MTU V 4000 M70 User manual

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

Printed in Germany
© 2011 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.

Commissioning Note
Important
Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐
ranty, spare parts, etc.).

Table of Contents
1 Safety
1.1 General conditions 8
1.2 Personnel and organizational requirements 9
1.3 Transport 10
1.4 Safety regulations for startup and operation 11
1.5 Explosion hazard when removing
inspection port cover on engine 12
1.6 Safety regulations for maintenance and
repair work 13
1.7 Auxiliary materials, fire prevention and
environmental protection 16
1.8 Conventions for safety instructions in the
text 19
2 General Information
2.1 Engine side and cylinder designations 20
2.2 Product description 21
2.3 Engine layout 28
3 Technical Data
3.1 8V 4000 M70 engine data: IMO, separate
heat exchanger, copper-based alloy
intercooler 30
3.2 8V 4000 M70 engine data: engine-mounted
heat exchanger, IMO 33
3.3 12V 4000 M70 engine data: IMO -20%,
separate heat exchanger, copper-based
alloy intercooler 36
3.4 12V 4000 M70 engine data: IMO -20%,
engine-mounted heat exchanger, copper-
based alloy intercooler 39
3.5 12V 4000 M70 engine data: engine-
mounted heat exchanger, EPA stage 2 42
3.6 12V 4000 M70 engine data: separate heat
exchanger, EPA stage 2 45
3.7 16V 4000 M70 engine data: IMO, separate
heat exchanger, copper-based alloy
intercooler 48
3.8 16V 4000 M70 engine data: IMO, engine-
mounted heat exchanger, copper-based
alloy intercooler 51
3.9 16V 4000 M70 engine data: IMO -20%,
separate heat exchanger, copper-based
alloy intercooler 54
3.10 16V 4000 M70 engine data: IMO -20%,
engine-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 63
3.13 12V 4000 M71 engine data: IMO, separate
heat exchanger, copper-based alloy
intercooler 66
3.14 12V 4000 M71 engine data: IMO, engine-
mounted heat exchanger, copper-based
alloy intercooler 69
3.15 12V 4000 M71 engine data: IMO, separate
heat exchanger, copper-based alloy
intercooler, intake air temperature 45° 72
3.16 16V 4000 M71 engine data: IMO, separate
heat exchanger, copper-based alloy
intercooler 75
3.17 16V 4000 M71 engine data: IMO, engine-
mounted heat exchanger, copper-based
alloy intercooler 78
3.18 16V 4000 M71 engine data: IMO, separate
heat exchanger, copper-based alloy
intercooler, intake air temperature 45° 81
3.19 Firing order 84
3.20 Engine – Main dimensions 85
4 Operation
4.1 LOP – Controls 86
4.2 Putting the engine into operation after
extended out-of-service periods (>3
months) 88
4.3 Putting the engine into operation after
scheduled out-of-service-period 89
4.4 Tasks after extended out-of-service periods
(>3 weeks) 90
4.5 Checks prior to start-up 91
4.6 Fuel treatment system – Putting into
operation 92
4.7 Starting the engine from LOP 94
4.8 Starting the engine at the BlueLine
automation system (control stand) 95
4.9 Fuel treatment system – Switching on 96
4.10 Operational checks 97
4.11 Clutch – Engaging from LOP 98
4.12 Clutch – Disengaging from LOP 99
4.13 Waterjet – Flushing from LOP (optional) 100
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4.14 Stopping the engine from LOP 101
4.15 Stopping the engine at the BlueLine
automation system (control stand) 102
4.16 Emergency stop from LOP 103
4.17 Engine emergency stop at BlueLine
automation system (control stand) 104
4.18 After stopping the engine 105
4.19 Fuel treatment system – Shutdown 106
4.20 Plant – Cleaning 107
5 Maintenance
5.1 Maintenance task reference table [QL1] 108
6 Troubleshooting
6.1 Troubleshooting 109
6.2 LOP fault messages 112
7 Task Description
7.1 Engine 113
7.1.1 Engine – Barring manually 113
7.1.2 Engine – Barring with starting system 114
7.2 Cylinder Liner 115
7.2.1 Cylinder liner – Endoscopic examination 115
7.2.2 Cylinder liner - Instructions and comments on
endoscopic and visual examination 117
7.3 Crankcase Breather 119
7.3.1 Crankcase breather – Oil separator check 119
7.3.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 120
7.4 Valve Drive 122
7.4.1 Valve gear - Lubrication 122
7.4.2 Valve clearance – Check and adjustment 123
7.4.3 Cylinder head cover – Removal and
installation 128
7.5 Injection Pump / HP Pump 129
7.5.1 HP pump – Relief bore check 129
7.6 Injection Valve / Injector 130
7.6.1 Injector – Replacement 130
7.6.2 Injector – Removal and installation 131
7.7 Fuel System 136
7.7.1 Fuel system – Venting and filling 136
7.8 Fuel Filter 138
7.8.1 Fuel filter – Replacement 138
7.8.2 Fuel prefilter – Draining 140
7.8.3 Fuel prefilter ‒ Flushing 141
7.8.4 Fuel prefilter – Differential pressure gauge
check and 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 Cooling 151
7.10.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 151
7.11 Air Filter 152
7.11.1 Air filter – Replacement 152
7.11.2 Air filter – Removal and installation 153
7.12 Starting Equipment 154
7.12.1 Starter – Condition check 154
7.12.2 Air starter – Manual operation 155
7.13 Air Intake 156
7.13.1 Contamination indicator – Signal ring position
check 156
7.13.2 Air flap – Check for ease of movement 157
7.14 Lube Oil System, Lube Oil Circuit 158
7.14.1 Engine oil level – Check 158
7.14.2 Engine oil – Change 159
7.14.3 Engine oil – Sample extraction and analysis 161
7.15 Oil Filtration / Cooling 162
7.15.1 Engine oil filter – Replacement 162
7.15.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 164
7.16 Coolant Circuit, General, High-
Temperature Circuit 166
7.16.1 Venting points 166
7.16.2 Coolant level - Check 167
7.16.3 Engine coolant – Change 168
7.16.4 Engine coolant – Draining 169
7.16.5 Engine coolant – Filling 170
7.16.6 Engine coolant pump – Relief bore check 173
7.16.7 Coolant – Sample extraction and analysis 174
7.17 Raw Water Pump with Connections 175
7.17.1 Raw water pump – Relief bore check 175
7.18 Battery-Charging Generator 176
7.18.1 Battery-charging generator drive – Coupling
condition check 176
7.19 Engine Mounting / Support 177
7.19.1 Engine mounts – Checking securing screws
for firm seating 177
7.19.2 Engine mounts – Resilient element check 178
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7.20 Drive Systems, Driving End and Free End
(Coupling) 180
7.20.1 Coupling – Condition check 180
7.21 Auxiliary PTO 181
7.21.1 Bilge pump – Relief bore check 181
7.22 Fuel Supply System 182
7.22.1 Water drain valve – Check 182
7.22.2 Differential pressure gauge – Check 183
7.22.3 Water level probe (3-in-1 rod electrode) –
Check 184
7.22.4 Pump capacity – Check 185
7.22.5 Coalescer filter element – Replacement 186
7.23 Wiring (General) for Engine/Gearbox/Unit 188
7.23.1 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 –
Cleaning 190
7.24.3 Start interlock limit switch – Check 191
7.24.4 Checking engine control unit plug connections 192
7.24.5 Engine monitoring unit, plug connections –
Check 193
7.24.6 Engine control unit – Removal and installation 194
7.24.7 LOP – Visual inspection 196
8 Appendix A
8. Abbreviations 0
8. MTU contacts/service partners 0
9 Appendix B
9.1 Spare Parts 201
9.2 Special Tools 203
9.3 Index 207
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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 operating instructions and mainte‐
nance and repair 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
Use only the lifting eyes provided to lift the engine.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
Transport the engine in the installation position only, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine by the lifting eyes of the trans‐
port pallet or transport with equipment suitable for heavy loads (forklift 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 additionally secured against
slipping or tilting when going up or down inclines and ramps.
Setting down the engine following transportation
Set the engine down on a firm, level surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis .
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