Operating instructions

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 – For
transport with flanged-on generator 8
1.5 Safety regulations for startup and operation 10
1.6 Safety regulations for maintenance and
repair work 11
1.7 Fire prevention and environmental
protection, consumable fluids and materials 14
1.8 Standards for safety notices in the text 16
2 General Information
2.1 Engine side and cylinder designations 17
2.2 Engine layout 18
2.3 Sensors and actuators – Overview 21
3 Technical Data
3.1 20V 4000 C22 engine data 24
3.2 Firing order 28
3.3 Main engine dimensions 29
4 Operation
4.1 Putting the engine into operation 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 After shutting down the engine 35
4.7 Cleaning the plant 36
5 Maintenance
5.1 Maintenance Schedule task reference table
[QL1] 37
6 Troubleshooting
6.1 Troubleshooting 38
6.2 ECU 4 alarms 41
7 Task Description
7.1 Engine 52
7.1.1 Engine – Barring manually 52
7.1.2 Engine – Barring with starting system 54
7.2 Cylinder Liner 55
7.2.1 Endoscopically examining cylinder liner 55
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 57
7.3 Crankcase Breather 59
7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 59
7.3.2 Crankcase breather – Cleaning 61
7.3.3 Crankcase breather (open-circuit crankcase
ventilation) – Filter element cleaning 62
7.3.4 Crankcase breather – Filter element
replacement 63
7.4 Running Gear 65
7.4.1 Grounding device – Carbon brush check 65
7.4.2 Grounding device – Carbon brush replacement 67
7.5 Valve Drive 68
7.5.1 Valve gear – Lubrication 68
7.5.2 Valve clearance – Check and adjustment 69
7.5.3 Cylinder head cover – Removal and
installation 74
7.6 Injection Pump / HP Pump 75
7.6.1 HP pump – Filling with engine oil 75
7.6.2 HP pump – Relief bore check 76
7.7 Injection Valve / Injector 77
7.7.1 Injector – Replacement 77
7.7.2 Injector – Removal and installation 78
7.8 Fuel System 83
7.8.1 Fuel system – Venting 83
7.9 Fuel Filter 84
7.9.1 Fuel filter – Replacement 84
7.9.2 Draining fuel prefilter 85
7.9.3 Edge-type fuel filter – Draining 86
7.9.4 Auxiliary fuel filter – Replacement 87
7.10 Charge-Air Cooling 88
7.10.1 Intercooler – Check water drain for coolant
leakage and absence of restrictions 88
7.11 Air Filter 89
7.11.1 Air filter element and dust bowl (optional) –
Cleaning 89
7.11.2 Air filter – Replacement 90
7.11.3 Air filter element – Removal and installation
(optional) 91
7.11.4 Service indicator – Signal ring position check
(optional) 92
7.12 Starting Equipment 93
7.12.1 Starter – Condition check 93
M015675/06E 2013-04 | Table of Contents | 3
DCL-ID: 0000014250 - 002