Table of Contents
1 Safety
1.1 Important provisions for all products
5
1.2 Personnel and organizational requirements
7
1.3 Transport
8
1.4 Safety regulations for startup and operation
9
1.5 Safety requirements for startup and
operation, special instructions for
applications with gaseous fuel
10
1.6 Safety regulations for maintenance and
repair work
11
1.7 Safety requirements for maintenance and
repair work, special instructions for
applications with gaseous fuel
14
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
15
1.9 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel
17
1.10 Standards for safety notices in the text
18
2 Product Summary
2.1 Engine overview
19
2.2 Engine side and cylinder designations
21
2.3 Engine – Main dimensions
22
2.4 Firing order
23
2.5 Technical Data
24
2.5.1 8V 4000 L32F engine data, fuel-optimized (TA-
Luft)
24
2.5.2 8V 4000 L32F engine data, emissions-
optimized (1/2 TA-Luft)
28
2.6 Monitoring, Control and Regulation
Equipment
32
2.6.1 Gas engine phase 3 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 task reference table [QL1]
50
5 Troubleshooting
5.1 Fault messages - Key
51
5.2 Fault messages in communication protocol
to genset control system
53
5.3 Fault messages – Engine Control Unit
95
6 Task Description
6.1 Engine
129
6.1.1 Engine – Barring manually
129
6.1.2 Machine room – Check for smell of gas
130
6.2 Crankcase Breather
131
6.2.1 Oil separator – Filter replacement
131
6.3 Ignition System
133
6.3.1 Spark plug – Replacement
133
6.3.2 Spark plug – Removal
134
6.3.3 Spark plug – Installation
135
6.3.4 Spark plug connector – Replacement
137
6.3.5 Spark plug connector – Removal
138
6.3.6 Spark plug connector – Installation
139
6.3.7 Ignition system – Ignition timing check
141
6.4 Valve Drive
142
6.4.1 Valve projection – Measurement
142
6.4.2 Valve clearance – Check and adjustment
145
6.4.3 Valve gear – Lubrication
147
6.4.4 Cylinder head cover ‒ Removal
148
6.4.5 Cylinder head cover ‒ Installation
149
6.5 Gas System
150
6.5.1 Gas supply – Checking gas lines for leaks
150
6.6 Air Filter
151
6.6.1 Air filter – Replacement
151
6.6.2 Air filter – Removal and installation
152
6.7 Lube Oil System, Lube Oil Circuit
153
6.7.1 Engine oil – Level check
153
6.7.2 Engine oil – Change
154
6.7.3 Engine oil – Sample extraction and analysis
155
MS150103/01E 2015-03
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DCL-ID: 0000028866 - 002
