Table of Contents
1 Safety
1.1 Important provisions for all products
5
1.2 Personnel and organizational requirements
6
1.3 Safety regulations for startup and operation
7
1.4 Safety regulations for maintenance and
repair work
8
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
11
1.6 Standards for warning notices in the text
13
1.7 Transport
14
2 General Information
2.1 Engine side and cylinder designations
15
2.2 Product description
16
2.3 Engine layout
36
2.4 Sensors, actuators and injectors – Overview
40
2.5 Sensors, actuators and injectors on 16V
engines – Overview
50
3 Technical Data
3.1 12V 4000 M63 engine data, EPA Tier 2, EU
Stage IIIA, IMO Tier II
70
3.2 16V 4000 M63 engine data, EPA Tier 2, EU
Stage IIIA, IMO Tier II
74
3.3 16V 4000 M63R engine data, IMO Tier II
78
3.4 Firing order
82
3.5 Engine – Main dimensions
83
4 Operation
4.1 Controls
85
4.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
86
4.3 Putting the engine into operation after
scheduled out-of-service-period
87
4.4 Starting the engine
88
4.5 Operational checks
89
4.6 Tasks after extended out-of-service periods
(>3 weeks)
90
4.7 Checks prior to start-up
91
4.8 Fuel treatment system – Putting into
operation
92
4.9 Fuel treatment system – Switching on
94
4.10 Fuel treatment system – Shutdown
95
4.11 Stopping the engine
96
4.12 Emergency engine stop
97
4.13 After stopping the engine
98
4.14 Plant cleaning
99
5 Maintenance
5.1 Maintenance task reference table [QL1]
100
6 Troubleshooting
6.1 Troubleshooting
102
6.2 Fuel treatment system – Troubleshooting
105
6.3 ADEC (ECU 7) fault codes for Series 4000
engines, marine application
106
6.4 ADEC engine governor – Fault codes
107
7 Task Description
7.1 Engine
133
7.1.1 Engine – Barring manually
133
7.1.2 Engine – Barring with starting system
134
7.2 Cylinder Liner
135
7.2.1 Cylinder liner – Endoscopic examination
135
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
137
7.3 Valve Drive
139
7.3.1 Valve gear – Lubrication
139
7.3.2 Valve clearance – Check and adjustment
140
7.3.3 Cylinder head cover – Removal and
installation
143
7.4 Injection Pump / HP Pump
144
7.4.1 HP pump – Filling with engine oil
144
7.4.2 HP pump – Relief bore check
145
7.5 Injection Valve / Injector
146
7.5.1 Injector – Replacement
146
7.5.2 Injector – Removal and installation
147
7.6 Fuel Filter
152
7.6.1 Supplementary fuel filter – Overview
152
7.6.2 Supplementary fuel filter – Replacement
153
7.6.3 Fuel filter – Replacement
154
7.6.4 Fuel prefilter – Differential pressure gauge
check and adjustment
156
7.6.5 Fuel prefilter – Draining
157
7.6.6 Fuel prefilter – Flushing
159
7.6.7 Fuel prefilter with water separator – Filter
element replacement
161
7.6.8 Fuel prefilter with water separator – O-ring
replacement in rotary slide valve
164
7.7 Exhaust Turbocharger
165
7.7.1 Compressor wheel – Cleaning
165
7.8 Charge-Air Cooling
173
MS150066/02E 2013-02 | Table of Contents | 3
DCL-ID: 0000005757 - 002
