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 side and cylinder designations
15
2.2 Product description
16
2.3 Engine overview
26
2.4 Sensors and actuators – Overview
27
2.5 Engine wiring harness – Overview
32
3 Technical Data
3.1 Engine data 20V 4000M73
38
3.2 Engine data 20V 4000M73
41
3.3 Engine data 20V 4000M73L
44
3.4 Engine data 20V 4000M73L
47
3.5 Engine – Main dimensions
50
3.6 Firing order
51
4 Operation
4.1 LOP controls
52
4.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
53
4.3 Putting the engine into operation after
scheduled out-of-service-period
54
4.4 Starting the engine
55
4.5 Operational checks
56
4.6 Tasks after extended out-of-service periods
(>3 weeks)
57
4.7 Checks prior to start-up
58
4.8 Fuel treatment system – Putting into
operation
59
4.9 Fuel treatment system – Switching on
62
4.10 Engine emergency stop at BlueLine
automation system (control stand)
63
4.11 Coupling – Engaging from LOP
64
4.12 Coupling – Disengaging from LOP
65
4.13 Waterjet – Flushing from LOP (optional)
66
4.14 Stopping the engine
67
4.15 Stopping the engine from LOP
68
4.16 Emergency stop from LOP
69
4.17 Stopping the engine at the BlueLine
automation system (control stand)
70
4.18 After stopping the engine
71
4.19 Fuel treatment system – Shutdown
72
4.20 Plant – Cleaning
73
5 Maintenance
5.1 Maintenance task reference table [QL1]
74
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting
75
6.2 Troubleshooting
76
6.3 ADEC (ECU 7) fault codes for Series 4000
engines, marine application
79
6.4 ADEC engine governor – Fault codes
80
7 Task Description
7.1 Engine
106
7.1.1 Engine – Barring manually
106
7.1.2 Engine – Barring with starting system
107
7.2 Cylinder Liner
108
7.2.1 Cylinder liner – Endoscopic examination
108
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
110
7.3 Valve Drive
112
7.3.1 Valve gear – Lubrication
112
7.3.2 Valve clearance – Check and adjustment
113
7.3.3 Cylinder head cover – Removal and
installation
117
7.4 Injection Pump / HP Pump
118
7.4.1 HP pump – Filling with engine oil
118
7.5 Injection Valve / Injector
119
7.5.1 Injector – Replacement
119
7.5.2 Injector – Removal and installation
120
7.6 Fuel Filter
125
7.6.1 Fuel filter – Replacement
125
7.6.2 Fuel prefilter – Differential pressure gauge
check and adjustment
127
7.6.3 Fuel prefilter – Draining
128
7.6.4 Fuel prefilter – Flushing
130
7.6.5 Fuel prefilter – Filter element replacement
132
7.7 Exhaust Turbocharger
134
7.7.1 Compressor wheel – Cleaning
134
7.8 Charge-Air Cooling
138
MS150046/02E 2013-07 | Table of Contents | 3
DCL-ID: 0000028441 - 001
