MTU 16V 4000 R43L Operating Instructions Manual Download Page 153

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8 Appendix A

8.1 Abbreviations

Abbre-
viation

Meaning

Explanation

Alternating Current

AdBlue -

Brand name of the German Association of Vehicle
Manufacturers (VDA)
Urea solution with 32.5% urea concentration

EGR

Exhaust gas recirculation

Alarm

ANSI

American National Standards Institute

BDM

Backup Data Module

Series

Fluids and lubricants specification/preser-
vation specification

MTU publication no. A00..

CAN

Controller Area Network

Data bus system, bus standard

CaPoS Capacitor Power System

Capacitor-based starting system

CDC

Calibration Drift Compensation

Drift compensation must be reset in the engine con-
trol system using DiaSys® to ensure optimum emis-
sions and consumption characteristics.

CRC

Cyclic Redundancy Control

Check sum procedure to detect data transmission
faults

Direct Current

DEF

Diesel Exhaust Fluid

Urea solution with 32.5% urea concentration
Designation used in North America

DIFF

Difference

DIN

Deutsches Institut für Normung e. V.

Also identifier of German standards (DIN = “Deut-
sche Industrie-Norm”)

Default Lost

Alarm: Default CAN bus failure

DOC

Diesel Oxidation Catalyst

DPF

Diesel Particulate Filter

ECU

Engine Control Unit

Engine control system

ETC

Exhaust turbocharger

ETK

Spare parts catalog

Frequency Output

GND

Ground

High pressure

High

Alarm: Measured value higher than 1st maximum
limit

HIHI

High High

Alarm: Measured value higher than 2nd maximum
limit

High Temperature

Identification number

MS15042/00E 2014-10

| Appendix A | 153

TIM-ID: 0000009959 - 010

Summary of Contents for 16V 4000 R43L

Page 1: ...Operating Instructions Diesel engine 16 V 4000 Rx3 x MS15042 00E...

Page 2: ...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...

Page 3: ...ring 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...

Page 4: ...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...

Page 5: ...guration 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 mainte...

Page 6: ...rk 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 Tra...

Page 7: ...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 t...

Page 8: ...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 in...

Page 9: ...nly 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 Tig...

Page 10: ...ote 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 s...

Page 11: ...or 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 l...

Page 12: ...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 c...

Page 13: ...e 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 hydrau...

Page 14: ...ent 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...

Page 15: ...are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncomplia...

Page 16: ...o be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equ...

Page 17: ...medial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This...

Page 18: ...gnated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 19: ...rger 7 Air intake 8 Intercooler 9 Starting equipment 10 Engine mount 11 Oil filler neck 12 Cylinder head 13 Fuel filter 14 HP fuel pump 15 Generator 16 Vibration damper free end 17 Auxiliary PTO batte...

Page 20: ...pump 14 Generator 15 Vibration damper free end 16 Auxiliary PTO 17 Coolant pump HT 18 Coolant pump LT 19 Automatic oil filter Engine model designation Key to the engine model designation 16 V 4000 R43...

Page 21: ...ture A side 6 Sensor B34 fuel pressure after filter 7 Sensor F46 leak off fuel 8 Sensor B5 1 engine oil pressure after filter 9 Sensor B5 3 engine oil pressure before filter 10 Sensor B7 2 engine oil...

Page 22: ...mperature B side 3 Sensor B44 2 turbocharg er B speed 4 Sensor B26 charge air coolant temperature 5 Sensor B13 charge air pressure 6 Sensor B9 charge air tem perature 7 Sensor B10 engine speed 22 Gene...

Page 23: ...Injector Y39 11 B2 Injector Y39 12 B3 Injector Y39 13 B4 Injector Y39 14 B5 Injector Y39 15 B6 Injector Y39 16 B7 Injector Y39 17 B8 Injector Y39 18 The injectors are numbered in ascending order and l...

Page 24: ...sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1800 UIC rated power fuel stop power ISO 3046 A kW 2200 General con...

Page 25: ...wn L C Coolant antifreeze content max L 50 Coolant pump inlet pressure max L bar 2 5 Thermostat Starts to open R C 79 Thermostat Fully open R C 92 Coolant system LT circuit Number of cylinders 16 Cool...

Page 26: ...own Option max op erating inclinations L Degrees 3 Longitudinal inclination temporary max driving end down Option max oper ating inclinations L Degrees Longitudinal inclination temporary max driving e...

Page 27: ...field sound pressure level Lp 1m dis tance ISO 6798 3dB A tolerance R dB A 117 Engine surface noise without intake noise BL free field sound pressure level Lp 1m distance ISO 6798 2dB A tolerance R dB...

Page 28: ...as per ISO 3046 Number of cylinders 16 Nominal engine speed A rpm 1800 UIC rated speed fuel stop power as per ISO 3046 A kW 2400 Boundary conditions for maximum power Number of cylinders 16 Intake de...

Page 29: ...umber of cylinders 16 Coolant temperature at engine connection outlet to cooling system R C 53 Coolant temperature before intercooler with up to 40 antifreeze A C Coolant temperature difference before...

Page 30: ...verse inclination option max operating inclinations L Angle 6 Capacities Number of cylinders 16 Engine coolant capacity engine side without cooling equipment R Liters 235 Charge air coolant engine sid...

Page 31: ...per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 1800 UIC rated power fuel stop power ISO 3046 A kW 2000 GENERAL CONDITIONS for max power Number of cylinders 16 Intake depression new filte...

Page 32: ...of cylinders 16 Coolant temperature at engine connection outlet to cooling equipment R C 52 Coolant temperature before intercooler with up to 40 antifreeze A C Coolant temperature difference after bef...

Page 33: ...inuous max option max operating inclinations L Degrees 6 CAPACITIES Number of cylinders 16 Engine coolant capacity engine side without cooling equipment R Liters 235 Charge air coolant engine side R L...

Page 34: ...g order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 34 Te...

Page 35: ...ox 2129 mm Length A 12 V approx 2497 mm Length A 16 V approx 3192 mm Length A 20 V approx 3591 mm Width B 8 V approx 1399 mm Width B 12 16 20 V approx 1562 mm Height C 8 V approx 1988 mm Height C 12 1...

Page 36: ...oil system Check engine oil level Page 117 Bar engine with starting equipment Page 77 Fuel system Vent Page 99 Coolant circuit Out of service period more than 1 year Change engine coolant Page 127 Cha...

Page 37: ...system Check engine oil level Page 117 Coolant circuit Check engine coolant level Page 126 Check charge air coolant level Page 138 Coolant circuit Heat coolant with coolant preheater if available see...

Page 38: ...ing Risk of damage to hearing Wear ear protectors Preparation Item Action Operating mode switch if applicable Switch to manual mode Coolant preheater If engine coolant temperature is 25 C Switch on pr...

Page 39: ...ing down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Preparations Item Action Engine Run engine at idling speed under zero load Stopping the en...

Page 40: ...to remain out of service for an extended period and engine coolant has no antifreeze additive the coolant is not maintained at a suitable temperature antifreeze concentration is 40 and outside tempera...

Page 41: ...ressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmenta...

Page 42: ...uel filter element Page 100 W1005 Replace air filter Page 113 W1006 Replace fuel injectors Page 93 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the...

Page 43: ...acks perform endoscop ic examination to check it internally for cracks replace if neces sary Page 104 W1713 Injector Reset drift compensation parameters CDC Page 150 Table 2 Maintenance task reference...

Page 44: ...act Service Engine turns but does not fire Component Probable Cause Measure Starter Poor rotation by starter Battery low or faulty Charge or replace battery see manufac turer s documentation Engine ca...

Page 45: ...use Measure Air supply Air filter clogged Check signal ring position of service in dicator if fitted Intercooler Contaminated Contact Service Exhaust turbocharger Faulty Contact Service Coolant leaks...

Page 46: ...ne Not at operating temperature Run engine to reach operating tempera ture Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter Intercooler Leaking Contact Service 46 Tro...

Page 47: ...n be continued However performance might be limited If a red alarm occurs serious fault continued operation may be impossible Engine power is reduced automatically or the engine is shut down automatic...

Page 48: ...SS T Charge Air L2 Yellow alarm power limitation 20 Cause Corrective action Charge air temperature too high 1 Reduce power 2 If fault code number 9 is signaled at the same time then it has priority 9...

Page 49: ...power 2 Check air filter 3 Request towing locomotive if required 20 SS T Exhaust A Red alarm power reduction 20 Cause Corrective action Exhaust gas temperature A side too high 1 Reduce power 2 Check a...

Page 50: ...rective action Engine speed too high 1 Acknowledge alarm 2 Request towing locomotive if required 31 HI ETC1 Overspeed L1 Yellow alarm power limitation 20 Cause Corrective action ETC1 A side speed too...

Page 51: ...aled at the same time then it has priority 59 SS T Coolant L3 Red alarm forced idle Cause Corrective action Coolant temperature too high 1 Activate fan emergency operating mode if required 2 Allow eng...

Page 52: ...SS P Fuel L2 No alarm fault is registered Cause Corrective action Fuel pressure before HP pump too low Possibly only reduced power is available 1 Check fuel lines for leakage 2 Drain fuel prefilter P...

Page 53: ...r reduction 20 Cause Corrective action Rail pressure set value MCR reduction suction restrictor of HP fuel control block faulty or leakage in HP fuel system 1 Request towing locomotive if required 2 C...

Page 54: ...too low coolant temperature too low for engine start Significantly increased engine wear Engine start might be inhibited by the locomotive control system Engine may be started in emergency situations...

Page 55: ...ly Voltage Yellow alarm warning Cause Corrective action Supply voltage too high u Check ECU supply voltage 121 HIHI ECU Power Supply Voltage L2 Red alarm engine stop Cause Corrective action Supply vol...

Page 56: ...ow alarm warning Cause Corrective action Connection to a node on CAN bus 2 failed 1 Check the devices connected to the CAN bus 2 Check wiring 2x121 terminating resistors in place 3 Contact Service 182...

Page 57: ...ing improve shielding as necessary 188 AL CAN2 Bus Off Yellow alarm warning Cause Corrective action CAN controller 2 is in Bus Off status Automatic changeover to CAN 1 short circuit massive interferen...

Page 58: ...u Check sensor B24 and wiring replace as necessary Page 149 205 SD T Coolant Intercooler Yellow alarm warning Cause Corrective action Intercooler coolant temperature sensor faulty short circuit or wi...

Page 59: ...Check sensor B50 and wiring replace as necessary Page 149 215 SD P HP Fuel Yellow alarm power limitation 20 Cause Corrective action Rail pressure sensor faulty high pressure regulator emergency mode...

Page 60: ...erating cycle 1 Check sensor and wiring to connectors B1 and B13 replace as necessary Page 149 2 Acknowledge alarm 3 Restart engine Page 38 230 SD Crankshaft Speed Yellow alarm power limitation 20 Cau...

Page 61: ...Engine Control Unit fault electronics faulty u Replace engine governor 266 SD Speed Setting Red alarm forced idle Cause Corrective action Analog nominal speed setting faulty short circuit or wire bre...

Page 62: ...Wiring Cylinder A5 Yellow alarm warning Cause Corrective action Short circuit in cylinder injector wiring Result Misfiring u Check solenoid valve 326 AL Wiring Cylinder A6 Yellow alarm warning Cause C...

Page 63: ...Wiring Cylinder B2 Yellow alarm warning Cause Corrective action Short circuit in cylinder injector wiring Result Misfiring u Check solenoid valve 333 AL Wiring Cylinder B3 Yellow alarm warning Cause...

Page 64: ...ring Cylinder B9 Yellow alarm warning Cause Corrective action Short circuit in cylinder injector wiring Result Misfiring u Check solenoid valve 340 AL Wiring Cylinder B10 Yellow alarm warning Cause Co...

Page 65: ...pen Load Cylinder A6 Yellow alarm warning Cause Corrective action Open circuit in cylinder injector wiring Result Misfiring u Check solenoid valve 347 AL Open Load Cylinder A7 Yellow alarm warning Cau...

Page 66: ...Open Load Cylinder B3 Yellow alarm warning Cause Corrective action Open circuit in cylinder injector wiring Result Misfiring u Check solenoid valve 354 AL Open Load Cylinder B4 Yellow alarm warning Ca...

Page 67: ...ause Corrective action Open circuit in cylinder injector wiring Result Misfiring u Check solenoid valve 361 AL Power Stage Low Red alarm engine stop Cause Corrective action Internal electronic fault e...

Page 68: ...ctive action Short circuit or wire break on transistor output 1 plant side 1 TOP 1 u Check wiring to plant Page 149 382 AL Wiring TOP 2 Yellow alarm warning Cause Corrective action Short circuit or wi...

Page 69: ...wiring Page 149 2 Check supply 3 Acknowledge alarm 4 Restart engine 5 Request towing locomotive if required 412 HI U PDU L2 L1 Yellow alarm warning Cause Corrective action Injector voltage too high 1...

Page 70: ...Yellow alarm warning Cause Corrective action Control of HP fuel control block faulty short circuit or wire break u Check sensor and wiring replace as necessary Page 149 474 AL Wiring FO Yellow alarm...

Page 71: ...nagement CPM has been detected This may be due to a missing consumer wire break or a short circuit u Check connection between POM and starter 502 AL Open Load POM Battery charging Generator Yellow ala...

Page 72: ...sible automatic starting attempts is executed the starting sequence is terminated 1 Repeat start 2 Check POM starter and wiring Page 149 519 Oil Level Calibration Fault Option Yellow alarm warning Cau...

Page 73: ...learance failed Yellow alarm warning Cause Corrective action Yellow alarm Warning CAN object Start clearance was not received within the expected time period u Contact Service 585 AL Engine Start supp...

Page 74: ...Exhaust temperature sensor on A and B sides defective short circuit or wire break u Check sensor and wiring B44 1 and B44 2 replace as necessary 602 AL CAN Engine Start Lock Yellow alarm warning Caus...

Page 75: ...ing engine parts Risk of crushing danger of parts of the body being caught or pulled in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work o...

Page 76: ...te No resistance other than compression re sistance must be encountered 4 Rotate crankshaft in engine direction of ro tation Result If the resistance exceeds the normal com pression resistance contact...

Page 77: ...ng engine with starting system Note Engine cranking only starts after a 4 second delay 1 Only crank engine under zero load Press and hold TURN key on the PAU 2 Crank engine until oil pressure is displ...

Page 78: ...er zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Performing test run 1 Start engine Page 38 2 Perform test run at least until...

Page 79: ...top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lowe...

Page 80: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 81: ...und the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and m...

Page 82: ...ation are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspec...

Page 83: ...log WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not...

Page 84: ...o the specified torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 6 Replace further oil filter elements in the same way 7 Check oil separator for leaks 84 Ta...

Page 85: ...pare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 90 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adju...

Page 86: ...Y20098771 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 90 2 Install barring device Page 75 Note The OT mark if...

Page 87: ...ram for 8V engines Two crankshaft positions Diagram for 12V engines Two crankshaft positions Diagram for 16V engines Two crankshaft positions MS15042 00E 2014 10 Task Description 87 TIM ID 0000000922...

Page 88: ...clearances in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use feel...

Page 89: ...ze Type Lubricant Value Standard Locknut M16 x 1 5 Tightening torque Engine oil 90 Nm 9 Nm 6 Replace or rectify adjusting screws and or locknuts which do not move freely 7 Check valve clearance Final...

Page 90: ...ad covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Check O...

Page 91: ...from the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP pump Relief bore check 1 Visually inspect relief bore 1 fo...

Page 92: ...pors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to components major...

Page 93: ...ector Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 94 MS15042 00E 2014 10 Tas...

Page 94: ...e wrench 60 320 Nm F30452768 1 Ratchet adapter F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Assembly compound Kluthe Hakuform 30 15 X00067260 1 Engine oil O ring Spare Parts Catalog WARNI...

Page 95: ...emove injector with installation removal tool 7 Remove installation removal tool 8 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 9 Remove O rings 3 O...

Page 96: ...e installation position of sealing ring 4 Fit new O rings 3 included in the scope of delivery of the injector O ring 2 and damping ring 1 onto the injector and coat with assembly compound 5 Remove oil...

Page 97: ...oil 5 Nm to 10 Nm 13 Tighten screw 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 14 Tighten adapte...

Page 98: ...screw Tightening torque Engine oil 40 Nm 5 Nm 18 Fit connectors on injector Note Failure to reset drift compensation CDC will void the emissions certification 19 Reset drift compensation CDC with Dia...

Page 99: ...cal sparks and ignition sources Do not smoke Venting LP fuel system 1 Open vent plug 1 2 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 3 Operate the pump with the handle 2...

Page 100: ...on Avoid open flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Remove easy change filter using filter wrench 2 Clean sealing face on filter head 3 Apply a thin coat...

Page 101: ...Do not smoke Fuel prefilter Draining 1 Open vent plug 1 of the filter 2 Unlock drain cock 2 by pressing toggle and open it 3 Drain water and contaminants from the fil ter until pure fuel emerges 4 Clo...

Page 102: ...ing filter element 1 Close shut off valve in fuel supply line 2 Open vent plug 1 of the filter 3 Unlock drain cock 2 by pressing toggle and open it 4 Drain water and dirt from filter 5 Close drain coc...

Page 103: ...ames electrical sparks and ignition sources Do not smoke Intermediate fuel filter Re placement 1 Remove easy change filter 2 with filter wrench 2 Clean sealing surface on filter head 1 3 Coat seal on...

Page 104: ...ply mirror inverted for the other side 1 Remove screws 4 6 and take off together with heat shield 2 washers 3 7 and spacer 5 2 Remove screws 8 and take off together with protective cover 1 and washers...

Page 105: ...th the marking 3 Tighten clamp 1 to the specified tightening torque Name Size Type Lubricant Value Standard Clamp 1 Tightening torque Assembly compound Ultra Therm MTU 24 Nm 3 Nm Note Secure bellows o...

Page 106: ...s 12 4 Install turbine housing 10 with clamp 11 on bellows 12 5 Tighten clamp 11 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Clamp Tightening torque A...

Page 107: ...specified in the relevant safety data sheet NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension o...

Page 108: ...screws 1 from charge air pipe to compressor housing 5 Loosen clamps on air intake 1 6 Remove air intake 7 Loosen clamp 2 8 Remove intake housing 1 108 Task Description MS15042 00E 2014 10 TIM ID 00000...

Page 109: ...g 1 Clean compressor housing with a smooth paint brush or brush 2 Clean compressor wheel 1 and bearing housing 2 3 Thoroughly remove cleaner from all compo nents 4 Install new sealing ring between bea...

Page 110: ...sealing ring 4 Position clamp 2 and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Clamp Tightening torque 15 Nm 2 Nm 5 Install air intake Note Install new...

Page 111: ...air jet at people Always wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain for coolant leakage and obstructions 1 With the engine running check if air es capes fr...

Page 112: ...aning Note Clean paper filter element dry only 1 Open air filter and remove filter element Page 114 2 Check seal for damage and cleanness re place if necessary 3 Clean all mating and sealing surfaces...

Page 113: ...pare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 114 2 Reset signal ring of service indicator Page 116 MS15042...

Page 114: ...emoval and installation 1 Release latches 9 2 Remove dust bowl 8 and partition 7 3 Remove collar nut 6 4 Screw off air filter element 4 5 Clean housing 3 and dust bowl 8 6 Check seal 5 for damage and...

Page 115: ...heck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 149 MS15042 00E...

Page 116: ...led Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 113 2 After installation of new filter press reset button 1 Result Engaged...

Page 117: ...xchanger flowing back into the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 118 5 Insert dipstick into guide tube up to the st...

Page 118: ...afety mask Avoid contact with skin Do not inhale oil vapor Version without semirotary hand pump Draining oil at drain plug s on oil pan 1 Provide a suitable container in which to collect the engine oi...

Page 119: ...drain plug s with new sealing ring 5 Tighten drain 2 and 3 with torque wrench to specified tightening torque Name Size Type Lubricant Value Standard Screw M26 x 1 5 Tightening torque Engine oil 100 Nm...

Page 120: ...ing Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear...

Page 121: ...soning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Unscrew engine oil filter with filter wrench 2 Clean seal...

Page 122: ...afety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Nev...

Page 123: ...m Findings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Notify Service Strainer Damaged Fit new part Square section ring Damaged Fit new part O ring Damaged Fi...

Page 124: ...ing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid...

Page 125: ...rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the outer wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor co...

Page 126: ...ape 2 Continue to turn cap counterclockwise and remove 3 Check engine coolant level engine coolant must be visible at bottom edge of cast in eye of filler neck Checking engine coolant level at remote...

Page 127: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 128 2 Fill with engine coolant Page 129 MS15042 00E 2014 10 Task Description...

Page 128: ...breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off separated c...

Page 129: ...nd scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill...

Page 130: ...and close 9 Start engine Page 38 10 After running the engine for 10 seconds un der zero load shut it down Page 39 11 Turn pressure cap of coolant expansion tank counterclockwise until the first stop...

Page 131: ...38 7 After running the engine for 10 seconds un der zero load shut it down Page 39 8 Turn pressure cap counterclockwise and remove 9 Check coolant level Page 126 and top up coolant as required a Add c...

Page 132: ...o hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 39 and disable en gine start observe general safety instruc ti...

Page 133: ...wn Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tion...

Page 134: ...7 16 7 Preheating unit Overview Preheating unit 1 Preheating unit 134 Task Description MS15042 00E 2014 10 TIM ID 0000014751 005...

Page 135: ...Coolant line holders 1 Preheating unit 2 Screw 3 Washer 4 Clamp 5 Washer 6 Nut MS15042 00E 2014 10 Task Description 135 TIM ID 0000014751 005...

Page 136: ...gine cool down Wear protective clothing gloves and goggles safety mask WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Pr...

Page 137: ...otwear WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Preheater unit Installation 1 Remove covers Note Pay attention to...

Page 138: ...st stop and allow pressure to escape 2 Continue to turn cap counterclockwise and remove Note Charge air coolant must be visible at mark er plate 3 Check charge air coolant level 4 Top up charge air co...

Page 139: ...pecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 140 2 Fill with charge air coolant Page 141 MS15042 00E 2014 10 Task Des...

Page 140: ...to the first stop and allow pressure to escape 3 Continue to turn valve cover counterclock wise and remove 4 Draw off separated corrosion inhibitor oil in expansion tank through the filler neck 5 Ope...

Page 141: ...lding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up...

Page 142: ...ck and close 9 Start engine Page 38 10 After 10 seconds of running the engine without load stop the engine Page 39 11 Turn breather valve on coolant expansion tank counterclockwise to the first stop a...

Page 143: ...d stop the engine Page 39 8 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 9 Turn breather valve counterclockwise and remove 10 Check coo...

Page 144: ...o hearing Wear ear protectors Charge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 39 and disable en gine start observe general safety instru...

Page 145: ...struction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounts Resilient ele ments ch...

Page 146: ...the cen tral buffer 2 Note Engine oil must not get in contact with the rubber elements of the resilient mount 4 Coat mating face of nut 3 and thread of central buffer 2 with a little engine oil 5 Tigh...

Page 147: ...run the engine at low power Keep away from the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Greasing antifriction be...

Page 148: ...sabled Special tools Material Spare parts Designation Use Part No Qty Vacuum cleaner Tools Catalog Cleaning intake air grille 1 Clean intake air grille on generator dry 2 Use vacuum cleaner to remove...

Page 149: ...lips are closed and intact 4 Replace faulty cable clips 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line com...

Page 150: ...parameters must be reset otherwise the emission certification of the engine is no longer ap plicable u Reset the CDC parameters with DiaSys Manufacturer s documentation Resetting CDC parameters DiaSy...

Page 151: ...surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels...

Page 152: ...itable test probe e g test prod The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all pl...

Page 153: ...timum emis sions and consumption characteristics CRC Cyclic Redundancy Control Check sum procedure to detect data transmission faults DC Direct Current DEF Diesel Exhaust Fluid Urea solution with 32 5...

Page 154: ...nit Module for monitoring control and plant related sys tem integration of peripheral components PDU Process Data Unit POM Power Output Module Module to control starter and battery charging gen erator...

Page 155: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Page 156: ...amination Page 79 Combination box and open end wrench Part No F30379609 Qty Used in 1 7 18 1 Engine mounts Resilient element check Page 145 Endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder lin...

Page 157: ...ement check Page 145 Filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter Replacement Page 100 Qty Used in 1 7 8 4 Intermediate fuel filter Replacement Page 103 Qty Used in 7 15 1 Engine oi...

Page 158: ...Injector Removal and installation Page 94 MTU test kit Part No 5605892099 00 Qty Used in 1 7 14 3 Engine oil Sample extraction and analysis Page 120 Qty Used in 1 7 16 6 Engine coolant Sample extract...

Page 159: ...Page 107 Ratchet adapter Part No F30027341 Qty Used in 1 7 6 2 Injector Removal and installation Page 94 Ratchet with extension Part No F30006212 Qty Used in 1 7 1 1 Engine Barring manually Page 75 Qt...

Page 160: ...1 4 Crankshaft transport locking device Page 8 Qty Used in 1 7 6 2 Injector Removal and installation Page 94 Qty Used in 1 7 9 2 Compressor wheel Cleaning Page 107 Qty Used in 1 7 15 3 Centrifugal oi...

Page 161: ...1 4 Crankshaft transport locking device Page 8 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 86 Qty Used in 1 7 6 2 Injector Removal and installation Page 94 Qty Used in 1 7 14 2 Engi...

Page 162: ...aning 112 E Engine Barring Manually 75 Cranking with starting system 77 Layout 19 Main dimensions 35 Performing test run 78 Preparation for extended out of service period 40 Start in manual mode 38 St...

Page 163: ...Installation 137 Removal 136 Preheating unit Overview 134 Putting the engine into operation Preparation after extended out of service periods 3 months 36 R Recommissioning Preparation after scheduled...

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Summary of Contents for 16V 4000 R43L

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MTU 16V 4000 R43L, Operating Instructions Manual

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Summary of Contents for 16V 4000 R43L

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