8V 10V 12V1600 Operation & Maintenance MS150076 02E

MTU_ Value V alueSer vi ce Techni ch nica call Documenta oc umentati tion on

Diesel engine

Operating Instructions

Printed in Germany © 2010 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 i ncluding 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.

Printed in Germany © 2010 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 i ncluding data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.

Commissioning Note

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

Postcard MTU Friedrichshafen GmbH Technical Information Management Management Dept. AST 88040 Friedrichshafen Friedrichshafen GERMANY



Commissioning Note

Please use block capitals!

Engine No.:

MTU works order no.: Commissioning Note

Engine model:

Date put into operation:

Application : * □ Marine □ Genset

Type : □ □

Rail .........................

End user`s address:

Remarks:

Manufacturer:

* Tick appropriate box

5

Table of Contents

2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.5.9 2.5.10 2.5.11 2.5.12 2.5.13 2.5.14 2.5.15 2.5.16 2.5.17

MS150076/02E

8/10/12V 1600 G10F/G20F engine data, emissions-optimized 8V/10V/12V 1600 G10F/G20F engine data, optimized fuel consumption 8V/10V/12V 1600 G10F/G20F engine data, EU Nonroad Stage III A 8V/10V/12V 1600 G10S/G20S engine data, EPA Tier 2, 3 8/10/12V 1600 G70F/G80F engine data, emissions-optimized 10/12V 1600 G70F/G80F engine data, optimized fuel consumption 8/10V 1600 G70F/G80F engine data, EU Nonroad Stage III A 8/12V 1600 G70S engine data, EPA Tier 2, 3 8/10/12V 1600 G80S engine data, EPA Tier 2, 3 8/10/12V 1600 G40F/G50F engine data, emissions-optimized 8/10/12V 1600 G40F/G50F engine data, optimized fuel consumption 8/10V 1600 G40F/G50F engine data, EU Nonroad Stage III A 8/12V 1600 B30S engine data 8/10/12V 1600 B40S engine data, switchable frequency 10V 1600 B50F engine data, emissions-optimized 10V 1600 B50F engine data, optimized fuel consumption 10V 1600 B50F engine data, EU Nonroad Stage IIIA

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© MTU Friedrichshafen GmbH

6

Table of Contents

6.1.1 6.1.2

Engine – Barring with starting system Engine test run

99 100

6.2.1 6.2.2

Valve clearance – Check and adjustment Cylinder head cover – Removal and installation

101 104

6.3.1

Fuel system – Venting

105

6.4.1

Fuel filter – Replacement

106

6.5.1 6.5.2

Air filter replacement Air filter – Removal and installation

107 108

6.6.1

Service indicator – Signal ring position check

109

6.7.1

Starter – Condition check

110

6.8.1 6.8.2

Engine oil level – Check Engine oil – Change

111 112

6.9.1

Engine oil filter – Replacement

114

6.10.1 6.10.2 6.10.3 6.10.4 6.10.5

Engine coolant – Level check Engine coolant – Change Engine coolant – Draining Engine coolant – Filling Coolant pump – Relief bore check

116 117 118 119 121

6.11.1 6.11.2 6.11.3 6.11.4

Drive belt – Adjustment Drive belt – Condition check Drive belt – Tension check Drive belt – Replacement

122 123 124 126


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Table of Contents

MS150076/02E

6.12.1 6.12.2

Sensors and actuators Engine wiring – Check

128 130

6.13.1 6.13.2

Engine governor and connectors – Cleaning Engine governor plug connections – Check

131 132

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Table of Contents

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9

Safety

In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory reg‐ ulations regarding accident prevention must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may nevertheless present a risk of injury or damage in the following cases: • Incorrect use • Operation, maintenance and repair by unqualified personnel • Modifications or conversions • Non-compliance with the Safety Instructions

The engine is intended solely for use in accordance with contractual agreements and the purpose envisaged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user alone. Correct use also includes observation of and compliance with the maintenance specifications.

Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.

Only genuine MTU spare parts must be used to replace components or assemblies. The engine manufacturer accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

Repair or engine overhaul must be carried out in workshops authorized by MTU.

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Safety

All work on the engine shall be carried out by trained and qualified personnel only. The specified legal minimum age must be observed. The operator must specify the responsibilities of the operating, maintenance and repair personnel.

This publication must be issued to all personnel involved in operation, maintenance, repair or transportation. Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and transport personnel at all times. Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety-relevant instructions. This is particularly important in the case of personnel which only occasionally performs work on or around the engine. This personnel must be instructed repeatedly. For the identification and layout of the spare parts during maintenance or repair work, take photos or use the s pare parts catalog.

Wear proper protective clothing for all work. Use the necessary protective equipment for the given work to be done.

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Safety

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).

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.

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• • • • • • • • • • • • • • • • • • • • • • • • • •

Safety

Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Take special care when removing vent screws or plugs from engine. In order to avoid discharge of highly pres‐ surized liquids, hold a cloth over the screw or plug. Take special care when draining hot fluids ⇒ Risk of injury. When changing the engine oil or working on the fuel system, ensure that the engine room is adequately venti‐ lated. Allow the engine / system to cool down before starting to work. Observe the maintenance and repair instructions. Never carry out maintenance and repair work with the engine running unless expressly instructed to do so. Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted. Close the main valve on the compressed-air system and vent the compressed-air line when air starters are fitted. Disconnect the control equipment from the assembly or system. Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly. Carry out work only on assembles and/or units 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 lines and pressurized oil lines have sufficient distance to other components to avoid contact with them. 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 engine, always use suitable ladders and work platforms. Make sure components are placed on stable surfaces. Observe special cleanness when conducting maintenance and repair work on the assembly or system. After completion of maintenance and repair work, make sure that no loose objects are in/on the assembly or system. Before barring the engine, make sure that nobody is standing in the danger zone. After completing work on the engine, check that all protective devices/safety guards have been installed and that all tools and loose parts have been removed from the engine.

Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which c ould conceivably damage the electrical system. Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand. 3 1 0

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified fixtures for hydraulic removal/installation procedures. Observe the max. permissible push-on pressure specified for the equipment. Do not attempt to bend or apply force to lines. Before starting work, pay attention to the following:


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Safety

• Vent the hydraulic installation/removal tool, 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 tool with the piston retracted. • For hydraulic removal, screw on the tool with the piston extended. For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft end until correct sealing is achieved. During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the component to be installed/removed.

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 cabling 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 binders to secure cables. Always use connector pliers to tighten connectors. Subject the device or system to a function check on completion of all repair work. Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack defective elec‐ tronic components and assemblies in a suitable manner when dispatched for repair, i.e. particularly protected against moisture and impact and wrapped in antistatic foil if necessary.

When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused radiation. Laser equipment must be fitted with the protective devices necessary for safe operation according to type and appli‐ cation. 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.

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Safety

Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires - therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying on or near the assembly or unit. Do not store i nflammable material near the assembly or unit. Do not weld 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 fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.

Noise can lead to an increased ri sk of accident if acoustic signals, warning shouts or noises indicating danger are drowned. Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).

Modification or removal of mechanical or electronic components or the installation of additional components as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations. Emission control units/systems may only be maintained, exchanged or repaired if the com‐ ponents used for this purpose are approved by MTU or equivalent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act and involves the termination of the operating license by the emission authorities. MTU does not accept any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliability and performance of MTU engines and must be complied with over the entire life cycle of the engine. Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and fil ters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU Friedrichshafen / MTU Onsite Energy, where they are subjected to proper recycling procedures.

Use only fluids and lubricants that have been tested and approved by MTU. Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions that apply to the product. Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do not smoke.

Used oil contains harmful combustion residues. Rub barrier cream into hands. Wash hands after contact with used oil.

• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Wash hands after contact with lead or lead-containing substances.

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Observe special safety precautions when working with compressed air:


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Safety

• Pay special attention to the pressure level in the compressed air network and pressure vessel. • Assemblies and equipment to be connected must either be designed for this pressure, or, if the permitted pres‐ sure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. • Hose couplings and connections must be securely attached. • Wear goggles when blowing off components or blowing away chips. • Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). • First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or before equipment or tool is to be replaced. • Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a risk of explosion. • Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of bursting. • Carry out leak test in accordance with the specifications.

• When painting in other than spray booths equipped with extractors, ensure good ventilation. Make sure that neighboring work areas are not impaired. • No open flames. • No smoking. • Observe fire prevention regulations. • Always wear a mask providing protection against paint and solvent vapors.

• • • • •

Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask. Make sure that working area is well ventilated. Avoid all knocks and jars to the containers, fixtures or workpieces.

• • • •

When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing. If such solutions are spilled onto clothing, remove the affected clothing immediately. Rinse injured parts of the body thoroughly with clean water. Rinse eyes immediately with eyedrops or clean tap water.

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Safety

In the event of immediate danger • Preventive measures In the event of possibly dangerous situations. • Preventive measures In the event of dangerous situations. • Preventive measures

This manual contains highlighted safety warnings i n accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard.

1. Read and familiarize yourself with all safety warnings before starting up or repairing the product! 2. Pass on all safety warnings to operating, maintenance, repair and transport personnel!

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Product Summary

1 2 3 4 5 6

Air filter Lifting equipment, driving end Engine governor Air supply Oil filter Lifting equipment, free end

7 8 9 10 11 12

Thermostat housing (return cooler) Belt drive Cylinder head Exhaust elbow Crankcase Engine mounting

13 14 15 16 17 18

Exhaust turbocharger Oil dipstick Oil pan Fuel filter Flywheel Flywheel housing

Key to the engine model designation 8/10/12V 1600 Gxyz

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Number of cylinders

V

Cylinder arrangement: V engine

1600

Series

G

Application

x

Application segment (1, 2, 4, 5, 7, 8)

y

Design index

z

Frequency code (F = 50Hz, S = 60Hz)

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Product Summary

Engine sides are always designated as viewed from the drivi ng end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 KGS = Free end 2 Right engine side

3 KS = Driving end 4 Left engine side

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Product Summary

Length (A)

Width (B)

Height (C)

1 0 0

8V

approx. –

10 V

approx. 1470 mm

12 V

approx. 1620 mm

8V

approx. 1240 mm

10 V

approx. 1240 mm

12 V

approx. 1240 mm

8V

approx. 1185 mm

10 V

approx. 1185 mm

12 V

approx. 1185 mm

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Product Summary

8V

A1–B4–A4–A2–B3–A3–B2–B1

10 V

A1–B4–A4–B3–A3–B2–A2–B5–A5–B1

12 V

A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6

Direction of rotation (as viewed on driving end) c.c.w., not reversible

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Product Summary

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

Application group Intake air tempera‐ ture

°C

Barometric pres‐ sure

mbar

Site altitude above sea level

m

Rated engine speed

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3B

3B

3B

3B

3B

3B

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

A

rpm

1500

1500

1500

1500

1500

1500

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

kW

325

358

407

448

524

576

Intake depression (new filter)

A

mbar

25

25

15

15

25

25

Intake depression, max.

L

mbar

50

50

50

50

50

50

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Product Summary

Exhaust overpres‐ sure

A

mbar

85

85

30

30

85

85

Exhaust overpres‐ sure, max.

L

mbar

150

150

150

150

150

150

Standard housing connecting flange (engine main PTO)

SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"

Charge-air pres‐ R sure before cylinder - DL

bar abs

2.9

3.0

2.65

2.92

3.0

3.4

Coolant tempera‐ A ture (at engine con‐ nection: outlet to cooling equipment)

°C

95

95

95

95

95

95

Coolant tempera‐ ture after engine, warning

R

°C

105

105

105

105

105

105

Coolant tempera‐ ture after engine, shutdown

L

°C

109

109

109

109

109

109

Coolant antifreeze content, max.

L

%

50

50

50

50

50

50

bar

0.7

0.7

0.7

0.7

1

1

Pressure loss in off- L engine cooling sys‐ tem, max.

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Product Summary

Lube oil operating R temperature before engine, from

°C

87

87

87

87

87

87

Lube oil operating R temperature before engine, to

°C

100

100

100

100

101

101

Lube oil operating pressure before engine, from

R

bar

4.5

4.5

4.5

4.5

4.0

4.0

Lube oil operating pressure before engine, to

R

bar

5.4

5.4

5.4

5.4

5.2

5.0

Fuel pressure at L engine inlet con‐ nection, min. (when engine is starting)

bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5

Fuel pressure at engine inlet con‐ nection, max. (when engine is starting)

L

bar

0.5

0.5

0.5

0.5

0.5

0.5

Cold start capabil‐ ity: air temperature (w/o start aid, w/o preheating) - (case A)

R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120

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Engine coolant capacity, engine side (without cool‐ ing equipment)

Product Summary

R

Liters

50*

50*

60*

60*

65

65

Oil change quantity, R max. (standard oil system) (Option: max. operating inclinations)

Liters

43

43

53

53

64

64

Oil pan capacity at L dipstick mark “min.” (standard oil sys‐ tem) (Option: max. operating inclina‐ tions)

Liters

36

36

46

46

56

56

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

Liters

43

43

53

53

64

64

Engine weight, dry (basic engine con‐ figuration acc. to scope of supply specification)

kg

1444

1444

1749

1749

2022

2022

121

121

121

122

121

122

R

Exhaust noise, R unsilenced - DL (sound power level LW, ISO 6798+3dB(A) toler‐ ance)

dB(A)

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Product Summary

Engine surface noise with attenu‐ ated intake noise (filter) - DL (sound power level LW, ISO 6798+2dB (A) tolerance)

R

dB(A)

-

-

-

-

120

122

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Product Summary



°C


mbar


m

Rated engine speed

3B

3B

3B

3B

3B

3B

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

A

rpm

1500

1500

1500

1500

1500

1500


kW

325

358

407

448

524

576


A

mbar

25

25

25

25

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

85

85

85

85


L

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mbar


150

150

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150

150

150

150

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Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"


bar abs

2.6

2.8

2.30

2.35

2.7

2.9


°C

95

95

95

95

95

95


R

°C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87

2 0 0


°C

100

100

100

100

101

101

M I T

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Product Summary


R

bar

4.5

4.5

4.5

4.5

4.0

4.0


R

bar

5.4

5.4

5.4

5.4

5.0

5.0


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.5

0.5

0.5

0.5


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120


R

Liters

50*

50*

60*

60*

65

65


2 0 0

Liters


43

43

53

53

64

64

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Product Summary


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


kg

1444

1444

1749

1749

2022

2022

R


dB(A)

121

121

121

122

121

122


dB(A)

-

-

-

-

120

122

R

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Product Summary



°C


mbar


m

Rated engine speed

3B

3B

3B

3B

3B

3B

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

A

rpm

1500

1500

1500

1500

1500

1500


kW

358

358

407

448

524

576


A

mbar

25

25

15

15

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

30

30

85

85


L

2 0 0

6 8 1 0 2 0 0 0 0 0 : D I M I T

mbar


150

150

2010-12

150

150

150

150

MS150076/02E

31

Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"


bar abs

3.04

3.12

2.65

2.92

3.0

3.4


°C

95

95

95

95

95

95


R

°C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87

2 0 0


°C

100

100

100

100

101

101

M I T

6 8 1 0 2 0 0 0 0 0 : D I

MS150076/02E

2010-12


32

Product Summary


R

bar

4.5

4.5

4.5

4.5

4.0

4.0


R

bar

5.4

5.4

5.4

5.4

5.2

5.0


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.5

0.5

0.5

0.5


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120


R

Liters

50*

50*

60*

60*

65

65


2 0 0

Liters


43

43

53

53

64

64

6 8 1 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

33

Product Summary


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


kg

1444

1444

1749

1749

2022

2022

R


dB(A)

121

121

121

122

121

122


dB(A)

-

-

-

-

120

122

R

2 0 0

6 8 1 0 2 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


34

Product Summary


Application group Intake air temperature

°C

Barometric pressure

mbar


m

3B

3B

3B

3B

3B

25

25

25

25

25

1000

1000

1000

1000

1000

100

100

100

100

100

Rated engine speed

A

rpm

1800

1800

1800

1800

1800

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

A

kW

371

408

511

561

608


A

mbar

25

25

25

25

25


L

mbar

50

50

50

50

50

Exhaust overpressure

A

mbar

85

85

85

85

85

Exhaust overpressure, max.

L

mbar

150

150

150

150

150


SAE

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"


2010-12

MS150076/02E

2 0 0

8 8 1 0 2 0 0 0 0 0 : D I M I T

35

Product Summary

Charge-air pressure before cyl‐ inder - DL

2 0 0

R

bar abs

3.1

2.77

2.77

3.1

3.1

Coolant temperature (at engine A connection: outlet to cooling equipment)

°C

95

95

95

95

95

Coolant temperature after engine, warning

R

°C

105

105

105

105

105

Coolant temperature after engine, shutdown

L

°C

109

109

109

109

109

Coolant antifreeze content, max. L

%

50

50

50

50

50

Pressure loss in off-engine cool‐ L ing system, max.

bar

0.7

0.7

0.7

1

1

Lube oil operating temperature before engine, from

R

°C

87

87

87

87

87

Lube oil operating temperature before engine, to

R

°C

100

100

101

101

101


R

bar

4.5

4.5

4.5

4.5

4.5


R

bar

5.4

5.4

5.4

5.4

5.4

Fuel pressure at engine inlet L connection, min. (when engine is starting)

bar

-0.5

-0.5

-0.5

-0.5

-0.5

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

bar

0.5

0.5

0.5

0.5

0.5

L

8 8 1 0 2 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


36

Product Summary

Cold start capability: air temper‐ R ature (w/o start aid, w/o preheat‐ ing) - (case A)

°C

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

Engine coolant capacity, engine R side (without cooling equipment)

Liters

50*

50*

60*

65

65

Oil change quantity, max. (stand‐ R ard oil system) (Option: max. operating inclinations)

Liters

43

43

53

64

64

Oil pan capacity at dipstick mark L “min.” (standard oil system) (Option: max. operating inclina‐ tions)

Liters

36

36

46

56

56

Oil pan capacity at dipstick mark L “max.” (standard oil system) (Option: max. operating inclina‐ tions)

Liters

43

43

53

64

64

Engine weight, dry (basic engine R configuration acc. to scope of supply specification)

kg

1444

1444

1749

1950

2022

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

R

dB(A)

121

121

121

120

121

Engine surface noise with atte‐ nuated intake noise (filter) - DL (sound power level LW, ISO 6798+2dB (A) tolerance)

R

dB(A)

-

-

-

123

122 2 0 0

8 8 1 0 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

37

Product Summary


Application group

2 0 0

9 9 1 0 2 0 0 0 0 0 : D I M I T

Intake air tempera‐ ture

°C


mbar


m

3D

3D

3D

3D

3D

3D

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

Rated engine speed

A

rpm

1500

1500

1500

1500

1500

1500

Fuel stop power ISO 3046

A

kW

358

394

448

493

576

634


A

mbar

25

25

15

15

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

30

30

85

85


L

mbar

150

150

150

150

150

150

MS150076/02E

2010-12


38

Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"

Charge-air pres‐ R sure before cylinder - BL

bar abs

3.0

3.1

2.92

2.94

3.4

3.4


°C

95

95

95

95

95

95


R

°C °C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87


°C °C


100

100

2010-12

100

100

101

101

MS150076/02E

2 0 0 9 9 1 0 2 0 0 0 0 0 : D I M I T

39

Product Summary

2 0 0 9 9 1 0 2 0 0 0 0 0 : D I M I T


R

ba bar

4.5

4.5

4.5

4.5

4.0

4.0


R

ba bar

5.4

5.4

5.4

5.4

5.2

5.0


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.5

0.5

0.5

0.5


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120


R

Li L iters

50*

50*

60*

60*

65

65

Engine oil, total, for R initial filling (stand‐ ard oil system) (option: max. oper‐ ating inclinations)

Liters

46

46

60.5

60.5

72.5

72.5

MS150076/02E

2010-12


40

Product Summary


Liters

43

43

53

53

64

64


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


R

kg

1444

1444

1749

1749

2022

2022

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m distance, ISO 6798, +3dB(A) tol‐ erance)

R

dB(A)

109

109

109

110

110

110

Exhaust noise, R unsilenced - BL (sound power level LW, ISO 6798+3dB(A) toler‐ ance)

dB(A)

122

122

122

123

123

123


2 0 0 9 9 1 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

41

Product Summary


Application group

2 0 0

0 0 2 0 2 0 0 0 0 0 : D I M I T


°C


mbar


m

3D

3D

3D

3D

3D

3D

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

Rated engine speed

A

rpm

1500

1500

1500

1500

1500

1500


A

kW

358

394

448

493

576

634


A

mbar

25

25

25

25

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

85

85

85

85


L

mbar

150

150

150

150

150

150

MS150076/02E

2010-12


42

Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"


bar abs

2.9

2.9

2.35

2.77

3.4

3.2


°C

95

95

95

95

95

95


R

°C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87


°C

2 0 0


100

100

100

100

101

101

0 0 2 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

43

Product Summary

2 0 0

0 0 2 0 2 0 0 0 0 0 : D I M I T


R

bar

4.5

4.5

4.5

4.5

4.0

4.2


R

bar

5.4

5.4

5.4

5.4

5.0

5.1


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.5

0.5

0.5

0.5


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120


R

Liters

50*

50*

60*

60*

65

65


Liters

46

46

60.5

60.5

72.5

72.5

MS150076/02E

2010-12


44

Product Summary


Liters

43

43

53

53

64

64


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


R

kg

1444

1444

1749

1749

2022

2022


R

dB(A)

109

109

109

110

109

110


dB(A)

122

122

122

123

122

123


2 0 0

0 0 2 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

45

Product Summary


Application group

2 0 0

9 2 2 0 2 0 0 0 0 0 : D I

Intake air temperature

°C

Barometric pressure

mbar


m

3D

3D

3D

3D

25

25

25

25

1000

1000

1000

1000

100

100

100

100

Rated engine speed

A

rpm

1500

1500

1500

1500


A

kW

358

394

448

493


A

mbar

25

25

25

25


L

mbar

50

50

50

50


A

mbar

85

85

85

85


L

mbar

150

150

150

150


SAE

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

3.12

3.27

3.12

3.27

M I T

Charge-air pressure before cylinder - BL

MS150076/02E

R

bar abs

2010-12


46

Product Summary

Coolant temperature (at engine connection: outlet to cooling equipment)

A

°C

95

95

95

95


R

°C

105

105

105

105


L

°C

109

109

109

109


L

%

50

50

50

50

Pressure loss in off-engine cooling system, max.

L

bar

0.7

0.7

0.7

0.7

Lube oil operating temperature before engine, R from

°C

87

87

87

87

Lube oil operating temperature before engine, R to

°C

100

100

100

100


R

bar

4.5

4.5

4.5

4.5

Lube oil operating pressure before engine, to R

bar

5.4

5.4

5.4

5.4

Fuel pressure at engine inlet connection, min. L (when engine is starting)

bar

-0.5

-0.5

-0.5

-0.5

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

bar

0.5

0.5

0.5

0.5

Cold start capability: air temperature (w/o start R aid, w/o preheating) - (case A)

°C

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

2 0 0

Engine coolant capacity, engine side (without R cooling equipment)

Liters

Engine oil, total, for initial filling (standard oil system) (option: max. operating inclinations)

Liters


R

50*

50*

60*

60*

9 2 2 0 2 0 0 0 0 0 : D I M I T

2010-12

46

46

60.5

60.5

MS150076/02E

47

Product Summary

Oil change quantity, max. (standard oil sys‐ tem) (Option: max. operating inclinations)

R

Liters

43

43

53

53

Oil pan capacity at dipstick mark “min.” (stand‐ L ard oil system) (Option: max. operating incli‐ nations)

Liters

36

36

46

46

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

Liters

43

43

53

53

Engine weight, dry (basic engine configuration R acc. to scope of supply specification)

kg

1444

1444

1749

1749

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

R

dB(A)

109

109

109

110

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

dB(A)

122

122

122

123

2 0 0

9 2 2 0 2 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


48

Product Summary



°C

Barometric pressure

mbar


m

3D

3D

3D

3D

25

25

25

25

1000

1000

1000

1000

100

100

100

100

Rated engine speed

A

rpm

1800

1800

1800

1800


A

kW

408

408

613

613


A

mbar

25

25

25

25


L

mbar

50

50

50

50


A

mbar

85

85

85

85


L

mbar

150

150

150

150


SAE

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

2 0 0

6 9 1 0 2 0 0 0 0 0 : D I M I T



R

bar abs

2010-12

3.1

3.

3.2

3.1

MS150076/02E

49

Product Summary


A

°C

95

95

95

95


R

°C

105

105

105

105


L

°C

109

109

109

109


L

%

50

50

50

50


L

bar

0.7

0.7

1

1


°C

87

87

87

87


°C

100

100

101

101


R

bar

4.5

4.5

4.5

4.5


bar

5.4

5.4

5.4

5.4


bar

-0.5

-0.5

-0.5

-0.5


bar

0.5

0.5

0.5

0.5


°C

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120


Liters

50*

50*

65

65


Liters

46

46

72.5

72.5

2 0 0

6 9 1 0 2 0 0 0 0 0 : D I M I T

MS150076/02E

R

2010-12


50


Product Summary

R

Liters

43

43

64

64


Liters

36

36

56

56


Liters

43

43

64

64


kg

1444

1444

2022

1950


R

dB(A)

109

109

109

109


dB(A)

122

122

122

122

2 0 0

6 9 1 0 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

51

Product Summary


Application group

2 0 0

7 9 1 0 2 0 0 0 0 0 : D I M I T


°C


mbar


m

3D

3D

3D

3D

3D

3D

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

Rated engine speed

A

rpm

1800

1800

1800

1800

1800

1800


A

kW

448

448

561

561

668

668


A

mbar

25

25

25

25

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

85

85

85

85


L

mbar

150

150

150

150

150

150

MS150076/02E

2010-12


52

Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"


bar abs

3.0

3.0

2.93

2.93

3.2

3.2


°C

95

95

95

95

95

95


R

°C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87


°C

2 0 0


100

100

101

101

101

101

7 9 1 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

53

Product Summary

2 0 0

7 9 1 0 2 0 0 0 0 0 : D I M I T


R

bar

4.5

4.5

4.5

4.5

4.5

4.5


R

bar

5.4

5.4

5.4

5.4

5.4

5.4


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.5

0.5

0.5

0.5


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120


R

Liters

50*

50*

60*

60*

65

65


Liters

46

46

60.5

60.5

72.5

72.5

MS150076/02E

2010-12


54

Product Summary


Liters

43

43

53

53

64

64


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


R

kg

1444

1444

1749

1749

2022

2022


R

dB(A)

109

109

110

110

110

110


dB(A)

122

122

123

123

123

123


2 0 0

7 9 1 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

55

Product Summary


Application group

2 0 0

9 8 1 0 2 0 0 0 0 0 : D I M I T


°C


mbar


m

3C

3C

3C

3C

3C

3C

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

Rated engine speed

A

rpm

1500

1500

1500

1500

1500

1500


A

kW

358

394

448

493

576

634


A

mbar

25

25

15

15

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

30

30

85

85


L

mbar

150

150

150

150

150

150

MS150076/02E

2010-12


56

Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"


bar abs

2.9

2.92

2.65

2.92

3.0

3.4


°C

95

95

95

95

95

95


R

°C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87


°C

2 0 0


100

100

100

100

101

101

9 8 1 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

57

Product Summary

2 0 0

9 8 1 0 2 0 0 0 0 0 : D I M I T


R

bar

4.5

4.5

4.5

4.5

4.0

4.0


R

bar

5.4

5.4

5.4

5.4

5.2

5.0


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.5

0.5

0.5

0.5


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

10

120


R

Liters

50*

50*

60*

60*

65

65


Liters

43

43

53

53

64

64

MS150076/02E

2010-12


58

Product Summary


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


kg

1444

1444

1749

1749

2022

2022

R


dB(A)

121

121

121

122

121

122


dB(A)

-

-

-

-

120

122

R

2 0 0

9 8 1 0 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

59

Product Summary


Application group

2 0 0

0 9 1 0 2 0 0 0 0 0 : D I M I T


°C


mbar


m

3C

3C

3C

3C

3C

3C

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

Rated engine speed

A

rpm

1500

1500

1500

1500

1500

1500


A

kW

358

394

448

493

576

634


A

mbar

25

25

25

25

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

85

85

85

85


L

mbar

150

150

150

150

150

150

MS150076/02E

2010-12


60

Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"


bar abs

2.6

2.8

2.30

2.35

2.7

2.9


°C

95

95

95

95

95

95


R

°C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87


°C

2 0 0


100

100

100

100

101

101

0 9 1 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

61

Product Summary

2 0 0

0 9 1 0 2 0 0 0 0 0 : D I M I T


R

bar

4.5

4.5

4.5

4.5

4.5

4.5


R

bar

5.4

5.4

5.4

5.4

5.4

5.4


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.5

0.5

0.5

0.5


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120


R

Liters

50*

50*

60*

60*

65

65


Liters

43

43

53

53

64

64

MS150076/02E

2010-12


62

Product Summary


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


kg

1444

1444

1749

1749

2022

2022

R


dB(A)

121

121

121

122

121

122


dB(A)

-

-

-

-

120

122

R

2 0 0

0 9 1 0 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

63

Product Summary


Application group

2 0 0

3 9 1 0 2 0 0 0 0 0 : D I


°C

Barometric pressure

mbar


m

3C

3C

3C

3C

25

25

25

25

1000

1000

1000

1000

100

100

100

100

Rated engine speed

A

rpm

1500

1500

1500

1500


A

kW

394

394

448

493


A

mbar

25

25

25

25


L

mbar

50

50

50

50


A

mbar

85

85

85

85


L

mbar

150

150

150

150


SAE

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

2.43

3.12

3.04

3.12

M I T

Charge-air pressure before cylinder - DL

MS150076/02E

R

bar abs

2010-12


64

Product Summary


A

°C

95

95

95

95


R

°C

105

105

105

105


L

°C

109

109

109

109


L

%

50

50

50

50


L

bar

0.7

0.7

0.7

0.7


°C

87

87

87

87


°C

100

100

100

100


R

bar

4.5

4.5

4.5

4.5


bar

5.4

5.4

5.4

5.4


bar

-0.5

-0.5

-0.5

-0.5


bar

0.5

0.5

0.5

0.5


°C

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

2 0 0


Liters


Liters


R

50*

50*

60*

60*

3 9 1 0 2 0 0 0 0 0 : D I M I T

2010-12

43

43

53

53

MS150076/02E

65

Product Summary


Liters

36

36

46

46


Liters

43

43

53

53


kg

1444

1444

1749

1749

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

dB(A)

121

121

121

122

2 0 0

3 9 1 0 2 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


66

Product Summary



°C

Barometric pressure

mbar


m

3B

3B

3B

3B

25

25

25

25

1000

1000

1000

1000

100

100

100

100

Rated engine speed

A

rpm

1500

1800

1500

1800

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

A

kW

325

371

524

561


A

kW

358

408

576

613


A

mbar

25

25

25

25


L

mbar

50

50

50

50


A

mbar

85

85

85

85


L

mbar

150

150

150

150

2 0 0


SAE

Flywheel interface (DISC)


2010-12

01

01

01

01

14"

14"

14"

14"

MS150076/02E

3 2 7 3 2 0 0 0 0 0 : D I M I T

67

Product Summary

2 0 0

3 2 7 3 2 0 0 0 0 0 : D I M I T


R

bar abs

2.5

2.9

2.7

3.1


R

bar abs

2.7

3.1

2.9

3.2


A

°C

95

95

95

95


R

°C

105

105

105

105


L

°C

109

109

109

109


L

%

50

50

50

50


L

bar

0.7

0.7

1

1


°C

87

87

87

87


°C

100

100

101

101


R

bar

4.5

4.5

4.0

4.5


bar

5.4

5.4

5.0

5.4


bar

-0.5

-0.5

-0.5

-0.5


bar

0.5

0.5

0.5

0.5


°C

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

MS150076/02E

2010-12


68

Product Summary


Liters

50*

50*

65

65


R

Liters

46

46

72.5

72.5


R

Liters

43

43

64

64


Liters

36

36

56

56


Liters

43

43

64

64

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

dB(A)

121

123

121

120


R

dB(A)

109

112

109

119


dB(A)

121

124

122

122

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

dB(A)

115

120

120

123

2 0 0

3 2 7 3 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

69

Product Summary



°C


mbar


m

Rated engine speed

2 0 0

2 7 1 0 2 0 0 0 0 0 : D I M I T

3B

3B

3B

3B

3B

3B

25

25

25

25

25

25

1000

1000

1000

1000

1000

1000

100

100

100

100

100

100

A

rpm

1500

1800

1800

1500

1800

1500


kW

394

408

511

448

608

576


A

mbar

25

25

25

25

25

25


L

mbar

50

50

50

50

50

50


A

mbar

85

85

85

85

85

85


L

mbar

150

150

150

150

150

150

MS150076/02E

2010-12


70

Product Summary


SAE

01

01

01

01

01

01

Flywheel interface

DISC

14"

14"

14"

14"

14"

14"


bar abs

3.12

2.77

2.77

3.12

3.1

2.9


°C

95

95

95

95

95

95


R

°C

105

105

105

105

105

105


L

°C

109

109

109

109

109

109


L

%

50

50

50

50

50

50


bar

0.7

0.7

0.7

0.7

1

1


°C

87

87

87

87

87

87


°C

2 0 0


100

100

101

100

101

101

2 7 1 0 2 0 0 0 0 0 : D I M I T

2010-12

MS150076/02E

71

Product Summary

2 0 0

2 7 1 0 2 0 0 0 0 0 : D I M I T


R

bar

4.5

4.5

4.5

4.5

4.5

4.0


R

bar

5.4

5.4

5.4

5.4

5.4

5.0


bar

-0.5

-0.5

-0.5

-0.5

-0.5

-0.5


L

bar

0.5

0.5

0.0

0.0

0.0

0.0


R

°C

-20

-20

-20

-20

-20

-20

Firing speed, from

R

rpm

80

80

80

80

80

80

Firing speed, to

R

rpm

120

120

120

120

120

120


R

Liters

50*

50*

60*

60*

65

65


Liters

43

43

53

53

64

64

MS150076/02E

2010-12


72

Product Summary


Liters

36

36

46

46

56

56


Liters

43

43

53

53

64

64


kg

1444

1444

1749

1749

2022

2022

R


dB(A)

121

121

121

122

121

122


dB(A)

-

-

-

-

122

122

R

2 0 0

2 7 1 0 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

73

Product Summary


Application group

3B


°C

Barometric pressure

mbar


m

Rated engine speed

2 0 0

5 7 1 0 2 0 0 0 0 0 : D I

25 1000 100

A

rpm

1500

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

kW

448


A

mbar

15


L

mbar

50


A

mbar

30


L

mbar

150


SAE

01

Flywheel interface

DISC

14"

M I T


MS150076/02E

R

2010-12

bar abs

2.92


74

Product Summary


A

°C

95


R

°C

105


L

°C

109


L

%

50


L

bar

0.7


R

°C

87


R

°C

100


R

bar

4.5


R

bar

5.4

Fuel pressure at engine inlet connection, min. (when engine is starting)

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

Engine coolant capacity, engine side (without cooling equipment)

R

Liters

60*

Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) R

Liters

53

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

Liters

46

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

Liters

53

2 0 0

5 7 1 0 2 0 0 0 0 0 : D I M I T

Engine weight, dry (basic engine configuration acc. to scope of supply specification) R


2010-12

kg

1749

MS150076/02E

75

Product Summary

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

dB(A)

122

2 0 0

5 7 1 0 2 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


76

Product Summary


Application group

3B


°C

Barometric pressure

mbar


m

Rated engine speed

25 1000 100

A

rpm

1500


kW

448


A

mbar

25


L

mbar

50


A

mbar

85


L

mbar

150


SAE

01

Flywheel interface

DISC

14"

2 0 0

9 7 1 0 2 0 0 0 0 0 : D I M I T



R

2010-12

bar abs

2.35

MS150076/02E

77

Product Summary

2 0 0

9 7 1 0 2 0 0 0 0 0 : D I


A

°C

95


R

°C

105


L

°C

109


L

%

50


L

bar

0.7


R

°C

87


R

°C

100


R

bar

4.5


R

bar

5.4


L

bar

-0.5


L

bar

0.0


R

°C

-20

Firing speed, from

R

rpm

80

Firing speed, to

R

rpm

120


R

Liters

60*


Liters

53


Liters

46


Liters

53


kg

M I T

MS150076/02E

2010-12

1749


78

Product Summary


dB(A)

122

2 0 0

9 7 1 0 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

79

Product Summary


Application group

3B


°C

Barometric pressure

mbar


m

Rated engine speed

2 0 0

5 8 1 0 2 0 0 0 0 0 : D I

25 1000 100

A

rpm

1500


kW

448


A

mbar

25


L

mbar

50


A

mbar

85


L

mbar

150


SAE

01

Flywheel interface

DISC

14"

M I T


MS150076/02E

R

2010-12

bar abs

3.12


80

Product Summary


A

°C

95


R

°C

105


L

°C

109


L

%

50


L

bar

0.7


R

°C

87


R

°C

100


R

bar

4.5


R

bar

5.4


L

bar

-0.5


L

bar

0.0


R

°C

-20

Firing speed, from

R

rpm

80

Firing speed, to

R

rpm

120


R

Liters

60*


Liters

53


Liters

46


Liters

53

2 0 0

5 8 1 0 2 0 0 0 0 0 : D I M I T



2010-12

kg

1749

MS150076/02E

81

Product Summary


dB(A)

122

2 0 0

5 8 1 0 2 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


82

Product Summary

2 0 0

5 8 1 0 2 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

83

Operation

• •

Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001063/..) are available.

Engine

Depreserve (→ MTU Fluids and Lubricants Specifications A001063/..).

Lube oil system

Check engine oil level (→ Page 111).

Fuel system

Vent (→ Page 105).

Coolant circuit

If engine is out of service for more than one year, change engine coolant (→ Page 117).

Coolant circuit

Check engine coolant level (→ Page 116).

Engine governor

Check plug-in connections (→ Page 132).

Monitoring equipment

Carry out lamp test (see manufacturer's documentation).

Engine/generator control sys‐ tem

Switch ON; select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.

1 0 0

4 6 8 0 0 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


84

•

Operation

Engine is stopped and starting disabled.

Lube oil system

Check engine oil level (→ Page 111).

Coolant system

Check engine coolant level (→ Page 116).

Monitoring equipment

Carry out lamp test (see manufacturer's documentation).

Engine/generator control sys‐ tem

Switch ON; select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.

1 0 0

6 7 8 0 0 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

85

Operation

• •

Generator is not connected to network. External start interlock is not activated.

Unguarded rotating and moving engine components. • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). • Wear ear protectors.

Operating mode selector switch (if provided)

Change to manual mode.

Switchgear cabinet, control Press start button. panel etc. (depending on man‐ • Automatic starting sequence is performed; ufacturer) • Engine speed display instrument indicates increasing speed; • After the starting sequence is completed, engine is running at rated speed.

Switchgear cabinet, control Close the generator circuit breaker. panel etc. (depending on man‐ ufacturer) Engine

Apply full load only after engine has reached operating temperature (coolant tem‐ perature approx. 60 °C).

1 0 0

5 6 8 0 0 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


86

Operation

Safety functions and engine shutdown alarms will be disregarded. • Initiate emergency start only in emergency situations. Inadmissible operational condition. • Use override function only in hazardous situations to ensure full capability in case of engine malfunctions.

This function is only available when a pushbutton is provided.

Switching cabinet, control Activate pushbutton for Override input of the ECU. panel etc. (depending on man‐ • Certain shutdown criteria and/or starting prerequisites are ignored. ufacturer) Switchgear cabinet, control Actuate start button, for further starting sequence see Engine start (→ Page 85). panel etc. (depending on man‐ ufacturer) Control and display panels

During operation, check the displayed operational data (speed, temperature, pres‐ sures). Constantly monitor plant limit values.

1 0 0

4 8 9 0 0 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

87

Operation

Unguarded rotating and moving engine components. • Take special care when working on a running engine. Engine noise above 85 dB (A). • Wear ear protectors.

Engine under load,

Visually inspect engine for leaks and general condition;

engine at nominal speed

Check for abnormal running noises and vibration; Check exhaust color (→ Page 95).

Air filter

Check signal ring position of service indicator (→ Page 109). Replace air filter (→ Page 107), if the signal ring is completely visi ble in the service indicator control window.

Engine coolant pump

Check relief bore for oil and coolant discharge and contamination (→ Page 121).

Engine oil

Check engine oil level (→ Page 111)

2 0 0

6 6 8 0 0 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


88

• •

Operation

Generator is not connected to network. Engine is running in manual mode.

Engine

After the generator breaker has been opened, allow the engine to cool down by running it idle for approx. 5 minutes.

Switchgear cabinet, control Press stop button. panel etc. (depending on man‐ • Automatic stopping sequence is performed; ufacturer) • engine is stopped.

1 0 0

7 6 8 0 0 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

89

Operation

An emergency stop causes extreme stress to the engine. • Initiate emergency stop only in emergency situations.

Emergency stop pushbutton

Press pushbutton. • •

Engine is stopped by disconnecting the power supply to the ECU; signalization (e.g. by horn, flashing lamp) is released.

Switchgear cabinet, control Press pushbutton for alarm acknowledgement. panel etc. (depending on man‐ • Audible and visual signalization stops. ufacturer)

1 0 0

8 6 8 0 0 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


90

Engine/generator/pump con‐ troller

Operation

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

1 0 0

3 8 9 0 0 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

91

Operation

•

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

Coolant circuit

Drain engine coolant (→ Page 118) 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.

Engine/generator/pump con‐ trol

Switch OFF.

1 0 0

7 7 8 0 0 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


92

Operation

1 0 0

7 7 8 0 0 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

93

Maintenance

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 troublefree 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 early detection of possible leaks and prevent subsequent 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.

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 compo‐ nents to be replaced.

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/... All fluids and lubricants used must meet MTU specifications. The following additional maintenance work must be carried out by the user/customer: • 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 the level of use and the ambient conditions. The battery manufacturer's instructions must be obeyed.

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/.... 1 0 0

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Maintenance

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.

Check engine oil level

(→ Page 87)

Visually inspect engine for leaks and general condition

(→ Page 87)

Check signal ring position of service indicator, replace air (→ Page 87) filter if necessary Replace fuel filter or fuel filter element

(→ Page 106)

Check drive belt condition and tension, replace if neces‐ (→ Page 126) sary Replace air filter

(→ Page 107)

Replace engine oil filter at each oil change or when the time limit (years) is reached, at the latest

(→ Page 114)

Check valve clearance, adjust if necessary. Attention! First adjustment after 1,000 operating hours!

(→ Page 101)

Replace poly-vee belt of fan

(→ Page 126)

Replace drive belt of battery-charging generator (if fitted) (→ Page 126) and coolant pump Table 1: Maintenance task reference table [QL1]

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Troubleshooting

Battery

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Low or defective

Charge or replace (see manufacturer's doc‐ umentation).

Cable connections defective

Check whether cable connections are prop‐ erly secured (see manufacturer's documen‐ tation).

Starter

Engine wiring or starter defective

Check whether cable connections are prop‐ erly secured, contact Service.

Engine wiring

Defective

Check (→ Page 130).

Engine/generator con‐ trol system

Secure seating of assemblies or connectors Perform visual inspection (see manufactur‐ not provided er's documentation).

Engine governor

Plug-in connections are loose

Check plug-in connections (→ Page 132).

Engine

Running gear blocked (engine cannot be barred manually)

Contact Service.

Starter

Poor rotation by starter: Battery low or defective

Charge or replace battery (s ee manufactur‐ er's documentation).

Engine wiring

Defective


Fuel system

Not vented

Vent fuel system (→ Page 105).

Engine governor

Defective

Contact Service.

Fuel injection equip‐ ment

Injector defective

Contact Service.

Engine wiring

Defective


Fuel system

Not vented


Engine governor

Defective

Contact Service.

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Troubleshooting

Fuel supply

Easy-change fuel filter clogged

Replace (→ Page 106).

Air supply

Air filter clogged

Check signal ring position of service indica‐ tor (→ Page 109).


Injector defective

Contact Service.

Engine wiring

Defective


Engine

Overload

Contact Service.


Injector defective

Contact Service.

Speed sensor

Defective

Contact Service.

Fuel system

Not vented


Engine governor

Defective

Contact Service.

Engine room

Air-intake temperature too high

Check fans and air supply / ventilation ducts.

Air supply

Air filter clogged


Exhaust turbocharger

Defective

Contact Service. 1 0 0

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Troubleshooting

Air supply

Air filter clogged



Injector defective

Contact Service.

Engine

Overload

Contact Service.

Engine oil

Too much oil in engine

Drain engine oil (→ Page 112).

Exhaust turbocharger, cylinder head, piston rings, cylinder liner

Defective

Contact Service.

Engine

Not at operating temperature

Run up to operating temperature.

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Troubleshooting

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Task Description

•

External pushbutton “Bar engine without starting” is provided.

Unguarded rotating and moving engine components. • before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

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.

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Task Description

Unguarded rotating and moving engine components. • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). • Wear ear protectors.

1. Start engine (→ Page 85). 2. Perform test run at not below 1/3 load and at least until steady-state temperature is reached. 3. Carry out operational checks (→ Page 87). 4. Stop engine (→ Page 88).

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Task Description

• • •

Engine is stopped and starting disabled. Engine coolant temperature is max. 40 °C. Valves are closed.

Feeler gauge

Y20010128

1

Torque wrench, 20-200 Nm

F30451339

1

Box wrench, 14 mm

F3625502

1

Allen key, 5 mm

F30002815

1

Barring device

F6790714

1

1. Remove cylinder head cover (→ Page 104). 2. Remove cover on the bottom of flywheel housing, A side. 3. Install barring device at opening. 4. Rotate crankshaft with barring device in engine direction of rotation until "OT-A1" mark and pointer are aligned.

• Two crankshaft positions

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1 2 I X

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Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve


102

Task Description


1 2 I X



2 0 0

1 2 I X


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M I T

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Task Description

1. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. 2. Check valve clearance with cold engine: • Inlet = 0.3 +/- 0.05 mm; • Exhaust = 0.6 +/- 0.05 mm. 3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram. 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.

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.

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.

1. Remove barring device. 2 0 0

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2. Install cover. 3. Install cylinder head cover (→ Page 104).

M I T

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104

•

Task Description


Cover the engine beneath the cylinder head with cloths to collect emerging oil. 1. Remove screws. 2. Remove cylinder head cover. 3. Clean mating faces. 4. Check condition of profile gasket and replace if required. 5. Fit cylinder head cover and tighten screws with tor‐ que wrench to the specified tightening torque.

Screw with twin collar

M8

Preload torque

10 Nm

6. Tighten screws with torque wrench to the specified tightening torque.

Screw with twin collar

M8

Tightening torque

20 Nm

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Task Description

•


Fuels are combustible. • Avoid open flames, electrical sparks and ignition sources. • Do not smoke.

1. Unlock fuel priming pump, screw out handle (1). 2. Loosen nut (2) on banjo union. Catch emerging fuel with a suitable cloth. 3. Operate the pump with the handle (1) until bubblefree fuel emerges. 4. Tighten nut (2) on banjo union. 5. Lock fuel priming pump, screw in handle (1).

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•

Task Description


Filter wrench

F30379104

1

Engine oil

Easy-change filter

1

Fuels are combustible. • Avoid open flames, electrical sparks and ignition sources. • Do not smoke.

1. Remove easy-change filter using the filter wrench. 2. Clean the sealing surface of the 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.

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Task Description

Air filter (→ Page 108) (→ Page 109)

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108

•

Task Description


1. Loosen clamp (2). 2. Remove air filter (3) and clamp (2) from flange of intake housing (1). 3. Verify that there are no objects in the flange of the intake housing (1) and clean it. 4. Place new air filter (3) with clamp (2) onto intake housing (1). 5. Tighten clamp (2).

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Task Description

•


1. Replace air filter, if the signal ring (2) is completely visible in the red area of the service indicator con‐ trol window (3) (→ Page 107). 2. After installation of new filter, press reset button (1). Result: Signal ring returns to initial position.

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•

Task Description


1. Check securing screws of starter for secure seating and tighten if required. 2. Check wiring (→ Page 130).

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Task Description

•


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. Top up with oil to the “max.” mark as necessary (→ Page 112). 5. Insert oil dipstick (1) in guide tube up to the stop.

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. Top up with oil to the “max.” mark as necessary (→ Page 112). 5. Insert oil dipstick (1) in guide tube up to the stop.

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• • •

Task Description

Engine is stopped and starting disabled. Engine is at operating temperature. MTU Fluids and Lubricants Specifications (A001063/..) are available.

Engine oil

Hot oil. Oil can contain combustion residues which are harmful to health. • Wear protective clothing, gloves, and goggles / safety mask. • Avoid cobtact with skin. • Do not inhale oil vapor.

1. Provide a suitable container in which 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.

Drain plug

Tightening torque

Engine oil

100 Nm 1 0 0

4. Replace engine oil filter (→ Page 114)

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Task Description

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 111).

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•

Task Description



F30510423

1

Ratchet adapter

F30027340

1

Socket, 32 mm

F30006120

1

Engine oil

Oil filter element

Hot oil. Oil can contain combustion residues which are harmful to health. • Wear protective clothing, gloves, and goggles / safety mask. • Avoid cobtact with skin. • Do not inhale oil vapor.

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Task Description

1. Unscrew the oil filter covers (1) approx. 3 to 4 rev‐ olutions. 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 bot‐ tom 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.

Cover

Tightening torque

Engine oil

35 Nm

9. Replace further oil filters in the same way. 10. Check oil level (→ Page 111).

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• •

Task Description


Coolant is hot and under pressure. • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask.

1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pres‐ sure 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 119). 5. Check breather valve (visual inspection) and clean if necessary. 6. Place breather valve on filler neck and close.

1. Switch on engine control system and check readings on the display. 2. Top up with treated coolant as necessary (→ Page 119).

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Task Description

Engine coolant (→ Page 118) (→ Page 119)

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•

Task Description


Engine oil

Sealing ring

Coolant is hot and under pressure. • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask.

1. Provide an appropriate container to drain the coolant into. 2. Switch off preheater, if installed.

1. Turn breather valve of filler neck on coolant expan‐ sion tank counterclockwise to first stop and allow pressure to escape. 2. Continue to turn breather valve counterclockwise and remove. 3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck. 4. Open drain screws and drain engine coolant at the following drain points: • on crankcase, left side (1); • on crankcase, right side (2). 5. Insert drain plug with new sealing ring and use tor‐ que wrench to tighten to specified tightening tor‐ que. 1 0 0

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Drain plug

Tightening torque

Engine oil

100 Nm

6. Place breather valve on filler neck and close.


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Task Description

• •


Engine coolant

Coolant is hot and under pressure. • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Engine noise above 85 dB (A). • Wear ear protectors. Cold coolant in hot engine can cause thermal stress. • Fill / top up coolant only into cold engine.

1. Turn breather valve of filler neck on coolant expan‐ sion tank counterclockwise to first stop and allow pressure to escape. 2. Continue to turn breather valve counterclockwise and remove.

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Task Description

1. Fill coolant through filler neck on expansion expansion tank or through filling line until coolant level reaches lower edge edge of cast-in eye or marking plate. 2. Check proper condition of breather valve, clean sealing faces if required. required. 3. Fit breath breather er valve valve and close it.

1. Start Start the engine engine and operate operate it at idle speed speed for some minutes. minutes. 2. Check coolant coolant level level (→ Page Page 116), top top up if required. required.

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Task Description

Unguarded rotating and moving engine components. • Take special special care when working working on a running running engine. engine. Engine noise above 85 dB (A). • Wear Wear ear ear pro prote tect ctor ors. s.

1. Check relief relief bore bore (1) for oil oil and coolant coolant discharge. discharge. • Permis Permissib sible le coola coolant nt disch discharg arge: e: up up to 10 10 drops/hour • Permis Permissib sible le oil oil dischar discharge: ge: up up to 5 drops drops per per hour 2. Stop engine engine (→ Page Page 88) and and disable disable engine engine start. start. 3. If discharge discharge exceeds exceeds the the specified specified limits, limits, contact contact Service.

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122

•

Task Description

Engine Engine is stopp stopped ed and and starti starting ng disa disable bled. d.

1. Slacke Slacken n off off screws screws (1). (1). 2. Screw in in nut (2) to set set the required required belt belt tension. tension. 3. Tighte Tighten n scre screws ws (1). (1). 4. Check drive drive belt tension tension for for compliance compliance with with spec‐ ifications (→ Page 124).

1. Slacken Slacken off off screws screws (1) and and locknut locknut (3). (3). 2. Screw in in adjusting adjusting screw screw to set the requir required ed drive belt tension. 3. Tighten Tighten screws screws (1) and and locknut locknut (3). 4. Check drive drive belt tension tension for for compliance compliance with with spec‐ ifications (→ Page 124).

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Task Description

• •

Engine Engine is stop stopped ped and startin starting g disab disabled led.. Prot Protec ecti tive ve cove coverr is is rem remov oved ed..

Drive belt A

Singular cracks

None

Drive belt

Belt is oily, shows signs of overheat‐ Replace (→ Page 126) ing

Drive belt B

Cracks on entire circumference

Drive belt C

Chunking

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•

Task Description


Tester

Y4345711

1

Belt tension tester, 500-1400 N

Y20097430

1


Y20097431

1

1. Remove protective cover. 2. Set belt tension tester onto the drive belt in the mid‐ dle between the belt pulleys (arrow). 3. Using pushbutton, press vertically on top side of drive belt exerting even pressure until spring dis‐ engages noticeably. 4. Do not press any further, otherwise the display value will be falsified. 5. Take off tension tester without changing the posi‐ tion of the display arm. 6. Read off measured value at the intersection of dis‐ play arm and "KG" scale. For specifications, refer to table below.

Fan drive belt

2250 N

1620 N

1080 N

7. If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 122). 8. Install protective cover. 2 0 0

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Task Description

1. Remove protective cover. 2. Set belt tension tester onto the drive belt in the mid‐ dle between the belt pulleys (arrow). 3. Using pushbutton, press vertically on top side of drive belt exerting even pressure until spring dis‐ engages noticeably. 4. Do not press any further, otherwise the display value will be falsified. 5. Take off tension tester without changing the posi‐ tion of the display arm. 6. Read off measured value at the intersection of dis‐ play arm and "KG" scale. For specifications, refer to table below.

Fan drive belt

1000 N

720 N

480 N

7. If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 122). 8. Install protective cover.

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126

•

Task Description


Drive belt

1. Remove protective cover from cooler. 2. Remove fan. 3. Slacken off securing screws (1). 4. Screw out tension nut (2) as far as necessary to allow drive belt removal. 5. Check belt pulley on cooler bearing mount and crankshaft for contamination and clean if neces‐ sary. Do not apply force when placing the drive belt in the grooves. 6. Fit new drive belt. 7. The fan bearing mount must be in contact with the retainer (3) to allow belt tensioning. 8. Adjust and check drive belt tension (→ Page 122). 9. Install fan. 10. Install protective cover.

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Task Description

1. Remove protective cover. 2. Remove drive belt from fan drive (→ Page 126). 3. Remove brace (2). 4. Use appropriate tool to release the automatic belt tensioner at hexagon (3) and take off drive belt (1). Do not apply force when placing the drive belt in the grooves. 5. Fit new drive belt (1) and unload belt tensioner. 6. Install drive belt on fan drive (→ Page 126). 7. Install protective cover.

1. Remove protective cover. 2. Remove drive belt from fan drive (→ Page 126). 3. Slacken off screws (1) and locknut (3). 4. Release adjusting screw (2) on mechanical belt tensioner (4) and take off drive belt. Do not apply force when placing the drive belt in the grooves. 5. Fit new drive belt (5) and tighten adjusting screw (2) on mechanical belt tensioner to set the required tension (→ Page 122). 6. Install drive belt on fan drive (→ Page 126). 7. Install protective cover.

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Task Description

1

B16

Coolant pressure

2

B6

Coolant temperature

3

B48.2

HP fuel, B side

4

XY39.BA

Injectors, B side

XY39.BA2 5

B9

Charge-air temperature

6

B10

Charge-air pressure

7

XY39.A1

Injectors, A side

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XY39.A

M I T

8

B48.1

HP fuel, A side

9

B5

Lube oil pressure


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Task Description

1

M8A

Fuel pump HDP A (time measurement unit)

2

M8B

Fuel pump HDP B (time measurement unit)

3

B1

Camshaft TDC

4

B13

Crankshaft speed

1 0 0

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•

Task Description


Isopropyl alcohol

46181

1

1. Check securing screws of cable retainers on the engine and tighten loose threaded connections. 2. Make sure cables are fixed in their retainers and can not swing freely. 3. Check that cable ties are firm, tighten loose cable ties. 4. Replace faulty cable ties. 5. Visually inspect the following electrical line components for damage: • connector housings; • contacts; • connector sockets; • cables and terminals; • plug-in contacts. 6. If cable conductors are damaged, (→ Contact Service). 7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. 8. Make certain that all sensor connectors are securely latched.

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Task Description

•


Isopropyl alcohol

46181

1

1. Remove coarse dirt from housing surface with isopropyl alcohol. 2. Remove dirt from connector and cable surfaces with isopropyl alcohol. 3. Check legibility of cable labels. Clean or replace illegible labels.

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 latch.

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•

Task Description


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 gov‐ ernor cable clamps. Ensure that cable clamps are not faulty.

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Appendix A

A/D

Analog/Digital

Transformer: transforms sensor voltages into numeric values

AFRS

Air Filter Restriction Sensor

ANSI

American National Standards Institute

ATL

Abgasturbolader

ATS

Air Temperature Sensor

BR

Baureihe

Series

CAN

Controller Area Network

Data bus system, bus standard

CEL

Check Engine Light

1st function: Warning lamp (rectify fault as soon as possible)

Exhaust turbocharger

2nd function: Read out fault codes

2 0 0

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CKT

Circuit

CLS

Coolant Level Sensor

Monitors coolant level

CPS

Coolant Pressure Sensor

Monitors coolant pressure

CTS

Coolant Temperature Sensor

Monitors coolant temperature

DDEC

Detroit Diesel Electronic Controls

Engine control system made by Detroit Diesel

DDL

Diagnostic Data Link

DDR

Diagnostic Data Reader

DIN

Deutsches Institut für Normung e. V.

German Standardization Organization, at the same time identifier of German standards ("Deutsche Industrie-Norm")

DL

Default Lost

Alarm: Default CAN bus failure

DT

Diagnostic Tool

ECM

Electronic Control Module

Electronic control unit of the DDEC system

ECU

Engine Control Unit

Engine Governor

EDM

Engine Data Module

Storage module engine data

EEPROM

Electrically Erasable Programmable Read Only Memory

EFPA

Electronic Foot Pedal Assembly

EGR

Exhaust Gas Recirculation

EMU

Engine Monitoring Unit

EUI

Electronic Unit Injector

FLS

Fluids and Lubricants Specifications

MTU Publication No. A01061/..

FPS

Fuel Pressure Sensor

Monitors fuel pressure

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134

Appendix A

FRS

Fuel - Differential Pressure Sensor

FTS

Fuel Temperature Sensor

FWCP

Fire Water Control Panel

GND

Ground

HI

High

Alarm: Measured value exceeds 1st maximum limit

HIHI

High High

Alarm: Measured value exceeds 2nd maximum limit

HT

High Temperature

IDM

Interface Data Module

INJ

Injector

ISO

International Organization for Standardiza‐ tion

KGS

Kraftgegenseite

Engine free end in accordance with DIN ISO 1204

KS

Kraftseite

Engine driving end in accordance with DIN ISO 1204

LED

Light Emitting Diode

LO

LOW

Alarm: Measured value lower than 1st minimum limit

LOLO

Low Low

Alarm: Measured value lower than 2nd minimum limit

LSG

Limiting Speed Governor

N/A

Not Applicable

OEM

Original Equipment Manufacturer

OI

Optimized Idle

OLS

Oil Level Sensor

Monitors oil level

OPS

Oil Pressure Sensor

Monitors oil pressure

OTS

Oil Temperature Sensor

Monitors oil temperature

OT

Oberer Totpunkt

Top dead center

PAN

Panel

PIM

Peripheral Interface Module

PWM

Pulsewidth modulated

P-xyz

Pressure-xyz

Monitors fuel temperature

Pressure measuring point xyz

RL

Redundancy Lost

Alarm: Redundant CAN bus failure

SAE

Society of Automotive Engineers

U.S. standardization organization

SD

Sensor Defect


2 0 0

8 5 8 0 0 0 0 0 0 0 : D I M I T

Alarm: Sensor failure

2010-12

MS150076/02E

135

Appendix A

SEL

Stop Engine Light

1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes

SID

System Identifier

SPC

Spare Parts Catalog

SRS

Synchronous Reference Sensor

TDC cylinder 1

SS

Safety System

Indicated alarm is initiated by the safety system

TBS

Turbocharger Boost Sensor

Monitors charge-air pressure

TC

Tools Catalog

TCI

Turbo Compressor Inlet

TCO

Turbo Compressor Outlet

TD

Transmitter Deviation

TPS

Throttle Position Sensor

TRS

Timing Reference Sensor

T-xyz

Temperature-xyz

Temperature measuring point xyz

UT

Unterer Totpunkt

Bottom dead center

VNT

Variable nozzle turbine

VSG

Variable Speed Governor

VSS

Vehicle Speed Sensor

Alarm: Sensor-comparison failure

2 0 0

8 5 8 0 0 0 0 0 0 0 : D I M I T

MS150076/02E

2010-12


136

Appendix A

Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures fast and direct support on site and the high availability of our products.

Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU internet site:http://www.mtu-online.com

With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply. Your contact at Headquarters: [email protected]

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare part at the right time at the right place. With this aim in mind, we can call on a globally networked spares logistics system, - a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representatives and con‐ tractual workshops. Your contact at Headquarters: E-mail: [email protected] Tel.: +49 7541 908555 Fax.: +49 7541 908121

4 0 0

3 7 8 0 0 0 0 0 0 0 : D I M I T


2010-12

MS150076/02E

137

Appendix B

Feeler gauge

Y20010128

1

6.2.1 Valve clearance – Check and adjustment (→ Page 101)

Torque wrench, 20-200 Nm F30451339

1


Box wrench, 14 mm

F3625502

1


Allen key, 5 mm

F30002815

1


Barring device

F6790714

1


Filter wrench

F30379104

1

6.4.1 Fuel filter – Replacement (→ Page 106)


F30510423

1

6.9.1 Engine oil filter – Replacement (→ Page 114)

Ratchet adapter

F30027340

1


Socket, 32 mm

F30006120

1


Tester

Y4345711

1

6.11.3 Drive belt – Tension check (→ Page 124)


Y20097430

1



Y20097431

1


MS150076/02E

2010-12


8V 10V 12V1600 Operation & Maintenance MS150076 02E

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