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 safety notices in the text
13
1.7 Transport
14
2 General Information
2.1 Engine layout
15
2.2 Product description
19
2.3 Engine side and cylinder designations
30
2.4 Overview of sensors – 12 V engines
31
2.5 Overview of sensors – 16 V engines
41
2.6 Engine wiring harness – Overview
51
3 Technical Data
3.1 Engine data 12V 4000 M54, EPA Tier 3, IMO
Tier II
58
3.2 Engine data 12V 4000 M64, EPA Tier 3, IMO
Tier II
62
3.3 Engine data 16V 4000 M54, EPA Tier 3, IMO
Tier II
66
3.4 Engine data – 16V 4000 M64, EPA Tier 3,
IMO Tier II
70
3.5 Firing order
74
3.6 Engine – Main dimensions
75
4 Operation
4.1 LOP controls
77
4.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
78
4.3 Putting the engine into operation after
scheduled out-of-service-period
79
4.4 Starting the engine via the automation
system
80
4.5 Operational checks
81
4.6 Tasks after extended out-of-service periods
(>3 weeks)
82
4.7 Checks prior to start-up
83
4.8 Fuel treatment system control cabinet –
Control elements
84
4.9 Fuel treatment system – Putting into
operation
85
4.10 Fuel treatment system – Switching on
88
4.11 Emergency engine shutdown via
automation system
89
4.12 Engaging from LOP
90
4.13 Disengaging from LOP
91
4.14 Waterjet – Flushing from LOP (optional)
92
4.15 Engine shutdown via the automation
system
93
4.16 After stopping the engine
94
4.17 Fuel treatment system – Shutdown
95
4.18 Plant – Cleaning
96
5 Maintenance
5.1 Maintenance task reference table [QL1]
97
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting
98
6.2 Troubleshooting
99
6.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application
102
6.4 Engine governor ADEC (ECU 7) – Fault
codes
103
7 Task Description
7.1 Engine
168
7.1.1 Engine – Barring manually
168
7.1.2 Engine – Barring with starting system
170
7.2 Cylinder Liner
171
7.2.1 Cylinder liner – Endoscopic examination
171
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
173
7.3 Valve Drive
175
7.3.1 Valve gear – Lubrication
175
7.3.2 Valve clearance – Check and adjustment
176
7.3.3 Cylinder head cover – Removal and
installation
179
7.4 Injection Pump / HP Pump
180
7.4.1 HP pump – Filling with engine oil
180
7.4.2 HP pump – Relief bore check
181
7.5 Injector
182
7.5.1 Injector – Replacement
182
7.5.2 Injector – Removal and installation
183
7.6 Fuel Filter
189
7.6.1 Supplementary fuel filter – Overview
189
MS150110/00E 2013-10 | Table of Contents | 3
DCL-ID: 0000029807 - 001
