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 Safety regulations for startup and operation 8
1.5 Safety regulations for maintenance and
repair work 9
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 12
1.7 Standards for safety notices in the text 14
2 General Information
2.1 Engine side and cylinder designations 15
2.2 Engine – Overview 16
2.3 Sensors and actuators – Overview 18
3 Technical Data
3.1 12/16/18 V 2000 Gx5 engine data,
optimized fuel consumption 20
3.2 12/16/18 V 2000 Gx5-TB engine data,
optimized fuel consumption 24
3.3 Firing order 28
3.4 Engine – Main 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 (test run) 32
4.4 Safety system – Override 33
4.5 Operational checks 34
4.6 Engine – Stopping in manual mode (test
run) 35
4.7 Engine – Emergency stop 36
4.8 After stopping the engine – Engine remains
ready for operation 37
4.9 After stopping the engine – Putting the
engine out of operation 38
5 Maintenance
5.1 Maintenance task reference table [QL1] 39
6 Troubleshooting
6.1 Fault indication on SAM display – Genset
applications 40
6.2 Troubleshooting 64
7 Task Description
7.1 Engine 67
7.1.1 Engine – Barring manually 67
7.1.2 Engine – Barring with starting system 68
7.1.3 Engine – Test run 69
7.2 Cylinder Liner 70
7.2.1 Cylinder liner – Endoscopic examination 70
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 72
7.3 Crankcase Breather 74
7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 74
7.3.2 Crankcase breather – Wire mesh cleaning 76
7.4 Valve Drive 77
7.4.1 Valve clearance – Check and adjustment 77
7.4.2 Cylinder head cover – Removal and
installation 80
7.5 Injection Pump / HP Pump 81
7.5.1 Injection pump – Replacement 81
7.5.2 Injection pump – Removal and installation 82
7.6 Injection Valve / Injector 85
7.6.1 Injector – Replacement 85
7.6.2 Injector – Removal and installation 86
7.7 Fuel System 89
7.7.1 Fuel injection line – Pressure pipe neck
replacement 89
7.7.2 Fuel – Draining 91
7.7.3 Fuel pressure maintaining valve – Removal
and installation 93
7.7.4 Fuel system – Venting 94
7.8 Fuel Filter 96
7.8.1 Fuel filter – Replacement 96
7.8.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 97
7.8.3 Fuel prefilter – Draining 98
7.8.4 Fuel prefilter – Flushing 99
7.8.5 Fuel prefilter – Cleaning 101
7.8.6 Fuel prefilter – Filter element replacement 102
7.9 Charge-Air Cooling General, Left-Hand Side 104
7.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 104
MS15018/02E 2013-09 |
Table of Contents | 3
DCL-ID: 0000019467 - 004
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