed, coverage under the terms of the limited warranty furnished by MTU
commences upon successful completion of initial operation of any engine supplied by MTU.
Completion of the initial operation procedure in no way releases the owner from his contractual obligations.
The owner of the MTU engine is ultimately responsible for correct installation of the engine.
Project-specific applications involving extension or modification of the standard MTU scope of delivery may
necessitate technical support from a local MTU dealer or sales partner . Such technical support may incur
additional cost for the owner.
Disclaimer
MTU accepts no liability whatsoever for damage of any kind incurred on the engine supplied by MTU, in the
installation room or other building parts and/or areas in which the engine is located, including personal in-
jury, resulting from installation of the MTU engine.
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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 rele-
vant 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 Lubricants
Specifications of the manufacturer)
With spare parts approved by the manufacturer in accordance with the ( Spare Parts Catalog/MTU con-
tact/Service partner)
In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding 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 use-
ful 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 re-
pair
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.
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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 author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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 engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, and
transport.
Personnel must not be under the influence of alcohol, drugs, or strong medication.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
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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 conceiva-
bly damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
At a reference temperature of 20 C, workpieces, components and measuring instrument are within the
specified tolerances.
Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Used oil
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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 con-
tainers, 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. Install
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 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.
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.
When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
Do not inhale vapors.
If urea solution is swallowed, rinse out mouth and drink plenty of water.
Remove any wet clothing immediately.
After contact skin, wash body areas with plenty of water.
Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
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 opera-
tion, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
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TEN data
Breakaway torque
Cold start current
Number of teeth on flywheel ring gear
Barometric pressure
Oil pressure
Flywheel ring gear drawing
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Disclaimer
MTU accepts no liability whatsoever for damage of any kind incurred on the engine supplied by MTU, in the
installation room or other building parts and/or areas in which the engine is located, including personal in-
jury, resulting from installation of the MTU engine.
DANGER
Unintended engine start.
Risk of serious injury danger to life!
Lift the engine-generator set only while the engine-generator set is in the OFF mode and locked-
out.
DANGER
Suspended load.
Risk of serious injury from falling objects danger to life!
Follow the lifting and handling procedures according to manufacturers guidelines.
Ensure all lifting equipment is maintained according to manufacturers guidelines.
Ensure lifting device with adequate capacity is used.
Ensure all personnel stand clear when heavy objects are lifted or suspended.
DANGER
Suspended load.
Risk of serious injury danger to life!
Lift the engine-generator set only by the lifting brackets provided for this purpose.
Do not use the lifting brackets provided with the engine and generator because they are designed to
withstand their individual loads only.
Ensure that the lifting brackets are not damaged prior to use.
Ensure that the lifting brackets are evenly loaded.
DANGER
Fall from heights.
Risk of serious injury danger to life!
Use suitable ladders and work platforms.
WARNING
Hazardous acids, alkaline solutions, coolant, fuel, paint and preservatives.
Risk of serious injury!
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Consult appropriate Material Safety Data Sheets for proper handling, use and storage information.
Immediately seek medical attention if contact or ingestion has occurred.
WARNING
Hazardous fluids.
Chemical contact with battery acid, alkaline electrolytes or caustic byproducts.
Risk of serious injury!
Wear protective clothing to prevent contact with skin.
Flush eyes and/or wash skin immediately with water for at least 15 minutes after contact.
Seek medical attention immediately after contact or ingestion.
CAUTION
Suspended load.
Risk of injury and damage to the equipment!
Prevent equipment from swinging while suspended.
NOTICE
Components of the engine-generator set are sensitive to magnetism.
Damage to engine-generator set!
Do not use magnetic lifting devices near the engine-generator set.
Do not come in the vicinity of the engine-generator set with any magnetic lifting devices.
NOTICE
Unintended crankshaft movement/inhibition.
Damage to engine-generator set!
Install the crankshaft locking device, if provided, prior to transport.
Remove the crankshaft locking device, if provided, prior to starting.
NOTICE
Mishandling of components.
Damage to engine-generator set!
Follow published recommendations for proper handling of the engine-generator set and its compo-
nents.
Refer to the relevant installation drawings for dimensions and instructions on using lifting gear for a certain
engine or genset. Follow the instructions below:
Lift the engine only by the lifting eyes provided for this purpose.
Lift and transport the entire genset only by the specified attachment points.
Use suitable lifting gear.
Secure lifting gear directly to the attachment points.
Ensure that slings run straight and do not snag.
Observe the admissible angle of diagonal pull.
Secure the engine or genset to prevent it tipping during transport.
Secure appropriately to prevent slipping and tipping when negotiating inclines and ramps.
Only use means of transport and lifting equipment recommended by MTU (MTN 5194), see ( Page 235).
Take care to avoid damaging the protective foil when handling seaworthy packing. Use appropriate han-
dling equipment (e.g. forklift truck).
Follow any additional information provided in the engine or genset Operating Instructions and installation
drawings.
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Figure 7: Example of a room for an engine-generator set with an MTU 2000 Series engine
Exhaust piping
Fuel supply
Accessibility
Maintenance and service
When installing an engine-generator set near residential areas, special measures must be introduced to mini-
mize noise and exhaust gas emissions. The building air inlets (ventilation system) must be taken into consid-
eration when planning the exhaust system.
The room should be located, with regard to the predominant wind direction, such that the exhaust gas and
noise are carried away by the wind.
Note: Only objects required for the correct operation of the engine-generator set from MTU must be kept
and stored in the installation room of the engine-generator set.
Concrete
Consider the following points when casting the inertial foundation in concrete:
Strength characteristics of the inertial foundation and the load-bearing soil
The ground in the installation room of the engine-generator set around the inertial foundation must have a
sufficient load-bearing capacity for the components of the genset.
Static stability of the mounts (tilting, slipping)
Dynamic stability of the mounts
Natural frequencies, resonance ratio, damping factor, amplitudes
Dynamics of the ground under the inertial foundation
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The engine-generator set must be mounted on a stable inertial foundation or base. The inertial foundation
must be in the form of a horizontal monoblock design. Do not repair incorrectly dimensioned or damaged
foundations but replace them completely.
The inertial foundation must be designed in accordance with regular technical specifications for the required
load. Regular specifications demand concrete with a compressive resistance of 17 MPa (2500 psi), rein-
forced with reinforcement steel mesh of 3.25 mm thick wire (8 AWG) or reinforcement rods No. 6 in the
middle of a grid square with 30 cm (12 inches) side length.
The following formula is used to determine the depth of the inertial foundation:
Steel
When installing an inertial foundation in a steel design, experienced technicians must guarantee compliance
with the legal requirements.
Ventilation methods
The installation room of the engine-generator set can be ventilated naturally or with forced-air ventilation.
MTU Onsite Energy does not recommend installing in rooms which depend entirely on natural ventilation
without any form of forced ventilation. This method is consequently not described in this manual.
The installation room can be force-ventilated by means of fans which may be driven by the engine or pow-
ered electrically.
Another version of vacuum ventilation is to install the cooler outside the installation room and to install the
electrically-driven fan at the air outlet ( Figure 10).
Overpressure in the installation room of the engine-generator set can cause the entrance door to open
abruptly when entering the area. To avoid injury, a mechanical brake should be installed at the entrance
door.
( Figure 11) shows an example of a high pressure ventilation system.
Exact calculation
V = Q / (cpm * t * ) + C
Q = QSM + QG + QAR + QZ
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Gravity shutters
Gravity shutters are often used in installation rooms for engine-generator sets. The fins of the shutters are
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opened by the air flow while the engine-generator set is in operation. The fins close due to their dead weight
when the engine-generator set is not in operation. If the gravity shutters are closed, they protect the air inlet
system against water, leaves and small animals. These shutter version must be installed carefully in the air
flow.
Fixed shutters
Fixed shutters protect the installation room against water, leaves and small animals.
WARNING
Coolant and fuel contact when engine is running.
Risk of serious injury!
Do not fill coolant or fuel tanks while the engine is running.
WARNING
Hazardous acids, alkaline solutions, coolant, fuel, paint and preservatives.
Risk of serious injury!
Consult appropriate Material Safety Data Sheets for proper handling, use and storage information.
Immediately seek medical attention if contact or ingestion has occurred.
WARNING
Slipping and falling caused by spilled liquids.
Risk of serious injury!
Immediately clean up spilled liquids with suitable cleaning agents or as defined by the manufacturers
specifications.
WARNING
Sections of the fuel system are under high pressure. Fluids under high pressure can penetrate skin and
clothing.
Risk of serious injury!
Do not open or disconnect fuel lines while the engine-generator set is hot or operating.
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WARNING
Pressurized lines or its connections could burst.
Risk of serious injury!
Never use pressurized lines for climbing or support.
WARNING
Flying debris and hazardous air stream when using compressed air.
Risk of serious injury!
Never use compressed air to clean contaminated clothing.
Never use compressed air to force flammable liquids out of containers.
Do not exceed 276 kPa (40 psi) air pressure (according to OSHA regulations).
Wear protective clothing and adequate eye and ear protection (face shield or safety goggles).
WARNING
Hot components/surfaces.
Risk of burns!
Allow the engine to cool down to below 50 C before beginning work.
Wear suitable protective equipment/thermal gloves.
Avoid unprotected contact with hot surfaces.
WARNING
Draining of hot liquids.
Risk of serious injury and burning!
Use proper heat-proof containers when draining liquids.
Wear protective gloves.
Allow adequate time for the engine to cool down before draining hot liquids into the appropriate heat-
proof container.
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The entire low-pressure fuel system (especially filters and HP pump) must be prefilled for initial start-up and
following maintenance of the fuel system to ensure reliable engine starting. The HP pump is lubricated by
fuel so the entire mechanism must be filled before initial start-up.
Important:
Do not attempt to install a prefilled filter cartridge. Only fill the filter cartridge after installation to prevent
contaminated fuel entering the HP fuel system.
Do not open the HP system in the course of initial start-up or when servicing.
Procedure:
This requires the use of a manual venting pump. Alternatively, the engine can be vented e.g. directly by ap-
plying upstream pressure or by means of an electrical venting pump.
Open the unpressurized fuel return to tank connection ( Figure 14) (5) and connect it to the tank or a
suitably large vessel.
Open vent valve (2) on filter.
Vent filter by actuating hand pump (1).
Close vent valve (2).
Actuate hand pump (1) until HP pump flow can be heard. Fuel now emerges from the return tank.
Switch off upstream pressure(optional)
Close return tank.
Crank engine until rail pressure exceeds 300 bar.
Start engine.
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The outlet of the return line into the tank must be arranged at a suitable distance away from the intake of the
suction line. This prevents return fuel being immediately drawn back into the fuel system. Furthermore, the
return line must be introduced into the tank at a point where atmospheric pressure prevails. Fuel tanks must
be made of fuel- and corrosion resistant materials. The tank must be adequately large and installed in a suit-
able location.
Fuel tank capacity is matter for careful consideration; it must be perfectly adapted to the needs of the en-
gine. Tanks designed for mobile applications must feature a supply pipe to ensure an adequate supply of fuel
when operating at any degree of inclination. Tank capacity must be at least 5% greater than the maximum
filling volume to allow for expansion of hot fuel.
A shut-off valve is required to facilitate replacing the primary filter if the fuel tank is positioned above the
primary filter. This valve prevents fuel from running out of the tank.
When designing tank capacity ensure that the fuel supply temperature limits specified for operation in the
technical sales documents are not exceeded at any level of fuel in the tank.
Tank capacity depends on engine power, fuel consumption and envisaged runtime. The equation below may
serve to make a rough estimation:
Whereby:
V(L) = Tank volume (liters)
P = Engine power (kW)
t = Runtime (hours)
be = Specific fuel consumption (g/kWh)
= Fuel density (weighted average 830 g/l)
Fuel tank volume in gallons V(gal) can be calculated with a conversion factor of 1 gal = 3.785 liters.
Fuel quality is a crucial factor determining satisfactory engine performance, long service life and acceptable
exhaust emission rates. MTU engines are designed to run on most diesel fuels available on the world market.
Refer to the MTU Fluids and Lubricants Specifications for details of approved fuels.
Validation requirements
Thorough validation of the air intake system must include:
A complete description of the system. We recommend describing the air intake system and its design on
initial start-up by taking photographs and making sketches.
Appropriate and well-maintained instrumentation. All instruments and equipment must be calibrated and
in satisfactory condition.
Correctly prepared tests and precise results. Thorough preparation ensures precise results.
Data recording and evaluation
Diagnostics (troubleshooting) and corrective action (as necessary)
The engine must be running at normal operating temperature under full load.
Engines are normally equipped with a correctly designed and assembled air intake system on delivery. Air
intake systems other than the one supplied by MTU may be necessary to meet the requirements of certain
projects and must be validated in the course of initial start-up in regard of intake air differential pressure, air
intake temperature and assembly (correct, no leaks).
genset installation room. A precision thermocouple and a suitable indicator are used to measure the temper-
ature. The thermocouple can be installed at a measuring point similar to the one used to measure the intake
air differential pressure.
Note: Intake air differential pressure and intake air temperature must be logged to validate initial engine
start-up.
The position of the air intake temperature measuring point is shown in the installation drawings.
WARNING
Exhaust gases are hot and pressurized.
Risk of injury and burning!
Wear protective clothing, gloves, and goggles / safety mask.
The exhaust gas system is intended to route the exhaust gas to a suitable outlet and attenuate exhaust noise
to admissible levels. This section describes the requirements on functionality, application and installation of
an exhaust gas system for an MTU engine typically comprising the following components:
Exhaust manifold
Turbocharger
Exhaust system
Silencer
Rain cap
Exhaust bellows
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to engine damage.
Back pressure
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When designing the exhaust gas system, ensure that flow resistance (back pressure) is kept as low as possi-
ble and well within the specified limits. Refer to the TEN data for MTU engines for technical data and other
requirements for the exhaust gas system. This data is available on the MTU Business Portal or from your
local MTU dealer/sales partner.
Any of the factors listed below may lead to excessive back pressure:
Undersized exhaust pipe diameter
Too many bends
Long exhaust pipes between engine and silencer
High flow resistance through the exhaust silencer
MTU dealer or sales partner when dealing with project-specific installations requiring insulation on parts of
the engine exhaust gas system.
Exhaust pipes are not usually insulated, but may have to be in some project-specific applications where insu-
lation materials are necessary to protect surrounding areas from high surface temperatures. Exhaust pipes
are then thermally insulated to prevent any negative impact associated with radiated heat.
Refer to the TEN data for MTU engines for technical data and other requirements of the exhaust gas system.
This data is available on the MTU Business Portal or from your local MTU dealer/sales partner.
Flexible connections (compensator bellows) permit relative movement and thermal expansion between tur-
bocharger exhausts and components of the exhaust system. We recommend using jacketed metal bellows. It
may prove necessary to install several sets of bellows depending on the length of the exhaust pipe. The bel-
lows must be designed to compensate axial expansion (in the longitudinal direction) and also, to a lesser
degree, angular deformation (bending) and lateral deformation (thrust), see ( Figure 24). Compensator bel-
lows are not designed to compensate for misalignment during assembly or to absorb the weight of exhaust
gas components. Avoid torsional stress (twisting). Incorrectly installed bellows may lead to premature failure
of the turbocharger, exhaust manifold, piping, silencer or pipe flanges. Refer to the relevant component
drawings for details of installation requirements for compensator bellows supplied by MTU.
Thermal expansion
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As a rule-of-thumb, the bellows can only be extended by up to 75% of their total range at temperatures ex-
ceeding 500 C (932 F) due to thermal expansion.
( Figure 25) shows thermal expansion of exhaust piping as a function of temperature.
NOTICE
Exhaust system support.
Product damage!
Never allow the engine exhaust turbochargers or exhaust manifolds to support the weight of the ex-
haust system.
Exhaust pipe outside diameter Minimum wall thickness for minimum mechanical strain
500 mm (19.7 inches) 3 mm (0.12 inches)
500 to 900 mm (19.7 to 35.4 inches) 5 mm (0.20 inches)
Exhaust pipe outside diameter Minimum wall thickness for significant mechanical strain
Up to 500 mm (19.7 inches) 5 mm (0.20 inches)
500 to 900 mm (19.7 to 35.4 inches) 7 mm (0.28 inches)
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Due to the corrosive effects of heat and moisture, MTU Onsite Energy recommends the use of exhaust pipes
with a wall thickness greater than 3 mm (0.12 inches).
Minimize the risk of corrosion by installing stainless steel exhaust pipes. However, do not install pipes with
walls which are thinner than 3 mm (0.12 inches).
Fixed mounts
Fixed mounts absorb the reaction forces of compensator bellows resulting from thermal expansion. These
mounts must be installed in the direct vicinity of the engine-generator set to protect the engine against the
weight of the exhaust system and to decouple the exhaust line from engine vibrations.
NOTICE
Expansion of flexible connections.
Product damage!
Flexible connections or bellows must be properly fitted between any two fixed points to compensate
for expansion.
For horizontal pipes, a clamp must be used to secure the line during installation on the ceiling, wall or floor
(see( Figure 29)).
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Floating mounts
Floating mounts accommodate the weight of the exhaust piping and transverse forces to ensure precise axial
guidance when bellows are installed, see ( Figure 32).
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In the case of encapsulated stationary engines, situating the exhaust silencer on the inside or outside can be
more or less beneficial depending on circumstances. Internal silencers are easier to maintain and drain than
those installed outside. External silencers, on the other hand, may only need covering with a protective grill
instead of insulation materials (providing that heat and noise do not present a problem).
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The diameter (D) of the bore in the exhaust pipe is 3.175 mm (0.125 inches). The top part is the nipple or
neck (2) into which the measuring instrument is inserted.
The measuring connection fitting must be installed in a straight section of the exhaust pipe. Install the con-
nection fitting perpendicular to the bending plane should it be necessary to locate it in an elbow or curved
section of the exhaust pipe.
Figure 43: Typical sources of noise emission emanating from a diesel engine
1 Unattenuated exhaust noise 3 Structure-borne noise in-
2 Unattenuated intake air duced in the foundation via
noise the engine mounts
4 Surface noise
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WARNING
Slipping and falling caused by spilled liquids.
Risk of serious injury!
Immediately clean up spilled liquids with suitable cleaning agents or as defined by the manufacturers
specifications.
WARNING
Engine oil and coolant are under relatively low pressure but liquids under pressure can penetrate skin
and clothing.
Risk of serious injury!
Do not open or disconnect coolant or oil lines while the engine-generator set is hot or operating.
WARNING
Pressurized lines or its connections could burst.
Risk of serious injury!
Never use pressurized lines for climbing or support.
WARNING
Pressurized systems and compressed-air lines.
Risk of injury!
Prior to starting work, relieve pressure in systems and compressed-air lines which are to be opened.
WARNING
Flying debris and hazardous air stream when using compressed air.
Risk of serious injury!
Never use compressed air to clean contaminated clothing.
Never use compressed air to force flammable liquids out of containers.
Do not exceed 276 kPa (40 psi) air pressure (according to OSHA regulations).
Wear protective clothing and adequate eye and ear protection (face shield or safety goggles).
WARNING
Hot components/surfaces.
Risk of burns!
Allow the engine to cool down to below 50 C before beginning work.
Wear suitable protective equipment/thermal gloves.
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WARNING
Draining of hot liquids.
Risk of serious injury and burning!
Use proper heat-proof containers when draining liquids.
Wear protective gloves.
Allow adequate time for the engine to cool down before draining hot liquids into the appropriate heat-
proof container.
There are several ways of preheating lube oil when starting the engine from cold. MTU does not recommend
the use of oil preheaters. It may be necessary to preheat the lube oil in extreme circumstances to maintain a
constant oil temperature when the engine is running. Consult an authorized MTU representative if you need a
solution for preheating the oil.
Disposable screw-on filter elements, automatic oil filters and centrifugal oil filters are all possible configura-
tions.
The centrifugal filter is a bypass filter that uses centrifugal force to remove fine particles of soot and dirt
from the oil. After leaving the oil cooler, the oil passes through the centrifugal filter as it flows back to the oil
pan. Centrifugal filters require regular maintenance, but prolong the oil change intervals.
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NOTICE
Overfill of the oil pan.
Engine damage!
Never overfill the oil pan.
Rotating parts can contact the oil and cause foaming.
Proper lubrication is prevented and leads to severe engine damage.
WARNING
Coolant and fuel contact when engine is running.
Risk of serious injury!
Do not fill coolant or fuel tanks while the engine is running.
WARNING
Hazardous acids, alkaline solutions, coolant, fuel, paint and preservatives.
Risk of serious injury!
Consult appropriate Material Safety Data Sheets for proper handling, use and storage information.
Immediately seek medical attention if contact or ingestion has occurred.
WARNING
Slipping and falling caused by spilled liquids.
Risk of serious injury!
Immediately clean up spilled liquids with suitable cleaning agents or as defined by the manufacturers
specifications.
WARNING
Engine oil and coolant are under relatively low pressure but liquids under pressure can penetrate skin
and clothing.
Risk of serious injury!
Do not open or disconnect coolant or oil lines while the engine-generator set is hot or operating.
WARNING
Pressurized lines or its connections could burst.
Risk of serious injury!
Never use pressurized lines for climbing or support.
WARNING
Pressurized systems and compressed-air lines.
TIM-ID: 0000055847 - 003
Risk of injury!
Prior to starting work, relieve pressure in systems and compressed-air lines which are to be opened.
WARNING
Hot liquid.
Risk of serious injury and burning!
Take precautions when the radiator or heat exchanger pressure cap is removed.
Wear protective gloves, face shield and goggles.
Allow adequate time for the engine to cool down before removing the radiator or heat exchanger
pressure cap.
WARNING
Hot components/surfaces.
Risk of burns!
Allow the engine to cool down to below 50 C before beginning work.
Wear suitable protective equipment/thermal gloves.
Avoid unprotected contact with hot surfaces.
WARNING
Draining of hot liquids.
Risk of serious injury and burning!
Use proper heat-proof containers when draining liquids.
Wear protective gloves.
Allow adequate time for the engine to cool down before draining hot liquids into the appropriate heat-
proof container.
NOTICE
An air bound coolant pump cannot adequately circulate coolant and could cause severe overheating of
the engine.
Engine damage!
Ensure that air is completely purged from the cooling system.
When draining coolant containing corrosion inhibitors or antifreeze, collect it in a separate container and dis-
pose of it appropriately.
NOTICE
Handling of used fluids and lubricants.
Environmental pollution and violation of regulatory requirements!
Dispose of used fluids and lubricants in accordance with local regulations.
Never dispose of or burn used oil in the fuel tank.
Corrosion inhibitors protect the engine, cooler and the rest of the cooling system from damage resulting
from corrosion. The antifreeze lowers the freezing point of the coolant to prevent frost damage.
Observe specified concentrations when mixing corrosion inhibitors and antifreeze. Protection from corrosion
is no longer afforded if the corrosion inhibitor ratio falls below the minimum concentration. Corrosion inhibi-
tor separates from the coolant if the ratio exceeds the maximum admissible concentration. As a result, de-
posits form in the cooling system which may impede or block the coolant flow leading to a drop in cooling
capacity. The thermal transfer capacity of the coolant decreases if the maximum admissible antifreeze con-
centration is exceeded. The cooling system is consequently unable to operate at full capacity.
Percentage figures are always based on the total volume of coolant in any circuit.
The filler neck must be located as close to the top center of the expansion tank as possible. This ar-
rangement allows the coolant cooler to be filled to the greatest possible extent even at an inclination.
Coolant level sensor
The coolant level sensor must be positioned just above the lowest acceptable coolant level following
coolant loss. The height above the coolant level following coolant loss must represent approx. 98% of
the reserve volume.
The coolant level sensor must be located immediately above the point at which bubbles form. This
point typically lies above the coolant level following coolant loss.
The pressure seal cap with pressure limiting valve maintains optimum pressure in the cooling system. The
cooling system is pressurized when the coolant expands as the temperature increases.
Note:
Pressure is released from the cooling system on removing the pressure seal cap when the coolant is hot.
The pressure in the cooling system only builds up again when the pressure seal cap is replaced and the
cooler has cooled down and warmed up once more.
Pressure builds up as the engine temperature rises and coolant and air in the system expand. The valve in
the pressure seal cap lifts off its seat allowing excess air to escape from the system. ( Figure 51) illustrates
this expansion.
TIM-ID: 0000055863 - 002
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Use of transparent tubing
Risk of injury and scalding!
Use transparent tubing of appropriate wall thickness and material temperature rating.
Install transparent tubing securely and carefully.
Check the coolant flow for any visible bubbles of air when completing the product questionnaire during the
test run. Preferably use transparent tubing which allows air bubbles to be detected easily. Sight glasses can
also be used nevertheless. Install sight glasses or transparent tubing in the coolant line running from the
engine to the cooler (in both the HT circuit and the LT circuit). Replace the venting and filling lines with trans-
parent tubing.
Note:
Only use sight glasses and transparent tubing during trials when the engine is not running under full load.
Remove any sight glasses and transparent tubing when conducting trials with the engine running under full
load, or if high coolant temperatures can be expected.
DANGER
Electric shock.
Risk of serious injury danger to life!
Strictly follow all codes, standards, regulations, and laws pertaining to the installation.
DANGER
Electric shock.
Risk of serious injury danger to life!
Exercise extreme caution when working on or around electrical components.
Ensure the main switch is in "OFF" position when servicing any part of the electrical system.
Remove all electrical power before removing protective shields for service or maintenance.
DANGER
Manipulation of interlocks on parts under high voltage. Live components and connections.
Risk of burns or death from electric shock!
Do not tamper with any interlocks in the system.
DANGER
Electric shock.
Risk of serious injury danger to life!
Do not touch battery terminals, generator terminals or cables while the engine-generator set is being
started or is running.
DANGER
Electric shock.
Risk of serious injury danger to life!
Verify that all power leads and control connections are properly insulated before starting the engine-
generator set.
DANGER
Fire and explosion.
Risk of serious injury - danger to life!
Refrain from smoking or using an open flame when near batteries.
Refrain from opening, dismantling or mutilating the battery/batteries.
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WARNING
Electric shock.
Risk of serious injury!
Disconnect battery ground cable when servicing any part of the electrical system.
WARNING
Electric shock.
Risk of serious injury!
Remove fuse in DC system when servicing any part of the electrical system.
WARNING
Chemical contact.
Risk of serious injury!
Check battery polarity before connecting the cables to the battery.
WARNING
Hazardous acids, alkaline solutions, coolant, fuel, paint and preservatives.
Risk of serious injury!
Consult appropriate Material Safety Data Sheets for proper handling, use and storage information.
Immediately seek medical attention if contact or ingestion has occurred.
WARNING
Hazardous fluids.
Chemical contact with battery acid, alkaline electrolytes or caustic byproducts.
Risk of serious injury!
Wear protective clothing to prevent contact with skin.
Flush eyes and/or wash skin immediately with water for at least 15 minutes after contact.
Seek medical attention immediately after contact or ingestion.
WARNING
Heavy objects.
Risk of serious injury!
Use adequate mechanical lifting equipment or seek assistance.
WARNING
Fire and sparks.
Risk of serious injury!
Keep sparks and open flames away from the battery/batteries.
WARNING
Sparks.
Risk of serious injury!
Check battery polarity before connecting the cables to the battery.
TIM-ID: 0000055962 - 003
NOTICE
Incorrect battery selection and installation.
Damage to battery/batteries!
Size battery/batteries appropriately according to the application.
Install battery/batteries away from environmental contaminants.
Protect battery/batteries from vibration.
WARNING
Batteries contain very caustic acid.
Risk of serious injury from chemical burn!
Wear protective clothing, gloves and goggles/safety mask.
If contact with battery acid occurs, flush skin with water, apply baking soda or lime to neutralize the
acid, flush eyes with water and get medical attention immediately.
WARNING
Battery acid is highly caustic.
Explosive gases develop during charging.
Metal objects between battery terminals cause short-ciruits.
Risk of burns, explosion, and short-circuiting!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
If battery filling gets into eyes, rinse immediately with water and seek medical attention.
Do not place metal objects on battery.
The recommended battery capacity is specified for each engine on the Business Portal.
When installing batteries ensure that they are well-protected from any sources of ignition or sparking, road
dirt and other forms of soiling. However, locate the batteries as close as possible to the starter motor (to
minimize starter cable cross section). Batteries must be protected from vibration and easily accessible for
visual inspection and maintenance.
NOTICE
Malfunction due to unsolved fault.
Damage to equipment!
Do not attempt to restart until the cause for shutdown has been identified and corrected.
NOTICE
Live voltages in the electronic control and monitoring system.
Damage to equipment!
Comply with the operating instructions given with this equipment.
NOTICE
Incautious handling in transit.
Damage to equipment!
Suitably pack electronic components when being returned for core credit, repair, warranty and/or
analysis.
NOTICE
False cable connection.
Damage to equipment!
Correctly connect and secure all cables prior to energizing the system.
NOTICE
Chafing of cables.
Damage to equipment!
Use cable clamps to limit vibration and restrict motion.
Use grommets to properly install wiring harnesses.
Note: Consult your MTU dealer or sales partner if documentation is not available. TIM-ID: 0000055996 - 002
The Engine Control Unit incorporates the control logic for all functions related to engine management. It
processes sensor inputs to determine fuel injection quantity and timing. It monitors itself and other engine
systems for faults which might disrupt correct operation of the engine.
The Engine Control Unit is designed to withstand the harsh environments commonly associated with oilfield
applications:
Extremely high or low temperatures
High humidity and direct contact with water
Exposure to chemicals
Effects of heavy impacts
TIM-ID: 0000056006 - 001
Engine signals
The following engine signals are received by the engine governor of the engine management system ADEC
for stationary engine-generator sets:
Figure 58: Double bearing generator directly flanged onto the engine
1 Generator shaft bearing B Flywheel housing
A Engine C Generator
An engine and the transmission to which it is connected can basically be represented as a series of masses.
These masses (rotating parts) are coupled by elements (shafts and couplings) which act like springs. The fol-
lowing information may be required to calculate torsional vibration:
Description of the system application.
Arrangement drawing of the overall drive system, including main PTO and auxiliary PTOs
Mass-elastic diagram of all rotary driven machinery including drive shafts, couplings, flanges etc.
Engine type and rated power
Load characteristics of the application
Order number of engine and plant
Part numbers of crankshaft pulley, vibration dampers, installed auxiliary drives and flywheel
Coupling brand and type
Brand and type of rotary driven machinery
Expected ambient temperature
An approved torsional vibration analysis is essential for a long useful life, reliability and ultimately the suc-
cess of any power transmission system. Submitting complete and informative driveline data together with
any request for a torsional vibration analysis is therefore vital. Information about all possible operating condi-
tions of the application concerned is also needed (e.g. power vs. speed).
The plant manufacturer is responsible for having torsional vibration calculated for any new configuration.
Even minor modifications to rotary driven machinery may have a major impact on the results of the torsional
vibration analysis.
The relevant form and details on how to apply are available on the Business Portal.
TIM-ID: 0000056143 - 001
Figure 60: Four-point mounting arrangement with front and rear mounting supports
When installing and securing four-point mounting arrangements ensure that alignment takes place before the
mounts are finally bolted to the engine and plant to avoid twisting and bending. Ensure that all bolts are
tightened to the specified torque. Loose bolts lead to fretting corrosion and wear under the screw heads re-
sulting in excessive engine movement or vibration.
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Figure 61: Six-point mounting arrangement with front and rear (x2) fixed bearing pedestals
TIM-ID: 0000056104 - 002
Note:
Consult MTU Engineering when dealing with applications involving more than 1000 lbft (1356 Nm) at the
rear flange face of the block.
NOTICE
Risk of engine damage due to incorrect action.
Risk of severe damage to property!
Ensure engine is ready for operation before starting. See engine documentation.
Carefully check all relevant documents, drawings and diagrams prior to initial start-up.
Read the section concerning Initial start-up in the Operating Instructions of the engine concerned.
Only use approved fuels, oils and coolants listed in the MTU Fluids and Lubricants Specifications.
We recommend users to keep a copy of the commissioning report from the initial sample test. Keep a log
book as evidence of maintenance and repair work performed on the engine and to prove that only approved
fluids and lubricants have been used. Proof of maintenance and repair work is of great help when resolving
warranty issues.
ID Identification number
IEC International Electrotechnical Committee International standards organization for all electrical
and electronic equipment and associated technolo-
gies
IEEE Institute of Electrical and Electronic Engi- International organization for the promotion of tech-
neers nology related to electricity
IIG Initiale Injektorgleichstellung Initial injector equalization. Input of the injector code
with DiaSys in the Engine Control Unit to ensure
optimum emission and consumption behavior
PVC Polyvinylchloride
P-xyz Pressure-xyz Pressure measuring point xyz
QL Qualification Level
RCM Reserve Capacity Minutes Unit of battery discharge
RDP Remote Desktop Protocol
RFOB Rear Face of Block
RMS Root Mean Square Mathematics: Root mean square
Area
Unit A multiplied by factor = Unit B
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.59 = km2
Volume
Unit A multiplied by factor = Unit B
in 3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.785 = dm3
TIM-ID: 0000002173 - 016
Velocity
Unit A multiplied by factor = Unit B
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (UK) 1.852 = km/h
Mass
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 =g
ton (imp.) 1.016 =t
Force
Unit A multiplied by factor = Unit B
lbf 0.4536 = kp
lbf 4.4482 =N
TIM-ID: 0000002173 - 016
kp 9.80665 =N
Torque
Unit A multiplied by factor = Unit B
lbf ft 1.3558 = Nm
Pressure
Unit A multiplied by factor = Unit B
2
lbf/in (psi) 703.1 = kp/m2 (mmH2O)
lbf/in2 (psi) 0.06895 = bar
2
lbf/ft (psf) 47.88 = Pa
inHg 0.03386 = bar
inHg 345.3 = kp/m2 (mmH2O)
Energy
Unit A multiplied by factor = Unit B
lbf ft 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
Power
Unit A multiplied by factor = Unit B
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.054 = kW
kcal/h 1.163 =W
HP 550 = lbf ft/s
Temperature
Celsius Kelvin
x C - = x + 273.15 K
xK = x 273.15 C -
x F = 5/9(x 32) C = 5/9(x 32) + 273.15 K
x R = 5/4x C = (5/4x) + 273.15 K
Fahrenheit Raumur
x C = 9/5x + 32 F = (4/5x) R
xK = 9/5(x 273.15) + 32 F = 4/5(x 273.15) R
x F - = 4/9(x 32) R
x R = (9/4x) + 32 F -
Fuel consumption
Unit A multiplied by factor = Unit B
mile/gal (US) 0.4251 = km/l
TIM-ID: 0000002173 - 016
Diagrams
C Annex 214
Checklist Diffusors
Cooling pump 151 Air intake system 82
Combustion air system Draining
Customized Exhaust system 110
Design 28 Drawings
Connection Annex 214
Fuel supply 57 General arrangement drawings 215
Conversion tables225 Installation drawings 213
Wiring 172
Installation and design requirements Piping
Air intake system 73 Air intake system
Installation drawings Material specifications 81
Engine 213 Plant design
Plant 213 General information 26
Installation guidelines Preface8
Mounting system 204 Putting back into operation
Installation room of engine-generator set After preservation 40
Requirements 41
Shutter 52
Ventilation 45
VERSTNDIGUNGSNORM
April 2001
EXPLANATORY STANDARD
1) The term "engine" is used to refer to engines/gas turbines including all application-specific
engine-mounted assem blies (e.g. gearboxes, generators, etc.).
Fortsetzung Seite 2 bis 3
Continued on pages 2 to 3
Bearbeitet Geprft Freigegeben Anderungsdienst TQMS Ordnungs-Nr.
Compil d by: Checked by: Approved by: Amendment Service TQMS Order No.
Koch Schatte! Schattel 2/2001 205F
MTU MOTOREN UND TURBINEN UNION FRIEDRICHSHAFEN GMBH
- -
Der Einfluss der Temperatur auf die The influence of temperature on the lifting
Tragfhigkeit ist zu bercksichtigen. capacity is to be considered.
Die Lastaufnahmeeinrichtungen mssen in The load acceptance equipment must be in
einem betriebssicheren Zustand sein. an operationally safe condition.
Den Motor nur an den vorgesehenen Suspend engine only from the specified
Anschlagpunkten anhngen. Nur von MTU lifting points. Lise only MTU-approved
vorgesehene Transport- und transportation and lifting equipment.
Hebevorrichtungen verwenden.
Die Anschlagpunkte und deren Ausfhrung The lifting points and their design are shown
sind in der gltigen Einbau- oder AO- in the valid installation and/or arrangement
Zeichnung angegeben. Ebenso das malich drawings. The dimensionally suitable lifting
dazu geeignete Lastaufnahmemittel equipment (beam) and, if necessary, the
(Traverse) und ggf. erforderliche required stabilisation equipment are also
Stabilisierungseinrichtungen. specified on these drawings.
Bei Aggregaten auf Grundrahmen sind zur In the case of gensets on base frames,
Kippsicherung zustzliche Fangzge additional safety links are to be used to
anzubringen prevent tilting
(4 Querzge z. B. auf Motor- und 84 transverse links e.g. to generator and
Generatoranschlagpunkte), wenn die engine lifting points) when the lifting points
Anschlagpunkte fr die Lastaufnahme tiefer are lower than the overall genset centre-of-
als der Aggregategesamtschwerpunkt liegen. gravity.
Die Anschlagpunkte sind mit weier Farbe, The lifting points are to be marked in white
bei weien Motoren mit schwarzer Farbe, paint, in the case of white engines with black
markiert. paint.
Hinweis: Aufhngesen von Motoren, Note: Lifting eyes on Series 2000 and 4000
Aggregaten und Getrieben der BR 2000 und engines, gensets and gearboxes are not
BR 4000 sind nicht gekennzeichnet. colour-coded.
Fr den Transport ist der zulssige The angle of deflection permissible for
Schrgzug an den Anschlagpunkten kenntlich transportation is to be indicated at the lifting
gemacht. points.
Zum Heben des Motors mssen alle When lifting engines, all available lifting
vorhandenen Anschlagpunkte gem AO- points as per arrangement/installation
/Einbauzeichnung genutzt werden. drawing are to be used.
Die Hebeseile bzw. -ketten (Anschlagmittel) The lifting ropes, or chains (connecting
zwischen dem Motor und den elements) between the engine and the lifting
Hebeeinrichtungen mssen senkrecht beam must be vertical (maximum angle of
verlaufen (maximaler Schrgzug von 10). Es deflection 10). lt is essential to ensure that
mu sichergestellt sein, dass die the lifting rig elements are not in contact with
Anschlagmittel nicht am Motor oder dessen the engine or its components. Exceptionally
Komponenten anliegen. Ausnahme: ein if the appropriate instructions are contained
entsprechender Hinweis ist in der AO- in the arrangement/installation drawing.
/Einbauzeichnung vorhanden.
Der Motor ist mit langsamer Geschwindigkeit The engine is to be lifted slowly. When the
TIM-ID: 0000059078 - 002
zu heben. Wenn der Motor um ca. 10 mm engine has been raised approximately 10
angehoben ist, ist zu berprfen, ob die mm it must verified that the ropes, or chains,
Hebeseile bzw. -ketten zwischen dem Motor between the engine and the lifting beam are
und den Hebeeinrichtungen senkrecht bzw. vertical, or in compliance with the data on
entsprechend den Angaben in der AO- the arrangement/installation drawing. If this
/Einbauzeichnung verlaufen. Wenn dies nicht is not the case, the lifting equipment must be
der Fall ist, mssen die Hebeeinrichtungen readjusted.
neu justiert werden.
Zur Verbindung des Motors mit den Only approved connecting elements may be
Hebeeinrichtungen drfen nur zugelassene employed to connect the engine to the lifting
Anschlagmittel verwendet werden. Es ist nicht rig. lt is prohibited to lay lifting ropes, or
zulssig Hebeseile bzw. -ketten um den Motor chains, directly around the engine.
herumzulegen.
Der Motor darf nicht gehoben oder The engine must not be lifted, or transported,
transportiert werden, wenn ungesicherte Teile when unsecured accessories are present on
auf dem Motor liegen. the engine.
Wird der Motor auf dem Boden abgestellt, ist If the engine is to be set down on the
darauf zu achten, dass der Boden eben, ground, it must be ensured that the ground is
sauber, trocken und ausreichend stabil ist. level, clean, dry and adequately stable.
Angaben ber geeignete Vorrichtungen zur Details of suitable mounting equipment, as
Aufnahme gem A0-/Einbauzeichnung per arrangement/installation drawing, are to
oder Bedienungshandbuch sind zu beachten. be observed.
Die Anschlagpunkte am Motor drfen nicht The on-engine lifting points may not be
verndert werden. modified.
Beschdigte Anschlagpunkte am Motor bzw. Damaged on-engine lifting points, or
beschdigte Lastaufnahmeeinrichtungen damaged lifting equipment, may not be
drfen nicht repariert werden, sondern mssen repaired. They must be replaced.
ausgetauscht werden.
Weitere Hinweise im Bedienungshandbuch Compliance with further instructions as
sind zu beachten. contained in the Operating Manual is
mandatory.