MTU 16V4000R43 User manual

Operating Instructions

Diesel engine

16 V 4000 Rx3 x

MS15042/00E

Engine model kW/cyl. Application group

16V4000R43 137.5 kW/cyl. 2A, continuous operation, unrestricted

16V 4000 R43L 150 kW/cyl. 2A, continuous operation, unrestricted

16V4000R43R 125 kW/cyl. 2A, continuous operation, unrestricted

Table 1: Applicability

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 Transport 7

1.4 Crankshaft transport locking device 8

1.5 Safety requirements for startup and

operation 11

1.6 Safety requirements for maintenance and

repair work 12

1.7 Fire prevention and environmental

protection, fluids and lubricants, auxiliary

materials 15

1.8 Standards for safety notices in the text 17

2 General Information

2.1 Engine side and cylinder designations 18

2.2 Engine layout 19

2.3 Sensors, actuators and injectors – Overview 21

3 Technical Data

3.1 16V 4000 R43 engine data 24

3.2 16 V 4000 R43L engine data 28

3.3 16 V 4000 R43R engine data 31

3.4 Firing order 34

3.5 Main engine dimensions 35

4 Operation

4.1 Putting the engine into operation after

extended out-of-service periods (>3 months) 36

4.2 Putting the engine into operation after

scheduled out-of-service-period 37

4.3 Starting the engine in manual mode 38

4.4 Stopping the engine in manual mode 39

4.5 Preparing the engine for extended out-of-

service period 40

4.6 Plant – Cleaning 41

5 Maintenance

5.1 Maintenance task reference table [QL1] 42

6 Troubleshooting

6.1 Troubleshooting 44

6.2 Fault messages on PAU display 47

6.3 Fault messages of engine governor ADEC

(ECU 7) for Series 4000, rail applications 48

7 Task Description

7.1 Engine 75

7.1.1 Engine – Barring manually 75

7.1.2 Cranking engine with starting system 77

7.1.3 Engine – Performing test run 78

7.2 Cylinder Liner 79

7.2.1 Cylinder liner – Endoscopic examination 79

7.2.2 Instructions and comments on endoscopic and

visual examination of cylinder liners 81

7.3 Crankcase Breather 83

7.3.1 Crankcase breather – Oil separator element

replacement 83

7.4 Valve Drive 85

7.4.1 Valve gear – Lubrication 85

7.4.2 Valve clearance – Check and adjustment 86

7.4.3 Cylinder head cover – Removal and

installation 90

7.5 Injection Pump / HP Pump 91

7.5.1 HP pump – Relief bore check 91

7.5.2 HP pump – Filling with engine oil 92

7.6 Injection Valve / Injector 93

7.6.1 Injector – Replacement 93

7.6.2 Injector – Removal and installation 94

7.7 Fuel System 99

7.7.1 Fuel system – Venting 99

7.8 Fuel Filter 100

7.8.1 Fuel filter – Replacement 100

7.8.2 Fuel prefilter – Draining 101

7.8.3 Fuel prefilter – Filter element replacement 102

7.8.4 Intermediate fuel filter – Replacement 103

7.9 Exhaust Turbocharger 104

7.9.1 Exhaust turbocharger – Turbine housing

check 104

7.9.2 Compressor wheel – Cleaning 107

7.10 Charge-Air Cooling 111

7.10.1 Intercooler – Checking condensate drain for

coolant leakage and obstruction 111

7.11 Air Filter 112

7.11.1 Air filter element and (optional) dust bowl ‒

Cleaning 112

7.11.2 Air filter ‒ Replacement 113

7.11.3 Air filter element – Removal and installation

(optional) 114

7.12 Starting Equipment 115

7.12.1 Starter – Condition check 115

7.13 Air Intake 116

7.13.1 Service indicator – Signal ring position check 116

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7.14 Lube Oil System, Lube Oil Circuit 117

7.14.1 Engine oil – Level check 117

7.14.2 Engine oil – Change 118

7.14.3 Engine oil – Sample extraction and analysis 120

7.15 Oil Filtration / Cooling 121

7.15.1 Engine oil filter – Replacement 121

7.15.2 Checking oil indicator filter 122

7.15.3 Centrifugal oil filter – Cleaning and filter-

sleeve replacement 124

7.16 Coolant Circuit, General, High-Temperature

Circuit 126

7.16.1 Engine coolant – Level check 126

7.16.2 Engine coolant – Change 127

7.16.3 Engine coolant – Draining 128

7.16.4 Replenishing engine coolant 129

7.16.5 Engine coolant pump – Relief bore check 132

7.16.6 Engine coolant – Sample extraction and

analysis 133

7.16.7 Preheating unit – Overview 134

7.16.8 Preheater unit – Removal 136

7.16.9 Preheater unit – Installation 137

7.17 Low-Temperature Circuit 138

7.17.1 Charge-air coolant – Level check 138

7.17.2 Charge-air coolant – Change 139

7.17.3 Charge-air coolant – Draining 140

7.17.4 Charge-air coolant – Filling 141

7.17.5 Charge-air coolant pump – Relief bore check 144

7.18 Engine Mounting / Support 145

7.18.1 Engine mounts – Resilient element check 145

7.19 Drive, Power Generation and Safety

Systems 147

7.19.1 Generator – Greasing antifriction bearing 147

7.19.2 Generator – Cleaning intake air grille 148

7.20 Wiring (General) for Engine/Gearbox/Unit 149

7.20.1 Еngine cabling ‒ Check 149

7.21 Accessories for (Electronic) Engine

Governor / Control System 150

7.21.1 CDC parameters – Reset with DiaSys® 150

7.21.2 Engine governor and connectors – Cleaning 151

7.21.3 Engine governor plug connections – Check 152

8 Appendix A

8.1 Abbreviations 153

8.2 MTU contact persons/service partners 155

9 Appendix B

9.1 Special Tools 156

9.2 Index 162

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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 Transport

Transport

Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.

Always use the lifting eyes on the engine when transporting an engine separately.

Only use transport and lifting devices approved by MTU.

The engine/genset must only be transported in installation position: maximum permissible diagonal pull

10°.

Remove any loose parts on the genset.

Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or

its components. Readjust lifting device as necessary.

Pay attention to the center of gravity of the engine/genset: Refer to installation drawing.

For special packaging with aluminium foil: Suspend the engine/genset by the lifting eyes on the bearing

pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.

Fit the crankshaft transportation lock on the engine and fit the engine mount locking devices prior to

transport.

Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip-

ping and tipping when driving up or down inclines and ramps.

Placement after transport

Place the engine/genset on a firm, flat surface only.

Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.

Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-

case basis.

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1.4 Crankshaft transport locking device

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 10-60 Nm F30452769 1

Torque wrench, 60-320 Nm F30452768 1

Engine oil

Transport locking device

Note: The transport locking device on both sides protects the crankshaft bearings from impact and vibration

damage during engine transport.

For installation and removal of the transport locking device, follow the in-

structions below:

1. The transport locking device must remain installed on both engine sides as long as possible during en-

gine installation in order to avoid damage.

2. Prior to every engine transport, the transport locking device must be reinstalled on both engine sides

according to the instructions.

3. If the engine is to be moved together with the generator, the transport locking device for the generator

must also be installed.

4. Always use the screws supplied with or installed in the transport locking device to secure it on the en-

gine.

5. Starting or barring the engine is allowed only with the transport locking device removed. If the genera-

tor is already installed on the engine, ensure that the transport locking device of the generator is also

removed.

Removing guard plates and en-

gine supports (if applicable) on

driving end (KS)

1. Remove screws (4) om both sides and take

off with washers (3), guard plates (1) and

engine supports (2).

2. Store the removed parts of the transport

locking device carefully for any reuse.

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Fitting the transport locking de-

vice on the driving end (KS)

Note: Screw plate (6) onto the upper part of the openings only.

1. Fasten the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the fly-

wheel housing and tighten to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm

2. Fit locknut (2) on screws (1) up to the end of the thread.

3. The long side of retainer (3) must point downwards. Insert retainer (3) through the openings of plate (6).

Note: Retainer (3) must tension only the flywheel, not the ring gear.

4. Insert screw (1) in bores of retainer (3) until retainer (3) is locked in position.

Note: Screw (1) must be tightened alternately on both sides of the flywheel housing.

5. Tighten screw (1) to specified tightening torque .

Name Size Type Lubricant Value/Standard

Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm

6. Fit locknut (2) of screw (1) on plate (6) and tighten.

Removing the transport locking

device from the driving end (KS)

1. Release the locknuts (2) on both sides of

the flywheel housing, remove screw (1) and

take off retainer (3).

2. Remove screws (4) and take off with wash-

ers (5) and plates (6).

3. Store the removed parts required for re-in-

stallation carefully together with this docu-

mentation.

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Installing guard plates and en-

gine supports (if applicable) on

driving end (KS)

Note: Always use the screws supplied with or re-

moved from the guard plates and engine

supports to secure them on the engine.

1. Install engine supports (2) on both sides

with guard plates (1) washers (3), and

screws (4).

2. Tighten screws (4).

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