Table of Contents
1 Safety
1.1 Important provisions for all products
5
1.2 Personnel and organizational requirements
6
1.3 Transport
7
1.4 Safety regulations for startup and operation
8
1.5 Safety regulations for startup and operation,
special instructions for applications with
gaseous fuel
9
1.6 Safety regulations for maintenance and
repair work
10
1.7 Safety regulations for maintenance and
repair work, special instructions for
applications with gaseous fuel
13
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
14
1.9 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials, special instructions for
applications with gaseous fuel
16
1.10 Standards for safety notices in the text
17
2 Product Summary
2.1 Engine layout
18
2.2 Engine side and cylinder designations
20
2.3 Engine – Main dimensions
21
2.4 Firing order
22
2.5 Technical Data
23
2.5.1 20V 4000 L63 engine data, fuel optimized (TA-
Luft)
23
2.5.2 20 V 4000 L63 engine data, emissions
optimized (1/2 TA-Luft)
27
2.6 Monitoring, Control and Regulation
Equipment
31
2.6.1 Gas engine phase 3 system – Overview
31
2.6.2 Control cabinet MIS – Overview
33
2.6.3 Purpose of the units
34
3 Operation
3.1 Runtimes at partial load
38
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
39
3.3 Putting the engine into operation after
scheduled out-of-service-period
40
3.4 Control, starting and stopping sequences
41
3.5 Engine – Start
43
3.6 Operational checks
44
3.7 Emission values – Check
45
3.8 Engine – Shutdown
46
3.9 Emergency stop
47
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 task reference table [QL1]
51
5 Troubleshooting
5.1 Fault indication on SAM display
52
5.2 SAM – Fault messages
56
5.3 Engine governor – Fault messages
106
6 Task Description
6.1 Engine
137
6.1.1 Engine – Barring manually
137
6.1.2 Machine room – Check for smell of gas
138
6.2 Crankcase Breather
139
6.2.1 Oil separator – Filter replacement
139
6.3 Ignition System
141
6.3.1 Spark plug – Replacement
141
6.3.2 Spark plug – Removal
142
6.3.3 Spark plug – Installation
143
6.3.4 Spark plug connector – Replacement
145
6.3.5 Spark plug connector – Removal
146
6.3.6 Spark plug connector – Installation
147
6.3.7 Ignition system – Ignition timing check
149
6.4 Valve Drive
150
6.4.1 Valve clearance – Check and adjustment
150
6.4.2 Valve depth – Measurement
153
6.4.3 Valve gear – Lubrication
156
6.4.4 Cylinder head cover – Removal
157
6.4.5 Cylinder head cover – Installation
158
6.5 Gas System
159
6.5.1 Gas supply – Checking gas lines for leaks
159
6.6 Air Filter
160
6.6.1 Air filter – Replacement
160
6.6.2 Air filter – Removal and installation
161
6.7 Lube Oil System, Lube Oil Circuit
162
6.7.1 Engine oil – Level check
162
6.7.2 Engine oil – Change
163
6.7.3 Engine oil – Sample extraction and analysis
164
MS150059/02E 2013-10
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