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 warning 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 G73 engine data, optimized
exhaust emissions (EPA - Tier 2) 24
3.2 Firing order 27
3.3 Engine – Main dimensions 28
4 Operation
4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months) 29
4.2 Putting the engine into operation after
scheduled out-of-service-period 30
4.3 Starting the engine in manual mode (test
run) 31
4.4 Starting the engine in emergency situations
(override mode) 32
4.5 Operational checks 33
4.6 Stopping the engine in manual mode (test
run) 34
4.7 Emergency stop 35
4.8 After stopping the engine – Engine remains
ready for operation 36
4.9 After stopping the engine – Putting the
engine out of operation 37
5 Maintenance
5.1 Maintenance task reference table [QL1] 38
6 Troubleshooting
6.1 Troubleshooting 39
6.2 Fault messages on the SAM display
(optional) 42
6.3 Fault messages of engine governor ADEC
(ECU 7) for Series 4000, application: oil &
gas 43
7 Task Description
7.1 Engine 84
7.1.1 Engine – Barring manually 84
7.1.2 Engine – Barring with starting system 85
7.1.3 Engine – Test run 86
7.2 Cylinder Liner 87
7.2.1 Cylinder liner – Endoscopic examination 87
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 89
7.3 Crankcase Breather 91
7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 91
7.4 Valve Drive 93
7.4.1 Valve gear – Lubrication 93
7.4.2 Valve clearance – Check and adjustment 94
7.4.3 Cylinder head cover – Removal and
installation 97
7.5 Injection Pump / HP Pump 98
7.5.1 HP pump – Filling with engine oil 98
7.6 Injection Valve / Injector 99
7.6.1 Injector – Replacement 99
7.6.2 Injector – Removal and installation 100
7.7 Fuel System 105
7.7.1 Fuel system – Venting 105
7.8 Fuel Filter 106
7.8.1 Fuel filter – Replacement 106
7.8.2 Fuel prefilter cleaning 107
7.8.3 Fuel prefilter – Differential pressure gauge
check and adjustment 108
7.8.4 Fuel prefilter – Draining 109
7.8.5 Fuel prefilter – Flushing 110
7.8.6 Fuel prefilter – Filter element replacement 112
7.9 Charge-Air Cooling 114
7.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 114
7.10 Air Filter 115
7.10.1 Air filter – Replacement 115
7.10.2 Air filter – Removal and installation 116
MS150029/02E 2013-03 |
Table of Contents | 3
DCL-ID: 0000021694 - 002