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 startup and operation
11
1.6 Safety regulations for maintenance and
repair work
12
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
15
1.8 Standards for safety notices in the text
17
2 General Information
2.1 Engine side and cylinder designations
18
2.2 Engine layout
19
2.3 Sensors and actuators – Overview
20
3 Technical Data
3.1 12/16V 4000 S83 4D engine data
24
3.2 Firing order
28
3.3 Engine ‒ Main dimensions
29
4 Operation
4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months)
30
4.2 Putting the engine into operation after
scheduled out-of-service-period
31
4.3 Engine – Starting in manual mode
32
4.4 Operational checks
33
4.5 Engine – Stopping in manual mode
34
4.6 Preparing the engine for extended out-of-
service period
35
4.7 Plant – Cleaning
36
5 Maintenance
5.1 Maintenance task reference table [QL1]
37
6 Troubleshooting
6.1 Troubleshooting
38
6.2 Fault messages from the ADEC (ECU 7)
engine management control unit for the
Series 4000 for C&I applications
41
7 Task Description
7.1 Engine
60
7.1.1 Engine – Performing test run
60
7.1.2 Engine – Barring manually
61
7.1.3 Engine – Barring with starting system
63
7.2 Cylinder Liner
64
7.2.1 Cylinder liner – Endoscopic examination
64
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
66
7.3 Crankcase Breather
68
7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement
68
7.4 Valve Drive
70
7.4.1 Valve gear – Lubrication
70
7.4.2 Valve clearance – Check and adjustment
71
7.4.3 Cylinder head cover – Removal and
installation
75
7.5 Injection Pump / HP Pump
76
7.5.1 HP pump – Filling with engine oil
76
7.6 Injector
77
7.6.1 Injector – Replacement
77
7.6.2 Injector – Removal and installation
78
7.7 Fuel System
83
7.7.1 Fuel system – Venting
83
7.8 Fuel Filter
84
7.8.1 Fuel filter – Replacement
84
7.9 Charge-Air Cooling
85
7.9.1 Intercooler – Checking condensate drain for
coolant leakage and obstruction
85
7.10 Starting Equipment
86
7.10.1 Starter – Condition check
86
7.11 Air Intake
87
7.11.1 Emergency air-shutoff flaps – Electric control
check
87
7.12 Lube Oil System, Lube Oil Circuit
88
7.12.1 Engine oil ‒ Level check
88
7.12.2 Engine oil – Change
89
7.12.3 Engine oil – Sample extraction and analysis
91
7.13 Oil Filtration / Cooling
92
7.13.1 Engine oil filter – Replacement
92
7.13.2 Automatic oil filter – Filter candles
replacement
93
7.13.3 Oil indicator filter – Cleaning and check
97
7.13.4 Centrifugal oil filter – Cleaning and filter-
sleeve replacement
99
MS150026/02E 2013-11
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