Operating Instructions: Diesel Engine 8V1600Gx0F/S 8V1600B30S 10V1600Gx0F/S 10V1600B40S 12V1600Gx0F/S 12V1600B30S/B40S

Operating Instructions
Diesel Engine
8V1600Gx0F/S
8V1600B30S
10V1600Gx0F/S
10V1600B40S
12V1600Gx0F/S
12V1600B30S/B40S
MS150076/06E
Engine model kW/cyl. Application group
8V1600B30S (50 Hz / 60 HZ) 40.6 / 46.4 kW/cyl. 3B, continuous operation, variable load, ICXN
8V1600G10F 40.6 kW/cyl. 3B, continuous operation, variable load, ICXN
8V1600G10S 46.5 kW/cyl. 3B, continuous operation, variable load, ICXN
8V1600G40F 40.6 kW/cyl. 3C, time-limited operation, ICXN
8V1600G70F 44.8 kW/cyl. 3D, standby power, fuel stop power, IFN
8V1600G70S 51.0 kW/cyl. 3D, standby power, fuel stop power, IFN
12V1600G20F 48 kW/cyl. 3B, continuous operation, variable load, ICXN
Table 1: Applicability
© 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 GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 4.12 Product data 8V/10V1600G40F/G50F – EU
Nonroad Stage IIIA 64
1.1 Important provisions for all products 5 4.13 Product data 8V/12V1600B30S –
1.2 Correct use of all products 7 Bifrequency 67
1.3 Personnel and organizational requirements 8 4.14 Product data 10V/12V1600B40S –
1.4 Initial start-up and operation – Safety Bifrequency 71
regulations 9 4.15 Firing order 74
1.5 Assembly, maintenance, and repair work – 4.16 Engine – Main dimensions 75
Safety regulations 11
1.6 Fire and environmental protection, fluids
5 Operation
and lubricants 15
1.7 Standards for warning notices in the text 5.1 Putting the engine into operation after
and highlighted information 17 extended out-of-service periods (>3 months) 76
5.2 Putting into operation after scheduled out-
2 Transport of-service-period 77
5.3 Starting the engine in manual mode (test
2.1 Transport 18 run) 78
2.2 Lifting specifications 19 5.4 Re-starting the engine following an
automatic safety shutdown 79
3 General Information 5.5 Safety system – Override 80
3.1 Engine – Overview 20 5.6 Operational checks 81
3.2 Engine side and cylinder designations 21 5.7 Emission label – Check 82
3.3 Sensors – Overview 22 5.8 Engine stop in manual operation (trials) 83
5.9 Emergency engine shutdown 84
5.10 After stopping the engine – Engine remains
4 Technical Data
ready for operation 85
4.1 Product data 8V/10V/12V1600G10F/G20F – 5.11 After stopping engine – Putting engine out
Emissions-optimized 24 of operation 86
4.2 Product data 8V/10V/12V1600G10F/20F –
Optimized fuel consumption 28 6 Maintenance
4.3 Product data 8V/10V1600G10F/20F – EU
Nonroad Stage IIIA 32 6.1 Maintenance task reference table [QL1] 87
4.4 Product data 8V1600G10S/G20S,
10V1600G20S, 12V1600G10S – EPA Tier 2, 7 Troubleshooting
3 35 7.1 Troubleshooting 88
4.5 Product data 10V1600G10S – Optimized 7.2 Fault messages 90
fuel consumption 38
4.6 Product data 8V/10V/12V1600G70F/G80F –
8 Task Description
Optimized fuel consumption 41
4.7 Product data 8V/10V1600G70F/G80F – EU 8.1 Engine 105
Nonroad Stage IIIA 45 8.1.1 Engine – Barring with starting system 105
DCL-ID: 0000001805 - 008
4.8 Product data 8V/10V/12V1600G70S – EPA 8.1.2 Engine – Test run 106
Tier 2,3-conform 48 8.2 Valve Drive 107
4.9 Product data 8V/10V/12V1600G80S EPA 8.2.1 Valve clearance – Check and adjustment 107
Tier 2,3-conform 52 8.2.2 Cylinder head cover ‒ Removal and
4.10 Product data 8V/10V/12V1600G40F/G50F – installation 110
Emissions-optimized 56
8.3 Fuel System 113
4.11 Product data 8V/10V/12V1600G40F/G50F – 8.3.1 Fuel system – Venting 113
Optimized fuel consumption 60
8.4 Fuel Filter 114
MS150076/06E 2018-08 | Table of Contents | 3

8.4.1 Fuel filter ‒ Replacement 114 8.11.1 Cooler – Checking cooler elements externally
8.4.2 Fuel prefilter – Draining 115 for dirt 131
8.4.3 Fuel prefilter – Replacement 116 8.11.2 Cooler – Cleaning cooler elements 132
8.5 Air Filter 117 8.12 Belt Drive 133

8.5.1 Air filter ‒ Replacement 117 8.12.1 Drive belt – Adjustment 133
8.5.2 Air filter – Removal and installation 118 8.12.2 Drive belt – Condition check 134
8.12.3 Drive belt – Tension check 135
8.6 Air Intake 119 8.12.4 Drive belt – Replacement 137
8.6.1 Service indicator – Signal ring position check 119
8.13 Wiring (General) for Engine/Gearbox/Unit 139
8.7 Starting Equipment 120 8.13.1 Engine cabling – Check 139
8.7.1 Starter – Condition check 120
8.14 Accessories for (Electronic) Engine
8.8 Lube Oil System, Lube Oil Circuit 121
Governor / Control System 140
8.8.1 Engine oil – Level check 121
8.14.1 Engine governor and connector – Cleaning 140
8.8.2 Engine oil – Change 122
8.14.2 Engine governor – Checking plug connections 141
8.9 Oil Filtration / Cooling 124
8.9.1 Engine oil filter – Replacement 124
9 Appendix A
8.10 Coolant Circuit, General, High-Temperature
Circuit 125 9.1 Abbreviations 142
8.10.1 Engine coolant – Level check 125 9.2 MTU Contact/Service Partners 145
8.10.2 Engine coolant – Change 126
8.10.3 Engine coolant – Draining 127 10 Appendix B
8.10.4 Engine coolant – Filling 128
8.10.5 Engine coolant pump – Relief bore check 130 10.1 Special Tools 146
8.11 Coolant System 131 10.2 Index 150
DCL-ID: 0000001805 - 008
4 | Table of Contents | MS150076/06E 2018-08

1 Safety
1.1 Important provisions for all products
General
This 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
Nameplates
The 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. This second nameplate is deliv-
ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system
is not visible without the removal of components, the system integrator must install the second nameplate in
a clearly visible area on the vehicle/system.
Emission specifications and emission label

Responsibility for compliance with emission regulations
Modification 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 the
product 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 by
the emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission 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 emission

certification in accordance with 40 CFR 1039
Extract from the standard:
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
Extract from the standard:
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If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.
When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This
paragraph describes the process for requesting and fitting the label, the documentation obligations and stor-
age obligations for the required documents.
MS150076/06E 2018-08 | Safety | 5

Replacing components with emission labels
On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
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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6 | Safety | MS150076/06E 2018-08

1.2 Correct use of all products
Correct use
The 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 such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held 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 conversions
Unauthorized 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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MS150076/06E 2018-08 | Safety | 7

1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This 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 requirements
All 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
and also for work with live parts
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 equipment

Always 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, Authorization and restriction of Chemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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8 | Safety | MS150076/06E 2018-08

1.4 Initial start-up and operation – Safety regulations
Safety regulations for initial start-up
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and 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 switched
on.
• 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 during
this 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 as
well as the monitoring, signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation

The 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 to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

Practice 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.
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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.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
MS150076/06E 2018-08 | Safety | 9

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 equipment

When 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 all
times.
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10 | Safety | MS150076/06E 2018-08

1.5 Assembly, maintenance, and repair work – Safety regulations
Safety regulations for work prior to assembly, maintenance, and repair
Have 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 are
fitted.
Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent
tank. 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 equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Setting down, lifting and climbing

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Carry 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 the
center 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 prevent
components/tools from falling down.
Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.
MS150076/06E 2018-08 | Safety | 11

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

Pay 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 a
suitable corrosion inhibitor as necessary.
Lines
Ensure 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 contact
with other components. Do not place fuel or oil lines near hot components.
Miscellaneous
Sufficient 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 protective
gloves 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 or
resinous 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 work

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Before 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.
12 | Safety | MS150076/06E 2018-08

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its 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. The
welding 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 removal

Check 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 end
until correct sealing is established.
During hydraulic installation and removal of components, ensure that nobody is standing in the immediate
vicinity of the component to be installed/removed.
Working with batteries

Observe 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 spray
acid if the battery terminals are connected incorrectly.
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Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work 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 discharge
must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive
work surfaces or antistatic wristbands.
MS150076/06E 2018-08 | Safety | 13

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 the
voltage 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. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)
Working with laser equipment

Work 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 type
and application.
Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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14 | Safety | MS150076/06E 2018-08

1.6 Fire and environmental protection, fluids and lubricants
Fire prevention and fire
Fire, 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 and
observe 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 cause
fires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on the
product. Do not store combustible materials near the product.
Incorrect refueling of the reducing agent system with fuel can result in fire.
Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground cable from the external power source to the
ground 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 familiar
with 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.
Noise
Wear 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 disposal

Dispose 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 and
other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained
from the relevant manufacturer or from MTU.
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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 contamination
can 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.
MS150076/06E 2018-08 | Safety | 15

Registration, evaluation, approval and restriction of chemicals (REACH
ordinance)
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
• 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)

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
TIM-ID: 0000040536 - 018
• 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.
Mistakenly filling the tank of the reducing agent system with fuel can cause leakage at the seals and in
the hoses.
16 | Safety | MS150076/06E 2018-08

1.7 Standards for warning notices in the text and highlighted
information
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Warning notices
1. 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 information
Important
This 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.
TIM-ID: 0000040578 - 006
MS150076/06E 2018-08 | Safety | 17

2 Transport
2.1 Transport
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80092479 1
DANGER
Suspended 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).
Transport
1. Use the lifting eyes provided to lift the engine (→ Page 18).
2. Use suitable transport and lifting gear only.
3. The engine must only be transported in installation position: max. admissible diagonal pull 10° (→ Page 18).
4. Do not place unsecured parts on the system, engine/generator/diesel particulate filter.
5. Always raise/lower the engine slowly. The lifting ropes or chains must not butt against the engine or its com-
ponents during the lifting procedure. Readjust lifting tackle as necessary.
6. For special packaging with aluminum foil: Suspend the engine by the lifting eyes on the bearing pedestal or
transport by means of handling equipment (forklift truck) capable of bearing the load.
7. Secure the engine against tipping during transportation. Secure such as to preclude slipping and tipping
when driving up or down inclines and ramps.
Placement after transport

1. The engine must only set down/transported on a horizontal surface and with the engine mounting bracket/
transportation braces provided for this purpose.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Never set the engine down on its oil pan unless expressly authorized to do so by MTU.
TIM-ID: 0000083151 - 001
18 | Transport | MS150076/06E 2018-08

2.2 Lifting specifications
Lifting specifications
DANGER
Suspended 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- 2 Center of gravity

onal pull 10° (*)
(*) Max. permissible diagonal pull must be observed:
• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in trans-
verse direction is impermissible.
• Max. permissible diagonal pull in longitudinal direction is 10 degrees; simultaneous diagonal pull in longi-
tudinal direction is impermissible.
Take note of the engine center of gravity

TIM-ID: 0000083152 - 001
Refer to the installation/arrangement drawings for details of the center of gravity of the system or engine.
MS150076/06E 2018-08 | Transport | 19

3 General Information
3.1 Engine – Overview
Illustration also applies to 8V1600 and 10V1600 engines.
1 Lifting eye, driving end 7 Belt drive 13 Oil dipstick

2 Engine governor 8 Cylinder head 14 Oil pan
3 Air supply 9 Exhaust elbow 15 Fuel filter
4 Lifting eye, free end 10 Crankcase 16 Flywheel
5 Oil filter 11 Engine mounting 17 Flywheel housing
6 Thermostat housing 12 Exhaust turbocharger KS Driving end
Engine model designation

Key to engine model designation 8/10/12V1600Gxyz
8/10/12 Number of cylinders
V Cylinder arrangement: V-engine
TIM-ID: 0000000861 - 004
1600 Series
G Application
x Application segment (1, 2, 4, 5, 7, 8)
y Design index
z Frequency (F = 50 Hz, S = 60 Hz)
20 | General Information | MS150076/06E 2018-08

3.2 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 014
MS150076/06E 2018-08 | General Information | 21

3.3 Sensors – Overview
Overview of sensors on engine free end
Illustrations are also applicable to all V1600Gx0y engines.
Item Designation Monitoring of

1 B48.2 HP fuel, B-side
2 B6 Coolant temperature
3 XY39.B1 Injectors, B-side
XY39.B2
4 XY39.A1 Injectors, A side
XY39.A2
5 B5 Lube oil pressure
6 B48.1 HP fuel, A side
TIM-ID: 0000000815 - 007
22 | General Information | MS150076/06E 2018-08

Overview of sensors on engine driving end
Item Designation Monitoring of

1 M8.1 Fuel pump HDP A (time measurement unit)
2 M8.2 Fuel pump HDP B (time measurement unit)
3 B10 Charge-air pressure
4 B9 Charge-air coolant temperature
5 B1 Camshaft speed
6 A19 EIL (Engine Ident Label)
7 B13 Crankshaft speed
TIM-ID: 0000000815 - 007
MS150076/06E 2018-08 | General Information | 23

4 Technical Data
4.1 Product data 8V/10V/12V1600G10F/G20F – Emissions-
optimized
Key
DL Reference value: Continuous power. Continuously attainable power at standard conditions
BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli-
cations (margin for load fluctuations)
A Design value. Value required to design an external system (plant)
R Guideline value. Typical average value for information, only partially suitable for design purposes
L Limit value. Value which must not be violated (lower limit value, min. value / upper limit value, max.
value), not suitable for design purposes
N Not yet defined value. Value has not yet been defined or will not be defined
- Not applicable. Module is not applicable to the given product type
X Applicable. Module is applicable to the given product type
> Actual value must be greater than the specified value.
< Actual value must be less than the specified value.
* Not sufficiently validated value (+/- 10% tolerance).
** Not sufficiently validated value (+/- 5% tolerance).
ID Product type Application Speed Nominal pow-

er
1 8V1600G10F Power generation 1500 rpm 325 kW Ref. 25 °C/-
3B continuous opera- 50 Hz 436 bhp TA-Luft-optimized (die-
tion, variable load, sel)
ICXN
ICXN
ICXN
ICXN
TIM-ID: 0000020173 - 003
ICXN
ICXN
24 | Technical Data | MS150076/06E 2018-08

Reference conditions
ID 1 2 3 4 5 6
Intake air temperature °C 25 25 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000 1000 1000
Site altitude above sea m 100 100 100 100 100 100
level
Power-related data
ID 1 2 3 4 5 6
Rated engine speed A rpm 1500 1500 1500 1500 1500 1500
Continuous power ISO A kW 325 358 407 448 524 576
3046 (10% overload capa-
bility) (power range DIN
6280, ISO 8528)
Site conditions (for max. power)

ID 1 2 3 4 5 6
Intake depression (new A mbar 25 25 15 15 25 25
filter)
Intake depression, max. L mbar 50 50 50 50 50 50
Exhaust gas overpressure A mbar 85 85 30 30 85 85
Exhaust gas overpres- L mbar 85 85 85 85 85 85
sure, max.
Model-related data (basic design)

ID 1 2 3 4 5 6
Standard housing con- SAE 01 01 01 01 01 01
nection flange (engine
main PTO)
Flywheel connection - 14" 14" 14" 14" 14" 14"
(DISC)
Air / exhaust gas

ID 1 2 3 4 5 6
Charge-air pressure be- R bar abs 2.9 3.1 2.65 2.92 3.0 3.4
fore cylinder – DL
Coolant system (HT circuit)

TIM-ID: 0000020173 - 003
ID 1 2 3 4 5 6
Coolant temperature (at A °C 95 95 95 95 95 95
engine connection: outlet
to cooling system)
Coolant temperature after L °C 105 105 105 105 105 105
engine, limit 1
engine, limit 2
MS150076/06E 2018-08 | Technical Data | 25

ID 1 2 3 4 5 6
Coolant antifreeze con- L % 50 50 50 50 50 50
tent, max.
Pressure loss in off-en- L bar 0.7 0.7 0.7 0.7 1 1
gine cooling system, max.
Lube oil system

ID 1 2 3 4 5 6
Lube oil operating tem- R °C 105 105 105 105 105 105
perature before engine,
from
perature before engine, to
Lube oil operating pres- R bar 4.5 4.5 4.5 4.5 4.5 4.5
sure before engine, from
sure before engine, to
Fuel system
ID 1 2 3 4 5 6
Fuel pressure at engine L bar -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
inlet connection, min.
(when engine is starting)
Fuel pressure at engine L bar 0.5 0.5 0.5 0.5 0.5 0.5
inlet connection, max.
General operating data

ID 1 2 3 4 5 6
Cold start capability: air R °C -20 -20 -20 -20 -20 -20
temperature (w/o start
aid, w/o preheating) –
(case A)
Firing speed, from R rpm 80 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120 120
Capacities
ID 1 2 3 4 5 6
Engine coolant, engine R Liters 50 * 50 * 60 * 60 * 65 65
TIM-ID: 0000020173 - 003
side (w/o cooling equip-

ment)
Oil change quantity, max. R Liters 43 43 53 53 64 64
(standard oil system) (op-
tion: max. operating incli-
nations)

ID 1 2 3 4 5 6
Oil pan capacity at dip- L Liters 36 36 46 46 56 56
stick mark “min.” (stand-
ard oil system) (option:
max. operating inclina-
tions)
stick mark “max.” (stand-
tions)
Masses / main dimensions

ID 1 2 3 4 5 6
Engine dry weight (with R kg 1480 * 1480 * 1694 * 1694 * 1855 * 1855 *
standard accessories in-
stalled, w/o coupling)
Acoustics
ID 1 2 3 4 5 6
Exhaust noise, unsilenced R dB(A) 124 121 121 122 121 122
– DL (sound power level
LW, ISO 6798, +3 dB(A)
tolerance)
Engine surface noise with R dB(A) 114 114 - - 120 122
attenuated intake noise
(filter) – DL (sound power
level LW, ISO 6798,
+2 dB(A) tolerance)
Engine surface noise with R dB(A) - - 100 101 100 101
(intake silencer) - DL
(free-field sound-pressure
level Lp, 1 m distance,
ISO 6798, +2 dB(A) toler-
ance)
TIM-ID: 0000020173 - 003

4.2 Product data 8V/10V/12V1600G10F/20F – Optimized fuel
consumption
Key

er
3B continuous opera- 50 Hz 436 bhp Optimized fuel con-
tion, variable load, sumption
ICXN NEA Singapore for
ORDE
ORDE
ORDE
ORDE
TIM-ID: 0000020187 - 003

ORDE
ORDE

ID 1 2 3 4 5 6
level
Power-related data
ID 1 2 3 4 5 6
6280, ISO 8528)

ID 1 2 3 4 5 6
filter)
sure, max.

ID 1 2 3 4 5 6
main PTO)
(DISC)
Air / exhaust gas

ID 1 2 3 4 5 6

TIM-ID: 0000020187 - 003
ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
engine, limit 2

ID 1 2 3 4 5 6
tent, max.
Lube oil system

ID 1 2 3 4 5 6
from
Fuel system
ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
(case A)
Capacities
ID 1 2 3 4 5 6
TIM-ID: 0000020187 - 003

ment)
nations)

ID 1 2 3 4 5 6
tions)
tions)

ID 1 2 3 4 5 6
Acoustics
ID 1 2 3 4 5 6
LW, ISO 6798, +3 dB(A)
tolerance)
level LW, ISO 6798,
+2 dB(A) tolerance)
Engine surface noise with R dB(A) - - 100 101 100 101
(intake silencer) - DL
(free-field sound-pressure
level Lp, 1 m distance,
ISO 6798, +2 dB(A) toler-
ance)
TIM-ID: 0000020187 - 003

4.3 Product data 8V/10V1600G10F/20F – EU Nonroad Stage IIIA
Key

er
3B continuous opera- 50 Hz 436 bhp EU Nonroad St IIIA
tion, variable load, (97/68/EC)
ICXN MoEF India / CPCB
Stage II
Stage II
Stage II
Stage II
ID 1 2 3 4
TIM-ID: 0000020186 - 003
Intake air temperature °C 25 25 25 25

Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100

Power-related data
ID 1 2 3 4
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 325 358 407 448
load capability) (power range DIN 6280,
ISO 8528)

ID 1 2 3 4
Intake depression (new filter) A mbar 25 25 25 25
Intake depression, max. L mbar 50 50 50 50
Exhaust gas overpressure A mbar 85 85 85 85
Exhaust gas overpressure, max. L mbar 85 85 85 85

ID 1 2 3 4
Standard housing connection flange (en- SAE 01 01 01 01
gine main PTO)
Flywheel connection (DISC) - 14" 14" 14" 14"
Air / exhaust gas

ID 1 2 3 4
Charge-air pressure before cylinder – DL R bar abs 2.9 3.0 3.04 3.12

ID 1 2 3 4
Coolant temperature (at engine connec- A °C 95 95 95 95
tion: outlet to cooling system)
Coolant temperature after engine, limit 1 L °C 105 105 105 105
Coolant antifreeze content, max. L % 50 50 50 50
Pressure loss in off-engine cooling sys- L bar 0.7 0.7 0.7 0.7
tem, max.
Lube oil system

ID 1 2 3 4
Lube oil operating temperature before R °C 105 105 105 105
TIM-ID: 0000020186 - 003
engine, from
engine, to
Lube oil operating pressure before en- R bar 4.5 4.5 4.5 4.5
gine, from
gine, to

Fuel system
ID 1 2 3 4
Fuel pressure at engine inlet connection, L bar -0.5 -0.5 -0.5 -0.5
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar 0.5 0.5 0.5 0.5
max. (when engine is starting)

ID 1 2 3 4
Cold start capability: air temperature R °C -20 -20 -20 -20
(w/o start aid, w/o preheating) – (case
A)
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120
Capacities
ID 1 2 3 4
Engine coolant, engine side (w/o cooling R Liters 50 * 50 * 60 * 60 *
equipment)
Oil change quantity, max. (standard oil R Liters 43 43 53 53
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 36 36 46 46
(standard oil system) (option: max. oper-
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 43 43 53 53
ating inclinations)

ID 1 2 3 4
Engine dry weight (with standard acces- R kg 1480 * 1480 * 1694 * 1694 *
sories installed, w/o coupling)
Acoustics
ID 1 2 3 4
Exhaust noise, unsilenced – DL (sound R dB(A) 124 123 121 122
power level LW, ISO 6798, +3 dB(A) tol-
erance)
TIM-ID: 0000020186 - 003
Engine surface noise with attenuated in- R dB(A) 114 114 - -

take noise (filter) – DL (sound power lev-
el LW, ISO 6798, +2 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) - - 100 101
take noise (intake silencer) - DL (free-
field sound-pressure level Lp, 1 m dis-
tance, ISO 6798, +2 dB(A) tolerance)

4.4 Product data 8V1600G10S/G20S, 10V1600G20S,
12V1600G10S – EPA Tier 2, 3
Key

er
1 8V1600G10S Power generation 1800 rpm 371 kW Ref. 25 °C/-
3B continuous opera- 60 Hz 498 bhp EPA Nonroad T3 Comp
tion, variable load, (40CFR89)
ICXN EPA Stationary EMERG
T3 (40CFR60)
T3 (40CFR60)
T2 (40CFR60)
T2 (40CFR60)
TIM-ID: 0000020188 - 003
ID 1 2 3 4

1. Power-related data
ID 1 2 3 4
ISO 8528)
2. General conditions (for maximum power)

ID 1 2 3 4
4. Model-related data (basic design)

ID 1 2 3 4
gine main PTO)
5. Air / exhaust gas

ID 1 2 3 4
7. Coolant system (HT circuit)

ID 1 2 3 4
Pressure loss in off-engine cooling sys- L bar 0.7 0.7 0.7 1
tem, max.
10. Lube oil system

ID 1 2 3 4
TIM-ID: 0000020188 - 003
engine, from
engine, to
gine, from
gine, to

11. Fuel system
ID 1 2 3 4
12. General operating data

ID 1 2 3 4
A)
18. Capacities
ID 1 2 3 4
Engine coolant, engine side (w/o cooling R Liters 50 * 50 * 60 * 65
equipment)
tions)
ating inclinations)
ating inclinations)
19. Masses / main dimensions

ID 1 2 3 4
22. Acoustics
ID 1 2 3 4
erance)
TIM-ID: 0000020188 - 003
Engine surface noise with attenuated in- R dB(A) 116 116 - 123
take noise (intake silencer) - DL (free-
field sound-pressure level Lp, 1 m dis-
tance, ISO 6798, +2 dB(A) tolerance)

4.5 Product data 10V1600G10S – Optimized fuel consumption
Key

er
ICXN
ID 1
Intake air temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100
ID 1
Rated engine speed A rpm 1800
Continuous power ISO 3046 (10% overload capability) (power range DIN A kW 465
6280, ISO 8528)

ID 1
Intake depression (new filter) A mbar 25
TIM-ID: 0000083179 - 001
Intake depression, max. L mbar 50

Exhaust gas overpressure A mbar 85
Exhaust gas overpressure, max. L mbar 150

ID 1
Standard housing connection flange (engine main PTO) SAE 01
Flywheel connection (DISC) - 14"

ID 1
Charge-air pressure before cylinder – DL R bar abs 2.72

ID 1
Coolant temperature (at engine connection: outlet to cooling system) A °C 95
Coolant temperature after engine, limit 1 L °C 105
Coolant temperature after engine, limit 2 L °C 109
Coolant antifreeze content, max. L % 50
Pressure loss in off-engine cooling system, max. L bar 0.7
10. Lube oil system

ID 1
Lube oil operating temperature before engine, from R °C 105
Lube oil operating temperature before engine, to R °C 115
Lube oil operating pressure before engine, from R bar 4.5
Lube oil operating pressure before engine, to R bar 5.5
11. Fuel system

ID 1
Fuel 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 0.0

ID 1
Cold start capability: air temperature (w/o start aid, w/o preheating) – (case R °C -20
A)
Firing speed, from R rpm 80
Firing speed, to R rpm 120
18. Capacities
ID 1
Engine coolant, engine side (w/o cooling equipment) R Liters 60 *
Oil change quantity, max. (standard oil system) (option: max. operating incli- R Liters 53
nations)
TIM-ID: 0000083179 - 001
Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. L Liters 46
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max. L Liters 53
operating inclinations)

ID 1
Engine dry weight (with standard accessories installed, w/o coupling) R kg 1694 *

22. Acoustics
ID 1
Exhaust noise, unsilenced – BL (sound power level LW, ISO 6798, +3 dB(A) R dB(A) 123
tolerance)
Engine surface noise with attenuated intake noise (intake silencer) - BL (free- R dB(A) 101
field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)
TIM-ID: 0000083179 - 001

4.6 Product data 8V/10V/12V1600G70F/G80F – Optimized fuel
consumption
Key

er
3D standby power, 50 Hz 480 bhp Optimized fuel con-
fuel stop power, IFN sumption
NEA Singapore for
ORDE
NEA Singapore for
ORDE
NEA Singapore for
ORDE
NEA Singapore for
ORDE
TIM-ID: 0000020200 - 003

NEA Singapore for
ORDE

ID 1 2 3 4 5 6
level
1. Power-related data (power ratings are net brake power to ISO 3046)
ID 1 2 3 4 5 6
Fuel stop power ISO A kW 358 394 448 493 576 634
3046

ID 1 2 3 4 5 6
filter)
sure, max.

ID 1 2 3 4 5 6
main PTO)
(DISC)

ID 1 2 3 4 5 6
fore cylinder – BL

ID 1 2 3 4 5 6
TIM-ID: 0000020200 - 003

to cooling system)
engine, limit 1
engine, limit 2

ID 1 2 3 4 5 6
tent, max.
10. Lube oil system

ID 1 2 3 4 5 6
from
11. Fuel system

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
(case A)
18. Capacities
ID 1 2 3 4 5 6
TIM-ID: 0000020200 - 003

ment)
Total engine oil capacity, R Liters 46 46 60.5 60.5 72.5 72.5
initial filling (standard oil
system) (option: max. op-
erating inclinations)
nations)

ID 1 2 3 4 5 6
tions)
tions)

ID 1 2 3 4 5 6
22. Acoustics
ID 1 2 3 4 5 6
– BL (free-field sound
pressure level Lp, 1 m
distance, ISO 6798,
+3 dB(A) tolerance)
– BL (sound power level
LW, ISO 6798, +3 dB(A)
tolerance)
TIM-ID: 0000020200 - 003

4.7 Product data 8V/10V1600G70F/G80F – EU Nonroad Stage
IIIA
Key

er
3D standby power, 50 Hz 480 bhp EU Nonroad St IIIA
fuel stop power, IFN (97/68/EC)
MoEF India / CPCB
Stage II
MoEF India / CPCB
Stage II
MoEF India / CPCB
Stage II
MoEF India / CPCB
Stage II
TIM-ID: 0000020229 - 003
ID 1 2 3 4

Power-related data
ID 1 2 3 4
Fuel stop power ISO 3046 A kW 358 394 448 493

ID 1 2 3 4

ID 1 2 3 4
gine main PTO)
Air / exhaust gas

ID 1 2 3 4
Charge-air pressure before cylinder – BL R bar abs 3.0 3.1 3.12 3.27

ID 1 2 3 4
tem, max.
Lube oil system

ID 1 2 3 4
engine, from
TIM-ID: 0000020229 - 003

engine, to
gine, from
gine, to

Fuel system
ID 1 2 3 4

ID 1 2 3 4
A)
Capacities
ID 1 2 3 4
equipment)
Total engine oil capacity, initial filling R Liters 46 46 60.5 60.5
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
Acoustics
ID 1 2 3 4
TIM-ID: 0000020229 - 003
Exhaust noise, unsilenced – BL (free-field R dB(A) 111 111 109 110

sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)
Exhaust noise, unsilenced – BL (sound R dB(A) 123 123 122 123
erance)

4.8 Product data 8V/10V/12V1600G70S – EPA Tier 2,3-conform
Key

er
3D standby power, 60 Hz 547 bhp EPA Nonroad T3 Comp
fuel stop power, IFN (40CFR89)
2 8V1600G70S Power generation 1800 rpm 408 kW Ref. 25 °C/- ; Opti-
3D standby power, 60 Hz 547 bhp mized altitude
fuel stop power, IFN EPA Stationary EMERG
T3 (40CFR60)
3D standby power, 60 Hz 685 bhp EPA Stationary EMERG
fuel stop power, IFN T3 (40CFR60)
ID 1 2 3 4 5 6
TIM-ID: 0000020196 - 003

level

Power-related data (power ratings are net brake power as per ISO 3046)
ID 1 2 3 4 5 6
3046

ID 1 2 3 4 5 6
filter)
sure, max.

ID 1 2 3 4 5 6
main PTO)
(DISC)
Air / exhaust gas

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
engine, limit 2
TIM-ID: 0000020196 - 003
tent, max.

Lube oil system
ID 1 2 3 4 5 6
from
Fuel system
ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
(case A)
Capacities
ID 1 2 3 4 5 6
ment)
TIM-ID: 0000020196 - 003

nations)

ID 1 2 3 4 5 6
tions)
tions)

ID 1 2 3 4 5 6
Acoustics
ID 1 2 3 4 5 6
distance, ISO 6798,
+3 dB(A) tolerance)
LW, ISO 6798, +3 dB(A)
tolerance)
TIM-ID: 0000020196 - 003

4.9 Product data 8V/10V/12V1600G80S EPA Tier 2,3-conform
Key

er
2 8V1600G80S Power generation 1800 rpm 448 kW Ref. 25 °C/- ; Opti-
3D standby power, 60 Hz 601 bhp mized altitude
fuel stop power, IFN EPA Stationary EMERG
T3 (40CFR60)
ID 1 2 3 4 5 6
TIM-ID: 0000020197 - 003

level

ID 1 2 3 4 5 6
3046

ID 1 2 3 4 5 6
filter)
sure, max.

ID 1 2 3 4 5 6
main PTO)
(DISC)
Air / exhaust gas

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
engine, limit 2
TIM-ID: 0000020197 - 003
tent, max.

Lube oil system
ID 1 2 3 4 5 6
from
Fuel system
ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
(case A)
Capacities
ID 1 2 3 4 5 6
ment)
TIM-ID: 0000020197 - 003

nations)

ID 1 2 3 4 5 6
tions)
tions)

ID 1 2 3 4 5 6
Acoustics
ID 1 2 3 4 5 6
distance, ISO 6798,
+3 dB(A) tolerance)
LW, ISO 6798, +3 dB(A)
tolerance)
TIM-ID: 0000020197 - 003

4.10 Product data 8V/10V/12V1600G40F/G50F – Emissions-
optimized
Key

er
3C, time-limited opera- 50 Hz 436 bhp TA-Luft-optimized (die-
tion, ICXN sel)
tion, ICXN sel)
tion, ICXN sel)
tion, ICXN sel)
tion, ICXN sel)
tion, ICXN sel)
ID 1 2 3 4 5 6
TIM-ID: 0000020189 - 003

level

ID 1 2 3 4 5 6
6280, ISO 8528)
3046

ID 1 2 3 4 5 6
filter)
sure, max.

ID 1 2 3 4 5 6
main PTO)
(DISC)
Air / exhaust gas

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
TIM-ID: 0000020189 - 003

engine, limit 2
tent, max.

Lube oil system
ID 1 2 3 4 5 6
from
Fuel system
ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
(case A)
Capacities
ID 1 2 3 4 5 6
ment)
nations)
TIM-ID: 0000020189 - 003

tions)
tions)

ID 1 2 3 4 5 6
Acoustics
ID 1 2 3 4 5 6
LW, ISO 6798, +3 dB(A)
tolerance)
level LW, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000020189 - 003

4.11 Product data 8V/10V/12V1600G40F/G50F – Optimized fuel
consumption
Key

er
3C, time-limited opera- 50 Hz 436 bhp Optimized fuel con-
tion, ICXN sumption
tion, ICXN sumption
tion, ICXN sumption
tion, ICXN sumption
tion, ICXN sumption
tion, ICXN sumption
ID 1 2 3 4 5 6
TIM-ID: 0000020190 - 003

level

1. Power-related data (power ratings are net brake power to ISO 3046)
ID 1 2 3 4 5 6
6280, ISO 8528)
3046

ID 1 2 3 4 5 6
filter)
sure, max.

ID 1 2 3 4 5 6
main PTO)
(DISC)

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
to cooling system)
engine, limit 1
TIM-ID: 0000020190 - 003

engine, limit 2
tent, max.

10. Lube oil system
ID 1 2 3 4 5 6
from
11. Fuel system

ID 1 2 3 4 5 6

ID 1 2 3 4 5 6
(case A)
18. Capacities
ID 1 2 3 4 5 6
ment)
nations)
TIM-ID: 0000020190 - 003

tions)
tions)

ID 1 2 3 4 5 6
22. Acoustics
ID 1 2 3 4 5 6
LW, ISO 6798, +3 dB(A)
tolerance)
level LW, ISO 6798,
+2 dB(A) tolerance)
TIM-ID: 0000020190 - 003

4.12 Product data 8V/10V1600G40F/G50F – EU Nonroad Stage
IIIA
Key

er
3C, time-limited opera- 50 Hz 436 bhp EU Nonroad St IIIA
tion, ICXN (97/68/EC)
ID 1 2 3 4
TIM-ID: 0000020193 - 003
ID 1 2 3 4
ISO 8528)

ID 1 2 3 4

ID 1 2 3 4
gine main PTO)

ID 1 2 3 4

ID 1 2 3 4
tem, max.
10. Lube oil system

ID 1 2 3 4
engine, from
engine, to
gine, from
gine, to
TIM-ID: 0000020193 - 003
11. Fuel system

ID 1 2 3 4

ID 1 2 3 4
A)
18. Capacities
ID 1 2 3 4
equipment)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
22. Acoustics
ID 1 2 3 4
erance) TIM-ID: 0000020193 - 003

4.13 Product data 8V/12V1600B30S – Bifrequency
Key

er
1 8V1600B30S Power generation 1500/1800 325/371 kW Ref. 25 °C/- ; Bifre-
3B continuous opera- rpm 436/498 bhp quency - 50 Hz data
tion, variable load, 50/60 Hz set
ICXN Optimized fuel con-
sumption
sumption
sumption
sumption
ID 1 2 3 4
TIM-ID: 0000023723 - 003


ID 1 2 3 4
ISO 8528)

ID 1 2 3 4

ID 1 2 3 4
gine main PTO)
Air / exhaust gas

ID 1 2 3 4
Charge-air pressure before cylinder – BL R bar abs 2.7 3.1 2.9 3.2

ID 1 2 3 4
Pressure loss in off-engine cooling sys- L bar 0.7 0.7 1 1
tem, max.
Lube oil system

TIM-ID: 0000023723 - 003
ID 1 2 3 4
engine, from
engine, to
gine, from
gine, to

Fuel system
ID 1 2 3 4

ID 1 2 3 4
A)
Capacities
ID 1 2 3 4
Engine coolant, engine side (w/o cooling R Liters 50 * 50 * 65 65
equipment)
Total engine oil capacity, initial filling R Liters 46 46 72.5 72.5
ating inclinations)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
Acoustics
ID 1 2 3 4
TIM-ID: 0000023723 - 003

erance)
Exhaust noise, unsilenced – BL (free-field R dB(A) 109 112 109 119
sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)

ID 1 2 3 4
Exhaust noise, unsilenced – BL (sound R dB(A) 121 124 122 122
erance)
Engine surface noise with attenuated in- R dB(A) 115 120 120 123
TIM-ID: 0000023723 - 003

4.14 Product data 10V/12V1600B40S – Bifrequency
Key

er
1 10V1600B40S Power generation 1500/1800 rp 448/511 kW Ref. 25 °C/- ; Bifre-
3B continuous opera- m 601/685 bhp quency - 50 Hz data
sumption
sumption
3 12V1600B40S Power generation 1500/1800 rp 576/608 kW Ref. 25 °C/-; Bifre-
sumption
sumption
ID 1 2 3 4
TIM-ID: 0000020172 - 003


ID 1 2 3 4
ISO 8528)

ID 1 2 3 4

ID 1 2 3 4
gine main PTO)
Air / exhaust gas

ID 1 2 3 4

ID 1 2 3 4
Pressure loss in off-engine cooling sys- L bar 0.7 0.7 1 1
tem, max.
Lube oil system

ID 1 2 3 4
TIM-ID: 0000020172 - 003
engine, from
engine, to
gine, from
gine, to

Fuel system
ID 1 2 3 4

ID 1 2 3 4
A)
Capacities
ID 1 2 3 4
Engine coolant, engine side (w/o cooling R Liters 60 * 60 * 65 65
equipment)
tions)
ating inclinations)
ating inclinations)

ID 1 2 3 4
Acoustics
ID 1 2 3 4
erance)
TIM-ID: 0000020172 - 003


4.15 Firing order
Firing order
Number of cylin- Firing order
ders
8V A1–B4–A4–A2–B3–A3–B2–B1
10 V A1–B4–A4–B3–A3–B2–A2–B5–A5–B1
12 V A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6
Direction of rotation
Direction of rotation (as viewed on driving end)c.c.w., not reversible
TIM-ID: 0000000878 - 004

4.16 Engine – Main dimensions
Engine – Main dimensions
Length (A) 8V Approx. 1433 mm

10V approx. 1598 mm
12V approx. 1763 mm
Width (B) 8V Approx. 1318 mm
10V approx. 1318 mm
12V approx. 1318 mm
Height (C) 8V Approx. 1327 mm
10V approx. 1327 mm
12V approx. 1327 mm
TIM-ID: 0000000862 - 002

5 Operation
5.1 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Preservation and Represervation Specifications (A001070/..) available.
Putting the engine into operation after extended out-of-service-periods (>3

months)
Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Lube oil system Check engine oil level (→ Page 121).
Fuel system Vent (→ Page 113).
Engine coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 126).
Engine coolant circuit Check engine coolant level (→ Page 125).
Engine coolant circuit Preheat engine coolant with coolant preheater (if applicable).
Engine governor Check plug connections (→ Page 141).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch on;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
TIM-ID: 0000000864 - 003
76 | Operation | MS150076/06E 2018-08

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

Item Action
Lube oil system Check engine oil level (→ Page 121).
Engine coolant circuit Check engine coolant level (→ Page 125).
Engine coolant circuit Preheat engine coolant with coolant preheater (if applicable).
Fuel prefilter Drain fuel prefilter (→ Page 115).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch on;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
TIM-ID: 0000000876 - 002
MS150076/06E 2018-08 | Operation | 77

5.3 Starting the engine in manual mode (test run)
Preconditions
☑ Generator is not connected to the mains.
☑ External start interlock is not activated.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
NOTICE
Re-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.
Preparation
Item Action
Operating mode switch (if Change to manual mode.
fitted)
Starting the engine

Item Action
Control cabinet, operator Press start button.
station etc. (depending on • Automatic starting sequence is performed;
manufacturer) • 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 operating

temperature
Item Action
Control cabinet, operator Close the generator circuit breaker.
TIM-ID: 0000000865 - 003
station etc. (depending on

manufacturer)
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 60 °C).
78 | Operation | MS150076/06E 2018-08

5.4 Re-starting the engine following an automatic safety
shutdown
NOTICE
Re-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.
Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault
has been identified and eliminated.
Procedure following an automatic safety shutdown

1. Eliminate fault.
2. If the root cause cannot be identified or eliminated, contact Service.
Important
The function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-
ed.
TIM-ID: 0000081383 - 001
MS150076/06E 2018-08 | Operation | 79

5.5 Safety system – Override
NOTICE
Safety functions and engine shutdown alarms will be disregarded.
Severe material damage!
• Initiate emergency start only in emergency situations.
NOTICE
Inadmissible operating status.
Severe damage to property!
• Use override function only in hazardous situations to ensure full capability in the event of engine
faults.
Preparation
Note: This function is only available when a pushbutton is provided.
Safety system – Override

Item Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
panel etc. (depending on (→ Page 78).
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM-ID: 0000000984 - 003
80 | Operation | MS150076/06E 2018-08

5.6 Operational checks
DANGER
Components are moving or rotating.
• Operate the engine at low load only. Keep clear of the danger zone of the engine.
WARNING
WARNING
Fuels 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.
Operational checks
Item Action
Engine under load Visually inspect engine for leaks and general condition;
Engine at nominal speed Check for abnormal running noises and vibration;
Check exhaust gas color (→ Page 88).
Air filter Check signal ring position of service indicator (→ Page 119).
Replace air filter (→ Page 117), if the signal ring is completely visible in the
service indicator control window.
Coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 130).
Engine oil Checking engine oil level(→ Page 121)
Fuel system Ventilation (→ Page 113)
TIM-ID: 0000000866 - 005
MS150076/06E 2018-08 | Operation | 81

5.7 Emission label – Check
Emission label – Check

Note: 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?
TIM-ID: 0000063752 - 002
82 | Operation | MS150076/06E 2018-08

5.8 Engine stop in manual operation (trials)
Preconditions
☑ Generator is not connected to network.
☑ Engine is running in manual mode.
Preparation
Item Task
Engine After the generator breaker has been opened, allow the engine to cool down
by running it idle for approx. 5 minutes.
Stop engine
Item Task
Switchgear cabinet, control Press stop button.
panel etc. (depending on • Automatic stopping sequence is performed;
manufacturer) • engine is stopped.
TIM-ID: 0000000867 - 001
MS150076/06E 2018-08 | Operation | 83

5.9 Emergency engine shutdown
NOTICE
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 shutdown

Item Action
Emergency 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 shutdown

Item Action
Control cabinet, operator Press pushbutton for alarm acknowledgment.
station etc. (depending on • Audible and visual alarm output stops
manufacturer)
TIM-ID: 0000000868 - 003
84 | Operation | MS150076/06E 2018-08

5.10 After stopping the engine – Engine remains ready for
operation
After stopping the engine

Item Action
Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
control
TIM-ID: 0000000983 - 003
MS150076/06E 2018-08 | Operation | 85

5.11 After stopping engine – Putting engine out of operation
Preconditions
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.
After shutdown
Item Action
Coolant circuit Drain engine coolant (→ Page 127)if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period but the coolant has no antifreeze addi-
tive;
• engine room is not heated;
• coolant is not kept at a suitable temperature;
• antifreeze concentration is insufficient for the engine-room temperature;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Engine/generator control Switch off.
system
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tem gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ MTU Preservation and Represerva-
tion Specifications A001070/..).
TIM-ID: 0000002705 - 002
86 | Operation | MS150076/06E 2018-08

6 Maintenance
6.1 Maintenance task reference table [QL1]
The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a separate publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
Task Measures
W0500 Check engine oil level. (→ Page 121)

W0501 Visually inspect engine for leaks and general condition. (→ Page 81)
W0502 X Check intercooler condensate drain. (This is not applicable to your
system.)
W0507 X Drain water and contamination from fuel prefilter. (→ Page 115)
W0521 Check signal ring position of maintenance indicator, replace (→ Page 119)
air filter if necessary.
W0800 Check if emissions label is present, legible and content-wise (→ Page 82)
correct.
W1001 Replace fuel filter or fuel filter element. (→ Page 114)
W1003 Check drive belt condition and tension, replace as necessa- (→ Page 134)
ry.
W1005 Replace air filter. (→ Page 117)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 124)
the interval (years) is reached, at the latest.
W1010 Check exterior of cooler elements for dirt. (→ Page 131)
W1207 Check valve clearance, adjust as necessary. IMPORTANT! (→ Page 107)
First adjustment after 1,000 operating hours.
W1483 Replace poly-Vee drive belt of fan. (→ Page 137)
W1505 X Replace drive belts of battery-charging generator and cool- (→ Page 137)
ant pump.
W1675 Replace fuel prefilter or filter element of fuel prefilter. (→ Page 116)
Table 2: Maintenance task reference table [QL1]

TIM-ID: 0000080654 - 001
MS150076/06E 2018-08 | Maintenance | 87

7 Troubleshooting
7.1 Troubleshooting
Engine does not turn when starter is actuated
Cause 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 starter u Check if cable connections are properly secured, contact Service.
defective
Engine cabling defective u Check (→ Page 139).
Engine / generator control: u Carry out visual inspection (→ manufacturer's documentation).
Assemblies or connectors
possibly loose
Engine governor: Plug-in u Check plug connections (→ Page 141).
connections loose
Running gear blocked (engine u Contact Service.
cannot be barred manually)
Engine turns on starting but does not fire

Poor rotation by starter: Battery u Charge or replace battery (→ manufacturer's documentation).
low or defective
Air in fuel system u Vent fuel system (→ Page 113).
Engine governor defective u Contact Service.
Engine fires unevenly

Injector defective u Contact Service.
Engine cabling defective u Check (→ Page 139)
Air in fuel system u Vent fuel system (→ Page 113)
Engine does not reach nominal speed

TIM-ID: 0000067865 - 001

Fuel filter clogged u Replace (→ Page 114).
Air filter clogged u Check, replace if necessary (→ Page 119).
Engine: Overload u Contact Service.
88 | Troubleshooting | MS150076/06E 2018-08

Engine speed not steady
Speed sensor defective u Contact Service.
Air in fuel system u Vent fuel system (→ Page 113).
Charge-air temperature too high

Engine room: Air-intake u Check fans and intake/exhaust lines.
temperature too high
Charge-air pressure too low

Exhaust turbocharger defective u Contact Service.
Black exhaust gas

Engine: Overload u Contact Service.
Blue exhaust gas

Too much engine oil in the engine u Drain engine oil (→ Page 122).
Exhaust turbocharger, cylinder u Contact Service.
head, piston rings or cylinder liner
defective
White exhaust gas

Engine is not at operating u Run up to operating temperature.
temperature
TIM-ID: 0000067865 - 001
MS150076/06E 2018-08 | Troubleshooting | 89

7.2 Fault messages
5 – HI T-Charge Air
The charge-air temperature at 1. Reduce power.
sensor B9 has exceeded limit 2. Check whether alarms 9 and 10 are pending.
value 1. The charge-air 3. Contact Service.
temperature is too high.
6 – SS T-Charge Air
The charge-air temperature at 1. Reduce power.
sensor B9 has exceeded limit 2. Check whether alarms 9 and 10 are pending.
value 2. The charge-air 3. Contact Service.
temperature is too high.
15 – LO P-Lube Oil
The lube oil pressure at sensor 1. Check engine oil level (→ Page 121).
B5.1 has undershot limit value 1. 2. Contact Service.
The lube oil pressure is too low.
16 – SS P-Lube Oil
The lube oil pressure at sensor 1. Check engine oil level (→ Page 121).
B5.1 has undershot limit value 2. 2. Contact Service.
The lube oil pressure is too low.
30 – SS Engine Overspeed
The engine speed has exceeded 1. If emergency stop was tripped by the engine overspeed test,
the limit value or the engine restart the engine.
overspeed test was tripped. 2. If emergency stop was tripped by the engine, notify Service.
Engine emergency stop was
tripped.
67 – HI T-Coolant
TIM-ID: 0000083125 - 001

The coolant temperature at 1. Reduce power.
sensor B6 has violated limit value 2. Check operation of cooler and fan (plant side).
1. Coolant temperature too high. 3. Check engine coolant level (→ Page 125).
4. Contact Service.

68 – SS T-Coolant
The coolant temperature at 1. Check operation of cooler and fan (plant side).
sensor B6 has violated limit value 2. Check engine coolant level (→ Page 125).
2. Coolant temperature too high. 3. Contact Service.
82 – HI P-Fuel (Common Rail)

The HP fuel pressure at sensor u Contact Service.
B48.1 has violated the upper limit
value. Fuel pressure is too high.
83 – LO P-Fuel (Common Rail)

B48.1 has violated lower limit
value 1. The fuel pressure is too
low.
89 – SS Engine Speed too Low

The engine speed has undershot 1. Acknowledge alarm.
the limit value. Engine emergency 2. Observe any other messages.
stop was tripped. 3. Contact Service.
90 – SS Starter Speed Not Reached

The engine speed does not reach u Contact Service.
idling within the specified time
after reaching starter
disengagement speed.
91 – SS Release Speed Not Reached

The engine speed does not reach 1. Check pressure supply (plant side) of starter.
starter disengagement speed 2. Observe any other messages.
within the specified time after 3. Contact Service.
reaching starter speed.
TIM-ID: 0000083125 - 001
92 – SS Starter Speed Not Reached

The engine has not reached the 1. Check pressure supply (plant side) of starter.
specified speed threshold within 2. Observe any other messages.
the specified time. 3. Contact Service.

93 – SS T-Preheat
The engine coolant temperature u Contact Service.
has not reached specified limit
value 2. Preheating is not
working. Start interlock.
93 – SS T-Preheat
The engine coolant temperature 1. Switch on preheater.
has not reached specified limit 2. Check preheater and overhaul if necessary (see manufacturer's
value 2. Preheating is not documentation).
working. Start interlock. 3. Contact Service.
94 – LO T-Preheat
The engine coolant temperature u Contact Service.
has not reached specified limit
value 1. Preheating is not
working.
94 – LO T-Preheat
The engine coolant temperature 1. Switch on preheater.
has not reached specified limit 2. Check preheater and overhaul if necessary (see manufacturer's
value 1. Preheating is not documentation).
working. 3. Contact Service.
118 – LO ECU Power Supply Voltage

The supply voltage of the ECU has 1. Check state of charge of the batteries (plant side).
undershot specified limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 141).
3. Contact Service.
119 – LOLO ECU Power Supply Voltage

undershot specified limit value 2. 2. Check plug connections to Engine Control Unit (→ Page 141).
TIM-ID: 0000083125 - 001
3. Contact Service.
120 – HI ECU Power Supply Voltage

exceeded specified limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 141).
3. Contact Service.

121 – HIHI ECU Power Supply Voltage
exceeded specified limit value 2. 2. Check plug connections to Engine Control Unit (→ Page 141).
3. Contact Service.
122 – HI T-ECU
The ECU-internal temperature 1. Check whether alarms 9 and/or 10 are active.
sensor has exceeded the limit 2. If ECU cooling is connected, check flow.
value. The internal temperature is 3. Contact Service.
too high.
180 – AL CAN1 Node Lost

Connection or communication 1. Check engine cabling (→ Page 139).
with a node at CAN bus 1 failed. 2. Disconnect voltage supply and reconnect again.
3. Contact Service.
181 – AL CAN2 Node Lost

Connection or communication 1. Check engine cabling (→ Page 139).
with a node at CAN bus 2 failed. 2. Disconnect voltage supply and reconnect again.
3. Contact Service.
186 – AL CAN1 Bus Off

CAN bus 1 to MTU automation 1. Check plug connections to Engine Control Unit (→ Page 141).
system (e.g. ECU/MAU/SAM) 2. Contact Service.
disrupted or defective.
187 – AL CAN1 Error Passive

CAN bus 1 to MTU automation 1. Check plug connections to Engine Control Unit (→ Page 141).
system (e.g. ECU/MAU/SAM) 2. Contact Service.
disrupted or defective.
TIM-ID: 0000083125 - 001
188 – AL CAN2 Bus Off

CAN bus 2 to plant automation 1. Check connection between plant-side automation and MTU
system (e.g. Murphy display) automation.
disrupted or defective. 2. Contact Service.

189 – AL CAN2 Error Passive
CAN bus 2 to plant automation 1. Check connection between plant-side automation and MTU
system (e.g. Murphy display) automation.
disrupted or defective. 2. Contact Service.
201 – SD T-Coolant
The signal from the coolant 1. Check engine cabling (→ Page 139).
temperature sensor (B6) at the 2. Contact Service.
coolant distribution housing is
faulty or missing.
203 – SD T-Charge Air

The charge-air temperature 1. Check engine cabling (→ Page 139).
sensor (B9), A-side, delivers 2. Contact Service.
incorrect or no signal.
208 – SD P-Charge Air

The signal from the charge-air 1. Check engine cabling (→ Page 139).
pressure sensor (B10) after the 2. Contact Service.
HP intercooler is faulty or missing.
211 – SD P-Lube Oil

The signal from the lube oil 1. Check engine cabling (→ Page 139).
pressure sensor after the filter 2. Contact Service.
(B5) is faulty or missing.
212 – SD P-Coolant
The signal from the coolant 1. Check engine cabling (→ Page 139).
pressure sensor after coolant 2. Contact Service.
pump (B16) is faulty or missing.
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215 – SD P-HD
The signal from the A side rail 1. Check engine cabling (→ Page 139).
pressure sensor (B48.1) is faulty 2. Contact Service.
or missing.

229 – AL Stop Camshaft Sensor Defect
Emergency engine stop following u Contact Service.
failure of the crankshaft sensor
(B13) and camshaft sensor (B1).
230 – SD Crankshaft Speed

The crankshaft speed sensor 1. Check engine cabling (→ Page 139).
(B13) delivers incorrect or no 2. Contact Service.
signal.
231 – SD Camshaft Speed

The camshaft speed sensor (B1) 1. Check engine cabling (→ Page 139).
delivers incorrect or no signal. 2. Contact Service.
266 – SD Speed Demand

Signal for analog speed setting 1. Switch on plant-side automation.
missing. 2. Contact Service.
321 – AL Wiring Cylinder A1

Short circuit fault in injector 1. Check wiring of affected injector (→ Page 139).
wiring cylinder A1 or injector 2. Contact Service.
defective.

defective.

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defective.

defective.

defective.

defective.
331 – AL Wiring Cylinder B1

wiring cylinder B1 or injector 2. Contact Service.
defective.

defective.

defective.

defective.

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defective.

defective.
341 – AL Open Load Cylinder A1

Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 139).
to cylinder A1. 2. Contact Service.

cylinder A2. 2. Contact Service.




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351 – AL Open Load Cylinder B1

cylinder B1. 2. Contact Service.





365 – AL Stop MV-Wiring Ground

Short circuit of injector positive 1. Check cabling (→ Page 139).
connection to ground of one or 2. Restart engine.
more injectors. Short circuit of 3. Contact Service.
the negative injector connection
of one or more injectors to
ground.
381 – AL Wiring TOP 1

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Short circuit or wire break at 1. Check cabling (→ Page 139).

transistor output 1 plant side (TOP 2. Contact Service.
1).

2).

3).

4).
390 – AL MCR exceeded

DBR/MCR feature: MCR u Contact Service.
(maximum continuous rating) was
violated.
408 – AL Open Load Emerg. Stop Input ESI

Open load detected at the 1. Check cabling (→ Page 139).
emergency stop input 2. Contact Service.
410 – LO U-PDU
The voltage for the ECU for 1. Check voltage supply (plant side).
activating the injectors has 2. Check cabling (→ Page 139).
undershot limit value 1. 3. Contact Service.
411 – LOLO U-PDU

undershot limit value 2. 3. Contact Service.
412 – HI U-PDU
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exceeded limit value 1. 3. Contact Service.

413 – HIHI U-PDU
exceeded limit value 2. 3. Contact Service.
420 – AL L1 Aux 1
Input signal from Aux 1 has u Contact Service.
violated limit value 1.
421 – AL L2 Aux1
Input signal from Aux 1 has u Contact Service.
violated limit value 2.
438 – LO P-Fuel 2 (Common Rail)

B48.2 has violated lower limit
value 1. The fuel pressure is too
low.
439 – HI P-Fuel 2 (Common Rail)

The fuel high pressure at sensor 1. Check wiring of HP fuel control block.
B48 2 has exceeded the limit 2. Contact Service.
value. The HP fuel pressure is too
high.
440 – AL L1 P-Aux 1
The pressure measurement u Contact Service.
sensor at the pressure
measurement channel has
undershot limit value 1. The
pressure value at the pressure
measurement channel is too low.
TIM-ID: 0000083125 - 001
442 – AL L2 P-Aux1
The pressure measurement u Contact Service.
sensor at the pressure
measurement channel has
undershot limit value 2. The
pressure value at the pressure
measurement channel is too low.

444 – SD U-PDU
Fault in internal supply voltage of u Contact Service.
injector end stage.
446 – SD P-HD2
The rail pressure sensor (B48.2), 1. Check engine cabling (→ Page 139).
B-side, delivers incorrect or no 2. Contact Service.
signal.
448 – HI P-Charge Air

The charge-air pressure at sensor 1. Power reduction.
B10 has exceeded limit value 1. 2. Check sensor B10 and replace as necessary.
Charge-air pressure is too high. 3. Contact Service.
449 – SS P-Charge Air

The charge-air pressure at sensor 1. Power reduction.
B10 has exceeded limit value 2. 2. Check sensor B10 and replace as necessary.
Charge-air pressure is too high. 3. Contact Service.
454 – SS Power Reduction Active

Power reduction activated. A main 1. Observe any other messages.
alarm that has occurred activates 2. Contact Service.
the power reduction.
470 – SD T-ECU
The ECU-internal temperature 1. Check engine cabling (→ Page 139).
sensor delivers incorrect or no 2. Contact Service.
signal
472 – AL Stop SD
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This fault is output if one or more 1. Check engine cabling (→ Page 139).
sensors which have been 2. Contact Service.
configured to initiate an engine
stop are faulty.

478 – AL Comb. Alarm Yel (Plant)
The alarm is issued if a plant 1. Observe any other messages.
device of the ECU indicates via 2. Contact Service.
the PCS5-CAN that it is to set the
yellow summary alarm.
479 – AL Comb. Alarm Red (Plant)

The alarm is issued if a plant 1. Observe any other messages.
device of the ECU indicates via 2. Contact Service.
the PCS5-CAN that it is to set the
red summary alarm.
480 – AL Ext. Engine Protection

External engine protection 1. Check plant signal.
function is active. 2. Contact Service.
536 – AL Wiring PWM_CM1

HP fuel control block M8 of the 1. Check engine cabling (→ Page 139).
HP fuel pump cannot be activated. 2. Contact Service.
549 – AL Power Cut-Off detected

ECU operating voltage was 1. Check engine cabling if the power supply was not disconnected
switched off while the engine was manually (→ Page 139).
running. Do not disconnect the 2. Contact Service.
voltage supply until the engine is
stationary.
558 – AL Wiring PWM_CM2

The HP fuel control block M8.2 (B- 1. Check engine cabling (→ Page 139).
side) of the HP fuel pump can not 2. Contact Service.
be activated.
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594 – AL L1 PRV Defective

The number of opening operations u Contact Service.
of the pressure relief valve on the
rail, A-side, has exceeded the
maximum number (limit value 1).

rail, A-side, has exceeded the
596 – AL Test Parameters

The parameter set is used for u No action required.
trials. The alarm remains set until
a series parameter set is loaded.

rail, B-side, has exceeded the

rail, B-side, has exceeded the
615 – AL EIL Protection

Engine number in EIL does not 1. Check engine cabling (→ Page 139).
match the engine number saved 2. Contact Service.
in the ECU
616 – AL EIL Fault

ECU can not recognize the EIL. u Contact Service.
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762 – AL Smart Connect Lost

Smart Connect device has failed 1. Check engine cabling (→ Page 139).
on CAN bus. 2. Check Smart Connect.
3. Contact Service.

832 – AL EIL Engine Number Different
Engine number in EIL does not 1. Check engine cabling (→ Page 139).
match the engine number saved 2. Contact Service.
in the ECU
973 – AL Checksum IIG

The entered IIG value does not 1. Check input of the IIG in the DiaSys and repeat if necessary.
correspond to the specified input 2. Contact Service.
format.
TIM-ID: 0000083125 - 001

8 Task Description
8.1 Engine
8.1.1 Engine – Barring with starting system
Preconditions
☑ External pushbutton 'Bar engine without starting' is provided.
DANGER
Rotating and moving engine parts.
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
Engine – Barring with starting system

1. 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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MS150076/06E 2018-08 | Task Description | 105

8.1.2 Engine – Test run
DANGER
WARNING
Exhaust 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.
WARNING
Engine – Test run

1. Start engine (→ Page 78).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 81).
4. Stop engine (→ Page 83).
TIM-ID: 0000000870 - 009
106 | Engine | MS150076/06E 2018-08

8.2 Valve Drive
8.2.1 Valve clearance – Check and adjustment
Preconditions
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.

Feeler gage Y20010128 1
Torque wrench, 20–100 Nm F30026582 1
Box wrench, 14 mm F30028346 1
Allen key, 2–10 mm F30453050 1
Barring gear F6790714 1
Preparatory steps
1. Remove cylinder head cover (→ Page 110).
2. Remove cover on the bottom of flywheel housing, A side.
3. Install barring gear at opening.
4. Rotate crankshaft with barring gear in engine direction of rotation until "OT-A1" mark and pointer are aligned.
Diagram for 8 V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
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MS150076/06E 2018-08 | Valve Drive | 107

I Inlet valve
X Exhaust valve

I Inlet valve
X Exhaust valve
Checking valve clearance at two crankshaft positions

1. 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 ±0.05 mm;
• Exhaust = 0.6 ±0.05 mm.
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram.
TIM-ID: 0000000899 - 009
4. Use feeler gage 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.
108 | Valve Drive | MS150076/06E 2018-08

Adjusting valve clearance
1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gage between valve bridge and
rocker arm (3).
3. Readjust adjusting screw (2) so that the feel-
er gage just passes through the gap.
4. Tighten locknut (1) to specified torque using a torque wrench, holding adjusting screw (2) firm with Allen
key (5 mm).
Name Size Type Lubricant Value/Standard
Nut M10 x 1 Tightening torque 43+4 Nm
5. Check if the feeler gage just passes through between valve bridge and rocker arm (3).
Result: If not, adjust valve clearance.
Final steps
1. Remove barring gear.
2. Install cover.
3. Install cylinder head cover (→ Page 110).
TIM-ID: 0000000899 - 009
MS150076/06E 2018-08 | Valve Drive | 109

8.2.2 Cylinder head cover ‒ Removal and installation
Preconditions

Ratchet bit F30027340 1
Torque screwdriver, 1.0–5.0 Nm F30452774 1
Engine oil
Sealing frame (→ Spare Parts Catalog)
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
Removing cylinder head cover

Note: Cover the engine beneath the cylinder head
with cloths to collect emerging oil.
1. Remove screws.
2. Remove cylinder head cover.
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110 | Valve Drive | MS150076/06E 2018-08

3. Unscrew wiring from injectors (1).
4. Remove gasket with wiring.
Installing cylinder head cover

1. Clean mating faces.
2. Check condition of gasket and replace as
necessary.
3. Wet the sealing lip along the trapezoidal
edges with engine oil on the side of the gas-
ket facing the cylinder head.
4. Fit gasket.
5. Screw wiring onto injectors (1).

Hex nut M4 Tightening torque 1.5 Nm
TIM-ID: 0000000900 - 005
MS150076/06E 2018-08 | Valve Drive | 111

6. Fit cylinder head cover and tighten screws at positions 1 to 4 to the specified initial tightening torque using a
torque wrench.
Screw with twin col- M8 Preload torque (Engine oil) 10 Nm
lar
Note: • Consecutive tightening sequence starting at position 1: 1 to 18 (on 12V engines).

• The same tightening specifications apply to 8V and 10V engines, making allowance for the smaller num-
ber of screws on the long sides.
7. Tighten screws at positions 1 to 18 to specified torque using a torque wrench.
Screw with twin col- M8 Tightening torque (Engine oil) 20±2 Nm
lar
TIM-ID: 0000000900 - 005
112 | Valve Drive | MS150076/06E 2018-08

8.3 Fuel System
8.3.1 Fuel system – Venting
Preconditions
WARNING
• Do not smoke.
Venting fuel system

Note: The inlet opening (3) of the fuel priming pump
is connected to the fuel inlet of the engine.
1. Unlock fuel priming pump, screw out han-
dle (2).
2. Loosen nut (1) on banjo union.
Note: Catch emerging fuel with a suitable cloth.
3. Operate the pump with the handle (2) until
bubble-free fuel emerges.
4. Tighten nut (1) on banjo union.
5. Lock fuel priming pump, screw in handle (2).

Handle Tightening torque 3±1 Nm
TIM-ID: 0000000901 - 005
MS150076/06E 2018-08 | Fuel System | 113

8.4 Fuel Filter
8.4.1 Fuel filter ‒ Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog) 1
WARNING
• Do not smoke.
Fuel filter ‒ Replacement

1. Use filter wrench to remove easy-change fil-
ter.
2. Clean sealing surface on filter head.
3. Slightly lubricate seal on the easy-change fil-
ter.
4. Screw on easy-change filter by hand until the
seal makes contact and then tighten by hand.
TIM-ID: 0000000902 - 004
114 | Fuel Filter | MS150076/06E 2018-08

8.4.2 Fuel prefilter – Draining
Preconditions
WARNING
• Do not smoke.
Fuel prefilter – Draining

1. 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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MS150076/06E 2018-08 | Fuel Filter | 115

8.4.3 Fuel prefilter – Replacement
Preconditions
☑ System is not under pressure.

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog) 1
WARNING
• Do not smoke.
WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.
NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Fuel prefilter – Replacement

Note: Collect escaping fuel and dispose of.
1. Use filter wrench to screw easy-change fil-
ter (2) off and take it off together with sight
glass (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 head
and tighten manually.
TIM-ID: 0000036955 - 005
6. Push on sight glass (3).
116 | Fuel Filter | MS150076/06E 2018-08

8.5 Air Filter
8.5.1 Air filter ‒ Replacement
Air filter (→ Spare Parts Catalog)
Air filter ‒ Replacement

1. Remove air filter and install new one (→ Page 118).
2. Reset signal ring of service indicator (→ Page 119).
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MS150076/06E 2018-08 | Air Filter | 117

8.5.2 Air filter – Removal and installation
Preconditions
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).
TIM-ID: 0000000904 - 012
118 | Air Filter | MS150076/06E 2018-08

8.6 Air Intake
8.6.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. Replace air filter if the signal ring (2) is com-
pletely visible in the red area of the observa-
tion window (3) (→ Page 117).
2. After installation of new filter, press reset
button (1).
Result: Signal ring returns to initial position.
TIM-ID: 0000000985 - 004
MS150076/06E 2018-08 | Air Intake | 119

8.7 Starting Equipment
8.7.1 Starter – Condition check
Preconditions
Starter – Condition check

1. Check securing screws of starter and nut on cable connection for secure seating and tighten if required.
2. Check cabling (→ Page 139).
TIM-ID: 0000000905 - 019
120 | Starting Equipment | MS150076/06E 2018-08

8.8 Lube Oil System, Lube Oil Circuit
8.8.1 Engine oil – Level check
Preconditions
Checking oil level prior to en-

gine start
1. Remove oil dipstick (1) from 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 122).
5. Insert oil dipstick (1) in guide tube up to the
stop.
Checking oil level after engine is stopped

1. 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 122).
5. Insert oil dipstick (1) in guide tube up to the stop.
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8.8.2 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Oil 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.
Draining engine oil at drain plug

on oil pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug (2) and drain oil.
3. Insert drain plug (2) with new sealing ring and use torque wrench to tighten to specified tightening torque.
TIM-ID: 0000000906 - 006

Drain plug Tightening torque (Engine oil) 100 Nm
4. Replace engine oil filter (→ Page 124).
122 | Lube Oil System, Lube Oil Circuit | MS150076/06E 2018-08

Extracting engine oil with hand
pump
1. Guide a hose (3) for collecting the oil into a
suitable container.
2. Use the lever (2) of the hand pump to extract
the engine oil completely from the oil pan.
3. Replace engine oil filter (→ Page 124).
Filling new oil

1. Open cap (1) on cylinder head cover.
2. Fill with oil; Oil filling capacity (→ Technical data).
3. Close cap (1) on cylinder head cover.
4. Check engine oil level (→ Page 121).
TIM-ID: 0000000906 - 006
MS150076/06E 2018-08 | Lube Oil System, Lube Oil Circuit | 123

8.9 Oil Filtration / Cooling
8.9.1 Engine oil filter – Replacement
Preconditions

Socket, 32 mm F30006120 1
Engine oil
Oil filter element (→ Spare Parts Catalog)
WARNING
Oil 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.
Replacing engine oil filter

1. Unscrew the 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 pressing
on 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.
TIM-ID: 0000000908 - 006
8. Screw on cover (1) with oil filter element (3) and use a torque wrench to tighten to the specified tightening
torque.
Cover Tightening torque (Engine oil) 35±3.5 Nm
9. Replace other engine oil filters in the same way.

10. Check oil level (→ Page 121)
124 | Oil Filtration / Cooling | MS150076/06E 2018-08

8.10 Coolant Circuit, General, High-Temperature Circuit
8.10.1 Engine coolant – Level check
Preconditions
WARNING
Coolant 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 at

filler neck
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
3. Check coolant level (coolant must be visible
at the lower edge of the cast-in eye or at the
marking plate).
4. Top up with treated coolant as necessary
(→ Page 128).
5. Check breather valve (visual inspection) and
clean if necessary.
6. Position breather valve on filler neck and
close.
Checking engine coolant level by means of level sensor

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 128).
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8.10.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 127).
2. Fill with engine coolant (→ Page 128).
TIM-ID: 0000000036 - 031
126 | Coolant Circuit, General, High-Temperature Circuit | MS150076/06E 2018-08

8.10.3 Engine coolant – Draining
Preconditions

Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheater, if installed.
Engine coolant – Draining

1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first stop
and allow pressure to escape.
2. Continue to turn breather valve counterclock-
wise and remove.
3. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
4. Open drain plugs and drain engine coolant at
the following drain points:
• on crankcase, left side
• on crankcase, right side
5. Insert drain plugs with new sealing ring and use torque wrench to tighten to specified tightening torque.
Drain plug Tightening torque (Engine oil) 100 Nm
TIM-ID: 0000000910 - 003
6. Position breather valve on filler neck and close.

8.10.4 Engine coolant – Filling
Preconditions

Coolant
DANGER
WARNING
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn valve cover (1) on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn valve cover (1) counter-
clockwise and remove.
TIM-ID: 0000000909 - 008

Filling coolant
1. 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 steps
1. Start engine and run at idle speed for some minutes.
2. Check coolant level (→ Page 125), top up with coolant if required.
TIM-ID: 0000000909 - 008

8.10.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump – Relief

bore check
1. Check relief bore (1) for engine coolant dis-
charge.
• Permissible engine coolant discharge: Up
to 0.1 ml per hour respectively or 100 ml
per 1,000 operating hours.
2. Contact Service if discharge exceeds the
specified limits.
3. If relief bore is dirty (1):
a) Stop engine (→ Page 83) and disable en-
gine start.
b) Clean relief bore (1) with wire.
TIM-ID: 0000000912 - 004

8.11 Coolant System
8.11.1 Cooler – Checking cooler elements externally for dirt
Preconditions
Check cooler elements externally for dirt

1. Inspect cooler elements visually for dirt.
2. Clean badly soiled cooler elements (→ Page 132).
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MS150076/06E 2018-08 | Coolant System | 131

8.11.2 Cooler – Cleaning cooler elements
Preconditions
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Use appropriate cleaning tool.
Cleaning cooler elements

1. Blow out the cooler elements with a jet of compressed air working against the direction of the cooling air
parallel to the cooling fins.
2. If cooler elements are badly soiled, treat cooling fins with a hot, grease-dissolving alkaline cleaning agent
before cleaning.
TIM-ID: 0000015784 - 002
132 | Coolant System | MS150076/06E 2018-08

8.12 Belt Drive
8.12.1 Drive belt – Adjustment
Preconditions
Fan drive – Belt tension adjust-

ment
1. Remove protective cover from cooler.
2. Loosen screw (2) and unscrew slightly.
3. Turn nut (1) clockwise (1 rotation => 1.25
mm height adjustment) and tension drive belt
to required level.
4. Tighten screws (2). If necessary, insert
screws in the other securing bore.
5. Check drive belt tension (→ Page 135) and
adjust if necessary.
Engine coolant pump drive,

checking belt tension (engine
with mechanical belt tensioner)
Note: Only applies to engines without battery-
charging generator.
1. Release screws with washers (2) on mechani-
cal belt tensioner (1) and place in position
lightly.
2. Screw in adjusting screw (3) to set the re-
quired drive belt tension (4).
3. Tighten screws with washers (2).
4. Check drive belt tension (→ Page 135) and
adjust if necessary.
TIM-ID: 0000083291 - 001
MS150076/06E 2018-08 | Belt Drive | 133

8.12.2 Drive belt – Condition check
Preconditions
Checking condition
Item Findings Action

Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Fit new part (→ Page 137)
Drive belt C Chunking
Drive belt Fouling by oil, overheating
TIM-ID: 0000000896 - 005
134 | Belt Drive | MS150076/06E 2018-08

8.12.3 Drive belt – Tension check
Preconditions

Belt tension tester, 500-1400 N Y20097430 1
Preload gauge, 1300–3100 N Y20097431 1
Fan drive – Belt tension check

1. Remove protective cover (if applicable).
2. Set preload gauge onto the drive belt in the
middle between the belt pulleys (arrow).
3. Use pushbutton to press vertically on top of
drive belt exerting even pressure until spring
can be heard or felt to engage.
4. Do not press any further, otherwise the dis-
play value will be falsified.
5. Remove preload gauge without changing the
position of the display arm.
6. Read off measured value at the intersection
of display arm and "KG" scale. For specifica-
tions, refer to table below.
Application Measured value Measured value Measured value

Initial assembly Operating tension after Minimum operating
1 hour tension
Fan drive belt 2250 N 1620 N ±300 N 1080 N ±300 N
7. If the measured values deviate from the prescribed values, adjust drive belt tension (→ Page 133).
8. Install protective cover.
TIM-ID: 0000000897 - 004
MS150076/06E 2018-08 | Belt Drive | 135

Engine coolant pump drive,
checking belt tension (engine
with mechanical belt tensioner)
charging generator.
1. Remove protective cover.
2. Set preload gauge onto the drive belt in the
middle between the belt pulleys (arrow).
3. Use pushbutton to press vertically on top of
drive belt exerting even pressure until spring
can be heard or felt to engage.
4. Do not press any further, otherwise the dis-
play value will be falsified.
5. Remove preload gauge without changing the
position of the display arm.
6. Read off measured value at the intersection
of display arm and "KG" scale. For specifica-
tions, refer to table below.
Application Measured value Measured value Measured value
Initial assembly Operating tension after Minimum operating
1 hour tension
Fan drive belt 1000 N 720 N ±80 N 480 N ±80 N
7. If the measured values deviate from the prescribed values, adjust drive belt tension (→ Page 133).
TIM-ID: 0000000897 - 004
136 | Belt Drive | MS150076/06E 2018-08

8.12.4 Drive belt – Replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Replacing fan drive belt

1. Remove protective cover from cooler.
2. Remove fan.
3. Loosen securing screws (3).
4. Turn clamping nut (1) counterclockwise until
the drive belt can be removed.
5. Check belt pulley on fan drive and crankshaft
for contamination and clean if necessary.
Note: When placing the drive belt in the grooves, no
force must be applied.
6. Fit new drive belt.
Note: During initial assembly of a belt, set the fan
height to 350 mm ±1 mm above the crank-
shaft. The fan drive must bear against the fan
bracket (2) when the drive belt is tensioned.
7. Adjust and check drive belt tension
(→ Page 133).
8. Install fan.
Battery-charging generator and

engine coolant pump drive, re-
placing drive belt
2. Remove drive belt from fan drive
(→ Page 137).
3. Use appropriate tool to release the automatic
belt tensioner at hexagon (2) and take off
drive belt (1).
Note: When placing the drive belt in the grooves, no
force must be applied.
4. Fit new drive belt (1) and unload belt tension-
TIM-ID: 0000083292 - 001
er.
5. Make sure that drive belt (1) is correctly seat-
ed in the grooves.
6. Install drive belt on fan drive (→ Page 137).
MS150076/06E 2018-08 | Belt Drive | 137

Engine coolant pump drive, re-
placing drive belt (engine with
mechanical belt tensioner, var-
iant B)
charging generator.
2. Remove drive belt from fan drive
(→ Page 137).
3. Release screws with washers (2) on mechani-
cal belt tensioner (1) and place in position
lightly.
4. Release adjusting screw (3) on mechanical
belt tensioner (1) and take off drive belt (4).
Note: When placing the drive belt (4) in the
grooves, no force must be applied.
5. Fit new drive belt (4).
6. Insert adjusting screw (3) on mechanical belt
tensioner (1) as far as the stop.
7. Check belt tension(→ Page 133)
8. Install drive belt on fan drive (→ Page 137).
TIM-ID: 0000083292 - 001
138 | Belt Drive | MS150076/06E 2018-08

8.13 Wiring (General) for Engine/Gearbox/Unit
8.13.1 Engine cabling – Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Engine cabling – Check

1. 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.
TIM-ID: 0000000029 - 025
MS150076/06E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 139

8.14 Accessories for (Electronic) Engine Governor / Control System
8.14.1 Engine governor and connector – Cleaning
Preconditions

Solvent (isopropyl alcohol) X00058037 1
NOTICE
Insertion 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 – Cleaning

1. 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 – Cleaning

Note: 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.
TIM-ID: 0000000047 - 014
140 | Accessories for (Electronic) Engine Governor / Control System | MS150076/06E 2018-08
8.14.2 Engine governor – Checking plug connections
Preconditions
Checking engine governor plug

connections
1. Check firm seating of all connectors on the
engine governor. Ensure that the clips (1) are
engaged.
2. Check firm seating of all screws (2) on engine
governor cable clamps. Make sure that cable
clamps are not defective.
TIM-ID: 0000000913 - 003
MS150076/06E 2018-08 | Accessories for (Electronic) Engine Governor / Control System | 141
9 Appendix A
9.1 Abbreviations
Abbre- Meaning Explanation
viation
A/D Analog/Digital converter Converter: converts sensor voltages into digital val-
ues
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
AL alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATS Air Temperature Sensor
BR Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-
tion No. A001061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-
nor
CEL Check Engine Lamp 1st function: Warning lamp (rectify fault as soon as
possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant level sensor Monitors coolant level
CM Current Measurement Current measured value
CPS Coolant pressure sensor Monitors coolant pressure
CR Common Rail
CTS Coolant temperature sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
Dia- Electronic dialog system
Sys®
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 failure
TIM-ID: 0000000858 - 016
DMC Data Matrix Code

DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particulate
filter
DPF Diesel Particulate Filter
DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
142 | Appendix A | MS150076/06E 2018-08

viation
EE- Electrically Erasable Programmable Read
PROM Only Memory
EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal
EGR Exhaust Gas Recirculation
EIL Engine Ident Label
EIM-ID Emission Identification Number
EMU Engine Monitoring Unit
ESCM Extreme Site Condition Management Power reduction for operation in extreme conditions
ESD Einzelspeicherdruck Injector accumulator pressure
ETC Exhaust turbocharger/exhaust turbocharg-
ing
EUI Electronic Unit Injector Electronic injection nozzle unit
FO Frequency Output
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel Restriction Sensor Monitors differential fuel pressure
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel Control cabinet
GND Ground
HP High Pressure
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
IDM Interface Data Module Memory module for interface data
IIG Initial injector equalization Initial input of injector code in Engine Control Unit
with DiaSys
INJ Injector
ISO International Organization for Standardiza- International umbrella organization for all national
tion standardization institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
L1 Limit 1 Limit value, limit 1
L2 Limit 2 Limit value, limit 2
Reference surface for heights above sea
level
LED Light Emitting Diode Light emitting diode
TIM-ID: 0000000858 - 016
LLK Ladeluftkühlung Charge-air cooling

LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LP Low Pressure
LSG Limit Speed Governor Maximum-speed governor
LSU Lambda Sonde Universal Universal Lambda probe
LT Low Temperature
MS150076/06E 2018-08 | Appendix A | 143

viation
MCR Maximum Continuous Rating Torque limitation curve
N/A Not Applicable
NN Normal Null Reference surface for heights above sea level
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil pressure sensor Monitors oil pressure
OTS Oil Temperature Sensor Monitors oil temperature
OT Oberer Totpunkt Top Dead Center (TDC)
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Pulse Width Modulation Modulated signal
P-xyz Pressure-xyz Pressure measuring point xyz
RL Redundancy Lost Alarm: Redundant CAN bus failure
rpm Revolutions per minute
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop Engine Lamp 1st function: Warning lamp (stop engine and rectify
fault); 2nd function: Read out fault codes
SID System Identifier
SPC Spare Parts Catalog
SRS Synchronous Reference Sensor TDC cylinder 1
SS Safety System / Security Shutdown Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TC Tool Catalog
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Sensor comparison fault
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point xyz
U_PDU Voltage Power Driver Unit Distribution voltage for solenoid valve output stages
UDV Überdruckventil Pressure relief valve
UT Unterer Totpunkt Bottom Dead Center (BDC)
TIM-ID: 0000000858 - 016
VNT Variable nozzle turbine

VSG Variable-speed governor
VSS Vehicle Speed Sensor
ZKP Zuordnung - Kategorie - Parameter A number allocated to a parameter describing its
function and assignment
144 | Appendix A | MS150076/06E 2018-08

9.2 MTU Contact/Service Partners
The 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 Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h Hotline
With our 24h hotline and 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 in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare Parts Service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part 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 at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
TIM-ID: 0000000873 - 016
MS150076/06E 2018-08 | Appendix A | 145

10 Appendix B
10.1 Special Tools
Allen key, 2–10 mm
Part No.: F30453050
Qty.: 1
Used in: 8.2.1 Valve clearance – Check and adjustment
(→ Page 107)
Barring gear
Part No.: F6790714
Qty.: 1
(→ Page 107)
Belt tension tester, 500-1400 N

Part No.: Y20097430
Qty.: 1
Used in: 8.12.3 Drive belt – Tension check (→ Page 135) DCL-ID: 0000001805 - 008
146 | Appendix B | MS150076/06E 2018-08

Box wrench, 14 mm
Part No.: F30028346
Qty.: 1
(→ Page 107)
Crossbeam
Part No.: T80092479
Qty.: 1
Used in: 2.1 Transport (→ Page 18)
Feeler gage
Part No.: Y20010128
Qty.: 1
(→ Page 107)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.4.1 Fuel filter ‒ Replacement (→ Page 114)
Qty.: 1
Used in: 8.4.3 Fuel prefilter – Replacement (→ Page 116)
DCL-ID: 0000001805 - 008
MS150076/06E 2018-08 | Special Tools | 147

Preload gauge, 1300–3100 N
Part No.: Y20097431
Qty.: 1
Used in: 8.12.3 Drive belt – Tension check (→ Page 135)
Ratchet bit
Part No.: F30027340
Qty.: 1
Used in: 8.2.2 Cylinder head cover ‒ Removal and installation
(→ Page 110)
Qty.: 1
Used in: 8.8.2 Engine oil – Change (→ Page 122)
Qty.: 1
Used in: 8.9.1 Engine oil filter – Replacement (→ Page 124)
Socket, 32 mm
Part No.: F30006120
Qty.: 1
Torque screwdriver, 1.0–5.0 Nm

Part No.: F30452774
Qty.: 1
(→ Page 110)
DCL-ID: 0000001805 - 008
148 | Special Tools | MS150076/06E 2018-08

Torque wrench, 20–100 Nm
Part No.: F30026582
Qty.: 1
(→ Page 107)
Qty.: 1
Used in: 8.8.2 Engine oil – Change (→ Page 122)
Torque wrench, 8–40 Nm

Part No.: F30043446
Qty.: 1
(→ Page 110)
Qty.: 1
DCL-ID: 0000001805 - 008
MS150076/06E 2018-08 | Special Tools | 149

10.2 Index
A Engine cabling
Abbreviations 142 – Check 139
After stopping engine – Putting engine out of operation Engine coolant
86 – Change 126
After stopping the engine – Check
– Engine remains ready for operation 85 – Level at filler neck 125
Air filter – Level with level sensor 125
– Installation 118 – Draining 127
– Removal 118 – Filling 128
– Replacement 117 Engine coolant level
– Service indicator check 119 – Check 125
Engine coolant pump
C – Relief bore check 130
Cabling Engine driving end
– Check – Definition 21
– On engine 139 Engine free end
Connector – Definition 21
– Cleaning 140 Engine governor
Contact persons 145 – Checking plug connections 141
Coolant – Cleaning 140
– Change 126 Engine monitoring 22
Coolant level Engine oil
– Check 125 – Change 122
Cooler Engine oil filter
– Cooler elements – Replacement 124
– Cleaning 132 Engine oil level
Cooler elements – Check 121
– Cleaning Engine sides
– On Cooler 132 – Designation 21
Cooler – Checking cooler elements externally for dirt 131 Engine – Overview 20
Cylinder
F
– Designation 21
Cylinder head cover Fault messages
– Installation 110 – ECS with ECU8 90
– Removal 110 Fuel filter
– Replacement 114
D Fuel prefilter
Drive belt – Draining 115
– Adjustment 133 – Replacement 116
– Condition check 134 Fuel system
– Replacement 137 – Venting 113
– Tension check 135
H
E Hotline 145
DCL-ID: 0000001805 - 008
ECS
L
– Fault messages 90
ECU8 Lifting specifications 19
– Fault messages 90
M
Emission label
– Check 82 Maintenance Schedule
Engine – Maintenance task reference table [QL1] 87
– Barring MTU contact persons 145
– With starting system 105
O
– Test run 106
Operational checks 81
150 | Index | MS150076/06E 2018-08

P Product data 12V1600G80F
Product data 10V1600B40S – Optimized fuel consumption 41
– Bifrequency 71 Product data 8V1600B30S
Product data 10V1600G10F – Bifrequency
– Emissions-optimized 24 – 50 Hz 67
– EU Nonroad St IIIA (97/68/EC) 32 – 60 Hz 67
– Optimized fuel consumption 28 Product data 8V1600G10F
Product data 10V1600G10S – Emissions-optimized 24
– Optimized fuel consumption 38 – EU Nonroad St IIIA (97/68/EC) 32
Product data 10V1600G20F – Optimized fuel consumption 28
– Emissions-optimized 24 Product data 8V1600G10S
– EU Nonroad St IIIA (97/68/EC) 32 – EPA Nonroad T3 Comp (40CFR89) 35
– Optimized fuel consumption 28 – EPA Stationary EMERG T3 (40CFR60) 35
Product data 10V1600G20S Product data 8V1600G20F
– EPA Nonroad T2 Comp (40CFR89) 35 – Emissions-optimized 24
– EPA Stationary EMERG T2 (40CFR60) 35 – EU Nonroad St IIIA (97/68/EC) 32
Product data 10V1600G40F – Optimized fuel consumption 28
– Emissions-optimized 56 Product data 8V1600G20S
– EU Nonroad Stage IIIA 64 – EPA Nonroad T3 Comp (40CFR89) 35
– Optimized fuel consumption 60 – EPA Stationary EMERG T3 (40CFR60) 35
Product data 10V1600G50F Product data 8V1600G40F
– Emissions-optimized 56 – Emissions-optimized 56
– EU Nonroad Stage IIIA 64 – EU Nonroad Stage IIIA 64
– Optimized fuel consumption 60 – Optimized fuel consumption 60
Product data 10V1600G70F Product data 8V1600G50F
– EU Nonroad Stage IIIA 45 – Emissions-optimized 56
– Optimized fuel consumption 41 – EU Nonroad Stage IIIA 64
Product data 10V1600G70S – Optimized fuel consumption 60
– EPA Tier 2,3-conform 48 Product data 8V1600G70F
Product data 10V1600G80F – EU Nonroad Stage IIIA 45
– EU Nonroad Stage IIIA 45 – Optimized fuel consumption 41
– Optimized fuel consumption 41 Product data 8V1600G70S
Product data 12V1600B30S – EPA Tier 2,3-conform 48
– Bifrequency Product data 8V1600G80F
– 50 Hz 67 – EU Nonroad Stage IIIA 45
– 60 Hz 67 – Optimized fuel consumption 41
Product data 12V1600B40S
R
– Bifrequency 71
Product data 12V1600G10F Relief bore
– Emissions-optimized 24 – Engine coolant pump check 130
– Optimized fuel consumption 28
S
Product data 12V1600G10S
– EPA Nonroad T2 Comp (40CFR89) 35 Safety regulations
– EPA Stationary EMERG T2 (40CFR60) 35 – Assembly work 11
Product data 12V1600G20F – Auxiliary materials 15
– Emissions-optimized 24 – Environmental protection 15
– Optimized fuel consumption 28 – Fire prevention 15
DCL-ID: 0000001805 - 008
Product data 12V1600G40F – Fluids and lubricants 15

– Emissions-optimized 56 – Important provisions 5, 7
– Optimized fuel consumption 60 – Initial start-up 9
Product data 12V1600G50F – Maintenance work 11
– Emissions-optimized 56 – Operation 9
– Optimized fuel consumption 60 – Organizational requirements 8
Product data 12V1600G70F – Personnel requirements 8
– Optimized fuel consumption 41 – Repair work 11
Product data 12V1600G70S Safety requirements
– EPA Tier 2,3-conform 48 – Warning notices, standards 17
Safety system
– Override 80
MS150076/06E 2018-08 | Index | 151

Sensors
– Overview 22
Service indicator
– Check 119
Service partners 145
Spare parts service 145
Starter
– Condition check 120
T
Transport
– Description 18
– Lifting specifications 19
Troubleshooting 88
V
Valve clearance
– Adjustment 107
– Check 107
W
Warning notices, standards 17
DCL-ID: 0000001805 - 008
152 | Index | MS150076/06E 2018-08

Operating Instructions: Diesel Engine 8V1600Gx0F/S 8V1600B30S 10V1600Gx0F/S 10V1600B40S 12V1600Gx0F/S 12V1600B30S/B40S

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Operating Instructions: Diesel Engine 8V1600Gx0F/S 8V1600B30S 10V1600Gx0F/S 10V1600B40S 12V1600Gx0F/S 12V1600B30S/B40S

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Operating Instructions

© 2018 Copyright MTU Friedrichshafen GmbH

MS150076/06E 2018-08 | Table of Contents | 3

8.5 Air Filter 117 8.12 Belt Drive 133

DCL-ID: 0000001805 - 008

4 | Table of Contents | MS150076/06E 2018-08

Emission specifications and emission label

Emission certification applicable to engines with EPA Nonroad Tier 4 emission

MS150076/06E 2018-08 | Safety | 5

TIM-ID: 0000040530 - 013

6 | Safety | MS150076/06E 2018-08

MS150076/06E 2018-08 | Safety | 7

Clothing and personal protective equipment

TIM-ID: 0000040531 - 012

8 | Safety | MS150076/06E 2018-08

Safety regulations during operation

Malfunctions and emergency stop

MS150076/06E 2018-08 | Safety | 9

Operation of electrical equipment

TIM-ID: 0000040533 - 020

10 | Safety | MS150076/06E 2018-08

Safety regulations when performing assembly, maintenance, and repair work

Setting down, lifting and climbing

MS150076/06E 2018-08 | Safety | 11

Removing, installing and cleanliness

Safety regulations after performing assembly, maintenance, and repair work

12 | Safety | MS150076/06E 2018-08

Hydraulic installation and removal

Working with batteries

Working on electrical and electronic assemblies

MS150076/06E 2018-08 | Safety | 13

Working with laser equipment

Measuring component dimensions

TIM-ID: 0000040535 - 021

14 | Safety | MS150076/06E 2018-08

Environmental protection and disposal

Fluids and lubricants/auxiliary materials (process materials)

MS150076/06E 2018-08 | Safety | 15

Acids/alkalines/reducing agents (e.g. AdBlue®, DEF)

16 | Safety | MS150076/06E 2018-08

MS150076/06E 2018-08 | Safety | 17

Placement after transport

18 | Transport | MS150076/06E 2018-08

1 Maximum permissible diag- 2 Center of gravity

Take note of the engine center of gravity

MS150076/06E 2018-08 | Transport | 19

1 Lifting eye, driving end 7 Belt drive 13 Oil dipstick

Engine model designation

20 | General Information | MS150076/06E 2018-08

1 Left engine side (A-side) 3 Right engine side (B-side)

MS150076/06E 2018-08 | General Information | 21

Item Designation Monitoring of

22 | General Information | MS150076/06E 2018-08

Item Designation Monitoring of

MS150076/06E 2018-08 | General Information | 23

ID Product type Application Speed Nominal pow-

24 | Technical Data | MS150076/06E 2018-08

Site conditions (for max. power)

Model-related data (basic design)

Air / exhaust gas

Coolant system (HT circuit)

MS150076/06E 2018-08 | Technical Data | 25

Lube oil system