MTU MS150112/01E - Table of Contents

Table of Contents
1 Safety
1.1 Important requirements for all products 5
1.2 Personnel and organizational requirements 6
1.3 Safety requirements for startup and
operation 7
1.4 Safety requirements for maintenance and
repair work 8
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 11
1.6 Standards for safety notices in the text 13
1.7 Transport 14
2 General Information
2.1 Engine side and cylinder designations 15
2.2 Engine – Overview 16
2.3 Sensors, actuators and injectors – Overview 17
3 Technical Data
3.1 12V 4000 C64 engine data 20
3.2 Firing order 24
3.3 Engine – Main dimensions 25
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 26
4.2 Putting the engine into operation after
scheduled out-of-service-period 27
4.3 Operational checks 28
4.4 Engine – Starting in manual mode 29
4.5 Engine – Stopping in manual mode 30
4.6 After stopping the engine 31
4.7 Plant – Cleaning 32
5 Maintenance
5.1 Maintenance task reference table [QL1] 33
6 Troubleshooting
6.1 Troubleshooting 35
6.2 Fault messages on the SAM display
(optional) 37
6.3 Fault messages of Engine Control Unit ECU
9 for Series 4000 38
7 Task Description
7.1 Engine 99
7.1.1 Engine – Barring manually 99
7.1.2 Barring engine with starting system 100
7.1.3 Engine – Test run 101
7.2 Auxiliary PTO 102
7.2.1 Auxiliary PTO – Replacement 102
7.3 Cylinder Liner 103
7.3.1 Cylinder liner – Endoscopic examination 103
7.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 105
7.4 Crankcase Breather 107
7.4.1 Crankcase breather – Oil mist fine separator
replacement 107
7.5 Valve Drive 108
7.5.1 Valve gear – Lubrication 108
7.5.2 Valve projection – Measurement 109
7.5.3 Valve clearance – Check and adjustment 112
7.5.4 Cylinder head cover ‒ Removal and
installation 115
7.6 Injection Pump / HP Pump 116
7.6.1 HP pump – Relief bore check 116
7.7 Injection Valve / Injector 117
7.7.1 Injector – Replacement 117
7.7.2 Injector – Removal and installation 118
7.8 Fuel System 122
7.8.1 Fuel system – Venting 122
7.9 Fuel Filter 123
7.9.1 Fuel filter – Replacement 123
7.9.2 Additional fuel filter – Replacement 124
7.10 Exhaust Turbocharger 125
7.10.1 Exhaust turbocharger – Turbine housing
check 125
7.10.2 Exhaust turbocharger (LP) – Turbine housing
check 126
7.10.3 Exhaust turbocharger (HP) – Turbine housing
check 134
7.11 Charge-Air Cooling 140
7.11.1 Intercooler – Leak check 140
7.12 Exhaust Gas Recirculation 141
7.12.1 EGR cooler – Overview 141
7.12.2 EGR cooler – Cleaning 142
7.12.3 EGR cooler ‒ Check 143
7.12.4 Exhaust flaps – Overview 144
7.12.5 Exhaust flaps – Actuator function check 145
7.12.6 Exhaust flaps – Overview 146
MS150112/01E 2014-10 | Table of Contents | 3
DCL-ID: 0000029808 - 003