MTU 12V4000S83 Manuel utilisateur
Operating Instructions
Diesel engine
12 V 4000 S83
16 V 4000 S83
MS150026/02E
Engine model kW/cyl. Application group
12V4000S83 139.8 kW/cyl. 4D, Frac operation (continuous opera-
tion at low load)
16V4000S83 139.8 kW/cyl. 4D, Frac operation (continuous opera-
tion at low load)
Table 1: Applicability
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 startup and operation 11
1.6 Safety regulations 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 and actuators – Overview 20
3 Technical Data
3.1 12/16V 4000 S83 4D engine data 24
3.2 Firing order 28
3.3 Engine ‒ Main dimensions 29
4 Operation
4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months) 30
4.2 Putting the engine into operation after
scheduled out-of-service-period 31
4.3 Engine – Starting in manual mode 32
4.4 Operational checks 33
4.5 Engine – Stopping in manual mode 34
4.6 Preparing the engine for extended out-of-
service period 35
4.7 Plant – Cleaning 36
5 Maintenance
5.1 Maintenance task reference table [QL1] 37
6 Troubleshooting
6.1 Troubleshooting 38
6.2 Fault messages from the ADEC (ECU 7)
engine management control unit for the
Series 4000 for C&I applications 41
7 Task Description
7.1 Engine 60
7.1.1 Engine – Performing test run 60
7.1.2 Engine – Barring manually 61
7.1.3 Engine – Barring with starting system 63
7.2 Cylinder Liner 64
7.2.1 Cylinder liner – Endoscopic examination 64
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 66
7.3 Crankcase Breather 68
7.3.1 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 68
7.4 Valve Drive 70
7.4.1 Valve gear – Lubrication 70
7.4.2 Valve clearance – Check and adjustment 71
7.4.3 Cylinder head cover – Removal and
installation 75
7.5 Injection Pump / HP Pump 76
7.5.1 HP pump – Filling with engine oil 76
7.6 Injector 77
7.6.1 Injector – Replacement 77
7.6.2 Injector – Removal and installation 78
7.7 Fuel System 83
7.7.1 Fuel system – Venting 83
7.8 Fuel Filter 84
7.8.1 Fuel filter – Replacement 84
7.9 Charge-Air Cooling 85
7.9.1 Intercooler – Checking condensate drain for
coolant leakage and obstruction 85
7.10 Starting Equipment 86
7.10.1 Starter – Condition check 86
7.11 Air Intake 87
7.11.1 Emergency air-shutoff flaps – Electric control
check 87
7.12 Lube Oil System, Lube Oil Circuit 88
7.12.1 Engine oil ‒ Level check 88
7.12.2 Engine oil – Change 89
7.12.3 Engine oil – Sample extraction and analysis 91
7.13 Oil Filtration / Cooling 92
7.13.1 Engine oil filter – Replacement 92
7.13.2 Automatic oil filter – Filter candles
replacement 93
7.13.3 Oil indicator filter – Cleaning and check 97
7.13.4 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 99
MS150026/02E 2013-11 |Table of Contents | 3
DCL-ID: 0000008057 - 004
7.14 Coolant Circuit, General, High-Temperature
Circuit 101
7.14.1 Engine coolant – Level check 101
7.14.2 Engine coolant – Change 102
7.14.3 Engine coolant pump pressure relief port –
Check 103
7.14.4 Draining engine coolant 104
7.14.5 Engine coolant – Filling 106
7.14.6 Engine coolant – Sample extraction and
analysis 108
7.14.7 Engine coolant filter – Replacement 109
7.15 Low-Temperature Circuit 110
7.15.1 Charge-air coolant – Change 110
7.15.2 Charge-air coolant – Draining 111
7.15.3 Charge-air coolant – Filling 112
7.15.4 Charge-air coolant – Level check 114
7.15.5 Charge-air coolant pump – Relief bore check 115
7.16 Belt Drive 116
7.16.1 Drive belt – Condition check 116
7.17 Battery-Charging Generator 117
7.17.1 Battery-charging generator ‒ Check 117
7.17.2 Battery-charging generator drive – Drive belt
tension adjustment 118
7.17.3 Battery-charging generator drive – Drive belt
replacement 119
7.18 Fan Drive 120
7.18.1 Fan drive – Drive belt tension check /
adjustment 120
7.18.2 Fan drive – Drive belt replacement 122
7.19 Engine Mounting / Support 123
7.19.1 Engine mounting – Check 123
7.20 Wiring (General) for Engine/Gearbox/Unit 124
7.20.1 Engine wiring – Check 124
7.21 Accessories for (Electronic) Engine
Governor / Control System 125
7.21.1 CDC parameters – Reset with DiaSys® 125
7.21.2 Engine governor and connectors – Cleaning 126
7.21.3 Engine governor plug connections – Check 127
8 Appendix A
8.1 Abbreviations 128
8.2 MTU contact persons/service partners 131
9 Appendix B
9.1 Special Tools 132
9.2 Index 139
4 | Table of Contents | MS150026/02E 2013-11
DCL-ID: 0000008057 - 004
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 (→ 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 control/parameters)
• In compliance with all safety regulations and in adherence with 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.
MS150026/02E 2013-11 |Safety | 5
TIM-ID: 0000040530 - 003
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.
6 | Safety | MS150026/02E 2013-11
TIM-ID: 0000040531 - 002
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.
MS150026/02E 2013-11 |Safety | 7
TIM-ID: 0000002618 - 006
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
Note: The locking device protects the crankshaft bearings from shocks 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 as long as possible during engine installation in or-
der to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both 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/transmission is already mounted on the engine, ensure that the transport locking device of the gen-
erator/transmission is also removed.
Removing the transport locking
device from driving end (KS),
variant A
1. Remove parts (1) to (8) from engine.
Spacer sleeves (5) are optional.
2. Store the removed parts of the transport
locking device carefully for possible reuse.
8 | Safety | MS150026/02E 2013-11
TIM-ID: 0000047151 - 001
Installing the transport locking
device on driving end (KS), var-
iant A
1. Screw retainer (4) with spacer sleeves (5)
and screws (6) on crankshaft. Spacer
sleeves (5) are optional.
2. Use torque wrench to tighten screws (6) to specified tightening torque .
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 160 Nm +16 Nm
3. Screw nut (3) with washer (2) onto retainer (4). Fit support (1) with washer (7) and nut (8) and tighten
nut (8) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut M24 Tightening torque (Engine oil) 100 Nm +10 Nm
4. Secure with nut (3).
5. Mark the engine as "Fitted with transportation locking device".
Removing the transport locking
device from driving end (KS),
variant B
1. Release the locknuts (2) on both sides of
the flywheel housing, remove screw (3) and
take off retainer (8).
2. Remove screws (5) and take off with wash-
ers (4), cover plate (7), label (6) and plates
(1).
3. Store the removed parts of the transport
locking device together with this documen-
tation carefully for possible reuse.
MS150026/02E 2013-11 |Safety | 9
TIM-ID: 0000047151 - 001
Installing the transport locking
device on driving end (KS), var-
iant B
1. Secure plate (1) with screws (5) and washers (4) together with cover sheet (7) at the bores on both
sides of the flywheel 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. Screw locknut (2) onto screws (3) up to the end of the thread.
3. Fit the retainers (8) through the openings of plate (1) and fasten with screw (3).
4. Tighten screws (3) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
5. Place locknut (2) of screw (3) in position on plate (1) and lock it.
6. Fit label (6) to mark the engine as "Fitted with transportation locking device".
10 | Safety | MS150026/02E 2013-11
TIM-ID: 0000047151 - 001
Ce manuel convient aux modèles suivants
1
Table des matières
