MTU V 4000 M70 Operating Instructions Manual
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MTU V 4000 M70 Operating Instructions Manual

MTU V 4000 M70 Operating Instructions Manual

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Operating Instructions

Diesel engine
V 4000 M70
V 4000 M71
Application group 1B
MW15412/05E

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January 28, 2025

AL turning activated FC891 alarm engine will not crank

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Summary of Contents for MTU V 4000 M70

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine V 4000 M70 V 4000 M71 Application group 1B MW15412/05E...
  • Page 2 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, micro‐ filming and storage or processing on electronic systems including data bases and online services.
  • Page 3 Commissioning Note Important Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ ranty, spare parts, etc.).

  • Page 5: Table Of Contents

    Table of Contents 1 Safety 3.10 16V 4000 M70 engine data: IMO -20%, engine-mounted heat exchanger, copper- 1.1 General conditions based alloy intercooler 1.2 Personnel and organizational requirements 3.11 16V 4000 M70 engine data: engine- 1.3 Transport mounted heat exchanger, EPA stage 2 1.4 Safety regulations for startup and operation 3.12 16V 4000 M70 engine data: separate heat 1.5 Explosion hazard when removing...
  • Page 6 4.14 Stopping the engine from LOP 7.8.2 Fuel prefilter – Draining 4.15 Stopping the engine at the BlueLine 7.8.3 Fuel prefilter ‒ Flushing 7.8.4 Fuel prefilter – Differential pressure gauge automation system (control stand) check and adjustment 4.16 Emergency stop from LOP 7.8.5 Fuel prefilter –...
  • Page 7 8 Appendix A 7.22.3 Water level probe (3-in-1 rod electrode) – Check 8. Abbreviations 7.22.4 Pump capacity – Check 8. MTU contacts/service partners 7.22.5 Coalescer filter element – Replacement 7.23 Wiring (General) for Engine/Gearbox/Unit 7.23.1 Engine wiring – Check 9 Appendix B 7.24 Accessories for (Electronic) Engine...

  • Page 8: Safety

    Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

  • Page 9: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company.

  • Page 10: Transport

    Set the engine down on a firm, level 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 .

  • Page 11: Safety Regulations For Startup And Operation

    Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: •...

  • Page 12: Explosion Hazard When Removing Inspection Port Cover On Engine

    1.5 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min.

  • Page 13: Safety Regulations For Maintenance And Repair Work

    1.6 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
  • Page 14 Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
  • Page 15 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 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

  • Page 16: Auxiliary Materials, Fire Prevention And Environmental Protection

    MTU will provide assistance and advice if emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliability and performance of MTU engines and must be complied with over the entire life cycle of the engine.
  • Page 17 Lead • When working with lead or lead-containing pastes, avoid direct contact with the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust! • Switch on fume extraction system. • After coming into contact with lead or lead-containing materials, wash hands! Acids and alkaline solutions •...
  • Page 18 Used oil Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil. 18 | Safety | MW15412/05E 2011-11...

  • Page 19: Conventions For Safety Instructions In The Text

    1.8 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 20: General Information

    2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).

  • Page 21: Product Description

    2.2 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving end), with direct injection, sequential turbocharging and charge air cooling. The engine is monitored by an engine control and monitoring system (MDEC). Monitoring in the engine room is carried out by the local operating panel (LOP).
  • Page 22 • Data processing logistics for analog and binary signals; • Interface for data transfer to CAN field bus for remote control and ship-side monitoring; • RS 232 interface for connection of MTU dialog unit. Electronic Engine Monitoring Unit (EMU), optional Functions: •...
  • Page 23 5 Fuel line on HP fuel 2 Fuel line on fuel delivery 4 Sealing cone pump pump 6 Fuel line on vent line All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. MW15412/05E 2011-11 | General Information | 23...
  • Page 24 13 Connection, oil line to ac‐ 5 Oil line, lube oil pump 10 Oil line, valve housing tuating cylinder All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are shown. 24 | General Information | MW15412/05E 2011-11...
  • Page 25 Special connections In case of leakage, the following connection types are spray-protected even without a cover and have been confirmed compliant with SOLAS by GL and DNV. Plug-in pipe connection The sleeve (4) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐...
  • Page 26 HP connections 1 Jacket pipe 8 Thrust ring 15 Union nut 2 HP line 9 Union nut 16 Thrust ring 3 O-ring 10 Union nut 17 External pipe of HP line 4 Union nut 11 Connecting piece 18 Internal pipe of HP line 5 Recess for O-ring 12 Snap ring 19 Ball-type seal area...
  • Page 27 Shielding of fuel filter and lube oil filter Shielding with a plastic ring The plastic ring (1) precludes lateral spray. The fluid is diverted to the catch basin whereby the pressure is significantly reduced. Shielding by overhang design The overhang (1) prevents lateral spray. The fluid is diverted to the catch basin whereby the pressure is significantly reduced.

  • Page 28: Engine Layout

    2.3 Engine layout 010 Crankcase and attach‐ 110 Intercooler 250 Drive systems, driving ments 120 Air intake / air supply end and free end (cou‐ 020 Gear train 140 Exhaust system pling)* 030 Running gear 170 Starting equipment 360 Auxiliary systems / ac‐ 040 Cylinder head 180 Lube oil system cessory equipment*...
  • Page 29 Key to the engine model designations 8/12/16V 4000 Mxyz 4000 Series Application Application segment (4,5, 6,7,9) Design index (0, 1, 2,...) Special features MW15412/05E 2011-11 | General Information | 29...

  • Page 30: Technical Data

    3 Technical Data 3.1 8V 4000 M70 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 31 Number of cylinders Number of inlet valves per cylinder Number of exhaust valves per cylinder LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas.
  • Page 32 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 33: 4000 M70 Engine Data: Engine-Mounted Heat Exchanger, Imo

    3.2 8V 4000 M70 engine data: engine-mounted heat exchanger, Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 34 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 35 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 36: 4000 M70 Engine Data: Imo -20%, Separate Heat Exchanger, Copper-Based Alloy Intercooler

    3.3 12V 4000 M70 engine data: IMO -20%, separate heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 37 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 38 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 39: 4000 M70 Engine Data: Imo -20%, Engine-Mounted Heat Exchanger, Copper-Based Alloy Intercooler

    3.4 12V 4000 M70 engine data: IMO -20%, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 40 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. +0.5 Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 41 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 42: 4000 M70 Engine Data: Engine-Mounted Heat Exchanger, Epa Stage

    3.5 12V 4000 M70 engine data: engine-mounted heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 43 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 44 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 45: V 4000 M70 Engine Data: Separate Heat Exchanger, Epa Stage 2

    3.6 12V 4000 M70 engine data: separate heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 46 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 47 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 48: 4000 M70 Engine Data: Imo, Separate Heat Exchanger, Copper-Based Alloy Intercooler

    3.7 16V 4000 M70 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 49 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 50 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 51: 4000 M70 Engine Data: Imo, Engine-Mounted Heat Exchanger, Copper-Based Alloy Intercooler

    3.8 16V 4000 M70 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 52 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 53 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 54: 4000 M70 Engine Data: Imo -20%, Separate Heat Exchanger, Copper-Based Alloy Intercooler

    3.9 16V 4000 M70 engine data: IMO -20%, separate heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 55 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 56 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 57: 4000 M70 Engine Data: Imo -20%, Engine-Mounted Heat Exchanger, Copper-Based Alloy Intercooler

    3.10 16V 4000 M70 engine data: IMO -20%, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 58 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. +0.5 Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 59 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 60: 4000 M70 Engine Data: Engine-Mounted Heat Exchanger, Epa Stage

    3.11 16V 4000 M70 engine data: engine-mounted heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 61 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 62 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 63: 4000 M70 Engine Data: Separate Heat Exchanger, Epa Stage

    3.12 16V 4000 M70 engine data: separate heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 64 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 65 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 66: 4000 M71 Engine Data: Imo, Separate Heat Exchanger, Copper-Based Alloy Intercooler

    3.13 12V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 67 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 68 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 69: 4000 M71 Engine Data: Imo, Engine-Mounted Heat Exchanger, Copper-Based Alloy Intercooler

    3.14 12V 4000 M71 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 70 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 71 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 72: 4000 M71 Engine Data: Imo, Separate Heat Exchanger, Copper-Based Alloy Intercooler, Intake Air Temperature

    3.15 12V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler, intake air temperature 45° Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 73 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 74 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 75: 4000 M71 Engine Data: Imo, Separate Heat Exchanger, Copper-Based Alloy Intercooler

    3.16 16V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 76 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 77 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 78: 4000 M71 Engine Data: Imo, Engine-Mounted Heat Exchanger, Copper-Based Alloy Intercooler

    3.17 16V 4000 M71 engine data: IMO, engine-mounted heat exchanger, copper-based alloy intercooler Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 79 RAW-WATER CIRCUIT (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.2 Raw water pump: Inlet pressure , max. Pressure loss in the external raw-water system, max. LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C...
  • Page 80 INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Option: max. degree operating inclinations) Longitudinal inclination, temporary max. driving end down (Option: max. op‐ degree 22.5 erating inclinations) Longitudinal inclination, continuous max. driving end up (Option: max. oper‐ degree ating inclinations) Transverse inclination, continuous max.

  • Page 81: 4000 M71 Engine Data: Imo, Separate Heat Exchanger, Copper-Based Alloy Intercooler, Intake Air Temperature

    3.18 16V 4000 M71 engine data: IMO, separate heat exchanger, copper-based alloy intercooler, intake air temperature 45° Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated without changes (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 82 LUBE OIL SYSTEM Number of cylinders Lube-oil operating temperature before engine, from °C Lube oil temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min.
  • Page 83 CAPACITIES Number of cylinders Engine oil at initial filling (standard oil system) (Option: max. operating incli‐ liter nations) Oil change quantity, max. (standard oil system) (Option: max. operating in‐ liter clinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ liter erating inclinations) Oil pan capacity, dipstick mark max.

  • Page 84: Firing Order

    3.19 Firing order Firing order Number of cylin‐ Firing order ders A1-B4-A4-A2-B3-A3-B2-B1 A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 84 | Technical Data | MW15412/05E 2011-11...

  • Page 85: Engine - Main Dimensions

    3.20 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 8V 4000 M70 approx. 2340 mm approx. 1380 mm approx. 1750 mm 12V 4000 M70 approx. 3220 mm approx. 1520 mm approx. 1835 mm 12V 4000 M71 approx.

  • Page 86: Operation

    4 Operation 4.1 LOP – Controls LOP – Controls Item Color Inscription Meaning / Function White Function keys to control the man-machine inter‐ face. Functions vary and are displayed on the White LCD screen. White White White White ALARM ACKNOWL Pressing the button the first time stops alarm sig‐...
  • Page 87 Item Color Inscription Meaning / Function White DIM ↓ Holding down the button decreases LCD back‐ ground illumination. White LAMP TEST Pressing the button initiates lamp test. TEST OVERSPEED Pressing the button initiates overspeed test. LED (spot) lights up as long as the overspeed test is running.

  • Page 88: Putting The Engine Into Operation After Extended Out-Of-Service Periods

    4.2 Putting the engine into operation after extended out-of- service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after extended out-of-service periods (>3 months) Item Action Engine Depreserve (→...

  • Page 89: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 158); , preheat engine oil, if required. Coolant circuit Check coolant level (→...

  • Page 90: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.4 Tasks after extended out-of-service periods (>3 weeks) Tasks after extended out-of-service periods (>3 weeks) Note: Operate fuel treatment system for at least 5 minutes. Start up fuel treatment system (→ Page 92). Shut down fuel treatment system (→ Page 106). 90 | Operation | MW15412/05E 2011-11...

  • Page 91: Checks Prior To Start-Up

    Checks prior to start-up Check tank and the entire pipework for cleanness. If microorganisms are detected: a) Clean affected components. b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..). Close drain valves on housing. Open all supply and discharge valves.

  • Page 92: Fuel Treatment System - Putting Into Operation

    4.6 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 96). Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system: 0.1 bar to 0.3 bar. Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
  • Page 93 Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 96). Start engine (→ Page 94). Run engine at idling speed. Close ball cock (5) at the inlet to the fuel treatment system. Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass (3) and bypass (2).

  • Page 94: Starting The Engine From Lop

    4.7 Starting the engine from LOP Preconditions ☑ Gearbox is in neutral position. ☑ External start interlock is not activated. ☑ Emergency air shutoff flaps (if fitted) are open. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...

  • Page 95: Starting The Engine At The Blueline Automation System (Control Stand)

    4.8 Starting the engine at the BlueLine automation system (control stand) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 96: Fuel Treatment System - Switching On

    4.9 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant is ready for operation. • Before switching on, ensure that all housings are closed. •...

  • Page 97: Operational Checks

    4.10 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 98: Clutch - Engaging From Lop

    4.11 Clutch – Engaging from LOP Preconditions ☑ LOCAL OPERATION button is illuminated brightly (local operating mode is active). ☑ Engine speed is within range for clutch engagement. ☑ No external clutch engagement interlock is activated. DANGER Vessel is sailing blind. In Local Operation mode, the propulsion plant is controlled from the engine room.

  • Page 99: Clutch - Disengaging From Lop

    4.12 Clutch – Disengaging from LOP Preconditions ☑ LOCAL OPERATION button is illuminated brightly (local operating mode is active). ☑ Engine speed in disengagement window. Disengaging clutch without reversing gearbox (CPP, WJ, VS) Item Action Press CLUTCH OUT button (→ Page 86). •...

  • Page 100: Waterjet - Flushing From Lop (Optional)

    4.13 Waterjet – Flushing from LOP (optional) Preconditions ☑ LOCAL OPERATION button is illuminated brightly (local operating mode is active). ☑ Vessel at a standstill and Waterjet bucket below the waterline. ☑ Engine speed is within range for clutch engagement. ☑...

  • Page 101: Stopping The Engine From Lop

    4.14 Stopping the engine from LOP Preconditions ☑ Engine is running in local mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed.

  • Page 102: Stopping The Engine At The Blueline Automation System (Control Stand)

    4.15 Stopping the engine at the BlueLine automation system (control stand) CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until engine temperatures have dropped and constant values are displayed.

  • Page 103: Emergency Stop From Lop

    4.16 Emergency stop from LOP CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Action Open cap of EMERGENCY STOP button (→ Page 86). Press EMERGENCY STOP button.

  • Page 104: Engine Emergency Stop At Blueline Automation System (Control Stand)

    4.17 Engine emergency stop at BlueLine automation system (control stand) CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Engine emergency stop at BlueLine automation system (→...

  • Page 105: After Stopping The Engine

    4.18 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. After stopping the engine Item Action Coolant circuit Drain coolant (→ Page 169) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze additive;...

  • Page 106: Fuel Treatment System - Shutdown

    4.19 Fuel treatment system – Shutdown Shutting down fuel treatment system Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.

  • Page 107: Plant - Cleaning

    4.20 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 108: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 109: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Measure Battery Discharged or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine cabling or starter faulty Check if cable connections are proper‐...
  • Page 110 Faulty Contact Service. Charge-air temperature too high Component Cause Measure Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge-air pressure too low...
  • Page 111 Blue exhaust gas Component Cause Measure Engine oil Too much oil in engine Drain engine oil (→ Page 159). Oil separator or oil preseparator of Replace. crankcase breather clogged Exhaust turbocharg‐ Faulty Contact Service. er, cylinder head, pis‐ ton rings, cylinder lin‐ White exhaust gas Component Cause...

  • Page 112: Lop Fault Messages

    6.2 LOP fault messages Fault messages and measuring points (status reports) are displayed as text messages on the LOP dis‐ play (DIS). Explanation of the displayed texts can be gathered by pressing the help button on the touch screen. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sen‐ sors/actuators checked and replaced as necessary if the troubleshooting measures listed in the table be‐...

  • Page 113: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet head with extension F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 114: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Barring using the automation system Refer to automation system operating instructions 114 | Task Description | MW15412/05E 2011-11...

  • Page 115: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 128). Remove injector (→...
  • Page 116 Final steps Install injector (→ Page 131). Install cylinder head cover (→ Page 128). 116 | Task Description | MW15412/05E 2011-11...

  • Page 117: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.2.2 Cylinder liner - Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 118 Findings Measure Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1.

  • Page 119: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator check Preconditions ☑ Engine is running Checking oil separator Note: A thin oil film is admissible. Check oil separator for damage and exces‐ sive oil discharge (arrow). Replace oil separator if it is defective (→...

  • Page 120: Crankcase Breather - Oil Separator Replacement, Diaphragm Check And Replacement

    7.3.2 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Engine oil Filter element (→...
  • Page 121 Crankcase breather – replacing filter element (variant B) Remove cover (2) with O-ring (3). Remove filter element (1) from housing (4). Insert new filter element in housing (4). Install cover (2) with new O-ring. Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Size Type...

  • Page 122: Valve Drive

    7.4 Valve Drive 7.4.1 Valve gear - Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear (valve bridge with guide) Remove cylinder head covers (→...

  • Page 123: Valve Clearance - Check And Adjustment

    7.4.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 Torque wrench 10-60 Nm F30510423...
  • Page 124 Checking valve bridge balance X Valve bridge with guide Y Flying valve bridge Note: Not applicable for engines with flying valve bridge. Prior to adjusting valve clearance, check valve bridge balance on all valve bridges. Use feeler gauge to determine distance be‐ tween valve bridge and rocker arm.
  • Page 125 Insert feeler gauge with determined value between valve bridge and valve-stem end (A). At the opposite valve-stem end (B), a feeler gauge thicker by 0.05 mm should not fit, otherwise adjust valve bridge balance. Adjusting valve bridge balance Note: Not applicable for engines with flying valve bridge.
  • Page 126 Tighten locknut (2) to 35 Nm +5 Nm, hold‐ ing valve bridge (1) in position with open- end spanner. Re-check valve bridge balance. Checking valve clearance at two crankshaft positions 1 Cylinder A1 is in firing 2 Cylinder A1 is in overlap I Inlet valve X Exhaust valve Check TDC position of piston in cylinder A1:...

  • Page 127: Adjusting Valve Clearance

    Adjusting valve clearance Release locknut (1). Insert feeler gauge between valve bridge and rocker arm. Turn adjusting screw (2) with Allen key until appropriate valve clearance is set. Feeler gauge must just pass through the gap. Tighten locknut (1) to 90 +9 Nm, holding adjusting screw (2) firm.

  • Page 128: Cylinder Head Cover - Removal And Installation

    7.4.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean cylinder head covers prior to removal if they are heavily soiled.

  • Page 129: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 HP pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 130: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 131). 130 | Task Description | MW15412/05E 2011-11...

  • Page 131: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal tool for injector F6790161 Milling cutter F30452739 Slotted nut screwdriver F30452578 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30510423...
  • Page 132 Removing injector Note: Always replace the first and last injectors of one engine side first. Replace the inner in‐ jectors only after the installation of the outer injectors on this engine side is completed. Undo cable terminal screws (arrow) on in‐ jector and remove cable terminals.
  • Page 133 Remove sealing ring (1) from injector or use a self-made wire hook to extract it from the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs. Installing injector Remove all plugs before installing. Coat nozzle retaining nut area of injector with assembly paste.
  • Page 134 Use slotted screwdriver to check thrust ring at both line ends for secure seating. Tighten loose thrust ring to the specified tightening torque. Name Size Type Lubricant Value/Standard Thrust ring Tightening torque 5 Nm to 10 Nm Coat screw head mating face (2) and thread with engine oil.
  • Page 135 Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 140 Nm + 10 Nm Tighten union nut of connecting piece (injector) to specified torque using a torque wrench. Name Size Type...

  • Page 136: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting and filling Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filling device B80144852 Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 137 Venting and filling HP fuel system Connect filling device to connection (3). Remove flushing line (4) from HP pump (1). Connect return hose of filling device to HP pump (1). Unscrew vent line (8) from connection (7). Seal connection (7) with sealing cone. Note: During filling, the opening of the valves in the HP pump must be audible (whistling noise).

  • Page 138: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Plastic ring (→...
  • Page 139 Replacing fuel filter with the engine stopped Cut out the filter to be replaced. A Both filters cut in (operating position) B Left filter cut out C Right filter cut out Unscrew cut-out easy-change filter with oil filter wrench. Clean sealing face on filter head. Check sealing ring on new easy-change fil‐...

  • Page 140: Fuel Prefilter - Draining

    7.8.2 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 141: Fuel Prefilter - Flushing

    7.8.3 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 142 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

  • Page 143: Fuel Prefilter - Differential Pressure Gauge Check And Adjustment

    7.8.4 Fuel prefilter – Differential pressure gauge check and adjustment DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 144: Fuel Prefilter - Filter Element Replacement

    7.8.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 145 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3).

  • Page 146: Exhaust Turbocharger

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Endoscope Y20097353 Engine oil Assembly paste (Ultra-Therm MTU) 50547 Turbine housing (→ Spare Parts Catalog) Removing oil supply Note: Procedure is only described for one side; applies inversely to the other side.
  • Page 147 Removing turbine housing Note: Mark positions of housing in relation to one another. Remove nuts (2) from turbine housing (4). Remove nuts (2) with spacer sleeves (3). Remove turbine housing (4) from bearing housing (1). Checking turbine housing Check turbine housing from the inside for cracks.
  • Page 148 Type Lubricant Value/Standard Tightening torque (Assembly paste (Ul‐ 21 Nm ±2.5 Nm tra-Therm MTU)) Installing exhaust line and charge- air line Insert exhaust turbocharger (3) into Y-pipe. Insert gasket (2). Screw in screws (1). Tighten screws (1) diagonally and evenly to specified tightening torque.
  • Page 149 Installing oil supply Insert gasket (3). Install oil line (1) with screws (2). Screw union nut (5) onto oil line (6). Tighten union nut (5) to specified tightening torque. Name Size Type Lubricant Value/Standard Union nut M18x1.5 Tightening torque 40 Nm +4 Nm MW15412/05E 2011-11 | Task Description | 149...

  • Page 150: Compressor Wheel - Cleaning

    7.9.2 Compressor wheel – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cold cleaner X00056750 WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. •...

  • Page 151: Charge-Air Cooling

    7.10 Charge-Air Cooling 7.10.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 152: Air Filter

    7.11 Air Filter 7.11.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Remove old air filter and install new air filter . (→ Page 153) Reset contamination indicator signal ring. (→...

  • Page 153: Air Filter - Removal And Installation

    7.11.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation Loosen clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it.

  • Page 154: Starting Equipment

    7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws and pressure hose of starter for secure seating and tighten if required. Check wiring (→ Page 188). 154 | Task Description | MW15412/05E 2011-11...

  • Page 155: Air Starter - Manual Operation

    7.12.2 Air starter – Manual operation DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 156: Air Intake

    7.13 Air Intake 7.13.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 152). After installation of new filter, press reset button (1).

  • Page 157: Air Flap - Check For Ease Of Movement

    7.13.2 Air flap – Check for ease of movement Preconditions ☑ Engine is stopped and starting disabled. Checking air flap for easy movement Actuate lever several times to check ease of movement. Result: The spring must push back the air flap. If spring does not return air flap to initial po‐...

  • Page 158: Lube Oil System, Lube Oil Circuit

    7.14 Lube Oil System, Lube Oil Circuit 7.14.1 Engine oil level – Check Preconditions ☑ Engine shut down and starting disabled. Checking oil level prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.

  • Page 159: Engine Oil - Change

    7.14.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200 Nm...
  • Page 160 Tighten drain plugs (2) and (3) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm Filling with new engine oil Open cap on filler neck. Pour in engine oil at filler neck up to “max.”...

  • Page 161: Engine Oil - Sample Extraction And Analysis

    7.14.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Unguarded rotating and moving engine components.

  • Page 162: Oil Filtration / Cooling

    7.15 Oil Filtration / Cooling 7.15.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 163: Engine Running

    Oil filter replacement with the engine running To cut out the filter to be replaced, set the three-way cock to the corresponding posi‐ tion. • Position A: Lower filters cut out • Position B: Both filters cut in (normal po‐ sition) •...

  • Page 164: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement

    7.15.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Cold cleaner (Hakutex 60) 50602 Grease (Kluthe Hakuform 30-10/emulsifier)
  • Page 165 Cleaning centrifugal oil filter and replacing filter sleeve Undo screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7). Take off rotor cap (8).

  • Page 166: Coolant Circuit, General, High-Temperature Circuit

    7.16 Coolant Circuit, General, High-Temperature Circuit 7.16.1 Venting points Coolant lines on ETC 1 Venting point Vent line – Cross-distributionn expansion tank 1 Venting point 166 | Task Description | MW15412/05E 2011-11...

  • Page 167: Coolant Level - Check

    7.16.2 Coolant level - Check Preconditions ☑ Engine shut down and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 168: Engine Coolant - Change

    7.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 169). Fill with engine coolant (→ Page 170). 168 | Task Description | MW15412/05E 2011-11...

  • Page 169: Engine Coolant - Draining

    7.16.4 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide an appropriate container to drain the coolant into.

  • Page 170: Engine Coolant - Filling

    7.16.5 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 171 Filling with coolant using a pump Connect appropriate pump with hose to fill‐ ing connection (arrow) on A side or B side. Alternatively: Connect a suitable pump with a hose to the drain valve (arrow). Pump coolant into engine at 0.5 bar mini‐ mum until coolant emerges from the loos‐...
  • Page 172 Filling with coolant through filler neck Alternatively: Fill coolant through filler neck on expansion tank until coolant emerges from the loosened unions at the coolant distribution. Tighten the union for coolant line at the coolant distributor (→ Page 166). Continue to fill until coolant level remains constant at top edge of filler neck. Tighten the coolant line union on both turbochargers (→...

  • Page 173: Engine Coolant Pump - Relief Bore Check

    7.16.6 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 174: Coolant - Sample Extraction And Analysis

    7.16.7 Coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...

  • Page 175: Raw Water Pump With Connections

    7.17 Raw Water Pump with Connections 7.17.1 Raw water pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 176: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine shut down and starting disabled. Checking condition of battery- charging generator drive coupling Remove protective cover. Check resilient coupling for cracks and de‐ formation (arrow). Contact Service in case of severe deforma‐ tion or cracking.

  • Page 177: Engine Mounting / Support

    7.19 Engine Mounting / Support 7.19.1 Engine mounts – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled. Engine mounts – Checking securing screws for firm seating Check securing screws for firm seating. Tighten loose threaded connections. MW15412/05E 2011-11 | Task Description | 177...

  • Page 178: Engine Mounts - Resilient Element Check

    7.19.2 Engine mounts – Resilient element check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is filled with coolant and engine oil. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 Calipers Y20001743 Box wrench F30379609 Engine oil...
  • Page 179 Engine mounts – Checking buffer clearance Take off protective cap (2). Check marking (1): • With marking 30: a = 3 mm +0,3 mm. • With marking 40: a = 4 mm +0,3 mm. Check dimension (a) with feeler gauge on measuring groove (4).

  • Page 180: Drive Systems, Driving End And Free End (Coupling)

    7.20 Drive Systems, Driving End and Free End (Coupling) 7.20.1 Coupling – Condition check Preconditions ☑ Engine is stopped and starting disabled. Coupling – Condition check Remove perforated plate(s). Wipe rubber element with dry cloth, do not use organic detergents. Check condition of coupling through assembly hole(s), using a torch.

  • Page 181: Auxiliary Pto

    7.21 Auxiliary PTO 7.21.1 Bilge pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 182: Fuel Supply System

    7.22 Fuel Supply System 7.22.1 Water drain valve – Check Checking water drain valve Open water drain valve. Check water outlet for obstructions. Close water drain valve. 182 | Task Description | MW15412/05E 2011-11...

  • Page 183: Differential Pressure Gauge - Check

    7.22.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking differential pressure gauge Switch on fuel treatment system (→ Page 96). Set the alarm points at the differential pressure gauge to zero.

  • Page 184: Water Level Probe (3-In-1 Rod Electrode Check

    7.22.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) –...

  • Page 185: Pump Capacity - Check

    7.22.4 Pump capacity – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking pump capacity Install suitable pressure gauge at the neck of the intake side of the pump. Check pump pressure.

  • Page 186: Coalescer Filter Element - Replacement

    7.22.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 187 Tighten nut (3) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system.

  • Page 188: Wiring (General) For Engine/Gearbox/Unit

    7.23 Wiring (General) for Engine/Gearbox/Unit 7.23.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 189: Accessories For (Electronic) Engine Governor / Control System

    7.24 Accessories for (Electronic) Engine Governor / Control System 7.24.1 Engine control unit and connectors – Cleaning Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol 46181 Cleaning engine control unit and connectors...

  • Page 190: Engine Monitoring Unit And Connectors - Cleaning

    7.24.2 Engine monitoring unit and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol 46181 Cleaning engine monitoring unit and connectors Remove coarse contamination from hous‐ ing surface with isopropyl alcohol.

  • Page 191: Start Interlock Limit Switch - Check

    7.24.3 Start interlock limit switch – Check Preconditions ☑ Engine is stopped and starting disabled. Note: Being in OFF-position, the limit switch initiates start interlock, i.e. the engine cannot be started. Start interlock limit switch – Check Check if switch housing (1) and cover plate (3) are mounted and the switch (2) is in ON- position.

  • Page 192: Checking Engine Control Unit Plug Connections

    7.24.4 Checking engine control unit plug connections Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking engine control unit plug connections Use connector pliers (3) to make certain that all plug-in connections on engine con‐...

  • Page 193: Engine Monitoring Unit, Plug Connections - Check

    7.24.5 Engine monitoring unit, plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking engine monitoring unit plug connections Use connector pliers (3) to make certain that all engine monitoring unit plug connec‐...

  • Page 194: Engine Control Unit - Removal And Installation

    7.24.6 Engine control unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Covering caps for Cannon sockets Removing control unit from engine Note or mark assignment of cables to con‐...
  • Page 195 Disconnect ground strap from engine con‐ trol unit grounding stud (7). If the screws (4) are easily accessible: 1. Remove screws (4). 2. Remove engine control unit housing (3) from mounting plates (2). 3. Unscrew mounting plates (2), cable shock absorbers (5) and further fasten‐ ing parts (6) as one unit from engine.

  • Page 196: Lop - Visual Inspection

    7.24.7 LOP – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps If READY FOR OPERATION button is illuminated brightly, press switch briefly. Result: READY FOR OPERATION button returns to basic brightness. Switch master power switch to OFF. Disconnect battery in accordance with battery manufacturer's instructions.
  • Page 197 Checking unassigned connector sockets Ensure that non-assigned connector sock‐ ets are protected with covering caps. Make certain that the two securing ele‐ ments (1) are engaged in the lugs (2) so that the covering cap (3) is held firmly in place in the socket.

  • Page 198: Abbreviations

    American National Standards Institute Governing body for US American standards Abgasturbolader Exhaust turbocharger Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica‐ tion No. A01061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller Deutsches Institut für Normung e. V German Standardization Organization, at the same time identifyer of German standards ("Deutsche In‐...

  • Page 199: Mtu Contacts/Service Partners

    Tools Catalog Zugehörigkeit-Kategorie-Parameter Numbering plan for ADEC ECU signals MTU contacts/service partners Service Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures fast and direct support on site and the high availability of our products.
  • Page 200 Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply.

  • Page 201: Spare Parts

    9 Appendix B 9.1 Spare Parts Air filter Part No.: Qty.: Used in: 7.11.1 Air filter – Replacement (→ Page 152) Coalescer filter element Part No.: Qty.: Used in: 7.22.5 Coalescer filter element – Replacement (→ Page 186) Diaphragm Part No.: Qty.: Used in: 7.3.2 Crankcase breather –...
  • Page 202 Gasket Part No.: Qty.: Used in: 7.3.2 Crankcase breather – Oil separator replacement, diaphragm check and replace‐ ment (→ Page 120) Qty.: Used in: 7.4.3 Cylinder head cover – Removal and installation (→ Page 128) Qty.: Used in: 7.8.2 Fuel prefilter – Draining (→ Page 140) Qty.: Used in: 7.8.3 Fuel prefilter ‒...

  • Page 203: Special Tools

    9.2 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 113) Box wrench Part No.: F30379609 Qty.: Used in: 7.19.2 Engine mounts – Resilient element check (→ Page 178) Calipers Part No.: Y20001743 Qty.: Used in:...
  • Page 204 7.6.2 Injector – Removal and installation (→ Page 131) Milling cutter Part No.: F30452739 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 131) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.14.3 Engine oil – Sample extraction and analysis (→ Page 161) Qty.: Used in: 7.16.7 Coolant –...
  • Page 205 Ratchet head with extension Part No.: F30006212 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 113) Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 115) Slotted nut screwdriver Part No.: F30452578 Qty.: Used in:...
  • Page 206 Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 7.14.2 Engine oil – Change (→ Page 159) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.22.5 Coalescer filter element – Replacement (→ Page 186) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.:...

  • Page 207: Index

    9.3 Index 12V 4000 M70 engine data: engine-mounted heat ex‐ Bilge pump changer, EPA stage 2 42 – Relief bore check  181 12V 4000 M70 engine data: IMO -20%, engine-mounted heat exchanger, copper-based alloy intercooler 39 Centrifugal oil filter 12V 4000 M70 engine data: IMO -20%, separate heat –...
  • Page 208 – Replacement  162 Engine oil level Maintenance and repair work – Check  158 – Safety regulations  13 Engine side and cylinder MTU contact persons 199 – Designations  20 Engine starting from the BlueLine automation system (control stand) 95 Operational checks  97 Engine wiring –...
  • Page 209 Transport 10 Troubleshooting 109 Turbine housing – Check  146 Valve clearance – Adjsutment  123 – Check  123 Valve gear – Lubrication  122 Venting points 166 Water drain valve – Check  182 Water level probe (3-in-1 rod electrode) – Check  184 Waterjet – Flushing from LOP (optional) 100 Wiring - engine –...

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