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
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