MTU 12 V 4000 S83L User manual
Operating Instructions
Diesel engine
12 V 4000 S83L
16 V 4000 S83L
MS150027/02E
Printed in Germany
© 2013 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 permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety
1.1 Important provisions 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 regulations for maintenance and
repair work 11
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 14
1.7 Conventions for safety instructions in the
text 16
2 General Information
2.1 Engine side and cylinder designations 17
2.2 Engine layout 18
2.3 Sensors and actuators – Overview 19
3 Technical Data
3.1 12/16V 4000 S83L 4D engine data 23
3.2 Firing order 27
3.3 Engine – Main dimensions 28
4 Operation
4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months) 29
4.2 Putting the engine into operation after
scheduled out-of-service period 30
4.3 Starting the engine in manual mode 31
4.4 Operational checks 32
4.5 Stopping the engine in manual mode 33
4.6 After shutting down the engine 34
4.7 Plant cleaning 35
5 Maintenance
5.1 Maintenance task reference table [QL1] 36
6 Troubleshooting
6.1 Troubleshooting 37
6.2 Fault messages from the ADEC (ECU 7)
engine management control unit for the
Series 4000 for C&I applications 40
7 Task Description
7.1 Engine 59
7.1.1 Cranking engine manually 59
7.1.2 Engine – Barring with starting system 61
7.1.3 Engine – Test run 62
7.2 Cylinder Liner 63
7.2.1 Cylinder liner – Endoscopic examination 63
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 65
7.3 Crankcase Breather 67
7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 67
7.4 Valve Drive 69
7.4.1 Valve gear – Lubrication 69
7.4.2 Valve clearance – Check and adjustment 70
7.4.3 Cylinder head cover – Removal and
installation 74
7.5 Injection Pump / HP Pump 75
7.5.1 HP pump – Filling with engine oil 75
7.6 Injection Valve / Injector 76
7.6.1 Injector – Replacement 76
7.6.2 Injector – Removal and installation 77
7.7 Fuel System 82
7.7.1 Fuel system – Venting 82
7.8 Fuel Filter 83
7.8.1 Fuel filter – Replacement 83
7.9 Charge-Air Cooling 84
7.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 84
7.10 Air Filter 85
7.10.1 Air filter – Replacement 85
7.10.2 Air filter element – Removal and installation
(optional) 86
7.11 Starting Equipment 87
7.11.1 Starter – Condition check 87
7.12 Air Intake 88
7.12.1 Emergency air-shutoff flaps – Electric control
check 88
7.12.2 Service indicator – Signal ring position check
(optional) 89
7.13 Lube Oil System, Lube Oil Circuit 90
7.13.1 Checking engine oil level 90
7.13.2 Engine oil – Change 91
7.13.3 Engine oil – Sample extraction and analysis 93
7.14 Oil Filtration / Cooling 94
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7.14.1 Automatic oil filter – Oil filter candles
replacement 94
7.14.2 Oil indicator filter – Cleaning and check 97
7.14.3 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 99
7.15 Coolant Circuit, General, High-Temperature
Circuit 101
7.15.1 Engine coolant – Level check 101
7.15.2 Engine coolant – Change 102
7.15.3 Draining engine coolant 103
7.15.4 Engine coolant – Filling 105
7.15.5 Engine coolant pump – Checking pressure
relief port 107
7.15.6 Engine coolant – Sample extraction and
analysis 108
7.15.7 Engine coolant filter – Replacement 109
7.16 Low-Temperature Circuit 110
7.16.1 Charge-air coolant – Level check 110
7.16.2 Charge-air coolant – Change 111
7.16.3 Charge-air coolant – Draining 112
7.16.4 Charge-air coolant – Filling 113
7.16.5 Charge-air coolant pump – Checking pressure
relief port 115
7.17 Belt Drive 116
7.17.1 Drive belt – Condition check 116
7.18 Battery-Charging Generator 117
7.18.1 Battery-charging generator – Check 117
7.18.2 Battery-charging generator drive – Drive belt
tension adjustment 118
7.18.3 Battery-charging generator drive – Drive belt
replacement 119
7.19 Fan Drive 120
7.19.1 Fan drive – Drive belt tension check /
adjustment 120
7.19.2 Fan drive – Drive belt replacement 122
7.20 Engine Mounting / Support 123
7.20.1 Engine mounting – Check 123
7.21 Wiring (General) for Engine/Gearbox/Unit 124
7.21.1 Engine wiring – Check 124
7.22 Accessories for (Electronic) Engine
Governor / Control System 125
7.22.1 Engine governor and connectors – Cleaning 125
7.22.2 Engine governor plug connections – Check 126
8 Appendix A
8.1 Abbreviations 127
8.2 MTU contact persons/service partners 130
9 Appendix B
9.1 Special Tools 131
9.2 Index 137
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with 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:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ product 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 (→ applicable Spare Parts
Catalog)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• 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 is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
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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 protective equipment
Wear proper protective clothing for all work.
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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.
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
Transport locking device
This locking device protects the crankshaft bearings from shocks and vibration damage during engine
transport.
For removal of the transport locking device follow the following instructions:
• The transport locking device should remain installed as long as possible during engine installation in
order to avoid damage.
• Starting or barring the engine is allowed only with the transport locking device removed. If the gener-
ator/transmission is already mounted on the engine, ensure that the transport locking device of the
generator/transmission is also removed.
• Prior to every engine transport, this transport locking device must be reinstalled according to the in-
structions.
Transport locking device – Removal and installation, variant A
Removing the transport locking device from driving end (KS)
• Remove parts (1) to (8) from engine.
• Spacer sleeves (5) are optional.
Store the removed parts of the transport locking device carefully for possible reuse!
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Fitting the transport locking device on driving end (KS)
• Fit holder (4) with spacer sleeves(5) and screws (6) on crankshaft.
• Spacer sleeves (5) are optional.
• Use torque wrench to tighten screws (6) to the specified tightening torque 160 Nm +16 Nm. Lubri-
cant: Engine oil.
• Screw nut (3) with washer (2) onto holder (4) and turn towards crankshaft.
• Slide bracket (1) onto holder (4) until it makes contact with the flywheel housing front face.
• Screw nut (8) with washer (7) onto holder (4). Use torque wrench to tighten nut (8) to the specified
tightening torque: 100 Nm +10 Nm. Lubricant: Engine oil.
• Secure with nut (3).
• Mark the engine as "Fitted with transport locking device".
Transport locking device – Removal and installation, variant B
Removing the transport locking device from driving end (KS)
• Release nuts (6) on both sides of the flywheel housing, remove screws (5) and take off holder (4).
• Remove screws (2) with washers (3) and take off plates (1).
• Fit covers with gaskets to seal the lateral openings of the flywheel housing.
Store the removed parts of the transport locking device carefully for possible reuse!
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Fitting the transport locking device on driving end (KS)
• Remove covers on the left and right side of the flywheel housing and take off gaskets.
• Install plates (1) with screws (2) and washers (3) on the lateral openings of the flywheel housing. Use
torque wrench to tighten screws (2) to the specified tightening torque 250 Nm +25 Nm. Lubricant:
Engine oil.
• Screw on nuts (6) up to the end of the threads of screws (5).
• Fit holders (4) through the openings in plates (1) on both sides and lock in position with screws (5).
• Use torque wrench to tighten screws (5) alternately to the specified tightening torque
30 Nm + 3 Nm. Lubricant: Engine oil.
• Secure screws (5) with nuts (6).
• Mark the engine as "Fitted with transport locking device".
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