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
MS15042/00E 2014-10
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