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 Safety regulations for maintenance and
repair work
11
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
14
1.7 Conventions for safety instructions in the
text
16
2 General Information
2.1 Engine side and cylinder designations
17
2.2 Engine layout
18
2.3 Sensors and actuators – Overview
19
3 Technical Data
3.1 12/16V 4000 S83L 4D engine data
23
3.2 Firing order
27
3.3 Engine – Main dimensions
28
4 Operation
4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months)
29
4.2 Putting the engine into operation after
scheduled out-of-service period
30
4.3 Starting the engine in manual mode
31
4.4 Operational checks
32
4.5 Stopping the engine in manual mode
33
4.6 After shutting down the engine
34
4.7 Plant cleaning
35
5 Maintenance
5.1 Maintenance task reference table [QL1]
36
6 Troubleshooting
6.1 Troubleshooting
37
6.2 Fault messages from the ADEC (ECU 7)
engine management control unit for the
Series 4000 for C&I applications
40
7 Task Description
7.1 Engine
59
7.1.1 Cranking engine manually
59
7.1.2 Engine – Barring with starting system
61
7.1.3 Engine – Test run
62
7.2 Cylinder Liner
63
7.2.1 Cylinder liner – Endoscopic examination
63
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
65
7.3 Crankcase Breather
67
7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement
67
7.4 Valve Drive
69
7.4.1 Valve gear – Lubrication
69
7.4.2 Valve clearance – Check and adjustment
70
7.4.3 Cylinder head cover – Removal and
installation
74
7.5 Injection Pump / HP Pump
75
7.5.1 HP pump – Filling with engine oil
75
7.6 Injection Valve / Injector
76
7.6.1 Injector – Replacement
76
7.6.2 Injector – Removal and installation
77
7.7 Fuel System
82
7.7.1 Fuel system – Venting
82
7.8 Fuel Filter
83
7.8.1 Fuel filter – Replacement
83
7.9 Charge-Air Cooling
84
7.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions
84
7.10 Air Filter
85
7.10.1 Air filter – Replacement
85
7.10.2 Air filter element – Removal and installation
(optional)
86
7.11 Starting Equipment
87
7.11.1 Starter – Condition check
87
7.12 Air Intake
88
7.12.1 Emergency air-shutoff flaps – Electric control
check
88
7.12.2 Service indicator – Signal ring position check
(optional)
89
7.13 Lube Oil System, Lube Oil Circuit
90
7.13.1 Checking engine oil level
90
7.13.2 Engine oil – Change
91
7.13.3 Engine oil – Sample extraction and analysis
93
7.14 Oil Filtration / Cooling
94
MS150027/02E 2013-02
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DCL-ID: 0000005665 - 003
