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20 V 4000 G83
MTU 20 V 4000 G83 User Manual
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Operating Instructions
Diesel engine
20 V 4000 G23
20 V 4000 G43
20 V 4000 G63, G63L
20 V 4000 G83, G83L
M015715/03E
2
Table of Contents
Default Chapter
1
Operating Instructions
1
Table of Contents
3
1 Safety
5
Important Provisions for All Products
5
Personnel and Organizational Requirements
6
Transport
7
Crankshaft Transport Locking Device
8
Safety Regulations for Startup and Operation
11
Safety Regulations for Maintenance and Repair Work
12
Fire Prevention and Environmental Protection, Fluids and Lubricants, Auxiliary Materials
15
Compressed Air
16
Conventions for Safety Instructions in the Text
17
2 General Information
18
Engine Side and Cylinder Designations
18
Engine Layout
19
Sensors, Actuators and Injectors - Overview
21
3 Technical Data
24
4000 Gx3 Engine Data: Continuous Operation, Unrestricted 3A, Optimized Fuel Consumption
24
4000 Gx3 Engine Data: Continuous
29
Consumption
29
Operation, Variable 3B, Optimized Fuel Consumption
29
Emissions (EPA2)
35
Operation, Variable 3B, Optimized Exhaust Emissions (EPA2)
35
Emissions (TA-Luft)
39
Operation, Variable 3B, Optimized Exhaust Emissions (TA-Luft)
39
4000 Gx3 Engine Data: Standby Operation 3D, Optimized Fuel Consumption
43
4000 Gx3 Engine Data: Standby Operation 3D, Optimized Exhaust Emissions (EPA Stage 2)
49
Firing Order
53
Engine - Main Dimensions
54
4 Operation
55
Putting the Engine into Operation after Extended Out-Of-Service Periods (>3 Months)
55
Putting the Engine into Operation after Scheduled Out-Of-Service-Period
56
Starting the Engine in Manual Mode (Test Run)
57
Safety System - Override
58
Starting the Engine in Emergency Situations (Override Mode)
59
Operational Checks
60
Stopping the Engine in Manual Mode (Test Run)
61
Emergency Stop
62
After Stopping the Engine - Engine Remains Ready for Operation
63
After Stopping the Engine - Putting the Engine out of Operation
64
Plant Cleaning
65
5 Maintenance
66
Maintenance Task Reference Table [QL1]
66
6 Troubleshooting
67
Fault Messages on PAU Display
70
Engine Governor ADEC (ECU 7) for Series 4000 Genset Engines - Fault Messages
71
Engine
120
Engine - Barring Manually
120
Engine - Barring with Starting System
121
Engine - Test Run
122
7 Task Description
120
Cylinder Liner
123
Cylinder Liner - Endoscopic Examination
123
Instructions and Comments on Endoscopic and Visual Examination of Cylinder Liners
125
Crankcase Breather
127
Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check and Replacement
127
Valve Drive
129
Valve Gear - Lubrication
129
Valve Clearance - Check and Adjustment
130
Adjusting Valve Clearance
131
Cylinder Head Cover - Removal and Installation
132
Injection Pump / HP Pump
133
HP Pump - Filling with Engine Oil
133
Injection Valve / Injector
134
Injector - Replacement
134
Injector - Removal and Installation
135
Fuel System
140
Replacement
141
Fuel Prefilter – Differential Pressure Gauge
143
Replacement
147
Intercooler – Checking Condensate Drain for
149
Air Filter
150
Air Intake
153
Starting Equipment
154
Lube Oil System, Lube Oil Circuit
155
Oil Filtration / Cooling
159
Centrifugal Oil Filter – Cleaning and Filter
162
Coolant Circuit, General, High-Temperature
164
Engine Coolant Pump – Relief Bore Check
170
Engine Coolant – Sample Extraction and
171
Low-Temperature Circuit
172
Charge-Air Coolant – Change
173
Draining Charge-Air Coolant
174
Charge-Air Coolant – Filling
175
Charge-Air Coolant Pump – Relief Bore Check
178
Engine Mounting / Support
179
Belt Drive
180
Battery-Charging Generator
181
Battery-Charging Generator Drive – Drive Belt
183
Wiring (General) for Engine/Gearbox/Unit
184
Accessories for (Electronic) Engine
185
Engine Governor and Connectors – Cleaning
186
Engine Governor Plug Connections – Check
187
ECU 7 Engine Governor – Removal and
188
8 Appendix A
189
MTU Contact Persons/Service Partners
191
9 Appendix B
192
Index
198
Other manuals for MTU 20 V 4000 G83
Technical Publication
178 pages
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MTU 20 V 4000 G83 Specifications
General
Engine Type
Diesel
Fuel Type
Diesel
Cooling System
Water-cooled
Compression Ratio
16.5:1
Bore
170 mm
Stroke
210 mm
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