MTU V 4000 M70 Operating Instructions Manual Download Page 131

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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

Torque wrench, 60-320 Nm

F30047446

Assembly paste (Optimoly Paste White T)

40477

Grease (Kluthe Hakuform 30-10/emulsifier)

X00058060

Engine oil

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

CAUTION

Removal of all injectors.

Damage to component!

• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.

CAUTION

Cable damage during operation.

Fire hazard!

• Twist cables when installing.

• Ensure that cables do not touch components.

Preparatory steps

Shut off fuel inlet to engine.

Remove cylinder head cover (→ Page 128).

MW15412/05E 2011-11 | Task Description | 131

TIM-ID: 0000000952 - 004

Summary of Contents for V 4000 M70

Page 1: ...Operating Instructions Diesel engine V 4000 M70 V 4000 M71 Application group 1B MW15412 05E...

Page 2: ...ten 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 on...

Page 3: ...portant 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...

Page 4: ......

Page 5: ...ne mounted heat exchanger copper based alloy intercooler 57 3 11 16V 4000 M70 engine data engine mounted heat exchanger EPA stage 2 60 3 12 16V 4000 M70 engine data separate heat exchanger EPA stage 2...

Page 6: ...adjustment 143 7 8 5 Fuel prefilter Filter element replacement 144 7 9 Exhaust Turbocharger 146 7 9 1 Exhaust turbocharger Turbine housing check 146 7 9 2 Compressor wheel Cleaning 150 7 10 Charge Air...

Page 7: ...1 Engine wiring Check 188 7 24 Accessories for Electronic Engine Governor Control System 189 7 24 1 Engine control unit and connectors Cleaning 189 7 24 2 Engine monitoring unit and connectors Cleani...

Page 8: ...other use is considered improper use The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case The responsibility is borne by the user alone Correct use also...

Page 9: ...accessible to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair In particular person nel must have r...

Page 10: ...truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transportation The engine must be addi...

Page 11: ...ing units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must be taken if a malfunction of the system...

Page 12: ...ry danger to life Allow the engine to cool down before opening the crankcase Avoid open flames electrical sparks and ignition sources Safety instructions u Before starting maintenance work allow the e...

Page 13: ...ions clean Always seal connections with caps or covers if a line is removed or opened Take care not to damage lines in particular fuel lines during maintenance and repair work Ensure that all retainer...

Page 14: ...haft end until correct sealing is established During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working on ele...

Page 15: ...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 surfac...

Page 16: ...n of additional compo nents as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations Emission control units...

Page 17: ...air is air compressed at excess pressure and is stored in tanks from which it can be extract ed The pressure at which the air is kept can be read off at pressure gauges which must be connected to the...

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 TIM ID 0000002828 004...

Page 19: ...es Minor injury or material damage Remedial action Note This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed ab...

Page 20: ...ted A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end of the engine Other components are numbered in the s...

Page 21: ...lute gas tightness Turbocharging Sequential turbocharging with internal engine coolant controlled charge air cooling The right hand ex haust turbocharger is cut in and cut out with electronically cont...

Page 22: ...ntrol and ship side monitoring Electronic Gear Control Unit GCU ship side wall mounting Functions Data processing logistics for gear coupling control Input output signals as well as data transfer to C...

Page 23: ...urn line 2 Fuel line on fuel delivery pump 3 Check valve 4 Sealing cone 5 Fuel line on HP fuel pump 6 Fuel line on vent line All lines with SOLAS compliant covers for pipe connections according to MTU...

Page 24: ...line on control block 8 Oil line on control block 9 Oil lines on T piece 10 Oil line valve housing 11 Oil line actuating cylinder to control block 12 Oil line actuating cylinder to control block 13 C...

Page 25: ...significantly if an O ring 3 defect oc curs The connection is confirmed as compliant with SOLAS by DNV and GL Plugs and sensors Screw in plugs 2 are sealed toward the outside either with a copper seal...

Page 26: ...type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 If leakage in the area of the thrust ring 8 or the HP line 5 occurs the emerging fuel is routed to the leakage ch...

Page 27: ...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...

Page 28: ...system 210 Electric power supply en gine related 230 Mounting system 250 Drive systems driving end and free end cou pling 360 Auxiliary systems ac cessory equipment 500 Monitoring and control system...

Page 29: ...e engine model designations 8 12 16V 4000 Mxyz 4000 Series m Application x Application segment 4 5 6 7 9 Y Design index 0 1 2 z Special features MW15412 05E 2011 11 General Information 29 TIM ID 00000...

Page 30: ...emperature C 25 Raw water inlet temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders...

Page 31: ...ow max R liter min 15 5 GENERAL OPERATING DATA Number of cylinders 8 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 8 Starter rated voltage standard design...

Page 32: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 140 WEIGHTS MAIN DIMENSIONS Number of cylinders 8 Engine dry weight with attached standard accessories without c...

Page 33: ...pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 8 Engine rated speed A rpm 2000 Fuel stop power ISO 3046 A k...

Page 34: ...L SYSTEM Number of cylinders 8 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 35: ...0 Engine oil at initial filling standard oil system Option max operating incli nations R liter 145 Oil change quantity max standard oil system Option max operating in clinations R liter 120 Oil pan ca...

Page 36: ...5 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 2000 Fuel stop powe...

Page 37: ...er of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 38: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without...

Page 39: ...C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 2000 Fuel stop p...

Page 40: ...SYSTEM Number of cylinders 12 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 41: ...oil system Option max operating incli nations R liter 265 Oil change quantity max standard oil system Option max operating in clinations R liter 215 Oil pan capacity dipstick mark min standard oil sy...

Page 42: ...ic pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 2000 Fuel stop power ISO 3046...

Page 43: ...SYSTEM Number of cylinders 12 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 44: ...oil system Option max operating incli nations R liter 265 Oil change quantity max standard oil system Option max operating in clinations R liter 215 Oil pan capacity dipstick mark min standard oil sy...

Page 45: ...pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 2000 Fuel stop power ISO 3046 A...

Page 46: ...er of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 47: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without...

Page 48: ...Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop power...

Page 49: ...er of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 50: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 230 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without...

Page 51: ...25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop po...

Page 52: ...SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 53: ...oil system Option max operating incli nations R liter 320 Oil change quantity max standard oil system Option max operating in clinations R liter 250 Oil pan capacity dipstick mark min standard oil sy...

Page 54: ...5 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop powe...

Page 55: ...er of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 56: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 230 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without...

Page 57: ...C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop...

Page 58: ...SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 59: ...oil system Option max operating incli nations R liter 320 Oil change quantity max standard oil system Option max operating in clinations R liter 250 Oil pan capacity dipstick mark min standard oil sy...

Page 60: ...ric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop power ISO 304...

Page 61: ...SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 62: ...oil system Option max operating incli nations R liter 320 Oil change quantity max standard oil system Option max operating in clinations R liter 250 Oil pan capacity dipstick mark min standard oil sy...

Page 63: ...pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop power ISO 3046 A...

Page 64: ...er of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 65: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 230 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without...

Page 66: ...Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 2000 Fuel stop power...

Page 67: ...SYSTEM Number of cylinders 12 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 68: ...oil system Option max operating incli nations R liter 265 Oil change quantity max standard oil system Option max operating in clinations R liter 215 Oil pan capacity dipstick mark min standard oil sy...

Page 69: ...25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 2000 Fuel stop po...

Page 70: ...er of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 71: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without...

Page 72: ...perature C 32 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 Engine rated speed A rpm 2000 Fu...

Page 73: ...er of cylinders 12 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 12 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 74: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 200 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight with attached standard accessories without...

Page 75: ...Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop power...

Page 76: ...er of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 77: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 230 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without...

Page 78: ...25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fuel stop po...

Page 79: ...SYSTEM Number of cylinders 16 Fuel pressure at engine supply connection min when engine is starting L bar 0 1 Fuel pressure at supply connection to engine when engine is running min L bar 0 3 Fuel pr...

Page 80: ...oil system Option max operating incli nations R liter 320 Oil change quantity max standard oil system Option max operating in clinations R liter 250 Oil pan capacity dipstick mark min standard oil sy...

Page 81: ...perature C 32 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2000 Fu...

Page 82: ...er of cylinders 16 Firing speed from R rpm 80 Firing speed to R rpm 120 STARTING electric Number of cylinders 16 Starter rated voltage standard design R V 24 STARTING with pneumatic hydraulic starter...

Page 83: ...pacity dipstick mark max standard oil system Option max op erating inclinations L liter 230 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached standard accessories without...

Page 84: ...ng order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V 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 T...

Page 85: ...prox 1380 mm approx 1750 mm 12V 4000 M70 approx 3220 mm approx 1520 mm approx 1835 mm 12V 4000 M71 approx 3220 mm approx 1520 mm approx 1835 mm 16V 4000 M70 approx 3690 mm approx 1520 mm approx 1835 m...

Page 86: ...the LCD screen 2 White F2 3 White F3 4 White F4 5 White F5 6 White ALARM ACKNOWL Pressing the button the first time stops alarm sig nalization Pressing the button a second time acknowledges an active...

Page 87: ...E Engine speed is increased as long as the button is held down 15 White ENGINE SPEED DE CREASE Engine speed is decreased as long as the button is held down 16 Green READY FOR OPERA TION Pressing the b...

Page 88: ...el Page 144 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 143 Fuel system Vent Page 136 Raw water pump if raw water pump lies above the water line Fil...

Page 89: ...lant circuit Check coolant level Page 167 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water Page 140 Check if suction side pressure indicated at the fuel pref...

Page 90: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 92 2 Shut down fuel treatment system Page 106 90...

Page 91: ...ves 4 Switch on fuel treatment system Page 96 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Page 92: ...ine 3 Switch on fuel treatment system and operate it for some minutes Page 96 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 93: ...ency HAT 1 Switch on fuel treatment system Page 96 2 Start engine Page 94 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel vi...

Page 94: ...Starting the engine from LOP Item Action Engine Start in unloaded condition Plant Switch on LOP LOCAL OPERATION button lights up brightly local control mode is ac tive Page 86 GEARBOX NEUTRAL button...

Page 95: ...ing the engine make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Barring engine with out of service period 1 month Item Actio...

Page 96: ...hing on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Switching on fuel treatment system 1 Carry out checks prior to start up...

Page 97: ...haust color Page 109 HP pump Check relief bore Page 129 Fuel prefilter Check fuel prefilter maintenance indicator for max admissible value Page 143 Drain off water and dirt Page 140 Intercooler Check...

Page 98: ...IN button Page 86 CLUTCH IN button flashes Clutch is engaged After receiving the feedback signal from clutch the CLUTCH IN button is illuminated brightly Engaging clutch in ahead direction with rever...

Page 99: ...CLUTCH OUT button flashes Clutch is disengaged After receiving the feedback signal from clutch the CLUTCH OUT but ton is illuminated brightly Disengaging clutch with reversing gearbox FPP WJ Item Acti...

Page 100: ...age Do not flush waterjet for too long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Action LOP Press FLUSH button and keep pressed Page 86 FL...

Page 101: ...and run the engine at idle speed for at least 10 mins until engine temperatures have dropped and constant values are displayed Stopping the engine from LOP Item Action LOP Disengage gearbox Page 86 LO...

Page 102: ...o 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 valu...

Page 103: ...ting the power supply to the ECU On engines with emergency air shutoff flaps flaps close EMERGENCY STOP button flashes Horn flashing lamp etc are trip ped After emergency stop from LOP Item Action LOP...

Page 104: ...ergency 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 u Blu...

Page 105: ...at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water Drain If free...

Page 106: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 107: ...sensors with compressed air Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into...

Page 108: ...r element Page 138 W1005 Replace air filter Page 152 W1006 Replace fuel injectors Page 130 W1008 Replace engine oil filter at each oil change or when the time limit years is reached at the latest Page...

Page 109: ...manually Contact Service Engine turns but does not fire Component Cause Measure Starter Poor rotation by starter Battery dis charged or faulty Charge or replace battery see manu facturer s documentat...

Page 110: ...act Service Engine room Air intake temperature too high Check fans and air supply ventilation ducts Charge air pressure too low Component Cause Measure Air supply Air filter clogged Check signal ring...

Page 111: ...charg er cylinder head pis ton rings cylinder lin er Faulty Contact Service White exhaust gas Component Cause Measure Engine Not at operating temperature Run engine to reach operating temper ature Fue...

Page 112: ...ayed 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...

Page 113: ...ore barring the engine ensure that nobody is in the danger zone Engine Barring manually 1 Remove guard plate Result Safety switch preventing engine starting ac tivated 2 Engage barring device 2 in rin...

Page 114: ...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 TIM ID 0000017532 003...

Page 115: ...ns First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are...

Page 116: ...Final steps 1 Install injector Page 131 2 Install cylinder head cover Page 128 116 Task Description MW15412 05E 2011 11 TIM ID 0000000015 009...

Page 117: ...moothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Bright area Bright areas are on the running surface and show local removal of the honing p...

Page 118: ...ion starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the pis ton skirt or the piston crown Material deposits on the...

Page 119: ...econditions Engine is running Checking oil separator Note A thin oil film is admissible 1 Check oil separator for damage and exces sive oil discharge arrow 2 Replace oil separator if it is defective P...

Page 120: ...ING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale o...

Page 121: ...oil separator elements in the same way Checking diaphragm variant B 1 Remove cover 4 2 Remove spring 5 gasket 2 and dia phragm 3 3 Check diaphragm 3 for damage fit new diaphragm if used one is damaged...

Page 122: ...linder head covers Page 128 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjust ing screws with oil 4 Install cylinder head covers Page 128 Lubricating valve ge...

Page 123: ...Part No Qty Feeler gauge Y20010128 1 Torque wrench 10 60 Nm F30510423 1 Torque wrench 60 320 Nm F30047446 1 Socket box wrench F30039518 1 Preparatory steps 1 Remove cylinder head cover Page 128 2 Inst...

Page 124: ...te Not applicable for engines with flying valve bridge 1 Prior to adjusting valve clearance check valve bridge balance on all valve bridges 2 Use feeler gauge to determine distance be tween valve brid...

Page 125: ...with open end spanner and release locknut 2 2 Use feeler gauge to determine distance be tween valve bridge and rocker arm 3 Place one feeler gauge of the determined value each between valve bridge and...

Page 126: ...A1 the piston is in firing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 2 mm Exhaust valve...

Page 127: ...arance is set 4 Feeler gauge must just pass through the gap 5 Tighten locknut 1 to 90 9 Nm holding adjusting screw 2 firm 6 Replace or rectify adjusting screws and or locknuts which do not move freely...

Page 128: ...r head cover 1 Clean cylinder head covers prior to removal if they are heavily soiled 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1 Clean...

Page 129: ...s Checking HP pump relief bore 1 Check relief bore for oil and fuel discharge by visual inspection 2 If relief bore is contaminated stop the en gine disable engine start and clean relief bore 3 Note t...

Page 130: ...or Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 131 130 Task Description M...

Page 131: ...40477 1 Grease Kluthe Hakuform 30 10 emulsifier X00058060 1 Engine oil WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke C...

Page 132: ...e side is completed 1 Undo cable terminal screws arrow on in jector and remove cable terminals 2 Remove screw 2 and take off hold down clamp 1 3 Remove high pressure fuel line 5 4 Install installation...

Page 133: ...th assembly paste 3 Fit new O rings on injector and coat with grease 4 Fit new sealing ring on injector with grease ensuring correct installation position of seal ing ring 5 Clean sealing surface on c...

Page 134: ...nch to the specified initial tightening torque Name Size Type Lubricant Value Standard Screw M12 Preload torque Engine oil 5 Nm to 10 Nm 13 Fit O rings 4 and 6 on high pressure fuel line 5 and coat wi...

Page 135: ...ue wrench Name Size Type Lubricant Value Standard Union nut Tightening torque 120 Nm 10 Nm 18 Twist cable several times 19 Insert cable terminals arrows underneath screws on injector and tighten screw...

Page 136: ...nd explosion Avoid open flames electrical sparks and ignition sources Do not smoke Venting and filling LP fuel system 1 Connect filling device to connection 2 2 Open vent plugs 6 on filter 5 3 Use han...

Page 137: ...must be provided 6 Fill fuel system with hand pump providing 9 bar minimum pressure 7 If no whistling sound is audible pump must be operated faster 8 Filling is completed if Whistling noise is no mor...

Page 138: ...y danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNI...

Page 139: ...uel filters in the same way 9 Vent fuel system Page 136 Replacing fuel filter with the engine running 1 Cut out the filter to be replaced 2 Open threaded vent plugs at filter head of cut out filter an...

Page 140: ...drained I Left filter cut in II Right filter cut in 2 Open threaded vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from filter...

Page 141: ...life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine no...

Page 142: ...6 Fuel prefilter Topping up with fuel 1 Stop engine Page 101 and disable engine start 2 Remove screws for cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cover...

Page 143: ...n installing the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Check differential pressure Checking differential pressure of fuel prefilter 1...

Page 144: ...Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smok...

Page 145: ...2 7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and s...

Page 146: ...zzle retaining cap 5 Note Catch escaping fluid in a suitable vessel 2 Release oil line 6 from exhaust turbo charger 4 Note Catch escaping fluid in a suitable vessel 3 Remove screws 2 4 Remove screws 2...

Page 147: ...ck turbine housing from the inside for cracks Note Cracks are only permissible in the direction of circumference of the spiral 2 Length of crack exceeding max crack length x 30 mm or transverse cracks...

Page 148: ...Screws M10x1 5 Preload torque Assembly paste Ul tra Therm MTU 5 Nm 5 Tighten screws 1 diagonally and evenly to specified tightening torque Name Size Type Lubricant Value Standard Screws M10x1 5 Tight...

Page 149: ...e 1 with screws 2 3 Screw union nut 5 onto oil line 6 4 Tighten union nut 5 to specified tightening torque Name Size Type Lubricant Value Standard Union nut M18x1 5 Tightening torque 40 Nm 4 Nm MW1541...

Page 150: ...TION Unsuitable cleaning tool Damage to component Observe manufacturer s instructions Use appropriate cleaning tool Preparatory steps 1 Drain engine coolant Page 169 2 Remove air filter Page 153 3 Rem...

Page 151: ...oolant discharge and obstruction 1 With the engine running verify that air emerges from the condensate drain line at driving end left and right engine side If no air escapes 2 Clean condensate drain l...

Page 152: ...s Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Remove old air filter and install new air filter u Page 153 Reset contamination indicator signal ring u Page 156 152 T...

Page 153: ...nstallation 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and clean it 4 Place new air fil...

Page 154: ...conditions Engine is stopped and starting disabled Starter Condition check 1 Check securing screws and pressure hose of starter for secure seating and tighten if required 2 Check wiring Page 188 154 T...

Page 155: ...make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Air starter Manual operation 1 Press pushbutton for manual start and hold...

Page 156: ...sabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 152 2 After installation of new filter press reset button 1 Result Engag...

Page 157: ...g disabled Checking air flap for easy movement 1 Actuate lever several times to check ease of movement Result The spring must push back the air flap 2 If spring does not return air flap to initial po...

Page 158: ...or heat exchanger back to the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 159 5 Insert oil dipstick into guide tube up to the...

Page 159: ...t drain plug s on oil pan 1 Provide a suitable container in which to collect the engine oil 2 Remove drain plug s and drain engine oil 3 Install drain plug s with new sealing ring Oil change with semi...

Page 160: ...ne oil 100 Nm 10 Nm Filling with new engine oil 1 Open cap on filler neck 2 Pour in engine oil at filler neck up to max mark on oil dipstick 3 Close cap on filler neck 4 Check engine oil level Page 15...

Page 161: ...ear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine oil sampl...

Page 162: ...tact with skin Do not inhale oil vapor CAUTION Damage to component Serious damage to plant For filter replacement with the engine running operate the engine at low engine load The filter which is to b...

Page 163: ...al po sition Position C Upper filters cut out 2 Unscrew oil filter with oil filter wrench 3 Clean sealing face on connecting piece 4 Check condition of the new sealing ring and coat it with oil 5 Fit...

Page 164: ...mulsifier X00029933 1 Filter sleeve Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to healt...

Page 165: ...12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that smooth surface of filter sleeve 9 faces ro tor cap 8 14 Check sealing ring 11 repl...

Page 166: ...it 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 TIM...

Page 167: ...p and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye Checking coolant level a...

Page 168: ...ecial tools Material Spare parts Designation Use Part No Qty Engine coolant Changing engine coolant 1 Drain engine coolant Page 169 2 Fill with engine coolant Page 170 168 Task Description MW15412 05E...

Page 169: ...p and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off separated corrosion inhibitor oil in expansion tank through the filler neck 4 Open drain valves...

Page 170: ...es and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather val...

Page 171: ...lant emerg es from the loosened unions at the two tur bochargers 9 Tighten the coolant line union on both tur bochargers Page 166 10 Start engine Page 94 11 After the engine has run at idling speed fo...

Page 172: ...breather valve and clean sealing faces if required 6 Set breather valve onto filler neck and turn until the first stop to close 7 Start engine Page 94 8 After the engine has run at idling speed for 1...

Page 173: ...relief bore on engine coolant pump 1 Checking relief bore for oil and coolant dis charge 2 Stop engine Page 101 and disable en gine start observe general safety instruc tions for maintenance and repai...

Page 174: ...wn Wear protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Coolant sample extraction and analysis 1 With the engine run...

Page 175: ...otectors Checking relief bore on raw water pump 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 101 and disable en gine start observe general safety instruc tions for maintenan...

Page 176: ...n and starting disabled Checking condition of battery charging generator drive coupling 1 Remove protective cover 2 Check resilient coupling for cracks and de formation arrow 3 Contact Service in case...

Page 177: ...ews for firm seating Preconditions Engine is stopped and starting disabled Engine mounts Checking securing screws for firm seating 1 Check securing screws for firm seating 2 Tighten loose threaded con...

Page 178: ...Wipe rubber surface with dry cloth do not use organic detergents 2 Check resilient elements for crack formation and deformation by visual inspection 3 Have cracked mounts replaced contact Service Engi...

Page 179: ...ent 1 Undo nut 3 2 Adjust buffer clearance by turning the central buffer 1 3 Coat mating face of nut 3 and thread of central buffer 1 with a little engine oil Engine oil must not get in contact with t...

Page 180: ...ate s 2 Wipe rubber element with dry cloth do not use organic detergents 3 Check condition of coupling through assembly hole s using a torch Hair cracks in the rubber elements are permissible 4 If a c...

Page 181: ...of damage to hearing Wear ear protectors Bilge pump Relief bore check 1 Check relief bores for oil and water dis charge 2 Stop engine Page 101 and disable en gine start 3 Clean the relief bores with a...

Page 182: ...System 7 22 1 Water drain valve Check Checking water drain valve 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 182 Task Description MW15412 05E 2011 11 TIM I...

Page 183: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 96 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 184: ...w water level probe 3 Disconnect plug from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread Result Water drain valve opens 5 Leave water...

Page 185: ...heck pressure at the pressure gauge in the inlet to the fuel treatment system and note it 3 Check pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shutoff valve...

Page 186: ...tion of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Replacing...

Page 187: ...ightening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screw 1 washer 2 and nut 9 20 Tighten nut 9 21 Open ball valve at the inlet and outlet of the fuel treatment system...

Page 188: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Page 189: ...surface of connectors 1 connector sockets and shrink formed com ponents 2 using a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning...

Page 190: ...of connectors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alco hol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning severely contamina...

Page 191: ...ing 1 and or cover plate 3 is are not mounted Secure cover plate 3 with screws Then install switch housing 1 with screws ensuring that the switch 2 is actuated by the cover plate 3 3 If switch housing...

Page 192: ...plug connections 1 Use connector pliers 3 to make certain that all plug in connections on engine con trol unit are securely seated 2 Tighten loose bayonet couplings 2 with connector pliers 3 by turnin...

Page 193: ...it plug connections 1 Use connector pliers 3 to make certain that all engine monitoring unit plug connec tions are securely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turni...

Page 194: ...483 1 Covering caps for Cannon sockets Removing control unit from engine 1 Note or mark assignment of cables to con nector sockets 2 Use connector pliers 2 to disengage the bayonet union nuts 4 of the...

Page 195: ...he screws 4 are not easily accessible 1 Unscrew screws 1 2 Remove engine control unit housing 3 together with mounting plates 2 3 Unscrew cable shock absorbers 5 and further fastening parts 6 as one u...

Page 196: ...k securing screws 1 3 4 7 for firm seating Tighten loose threaded connec tions 3 Check internal assemblies for firm seating this applies in particular to printed circuit board 2 and PIMs 5 6 Tighten l...

Page 197: ...similar damage Buttons move easily Button housings are seated securely Seals 2 between PAN control panels and LOP housing are not damaged 2 Display Ensure that Front glass is not damaged or pressed in...

Page 198: ...ine Control System ECU Engine Control Unit Engine governor EDM Engine Data Module EIM Engine Interface Module Interface to engine monitoring system EMU Engine Monitoring Unit ETK Ersatzteilkatalog Spa...

Page 199: ...larm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization organization SAT Sea Acceptance Test SD Sensor Defect Alarm Sensor failure SDAF Shut Down Air Flaps SS Safety Sys...

Page 200: ...conditions or for spare parts supply Your contact at Headquarters Service support mtu online com Spare parts service Fast simple and correct identification of spare parts for your drive system or vehi...

Page 201: ...hragm check and replace ment Page 120 Easy change filter Part No Qty Used in 7 8 1 Fuel filter Replacement Page 138 Filter element Part No Qty Used in 7 3 2 Crankcase breather Oil separator replacemen...

Page 202: ...age 186 Injector Part No Qty Used in 7 6 1 Injector Replacement Page 130 Oil filter Part No Qty Used in 7 15 1 Engine oil filter Replacement Page 162 Plastic ring Part No Qty Used in 7 8 1 Fuel filter...

Page 203: ...rs Cleaning Page 190 Qty Used in 1 7 24 4 Checking engine control unit plug connections Page 192 Qty Used in 1 7 24 5 Engine monitoring unit plug connections Check Page 193 Qty Used in 1 7 24 6 Engine...

Page 204: ...Coolant Sample extraction and analysis Page 174 Oil filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter Replacement Page 138 Qty Used in 1 7 15 1 Engine oil filter Replacement Page 162 Ra...

Page 205: ...heck and adjustment Page 123 Steam jet cleaner Part No Qty Used in 1 4 20 Plant Cleaning Page 107 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page...

Page 206: ...rque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 3 2 Crankcase breather Oil separator replacement diaphragm check and replace ment Page 120 Qty Used in 1 7 15 2 Centrifugal oil filter Cleaning an...

Page 207: ...e air temperature 45 81 8V 4000 M70 engine data engine mounted heat ex changer IMO 33 8V 4000 M70 engine data IMO separate heat exchang er copper based alloy intercooler 30 A Abbreviations 198 After s...

Page 208: ...96 G General conditions 8 H HP pump Relief bore check 129 I Injector Removal and installation 131 Replacement 130 Inspection port cover Explosion hazard 12 Intercooler Checking condensate drain line...

Page 209: ...ce Adjsutment 123 Check 123 Valve gear Lubrication 122 Venting points 166 W Water drain valve Check 182 Water level probe 3 in 1 rod electrode Check 184 Waterjet Flushing from LOP optional 100 Wiring...

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MTU V 4000 M70, Operating Instructions Manual

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Summary of Contents for V 4000 M70

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