Table of Contents
1 Safety
1.1 Important provisions for all products
5
1.2 Correct use for all products
6
1.3 Personnel and organizational requirements
7
1.4 Safety regulations for startup and operation
8
1.5 Safety precautions when working on the
engine
10
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
13
1.7 Standards for safety notices in the text
15
2 Transport
2.1 Transportation
16
2.2 Lifting requirements
17
2.3 Crankshaft transport locking device
18
3 General Information
3.1 Engine side and cylinder designations
21
3.2 Engine overview
22
4 Technical Data
4.1 20V4000 continuous operation, unrestricted
3A, optimized fuel consumption G62,
emissions-optimized (EPA) G82
23
4.2 20V4000 continuous operation, variable 3B,
optimized fuel consumption G22/G62,
emissions-optimized (“TA-Luft”) G22/G62,
emissions-optimized (EPA) G42/G82
27
4.3 20V4000 continuous operation, restricted
3C, optimized fuel consumption G22/G62,
emissions-optimized (“TA-Luft”) G22/G62
32
4.4 20V4000 standby power 3D, optimized fuel
consumption G22/G62, emissions-optimized
(EPA) G42/G82
36
4.5 Final compression pressure
40
4.6 Firing order
41
4.7 Main engine dimensions
42
5 Operation
5.1 Putting the engine into operation after
extended out-of-service periods (>3 months)
43
5.2 Putting the engine into operation after
scheduled out-of-service-period
44
5.3 Engine – Starting in manual mode (test run)
45
5.4 Starting the engine in emergency situations
(override mode)
46
5.5 Operational monitoring
47
5.6 Engine – Stopping in manual mode (test
run)
48
5.7 Engine – Emergency stop
49
5.8 After stopping the engine – Putting the
engine out of operation
50
5.9 Plant – Cleaning
51
6 Maintenance
6.1 Maintenance task reference table [QL1]
52
7 Troubleshooting
7.1 Troubleshooting
53
7.2 Fault messages on engine governor
56
8 Task Description
8.1 Engine
67
8.1.1 Engine – Barring manually
67
8.1.2 Engine – Cranking on starting system
69
8.1.3 Engine – Test run
70
8.2 Cylinder Liner
71
8.2.1 Cylinder liner – Endoscopic examination
71
8.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
73
8.3 Crankcase Breather
75
8.3.1 Crankcase breather – Oil separator element
replacement
75
8.4 Valve Drive
77
8.4.1 Cylinder head cover – Removal and
installation
77
8.4.2 Valve gear – Lubrication
78
8.4.3 Valve clearance – Check and adjustment
79
8.5 Injection Pump / HP Pump
84
8.5.1 HP fuel pump – Relief bore check
84
8.6 Injector
85
8.6.1 Injector – Replacement
85
8.6.2 Injector – Removal and installation
86
8.7 Fuel System
91
8.7.1 Fuel system – Venting
91
8.8 Fuel Filter
92
8.8.1 Fuel filter – Replacement
92
8.8.2 Fuel prefilter – Cleaning
93
8.8.3 Fuel prefilter – Differential pressure gage
check and adjustment of gage
94
M015565/03E 2016-02
| Table of Contents | 3
DCL-ID: 0000034750 - 001
