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 layout
16
2.2 Engine side and cylinder designations
18
2.3 Engine – Main dimensions
19
2.4 Firing order
20
2.5 Technical Data
21
2.5.1 Runtimes at partial load
21
2.5.2 20V 4000 L63 engine data, fuel optimized
(TA-Luft)
22
2.5.3 20 V 4000 L63 engine data, optimized
exhaust emissions (1/2 TA-Luft)
26
3 Monitoring, Control and Regulation
Equipment
3.1 Gas engine phase 3 system – Overview
30
3.2 Control cabinet MIS – Overview
32
3.3 Purpose of the units
33
4 Operation
4.1 Putting the engine into operation after
extended out-of-service-periods (>3
months)
37
4.2 Putting the engine into operation after
scheduled out-of-service-period
38
4.3 Control, starting and stopping sequences
39
4.4 Starting the engine
40
4.5 Operational checks
41
4.6 Stopping the engine
42
4.7 Emergency stop
43
4.8 After stopping the engine – Engine remains
ready for operation
44
4.9 After stopping the engine – Putting the
engine out of operation
45
5 Maintenance
5.1 50-hours check
46
5.2 Maintenance task reference table [QL1]
47
6 Troubleshooting
6.1 Fault indication on SAM display
48
6.2 SAM – Fault messages
52
6.3 Engine governor – Fault messages
102
7 Task Description
7.1 Engine
133
7.1.1 Engine – Barring manually
133
7.1.2 Checking machine room for smell of gas
134
7.2 Crankcase Breather
135
7.2.1 Oil separator – Filter element replacement
135
7.3 Ignition System
137
7.3.1 Ignition system – Ignition timing check
137
7.3.2 Spark plug connector – Replacement
138
7.3.3 Spark plug connector – Removal and
installation
139
7.3.4 Spark plug – Replacement
141
7.3.5 Spark plug – Removal and installation
142
7.4 Valve Drive
144
7.4.1 Valve gear – Lubrication
144
7.4.2 Valve clearance – Check and adjustment
145
7.4.3 Valve depth – Measurement
148
7.4.4 Cylinder head cover – Removal and
installation
151
7.5 Gas System
152
7.5.1 Gas supply – Checking gas lines for leaks
152
7.6 Air Filter
153
7.6.1 Air filter – Replacement
153
7.6.2 Air filter – Removal and installation
154
7.7 Lube Oil System, Lube Oil Circuit
155
7.7.1 Engine oil level – Check
155
7.7.2 Engine oil – Change
156
7.7.3 Engine oil – Sampling and analysis
157
7.8 Oil Filtration / Cooling
158
MS150059/01E 2012-07 | Table of Contents | 3
DCL-ID: 0000016447 - 003
