Table of Contents
1 Safety
1.1 General conditions 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Crankshaft transport locking device 8
1.5 Safety regulations for startup and operation 12
1.6 Explosion hazard when removing
inspection port cover on engine 13
1.7 Safety regulations for maintenance and
repair work 14
1.8 Auxiliary materials, fluids and lubricants,
fire prevention and environmental
protection 17
1.9 Conventions for safety instructions in the
text 19
2 General Information
2.1 Engine side and cylinder designations 20
2.2 Engine layout 21
2.3 Sensors, actuators and injectors ‒
Overview 22
3 Technical Data
3.1 Engine data 12V 4000 T94, T94L 26
3.2 Firing order 30
3.3 Main engine dimensions 31
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 32
4.2 Putting the engine into operation after
scheduled out-of-service-period 33
4.3 Operational checks 34
4.4 Starting the engine in manual mode 35
4.5 Stopping the engine in manual mode 36
4.6 After stopping the engine 37
4.7 Plant cleaning 38
5 Maintenance
5.1 Maintenance task reference table [QL1] 39
6 Troubleshooting
6.1 Troubleshooting 41
6.2 Fault messages on the SAM display
(optional) 44
6.3 Fault messages of Engine Control Unit
ECU 9 for Series 4000 45
7 Task Description
7.1 Engine 107
7.1.1 Engine – Barring manually 107
7.1.2 Engine – Barring with starting system 108
7.1.3 Engine – Test run 109
7.2 Cylinder Liner 110
7.2.1 Cylinder liner – Endoscopic examination 110
7.2.2 Instructions and comments on endoscopic
and visual examination of cylinder liners 112
7.3 Valve Drive 114
7.3.1 Valve gear – Lubrication 114
7.3.2 Valve clearance – Check and adjustment 115
7.3.3 Cylinder head cover – Removal and
installation 118
7.4 Injection Pump / HP Pump 119
7.4.1 HP pump – Filling with engine oil 119
7.5 Injection Valve / Injector 120
7.5.1 Injector – Replacement 120
7.5.2 Injector – Removal and installation 121
7.6 Fuel System 125
7.6.1 Fuel system – Venting 125
7.7 Fuel Filter 126
7.7.1 Fuel filter – Replacement 126
7.7.2 Auxiliary fuel filter – Replacement 127
7.8 Exhaust Turbocharger 128
7.8.1 Exhaust turbocharger – Turbine housing
check 128
7.8.2 Exhaust turbocharger (LP) – Turbine housing
check 129
7.8.3 Exhaust turbocharger (HP) – Turbine housing
check 134
7.9 Charge-Air Cooling 139
7.9.1 Intercooler – Leak check 139
7.10 Air Intake 140
7.10.1 Emergency air-shutoff flaps – Functional
check with electric actuation 140
7.11 Exhaust Gas Recirculation 141
MS150096/01E 2012-08 | Table of Contents | 3
DCL-ID: 0000009793 - 004