Operating Instructions

Transcription

1 Operating Instructions Diesel engine 6R 1600 G10F, G20F 6R 1600 G40F, G50F 6R 1600 G70F, G80F 6R 1600 G10S, G20S 6R 1600 G70S, G80S 6R 1600 B30S, B40S MS15022/03E

2 Printed in Germany 2014 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.

3 DCL-ID: Table of Contents 1 Safety 1.1 Important provisions for all products Personnel and organizational requirements Transport Safety regulations for startup and operation Safety regulations for maintenance and repair work Fire prevention and environmental protection, fluids and lubricants, auxiliary materials Standards for safety notices in the text 14 2 General Information 2.1 Engine overview Engine side and cylinder designations Sensors and actuators 18 3 Technical Data 3.1 6R 1600 B30S 60Hz engine data, optimized fuel consumption R 1600 B30S 50Hz engine data, optimized fuel consumption R 1600 B40S 50Hz engine data, optimized emissions R 1600 B40S 50Hz engine data, optimized fuel consumption R 1600 B40S 60Hz engine data, optimized emissions R 1600 B40S 60Hz engine data, optimized fuel consumption R 1600 G10F, G20F engine data, optimized fuel consumption R 1600 G10F, G20F engine data, optimized exhaust emissions R 1600 G10S, G20S engine data, EPA stage R 1600 G10F, G20F engine data, Nonroad stage III a R 1600 G40F, G50F engine data, optimized fuel consumption R 1600 G40F, G50F engine data, optimized exhaust emissions R 1600 G40F, G50F engine data, Nonroad stage III a R 1600 G70F, G80F engine data, optimized fuel consumption R 1600 G70F, G80F engine data, optimized exhaust emissions R 1600 G70S, G80S engine data, EPA stage R 1600 G70F, G80F engine data, Nonroad stage III a Firing order Engine Main dimensions 66 4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Putting the engine into operation after scheduled out-of-service-period Engine start in manual operation (trials) Safety system Override Operational checks Engine stop in manual operation (trials) Emergency stop After stopping the engine Engine remains ready for operation After stopping the engine Putting the engine out of operation 75 5 Maintenance 5.1 Maintenance and servicing Maintenance task reference table 77 6 Troubleshooting 6.1 Troubleshooting 78 7 Task Description 7.1 Engine Engine Barring with starting system Engine Test run Valve Drive Valve clearance Check and adjustment Cylinder head cover Removal and installation Fuel System Fuel system Venting Fuel Filter Fuel filter Replacement Fuel prefilter Replacement Air Filter Air filter Replacement Air filter Removal and installation Air Intake 90 MS15022/03E Table of Contents 3

4 7.6.1 Service indicator Signal ring position check Starting Equipment Starter Condition check Lube Oil System, Lube Oil Circuit Engine oil level Check Engine oil Change Oil Filtration / Cooling Engine oil filter Replacement Coolant Circuit, General, High-Temperature Circuit Engine coolant Level check Engine coolant Change Engine coolant Draining Engine coolant Filling Engine coolant pump Relief bore check Belt Drive Drive belt Adjustment Drive belt Condition check Drive belt Tension check Drive belt Replacement Wiring (General) for Engine/Gearbox/Unit Engine wiring Check Accessories for (Electronic) Engine Governor / Control System Engine governor and connectors Cleaning Engine governor Checking plug connections Appendix A 8.1 Abbreviations MTU contact persons/service partners Appendix B 9.1 Special Tools Index 115 DCL-ID: Table of Contents MS15022/03E

5 1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. General information This product may pose a risk of injury or damage in the following cases: Incorrect use Operation, maintenance and repair by unqualified personnel Modifications or conversions Noncompliance with the safety instructions and warning notices Correct use The product is intended exclusively for the application specified in the contract or defined at the time of delivery. This means that the equipment must be operated: 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 spare parts approved by the manufacturer in accordance with the ( Spare Parts Catalog/MTU contact/service partner) In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (including engine control/parameters) In compliance with all safety regulations and in adherence with all warning notices in this manual In accordance with the maintenance requirements over the entire service life of the product ( Maintenance Schedule) 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 repair By contracting only workshops authorized by the manufacturer to carry out repair and overhaul Any other use is considered improper use and increases the risk of personnel injury or material damage in product operation. The manufacturer will accept no liability for such damage. TIM-ID: Modifications or conversions Unauthorized modifications to the product compromise safety. The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine spare parts must be used to replace components or assemblies. The manufacturer will accept no liability or warranty claims for any damage caused by the use of other spare parts. MS15022/03E Safety 5

6 1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair and transport personnel at all times. Use this manual as a basis for instructing personnel on product operation and repair, whereby the safety-relevant instructions, in particular, must be read and understood. This is particularly important in the case of personnel who only occasionally perform work on or around the product. This personnel must be instructed repeatedly. Personnel requirements All work on the product shall be carried out by trained and qualified personnel only. Training at the Training Center of the manufacturer Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation, maintenance, repair and transport. Working clothes and personal protective equipment Wear proper protective clothing for all work. When working, always wear the necessary personal protective equipment (e.g. ear protectors, protective gloves, goggles, breathing protection). Observe the information on personal protective equipment in the respective activity description. TIM-ID: Safety MS15022/03E

7 1.3 Transport Transport Lift the engine only with the lifting eyes provided. Use only the transport and lifting equipment approved by MTU. Take note of the engine center of gravity. The engine must only be transported in installation position, max. permissible diagonal pull 10. In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck). Setting the engine down after transport Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so. TIM-ID: MS15022/03E Safety 7

8 1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met. When putting the product into operation, always ensure that All maintenance and repair work has been completed. All loose parts have been removed from rotating machine components. All personnel is clear of the danger zone surrounding moving parts of the machine. The service room is adequately ventilated. The exhaust system is leak-tight and that the gases are vented to atmosphere. Protect battery terminals, generator terminals or cables against accidental contact. 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. Safety regulations for equipment operation The operator must be familiar with the controls and displays. 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 The procedures for cases of emergency, in particular, emergency stop, must be practiced regularly. The following steps must be taken if a malfunction of the system is recognized or reported by the system: Inform supervisor(s) in charge. Analyze the message. If required, carry out emergency operations e.g. emergency stop. Operation Do not remain in the operating room when the product is running for any longer than absolutely necessary. Keep a safe distance away from the product if at all possible. Do not touch the product unless expressly instructed to do so following a written procedure. 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 binder agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live. Observe the safety instructions for these devices. TIM-ID: Safety MS15022/03E

9 1.5 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use suitable containers of adequate capacity to catch fluids and lubricants. When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated. Never carry out maintenance and repair work with the product in operation, unless: Expressly permitted to do so following a written procedure. The product is running in the low load range and only for as long as absolutely necessary. Secure the product against unintentional starting, e.g. with start interlock. Attach Do not operate sign in the operating area or to control equipment. Disconnect the battery. Lock contactors. Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic starters are fitted. Disconnect the control equipment from the product. The following applies to starters with copper-beryllium alloy pinions: Wear breathing protection of filter class P3 during maintenance work. 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. TIM-ID: Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the product. Cover the screw or plug with a rag to prevent fluids escaping under pressure. Take care when draining hot fluids and lubricants (risk of burning). Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassembly. Carry out work only on assemblies or plants which are properly secured. Never use lines for climbing. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened. Take care not to damage lines, in particular fuel lines, during maintenance and repair work. Ensure that all retainers and dampers are installed correctly. 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. Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are properly protected. Note cooling time for components which are heated for installation or removal (risk of burning). When working high on the equipment, always use suitable ladders and work platforms. Make sure components or assemblies are placed on stable surfaces. MS15022/03E Safety 9

10 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths and cable ties). Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the product (in particular, the barring tool). 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. Separate the electrical ground of electronic equipment from the ground of the unit. No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants. 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 may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system. Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand. Hydraulic installation and removal Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the specified jigs and fixtures for hydraulic removal/installation procedures. Observe the max. permissible force-on pressure specified for the jig/fixture. Do not attempt to bend or apply force to lines. Before starting work, pay attention to the following: Vent the hydraulic installation/removal jig, the pumps and the lines at the relevant points for the equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs). 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, 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 battery manufacturer when working with batteries. Gases emanating from the battery are explosive. Avoid sparks and naked flames. Do not allow electrolyte to come in contact with skin or clothing. Wear goggles and protective gloves. Never place tools on the battery. Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. TIM-ID: Safety MS15022/03E

11 Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during operation by contact with sharp objects, by rubbing against other components or by a hot surface. Do not secure cables on lines carrying fluids. Do not use cable straps to secure cables. Always use connector pliers to tighten union nuts on connectors. Subject the device as well as the product to a function check on completion of all repair work. In particular, check the function of the engine emergency stop feature. Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. protected, in particular, against moisture and impact and wrapped in antistatic foil if necessary. Working with laser equipment When working with laser equipment, always wear special laser-protection goggles (hazard due to heavily focused radiation). Laser equipment must be equipped with the protective devices necessary for safe operation according to type and application. For conducting light-beam procedures and measurement work, only the following laser devices must be used: Laser devices of classes 1, 2 or 3A. Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mw, and in which the beam axis and surface are designed to prevent any risk to the eyes. TIM-ID: MS15022/03E Safety 11

12 1.6 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials Fire prevention Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires therefore always keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product. Do not store combustible materials near the product. Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid. 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 lead from the external power source to the ground lead of the engine or to the ground terminal of the starter. Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their use. Noise Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals, warning calls or noises indicating danger. Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A). Environmental protection and disposal Modification or removal of any mechanical/electronic components or the installation of additional components including the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations. Emission control units/systems may only be maintained, exchanged or repaired if the components used for this purpose are approved by the manufacturer. Noncompliance with these guidelines will invalidate the design type approval issued by the emissions regulation authorities. The manufacturer does not accept any liability for violations of the emission regulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recycled. Consumable fluids and materials The Fluids and Lubricants Specifications 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 website on the "Technical Info" or "Spare Parts and Service" tabs at Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consumables and other chemical substances, follow the safety regulations that apply to the product. Take special care when using hot, chilled or caustic substances. When using flammable materials, prevent them coming into contact with ignition sources and do not smoke. Used oil Used oil contains combustion residues that are harmful to health. Rub barrier cream into hands. Wash hands after contact with used oil. TIM-ID: Safety MS15022/03E

13 Lead Adopt suitable measures to avoid the formation of lead dust. Switch on extraction system. When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of containers, risks causing an explosion. Wear goggles when blowing dirt off workpieces or blowing away swarf. 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 to be connected must either be designed for that pressure, or, if the permissible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to the permissible pressure) must be connected between the assemblies/products and the system. Hose couplings and connections must be securely attached. Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). First shut off compressed air lines before compressed air device is disconnected from the supply line, or before device or tool is to be replaced. Carry out leak test in accordance with the specifications. Paints and varnishes Observe the relevant safety data sheet for all materials. When painting in areas other than spray booths equipped with extractors, ensure good ventilation. Make sure that neighboring work areas are not adversely affected. There must be no naked flames in the vicinity. No smoking. Observe fire prevention regulations. Always wear a mask providing protection against paint and solvent vapors. Liquid nitrogen Observe the relevant safety data sheet for all materials. Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight caps). Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and safety goggles. Make sure that working area is well ventilated. Avoid knocking or jolting the containers, valves and fittings or workpieces in any way. TIM-ID: Acids/alkaline solutions/urea (AdBlue, DEF) Observe the relevant safety data sheet for all materials. When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective clothing. Do not inhale vapors. If urea solution is swallowed, rinse out mouth and drink plenty of water. If spilled onto clothing, remove the affected clothing immediately. After contact with skin, rinse affected parts of the body with plenty of water. Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible. MS15022/03E Safety 13

14 1.7 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! Remedial action. CAUTION In the event of a situation involving potential danger. Consequences: Minor or moderate injuries! Remedial action. NOTICE In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage! Remedial action. Additional product information. u Safety notices This manual with all safety instructions and safety notices must be issued to all personnel involved in operation, maintenance, repair or transportation. TIM-ID: Safety MS15022/03E

15 2 General Information 2.1 Engine overview 1 Lifting eye, driving end 2 Service indicator 3 Cylinder head 4 Exhaust elbow 5 Engine mounting 6 Exhaust turbocharger 7 Oil pan 8 Starter 9 Flywheel 10 Flywheel housing TIM-ID: MS15022/03E General Information 15

16 1 Lifting eye, free end 2 Air filter 3 Air supply 4 Fuel filter 5 Crankcase 6 Oil pan 7 Engine governor 8 Oil filter 9 Thermostat housing (return cooler) 10 Belt drive Engine model designation Key to the engine model designation 6R 1600 Gxyz 6 Number of cylinders R Cylinder arrangement: In-line engine 1600 Series G Application x Application segment (1, 2, 4, 5, 7, 8) y Design index z Frequency code (F = 50Hz, S = 60Hz) TIM-ID: General Information MS15022/03E

17 2.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). For cylinder identification (as per DIN ISO 1204), the individual cylinders of the in-line engine are numbered. The cylinders are numbered starting with No. 1 on driving end. Other components are numbered in the same way, i.e. starting with No. 1 on driving end. 1 KGS = Engine free end 2 Right engine side 3 KS = Engine driving end 4 Left engine side TIM-ID: MS15022/03E General Information 17

18 2.3 Sensors and actuators Item Name Monitoring of 1 B1 Camshaft speed 2 B13 Crankshaft speed TIM-ID: General Information MS15022/03E

19 Item Name Monitoring of 1 B48 Fuel high pressure 2 XY39.A2 Injectors 3 B10 Charge-air pressure 4 XY39.A1 Injectors 5 M8 HP fuel pump (metering unit) 6 B9 Charge-air coolant temperature 7 B5 Lube oil pressure 8 B16 Coolant pressure 9 B6 Coolant temperature TIM-ID: MS15022/03E General Information 19

20 3 Technical Data 3.1 6R 1600 B30S 60Hz engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group 6R1600B 30S Intake air temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm 1800 Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) 3B A kw 284 Intake depression (new filter) A mbar 25 Intake depression, max. L mbar 50 Exhaust overpressure A mbar 85 Exhaust overpressure, max. L mbar 150 MODEL RELATED DATA (basic design) Standard housing connecting flange (engine main PTO) SAE 01 Flywheel interface (DISC) 14" TIM-ID: COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - DL R bar abs Technical Data MS15022/03E

21 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling system) A C 95 Coolant temperature after engine, warning R C 105 Coolant temperature after engine, shutdown L C 109 Pressure loss in off-engine cooling system, max. L bar 0.7 LUBE OIL SYSTEM Lube oil operating pressure before engine, warning R bar 3.2 Lube oil operating pressure before engine, shutdown L bar 3.0 FUEL SYSTEM 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 0.5 GENERAL OPERATING DATA Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C -20 Firing speed, from R rpm 80 Firing speed, to R rpm 120 CAPACITIES Engine coolant, engine-side (without cooling system) R Liters 45 Engine oil on initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) R Liters 46 R Liters 45 L Liters 36 L Liters 45 TIM-ID: ACOUSTICS Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO dB(A) tolerance) R db(a) 113 R db(a) 118 MS15022/03E Technical Data 21

22 3.2 6R 1600 B30S 50Hz engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group 6R1600B 30S Intake air temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm 1500 Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) 3B A kw 249 Intake depression (new filter) A mbar 25 Intake depression, max. L mbar 50 Exhaust overpressure A mbar 85 Exhaust overpressure, max. L mbar 150 MODEL RELATED DATA (basic design) Cylinder displacement Liters 1.75 Standard housing connecting flange (engine main PTO) SAE 01 Flywheel interface (DISC) 14" COMBUSTION AIR / EXHAUST GAS TIM-ID: Charge-air pressure before cylinder - DL R bar abs Technical Data MS15022/03E

23 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling system) A C 95 Coolant temperature after engine, warning R C 105 Coolant temperature after engine, shutdown L C 109 Coolant antifreeze content, max. L % 50 Pressure loss in off-engine cooling system, max. L bar 0.7 LUBE OIL SYSTEM Lube oil operating pressure before engine, warning R bar 2.6 Lube oil operating pressure before engine, shutdown L bar 2.4 FUEL SYSTEM 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 0.5 GENERAL OPERATING DATA Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C -20 Firing speed, from R rpm 80 Firing speed, to R rpm 120 CAPACITIES TIM-ID: Engine coolant, engine-side (without cooling system) R Liters 45* Engine oil on initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) ACOUSTICS R Liters 46 R Liters 45 L Liters 36 L Liters 45 Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO dB(A) tolerance) R db(a) 114 R db(a) 116 MS15022/03E Technical Data 23

24 3.3 6R 1600 B40S 50Hz engine data, optimized emissions Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group 6R1600B 40S Intake air temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm 1500 Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) 3B A kw 274 Intake depression (new filter) A mbar 25 Intake depression, max. L mbar 50 Exhaust overpressure A mbar 85 Exhaust overpressure, max. L mbar 150 MODEL RELATED DATA (basic design) Standard housing connecting flange (engine main PTO) SAE 01 Flywheel interface (DISC) 14" COOLANT SYSTEM (HT circuit) TIM-ID: Coolant temperature (at engine connection: outlet to cooling system) A C 95 Coolant temperature after engine, warning R C 105 Coolant temperature after engine, shutdown L C Technical Data MS15022/03E

25 Coolant antifreeze content, max. L % 50 Pressure loss in off-engine cooling system, max. L bar 0.7 LUBE OIL SYSTEM Lube oil operating pressure before engine, warning R bar 2.6 Lube oil operating pressure before engine, shutdown L bar 2.4 FUEL SYSTEM 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 0.5 GENERAL OPERATING DATA Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C -20 Firing speed, from R rpm 80 Firing speed, to R rpm 120 CAPACITIES Engine oil on initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) ACOUSTICS R Liters 42 R Liters 42 L Liters 33 L Liters 41 TIM-ID: Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO dB(A) tolerance) R db(a) 115 R db(a) 117 MS15022/03E Technical Data 25

26 3.4 6R 1600 B40S 50Hz engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group 6R1600B 40S Intake air temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm 1800 Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) 3B A kw 274 Intake depression (new filter) A mbar 25 Intake depression, max. L mbar 50 Exhaust overpressure A mbar 85 Exhaust overpressure, max. L mbar 150 MODEL RELATED DATA (basic design) Standard housing connecting flange (engine main PTO) SAE 01 Flywheel interface (DISC) 14" COOLANT SYSTEM (HT circuit) TIM-ID: Coolant temperature (at engine connection: outlet to cooling system) A C 95 Coolant temperature after engine, warning R C 105 Coolant temperature after engine, shutdown L C Technical Data MS15022/03E

27 Coolant antifreeze content, max. L % 50 Pressure loss in off-engine cooling system, max. L bar 0.7 LUBE OIL SYSTEM Lube oil operating pressure before engine, warning R bar 2.6 Lube oil operating pressure before engine, shutdown L bar 2.4 FUEL SYSTEM 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 0.5 GENERAL OPERATING DATA Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C -20 Firing speed, from R rpm 80 Firing speed, to R rpm 120 CAPACITIES Engine coolant, engine-side (without cooling system) R Liters 45* Engine oil on initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) ACOUSTICS R Liters 42 R Liters 42 L Liters 33 L Liters 41 TIM-ID: Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO dB(A) tolerance) R db(a) 115 R db(a) 117 MS15022/03E Technical Data 27

28 3.5 6R 1600 B40S 60Hz engine data, optimized emissions Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group 6R1600B 40S Intake air temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm 1800 Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) 3B A kw 312 Intake depression (new filter) A mbar 25 Intake depression, max. L mbar 50 Exhaust overpressure A mbar 85 Exhaust overpressure, max. L mbar 150 MODEL RELATED DATA (basic design) Standard housing connecting flange (engine main PTO) SAE 01 Flywheel interface (DISC) 14" COOLANT SYSTEM (HT circuit) TIM-ID: Coolant temperature (at engine connection: outlet to cooling system) A C 95 Coolant temperature after engine, warning R C 105 Coolant temperature after engine, shutdown L C Technical Data MS15022/03E

29 Coolant antifreeze content, max. L % 50 Pressure loss in off-engine cooling system, max. L bar 0.7 LUBE OIL SYSTEM Lube oil operating pressure before engine, warning R bar 3.2 Lube oil operating pressure before engine, shutdown L bar 3.0 FUEL SYSTEM 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 0.5 GENERAL OPERATING DATA Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C -20 Firing speed, from R rpm 80 Firing speed, to R rpm 120 CAPACITIES Fuel, engine side R Liters 3* Engine oil on initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) ACOUSTICS R Liters 46 R Liters 45 L Liters 36 L Liters 45 TIM-ID: Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO dB(A) tolerance) R db(a) 113 R db(a) 118 MS15022/03E Technical Data 29

30 3.6 6R 1600 B40S 60Hz engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group 6R1600B 40S Intake air temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm 1800 Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) 3B A kw 312 Intake depression (new filter) A mbar 25 Intake depression, max. L mbar 50 Exhaust overpressure A mbar 85 Exhaust overpressure, max. L mbar 150 MODEL RELATED DATA (basic design) Standard housing connecting flange (engine main PTO) SAE 01 Flywheel interface (DISC) 14" COMBUSTION AIR / EXHAUST GAS TIM-ID: Charge-air pressure before cylinder - DL R bar abs Technical Data MS15022/03E

31 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling system) A C 95 Coolant temperature after engine, warning R C 105 Coolant temperature after engine, shutdown L C 109 Coolant antifreeze content, max. L % 50 Pressure loss in off-engine cooling system, max. L bar 0.7 LUBE OIL SYSTEM Lube oil operating temperature after engine, to R C 114 Lube oil operating pressure before engine, warning R bar 3.2 Lube oil operating pressure before engine, shutdown L bar 3.0 FUEL SYSTEM 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 0.5 GENERAL OPERATING DATA Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C -20 Firing speed, from R rpm 80 Firing speed, to R rpm 120 CAPACITIES TIM-ID: Engine oil on initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) ACOUSTICS R Liters 46 R Liters 45 L Liters 36 L Liters 45 Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO dB(A) tolerance) R db(a) 113 R db(a) 118 MS15022/03E Technical Data 31

32 3.7 6R 1600 G10F, G20F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G10F 6R 1600 G20F Application group 3B 3B Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) A kw Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" TIM-ID: COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - DL R bar abs Technical Data MS15022/03E

33 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * * Lube-oil operating temperature before engine, to R C * * Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * * Lube-oil operating pressure before engine, to R bar * * Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm TIM-ID: CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters MS15022/03E Technical Data 33

34 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO 6798) R db(a) TIM-ID: Technical Data MS15022/03E

35 3.8 6R 1600 G10F, G20F engine data, optimized exhaust emissions Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G10F 6R 1600 G20F Application group 3B 3B Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) A kw Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) TIM-ID: Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - DL R bar abs MS15022/03E Technical Data 35

36 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * * Lube-oil operating temperature before engine, to R C * * Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * * Lube-oil operating pressure before engine, to R bar * * Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters TIM-ID: Technical Data MS15022/03E

37 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO 6798) R db(a) TIM-ID: MS15022/03E Technical Data 37

38 3.9 6R 1600 G10S, G20S engine data, EPA stage 3 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G10S 6R 1600 G20S Application group 3B 3B Intake air temperature C * 25 Barometric pressure mbar * 1000 Site altitude above sea level m * 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) A kw Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" TIM-ID: COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - DL R bar abs Technical Data MS15022/03E

39 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C * 95 Coolant temperature after engine, alarm R C * 105 Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % * 50 Pressure loss in off-engine cooling system, max. L bar * 0.7 LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * * Lube-oil operating temperature before engine, to R C * * Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * * Lube-oil operating pressure before engine, to R bar * * Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar * -0.5 L bar * 0.0 Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C * -20 Firing speed, from R rpm * 80 Firing speed, to R rpm * 120 TIM-ID: CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters * 45 Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters * 45 MS15022/03E Technical Data 39

40 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters * 36 L Liters * 45 Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg * 1150 Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO 6798) R db(a) TIM-ID: Technical Data MS15022/03E

41 3.10 6R 1600 G10F, G20F engine data, Nonroad stage III a Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G10F 6R 1600 G20F Application group 3B 3B Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) A kw Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) TIM-ID: Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - DL R bar abs MS15022/03E Technical Data 41

42 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * * Lube-oil operating temperature before engine, to R C * * Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * * Lube-oil operating pressure before engine, to R bar * * Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters TIM-ID: Technical Data MS15022/03E

43 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO 6798) R db(a) TIM-ID: MS15022/03E Technical Data 43

44 3.11 6R 1600 G40F, G50F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G40F 6R 1600 G50F Application group 3C 3C Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Fuel stop power ISO 3046 A kw GENERAL CONDITIONS (for maximum power) Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" TIM-ID: COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - DL R bar abs Technical Data MS15022/03E

45 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * 85 Lube-oil operating temperature before engine, to R C * 100 Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * * Lube-oil operating pressure before engine, to R bar * * Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm TIM-ID: CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters MS15022/03E Technical Data 45

46 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO 6798) R db(a) TIM-ID: Technical Data MS15022/03E

47 3.12 6R 1600 G40F, G50F engine data, optimized exhaust emissions Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G40F 6R 1600 G50F Application group 3C 3C Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Fuel stop power ISO 3046 A kw GENERAL CONDITIONS (for maximum power) Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) TIM-ID: Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - DL R bar abs MS15022/03E Technical Data 47

48 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * * Lube-oil operating temperature before engine, to R C * + Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * * Lube-oil operating pressure before engine, to R bar * * Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters TIM-ID: Technical Data MS15022/03E

49 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO 6798) R db(a) TIM-ID: MS15022/03E Technical Data 49

50 3.13 6R 1600 G40F, G50F engine data, Nonroad stage III a Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G40F 6R 1600 G50F Application group 3C 3C Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Fuel stop power ISO 3046 A kw GENERAL CONDITIONS (for maximum power) Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" COMBUSTION AIR / EXHAUST GAS TIM-ID: Charge-air pressure before cylinder - DL R bar abs Technical Data MS15022/03E

51 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * 85 Lube-oil operating temperature before engine, to R C * 100 Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * * Lube-oil operating pressure before engine, to R bar * * Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid. w/o preheating) - (case A) R C Firing speed. from R rpm Firing speed. to R rpm TIM-ID: CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters MS15022/03E Technical Data 51

52 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO 6798) R db(a) TIM-ID: Technical Data MS15022/03E

53 3.14 6R 1600 G70F, G80F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G70F 6R 1600 G80F Application group 3D 3D Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Fuel stop power ISO 3046 A kw GENERAL CONDITIONS (for maximum power) Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) TIM-ID: Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - BL R bar abs MS15022/03E Technical Data 53

54 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * 88 Lube-oil operating temperature before engine, to R C * 94 Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * 4.2 Lube-oil operating pressure before engine, to R bar * 4.8 Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters TIM-ID: Technical Data MS15022/03E

55 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - BL (sound power level LW, ISO 6798) R db(a) TIM-ID: MS15022/03E Technical Data 55

56 3.15 6R 1600 G70F, G80F engine data, optimized exhaust emissions Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G70F 6R 1600 G80F Application group 3D 3D Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Fuel stop power ISO 3046 A kw GENERAL CONDITIONS (for maximum power) Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" TIM-ID: COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - BL R bar abs Technical Data MS15022/03E

57 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C Lube-oil operating temperature before engine, to R C Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * 4.2 Lube-oil operating pressure before engine, to R bar * 4.8 Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm TIM-ID: CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters MS15022/03E Technical Data 57

58 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - BL (sound power level LW, ISO 6798) R db(a) TIM-ID: Technical Data MS15022/03E

59 3.16 6R 1600 G70S, G80S engine data, EPA stage 3 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G70S 6R 1600 G80S Application group 3D 3D Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Fuel stop power ISO 3046 A kw GENERAL CONDITIONS (for maximum power) Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) TIM-ID: Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" COMBUSTION AIR / EXHAUST GAS Charge-air pressure before cylinder - BL R bar abs MS15022/03E Technical Data 59

60 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C * 88 Lube-oil operating temperature before engine, to R C * 94 Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * 5.7 Lube-oil operating pressure before engine, to R bar * 6.0 Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters TIM-ID: Technical Data MS15022/03E

61 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - BL (sound power level LW, ISO 6798) R db(a) TIM-ID: MS15022/03E Technical Data 61

62 3.17 6R 1600 G70F, G80F engine data, Nonroad stage III a Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable * Data not yet available when at time of publication REFERENCE CONDITIONS Engine model 6R 1600 G70F 6R 1600 G80F Application group 3D 3D Intake air temperature C Barometric pressure mbar Site altitude above sea level m POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Rated engine speed A rpm Fuel stop power ISO 3046 A kw GENERAL CONDITIONS (for maximum power) Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust gas overpressure A mbar Exhaust gas overpressure, max. L mbar MODEL RELATED DATA (basic design) Cooling method: conditioned water X X Direction of rotation: c.c.w. (facing driving end) X X Standard housing connecting flange (engine main PTO) SAE Flywheel interface DISC 14" 14" COMBUSTION AIR / EXHAUST GAS TIM-ID: Charge-air pressure before cylinder - BL R bar abs Technical Data MS15022/03E

63 COOLANT SYSTEM (HT circuit) Coolant temperature (at engine connection: outlet to cooling equipment) A C Coolant temperature after engine, alarm R C Coolant temperature after engine, shutdown L C Coolant antifreeze content, max. L % Pressure loss in off-engine cooling system, max. L bar LUBE-OIL SYSTEM Lube-oil operating temperature before engine, from R C Lube-oil operating temperature before engine, to R C Lube-oil temperature before engine, alarm R C - - Lube-oil temperature before engine, shutdown L C - - Lube-oil operating pressure before engine, from R bar * 4.2 Lube-oil operating pressure before engine, to R bar * 4.8 Lube-oil operating pressure before engine, warning (speed-dependent value, consult MTU) Lube-oil operating pressure before engine, shutdown (speed-dependent value, consult MTU) FUEL SYSTEM Fuel pressure at engine inlet connection, min. (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA R L bar bar L bar L bar Cold start capability: air temperature (w/o start aid, w/o preheating) - (case A) R C Firing speed, from R rpm Firing speed, to R rpm TIM-ID: CAPACITIES Engine coolant capacity, engine side (without cooling equipment) R Liters Total engine oil capacity for initial filling (standard oil system) R Liters - - Oil change capacity, max. (standard oil system) R Liters - - Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R Liters MS15022/03E Technical Data 63

64 Oil pan capacity at dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark max. (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS L Liters L Liters Engine weight, dry (basic engine configuration acc. to scope of delivery specification) ACOUSTICS R kg Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798) R db(a) Engine surface noise with attenuated intake noise (filter) - BL (sound power level LW, ISO 6798) R db(a) TIM-ID: Technical Data MS15022/03E

65 3.18 Firing order Firing order Number of cylinders Firing order 6 R TIM-ID: MS15022/03E Technical Data 65

66 3.19 Engine Main dimensions Engine Main dimensions Length (A) Width (B) Height (C) approx mm approx. 920 mm approx mm TIM-ID: Technical Data MS15022/03E

67 4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions Engine is stopped and starting disabled. MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the PowerPack into operation after extended out-of-service-periods (>3 months) Item Engine Action Depreserve ( MTU Preservation and Represervation Specifications A001070/..). Lube oil system Check engine oil level ( Page 92). Fuel system Vent ( Page 85). Engine coolant circuit If engine is out of service for more than one year, change engine coolant ( Page 96). Engine coolant circuit Check engine coolant level ( Page 95). Engine governor Check plug connections ( Page 107). Monitoring system Engine/generator control system Carry out lamp test (see manufacturer's documentation). Switch ON; select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. TIM-ID: MS15022/03E Operation 67

68 4.2 Putting the engine into operation after scheduled out-ofservice-period Preconditions Engine is stopped and starting disabled. Startup Item Task Lube oil system Check engine oil level ( Page 92). Coolant system Check engine coolant level ( Page 95). Monitoring equipment Engine/generator control system Carry out lamp test (see manufacturer's documentation). Switch ON; select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. TIM-ID: Operation MS15022/03E

69 4.3 Engine start in manual operation (trials) Preconditions Generator is not connected to network. External start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! 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! Wear ear protectors. Preparation Item Operating mode switch (if fitted) Action Change to manual mode. Starting the engine Item Switchgear cabinet, control panel etc. (depending on manufacturer) Action Press start button. Automatic starting sequence is performed; Engine speed display instrument indicates increasing 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 Switchgear cabinet, control panel etc. (depending on manufacturer) Engine Action Close the generator circuit breaker. Apply full load only after engine has reached operating temperature (coolant temperature approx. 60 C). TIM-ID: MS15022/03E Operation 69

70 4.4 Safety system Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! Use override function only in hazardous situations to ensure full capability in the event of engine faults. Preparation Note: This function is only available when a pushbutton is provided. Safety system Override Item Switchgear cabinet, control panel etc. (depending on manufacturer) Switchgear cabinet, control panel etc. (depending on manufacturer) Control and display panels Action Activate pushbutton for Override input of the ECU. Certain shutdown criteria and/or starting prerequisites are ignored. Actuate start button, for further starting sequence, refer to engine start ( Page 69). During operation, check the displayed operational data (speed, temperature, pressures). Constantly monitor plant limit values. TIM-ID: Operation MS15022/03E

71 4.5 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. Operational checks Item Engine under load, engine at nominal speed Action Visually inspect engine for leaks and general condition; Check for abnormal running noises and vibration; Check exhaust color ( Page 78). Air filter Check signal ring position of service indicator ( Page 90). Replace air filter ( Page 88), if the signal ring is completely visible in the service indicator control window. Engine coolant pump Check relief bore for oil and coolant discharge and contamination ( Page 100). Engine oil Check engine oil level( Page 92) TIM-ID: MS15022/03E Operation 71

72 4.6 Engine stop in manual operation (trials) Preconditions Generator is not connected to network. Engine is running in manual mode. Preparation Item Engine Task After the generator breaker has been opened, allow the engine to cool down by running it idle for approx. 5 minutes. Stop engine Item Switchgear cabinet, control panel etc. (depending on manufacturer) Task Press stop button. Automatic stopping sequence is performed; engine is stopped. TIM-ID: Operation MS15022/03E

73 4.7 Emergency stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! Initiate emergency stop only in emergency situations. Emergency stop Item Emergency stop pushbutton Action Press pushbutton. Engine is stopped by disconnecting the power supply to the ECU; signalization (e.g. by horn, flashing lamp) is released. After emergency stop Item Switchgear cabinet, control panel etc. (depending on manufacturer) Action Press pushbutton for alarm acknowledgment. Audible and visual alarm signaling stops. TIM-ID: MS15022/03E Operation 73

74 4.8 After stopping the engine Engine remains ready for operation After stopping the engine Item Engine/generator/pump control Action Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. TIM-ID: Operation MS15022/03E

75 4.9 After stopping the engine Putting the engine out of operation Preconditions MTU Fluids and Lubricants Specifications (A001063/..) are available. After stopping the engine Item Coolant circuit Engine/generator/pump control Task Drain engine coolant ( Page 97) if: the engine room is not heated; the engine coolant is not maintained at a suitable temperature; the antifreeze concentration is insufficient for the engine-room temperature; antifreeze concentration is 50 % and engine-room temperature is below -40 C. Switch OFF. TIM-ID: MS15022/03E Operation 75

76 5 Maintenance 5.1 Maintenance and servicing Preface Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with MTU's specifications and instructions. The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure trouble-free engine operation at all times. For this purpose always: ensure that sufficient fuel of approved quality is provided, ensure that the combustion air is dry and clean. Notes on maintenance: Special care should be taken to keep the machinery plant in a clean and serviceable condition at all times to facilitate detection of possible leaks and prevent consequential damage. Protect rubber and synthetic components from oil and fuel, never treat with organic detergents. Wipe with a dry cloth only. Always replace all seals and gaskets. Our Product Support Service will always be available should assistance be required. MTU maintenance concept The maintenance system for MTU products is based on preventive maintenance concept. Preventive maintenance permits advance operational planning and increases availability. The maintenance schedule is based on the load profile specified below. The time intervals at which the maintenance work is to be carried out and the relevant checks and tasks involved are average values based on operational experience and are therefore to be regarded as guidelines only. Specific operational conditions may require modification of the Maintenance Schedule. The Maintenance Schedule is part of the Maintenance Booklet. Exchange parts (reliabilt ) are available for components to be replaced. Note: The maintenance schedule matrix finishes with extended component maintenance. Following this, maintenance work must then be continued at the specified intervals. The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a list of approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications A001063/.. Use only fluids and lubricants which comply with the MTU Fluids and Lubricants Specifications. The user/customer must perform the following additional maintenance tasks: Fuel prefilter: The maintenance interval depends on how dirty fuel is. The filter elements of the fuel prefilters must be replaced every 2 years at the latest. Battery: Battery maintenance depends on duty and ambient conditions. The specifications of the battery manufacturer apply. Out-of-service periods If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures according to the Fluids and Lubricants Specifications, MTU Publication No. A001063/.... TIM-ID: Maintenance MS15022/03E

77 5.2 Maintenance task reference table The maintenance tasks and intervals for this product are defined in the Maintenance Booklet. The Maintenance Booklet is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Booklet. Task Check engine oil level ( Page 71) Visually inspect engine for leaks and general condition Check signal ring position of service indicator, replace air filter if necessary ( Page 71) ( Page 71) Replace fuel filter or fuel filter element ( Page 86) Replace fuel prefilter or filter element of fuel prefilter ( Page 87) Check cooler elements externally for dirt Check drive belt condition and tension, replace if necessary ( Page 104) Replace air filter ( Page 88) Replace engine oil filter at each oil change or when the time limit (years) is reached, at the latest Check valve clearance, adjust if necessary. Attention!First adjustment after 1,000 operating hours! ( Page 94) ( Page 82) Replace poly-vee belt of fan ( Page 104) Replace drive belt of battery-charging generator (if fitted) and coolant pump Table 1: Maintenance task reference table [QL1] ( Page 104) TIM-ID: MS15022/03E Maintenance 77

78 6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check whether cable connections are properly secured (see manufacturer's documentation). Starter Engine wiring or starter defective Check whether cable connections are properly secured, contact Service. Engine wiring Defective Check ( Page 105). Engine/generator control system Secure seating of assemblies or connectors not provided Perform visual inspection (see manufacturer's documentation). Engine governor Plug-in connections are loose Check plug-in connections ( Page 107). Engine Engine turns but does not fire Running gear blocked (engine cannot be barred manually) Component Probable Cause Task Starter Poor rotation by starter: Battery low or defective Contact Service. Charge or replace battery (see manufacturer's documentation). Engine wiring Defective Check ( Page 105). Fuel system Not vented Vent fuel system ( Page 85). Engine governor Defective Contact Service. Engine fires unevenly Component Probable Cause Task Fuel injection equipment Injector defective Contact Service. Engine wiring Defective Check ( Page 105). Fuel system Not vented Vent fuel system ( Page 85). Engine governor Defective Contact Service. Engine does not reach nominal speed Component Probable Cause Task Fuel supply Easy-change fuel filter clogged Replace ( Page 86). Air supply Air filter clogged Check signal ring position of service indicator ( Page 90). Fuel injection equipment Injector defective Contact Service. TIM-ID: Troubleshooting MS15022/03E

79 Component Probable Cause Task Engine wiring Defective Check ( Page 105). Engine Overload Contact Service. Engine speed not steady Component Probable Cause Task Fuel injection equipment Injector defective Contact Service. Speed sensor Defective Contact Service. Fuel system Not vented Vent fuel system ( Page 85). Engine governor Defective Contact Service. Charge-air temperature too high Component Probable Cause Task Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge-air pressure too low Component Probable Cause Task Air supply Air filter clogged Check signal ring position of service indicator ( Page 90). Exhaust turbocharger Defective Contact Service. Exhaust gas black Component Probable Cause Task Air supply Air filter clogged Check signal ring position of service indicator ( Page 90). Fuel injection equipment Injector defective Contact Service. Engine Overload Contact Service. Exhaust gas blue TIM-ID: Component Probable Cause Task Engine oil Too much oil in engine Drain engine oil ( Page 93). Exhaust turbocharger, cylinder head, piston rings, cylinder liner Exhaust gas white Defective Component Probable Cause Task Contact Service. Engine Not at operating temperature Run up to operating temperature. MS15022/03E Troubleshooting 79

80 7 Task Description 7.1 Engine Engine Barring with starting system Preconditions External pushbutton Bar engine without starting is provided. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! 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 this procedure after approx. 20 seconds if required. TIM-ID: Task Description MS15022/03E

81 7.1.2 Engine Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. Engine Test run 1. Start engine ( Page 69). 2. Perform test run not below 1/3 load and at least until steady-state temperature is reached. 3. Carry out operational checks ( Page 71). 4. Stop engine ( Page 72). TIM-ID: MS15022/03E Task Description 81

82 7.2 Valve Drive Valve clearance Check and adjustment Preconditions Engine is stopped and starting disabled. Engine coolant temperature is max. 40 C. Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y Torque wrench, Nm F Box wrench, 14 mm F Angular screw driver, set 2-10 mm F Preparatory steps 1. Remove cylinder head cover ( Page 84). 2. Bar engine manually in engine direction of rotation to bring the A1 piston to top dead center position. Diagram: Two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC E Inlet valve A 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 mm; Exhaust = 0.6 mm. 3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram. 4. Use feeler gauge to determine the distance between valve bridge and rocker arm. 5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance. TIM-ID: Task Description MS15022/03E

83 Adjusting valve clearance 1. Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. 2. Insert feeler gauge between valve bridge and rocker arm (3). 3. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. 4. Tighten locknut (1) with torque wrench to specified torque, holding adjusting screw (2) firm with Allen screw. Name Size Type Lubricant Value/Standard Nut M10 x 1 Tightening torque 43 Nm +4 Nm 5. Check if the feeler gauge just passes through between valve bridge and rocker arm (3). Result: If not, adjust valve clearance. Final steps 1. Install cylinder head cover ( Page 84). 2. Install plug. TIM-ID: MS15022/03E Task Description 83

84 7.2.2 Cylinder head cover Removal and installation Preconditions Engine is stopped and starting disabled. Cylinder head cover Removal and installation 1. Loosen and remove screws. 2. Remove cylinder head cover. 3. Clean installation surface. 4. Check condition of profile gasket and replace if required. 5. Fit cylinder head cover and tighten screws with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Screw with twin collar M8 Preload torque 10 Nm 6. Tighten screws to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw with twin collar M8 Tightening torque 20 Nm ±2 Nm TIM-ID: Task Description MS15022/03E

85 7.3 Fuel System Fuel system Venting Preconditions Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Fuel system Venting 1. Unlock fuel priming pump, screw out handle (1). 2. Loosen nut (2) on banjo union. Note: Catch emerging fuel with a suitable cloth. 3. Operate the pump with the handle (1) until bubble-free fuel emerges. 4. Tighten nut (2) on banjo union. 5. Lock fuel priming pump, screw in handle (1). TIM-ID: MS15022/03E Task Description 85

86 7.4 Fuel Filter Fuel filter Replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F Engine oil Easy-change filter ( Spare Parts Catalog) 1 WARNING Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Fuel filter Replacement 1. Remove easy-change filter using the filter wrench. 2. Clean sealing surface on filter head. 3. Slightly lubricate seal on the easy-change filter. 4. Screw on easy-change filter by hand until the seal makes contact and then tighten by hand. TIM-ID: Task Description MS15022/03E

87 7.4.2 Fuel prefilter Replacement Preconditions Engine is stopped and starting disabled. System is not under pressure. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F Engine oil Easy-change filter ( Spare Parts Catalog) 1 WARNING Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. 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! Observe manufacturer's instructions. Check components for special cleanliness. Replacing fuel prefilter 1. Remove easy-change filter (2) with filter wrench. 2. Clean sealing surface on filter head (1). 3. Lightly lubricate seal on the easy-change filter (2). 4. Screw on easy-change filter (2) by hand until the seal makes contact with the filter head and tighten manually. TIM-ID: MS15022/03E Task Description 87

88 7.5 Air Filter Air filter Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter Air filter Replacement 1. Remove air filter and install new one ( Page 89). 2. Reset signal ring of service indicator ( Page 90). ( Spare Parts Catalog) TIM-ID: Task Description MS15022/03E

89 7.5.2 Air filter Removal and installation Preconditions Engine is stopped and starting disabled. Air filter Removal and installation 1. Loosen clamp (2). 2. Remove air filter (1) and clamp (2) from connecting 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 intake housing (3). 5. Tighten clamp (2). TIM-ID: MS15022/03E Task Description 89

90 7.6 Air Intake Service indicator Signal ring position check Preconditions Engine is stopped and starting disabled. Checking signal ring position 1. Replace air filter, if the signal ring (2) is completely visible in the red area of the service indicator control window (3) ( Page 88). 2. After installation of new filter, press reset button (1). Result: Signal ring returns to initial position. TIM-ID: Task Description MS15022/03E

91 7.7 Starting Equipment Starter Condition check Preconditions Engine is stopped and starting disabled. Checking starter condition 1. Check securing screws of starter for secure seating and tighten if required. 2. Check wiring ( Page 105). TIM-ID: MS15022/03E Task Description 91

92 7.8 Lube Oil System, Lube Oil Circuit Engine oil level Check Preconditions Engine is stopped and starting disabled. Oil level check prior to engine 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 93). 5. Insert oil dipstick (1) in guide tube up to the stop. Oil level check after the 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 93). 5. Insert oil dipstick (1) in guide tube up to the stop. TIM-ID: Task Description MS15022/03E

93 7.8.2 Engine oil Change Preconditions Engine is stopped and starting disabled. Engine is at operating temperature. MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Wear protective clothing, gloves, and goggles / safety mask. Avoid contact with skin. Do not inhale oil vapor. Draining oil at drain plug on oil pan 1. Provide a suitable container to collect the oil. 2. Remove drain plug(s) (2) and drain oil. 3. Insert drain plug (2) and use torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Drain screw Tightening torque (Engine oil) 100 Nm ±10 Nm TIM-ID: Replace engine oil filter ( Page 94). Filling with new oil 1. Open cap (1) on cylinder head cover. 2. Fill with oil, oil filling capacity ( Product Summary - Technical Data). 3. Close cap (1) on cylinder head cover. 4. Check engine oil level ( Page 92). MS15022/03E Task Description 93

94 7.9 Oil Filtration / Cooling Engine oil filter Replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F Ratchet adapter F Socket, 32 mm F Engine oil Oil filter element ( Spare Parts Catalog) WARNING Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Wear protective clothing, gloves, and goggles / safety mask. Avoid contact with skin. Do not inhale oil vapor. Engine oil filter Replacement 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. 8. Screw on cover (1) with oil filter element (3) and tighten to the specified torque with a torque wrench. Name Size Type Lubricant Value/Standard Cover Tightening torque (Engine oil) 35 Nm 9. Replace other engine oil filters in the same way. 10. Check oil level ( Page 92) TIM-ID: Task Description MS15022/03E

95 7.10 Coolant Circuit, General, High-Temperature Circuit Engine coolant Level check Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001063/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. Coolant-level check 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 counterclockwise 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 98). 5. Check breather valve (visual inspection) and clean if necessary. 6. Place breather valve on filler neck and close. Coolant-level check 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 98). TIM-ID: MS15022/03E Task Description 95

96 Engine coolant Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change 1. Drain engine coolant ( Page 97). 2. Fill with engine coolant ( Page 98). TIM-ID: Task Description MS15022/03E

97 Engine coolant Draining Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring ( Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps 1. Provide a suitable container to catch the coolant. 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 counterclockwise and remove. 3. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck. 4. Remove drain plug (1) and drain coolant. 5. Insert drain plug with new sealing ring and use torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Drain screw Tightening torque (Engine oil) 70 Nm TIM-ID: Place breather valve on filler neck and close. MS15022/03E Task Description 97

98 Engine coolant Filling Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. 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 breather valve (1) of coolant expansion tank counterclockwise until the first stop and allow pressure to escape. 2. Continue to turn valve cover (1) counterclockwise and remove. Coolant Filling 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 breather valve (1), clean sealing faces if required. 3. Fit breather valve (1) and close it. TIM-ID: Task Description MS15022/03E

99 Final steps 1. Start the engine and operate it at idle speed for some minutes. 2. Check coolant level ( Page 95), top up with coolant if required. TIM-ID: MS15022/03E Task Description 99

100 Engine coolant pump Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. Engine coolant pump Relief bore check 1. Check relief bore (1) for engine coolant discharge. Permissible engine coolant discharge:up to 0.1 ml per hour respectively 100 ml per 1,000 operating hours. 2. If discharge exceeds the specified limits, contact Service. 3. If relief bore is dirty (1): Stop engine ( Page 72) and disable engine start. Clean relief bore (1) with a wire. TIM-ID: Task Description MS15022/03E

101 7.11 Belt Drive Drive belt Adjustment Preconditions Engine is stopped and starting disabled. Fan drive Adjusting belt tension 1. Loosen screws (1). 2. Screw in nut (2) to set the required belt tension. 3. Tighten screws (1). 4. Check drive belt tension for compliance with specifications ( Page 103). TIM-ID: MS15022/03E Task Description 101

102 Drive belt Condition check Preconditions Engine is stopped and starting disabled. Checking condition Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Fit new part ( Page 104) Drive belt C Chunking Drive belt Fouling by oil, overheating TIM-ID: Task Description MS15022/03E

103 Drive belt Tension check Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y Belt tension tester, N Y Belt tension tester, N Y Fan drive Checking belt tension 1. Remove protective cover. 2. Set belt tension tester onto the drive belt in the middle between the belt pulleys (arrow). 3. Actuate pushbutton to press the tester uniformly on the drive belt surface until the spring disengages. 4. Do not press any further, otherwise the display value will be falsified. 5. Take off tension tester without changing the position of the display arm. 6. Read off measured value at the intersection of display arm and "KG" scale. For specifications, refer to table below. Application Spec. value Initial assembly Spec. value Operating tension after 1 hour Fan drive belt 2250 N 1620 N 1080 N Spec. value Minimum operating tension 7. If the measured values deviate from the specifications above, adjust drive belt tension ( Page 101). 8. Install protective cover. TIM-ID: MS15022/03E Task Description 103

104 Drive belt Replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt Replacing fan drive belt 1. Remove protective cover from radiator. 2. Remove fan. 3. Loosen securing screws (3). 4. Screw out tension nut (1) as far as necessary to allow drive belt removal. 5. Check belt pulley on cooler bearing mount and crankshaft for contamination and clean if necessary. Note: When placing the drive belt in the grooves, no force must be applied. 6. Fit new drive belt. 7. The fan bearing mount must be in contact with the retainer (2) to allow belt tensioning. 8. Adjust and check drive belt tension ( Page 101). 9. Install fan. 10. Install protective cover. ( Spare Parts Catalog) Replacing drive belts of batterycharging generator and coolant pump 1. Remove protective cover. 2. Remove drive belt from fan drive ( Step 1). 3. Use appropriate tool to release the automatic belt tensioner at hexagon (1) and take off drive belt (2). Note: When placing the drive belt in the grooves, no force must be applied. 4. Fit new drive belt (2) and unload belt tensioner. 5. Install drive belt on fan drive ( Step 1). 6. Install protective cover. TIM-ID: Task Description MS15022/03E

105 7.12 Wiring (General) for Engine/Gearbox/Unit Engine wiring Check Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X Checking engine wiring 1. Check securing screws of cable clamps on engine and tighten loose threaded connections. 2. Ensure that cables are fixed in their clamps and cannot swing freely. 3. Check that cable clamps are firm, tighten loose cable clamps. 4. Replace faulty cable clamps. 5. Visually inspect the following electrical line components for damage: Connector housing Contacts Sockets Cables and terminals Plug-in contacts Result: Contact Service if cable conductors are damaged. Note: Close male connectors that are not plugged in with the protective cap supplied. 6. Clean dirty connector housings, sockets and contacts using isopropyl alcohol. 7. Ensure that all sensor connectors are securely engaged. TIM-ID: MS15022/03E Task Description 105

106 7.13 Accessories for (Electronic) Engine Governor / Control System Engine governor and connectors Cleaning Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise the contacts could be bent. Engine governor and connectors Cleaning 1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. 2. Remove dirt from the connector and cable surfaces with isopropyl alcohol. 3. Check legibility of cable labels. Clean or replace illegible labels. Cleaning severely contaminated connectors on the engine governor Note: Seal unused connectors with the supplied protective cap. 1. Release the latch and pull off 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 lock them. TIM-ID: Task Description MS15022/03E

107 Engine governor Checking plug connections Preconditions Engine is stopped and starting disabled. 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: MS15022/03E Task Description 107