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
10
1.5 Safety regulations for maintenance and
repair work
11
1.6 Safety requirements for maintenance and
repair work, special instructions for
applications with gaseous fuel
14
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
15
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel
17
1.9 Standards for safety notices in the text
18
1.10 Transport
19
2 Product Summary
2.1 Engine – Overview
20
2.2 Engine side and cylinder designations
22
2.3 Engine – Main dimensions
23
2.4 Firing order
24
2.5 Technical Data
25
2.5.1 8V4000L64 engine data, fuel-optimized (TA-
Luft)
25
2.5.2 8V4000L64 engine data, emissions optimized
(1/2 TA-Luft)
29
2.6 Monitoring, Control and Regulation
Equipment
33
2.6.1 Gas engine system – Overview
33
2.6.2 Purpose of the units
35
3 Operation
3.1 Runtimes at partial load
37
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
38
3.3 Putting the engine into operation after
scheduled out-of-service-period
39
3.4 Control, starting and stopping sequences
40
3.5 Engine – Start
42
3.6 Operational checks
43
3.7 Emission values – Check
44
3.8 Engine – Shutdown
45
3.9 Emergency engine shutdown
46
3.10 After stopping the engine – Engine remains
ready for operation
48
3.11 After stopping the engine – Putting the
engine out of operation
49
4 Maintenance
4.1 50-hours check
50
4.2 Maintenance schedule reference table [QL1]
51
5 Troubleshooting
5.1 Fault messages - Key
52
5.2 Fault messages in log for genset controller
54
5.3 Engine Control Unit – Fault messages
112
6 Task Description
6.1 Engine
151
6.1.1 Engine – Barring manually
151
6.1.2 Machine room – Check for smell of gas
152
6.2 Crankcase Breather
153
6.2.1 Oil separator – Filter replacement
153
6.3 Ignition System
155
6.3.1 Spark plug – Replacement
155
6.3.2 Spark plug – Removal
156
6.3.3 Spark plug – Installation
157
6.3.4 Spark plug connector – Replacement
159
6.3.5 Spark plug connector – Removal
160
6.3.6 Spark plug connector – Installation
161
6.3.7 Ignition system – Ignition timing check
163
6.4 Valve Drive
164
6.4.1 Valve projection – Measurement
164
6.4.2 Valve gear – Lubrication
167
6.4.3 Valve clearance – Check and adjustment
168
6.4.4 Cylinder head cover ‒ Removal
170
6.4.5 Cylinder head cover ‒ Installation
171
6.5 Gas System
172
6.5.1 Gas supply - Checking gas lines for leaks
172
6.6 Air Filter
173
6.6.1 Air filter – Replacement
173
6.6.2 Air filter – Removal and installation
174
6.7 Lube Oil System, Lube Oil Circuit
175
6.7.1 Engine oil – Level check
175
6.7.2 Engine oil – Change
176
6.7.3 Engine oil – Sample extraction and analysis
177
6.8 Oil Filtration / Cooling
178
MS15026/00E 2015-05
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DCL-ID: 0000029553 - 001
