MTU MS150112/01E User manual
Operating Instructions
Diesel engine
12V 4000 C64
Application group 5B
MS150112/01E
Engine model kW/cyl. Application group
12V4000C64 155 kW/cyl. 5B; Continuous operation, variable
Table 1: Applicability
© 2014 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.
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
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7.12.7 Exhaust flaps – Checking coupling rods
operability and play 147
7.12.8 Exhaust flaps – Coupling rod replacement 149
7.13 Starting Equipment 152
7.13.1 Starter – Condition check 152
7.14 Lube Oil System, Lube Oil Circuit 153
7.14.1 Engine oil level – Check at sight glass 153
7.14.2 Engine oil – Level check with oil dipstick 154
7.14.3 Engine oil – Change 155
7.14.4 Engine oil – Sample extraction and analysis 157
7.15 Oil Filtration / Cooling 158
7.15.1 Engine oil filter – Replacement 158
7.15.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 160
7.16 Coolant Circuit, General, High-Temperature
Circuit 162
7.16.1 Engine coolant – Level check 162
7.16.2 Engine coolant – Change 163
7.16.3 Engine coolant – Draining 164
7.16.4 Exhaust flaps – Draining coolant from
servomotors 166
7.16.5 Engine coolant – Filling 167
7.16.6 Engine coolant pump – Relief bore check 170
7.16.7 Engine coolant – Sample extraction and
analysis 171
7.17 Low-Temperature Circuit 172
7.17.1 Charge-air coolant – Level check 172
7.17.2 Charge-air coolant – Change 173
7.17.3 Charge-air coolant – Draining 174
7.17.4 Charge-air coolant – Filling 177
7.17.5 Checking charge-air coolant pump pressure
relief port 180
7.18 Belt Drive 181
7.18.1 Drive belt – Condition check 181
7.19 Battery-Charging Generator 182
7.19.1 Checking battery-charging generator 182
7.19.2 Battery-charging generator drive – Drive belt
tension adjustment 183
7.19.3 Battery-charging generator drive – Drive belt
replacement 184
7.20 Fan Drive 185
7.20.1 Fan drive – Drive belt check / adjustment 185
7.20.2 Fan drive – Drive belt replacement 187
7.21 Engine Mounting / Support 188
7.21.1 Engine mounting – Check 188
7.22 Wiring (General) for Engine/Gearbox/Unit 189
7.22.1 Еngine cabling ‒ Check 189
7.23 Accessories for (Electronic) Engine
Governor / Control System 190
7.23.1 Resetting CDC parameter and entering IIG
with DiaSys® 190
7.23.2 Actuators – Visual inspection and test 191
7.23.3 Engine governor and connectors – Cleaning 193
7.23.4 Engine governor plug connections – Check 194
7.23.5 NOx sensor – Replacement 195
7.23.6 Lambda sensor – Replacement 197
8 Appendix A
8.1 Abbreviations 199
8.2 MTU contact persons/service partners 202
9 Appendix B
9.1 Special Tools 203
9.2 Index 212
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1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
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1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment
Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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1.3 Safety requirements for startup and operation
Safety requirements for startup
The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.
All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.
Whenever the product is started, always ensure that:
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• Wearers of cardiac pacemakers or other active medical implants are well clear.
• The operating room is adequately ventilated.
• Exhaust pipework is leak-tight and routed to atmosphere.
• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.
• All personnel is clear of the danger zone represented by moving parts.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.
Safety requirements for operation
The operator must be familiar with the controls and displays.
The operator must be aware of the consequences of any operations he/she performs.
During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.
Malfunctions and emergency stop
Emergency procedures, in particular emergency stop, must be practiced on a regular basis.
Take the following steps if a system malfunction is detected or signaled by the system:
• Inform the duty supervisor(s).
• Evaluate the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.
Keep a safe distance away from the product whenever possible. Do not touch the product unless ex-
pressly instructed to do so.
Do not inhale exhaust gases emitted by the product.
Ensure that the following requirements have been fulfilled before starting the product:
• Ear protectors are worn.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
Operation of electrical equipment
Some components are live (high voltage) when electrical equipment is in operation.
Observe the safety instructions for these appliances.
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1.4 Safety requirements for maintenance and repair work
Safety requirements before commencing maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.
Safety requirements during maintenance and repair work
Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
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Pay particular attention to cleanliness at all times.
Safety requirements after completing maintenance and repair work
Ensure that all personnel is clear of danger zones before cranking.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal
Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries
Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
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Working on electrical/electronic assemblies
Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cabling to lines bearing fluids.
Do not use cable ties to secure cabling.
Always use connector pliers to tighten union nuts on connectors.
Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Working with laser equipment
Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.
Measuring component deviations
Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C.
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