MTU 8 V 2000 M70 User manual

Operating Instructions
Diesel engine
8 V 2000 M70
12 V 2000 M70
16 V 2000 M70
MW15407/14E

Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Table of Contents
1 Safety
1.1 General conditions 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Crankshaft transport locking device 8
1.5 Safety regulations for startup and operation 11
1.6 Explosion hazard when removing
inspection port cover on engine 12
1.7 Safety regulations for maintenance and
repair work 13
1.8 Auxiliary materials, fire prevention and
environmental protection 16
1.9 Conventions for safety instructions in the
text 18
2 General Information
2.1 Product description 19
2.2 2000 M70 engines 28
2.3 Engine side and cylinder designations 29
3 Technical Data
3.1 8V 2000 M70 engine data: Engine-
mounted heat exchanger 30
3.2 8V 2000 M70 engine data: Separate heat
exchanger 33
3.3 12V 2000 M70 engine data: Engine-
mounted heat exchanger 36
3.4 12V 2000 M70 engine data: Separate heat
exchanger 39
3.5 16V 2000 M70 engine data: Engine-
mounted heat exchanger 42
3.6 16V 2000 M70 engine data: Separate heat
exchanger 45
3.7 Firing order 48
3.8 Main engine dimensions 49
4 Operation
4.1 LOP controls (without Blue Line automation
system) 50
4.2 Putting the engine into operation (out-of-
service-period > 3 months) 52
4.3 Putting the engine into operation after
scheduled out-of-service period 53
4.4 Starting the engine from LOP (without Blue
Line automation system) 54
4.5 Engine starting from the BlueLine
automation system (control stand) 55
4.6 Engine emergency stop at BlueLine
automation system (control stand) 56
4.7 Operational checks 57
4.8 Clutch – Engaging from LOP 58
4.9 Clutch – Disengaging from LOP 59
4.10 Waterjet – Flushing from LOP (optional) 60
4.11 Stopping the engine from LOP (without
Blue Line automation system) 61
4.12 Stopping the engine at the BlueLine
automation system (control stand) 62
4.13 Emergency stop from LOP (without Blue
Line automation system) 63
4.14 After stopping the engine 64
4.15 Plant – Cleaning 65
5 Maintenance
5.1 Maintenance task reference table [QL1] 66
6 Troubleshooting
6.1 Troubleshooting 67
6.2 LOP alarms 70
7 Task Description
7.1 Engine 77
7.1.1 Engine – Barring manually 77
7.1.2 Engine cranking on starter 78
7.2 Cylinder Liner 79
7.2.1 Cylinder liner – Endoscopic examination 79
7.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 81
7.3 Crankcase Breather 83
7.3.1 Crankcase breather – Cleaning oil separator
element 83
7.3.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 84
7.4 Valve Drive 86
7.4.1 Valve clearance – Check and adjustment 86
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7.4.2 Cylinder head cover – Removal and
installation 89
7.5 Injection Pump / HP Pump 90
7.5.1 Injection pump – Replacement 90
7.5.2 Injection pump – Removal and installation 91
7.6 Injection Valve / Injector 94
7.6.1 Injector – Replacement 94
7.6.2 Injector – Removal and installation 95
7.7 Fuel System 99
7.7.1 HP fuel line – Pressure pipe neck
replacement 99
7.7.2 Fuel – Draining 101
7.7.3 Fuel system – Venting 102
7.8 Fuel Filter 104
7.8.1 Fuel filter – Replacement 104
7.8.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 106
7.8.3 Fuel prefilter – Draining 107
7.8.4 Fuel prefilter ‒ Flushing 108
7.8.5 Fuel prefilter – Filter element replacement 110
7.9 Charge-Air Cooling 112
7.9.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 112
7.10 Air Filter 113
7.10.1 Air filter – Replacement 113
7.10.2 Air filter – Removal and installation 114
7.11 Air Intake 115
7.11.1 Contamination indicator – Signal ring position
check 115
7.11.2 Air-flow control flap – Ease of movement
check 116
7.12 Exhaust Flap with Actuator 117
7.12.1 Exhaust flow control flap – Ease of movement
check 117
7.13 Starting Equipment 118
7.13.1 Starter – Condition check 118
7.14 Lube Oil System, Lube Oil Circuit 119
7.14.1 Engine oil – Level check 119
7.14.2 Engine oil – Change 120
7.15 Oil Filtration / Cooling 121
7.15.1 Oil dipstick – Marking 121
7.15.2 Engine oil filter – Replacement 122
7.15.3 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 124
7.16 Coolant Circuit, General, High-
Temperature Circuit 127
7.16.1 Drain and venting points 127
7.16.2 Engine coolant – Level check 132
7.16.3 Engine coolant – Change 133
7.16.4 Engine coolant – Draining 134
7.16.5 Engine coolant – Filling 135
7.16.6 HT coolant pump – Relief bore check 136
7.16.7 Engine coolant – Sample extraction and
analysis 137
7.17 Raw Water Pump with Connections 138
7.17.1 Raw water pump – Relief bore check 138
7.18 Belt Drive 139
7.18.1 Drive belt – Condition check 139
7.19 Battery-Charging Generator 140
7.19.1 Battery-charging generator drive – Drive belt
check and adjustment 140
7.19.2 Battery-charging generator drive – Drive belt
replacement 142
7.20 Engine Mounting / Support 143
7.20.1 Engine mounting – Checking condition of
resilient mounts 143
7.21 Universal Shaft 144
7.21.1 Universal shaft – Greasing 144
7.22 Wiring (General) for Engine/Gearbox/Unit 145
7.22.1 Engine wiring – Check 145
7.23 Accessories for (Electronic) Engine
Governor / Control System 146
7.23.1 Engine governor and connectors – Cleaning 146
7.23.2 Engine monitoring unit and connectors –
Cleaning 147
7.23.3 Start interlock limit switch – Check 148
7.23.4 Engine control unit plug connections – Check 149
7.23.5 Engine monitoring unit – Plug connection
check 150
7.23.6 Engine control unit – Removal and installation 151
7.24 Emergency Instrumentation (Local
Operating Panel) 153
7.24.1 LOP and connectors – Cleaning 153
7.24.2 LOP – Visual inspection 154
7.24.3 LOP – Test procedures 156
8 Appendix A
8.1 Abbreviations 158
8.2 MTU contacts/service partners 161
9 Appendix B
9.1 Special Tools 162
9.2 Index 166
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any 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 includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is 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 read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.
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1.3 Transport
Transport
Lift the engine only with the lifting eyes provided.
The lifting eyes are designed for engine transport only.
Use only the transport and lifting equipment approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans‐
port pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and
engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured against
slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
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1.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Torque wrench, 60-320 Nm F30047446 1
Engine oil
Transport locking device
Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine
transport.
For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device must remain installed as long as possible during engine installation in order
to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both sides according
to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is also re‐
moved.
6. Attach these instructions, clearly visible, to the engine.
Removing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
1. Remove screws (4) om both sides and take
off with washers (3), guard plates (1) and
engine mounting brackets (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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Fitting the transport locking device
on driving end (KS)
Note: Attach plates (2) only to the upper part of the openings.
1. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Screw nut (3) onto screws (4) up to the end of the thread.
3. The long end of retainers (1) must face downwards. Push retainers (1) with the round front face through
the plate openings (2).
Note: The retainers (1) must lock the flywheel only, not the ring gear.
4. Install screws (4) into the bores of retainers (1) until the retainers (1) are locked in position.
5. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Screw on nuts (3) of both screws (4) at plates (2) and secure.
Removing the transport locking
device from driving end (KS)
1. Release the locknuts (3) on both sides of
the flywheel housing, remove screws (4)
and take off the two locks (1).
2. Unscrew screws (6) and remove together
with washers (5) and plates (2).
3. Store the removed parts of the transport
locking device together with this documen‐
tation carefully for possible reuse.
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Installing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
Note: Always use the screws supplied with the or
removed from the guard plates and engine
mounting brackets to secure them on the
engine.
1. Install engine mounting brackets (2) on both
sides with guard plates (1) washers (3), and
screws (4).
2. Tighten screws (4).
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