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 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 safety notices in the text
13
2 Product Summary
2.1 Engine Layout
14
2.1.1 Product description
14
2.1.2 Engine layout
34
2.1.3 Sensors, actuators and injectors on 12V
engines – Overview
38
2.1.4 Sensors, actuators and injectors on 16V
engines – Overview
48
2.2 Engine Side and Cylinder Designations
68
2.2.1 Engine side and cylinder designations
68
2.3 Main Engine Dimensions
69
2.3.1 Engine – Main dimensions
69
2.4 Firing Sequence
71
2.4.1 Firing order
71
2.5 Technical Data
72
2.5.1 12V 4000 M53 engine data
72
2.5.2 16V^4000 M53 engine data
76
3 Operation
3.1 Controls
80
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
81
3.3 Putting the engine into operation after
scheduled out-of-service-period
82
3.4 Starting the engine
83
3.5 Operational checks
84
3.6 Tasks after extended out-of-service periods
(>3 weeks)
85
3.7 Checks prior to start-up
86
3.8 Fuel treatment system – Putting into
operation
87
3.9 Fuel treatment system – Switching on
90
3.10 Fuel treatment system – Shutdown
91
3.11 Stopping the engine
92
3.12 Emergency engine stop
93
3.13 After stopping the engine
94
3.14 Plant – Cleaning
95
4 Maintenance
4.1 Maintenance task reference table [QL1]
96
5 Troubleshooting
5.1 Troubleshooting
98
5.2 Fuel treatment system – Troubleshooting
101
5.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application
102
5.4 ADEC engine governor – Fault codes
103
6 Task Description
6.1 Engine
129
6.1.1 Engine – Barring manually
129
6.1.2 Engine – Barring with starting system
131
6.2 Cylinder Liner
132
6.2.1 Cylinder liner – Endoscopic examination
132
6.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
134
6.3 Valve Drive
136
6.3.1 Valve gear – Lubrication
136
6.3.2 Valve clearance – Check and adjustment
137
6.3.3 Cylinder head cover – Removal and
installation
140
6.4 Injection Pump / HP Pump
141
6.4.1 HP pump – Filling with engine oil
141
6.4.2 HP pump – Relief bore check
142
6.5 Injection Valve / Injector
143
6.5.1 Injector – Replacement
143
6.5.2 Injector – Removal and installation
144
6.6 Fuel Filter
149
6.6.1 Supplementary fuel filter – Overview
149
6.6.2 Additional fuel filter – Replacement
150
6.6.3 Fuel filter – Replacement
151
6.6.4 Fuel prefilter – Differential pressure check
and adjustment of gauge
153
6.6.5 Fuel prefilter – Draining
154
6.6.6 Fuel prefilter – Flushing
156
6.6.7 Fuel prefilter with water separator – Filter
element replacement
158
6.6.8 Fuel prefilter with water separator – O-ring
replacement in rotary slide valve
160
6.7 Exhaust Turbocharger
161
6.7.1 Compressor wheel – Cleaning
161
MS150035/01E 2013-11 | Table of Contents | 3
DCL-ID: 0000005146 - 003
