Table of Contents
1 Safety
1.1 Important provisions for all products
5
1.2 Personnel and organizational requirements
7
1.3 Transport
8
1.4 Crankshaft transport locking device
9
1.5 Safety regulations for startup and operation
13
1.6 Safety regulations for maintenance and
repair work
14
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
17
1.8 Standards for safety notices in the text
19
2 General Information
2.1 Engine side and cylinder designations
20
2.2 Engine – Overview
21
2.3 Back Pack – Overview
22
2.4 Sensors, actuators and injectors – Overview
23
3 Technical Data
3.1 12 V 4000 T94/T94L engine data
27
3.2 Firing order
31
3.3 Engine – Main dimensions
32
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months)
33
4.2 Putting the engine into operation after
scheduled out-of-service-period
34
4.3 Operational checks
35
4.4 Starting the engine in manual mode
36
4.5 Stopping the engine in manual mode
37
4.6 After stopping the engine – Putting the
engine out of operation
38
4.7 Plant – Cleaning
39
5 Maintenance
5.1 Maintenance task reference table [QL1]
40
6 Troubleshooting
6.1 Troubleshooting
42
6.2 Engine governor ECU9 – Fault messages
45
7 Task Description
7.1 Engine
73
7.1.1 Engine – Barring manually
73
7.1.2 Barring engine with starting system
75
7.1.3 Engine – Test run
76
7.2 Cylinder Liner
77
7.2.1 Cylinder liner – Endoscopic examination
77
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
79
7.3 Crankcase Breather
81
7.3.1 Oil mist fine separator – Replacement
81
7.4 Valve Drive
82
7.4.1 Valve gear – Lubrication
82
7.4.2 Valve clearance – Check and adjustment
83
7.4.3 Cylinder head cover ‒ Removal and
installation
86
7.5 Injection Pump / HP Pump
87
7.5.1 HP pump – Filling with engine oil
87
7.6 Injection Valve / Injector
89
7.6.1 Injector – Replacement
89
7.6.2 Injector – Removal and installation
90
7.7 Fuel System
95
7.7.1 Fuel system – Venting
95
7.8 Fuel Filter
96
7.8.1 Fuel filter – Replacement
96
7.8.2 Additional fuel filter – Replacement
97
7.8.3 Fuel prefilter – Draining
98
7.8.4 Fuel prefilter – Filter element replacement
99
7.9 Exhaust Turbocharger
100
7.9.1 Exhaust turbocharger – Turbine housing
check
100
7.9.2 Exhaust turbocharger (LP) – Turbine housing
check
101
7.9.3 Exhaust turbocharger (HP) – Turbine housing
check
109
7.10 Charge-Air Cooling
115
7.10.1 Intercooler – Leak check
115
7.11 Air Filter
116
7.11.1 Air filter – Replacement
116
7.12 Air Intake
117
7.12.1 Service indicator – Signal ring position check
117
7.12.2 Emergency-air shutoff flaps – Functional
check with electric actuation
118
7.13 Exhaust Gas Recirculation
120
7.13.1 Exhaust flaps – Overview
120
7.13.2 Exhaust flaps – Checking operation of
actuators
122
7.13.3 Exhaust flaps – Checking coupling rods
operability and play
123
7.13.4 Exhaust flaps – Coupling rod replacement
125
MS150096/03E 2015-04
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DCL-ID: 0000009793 - 007
