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MTU 12 V 4000 S83L User Manual

MTU 12 V 4000 S83L
138 pages
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Operating Instructions
Diesel engine
12 V 4000 S83L
16 V 4000 S83L
MS150027/02E

Table of Contents

Questions and Answers:

MTU 12 V 4000 S83L Specifications

General IconGeneral
Engine TypeDiesel
Number of Cylinders12
Cylinder ConfigurationV
Fuel TypeDiesel
Cooling SystemWater-cooled
TurbochargerYes
AftercoolerYes
Displacement57.2 liters
Fuel SystemCommon Rail Injection
Emissions ComplianceIMO Tier II

Summary

1 Safety

1.1 Important provisions for all products

General safety advice, correct use, modifications, and spare parts.

1.2 Personnel and organizational requirements

Manual issuance, personnel qualifications, and protective equipment.

1.3 Transport

Procedures for safely transporting the engine/genset, including lifting and placement.

1.4 Crankshaft transport locking device

Details on the purpose, removal, and installation of the crankshaft transport locking device.

1.5 Safety regulations for maintenance and repair work

Safety measures before, during, and after maintenance and repair activities.

1.6 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials

Guidelines for fire prevention, environmental protection, and handling fluids.

1.7 Conventions for safety instructions in the text

Explanation of safety signal words (DANGER, WARNING, CAUTION, NOTICE) and their meanings.

2 General Information

2.1 Engine side and cylinder designations

Explanation of engine side and cylinder numbering conventions.

2.2 Engine layout

Illustration and key for engine components and model designation.

2.3 Sensors and actuators – Overview

Identification and location of various sensors and actuators on the engine.

3 Technical Data

3.1 12/16V 4000 S83L 4D engine data

Technical specifications and reference conditions for the engine models.

CONSUMPTION

Data related to fuel and lubricant consumption.

CAPACITIES

Engine coolant, charge-air coolant, and oil capacities.

3.2 Firing order

The sequence in which cylinders fire for different engine configurations.

3.3 Engine – Main dimensions

Overall dimensions (length, width, height) of the engine.

4 Operation

4.3 Starting the engine in manual mode

Step-by-step guide to starting the engine manually.

4.5 Stopping the engine in manual mode

Procedures for safely stopping the engine.

4.6 After shutting down the engine

Actions to take after the engine has been shut down.

4.7 Plant cleaning

Guidelines and procedures for cleaning the engine plant.

5 Maintenance

5.1 Maintenance task reference table [QL1]

A table referencing maintenance tasks and their corresponding pages.

6 Troubleshooting

6.1 Troubleshooting

Common engine problems and their probable causes and tasks.

7 Task Description

7.1 Engine

General tasks related to the engine.

7.1.1 Cranking engine manually

Step-by-step instructions for manually cranking the engine.

7.1.2 Engine – Barring with starting system

Procedure for barring the engine using the starting system.

7.1.3 Engine – Test run

Steps for performing an engine test run.

7.2 Cylinder Liner

Information regarding cylinder liners.

7.2.1 Cylinder liner – Endoscopic examination

Procedure for performing an endoscopic examination of cylinder liners.

7.3 Crankcase Breather

Details on the crankcase breather system.

7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement

Steps for replacing the oil separator and checking the diaphragm.

7.4 Valve Drive

Information about the valve drive system.

7.4.1 Valve gear – Lubrication

Procedure for lubricating the valve gear.

7.4.2 Valve clearance – Check and adjustment

Steps to check and adjust valve clearance.

7.4.3 Cylinder head cover – Removal and installation

Instructions for removing and installing the cylinder head cover.

7.5 Injection Pump / HP Pump

Information on the injection pump / HP pump.

7.5.1 HP pump – Filling with engine oil

Procedure for filling the HP pump with engine oil.

7.6 Injection Valve / Injector

Details on injectors.

7.6.1 Injector – Replacement

Instructions for replacing an injector.

7.6.2 Injector – Removal and installation

Step-by-step guide for injector removal and installation.

7.7 Fuel System

Information about the fuel system.

7.7.1 Fuel system – Venting

Procedure for venting the low-pressure fuel system.

7.8 Fuel Filter

Information on fuel filters.

7.8.1 Fuel filter – Replacement

Steps for replacing the fuel filter.

7.9 Charge-Air Cooling

Information on the charge-air cooling system.

7.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions

How to check the intercooler condensate drain for blockages.

7.10 Air Filter

Information on air filters.

7.10.1 Air filter – Replacement

Procedure for replacing the air filter.

7.10.2 Air filter element – Removal and installation (optional)

Steps for removing and installing the air filter element.

7.11 Starting Equipment

Information on starting equipment.

7.11.1 Starter – Condition check

How to check the condition of the starter.

7.12 Air Intake

Information on the air intake system.

7.12.1 Emergency air-shutoff flaps – Electric control check

Checking the electric control of emergency air-shutoff flaps.

7.12.2 Service indicator – Signal ring position check (optional)

Checking the signal ring position on the service indicator.

7.13 Lube Oil System, Lube Oil Circuit

Details about the lube oil system and circuit.

7.13.1 Checking engine oil level

How to check the engine oil level before and during operation.

7.13.2 Engine oil – Change

Procedures for changing the engine oil.

7.13.3 Engine oil – Sample extraction and analysis

How to extract and analyze engine oil samples.

7.14 Oil Filtration / Cooling

Information on oil filtration and cooling systems.

7.14.1 Automatic oil filter – Oil filter candles replacement

Steps for replacing automatic oil filter candles.

7.14.2 Oil indicator filter – Cleaning and check

How to clean and check the oil indicator filter.

7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement

Procedures for cleaning the centrifugal oil filter and replacing the sleeve.

7.15 Coolant Circuit, General, High-Temperature Circuit

Details on the general high-temperature coolant circuit.

7.15.1 Engine coolant – Level check

How to check the engine coolant level.

7.15.2 Engine coolant – Change

Steps for changing the engine coolant.

7.15.3 Draining engine coolant

Procedures for draining engine coolant.

7.15.4 Engine coolant – Filling

How to fill the engine coolant system.

7.15.5 Engine coolant pump – Checking pressure relief port

Checking the pressure relief port on the coolant pump.

7.15.6 Engine coolant – Sample extraction and analysis

How to extract and analyze engine coolant samples.

7.15.7 Engine coolant filter – Replacement

Steps for replacing the engine coolant filter.

7.16 Low-Temperature Circuit

Information on the low-temperature circuit.

7.16.1 Charge-air coolant – Level check

How to check the charge-air coolant level.

7.16.2 Charge-air coolant – Change

Procedures for changing the charge-air coolant.

7.16.3 Charge-air coolant – Draining

Procedures for draining charge-air coolant.

7.16.4 Charge-air coolant – Filling

How to fill the charge-air coolant system.

7.16.5 Charge-air coolant pump – Checking pressure relief port

Checking the pressure relief port on the charge-air coolant pump.

7.17 Belt Drive

Information on belt drives.

7.17.1 Drive belt – Condition check

How to check the condition of the drive belt.

7.18 Battery-Charging Generator

Information on the battery-charging generator.

7.18.1 Battery-charging generator – Check

How to check the battery-charging generator.

7.18.2 Battery-charging generator drive – Drive belt tension adjustment

Adjusting the drive belt tension for the generator.

7.18.3 Battery-charging generator drive – Drive belt replacement

Steps for replacing the drive belt of the generator.

7.19 Fan Drive

Information on the fan drive system.

7.19.1 Fan drive – Drive belt tension check / adjustment

Checking and adjusting the fan drive belt tension.

7.19.2 Fan drive – Drive belt replacement

Steps for replacing the fan drive belt.

7.20 Engine Mounting / Support

Information on engine mounting and support.

7.20.1 Engine mounting – Check

How to check the engine mounting.

7.21 Wiring (General) for Engine/Gearbox/Unit

General information about engine/gearbox/unit wiring.

7.21.1 Engine wiring – Check

How to check the engine wiring.

7.22 Accessories for (Electronic) Engine Governor / Control System

Accessories for the engine governor and control system.

7.22.1 Engine governor and connectors – Cleaning

Procedures for cleaning the engine governor and its connectors.

7.22.2 Engine governor plug connections – Check

How to check engine governor plug connections.

8 Appendix A

8.1 Abbreviations

A list of abbreviations used in the manual and their meanings.

8.2 MTU contact persons/service partners

Contact information for MTU service and support.

9 Appendix B

9.1 Special Tools

List of special tools required for various tasks.

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