Table of Contents
1 Safety
1.1 Important provisions for all products
5
1.2 Personnel and organizational requirements
6
1.3 Safety regulations for startup and operation
7
1.4 Safety regulations for startup and operation,
special instructions for applications with
gaseous fuel
8
1.5 Safety regulations for maintenance and
repair work
9
1.6 Safety regulations for maintenance and
repair work, special instructions for
applications with gaseous fuel
12
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
13
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel
15
1.9 Standards for safety notices in the text
16
1.10 Transport
17
2 Product Summary
2.1 Engine overview
18
2.2 Engine side and cylinder designations
20
2.3 Main engine dimensions
21
2.4 Ignition order
22
2.5 Technical Data
23
2.5.1 12 V 4000 L64, 16 V 4000 L64 engine data,
fuel optimized ("TA-Luft")
23
2.5.2 12V 4000 L64, 16V 4000 L64 engine data,
emissions-optimized (1/2 "TA-Luft")
27
2.6 Monitoring, Control and Regulation
Equipment
31
2.6.1 Gas engine phase 4 system – Overview
31
2.6.2 Purpose of the units
33
3 Operation
3.1 Runtimes at partial load
35
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
36
3.3 Putting the engine into operation after
scheduled out-of-service-period
37
3.4 Control, starting and stopping sequences
38
3.5 Engine – Start
40
3.6 Operational checks
41
3.7 Emission values – Check
42
3.8 Engine – Shutdown
43
3.9 Emergency engine shutdown
44
3.10 After stopping the engine – Engine remains
ready for operation
46
3.11 After stopping the engine – Putting the
engine out of operation
47
4 Maintenance
4.1 50-hours check
48
4.2 Maintenance schedule reference table [QL1]
49
5 Troubleshooting
5.1 Fault messages - Key
50
5.2 Fault messages on log for genset control
52
5.3 Engine governor – Fault messages
110
6 Task Description
6.1 Engine
147
6.1.1 Engine – Barring manually
147
6.1.2 Machine room – Check for smell of gas
148
6.2 Crankcase Breather
149
6.2.1 Oil separator – Filter replacement
149
6.3 Ignition System
151
6.3.1 Spark plug – Replacement
151
6.3.2 Spark plug – Removal
152
6.3.3 Spark plug – Installation
153
6.3.4 Spark plug connector – Replacement
155
6.3.5 Spark plug connector – Removal
156
6.3.6 Spark plug connector – Installing
157
6.3.7 Ignition system – Ignition timing check
160
6.4 Valve Drive
161
6.4.1 Valve depth – Measurement
161
6.4.2 Valve gear – Lubrication
164
6.4.3 Valve clearance – Check and adjustment
165
6.4.4 Cylinder head cover – Removal
168
6.4.5 Cylinder head cover – Installation
169
6.5 Gas System
170
6.5.1 Gas supply - Checking gas lines for leaks
170
6.6 Air Filter
171
6.6.1 Air filter – Replacement
171
6.6.2 Air filter – Removal and installation
172
6.7 Lube Oil System, Lube Oil Circuit
173
6.7.1 Engine oil – Level check
173
6.7.2 Engine oil – Change
174
6.7.3 Engine oil – Sample extraction and analysis
175
6.8 Oil Filtration / Cooling
176
MS15027/00E 2013-10
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