Table of Contents
1 Safety
1.1 Important requirements for all products
5
1.2 Personnel and organizational requirements
6
1.3 Transport
7
1.4 Safety requirements for maintenance and
repair work
8
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
11
1.6 Standards for safety notices in the text
13
2 General Information
2.1 Engine side and cylinder designations
14
2.2 Engine overview
15
3 Technical Data
3.1 Engine data 16 V 2000 G56 S
17
3.2 Engine data 18 V 2000 G76 S
21
3.3 Firing order
24
3.4 Engine – Main dimensions
25
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months)
27
4.2 Putting the engine into operation after
scheduled out-of-service-period
28
4.3 Starting the engine
29
4.4 Operational checks
30
4.5 Engine shutdown
31
4.6 Emergency engine stop
32
4.7 After stopping the engine – Putting the
engine out of operation
33
4.8 Plant – Cleaning
34
5 Maintenance
5.1 Maintenance task reference table [QL1],
application group 3B
35
5.2 Maintenance task reference table [QL1],
application group 3D
36
6 Troubleshooting
6.1 Troubleshooting
37
7 Task Description
7.1 Engine
40
7.1.1 Engine – Barring manually
40
7.1.2 Engine – Barring with starting system
41
7.1.3 Engine – Test run
42
7.2 Cylinder Liner
43
7.2.1 Cylinder liner – Endoscopic examination
43
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
45
7.3 Crankcase Breather
47
7.3.1 Crankcase breather – Oil mist fine separator
replacement
47
7.4 Valve Drive
48
7.4.1 Valve clearance – Check and adjustment
48
7.4.2 Cylinder head cover – Removal and
installation
50
7.5 Injection Valve / Injector
51
7.5.1 Injector ‒ Replacement
51
7.5.2 Injector – Removal and installation
52
7.5.3 Injector functions
57
7.6 Fuel System
58
7.6.1 HP fuel line and pressure pipe neck ‒
Replacement
58
7.6.2 Fuel system – Venting
60
7.6.3 Fuel – Draining
61
7.7 Fuel Filter
62
7.7.1 Fuel filter – Replacement
62
7.7.2 Fuel prefilter – Differential pressure gage
check and adjustment of gage
63
7.7.3 Fuel prefilter – Draining
64
7.7.4 Fuel prefilter – Flushing
65
7.7.5 Fuel prefilter – Filter element replacement
67
7.8 Air Filter
68
7.8.1 Air filter – Replacement
68
7.8.2 Air filter – Removal and installation
69
7.9 Air Intake
70
7.9.1 Service indicator – Signal ring position check
70
7.10 Exhaust Gas Recirculation
71
7.10.1 Exhaust gas recirculation flaps – Overview
71
7.10.2 Exhaust gas recirculation ‒ Checking flap
operation
72
7.11 Lube Oil System, Lube Oil Circuit
73
7.11.1 Engine oil – Level check
73
7.11.2 Engine oil – Change
74
7.12 Oil Filtration / Cooling
75
7.12.1 Engine oil filter – Replacement
75
7.12.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement
76
7.13 Coolant Circuit, General, High-Temperature
Circuit
78
MS150117/01E 2014-10
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