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 Ignition order
20
2.5 Technical Data
21
2.5.1 Runtimes at partial load
21
2.5.2 12 V 4000 L62, 16 V 4000 L62 engine data,
fuel optimized (TA-Luft)
22
2.5.3 12V 4000 L62, 16V 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 Troubleshooting
5.1 Fault indication on SAM display
48
5.2 SAM – Fault messages
52
5.3 Engine governor – Fault messages
102
6 Task Description
6.1 Engine
133
6.1.1 Engine – Barring manually
133
6.1.2 Checking machine room for smell of gas
134
6.2 Crankcase Breather
135
6.2.1 Oil separator – Filter replacement
135
6.3 Ignition System
137
6.3.1 Ignition system – Ignition timing check
137
6.3.2 Spark plug connector – Replacement
138
6.3.3 Spark plug connector – Removal and
installation
139
6.3.4 Spark plug – Replacement
141
6.3.5 Spark plug – Removal and installation
142
6.4 Valve Drive
144
6.4.1 Valve gear – Lubrication
144
6.4.2 Valve depth – Measurement
145
6.4.3 Valve clearance - Check and adjustment
148
6.4.4 Valve gear – Lubrication
151
6.4.5 Cylinder head cover – Removal and
installation
152
6.5 Gas System
153
6.5.1 Gas supply – Checking gas lines for leaks
153
6.6 Air Filter
154
6.6.1 Air filter – Replacement
154
6.6.2 Air filter – Removal and installation
155
6.7 Lube Oil System, Lube Oil Circuit
156
6.7.1 Engine oil level – Check
156
6.7.2 Engine oil – Change
157
6.7.3 Engine oil – Sampling and analysis
158
6.8 Oil Filtration / Cooling
159
6.8.1 Engine oil filter – Replacement
159
6.9 Coolant Circuit, General, High-
Temperature Circuit
160
6.9.1 Engine coolant – Level check
160
MS150033/04E 2012-07 | Table of Contents | 3
DCL-ID: 0000016352 - 003
