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
© 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 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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1.5 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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1.6 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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1.7 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal
Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product 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. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Fluids and lubricants and auxiliary materials
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to 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 equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)
• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.
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1.8 Standards for safety notices in the text
DANGER In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
CAUTION In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial 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 manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
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2 General Information
2.1 Engine side and cylinder designations
1 Left engine side (A-side)
2 Engine free end in accord-
ance with DIN ISO 1204
(KGS = Kupplungsgegen-
seite)
3 Right engine side (B-side)
4 Engine driving end in ac-
cordance with
DIN ISO 1204 (KS = Kup-
plungsseite)
Engine sides are always designated (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) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
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2.2 Engine layout
16 V 4000 R43 L/R
1 Oil heat exchanger
2 Crankcase breather
3 Power Output Module
(POM)
4 Centrifugal oil filter
5 Exhaust system
6 Exhaust turbocharger
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 (battery-
charging generator)
18 Coolant pump (HT)
19 Coolant filter
20 Coolant pump (LT)
21 Engine management
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1 Oil heat exchanger
2 Crankcase breather
3 Air intake
4 Exhaust turbocharger
5 Exhaust system
6 Intercooler
7 Charge-air manifold
8 Engine mount
9 Additional fuel filter
10 Oil filler neck
11 Cylinder head
12 Fuel filter
13 HP fuel 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 L/R
16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
R Application: Rail
4 Application segment (2, 4, 6, 8)
3 Design index
R / L Power-reduced / power-enhanced
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