diesel engine 6r1600gx0x 6r1600bx0x - mtu solutions · 2020. 8. 3. · 4.12 engine data 6r1600g40f,...

Operating InstructionsDiesel Engine6R1600Gx0x6R1600Bx0x

MS15022/04E

Engine model Power Application groupOverview 50 Hz6R1600B30S 41.5 kW/cyl. 3B, continuous operation at variable load6R1600B40S 45.7 kW/cyl. 3B, continuous operation at variable load6R1600G10F 41.5 kW/cyl. 3B, continuous operation at variable load6R1600G20F 45.7 kW/cyl. 3B, continuous operation at variable load6R1600G40F 41.5 kW/cyl. 3C, continuous operation, time-limited6R1600G50F 45.7 kW/cyl. 3C, continuous operation, time-limited6R1600G70F 45.7 kW/cyl. 3D, short-time operation, fuel stop6R1600G80F 50.2 kW/cyl. 3D, short-time operation, fuel stopOverview 60 Hz6R1600B30S 47.3 kW/cyl. 3B, continuous operation at variable load6R1600B40S 52.0 kW/cyl. 3B, continuous operation at variable load6R1600G10S 47.3 kW/cyl. 3B, continuous operation at variable load6R1600G20S 52.0 kW/cyl. 3B, continuous operation at variable load6R1600G70S 52.0 kW/cyl. 3D, short-time operation, fuel stop6R1600G80S 57.2 kW/cyl. 3D, short-time operation, fuel stop

© 2018 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 writ-ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-filming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbHreserves the right to change, delete or supplement the information provided as and when required.

Table of Contents1 Safety

1.1 Important provisions for all products 51.2 Correct use of all products 71.3 Personnel and organizational requirements 81.4 Initial start-up and operation – Safety

regulations 91.5 Assembly, maintenance, and repair work –

Safety regulations 111.6 Fire and environmental protection, fluids

and lubricants 151.7 Standards for warning notices in the text

and highlighted information 17

2 Transport

2.1 Transport 182.2 Lifting specifications 19

3 General Information

3.1 Engine – Overview 203.2 Engine side and cylinder designations 223.3 Sensors and actuators 23

4 Technical Data

4.1 Engine data 6R1600B30S 60 Hz, fueloptimized 25


4.3 Engine data 6R1600B40S 50 Hz, emissionsoptimized 31



4.6 Engine data 6R1600B40S 60 Hz, emissionsoptimized 38

4.7 Engine data 6R1600G10F, G20F, fueloptimized 40

4.8 Engine data 6R1600G10F, G20F, emissionsoptimized 43

4.9 Engine data 6R1600G10F, G20F, Nonroadstage III a 46

4.10 Engine data 6R1600G10S, G20S, EPA stage3 49







4.17 Engine data 6R1600G70S, G80S, EPA stage3 70

4.18 Firing order 734.19 Engine – Main dimensions 74

5 Operation

5.1 Putting the engine into operation afterextended out-of-service periods (>3 months) 75

5.2 Putting into operation after scheduled out-of-service-period 76

5.3 Starting the engine in manual mode (testrun) 77

5.4 Safety system – Override 785.5 Operational monitoring 795.6 Emission label – Check 805.7 Engine stop in manual operation (trials) 815.8 Emergency engine shutdown 825.9 After stopping the engine – Engine remains

ready for operation 835.10 After stopping the engine – Putting the

engine out of operation 84

6 Maintenance

6.1 Maintenance task reference table [QL1] 85

7 Troubleshooting

7.1 Troubleshooting 86

8 Task Description

8.1 Engine 888.1.1 Engine – Barring with starting system 888.1.2 Engine – Test run 89

8.2 Valve Drive 908.2.1 Valve clearance – Check and adjustment 908.2.2 Cylinder head cover – Removal and

installation 92

8.3 Fuel System 938.3.1 Fuel system – Venting 93

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8.4 Fuel Filter 948.4.1 Fuel filter – Replacement 948.4.2 Fuel prefilter – Draining 958.4.3 Fuel prefilter – Replacement 96

8.5 Air Filter 978.5.1 Air filter ‒ Replacement 978.5.2 Air filter – Removal and installation 98

8.6 Air Intake 998.6.1 Service indicator – Signal ring position check 99

8.7 Starting Equipment 1008.7.1 Starter – Condition check 100

8.8 Lube Oil System, Lube Oil Circuit 1018.8.1 Engine oil level – Check 1018.8.2 Engine oil – Change 102

8.9 Oil Filtration / Cooling 1038.9.1 Engine oil filter – Replacement 103

8.10 Coolant Circuit, General, High-TemperatureCircuit 1048.10.1 Engine coolant – Level check 1048.10.2 Engine coolant – Change 1058.10.3 Engine coolant – Draining 1068.10.4 Engine coolant – Filling 1078.10.5 Engine coolant pump – Relief bore check 109

8.11 Cooling System 1108.11.1 Coolant cooler – Check 110

8.12 Belt Drive 1118.12.1 Drive belt – Adjustment 1118.12.2 Drive belt – Condition check 1128.12.3 Drive belt – Tension check 1138.12.4 Drive belt – Replacement 114

8.13 Wiring (General) for Engine/Gearbox/Unit 1158.13.1 Engine cabling – Check 115

8.14 Accessories for (Electronic) EngineGovernor / Control System 1168.14.1 Engine governor and connector – Cleaning 1168.14.2 Engine governor – Checking plug connections 117

9 Appendix A

9.1 Abbreviations 1189.2 MTU Contact/Service Partners 121

10 Appendix B

10.1 Special Tools 12210.2 Index 126

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1 Safety

1.1 Important provisions for all products

GeneralThis product may pose a risk of injury or damage in the following cases:• Incorrect use• Operation, maintenance and repair by unqualified personnel• Changes or modifications which are neither made nor authorized by the manufacturer• Noncompliance with the safety instructions and warning notices

NameplatesThe product is identified by nameplate, model designation or serial number. This data must match the speci-fications in these instructions.

Nameplates, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in theEU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-cations.

Emission regulations and emission labels

Responsibility for compliance with emission regulationsModification or removal of any mechanical/electronic components or the installation of additional compo-nents including the execution of calibration processes that might affect the emission characteristics of theproduct are prohibited by emission regulations. Emission-related components must only be serviced, ex-changed or repaired if the components used for this purpose are approved by the manufacturer.

Noncompliance with these specifications will invalidate the design type approval or certification issued bythe emissions regulation authorities. The manufacturer does not accept any liability for violations of theemission regulations.

The product must be operated over its entire life cycle according to the conditions defined as "Intended use"(→ Page 7).

Emission certification applicable to engines with EPA Nonroad Tier 4 emissioncertification in accordance with 40 CFR 1039Extract from the standard:

Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violatesfederal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.

Extract from the standard:

If you install the engine in a way that makes the engine's emission control information label hard to readduring normal engine maintenance, you must place a duplicate label on the equipment, as described in 40CFR 1068.105.

When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. Thisparagraph describes the process for requesting and fitting the label, the documentation obligations and stor-age obligations for the required documents.

Replacing components with emission labelsOn all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-tional life.

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Exception: Engines used exclusively in land-based, military applications other than by US government agen-cies.

Please note the following when replacing components with emission labels:• The relevant emission labels must be affixed to the spare part.• Emission labels shall not be transferred from the replaced part to the spare part.• The emission labels must be removed from the replaced part and destroyed.

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1.2 Correct use of all products

Correct useThe product is intended for use in accordance with its contractually-defined purpose as described in the rele-vant technical documents only.

Intended use entails operation:• Within the permissible operating parameters in accordance with the (→ Technical data)• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants

Specifications of the manufacturer)• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-

tion Specifications of the manufacturer)• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-

tact/Service partner)• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-

so applies to engine control/parameters)• In compliance with all safety regulations and in adherence with all warning notices in this manual• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)

throughout the useful life of the product• In compliance with the maintenance and repair instructions contained in this manual, in particular with

regard to the specified tightening torques• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-

pair

The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for suchuse and approval has been granted.

Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improperuse increases the risk of injury and damage when working with the product. The manufacturer shall not beheld liable for any damage resulting from improper, non-intended use.

The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,make sure that the latest version is used. The latest version can be found on the websites:• For drive systems: http://www.mtu-online.com• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversionsUnauthorized changes to the product represent a contravention of its intended use and compromise safety.

Changes or modifications shall only be considered to comply with the intended use when expressly author-ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-ized changes or modifications.

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1.3 Personnel and organizational requirements

Organizational measures of the user/manufacturerThis manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-tion, or transportation.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,repair, assembly, installation, and transport personnel at all times.

Personnel must receive instruction on product handling and repair based on this manual. In particular, per-sonnel must have read and understood the safety requirements and warnings before starting work.

This is important in the case of personnel who only occasionally perform work on or around the product.Such personnel must be instructed repeatedly.

Personnel requirementsAll work on the product must be carried out by trained, instructed and qualified personnel only:• Training at the Training Center of the manufacturer• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-sembly, installation, and transport in writing.

Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipmentAlways wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-tions of the individual activities.

Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-tion, Authorisation and restriction of CHemicals): We recommend wearing protective gloves at all times inorder to reduce risk when working.

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1.4 Initial start-up and operation – Safety regulations

Safety regulations for initial start-upInstall the product correctly and carry out acceptance in accordance with the manufacturer's specificationsbefore putting the product into service. All necessary approvals must be granted by the relevant authoritiesand all requirements for initial startup must be fulfilled.

Whenever the product is subsequently taken into operation ensure that:• All personnel is clear of the danger zone surrounding moving parts of the machine.

Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switchedon.

• All maintenance and repair work has been completed.• All loose parts have been removed from rotating machine components.• All safeguards are in place.• All components must be properly grounded. Ground separately by means of a grounding stake as neces-

sary.• No persons wearing pacemakers or any other technical body aids are present.• The service room is adequately ventilated.• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.

These gases may be hazardous to health. Always wear respiratory protection in the operating room duringthis period.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.• The product must be free of any damage, this applies in particular to lines and cabling.• Protect battery terminals, generator terminals or cables against accidental contact.• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/reduction agent line,

supply/return.

Immediately after putting the product into operation, make sure that all control and display instruments aswell as the monitoring, signaling and alarm systems work properly.

Smoking is prohibited in the area of the product.

Safety regulations during operationThe operator must be familiar with the control and display elements.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with regard topresent operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stopPractice emergency procedures, especially emergency stopping, at regular intervals.

Take the following steps if any system malfunctions are detected or signaled by the system:• Inform supervisor(s) in charge.• Analyze the message.• Respond by taking any necessary emergency action, e.g. emergency stop.

After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-ed.

Contact Service if the root cause of the malfunction cannot be clearly identified.

OperationDo not remain in the operating room when the product is running unless absolutely necessary. Keep yourstay as short as possible.

Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructedto do so following a written procedure.

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Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:• Wear ear protectors.• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.

Operation of electrical equipmentWhen electrical equipment is in operation, certain components of these appliances are electrically live.

Follow the applicable operating and safety instructions when operating the devices and heed warnings at alltimes.

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1.5 Assembly, maintenance, and repair work – Safety regulations

Safety regulations for work prior to assembly, maintenance, and repairHave assembly, maintenance, or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants,risk of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-ble containers of adequate capacity to catch fluids and lubricants.

Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-surized lines, shut off the lines first, then release the residual pressure.

Work must only be carried out on lines when they are free of fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.

Never carry out assembly, maintenance, or repair work with the product in operation, unless:• It is expressly permitted to do so following a written procedure.

Lock-out the product to preclude undesired starting, e.g.• Start interlock• Key switch• Close supply line for hydraulic starting.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.

Before starting work on CaPoS, if used:• Switch off the charging system (DC/DC converter).• Discharge the UltraCap modules using the appropriate discharger.• Short-circuit the UltraCap modules with a suitable wire jumper.

Close the main valve on the compressed-air system and vent the compressed-air line when air starters arefitted.

Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agenttank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.

Disconnect the control equipment from the product.

Use the recommended special tools or suitable equivalents when instructed to do so.

Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipmentUse only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-bly.

Setting down, lifting and climbingCarry out work only on assemblies or plants which are properly secured.

Use appropriate lifting equipment for all components. Use all specified attachment points and observe thecenter of gravity.

Never work on engines or components when they are held in place by lifting equipment.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to preventcomponents/tools from falling down.

Assume a safe standing position when performing assembly work.

Never use the product as a climbing aid.

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When working high on the equipment, always use suitable ladders and work platforms. Special instructionsfor outdoor areas: There must be no risk of slipping e.g. due to icing.

Removing, installing and cleanlinessPay particular attention to cleanliness at all times.

Completely wipe up escaped fluids and lubricants due to the risk of slipping.

Take special care when removing ventilation or plug screws from the product.

Ensure that O-rings are not installed in a slanted/twisted condition.

Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness(e.g. components carrying oil, fuel, or air).

Note cooling time for components which are heated for installation or removal (risk of burning).

Ensure that all mounts and dampers are installed correctly.

Remove any accumulation of condensate after assembling chilled components. Coat the components with asuitable corrosion inhibitor as necessary.

LinesEnsure that lines for all fluids and lubricants and their connections are clean.

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Never bend lines and avoid damaging lines, particularly the fuel lines.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contactwith other components. Do not place fuel or oil lines near hot components.

MiscellaneousSufficient ventilation must be guaranteed during the work.

Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protectivegloves and goggles for protection against acidic condensate.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized orresinous appearance.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.Only install them after painting the engine or mask them prior to painting.

The following applies to starters with copper-beryllium alloy pinions:• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter

with compressed air. Clean the flywheel housing inside with a class H dust extraction device.• Observe the safety data sheet.

Safety regulations after performing assembly, maintenance, and repair workBefore barring the engine, make sure no one is in the danger zone of the engine.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safeguards have been installed and that all tools and loose parts have been removed (especial-ly the barring tool).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Ensure that the grounding system is properly connected.

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Welding workWelding operations on the product or mounted units are not permitted. Cover the product when welding inits vicinity.

Before starting welding work:• Switch off the power supply master switch.• Disconnect the battery cables or actuate the battery isolating switch.• Separate the electrical ground of electronic equipment from the ground of the unit.

No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-cants.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. Thewelding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-tem.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removalCheck the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-ces for hydraulic removal/installation procedures.

Observe the max. permissible push-on pressure specified for the equipment.

Do not attempt to bend or apply force to lines which are under pressure.

Before starting work, pay attention to the following:• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.• For hydraulic installation, screw on the jig with the piston retracted.• For hydraulic removal, screw on the jig with the piston extended.

For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft enduntil correct sealing is established.

During hydraulic installation and removal of components, ensure that nobody is standing in the immediatevicinity of the component to be installed/removed.

Working with batteriesObserve the safety instructions of the manufacturer when working on batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow battery acids to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.

Do not place objects on the battery.

Before connecting the cable to the battery, check the battery polarity. The battery may explode and sprayacid if the battery terminals are connected incorrectly.

Working on electrical and electronic assembliesAlways obtain the permission of the person in charge before commencing assembly, maintenance, and repairwork or switching off any part of the electronic system required to do so.

De-energize the relevant areas prior to working on assemblies.

ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic dischargemust always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductivework surfaces or antistatic wristbands.

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Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-ing operation by:• Contact with sharp edges• Chafing on components• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable ties to secure lines.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to functional testing on completion of all repair work. The emergen-cy stop function must be tested in particular. The functional check of the emergency stop, during which thevoltage supply of the ECU is switched off, must only be carried out when the product is cold.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Packagefaulty electronic components or assemblies properly before dispatching for repair:• Moisture-proof• Shock-proof• Wrapped in antistatic foil (as necessary)

Working with laser equipmentWork with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-structions in the manufacturer's user manual when working with laser equipment.

Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).

Laser equipment must be fitted with the protective devices necessary for safe operation according to typeand application.

Measuring component dimensionsWorkpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-perature of 20 °C.

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1.6 Fire and environmental protection, fluids and lubricants

Fire prevention and fireFire, naked light and smoking are prohibited.

In case of a fire, stop the fuel supply if this is possible without endangering personnel.

The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.The operating company must install and operate the product a safe distance away from danger sources andobserve any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-tion do not constitute such as danger.

After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.

Eliminate leaks of fluids and lubricants immediately. Fluids and lubricants on hot components can causefires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on theproduct. Do not store combustible materials near the product.

Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work onpipes and components carrying oil or fuel.

When starting the engine with an external power source, connect the ground lead last and remove it first. Toavoid sparks in the vicinity of the battery, connect the ground cable from the external power source to theground cable of the engine or to the ground terminal of the starter.

Ensure that suitable extinguishing agents (fire extinguishers) are always available and that staff are familiarwith their correct handling.

A fire can result in the creation of toxic substances. Always wear protective gloves when handling compo-nents and wear additional personal protective equipment is necessary.

NoiseWear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).

Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-ger are compromised.

Environmental protection and disposalDispose of used fluids, lubricants and components in accordance with local regulations.

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-cled.

Fluids and lubricants/auxiliary materials (process materials)Process materials can also be or contain hazardous or toxic substances. When using process materials andother chemical substances, observe the associated safety data sheet. The safety data sheet may be obtainedfrom the relevant manufacturer or from MTU.

Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi-cations must be used. The most recent respective version must be requested from the manufacturer.

Contamination of process materials with reducing agent (e.g. AdBlue®, DEF): Store process materials in sep-arate containers and their own drip trays. Even extremely small amounts of reducing agent contaminationcan result in malfunctions in sensors and other components.

Used oil contains combustion residues that are harmful to health.

When handling used oil, protective gloves must be used.

Wash relevant areas after contact with used oil.

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Registration, evaluation, approval and restriction of chemicals (REACHordinance)Particularly hazardous substances used with our products are named in a list:

www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products

Compressed air• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-

tainers, risks causing an explosion.• Wear goggles when blowing dirt off workpieces or blowing away chips.• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)

for drying purposes or to check for leaks risks bursting them.• Pay special attention to the pressure in the compressed air system or pressure vessel.• Assemblies or products which are to be connected must be designed to withstand this pressure. Install

pressure-reducing or safety valves set to the admissible pressure if this is not the case.• Hose couplings and connections must be securely attached.• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).• Release residual pressure before removing a compressed air device from the supply line. To depressurize

compressed-air lines, shut off the lines first, then release the residual pressure.• Carry out a leak test in the specified manner.

Painting• Observe the relevant safety data sheet for all materials.• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure

that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.• Avoid open flames in the surrounding area.• No smoking.• Observe fire-prevention regulations.• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen• Observe the relevant safety data sheet for all materials.• Work with liquid nitrogen may be carried out only by qualified personnel.• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.• Avoid body contact (eyes, hands).• Wear protective clothing, protective gloves, closed shoes and safety goggles.• Make sure that the working area is well ventilated.• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkalines/reducing agents (e.g. AdBlue®, DEF)• Observe the relevant safety data sheet for all materials.• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-

ing.• Do not inhale vapors.• If reducing agent is swallowed, rinse out mouth and drink plenty of water.• Remove any wet clothing immediately.• After skin contact, wash affected body areas with plenty of water.• Rinse eyes immediately with eyedrops or clean mains water. Consult a doctor as soon as possible.

Contamination of reducing agent with other process materials: Store reducing agent in separate contain-ers and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the ex-haust aftertreatment system.

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1.7 Standards for warning notices in the text and highlightedinformation

DANGERIn the event of immediate danger.Consequences: Death, serious or permanent injury!• Remedial action.

WARNINGIn the event of a situation involving potential danger.Consequences: Death, serious or permanent injury!• Remedial action.

CAUTIONIn the event of a situation involving potential danger.Consequences: Minor or moderate injuries!• Remedial action.

NOTICEIn the event of a situation involving potentially adverse effects on the product.Consequences: Material damage!• Remedial action.• Additional product information.

Warning notices1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-

ation, maintenance, repair, assembly, installation, or transportation.2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-

sonal injury shall be considered to include a warning of potential damage.

Highlighted informationImportantThis field contains product information which is important or useful for the user.This information must not refer to hazards related to personal injury or material damage.

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2 Transport

2.1 Transport

Special tools, Material, Spare partsDesignation / Use Part No. Qty.

Crossbeam T80092479 1

DANGERSuspended load.Danger to life!• Use suitable equipment and lifting devices.• Never stand beneath a suspended load and keep a safe distance.• Wear personal protective equipment (e.g. protective helmet, safety shoes).

Transport1. Lift the engine only with the lifting eyes provided.2. Only use suitable and tested transport and lifting equipment.3. Use all lifting eyes as shown on the installation drawing to lift the engine .4. Take the engine's center of gravity into account. For information regarding the center of gravity of the en-

gine, refer to the installation/arrangement drawing of the engine.5. Always transport the in installation position, do not exceed max. permissible diagonal pull (→ Page 19).6. Lift engine by approx. 10 mm and verify that the lifting ropes / chains between engine and lifting equipment

run vertically or in accordance with the specifications on the installation drawing. If this is not the case, thelifting equipment must be re-adjusted.

7. If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bearingpedestal or use a means of transportation which is appropriate for the given weight (forklift truck).

8. Secure the engine against tipping during transportation.9. Secure such as to preclude slipping and tipping when driving up or down inclines and ramps.

Setting the engine down after transport1. Make sure that consistency and load-bearing capacity of ground or support surface is adequate.2. Never set down engine onto the oil pan unless expressly permitted by MTU on an engine-specific base.3. Only set down engine on a firm, level surface.

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2.2 Lifting specificationsLifting specifications

DANGERSuspended load.Danger to life!• Use suitable equipment and lifting devices.• Never stand beneath a suspended load and keep a safe distance.• Wear personal protective equipment (e.g. protective helmet, safety shoes).

1 Maximum permissible diag-onal pull 10° (*) in longitu-dinal direction

2 Maximum permissible diag-onal pull 3° (*) in trans-verse direction

3 Center of gravity

(*) Observe max. admissible diagonal pull:• Max. permissible diagonal pull in longitudinal direction is 10 degrees; no transverse diagonal pull is admis-

sible in this case.• Max. permissible diagonal pull in longitudinal direction is 3 degrees; no longitudinal diagonal pull is admis-

sible in this case.

Taking note of the engine center of gravityRefer to the installation/arrangement drawings for details of the center of gravity of the system or engine.

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3 General Information

3.1 Engine – Overview

1 Lifting eye, driving end2 Service indicator3 Cylinder head4 Exhaust elbow

5 Engine mounting6 Exhaust turbocharger7 Oil pan8 Starter

9 Flywheel10 Flywheel housingKS Driving end

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1 Lifting eye, free end2 Air filter3 Air supply pipework4 Fuel filter

5 Crankcase6 Oil pan7 Engine governor8 Oil filter

9 Thermostat housing (returncooler)

10 Belt driveKGS Free end

Engine model designationKey to the engine model designation 6R1600Gxyz / 6R1600Bxyz6 Number of cylindersR Cylinder arrangement: In-line engine1600 SeriesG/B Application (G/B for Diesel Gendrive)x Application segment (1, 2, 4, 5, 7, 8)y Design statusz Frequency (F = 50 Hz, S = 60 Hz)

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3.2 Engine side and cylinder designations

1 Engine free end in accord-ance with DIN ISO 1204(KGS = Kupplungsgegen-seite)

2 Right engine side

3 Engine driving end in ac-cordance withDIN ISO 1204 (KS = Kup-plungsseite)

4 Left engine side

For engine side designation (acc. to DIN ISO 1204), the engine is viewed on driving end (3).

For cylinder designation (acc. to DIN ISO 12041), cylinders are numbered consecutively from engine drivingend (3) starting with No. 1.

The numbering of other engine components is also from the driving end (3), starting with No. 1.


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3.3 Sensors and actuators

Item Name Monitoring of1 B1 Camshaft speed2 B13 Crankshaft speed

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Item Name Monitoring of1 B48 Fuel high pressure2 XY39.A2 Injectors3 B10 Charge-air pressure4 XY39.A1 Injectors5 M8 HP fuel pump (metering unit)6 B9 Charge-air coolant temperature7 B5 Lube oil pressure8 B16 Coolant pressure9 B6 Coolant temperature


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4 Technical Data

4.1 Engine data 6R1600B30S 60 Hz, fuel optimizedExplanation:

DL Reference value: Continuous powerBL Reference value: Fuel stop powerA Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated, without change (e.g. of power setting).N Not yet defined value- Not applicable

X Applicable* Value not verified (tolerance ± 10%)

Reference conditionsEngine model 6R1600B

30SApplication group 3B

Intake air temperature °C 25

Barometric pressure mbar 1000

Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)Number of cylinders 6Rated engine speed A rpm 1800

Continuous power ISO 3046 (10% overload capability) (power range DIN 6280,ISO 8528)

A kW 284

Site conditions (for max. power)Number of cylinders 6Intake depression (new filter) A mbar 25

Intake depression, max. L mbar 50

Exhaust gas overpressure A mbar 85

Exhaust gas overpressure, max. L mbar 150

Model-related data (basic design)Number of cylinders 6Number of cylinders 6

Standard housing connecting flange (engine main PTO) SAE 01

Flywheel connection (DISC) 14"

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Air / exhaust gasNumber of cylinders 6Charge-air pressure before cylinder – DL R bar abs 3,6

Coolant system (HT circuit)Number of cylinders 6Coolant temperature (at engine connection: outlet to cooling system) A °C 95

Coolant temperature after engine, warning L °C 105

Coolant temperature after engine, shutdown L °C 109

Pressure loss in off-engine cooling system, max. L bar 0.7

Lube oil systemNumber of cylinders 6Lube oil pressure before engine, warning L bar 3.2

Lube oil pressure before engine, shutdown L bar 3.0

Fuel systemNumber of cylinders 6Fuel pressure at engine supply connection, min. (when engine is started) L bar -0.5

Fuel pressure at engine supply connection, max. (when engine is started) L bar 0.5

General operating dataNumber of cylinders 6Cold start capability: air temperature (w/o start aid, w/o preheating) – (caseA)

R °C -20

Firing speed, from R rpm 80

Firing speed, to R rpm 120

CapacitiesNumber of cylinders 6Engine coolant, engine side (w/o cooling equipment) R Liters 45

Total engine oil capacity, initial filling (standard oil system) (option: max. oper-ating inclinations)

R Liters 46

Oil change quantity, max. (standard oil system) (option: max. operating inclina-tions)

R Liters 45

Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op-erating inclinations)

L Liters 36

Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max.operating inclinations)

L Liters 45

MassesNumber of cylinders 6Engine dry weight (with standard accessories installed, w/o coupling) R kg 1185*

Engine weight, filled (with standard accessories installed, w/o coupling) R kg 1218

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AcousticsNumber of cylinders 6Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3 dB(A) tol-erance)

R dB(A) 113

Engine surface noise with attenuated intake noise (filter) – DL (sound powerlevel LW, ISO 6798, +2 db(A) tolerance)

R dB(A) 118


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A kW 249






Cylinder displacement Liters 1,75



COMBUSTION AIR / EXHAUST GASNumber of cylinders 6Charge-air pressure before cylinder – DL R bar abs 2.8


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Coolant antifreeze content, max. L % 50







R °C -20



CapacitiesNumber of cylinders 6Engine coolant, engine side (w/o cooling equipment) R Liters 45*


R Liters 46


R Liters 45


L Liters 36


L Liters 45




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R dB(A) 114


R dB(A) 116


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4.3 Engine data 6R1600B40S 50 Hz, emissions optimizedExplanation:










A kW 274









Coolant temperature after engine, warning R °C 105



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Number of cylinders 6Coolant antifreeze content, max. L % 50


Lube oil systemNumber of cylinders 6Lube oil pressure before engine, warning R bar 2.6





R °C -20



CapacitiesNumber of cylinders 6Engine oil capacity, initial filling (standard oil system) (option: max. operatinginclinations)

R Liters 42


R Liters 42


L Liters 33


L Liters 41




R dB(A) 115

Engine surface noise with attenuated intake noise (filter) - DL (sound powerlevel LW, ISO 6798, +2 dB(A) tolerance)

R dB(A) 117


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2625

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A kW 274






Standard housing connection flange (engine main PTO) SAE 01






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Fuel systemNumber of cylinders 6Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.5

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5


R °C -20



CapacitiesNumber of cylinders 6Engine coolant, engine side (w/o cooling equipment) R Liters 45*


R Liters 42


R Liters 42


L Liters 33


L Liters 41




R dB(A) 115


R dB(A) 117


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2627

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A kW 312






Standard housing connection flange (engine main PTO) SAE 01


Air / exhaust gasNumber of cylinders 6Charge-air pressure before cylinder – DL R bar abs 3.5


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2630

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Coolant antifreeze content, max. L % 50


Lube oil systemNumber of cylinders 6Lube oil operating temperature after engine, to R °C 114

Lube oil pressure before engine, warning L bar 3.2


Fuel systemNumber of cylinders 6Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.5

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5


R °C -20



CapacitiesNumber of cylinders 6Total engine oil capacity, initial filling (standard oil system) (option: max. oper-ating inclinations)

R Liters 46


R Liters 45


L Liters 36


L Liters 45




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2630

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R dB(A) 113


R dB(A) 118


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4.6 Engine data 6R1600B40S 60 Hz, emissions optimizedExplanation:










A kW 312












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Lube oil systemNumber of cylinders 6Lube oil pressure before engine, warning R bar 3.2





R °C -20



CapacitiesNumber of cylinders 6Fuel, engine side R Liters 3*

Engine oil capacity, initial filling (standard oil system) (option: max. operatinginclinations)

R Liters 46


R Liters 45


L Liters 36


L Liters 45




R dB(A) 113

Engine surface noise with attenuated intake noise (filter) - DL (sound powerlevel LW, ISO 6798, +2 dB(A) tolerance)

R dB(A) 118


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4.7 Engine data 6R1600G10F, G20F, fuel optimizedExplanation:


X Applicable* Value not adequately verified (tolerance ± 10%)

Reference conditionsEngine model 6R1600

G10F6R1600

G20FApplication group 3B 3B

Intake air temperature °C 25 25

Barometric pressure mbar 1000 1000

Site altitude above sea level m 100 100

Power-related data (power ratings are net brake power as per ISO 3046)Number of cylinders 6 6Rated engine speed A rpm 1500 1500

Continuous power ISO 3046 (10% overload capability) (powerrange DIN 6280, ISO 8528)

A kW 249 274

Site conditions (for max. power)Number of cylinders 6 6Intake depression (new filter) A mbar 25 25

Intake depression, max. L mbar 50 50

Exhaust gas overpressure A mbar 85 85

Exhaust gas overpressure, max. L mbar 85 85

Model-related data (basic design)Number of cylinders 6 6Cooling method: treated water X X

Direction of rotation: c.c.w. (facing driving end) X X

Standard housing connection flange (engine main PTO) SAE 01 01

Flywheel interface DISC 14" 14"

Air / exhaust gasNumber of cylinders 6 6Charge-air pressure before cylinder – DL R bar abs 2.8 2.6


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Coolant system (HT circuit)Number of cylinders 6 6Coolant temperature (at engine connection: outlet to cooling sys-tem)

A °C 95 95

Coolant temperature after engine, warning R °C 105 105

Coolant temperature after engine, shutdown L °C 109 109

Coolant antifreeze content, max. L % 50 50

Pressure loss in off-engine cooling system, max. L bar 0.7 0.7

Lube oil systemNumber of cylinders 6 6Lube oil operating temperature before engine, from R °C 105 105

Lube oil operating temperature before engine, to R °C 115 115

Lube oil temperature before engine, warning R °C - -

Lube oil temperature before engine, shutdown L °C - -

Lube oil operating pressure before engine, from R bar 4.5 4.5

Lube oil operating pressure before engine, to R bar 5.5 5.5

Lube oil pressure before engine, warning L bar 2.6 2.6

Lube oil pressure before engine, shutdown L bar 2.4 2.4

Fuel systemNumber of cylinders 6 6Fuel pressure at engine supply connection, min. (when engine isstarted)

L bar -0.5 -0.5

Fuel pressure at engine supply connection, max. (when engine isstarted)

L bar 0.5 0.5

General operating dataNumber of cylinders 6 6Cold start capability: air temperature (w/o start aid, w/o preheat-ing) – (case A)

R °C -20 -20

Firing speed, from R rpm 80 80

Firing speed, to R rpm 120 120

CapacitiesNumber of cylinders 6 6Engine coolant, engine side (w/o cooling equipment) R Liters 45* 45*

Total engine oil capacity, initial filling (standard oil system) (option:max. operating inclinations)

R Liters 42 42

Max. oil change quantity (standard oil system) R Liters - -

Oil change quantity, max. (standard oil system) (option: max. oper-ating inclinations)

R Liters 41 41


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Number of cylinders 6 6Oil pan capacity at dipstick mark “min.” (standard oil system) (op-tion: max. operating inclinations)

L Liters 32 32

Oil pan capacity at dipstick mark “max.” (standard oil system) (op-tion: max. operating inclinations)

L Liters 40 40

MassesNumber of cylinders 6 6Engine weight, dry (basic engine configuration acc. to scope ofsupply specification)

R kg 1185* 1185*

Engine weight, filled (with standard accessories installed, w/ocoupling)

R kg 1218 1218

AcousticsNumber of cylinders 6 6Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798,+3 dB(A) tolerance)

R dB(A) 114 115

Engine surface noise with attenuated intake noise (filter) – DL(sound power level LW, ISO 6798, +2 db(A) tolerance)

R dB(A) 116 116


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4.8 Engine data 6R1600G10F, G20F, emissions optimizedExplanation:




G10F6R1600







A kW 249 274











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A °C 95 95

Coolant temperature after engine, warning L °C 105 105










Lube oil pressure before engine, warning L bar 2.6 2.6


Fuel systemNumber of cylinders 6 6Fuel pressure at engine inlet connection, min. (when engine isstarting)

L bar -0.5 -0.5

Fuel pressure at engine inlet connection, max. (when engine isstarting)

L bar 0.5 0.5


R °C -20 -20




Total engine oil capacity for initial filling (standard oil system) R Liters 42 42

Oil change capacity, max. (standard oil system) R Liters - -


R Liters 45 45


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L Liters 32 32


L Liters 40 40

MassesNumber of cylinders 6 6Engine dry weight (with standard accessories installed, w/o cou-pling)

R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6

Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798,+3 dB(A) tolerance)

R dB(A) 114 115


R dB(A) 116 117


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4.9 Engine data 6R1600G10F, G20F, Nonroad stage III aExplanation:




G10F6R1600







A kW 249 274







Standard housing connecting flange (engine main PTO) SAE 01 01




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A °C 95 95











Lube oil pressure before engine, warning R bar 2.6 2.6



L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20




Total engine oil capacity for initial filling (standard oil system) R Liters - -



R Liters 42 42


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L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

AcousticsNumber of cylinders 6 6Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798,+3 dB(A) tolerance)

R dB(A) 114 115


R dB(A) 116 116


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4.10 Engine data 6R1600G10S, G20S, EPA stage 3Explanation:



** Data not yet available at time of publication


G10S6R1600

G20SApplication group 3B 3B

Intake air temperature °C ** 25

Barometric pressure mbar ** 1000

Site altitude above sea level m ** 100



A kW 284 312









Air / exhaust gasNumber of cylinders 6 6Charge-air pressure before cylinder – DL R bar abs 3,6 3,6


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A °C 95 95



Coolant antifreeze content, max. L % ** 50








Lube oil operating pressure before engine, warning (speed-de-pendent value, consult MTU)

R bar 3.2 3.2

Lube oil operating pressure before engine, shutdown (speed-de-pendent value, consult MTU)

L bar 3.0 3.0


L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20



CapacitiesNumber of cylinders 6 6Engine coolant, engine side (w/o cooling equipment) R Liters 45 45*

Total engine oil at initial filling (standard oil system) R Liters 42 42



R Liters 41 41


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L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6


R dB(A) 113 113


R dB(A) 118 118


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G40F6R1600

G50FApplication group 3C 3C





Fuel stop power ISO 3046 A kW 274 301











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A °C 95 95











Lube oil pressure before engine, warning R bar 2.6 2.6



L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20




Total engine oil at initial filling (standard oil system) R Liters 42 42



R Liters 41 41


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L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6


R dB(A) 114 115


R dB(A) 116 116


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1092

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G40F6R1600

















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A °C 95 95












L bar 2.6 2.6


L bar 2.4 2.4


L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20



General operating dataNumber of cylinders 6 6Engine coolant, engine side (w/o cooling equipment) R Liters 45* 45*


R Liters 42 42



R Liters 41 41


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1093

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L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6


R dB(A) 114 115


R dB(A) 116 117


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G40F6R1600

















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A °C 95 95












L bar 2.6 2.6


L bar 2.4 2.4


L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20





R Liters 42 42



R Liters 41 41


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L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6


R dB(A) 114 115


R dB(A) 116 116


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G70F6R1600

G80FApplication group 3D 3D














Air / exhaust gasNumber of cylinders 6 6Charge-air pressure before cylinder – BL R bar abs 3.2 3.4


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0000

1095

8 - 0

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A °C 95 95












L bar 2.6 2.6


L bar 2.4 2.4


L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20





R Liters 42 42



R Liters 41 41


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L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6

Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798,+3 dB(A) tolerance)

R dB(A) 115 115

Engine surface noise with attenuated intake noise (filter) - BL(sound power level LW, ISO 6798, +2 dB(A) tolerance)

R dB(A) 116 116


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1095

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X Applicable* Data not yet available at time of publication


G70F6R1600













Standard housing connecting flange (engine main PTO) SAE 01 01




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1096

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A °C 95 95









Lube oil operating pressure before engine, from R bar * 4,2

Lube oil operating pressure before engine, to R bar * 4,8


R bar


L bar


L bar -0.5 -0.5


L bar 0,0 0,0


R °C -20 -20



CapacitiesNumber of cylinders 6 6Engine coolant, engine side (w/o cooling equipment) R Liters 45 45

Total engine oil capacity for initial filling (standard oil system) R Liters - -



R Liters 45 45


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L Liters 36 36


L Liters 45 45


R kg 1185* 1185*


R kg 1218 1218

AcousticsNumber of cylinders 6 6Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798) R dB(A) 115 116

Engine surface noise with attenuated intake noise (filter) - BL(sound power level LW, ISO 6798)

R dB(A) 117 116


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0000

1096

6 - 0

02





G70F6R1600

















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1097

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A °C 95 95












L bar 2.6 2.6


L bar 2.4 2.4


L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20





R Liters 42 42



R Liters 41 41


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L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6


R dB(A) 115 115


R dB(A) 116 116


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4.17 Engine data 6R1600G70S, G80S, EPA stage 3Explanation:





G70S6R1600

G80SApplication group 3D 3D
















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A °C 95 95












L bar 3.2 3.2


L bar 3.0 3.0


L bar -0.5 -0.5


L bar 0.5 0.5


R °C -20 -20





R Liters 42 42



R Liters 41 41


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0000

1097

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02


L Liters 32 32


L Liters 40 40


R kg 1185* 1185*


R kg 1218 1218

Acoustics6 6


R dB(A) 113 117


R dB(A) 118 117


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4.18 Firing order

Firing orderNumber of cylinders Firing order6R 2–4–1–5–3–6


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1070

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4.19 Engine – Main dimensions

Engine – Main dimensions

Length (A) approx. 1630 mm

Width (B) approx. 920 mm

Height (C) approx. 1185 mm


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5 Operation

5.1 Putting the engine into operation after extended out-of-serviceperiods (>3 months)

Preconditions☑Engine is stopped and starting disabled.

☑MTU Preservation and Represervation Specifications (A001070/..) available.

Putting the engine into operation after extended out-of-service-periods (>3months)Item ActionEngine Depreserve (→ MTU Preservation and Represervation Specifications

A001070/..).Lube oil system Check engine oil level (→ Page 101).Fuel system Vent (→ Page 93).Engine coolant circuit If engine is out of service for more than one year, change engine coolant

(→ Page 105).Engine coolant circuit Check engine coolant level (→ Page 104).Engine coolant circuit Preheat engine coolant with coolant preheater (if applicable).Engine governor Check plug connections (→ Page 117).Monitoring system Carry out lamp test (see manufacturer's documentation).Engine/generator controlsystem

Switch on;Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.

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5.2 Putting into operation after scheduled out-of-service-period


Putting into operationItem ActionLube oil system Check engine oil level (→ Page 101).Engine coolant circuit Check engine coolant level (→ Page 104).Engine coolant circuit Preheat engine coolant with coolant preheater (if applicable).Fuel prefilter Drain fuel prefilter (→ Page 95).Monitoring system Carry out lamp test (see manufacturer's documentation).Engine/generator controlsystem

Switch on;Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.

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5.3 Starting the engine in manual mode (test run)

Preconditions☑Generator is not connected to the mains.

☑External start interlock is not activated.

DANGERRotating 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 engine's

danger zone.

WARNINGHigh level of engine noise when the engine is running.Risk of damage to hearing!• Wear ear protectors.

NOTICERe-starting the engine following an automatic safety shutdown.Risk of severe engine damage!• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.• If the root cause cannot be identified or eliminated, contact Service.

PreparationItem ActionOperating mode switch (iffitted)

Change to manual mode.

Starting the engineItem ActionControl cabinet, operatorstation etc. (depending onmanufacturer)

Press start button.• Automatic starting sequence is performed;• Engine speed display instrument indicates increasing crankshaft speed;• After the starting sequence is completed, engine is running at rated

speed.

Connecting the generator to network, running the engine to reach operatingtemperatureItem ActionControl cabinet, operatorstation etc. (depending onmanufacturer)

Close the generator circuit breaker.

Engine Apply full load only after engine has reached operating temperature (coolanttemperature approx. 60 °C).

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5.4 Safety system – OverrideNOTICE

Safety functions and engine shutdown alarms will be disregarded.Severe material damage!• Initiate emergency start only in emergency situations.

NOTICEInadmissible operating status.Severe damage to property!• Use override function only in hazardous situations to ensure full capability in the event of engine

faults.

Preparation

Note: This function is only available when a pushbutton is provided.

Safety system – OverrideItem ActionSwitchgear cabinet, controlpanel etc. (depending onmanufacturer)

Activate pushbutton for Override input of the ECU.• Certain shutdown criteria and/or starting prerequisites are ignored.

Switchgear cabinet, controlpanel etc. (depending onmanufacturer)

Actuate start button, for further starting sequence, refer to engine start(→ Page 77).

Control and display panels During operation, check the displayed operational data (speed, temperature,pressures).Constantly monitor plant limit values.

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5.5 Operational monitoringDANGER

Components are moving or rotating.Risk of crushing, danger of parts of the body being caught or pulled in!• Operate the engine at low load only. Keep clear of the danger zone of the engine.


Operational monitoringItem ActionEngine under loadEngine at nominal speed

Visually inspect engine for leaks and general condition;Check for abnormal running noises and vibration;Check exhaust gas color (→ Page 86).

Air filter Check signal ring position of service indicator (→ Page 99).Replace air filter (→ Page 97), if the signal ring is completely visible in theservice indicator control window.

Coolant pump Check relief bore for oil and coolant discharge and contamination(→ Page 109).

Engine oil Check engine oil level(→ Page 101)

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5.6 Emission label – Check

Emission label – CheckNote: If there are any irregularities, notify your MTU contact person/service partner without delay.

1. Check that emission labels are present (there can be more than one).2. Check emission label for intactness.3. Check that emission label is fully legible.4. Check content of emission label:

• Does the label on the engine match the label document in the Business Portal/Equipment?• Does the engine number on the emission label match the engine identification plate?• Does the Manufacturing Date match the year of manufacture on the identification plate?

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5.7 Engine stop in manual operation (trials)

Preconditions☑Generator is not connected to network.

☑Engine is running in manual mode.

PreparationItem TaskEngine After the generator breaker has been opened, allow the engine to cool down

by running it idle for approx. 5 minutes.

Stop engineItem TaskSwitchgear cabinet, controlpanel etc. (depending onmanufacturer)

Press stop button.• Automatic stopping sequence is performed;• engine is stopped.

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5.8 Emergency engine shutdownNOTICE

An emergency stop subjects the engine system to an extremely high load.Risk of overheating, damage to components!• Trigger an emergency stop only in emergency situations.

Emergency engine shutdownItem ActionEmergency stop pushbutton Press pushbutton.

• Engine is stopped by disconnecting the power supply to the ECU;• Signalization (e.g. by horn, beacon) is activated.

After emergency engine shutdownItem ActionControl cabinet, operatorstation etc. (depending onmanufacturer)

Press pushbutton for alarm acknowledgment.• Audible and visual alarm output stops

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5.9 After stopping the engine – Engine remains ready foroperation

After stopping the engineItem ActionEngine/generator/pumpcontrol

Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.

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5.10 After stopping the engine – Putting the engine out ofoperation

Preconditions☑MTU Fluids and Lubricants Specifications (A001063/..) are available.

After stopping the engineItem TaskCoolant circuit Drain engine coolant (→ Page 106) if:

• the engine room is not heated;• the engine coolant is not maintained 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.Engine/generator/pumpcontrol

Switch OFF.

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6 Maintenance

6.1 Maintenance task reference table [QL1]The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. TheMaintenance Schedule is a separate publication.

The task numbers in this table provide reference to the maintenance tasks specified in the MaintenanceSchedule.

Task

Opt

ion Maintenance tasks

W0500 Check engine oil level. (→ Page 101)W0501 Visually inspect engine for leaks and general condition. (→ Page 79)W0502 X Check intercooler condensate drain. (This is not applicable to your

system.)W0507 X Drain water and contamination from fuel prefilter. (→ Page 95)W0521 Check signal ring position of maintenance indicator, replace

air filter if necessary.(→ Page 99)

W0800 Check if emissions label is present, legible and content-wisecorrect.

(→ Page 80)

W1001 Replace fuel filter or fuel filter element. (→ Page 94)W1003 Check belt condition and tension, replace if necessary. (→ Page 112), (→ Page 113)W1005 Replace air filter. (→ Page 97)W1008 Replace engine oil filter when changing engine oil, or when

the interval (years) is reached, at the latest.(→ Page 103)

W1010 Check exterior of cooler elements for dirt. (→ Page 110)W1207 Check valve clearance, adjust as necessary. IMPORTANT!

First adjustment after 1,000 operating hours.(→ Page 90)

W1483 Replace poly-Vee drive belt of fan. (→ Page 114)W1505 X Replace drive belts of battery-charging generator and cool-

ant pump.(→ Page 114)

W1675 Replace fuel prefilter or filter element of fuel prefilter. (→ Page 96)

Table 1: Maintenance task reference table [QL1]

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7 Troubleshooting

7.1 Troubleshooting

Engine does not turn when starter is actuatedCause Corrective action

Battery low or defective u Charge or replace (→ manufacturer's documentation).Cable connections defective u Check cable connections for secure seating (→ manufacturer's

documentation).Starter: Engine cabling or starterdefective

u Check if cable connections are properly secured, contact Service.

Engine cabling defective u Check (→ Page 115).Engine / generator control:Assemblies or connectorspossibly loose

u Carry out visual inspection (→ manufacturer's documentation).

Engine governor: Plug-inconnections loose

u Check plug connections (→ Page 117).

Running gear blocked (enginecannot be barred manually)

u Contact Service.

Engine turns on starting but does not fireCause Corrective action

Poor rotation by starter: Batterylow or defective

u Charge or replace battery (→ manufacturer's documentation).

Engine cabling defective u Check (→ Page 115).Air in fuel system u Vent fuel system (→ Page 93).Engine governor defective u Contact Service.

Engine fires unevenlyCause Corrective action

Injector defective u Contact Service.Engine cabling defective u Check (→ Page 115)Air in fuel system u Vent fuel system (→ Page 93)Engine governor defective u Contact Service.

Engine does not reach nominal speedCause Corrective action

Fuel filter clogged u Replace (→ Page 94).Air filter clogged u Check, replace if necessary (→ Page 99).Injector defective u Contact Service.Engine cabling defective u Check (→ Page 115).Engine: Overload u Contact Service.

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Engine speed not steadyCause Corrective action

Injector defective u Contact Service.Speed sensor defective u Contact Service.Air in fuel system u Vent fuel system (→ Page 93).Engine governor defective u Contact Service.

Charge-air temperature too highCause Corrective action

Engine room: Air-intaketemperature too high

u Check fans and intake/exhaust lines.

Charge-air pressure too lowCause Corrective action

Air filter clogged u Check, replace if necessary (→ Page 99).Exhaust turbocharger defective u Contact Service.

Black exhaust gasCause Corrective action

Air filter clogged u Check, replace if necessary (→ Page 99).Injector defective u Contact Service.Engine: Overload u Contact Service.

Blue exhaust gasCause Corrective action

Too much engine oil in the engine u Drain engine oil (→ Page 102).Exhaust turbocharger, cylinderhead, piston rings or cylinder linerdefective

u Contact Service.

White exhaust gasCause Corrective action

Engine is not at operatingtemperature

u Run up to operating temperature.

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8 Task Description

8.1 Engine

8.1.1 Engine – Barring with starting system

Preconditions☑External pushbutton 'Bar engine without starting' is provided.

DANGERRotating 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 engine's

danger zone.

Engine – Barring with starting system1. Press pushbutton 'Bar engine without starting' and keep depressed.2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.3. Repeat procedure after approx. 20 seconds if necessary.

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8.1.2 Engine – Test run

DANGERComponents are moving or rotating.Risk of crushing, danger of parts of the body being caught or pulled in!• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNINGExhaust gases are harmful to health and may cause cancer.Risk of poisoning and suffocation!• Keep the engine room well-ventilated at all times.• Repair leaking exhaust pipework immediately.


Engine – Test run1. Start engine (→ Page 77).2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.3. Carry out operational checks (→ Page 79).4. Stop engine (→ Page 81).

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8.2 Valve Drive

8.2.1 Valve clearance – Check and adjustment


☑Engine coolant temperature is max. 40 °C.

☑Valves are closed.


Feeler gage Y20098771 1Torque wrench, 20–100 Nm F30026582 1Box wrench, 14 mm F30028346 1Angular screw driver, set 2–10 mm F30453050 1

Preparatory steps1. Remove cylinder head cover (→ Page 92).2. Bar engine manually in engine direction of rotation to bring the A1 piston to top dead center position.

Diagram: Two crankshaft posi-tions

1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCE Inlet valveA Exhaust valve

Checking valve clearance at two crankshaft positions1. Check TDC position of piston in cylinder A1:

• If the rocker arms are unloaded on cylinder 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 = 0.3 mm;• Exhaust = 0.6 mm.

3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as perdiagram.

4. Use feeler gauge to determine the distance between valve bridge and rocker arm.5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

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Adjusting valve clearance1. Loosen locknut (1) and unscrew adjusting

screw (2) by a few threads.2. Insert feeler gauge between valve bridge and

rocker arm (3).3. Readjust adjusting screw (2) so that the feel-

er gauge just passes through the gap.

4. Tighten locknut (1) with torque wrench to specified torque, holding adjusting screw (2) firm with Allen screw.

Name Size Type Lubricant Value/Standard

Nut M10 x 1 Tightening torque 43 Nm +4 Nm

5. Check if the feeler gauge just passes through between valve bridge and rocker arm (3).Result: If not, adjust valve clearance.

Final steps1. Install cylinder head cover (→ Page 92).2. Install plug.

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8.2.2 Cylinder head cover – Removal and installation


Cylinder head cover – Removaland installation

1. Loosen and remove screws.2. Remove cylinder head cover.3. Clean installation surface.4. Check condition of profile gasket and replace

if required.

5. Fit cylinder head cover and tighten screws with torque wrench to specified tightening torque.


Screw with twin col-lar

M8 Preload torque 10 Nm

6. Tighten screws to specified torque using a torque wrench.


Screw with twin col-lar

M8 Tightening torque 20 Nm ±2 Nm

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8.3 Fuel System

8.3.1 Fuel system – Venting


WARNINGFuels are combustible and explosive.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition sources.• Do not smoke.• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Fuel system – Venting1. Unlock fuel priming pump, screw out han-

dle (1).2. Loosen nut (2) on banjo union.

Note: Catch emerging fuel with a suitable cloth.3. Operate the pump with the handle (1) until

bubble-free fuel emerges.4. Tighten nut (2) on banjo union.5. Lock fuel priming pump, screw in handle (1).

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8.4 Fuel Filter

8.4.1 Fuel filter – Replacement



Filter wrench F30379104 1Engine oilEasy-change filter (→ Spare Parts Catalog) 1


Fuel filter – Replacement1. Use filter wrench to remove easy-change fil-

ter.2. Clean sealing surface on filter head.3. Slightly lubricate seal on easy-change filter.4. Screw on easy-change filter by hand until the

seal makes contact and then tighten by hand.

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8.4.2 Fuel prefilter – Draining



Fuel prefilter – Draining1. Provide a suitable container to collect the wa-

ter.2. Open drain plug (1).3. Allow the water to drain off.4. Close drain plug (1) again.

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8.4.3 Fuel prefilter – Replacement


☑System is not under pressure.


Filter wrench F30379104 1Engine oilEasy-change filter (→ Spare Parts Catalog) 1


WARNINGTank is pressurized.Risk of eye injuries resulting from fluid escaping under high pressure!• Open tank slowly.• Wear goggles or safety mask.

NOTICEContamination of components.Damage to component!• Observe manufacturer's instructions.• Check components for special cleanliness.

Fuel prefilter – ReplacementNote: Collect escaping fuel and dispose of.

1. Use filter wrench to screw easy-change fil-ter (2) off and take it off together with sightglass (3).

2. Discard old easy-change filter (2).3. Clean sealing surface on filter head (1).4. Coat seal on new easy-change filter (2) with

little engine oil.5. Screw on easy-change filter (2) by hand until

the seal makes contact with the filter headand tighten manually.

6. Push on sight glass (3).

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8.5 Air Filter

8.5.1 Air filter ‒ Replacement


Air filter (→ Spare Parts Catalog)

Air filter ‒ Replacement1. Remove air filter and install new one (→ Page 98).2. Reset signal ring of service indicator (→ Page 99).

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8.5.2 Air filter – Removal and installation


Air filter – Removal and installa-tion

1. Loosen clamp (2).2. Remove air filter (1) and clamp (2) from con-

necting flange of intake housing (3).3. Verify that there are no objects in the flange

of the intake housing (3) and clean it.4. Place new air filter (1) with clamp (2) onto in-

take housing (3).5. Tighten clamp (2).

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8.6 Air Intake

8.6.1 Service indicator – Signal ring position check


Checking signal ring position1. Replace air filter if the signal ring (2) is com-

pletely visible in the red area of the observa-tion window (3) (→ Page 97).

2. After installation of new filter, press resetbutton (1).

Result: Signal ring returns to initial position.

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8.7 Starting Equipment

8.7.1 Starter – Condition check


Starter – Condition check1. Check securing screws of starter and nut on cable connection for secure seating and tighten if required.2. Check cabling (→ Page 115).

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8.8 Lube Oil System, Lube Oil Circuit

8.8.1 Engine oil level – Check


Oil level check prior to enginestart

1. Remove oil dipstick (1) from guide tube andwipe it.

2. Insert oil dipstick (1) into guide tube up to thestop, withdraw after approx. 10 seconds andcheck oil level.

3. Oil level must be between “min.” and “max.”marks.

4. If necessary, top up to "max." mark(→ Page 102).

5. Insert oil dipstick (1) in guide tube up to thestop.

Oil level check after the engine is stopped1. 5 minutes after stopping the engine, remove oil dipstick (1) from the guide tube and wipe it.2. Insert oil dipstick (1) into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.3. Oil level must be between “min.” and “max.” marks.4. If necessary, top up to "max." mark (→ Page 102).5. Insert oil dipstick (1) in guide tube up to the stop.

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8.8.2 Engine oil – Change


☑Engine is at operating temperature.

☑MTU Fluids and Lubricants Specifications (A001063/..) are available.


Engine oil

WARNINGOil is hot.Oil can contain residue/substances which are harmful to health.Risk of injury and poisoning!• Allow the product to cool to below 50 °C before beginning work.• Wear protective clothing, protective gloves and goggles/safety mask.• Avoid contact with skin.• Do not inhale oil vapor.

Engine oil – Draining at drainplug on oil pan

1. Provide a suitable container to collect the oil.2. Remove drain plug(s) (2) and drain oil.

3. Insert drain plug (2) with new sealing ring and use torque wrench to tighten to specified tightening torque.


Drain plug Tightening torque (Engine oil) 100 Nm ±10 Nm

4. Replace engine oil filter (→ Page 103).

Filling with new oil1. Open cap (1) on cylinder head cover.2. Fill with oil, oil filling capacity (→ Product Summary - Technical Data).3. Close cap (1) on cylinder head cover.4. Check engine oil level (→ Page 101).

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8.9 Oil Filtration / Cooling

8.9.1 Engine oil filter – Replacement



Torque wrench, 8–40 Nm F30043446 1Ratchet bit F30027340 1Socket, 32 mm F30006120 1Engine oilOil filter element (→ Spare Parts Catalog)

WARNINGOil is hot.Oil can contain residue/substances which are harmful to health.Risk of injury and poisoning!• Allow the product to cool to below 50 °C before beginning work.• Wear protective clothing, protective gloves and goggles/safety mask.• Avoid contact with skin.• Do not inhale oil vapor.

Engine oil filter – Replacement1. Unscrew oil filter covers (1) approx. 3 to 4

revolutions.2. Wait 10 minutes until the oil has drained from

the filter housings.3. Remove cover (1) with oil filter element (3)

and remove oil filter element (3) by pressingon the bottom edge from the side.

4. Check condition of sealing ring (2) on cover.5. Replace sealing ring (2) if damaged.6. Coat sealing ring (2) with oil.7. Insert new oil filter element (3) in cover (1)

and press in until it locks in place.

8. Screw on cover (1) with oil filter element (3) and use a torque wrench to tighten to the specified tighteningtorque.


Cover Tightening torque (Engine oil) 35 Nm

9. Replace other engine oil filters in the same way.10. Check oil level (→ Page 101)

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8.10 Coolant Circuit, General, High-Temperature Circuit

8.10.1 Engine coolant – Level check



WARNINGCoolant is hot and under pressure.Risk of injury and scalding!• Let the engine cool down.• Wear protective clothing, gloves, and goggles / safety mask.

Checking engine coolant level atfiller neck

1. Turn breather valve on coolant expansiontank counterclockwise to the first stop andallow pressure to escape.

2. Continue to turn breather valve counterclock-wise and remove.

3. Check coolant level (coolant must be visibleat the lower edge of the cast-in eye or at themarking plate).

4. Top up with treated coolant as necessary(→ Page 107).

5. Check breather valve (visual inspection) andclean if necessary.

6. Position breather valve on filler neck andclose.

Checking engine coolant level by means of level sensor1. Switch on engine control system and check readings on the display.2. Top up with treated coolant as necessary (→ Page 107).

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8.10.2 Engine coolant – Change


Coolant

Engine coolant change1. Drain engine coolant (→ Page 106).2. Fill with engine coolant (→ Page 107).

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8.10.3 Engine coolant – Draining



Engine oilSealing ring (→ Spare Parts Catalog)


Preparatory steps1. Provide a suitable container to catch the coolant.2. Switch off preheater, if installed.

Engine coolant – Draining1. Turn breather valve of filler neck on coolant

expansion tank counterclockwise to first stopand allow pressure to escape.

2. Continue to turn breather valve counterclock-wise and remove.

3. Draw off separated corrosion inhibitor oil inexpansion tank through the filler neck.

4. Remove drain plug (1) and drain coolant.

5. Insert drain plug with new sealing ring and use torque wrench to tighten to specified tightening torque.


Drain screw Tightening torque (Engine oil) 70 Nm

6. Place breather valve on filler neck and close.


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8.10.4 Engine coolant – Filling




Coolant




NOTICECold coolant in hot engine can cause thermal stress.Possible formation of cracks in the engine!• Fill / top up coolant only into cold engine.

Preparatory steps1. Turn valve cover (1) on coolant expansion

tank counterclockwise to the first stop andallow pressure to escape.

2. Continue to turn valve cover (1) counter-clockwise and remove.


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Filling coolant1. Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower edge

of cast-in eye or marking plate.2. Check proper condition of valve cover (1), clean sealing faces if required.3. Fit valve cover (1) and close it.

Final steps1. Start engine and run at idle speed for some minutes.2. Check coolant level (→ Page 104), top up with coolant if required.


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8.10.5 Engine coolant pump – Relief bore check



Engine coolant pump – Reliefbore check

1. Check relief bore (1) for engine coolant dis-charge.• Permissible engine coolant discharge: Up

to 0.1 ml per operating hour respectively100 ml per 1,000 operating hours.

2. If discharge exceeds the specified limits, con-tact Service.

3. If relief bore is dirty (1):• Stop engine (→ Page 81) and disable en-

gine start.• Clean relief bore (1) with wire.


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8.11 Cooling System

8.11.1 Coolant cooler – Check

NOTICEContamination of components.Damage to component!• Observe manufacturer's instructions.• Check components for special cleanliness.

Coolant cooler – Check1. Check coolant cooler for external contamination (visual inspection) and clean surfaces.2. Check coolant cooler for leaks (visual inspection).3. If a large amount of coolant is continuously discharged, the coolant cooler is leaking. Contact Service.

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8.12 Belt Drive

8.12.1 Drive belt – Adjustment


Fan drive – Adjusting belt ten-sion

1. Loosen screws (1).2. Screw in nut (2) to set the required belt ten-

sion.3. Tighten screws (1).4. Check drive belt tension for compliance with

specifications (→ Page 113).

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8.12.2 Drive belt – Condition check


Checking condition

Item Findings ActionDrive belt A Singular cracks NoneDrive belt B Cracks on entire circumference Fit new part (→ Page 114)Drive belt C ChunkingDrive belt Fouling by oil, overheating

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8.12.3 Drive belt – Tension check



Tester Y4345711 1Belt tension tester, 500–1400 N Y20097430 1Belt tension tester, 1300–3100 N Y20097431 1

Fan drive – Checking belt ten-sion

1. Remove protective cover.2. Set belt tension tester onto the drive belt in

the middle between the belt pulleys (arrow).3. Actuate pushbutton to press the tester uni-

formly on the drive belt surface until thespring disengages.

4. Do not press any further, otherwise the dis-play value will be falsified.

5. Take off tension tester without changing theposition of the display arm.

6. Read off measured value at the intersectionof display arm and "KG" scale. For specifica-tions, refer to table below.

Application Spec. valueInitial assembly

Spec. valueOperating tension after1 hour

Spec. valueMinimum operatingtension

Fan drive belt 2250 N 1620 N 1080 N

7. If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 111).8. Install protective cover.

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8.12.4 Drive belt – Replacement



Drive belt (→ Spare Parts Catalog)

Replacing fan drive belt1. Remove protective cover from radiator.2. Remove fan.3. Loosen securing screws (3).4. Screw out tension nut (1) as far as necessary

to allow drive belt removal.5. Check belt pulley on cooler bearing mount

and crankshaft for contamination and clean ifnecessary.

Note: When placing the drive belt in the grooves, noforce must be applied.

6. Fit new drive belt.7. The fan bearing mount must be in contact

with the retainer (2) to allow belt tensioning.8. Adjust and check drive belt tension

(→ Page 111).9. Install fan.

10. Install protective cover.

Replacing drive belts of battery-charging generator and coolantpump

1. Remove protective cover.2. Remove drive belt from fan drive (→ Step 1).3. Use appropriate tool to release the automatic

belt tensioner at hexagon (1) and take offdrive belt (2).

Note: When placing the drive belt in the grooves, noforce must be applied.

4. Fit new drive belt (2) and unload belt tension-er.

5. Install drive belt on fan drive (→ Step 1).6. Install protective cover.

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8.13 Wiring (General) for Engine/Gearbox/Unit

8.13.1 Engine cabling – Check



Solvent (isopropyl alcohol) X00058037 1

Engine cabling – Check1. Check securing screws of cable clamps on engine and tighten loose screw connections.2. Ensure that cables are securely seated in clamps and cannot move freely.3. Check if all cable clips are closed and intact.4. Replace faulty cable clips.5. Check cable clamps for secure fit, tighten loose clamps.6. Replace faulty cable clamps.7. Visually inspect the following electrical components for damage:

• Connector housings• Contacts• Plug connectors• Cables and terminals• Plug-in contacts

Result: If cable conductors are damaged, contact Service.

Note: Close connectors that are not plugged in with the protective cap supplied.8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.9. Ensure that all connecting plugs of the sensors are correctly engaged.

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8.14 Accessories for (Electronic) Engine Governor / Control System

8.14.1 Engine governor and connector – Cleaning



Solvent (isopropyl alcohol) X00058037 1

NOTICEInsertion of unsuitable test probe, e.g. test prod.The contacts in the plug connection can be bent!• Carry out check of plug connection only with test connectors.

Engine governor and connector – Cleaning1. Use isopropyl alcohol to remove coarse dirt from housing surface.2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.3. Check legibility of cable labels. Clean or replace illegible labels.

Heavily contaminated connectors on engine governor – CleaningNote: Close connectors that are not plugged in with the protective cap supplied.

1. Release latches of connectors and withdraw connectors.2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.

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8.14.2 Engine governor – Checking plug connections


Checking engine governor plugconnections

1. Check firm seating of all connectors on theengine governor. Ensure that the clips (1) areengaged.

2. Check firm seating of all screws (2) on enginegovernor cable clamps. Make sure that cableclamps are not defective.

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9 Appendix A

9.1 AbbreviationsAbbre-viation

Meaning Explanation

A/D Analog/Digital converter Converter: converts sensor voltages into digital val-ues

ADEC Advanced Diesel Engine Controller Engine management systemAFRS Air Filter Restriction SensorAL alarmANSI American National Standards Institute Association of American standardization organiza-

tionsATS Air Temperature SensorBR SeriesBV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-

tion No. A001061/..CAN Controller Area Network Data bus system, bus standardCDC Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-

norCEL Check Engine Lamp 1st function: Warning lamp (rectify fault as soon as

possible)2nd function: Read out fault codes

CKT CircuitCLS Coolant level sensor Monitors coolant levelCM Current Measurement Current measured valueCPS Coolant pressure sensor Monitors coolant pressureCR Common RailCTS Coolant temperature sensor Monitors coolant temperatureDDEC Detroit Diesel Electronic Controls Engine control system made by Detroit DieselDDL Diagnostic Data Link Diagnostic linesDDR Diagnostic Data Reader Diagnostic unitDia-Sys®

Electronic dialog system

DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards(DIN = “Deutsche Industrie-Norm”)

DL Default Lost Alarm: Default CAN bus failureDMC Data Matrix CodeDOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particulate

filterDPF Diesel Particulate FilterDT Diagnostic Tool Diagnostic unitECM Electronic Control Module Electronic control unit of the DDEC systemECU Engine Control Unit Engine governorEDM Engine Data Module Memory module for engine data

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Abbre-viation

Meaning Explanation

EE-PROM

Electrically Erasable Programmable ReadOnly Memory

EFPA Electronic Foot Pedal Assembly Electronic accelerator pedalEGR Exhaust Gas RecirculationEIL Engine Ident LabelEIM-ID Emission Identification NumberEMU Engine Monitoring UnitESCM Extreme Site Condition Management Power reduction for operation in extreme conditionsESD Einzelspeicherdruck Injector accumulator pressureETC Exhaust turbocharger/exhaust turbocharg-

ingEUI Electronic Unit Injector Electronic injection nozzle unitFO Frequency OutputFPS Fuel Pressure Sensor Monitors fuel pressureFRS Fuel Restriction Sensor Monitors differential fuel pressureFTS Fuel Temperature Sensor Monitors fuel temperatureFWCP Fire Water Control Panel Control cabinetGND GroundHP High PressureHI High Alarm: Measured value exceeds 1st maximum limitHIHI High High Alarm: Measured value exceeds 2nd maximum limitHT High TemperatureIDM Interface Data Module Memory module for interface dataIIG Initial injector equalization Initial input of injector code in Engine Control Unit

with DiaSysINJ InjectorISO International Organization for Standardiza-

tionInternational umbrella organization for all nationalstandardization institutes

KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204L1 Limit 1 Limit value, limit 1L2 Limit 2

Reference surface for heights above sealevel

Limit value, limit 2

LED Light Emitting Diode Light emitting diodeLLK Ladeluftkühlung Charge-air coolingLO Low Alarm: Measured value lower than 1st minimum limit

valueLOLO Low Low Alarm: Measured value lower than 2nd minimum lim-

it valueLP Low PressureLSG Limit Speed Governor Maximum-speed governorLSU Lambda Sonde Universal Universal Lambda probeLT Low Temperature

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Abbre-viation

Meaning Explanation

MCR Maximum Continuous Rating Torque limitation curveN/A Not ApplicableNN Normal Null Reference surface for heights above sea levelOEM Original Equipment ManufacturerOI Optimized IdleOLS Oil Level Sensor Monitors oil levelOPS Oil pressure sensor Monitors oil pressureOTS Oil Temperature Sensor Monitors oil temperatureOT Oberer Totpunkt Top Dead Center (TDC)PAN Panel Control panelPIM Peripheral Interface ModulePWM Pulse Width Modulation Modulated signalP-xyz Pressure-xyz Pressure measuring point xyzRL Redundancy Lost Alarm: Redundant CAN bus failurerpm Revolutions per minuteSAE Society of Automotive Engineers U.S. standardization organizationSD Sensor Defect Alarm: Sensor failureSEL Stop Engine Lamp 1st function: Warning lamp (stop engine and rectify

fault); 2nd function: Read out fault codesSID System IdentifierSPC Spare Parts CatalogSRS Synchronous Reference Sensor TDC cylinder 1SS Safety System / Security Shutdown Safety system alarmTBS Turbocharger Boost Sensor Monitors charge-air pressureTC Tool CatalogTCI Turbo Compressor InletTCO Turbo Compressor OutletTD Transmitter Deviation Alarm: Sensor comparison faultTPS Throttle Position SensorTRS Timing Reference SensorT-xyz Temperature-xyz Temperature measuring point xyzU_PDU Voltage Power Driver Unit Distribution voltage for solenoid valve output stagesUDV Überdruckventil Pressure relief valveUT Unterer Totpunkt Bottom Dead Center (BDC)VNT Variable nozzle turbineVSG Variable-speed governorVSS Vehicle Speed SensorZKP Zuordnung - Kategorie - Parameter A number allocated to a parameter describing its

function and assignment

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9.2 MTU Contact/Service PartnersThe worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-er service centers ensure fast and direct support on site and ensure the high availability of our products.

Local SupportExperienced 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 HotlineWith our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,preventive maintenance and corrective operations in case of a malfunction, for information on changes inconditions of use and for supplying spare parts.

Your contact person in our Customer Assistance Center:

E-mail: [email protected]

Tel.: +49 7541 9077777

Fax.: +49 7541 9077778

Asia/Pacific: +65 6100 2688

North and Latin America: +1 248 560 8000

Spare Parts ServiceFast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right sparepart at the right time at the right place.

With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse atheadquarters and on-site stores at our subsidiary companies, agencies and service workshops.

Your contact at Headquarters:

E-mail: [email protected]

Tel.: +49 7541 9077777

Fax.: +49 7541 9077778

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10 Appendix B

10.1 Special ToolsAngular screw driver, set 2–10 mm

Part No.: F30453050Qty.:Used in:

1 8.2.1 Valve clearance – Check and adjustment(→ Page 90)

Belt tension tester, 1300–3100 N

Part No.: Y20097431Qty.:Used in:

1 8.12.3 Drive belt – Tension check (→ Page 113)

Belt tension tester, 500–1400 N



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Box wrench, 14 mm



Crossbeam

Part No.: T80092479Qty.:Used in:

1 2.1 Transport (→ Page 18)

Feeler gage



Filter wrench


1 8.4.1 Fuel filter – Replacement (→ Page 94)

Qty.:Used in:

1 8.4.3 Fuel prefilter – Replacement (→ Page 96)

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Ratchet bit


1 8.9.1 Engine oil filter – Replacement (→ Page 103)

Socket, 32 mm



Tester



Torque wrench, 8–40 Nm



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Torque wrench, 20–100 Nm



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10.2 IndexA

Abbreviations 118After stopping the engine – Engine remains ready for operation 83Air filter – Installation 98– Removal 98– Replacement 97– Service indicator check 99

C

Cabling – Check

– On engine 115Connector – Cleaning 116Contact persons 121Coolant – Change 105Coolant cooler – Check 110Coolant level – Check 104Cylinder head cover – Installation 92– Removal 92Cylinders – Designation 22

D

Drain engine coolant 106Drive belt – Condition check 112– Replacement 114– Tension check 113Drive belt – Adjustment 111

E

Emission label – Check 80Engine – Barring

– With starting system 88– Setting down after transport 18– Test run 89Engine cabling – Check 115Engine coolant – Change 105– Check

– Level at filler neck 104– Level with level sensor 104

– Filling 107Engine coolant level – Check 104

Engine coolant pump – Relief bore check 109Engine data – 6R1600B30S 50 Hz

– Fuel optimized 28– 6R1600B30S 60 Hz


– Emissions optimized 31– 6R1600B40S 50 Hz


– Emissions optimized 38– Fuel optimized 35

– 6R1600G10F, G20F – Emissions optimized 43– Fuel optimized 40– Nonroad stage III a 46

– 6R1600G10S, G20S – EPA stage 3 49



– 6R1600G70S, G80S – EPA stage 3 70

Engine driving end – Definition 22Engine free end – Definition 22Engine governor – Checking plug connections 117– Cleaning 116Engine oil – Change 102Engine oil filter – Replacement 103Engine oil level – Check 101Engine overview 20Engine sides – Designation 22Engine – Main dimensions 74

F

Firing order 73Fuel filter – Replacement 94Fuel prefilter – Draining 95– Replacement 96

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Fuel system – Venting 93

H

Hotline 121

L

Lifting specifications 19

M

Maintenance Schedule – Maintenance task reference table [QL1] 85MTU contact persons 121

O

Operational monitoring 79

S

Safety regulations – Assembly work 11– Auxiliary materials 15– Environmental protection 15– Fire prevention 15– Fluids and lubricants 15– Important provisions 5, 7– Initial start-up 9– Maintenance work 11– Operation 9– Organizational requirements 8– Personnel requirements 8– Repair work 11Safety requirements – Warning notices, standards 17Safety system – Override 78Sensors and actuators 23Service indicator – Check 99Service partners 121Spare parts service 121Starter – Condition check 100

T

Transport – Description 18– Lifting specifications 19Troubleshooting 86

V

Valve clearance – Adjustment 90– Check 90

W

Warning notices, standards 17

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