MTU 8V1600 G10F Operating Instructions Manual
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MTU 8V1600 G10F Operating Instructions Manual

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Operating Instructions
Operating Instructions
Diesel engine
Diesel engine
8, 10, 12 V 1600 G10F, G20F
8, 10, 12 V 1600 G10F, G20F
8, 10, 12 V 1600 G40F, G50F
8, 10, 12 V 1600 G40F, G50F
8, 10, 12 V 1600 G70F, G80F
8, 10, 12 V 1600 G70F, G80F
8, 12 V 1600 B30S
8, 12 V 1600 B30S
8, 10 V 1600, B40S, B50F
8, 10 V 1600, B40S, B50F
12 V 1600, B40S
12 V 1600, B40S
8, 10, 12 V 1600 G10S, G20S
8, 10, 12 V 1600 G10S, G20S
8, 10, 12 V 1600 G70S, G80S
8, 10, 12 V 1600 G70S, G80S
MS150076/05E
MS150076/05E

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Summary of Contents for MTU 8V1600 G10F

  • Page 1 Operating Instructions Operating Instructions Diesel engine Diesel engine 8, 10, 12 V 1600 G10F, G20F 8, 10, 12 V 1600 G10F, G20F 8, 10, 12 V 1600 G40F, G50F 8, 10, 12 V 1600 G40F, G50F 8, 10, 12 V 1600 G70F, G80F 8, 10, 12 V 1600 G70F, G80F 8, 12 V 1600 B30S 8, 12 V 1600 B30S...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to written permission of MTU Friedrichshafen GmbH. This restriction also applies to...
  • Page 3 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 written permission of MTU Friedrichshafen GmbH. This restriction also applies to...
  • Page 4 Table of Contents Table of Contents 3.17 3.17 10V 16 1600 B5 B50F eng engine da data, E EU Nonr Nonroad rs rso l an and o org rga io ion l re – – Safety Safety regula regulations tions for ma mainten intenance a...

  • Page 5: Table Of Contents

    7.10.1 Engine coolant – Level check 7.10.2 Engine coolant – Change 8.1 Abbreviations 7.10.3 Engine coolant – Draining 8.2 MTU contact persons/service partners 7.10.4 Engine coolant – Filling 7.10.5 Engine coolant pump – Relief bore check 9 Appendix B 7.11 Belt Drive 7.11.1 Drive belt –...
  • Page 6 • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...
  • Page 7 1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.
  • Page 8 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.
  • Page 9 1.4 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 10 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths and cable ties). Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
  • Page 11 Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work.
  • Page 12 The latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product.
  • Page 13 Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...
  • Page 14 1.6 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...
  • Page 15 2 General Information 2.1 Engine layout 1 Air filter 7 Thermostat housing (re- 13 Exhaust turbocharger 2 Lifting equipment, driving turn cooler) 14 Oil dipstick 8 Belt drive 15 Oil pan 3 Engine governor 9 Cylinder head 16 Fuel filter 4 Air supply 10 Exhaust elbow 17 Flywheel...
  • Page 16 2.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B"...
  • Page 17 2.3 Sensors and actuators – Overview Sensors on engine free end – Overview Illustration applies in the same way to 10V 1600 Gx0. Item Designation Monitoring of Coolant pressure Coolant temperature B48.2 HP fuel, B side XY39.B1 Injectors, B side XY39.B2 Charge-air temperature Charge-air pressure...
  • Page 18 Item Designation Monitoring of M8.1 Fuel pump HDP A (time measurement unit) M8.2 Fuel pump HDP B (time measurement unit) Camshaft TDC Crankshaft speed    4    0    0   -    5    1    8    0    0    0    0    0    0    0   :    D    I   -    M...
  • Page 19 3 Technical Data 3.1 8/10/12V 1600 G10F/G20F engine data, emissions-optimized Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 20 Number of cylin- ders Exhaust overpres- mbar sure Exhaust overpres- mbar sure, max. MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres-...
  • Page 21 LUBE-OIL SYSTEM Number of cylin- ders Lube oil operating °C temperature be- fore engine, from Lube oil operating °C temperature be- fore engine, to Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to FUEL SYSTEM Number of cylin- ders Fuel pressure at...
  • Page 22 CAPACITIES Number of cylin- ders Engine coolant Liters capacity, engine side (without cooling equip- ment) Oil change quanti- Liters ty, max. (standard oil system) (Op- tion: max. operat- ing inclinations) Oil pan capacity Liters at dipstick mark “min.” (standard oil system) (Op- tion: max.
  • Page 23 3.2 8V/10V/12V 1600 G10F/G20F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 24 MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 2.30 2.35 sure before cylin- der - DL COOLANT SYSTEM (HT circuit) Number of cylin-...

  • Page 25: Number Of Cylin

    FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...

  • Page 26: Number Of Cylin

    WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight, 1444 1444 1749 1749 2022 2022 dry (basic engine configuration acc. to scope of supply specification) ACOUSTICS Number of cylin- ders Exhaust noise, un- dB(A) silenced - DL (sound power lev- el LW, ISO 6798+3dB(A) tol- erance)

  • Page 27: Bar

    3.3 8V/10V/12V 1600 G10F/G20F engine data, EU Nonroad Stage III A Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...

  • Page 28: Off-Engine Cooling System, Max

    MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 3.04 3.12 2.65 2.92 sure before cylin- der - DL COOLANT SYSTEM (HT circuit) Number of cylin-...
  • Page 29 FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...
  • Page 30 WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight, 1444 1444 1749 1749 2022 2022 dry (basic engine configuration acc. to scope of supply specification) ACOUSTICS Number of cylin- ders Exhaust noise, un- dB(A) silenced - DL (sound power lev- el LW, ISO 6798+3dB(A) tol- erance)

  • Page 31: Model-Related Data (Basic Design)

    3.4 8V/10V/12V 1600 G10S/G20S engine data, EPA Tier 2, 3 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...

  • Page 32: Coolant System (Ht Circuit)

    COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at en- °C gine connection: outlet to cooling equipment) Coolant temperature after en- °C gine, warning Coolant temperature after en- °C gine, shutdown Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max.
  • Page 33 CAPACITIES Number of cylinders Engine coolant capacity, en- Liters gine side (without cooling equipment) Oil change quantity, max. Liters (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick Liters mark “min.” (standard oil sys- tem) (Option: max. operating inclinations) Oil pan capacity at dipstick Liters...

  • Page 34: Number Of Cylin

    3.5 8/10/12V 1600 G70F/G80F engine data, emissions-optimized Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...

  • Page 35: Ture After Engine, Warning

    MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 2.92 2.94 sure before cylin- der - BL COOLANT SYSTEM (HT circuit) Number of cylin-...
  • Page 36 FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...
  • Page 37 Number of cylin- ders Oil pan capacity Liters at dipstick mark “min.” (standard oil system) (Op- tion: max. operat- ing inclinations) Oil pan capacity Liters at dipstick mark “max.” (standard oil system) (Op- tion: max. operat- ing inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight,...
  • Page 38 3.6 10/12V 1600 G70F/G80F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 39 MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 2.35 2.77 sure before cylin- der - BL COOLANT SYSTEM (HT circuit) Number of cylin-...
  • Page 40 FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...
  • Page 41 Number of cylin- ders Oil pan capacity Liters at dipstick mark “min.” (standard oil system) (Op- tion: max. operat- ing inclinations) Oil pan capacity Liters at dipstick mark “max.” (standard oil system) (Op- tion: max. operat- ing inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight,...
  • Page 42 3.7 8/10V 1600 G70F/G80F engine data, EU Nonroad Stage III A Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 43 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connec- °C tion: outlet to cooling equipment) Coolant temperature after engine, warning R °C Coolant temperature after engine, shut- °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys- tem, max.

  • Page 44: Number Of Cylinders

    Number of cylinders Oil pan capacity at dipstick mark “min.” Liters (standard oil system) (Option: max. oper- ating inclinations) Oil pan capacity at dipstick mark “max.” Liters (standard oil system) (Option: max. oper- ating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configu- 1444 1444...
  • Page 45 3.8 8/12V 1600 G70S engine data, EPA Tier 2, 3 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...

  • Page 46: Coolant Temperature (At Engine Connec- Tion: Outlet To Cooling Equipment)

    COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connec- °C tion: outlet to cooling equipment) Coolant temperature after engine, warning R °C Coolant temperature after engine, shut- °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys- tem, max.
  • Page 47 Number of cylinders Oil pan capacity at dipstick mark “min.” Liters (standard oil system) (Option: max. oper- ating inclinations) Oil pan capacity at dipstick mark “max.” Liters (standard oil system) (Option: max. oper- ating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configu- 1444 1444...

  • Page 48: Number Of Cylinders

    3.9 8/10/12V 1600 G80S engine data, EPA Tier 2, 3 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 49 MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 2.93 2.93 sure before cylin- der - BL COOLANT SYSTEM (HT circuit) Number of cylin-...

  • Page 50: Rpm

    FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...
  • Page 51 Number of cylin- ders Oil pan capacity Liters at dipstick mark “min.” (standard oil system) (Op- tion: max. operat- ing inclinations) Oil pan capacity Liters at dipstick mark “max.” (standard oil system) (Op- tion: max. operat- ing inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight,...
  • Page 52 3.10 8/10/12V 1600 G40F/G50F engine data, emissions-optimized Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 53 MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 2.92 2.65 2.92 sure before cylin- der - DL COOLANT SYSTEM (HT circuit) Number of cylin-...
  • Page 54 FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...
  • Page 55 WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight, 1444 1444 1749 1749 2022 2022 dry (basic engine configuration acc. to scope of supply specification) ACOUSTICS Number of cylin- ders Exhaust noise, un- dB(A) silenced - DL (sound power lev- el LW, ISO 6798+3dB(A) tol- erance)
  • Page 56 3.11 8/10/12V 1600 G40F/G50F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 57 MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 2.30 2.35 sure before cylin- der - DL COOLANT SYSTEM (HT circuit) Number of cylin-...
  • Page 58 FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...
  • Page 59 WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight, 1444 1444 1749 1749 2022 2022 dry (basic engine configuration acc. to scope of supply specification) ACOUSTICS Number of cylin- ders Exhaust noise, un- dB(A) silenced - DL (sound power lev- el LW, ISO 6798+3dB(A) tol- erance)
  • Page 60 3.12 8/10V 1600 G40F/G50F engine data, EU Nonroad Stage III A Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 61 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connec- °C tion: outlet to cooling equipment) Coolant temperature after engine, warning R °C Coolant temperature after engine, shut- °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys- tem, max.
  • Page 62 Number of cylinders Oil pan capacity at dipstick mark “min.” Liters (standard oil system) (Option: max. oper- ating inclinations) Oil pan capacity at dipstick mark “max.” Liters (standard oil system) (Option: max. oper- ating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configu- 1444 1444...
  • Page 63 3. 3.13 8/ 8/12 12V 1 600 B 30S e ngin ine d dat ata Explanation: Explanation: Ref. Ref. valu value: Contin Continuous uous power power Ref. val value: F Fuel s stop p powe ower Desi sign v val alue Guar aran ante teed va valu lue Guid idel elin ine va...
  • Page 64 COOLANT SYSTEM (HT circuit) COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connec- Coolant temperature (at engine connec- ° ° tion: outlet to cooling equipment) tion: outlet to cooling equipment) ° ° Coolant temperature after engine, shut- Coolant temperature after engine, shut- °...
  • Page 65 Oil pan capacity at dipstick mark “min.” Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. oper- (standard oil system) (Option: max. oper- ating inclinations) ating inclinations) Oil pan capacity at dipstick mark “max.” Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max.
  • Page 66 3.14 8/10/12V 1600 B40S engine data, switchable frequency Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 67 MODEL-RELATED DATA (basic design) Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC 14" 14" 14" 14" 14" 14" AIR / EXHAUST Number of cylin- ders Charge-air pres- bar abs 3.12 2.77 2.77 3.12 sure before cylin- der - DL COOLANT SYSTEM (HT circuit) Number of cylin-...
  • Page 68 FUEL SYSTEM Number of cylin- ders Fuel pressure at -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylin- ders Cold start capabil- °C...
  • Page 69 WEIGHTS / MAIN DIMENSIONS Number of cylin- ders Engine weight, 1444 1444 1749 1749 2022 2022 dry (basic engine configuration acc. to scope of supply specification) ACOUSTICS Number of cylin- ders Exhaust noise, un- dB(A) silenced - DL (sound power lev- el LW, ISO 6798+3dB(A) tol- erance)
  • Page 70 3.15 10V 1600 B50F engine data, emissions-optimized Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 71 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) °C Coolant temperature after engine, warning °C Coolant temperature after engine, shutdown °C Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from...
  • Page 72 ACOUSTICS Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798+3dB(A) toler- dB(A) ance)    2    0    0   -    5    7    1    0    2    0    0    0    0    0   :    D    I   -    M    I    T MS150076/05E 2014-02 | Technical Data | 71...
  • Page 73 3.16 10V 1600 B50F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 74 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) °C Coolant temperature after engine, warning °C Coolant temperature after engine, shutdown °C Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from...
  • Page 75 ACOUSTICS Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798+3dB(A) toler- dB(A) ance)    2    0    0   -    9    7    1    0    2    0    0    0    0    0   :    D    I   -    M    I    T MS150076/05E 2014-02 74 | Technical Data |...
  • Page 76 3.17 10V 1600 B50F engine data, EU Nonroad Stage IIIA Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 77 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) °C Coolant temperature after engine, warning °C Coolant temperature after engine, shutdown °C Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from...
  • Page 78 ACOUSTICS Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798+3dB(A) toler- dB(A) ance)    2    0    0   -    5    8    1    0    2    0    0    0    0    0   :    D    I   -    M    I    T MS150076/05E 2014-02 | Technical Data | 77...
  • Page 79 3.18 Firing order Firing order Number of cylin- Firing order ders A1–B4–A4–A2–B3–A3–B2–B1 10 V A1–B4–A4–B3–A3–B2–A2–B5–A5–B1 12 V A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6 Direction of rotation Direction of rotation (as viewed on driving end)c.c.w., not reversible    4    0    0   -    8    7    8    0    0    0    0    0...
  • Page 80 3.19 Engine – Main dimensions Engine – Main dimensions Length (A) approx. – 10 V approx. 1470 mm 12 V approx. 1620 mm Width (B) approx. 1240 mm 10 V approx. 1240 mm 12 V approx. 1240 mm Height (C) approx.
  • Page 81 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. ☑ Putting the PowerPack into operation after extended out-of-service-periods (>3 months) Item...
  • Page 82 4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions Engine is stopped and starting disabled. ☑ Startup Item Task Lube oil system Check engine oil level (→ Page 106). Coolant system Check engine coolant level (→ Page 109). Monitoring equipment Carry out lamp test (see manufacturer's documentation).
  • Page 83 4.3 Engine start in manual operation (trials) Preconditions Generator is not connected to network. ☑ External start interlock is not active. ☑ DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 84 4.4 Safety system – Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! • Use override function only in hazardous situations to ensure full capability in the event of engine faults.
  • Page 85 4.5 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 86 4. 4.6 Engi gine s sto top in p in manu nual o pera rati tion ( (tr tria ials ls) Preconditions Preconditions Generator is not connected to network. Generator is not connected to network. ☑ ☑ Engine is running in manual mode. Engine is running in manual mode.
  • Page 87 NOTICE NOTICE An emergency stop causes extreme stress An emergency stop causes extreme stress to the engine plant. to the engine plant. Risk of overheating, damage to components! Risk of overheating, damage to components! • • Initiate eme Initiate emergency stop rgency stop only in only in...
  • Page 88 After stop stoppin ping th the en engin gine – e – Engine remain ains re ready operation operation After stopping the engine After stopping the engine Engine/generator/pump Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control control    3...
  • Page 89 4.9 After stopping the engine – Putting the engine out of operation Preconditions MTU Fluids and Lubricants Specifications (A001063/..) are available. ☑ After stopping the engine Item Task Coolant circuit Drain engine coolant (→ Page 111) if: • the engine room is not heated;...
  • Page 90 The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a list of approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications A001063/.. Use only fluids and lubricants which comply with the MTU Fluids and Lubricants Specifica- tions.
  • Page 91 5.2 Maintenance task reference table The maintenance tasks and intervals for this product are defined in the Maintenance Booklet. The Main- tenance Booklet is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Booklet.
  • Page 92 6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check whether cable connections are properly secured (see manufacturer's documentation). Starter Engine wiring or starter defective Check whether cable connections are properly secured, contact Service.
  • Page 93 Component Probable Cause Task Engine wiring Defective Check (→ Page 121). Engine Overload Contact Service. Engine speed not steady Component Probable Cause Task Fuel injection equip- Injector defective Contact Service. ment Speed sensor Defective Contact Service. Fuel system Not vented Vent fuel system (→...
  • Page 94 7 Task Description 7.1 Engine 7.1.1 Engine – Barring with starting system Preconditions External pushbutton “Bar engine without starting” is provided. ☑ DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 95 7.1.2 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.
  • Page 96 7.2 Valve Drive 7.2.1 Valve clearance – Check and adjustment Preconditions Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40°C. ☑ Valves are closed. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Torque wrench, 20-100 Nm...
  • Page 97 Diagram for 10 V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Diagram for 12 V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve...
  • Page 98 Adjusting valve clearance Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm (3). Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. Tighten locknut (1) to specified torque using a torque wrench, holding adjusting screw (2) firm with Al- len key (5 mm).
  • Page 99 7.2.2 Cylinder head cover – Removal and installation Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet F30027340 Removing and installing cylin- der head cover Note: Cover the engine beneath the cylinder head with cloths to collect emerging oil.
  • Page 100 7.3 Fuel System 7.3.1 Fuel system – Venting Preconditions Engine is stopped and starting disabled. ☑ WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Venting fuel system Unlock fuel priming pump, screw out han- dle (2).
  • Page 101 7.4 Fuel Filter 7.4.1 Fuel filter – Replacement Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 102 7. 7.4. 4.2 Fuel pr pref efil ilte ter – r – Repl plac acem emen Preconditions Preconditions Engine is stopped and starting disabled. Engine is stopped and starting disabled. ☑ ☑ System is not under pressure. System is not under pressure. ☑...
  • Page 103 7. 7.5. 5.1 Ai Air f fil ilte ter ‒ R r ‒ epla lace ceme ment Special tools, Material, Spare parts Special tools, Material, Spare parts Air filter Air filter (→ Spare Parts Catalog) (→ Spare Parts Catalog) Air filter ‒ Replacement Air filter ‒...
  • Page 104 7. 7.5. 5.2 Ai Air fi filt lter – R er – emov oval a and i ins nsta tall llat atio ion Preconditions Preconditions Engine is stopped and starting disabled. Engine is stopped and starting disabled. ☑ ☑ Air filter – Removal and installa- Air filter –...
  • Page 105 7.6 Air Intake 7.6.1 Service indicator – Signal ring position check Preconditions Engine is stopped and starting disabled. ☑ Checking signal ring position Replace air filter, if the signal ring (2) is completely visible in the red area of the service indicator control window (3) (→...

  • Page 106: Starting Equipment

    7.7 Starting Equipment 7.7.1 Starter – Condition check Preconditions Engine is stopped and starting disabled. ☑ Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 121).    7    1    0   -    5    0    9...

  • Page 107: Lube Oil System, Lube Oil Circuit

    7.8 Lube Oil System, Lube Oil Circuit 7.8.1 Engine oil – Level check Preconditions Engine is stopped and starting disabled. ☑ Checking oil level prior to en- gine start Remove oil dipstick (1) from guide tube and wipe it. Insert oil dipstick (1) into guide tube up to the stop, withdraw after approx.

  • Page 108: Engine Oil - Change

    Engine oil – Change Preconditions Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm...

  • Page 109: Oil Filtration / Cooling

    7.9 Oil Filtration / Cooling 7.9.1 Engine oil filter – Replacement Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet F30027340 Socket, 32 mm F30006120 Engine oil Oil filter element...

  • Page 110: Coolant Circuit, General, High-Temperature Circuit

    7.10.1 Engine coolant – Level check Preconditions Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. ☑ WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 111: Engine Coolant - Change

    7.10.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 111). Fill with engine coolant (→ Page 112).    1    3    0   -    6    3    0    0    0    0...

  • Page 112: Engine Coolant - Draining

    7.10.3 Engine coolant – Draining Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 113: Engine Coolant - Filling

    7.10.4 Engine coolant – Filling Preconditions Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 114 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 109), top up with coolant if required.    7    0    0   -    9    0    9    0    0    0    0    0    0    0   :    D    I...

  • Page 115: Engine Coolant Pump - Relief Bore Check

    7.10.5 Engine coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 116: Belt Drive

    7.11 Belt Drive 7.11.1 Drive belt – Adjustment Preconditions Engine is stopped and starting disabled. ☑ Fan drive – Belt tension adjust- ment Undo screws (2). Screw in nut (1) to set the required belt tension. Tighten screws (2). Check drive belt tension for compliance with specifications (→...

  • Page 117: Drive Belt - Condition Check

    7.11.2 Drive belt – Condition check Preconditions Engine is stopped and starting disabled. ☑ Checking condition Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Fit new part (→ Page 119) Drive belt C Chunking Drive belt Fouling by oil, overheating...

  • Page 118: Drive Belt - Tension Check

    7.11.3 Drive belt – Tension check Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester, 500-1400 N Y20097430 Belt tension tester, 1300-3100 N Y20097431 Fan drive – Belt tension check Remove protective cover.
  • Page 119 Application Measured value Measured value Measured value Initial assembly Operating tension after Minimum operating 1 hour tension Fan drive belt 1000 N 720 N 480 N If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 115). Install protective cover.

  • Page 120: Drive Belt - Replacement

    7.11.4 Drive belt – Replacement Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Fan drive – Drive belt replace- ment Remove protective cover from cooler. Remove fan.
  • Page 121 Engine coolant pump drive – Drive belt replacement (engine with mechanical belt tensioner) Remove protective cover. Remove drive belt from fan drive (→ Page 119). Slacken off screws (1) and locknut (3). Release adjusting screw (2) on mechanical belt tensioner (4) and take off drive belt. Note: When placing the drive belt in the grooves, no force must be applied.

  • Page 122: Wiring (General) For Engine/Gearbox/Unit

    7.12 Wiring (General) for Engine/Gearbox/Unit 7.12.1 Engine wiring – Check Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Checking engine wiring Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 123: Accessories For (Electronic) Engine Governor / Control System

    7.13 Accessories for (Electronic) Engine Governor / Control System 7.13.1 Engine governor and connectors – Cleaning Preconditions Engine is stopped and starting disabled. ☑ Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise the contacts could be bent.

  • Page 124: Engine Governor - Checking Plug Connections

    7.13.2 Engine governor – Checking plug connections Preconditions Engine is stopped and starting disabled. ☑ Checking engine governor plug connections Check firm seating of all connectors on the engine governor. Ensure that the clips (1) are engaged. Check firm seating of all screws (2) on en- gine governor cable clamps.

  • Page 125: Abbreviations

    Association of American standardization organiza- tions Exhaust turbocharger/exhaust turbocharg- Air Temperature Sensor Baureihe (Series) Betriebsstoffvorschrift (Fluids and Lubri- MTU Publication No. A01061/.. cants Specifications) Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-...
  • Page 126 Abbre- Meaning Explanation viation Engine Data Module Memory module for engine data Electrically Erasable Programmable Read PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal Exhaust Gas Recirculation Engine Ident Label Engine Monitoring Unit Engine monitoring unit ESCM Extreme Site Condition Management Power reduction with extreme site conditions Spare Parts Catalog...
  • Page 127 Abbre- Meaning Explanation viation Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil pressure sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Top Dead Center Panel Control panel Peripheral Interface Module Pulse Width Modulation Modulated signal P-xyz Pressure-xyz Pressure measuring point xyz...

  • Page 128: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 129: Special Tools

    9 Appendix B 9.1 Special Tools Allen key, set 2-10 mm Part No.: F30453050 Qty.: Used in: 7.2.1 Valve clearance – Check and adjustment (→ Page 95) Barring gear Part No.: F6790714 Qty.: Used in: 7.2.1 Valve clearance – Check and adjustment (→...
  • Page 130 Belt tension tester, 500-1400 N Part No.: Y20097430 Qty.: Used in: 7.11.3 Drive belt – Tension check (→ Page 117) Box wrench, 14 mm Part No.: F30028346 Qty.: Used in: 7.2.1 Valve clearance – Check and adjustment (→ Page 95) Feeler gauge Part No.: Y20098771...
  • Page 131 Ratchet Part No.: F30027340 Qty.: Used in: 7.2.2 Cylinder head cover – Removal and installation (→ Page 98) Qty.: Used in: 7.8.2 Engine oil – Change (→ Page 107) Qty.: Used in: 7.9.1 Engine oil filter – Replacement (→ Page 108) Socket, 32 mm Part No.: F30006120...

  • Page 132: Index

       0   -    5    0    8    1    0    0    0    0    0    0 Hotline 127   :    D    I   -    L    C    D Maintenance task reference table 90 MTU contact persons 127 Operational checks 84 MS150076/05E 2014-02 | Appendix B | 131...

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