Table of Contents
1 Safety
1.1 Important provisions for all products 7
1.2 Personnel and organizational requirements 8
1.3 Transport 9
1.4 Safety regulations for maintenance and
repair work 10
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13
1.6 Standards for safety notices in the text 15
2 Product Summary
2.1 Engine Layout 16
2.1.1 Product description 16
2.1.2 Engine layout 28
2.1.3 Overview of sensors and actuators 32
2.2 Engine Side and Cylinder Designations 52
2.2.1 Engine side and cylinder designations 52
2.3 Main Engine Dimensions 53
2.3.1 Engine – Main dimensions 53
2.4 Firing Sequence 55
2.4.1 Firing order 55
2.5 Technical Data 56
2.5.1 12V 4000 M23F engine data, RheinSchUO,
stage II, IMO Tier II 56
2.5.2 12V 4000 M23S engine data, RheinSchUO,
stage II, IMO Tier II 59
2.5.3 12V 4000 M23S engine data, IMO Tier II, EPA
Tier 2 62
2.5.4 16V 4000 M23F engine data, RheinSchUO,
stage II, IMO Tier II 65
2.5.5 16V 4000 M23S engine data, RheinSchUO,
stage II, IMO Tier II 68
2.5.6 16V 4000 M23S engine data, IMO Tier II, EPA
Tier 2 71
3 Operation
3.1 Controls 74
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 75
3.3 Putting the engine into operation after
scheduled out-of-service-period 76
3.4 Starting the engine 77
3.5 Operational checks 78
3.6 Tasks after extended out-of-service periods
(>3 weeks) 79
3.7 Checks prior to start-up 80
3.8 Fuel treatment system – Putting into
operation 81
3.9 Fuel treatment system – Switching on 84
3.10 Fuel treatment system – Shutdown 85
3.11 Stopping the engine 86
3.12 Emergency engine stop 87
3.13 After stopping the engine 88
3.14 Plant – Cleaning 89
4 Maintenance
4.1 Maintenance task reference table [QL1] 90
5 Troubleshooting
5.1 Troubleshooting 92
5.2 Fuel treatment system – Troubleshooting 95
5.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application 96
5.4 Engine governor ADEC (ECU 7) – Fault
codes 97
6 Task Description
6.1 Engine 162
6.1.1 Engine – Barring manually 162
6.1.2 Engine – Barring with starting system 164
6.2 Cylinder Liner 165
6.2.1 Cylinder liner – Endoscopic examination 165
6.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 167
6.3 Crankcase Breather 169
6.3.1 Crankcase breather – Overview 169
6.3.2 Crankcase breather – Oil mist fine separator
replacement 171
6.4 Valve Drive 172
6.4.1 Valve gear – Lubrication 172
6.4.2 Valve clearance – Check and adjustment 173
6.4.3 Cylinder head cover – Removal and
installation 176
6.5 Injection Pump / HP Pump 177
6.5.1 HP pump – Filling with engine oil 177
6.5.2 HP pump – Relief bore check 178
6.6 Injection Valve / Injector 179
6.6.1 Injector – Replacement 179
6.6.2 Injector – Removal and installation 180
6.7 Fuel Filter 185
6.7.1 Supplementary fuel filter – Overview 185
6.7.2 Additional fuel filter – Replacement 186
MS150068/01E 2014-01 | Table of Contents | 5
DCL-ID: 0000005758 - 004
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