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 | Table of Contents | 3
DCL-ID: 0000029553 - 001