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 Engine data 16V4000L32FNER, fuel-optimized
(TA-Luft), 100 kW/cylinder
25
2.5.2 Engine data 16V4000L32FNER, fuel-optimized
(TA-Luft), 110 kW/cylinder
30
2.6 Monitoring, Control and Regulation
Equipment
35
2.6.1 Gas engine phase 3 system – Overview
35
2.6.2 Purpose of the units
37
3 Operation
3.1 Runtimes at partial load
39
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
40
3.3 Putting the engine into operation after
scheduled out-of-service-period
41
3.4 Control, starting and stopping sequences
42
3.5 Engine – Start
44
3.6 Operational checks
45
3.7 Emission values – Check
46
3.8 Engine – Shutdown
47
3.9 Emergency engine shutdown
48
3.10 After stopping the engine – Engine remains
ready for operation
50
3.11 After stopping the engine – Putting the
engine out of operation
51
4 Maintenance
4.1 50-hours check
52
4.2 Maintenance task reference table [QL1]
53
5 Troubleshooting
5.1 Fault messages - Key
54
5.2 Fault messages in log for genset controller
56
5.3 Fault messages – Engine Control Unit
99
6 Task Description
6.1 Engine
133
6.1.1 Engine – Barring manually
133
6.1.2 Machine room – Check for smell of gas
134
6.2 Crankcase Breather
135
6.2.1 Oil separator – Filter replacement
135
6.3 Ignition System
137
6.3.1 Spark plug – Replacement
137
6.3.2 Spark plug – Removal
138
6.3.3 Spark plug – Installation
139
6.3.4 Spark plug connector – Replacement
141
6.3.5 Spark plug connector – Removal
142
6.3.6 Spark plug connector – Installation
143
6.3.7 Ignition system – Ignition timing check
145
6.4 Valve Drive
146
6.4.1 Valve projection – Measurement
146
6.4.2 Valve clearance – Check and adjustment
149
6.4.3 Valve gear – Lubrication
151
6.4.4 Cylinder head cover ‒ Removal
152
6.4.5 Cylinder head cover ‒ Installation
153
6.5 Gas System
154
6.5.1 Gas supply - Checking gas lines for leaks
154
6.6 Air Filter
155
6.6.1 Air filter – Replacement
155
6.6.2 Air filter – Removal and installation
156
6.7 Lube Oil System, Lube Oil Circuit
157
6.7.1 Engine oil – Level check
157
6.7.2 Engine oil – Change
158
6.7.3 Engine oil – Sample extraction and analysis
159
6.8 Oil Filtration / Cooling
160
MS150121/00E 2015-07
| Table of Contents | 3
DCL-ID: 0000038659 - 001
