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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.

Task

Maintenance tasks

W0500

Check engine oil level

(→ Page 158)

W0501

Visually inspect engine for leaks and general condition

(→ Page 97)

W0502

Check intercooler drain (if fitted)

(→ Page 151)

W0503

Check signal ring position of service indicator on air filter

(→ Page 156)

W0504

Check HP fuel pump weep holes

(→ Page 97)

W0505

Check relief bores of coolant pump(s)

(→ Page 173)

W0506

Check engine for abnormal running noises, exhaust color

and vibrations

(→ Page 97)

W0507

Drain water and dirt from fuel prefilter (if fitted)

(→ Page 97)

W0508

Check vacuum gage reading on fuel prefilter (if fitted)

(→ Page 97)

W1001

Replace fuel filter or fuel filter 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 162)

W1009

Check layer thickness of oil residue, clean and replace filter

sleeve (if fitted)

(→ Page 164)

W1011

Perform endoscopic inspection of combustion chambers

(→ Page 115)

W1012

Crankcase breather, 8V only: Replace filter

(→ Page 120)

W1014

Crankcase breather, 12/16V only: Replace filter

(→ Page 120)

W1016

Battery-charging generator:Check condition of coupling

(→ Page 176)

W1029

Check air pipework between air filter and turbocharger for

leaks and damage

(→ Maintenance Schedule)

W1076

Exhaust turbocharger: Clean compressor wheel

(→ Page 150)

W1207

Check valve clearance, adjust if necessary. Attention!First

adjustment after 1,000 operating hours!

(→ Page 123)

W1244

Check operation of rod electrode (if fitted)

(→ Page 184)

W1245

Check alarm function of differential pressure gauge (if fitted) (→ Page 143)

W1246

Check pump capacity (if fitted)

(→ Maintenance Schedule)

Table 1: Maintenance task reference table [QL1]

108 | Maintenance | MW15412/05E 2011-11

TIM-ID: 0000034059 - 001

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Содержание V 4000 M70

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

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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