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 Crankshaft transport locking device
8
1.5 Crankshaft transportation lock – For
transport with flange-mounted generator
10
1.6 Safety regulations for startup and operation
12
1.7 Safety regulations for maintenance and
repair work
13
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
16
1.9 Standards for safety notices in the text
18
2 General Information
2.1 Engine side and cylinder designations
19
2.2 Engine layout
20
2.3 Sensors and actuators – Overview
21
3 Technical Data
3.1 12/16 V 4000 C13/13R/13L engine data:
Application group 5A, optimized fuel
consumption
25
3.2 12/16 V 4000 C13/13R/13L engine data:
Application group 5A, optimized exhaust
emissions (EPA Stage 2)
32
3.3 12/16 V 4000 C23/23R engine data:
Application group 5B, optimized fuel
consumption
39
3.4 12/16 V 4000 C23/23R engine data:
Application group 5B, optimized exhaust
emissions (EPA Stage 2)
43
3.5 Firing order
47
3.6 Main engine dimensions
48
4 Operation
4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months)
49
4.2 Putting the engine into operation after
scheduled out-of-service-period
50
4.3 Starting the engine in manual mode
51
4.4 Stopping the engine in manual mode
52
4.5 After shutting down the engine
53
4.6 Plant cleaning
54
5 Maintenance
5.1 Maintenance task reference table [QL1]
55
6 Troubleshooting
6.1 Troubleshooting
56
6.2 Fault messages of the engine governor
ADEC (ECU 7) for series 4000 C&I engines
59
7 Task Description
7.1 Engine
78
7.1.1 Cranking engine manually
78
7.1.2 Engine – Barring with starting system
80
7.2 Cylinder Liner
81
7.2.1 Cylinder liner – Endoscopic examination
81
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
83
7.3 Crankcase Breather
85
7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement
85
7.4 Running Gear
87
7.4.1 Grounding device – Carbon brush check
87
7.4.2 Grounding device – Carbon brush replacement
89
7.5 Valve Drive
90
7.5.1 Valve gear – Lubrication
90
7.5.2 Valve clearance – Check and adjustment
91
7.5.3 Cylinder head cover – Removal and
installation
95
7.6 Injection Pump / HP Pump
96
7.6.1 HP pump – Filling with engine oil
96
7.7 Injection Valve / Injector
97
7.7.1 Injector – Replacement
97
7.7.2 Injector – Removal and installation
98
7.8 Fuel System
103
7.8.1 Fuel system – Venting
103
7.9 Fuel Filter
104
7.9.1 Fuel filter – Replacement
104
7.9.2 Draining fuel prefilter
105
7.9.3 Fuel prefilter – Draining
106
7.10 Charge-Air Cooling
107
7.10.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions
107
7.11 Air Intake
108
7.11.1 Service indicator – Signal ring position check
108
7.12 Starting Equipment
109
M015695/03E 2013-03
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