Table of Contents
1 Safety
1.1 Important provisions for all products
5
1.2 Personnel and organizational requirements
7
1.3 Safety regulations for startup and operation
8
1.4 Safety requirements for startup and
operation, special instructions for
applications with gaseous fuel
9
1.5 Safety regulations for maintenance and
repair work
10
1.6 Safety requirements for maintenance and
repair work, special instructions for
applications with gaseous fuel
13
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
14
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel
16
1.9 Standards for safety notices in the text
17
1.10 Transport
18
2 Product Summary
2.1 Engine overview
19
2.2 Engine side and cylinder designations
21
2.3 Main engine dimensions
22
2.4 Firing order
23
2.5 Technical Data
24
2.5.1 12 V 4000 L64, 16 V 4000 L64 engine data,
fuel optimized ("TA-Luft")
24
2.5.2 12V 4000 L64, 16V 4000 L64 engine data,
emissions-optimized (1/2 "TA-Luft")
28
2.6 Monitoring, Control and Regulation
Equipment
32
2.6.1 Gas engine system – Overview
32
2.6.2 Purpose of the units
34
3 Operation
3.1 Runtimes at partial load
36
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
37
3.3 Putting the engine into operation after
scheduled out-of-service-period
38
3.4 Control, starting and stopping sequences
39
3.5 Engine – Start
41
3.6 Operational checks
42
3.7 Emission values – Check
43
3.8 Engine – Shutdown
44
3.9 Emergency engine shutdown
45
3.10 After stopping the engine – Engine remains
ready for operation
47
3.11 After stopping the engine – Putting the
engine out of operation
48
4 Maintenance
4.1 50-hours check
49
4.2 Maintenance schedule reference table [QL1]
50
5 Troubleshooting
5.1 Fault messages - Key
51
5.2 Fault messages in log for genset controller
53
5.3 Engine Control Unit – Fault messages
111
6 Task Description
6.1 Engine
150
6.1.1 Engine – Barring manually
150
6.1.2 Machine room – Check for smell of gas
151
6.2 Crankcase Breather
152
6.2.1 Oil separator – Filter replacement
152
6.3 Ignition System
154
6.3.1 Spark plug – Replacement
154
6.3.2 Spark plug – Removal
155
6.3.3 Spark plug – Installation
156
6.3.4 Spark plug connector – Replacement
158
6.3.5 Spark plug connector – Removal
159
6.3.6 Spark plug connector – Installation
160
6.3.7 Ignition system – Ignition timing check
162
6.4 Valve Drive
163
6.4.1 Valve projection – Measurement
163
6.4.2 Valve gear – Lubrication
166
6.4.3 Valve clearance – Check and adjustment
167
6.4.4 Cylinder head cover ‒ Removal
169
6.4.5 Cylinder head cover ‒ Installation
170
6.5 Gas System
171
6.5.1 Gas supply - Checking gas lines for leaks
171
6.6 Air Filter
172
6.6.1 Air filter – Replacement
172
6.6.2 Air filter – Removal and installation
173
6.7 Lube Oil System, Lube Oil Circuit
174
6.7.1 Engine oil – Level check
174
6.7.2 Engine oil – Change
175
6.7.3 Engine oil – Sample extraction and analysis
176
6.8 Oil Filtration / Cooling
177
MS15027/02E 2015-04
| Table of Contents | 3
DCL-ID: 0000028920 - 004
