Dvigatel Mtu 12v1600g20f PDF

User guide and maintenance
manual
MTU
Engine
8V-10V-12V 1600 G10F-G20F
8V-10V-12V 1600 G40F-G50F
8V-10V-12V 1600 G70F-G80F
8V-10V 1600 B40S-B50F
12V 1600 B40S
8V-10V-12V 1600 G10S-G20S
8V-10V-12V 1600 G70S-G80S
12V1600G20F-E
MS150076/01E
33522916001_1_1
01/09/2010
MTU_ValueService
Technical Documentation
Diesel engine
8, 10, 12 V 1600 G10F, G20F
8, 10, 12 V 1600 G40F, G50F
8, 10, 12 V 1600 G70F, G80F
8, 10 V 1600 B40S, B50F
12 V 1600 B40S
8, 10, 12 V 1600 G10S, G20S
8, 10, 12 V 1600 G70S, G80S
Operating Instructions
MS150076/01E
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
88040 Friedrichshafen
GERMANY

Commissioning Note
Please use block capitals!
Motornr.: Auftragsnr.: Commissioning

Engine No.: MTU works order No.:
Noo du moteur: N° de commande: Note
N de motor: N° de pedido:
Motore N.: N. commessa:
No. do motor: No. do pedido:
Motortyp: Inbetriebnahmedatum:
Engine model: Date put into operation:
Type du moteur: Mise en service le:
Tipo de motor: Fecha de puesta en servicio:
Motore tipo: Messa in servizio il:
Tipo do motor: Data da colocação em serviço:
Eingebaut in: Schiffstyp / Schiffshersteller:

Installation site: Vessel/type/class / Shipyard:
Lieu de montage: Type du bateau / Constructeur:
Lugar de montaje: Tipo de buque / Constructor:
Installato: Tipo di barca / Costruttore
Incorporado em: Tipo de embarcação/estaleiro naval:
Endabnehmer/Anschrift:
End user`s address:
Adresse du client final:
Dirección del cliente final:
Indirizzo del cliente finale:
Usuário final/endereço:
Bemerkung:
Remarks:
Remarques:
Observaciones:
Commento:
Observações:
Table of Contents 5
1 Safety 9
1.1 General conditions 9
1.2 Personnel and organizational requirements 10
1.3 Transport 11
1.4 Safety requirements when working on the engine 12
1.5 Auxiliary materials, fire prevention and environmental protection 15
1.6 Conventions for safety instructions in the text 17
2 Product Summary 19
2.1 Engine Layout 19

2.1.1 Engine layout 19
2.2 Engine Side and Cylinder Designations 21

2.2.1 Engine side and cylinder designations 21
2.3 Main Engine Dimensions 22

2.3.1 Engine – Main dimensions 22
2.4 Firing Sequence 23

2.4.1 Firing order 23
2.5 Technical Data 24

2.5.1 8V/10V/12V 1600 G10F/G20F engine data, emissions-optimized 24
2.5.2 8V/10V/12V 1600 G10F/G20F engine data, optimized fuel consumption 29
2.5.3 8V/10V/12V 1600 G10F/G20F engine data, EU Nonroad Stage III A 33
2.5.4 8V/10V/12V 1600 G10S, G20S engine data, EPA Tier 2, 3 37
2.5.5 8/10/12V 1600 G70F, G80F engine data, emissions-optimized 40
2.5.6 8/10/12V 1600 G70F, G80F engine data, optimized fuel consumption 45
2.5.7 8/10V 1600 G70F, G80F engine data, EU Nonroad Stage III A 50
2.5.8 8/12V 1600 G70S engine data, EPA Tier 2, 3 53
2.5.9 8/10/12V 1600 G80S engine data, EPA Tier 2, 3 56
2.5.10 8/10/12V 1600 G40F, G50F engine data, emissions-optimized 61
2.5.11 8/10/12V 1600 G40F, G50F engine data, optimized fuel consumption 65
2.5.12 8/10V 1600 G40F, G50F engine data, EU Nonroad stage III A 69
2.5.13 8/10//12V 1600 B40S engine data, switchable frequency 72
2.5.14 10V 1600 B50F engine data, emissions-optimized 76
2.5.15 10V 1600 B50F engine data, optimized fuel consumption 79
2.5.16 10V 1600 B50F engine data, EU Nonroad Stage IIIA 82
3 Operation 85
3.1 Putting the engine into operation after extended out-of-service-periods (>3 months) 85
3.2 Putting the engine into operation after scheduled out-of-service-period 86
3.3 Engine start in manual operation (trials) 87
3.4 Bypassing the safety system (Override) 88
3.5 Operational checks 89
3.6 Engine stop in manual operation (trials) 90
MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

6 Table of Contents
3.7 Emergency engine shutdown 91
3.8 After stopping the engine – engine remains ready for operation 92
3.9 After stopping the engine – Putting the engine out of operation 93
4 Maintenance 95
4.1 Maintenance and servicing 95
5 Troubleshooting 97
5.1 Troubleshooting 97
6 Task Description 101
6.1 Engine 101

6.1.1 Engine – Barring with starting system 101
6.1.2 Engine test run 102
6.2 Valve Drive 103

6.2.1 Valve clearance – Check and adjustment 103
6.2.2 Cylinder head cover – Removal and installation 107
6.3 Fuel System 108

6.3.1 Fuel system – Venting 108
6.4 Fuel Filter 109

6.4.1 Fuel filter – Replacement 109
6.5 Air Filter 110

6.5.1 Air filter replacement 110
6.5.2 Air filter – Removal and installation 111
6.6 Air Intake 112

6.6.1 Service indicator – Signal ring position check 112
6.7 Starting Equipment 113

6.7.1 Starter – Condition check 113
6.8 Lube Oil System, Lube Oil Circuit 114
6.8.1 Engine oil level – Check 114
6.8.2 Engine oil – Change 115
6.9 Oil Filtration / Cooling 117

6.9.1 Engine oil filter – Replacement 117
6.10 Coolant Circuit, General, High-Temperature Circuit 119

6.10.1 Engine coolant – Level check 119
6.10.2 Engine coolant – Change 120
6.10.3 Engine coolant – Draining 121
6.10.4 Engine coolant – Filling 123
6.10.5 Coolant pump – Relief bore check 125
6.11 Belt Drive 126

6.11.1 Drive belt – Adjustment 126
6.11.2 Drive belt – Condition check 127
6.11.3 Drive belt – Tension check 128
© MTU Friedrichshafen GmbH 2010-09 MS150076/01E

Table of Contents 7
6.11.4 Drive belt – Replacement 130
6.12 Wiring (General) for Engine/Gearbox/Unit 132

6.12.1 Sensors and actuators 132
6.12.2 Engine wiring – Check 134
6.13 Accessories for (Electronic) Engine Governor / Control System 135

6.13.1 Engine governor and connectors – Cleaning 135
6.13.2 Engine governor plug connections – Check 136
7 Appendix A 137
7.1 Abbreviations 137
7.2 MTU contact person / service partner 140
8 Appendix B 141
8.1 Special Tools 141

8 Table of Contents

Safety 9
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations 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
Correct use
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.
Modifications or conversions
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.
Spare parts
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.
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10 Safety
1.2 Personnel and organizational requirements

Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The responsibilities of the operating, maintenance and repair personnel must be specified.
Organizational measures
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.
Such persons must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Put on additional safety wear as dictated by the nature of the work, e.g. safety goggles, gloves, helmet, apron!
Work clothing must be tight fitting so that it does not get caught on rotating or protruding components.
Do not wear jewelry (e.g. rings, chains etc.).
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Safety 11
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.
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12 Safety
1.4 Safety requirements when working on the engine

Safety precautions when putting the equipment into operation
Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Immediately after putting the device or system into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Safety requirements for operators
Procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard to present operating
status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard.
The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Strict adherence to the maintenance and repair schedule is an essential safety factor.
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. Post the "Do
Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required.
Have maintenance and repair work carried out by qualified and authorized personnel only.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane. Always support by suitable
means which conform with the applicable regulations before commencing maintenance or repair work.
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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.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before starting
work, relieve pressure in systems and compressed-air lines which are to be opened.
Never put lines to any use other than that for which they are intended. Never use lines for climbing.

Safety 13
Never bend a fuel line and do not install bent lines. 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 fuel lines during maintenance and repair work. To tighten the connections when installing
the lines, use the correct tightening torque and 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, except when necessary for design reasons
during installation.
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes when
exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this case. The resulting
acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals if they have carbonized or resinous
appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of burning!
Note cooling period for components which are heated for installation or removal ⇒ Risk of burning!
Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of highly pressurized
liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently been shut down, as
the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of burning!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or soak them with a suitable binding
agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make sure components are placed
on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex, should only lift
weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that hooks are
correctly positioned. Lifting eyes must not be unevenly loaded.
Observe special cleanness when conducting maintenance and repair work on the engine plant. After completion of
maintenance and repair work, make sure that no loose objects are in/on the engine plant.
Welding work
Never carry out welding work on the engine or engine-mounted units. Cover the engine when welding in its vicinity!
Never use the engine as a ground connection. This prevents the welding current passing through the engine resulting
in burnt/scorched bearings, sliding surfaces and tooth flanks which may lead to bearing seizure and/or other material
damage.
Never 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 could conceivably damage the electrical system.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation on MTU
electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire is disconnected from
the negative and positive poles on the battery.
Hydraulic installation and removal
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Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly instructions
must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:

14 Safety
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system 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. As long as the system is under pressure, there is the risk that the component to be installed/
removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
Working on electrical/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. Any measures requiring a power supply are
expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come
in contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before connecting the
cable to the battery, check battery polarity. Battery pole reversal may lead to injury through the sudden discharge of
acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not
damaged by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose must be correctly connected
and secured.
On completion of all repair work, the component and system must be subjected to a function check. Separate testing
of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use cable clamps to properly support
the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work, the binders can be
removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly protected
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.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission in the
range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and optomechanical
effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted 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
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maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to
property.

Safety 15
1.5 Auxiliary materials, fire prevention and environmental protection

Fire prevention
Rectify any fuel or oil leaks immediately; even quantities of oil or fuel on hot components can cause fires – therefore
always keep the engine in a clean condition. Do not leave cloths soaking with fluids and lubricants on the engine. Do
not store combustible materials near the engine.
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
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are
drowned.
In all work areas with a sound pressure level in excess of 85 dB (A), wear ear protection (cotton wool, ear plug or
capsules).
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As a
result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS applies (regulations for plants involving the use of water pollutants), i.e. work on such plants
must only be carried out by a specialist company (MTU is such a specialist company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept 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 inflammable materials, avoid sparks and do not smoke.
Lead
• 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 fume extraction system!
• Wash hands after contact with lead or lead-containing substances!
Acids and alkaline solutions
• 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 mains water!
Painting
• When painting in other than spray booths equipped with extractors, ensure good ventilation. Make sure that
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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!

16 Safety
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands). Contact of this nature would cause frostbite and numbing.
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask!
• Make sure that working area is well ventilated. 88% contamination of breathing air with nitrogen will result in
suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected to the compressed
air tanks and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Connecting devices and equipment must either be assembled for this pressure, or, if the permitted pressure 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 swarf!
• The snout of the air nozzle is provided with a protective disk (e.g. rubber disk), which prevents airborne particles
being reflected and thereby prevents injury to eyes.
• 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!
• Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain harmful combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.
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Safety 17
1.6 Conventions for safety instructions in the text

Cautions
In the event of immediate danger
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.

Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.

Consequences: Slight injury or material damage.
CAUTION • Preventive measures
Procedure
Note: This publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Safety notes
1. Read and familiarize yourself with all warnings before starting up or repairing the product!
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!
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18 Safety
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Product Summary 19
2 Product Summary
2.1 Engine Layout
2.1.1 Engine layout
1 Air filter 7 Thermostat housing (return cooler) 13 Exhaust turbocharger

2 Lifting equipment, driving end 8 Belt drive 14 Oil dipstick
3 Engine governor 9 Cylinder head 15 Oil pan
4 Air supply 10 Exhaust elbow 16 Fuel filter
5 Oil filter 11 Crankcase 17 Flywheel
6 Lifting equipment, free end 12 Engine mounting 18 Flywheel housing
Engine model designation

Key to the engine model designation 8/10/12V 1600 Gxyz
12 Number of cylinders
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V Cylinder arrangement: V engine

1600 Series
G Application
x Application segment (1, 2, 4, 5, 7, 8)

20 Product Summary
y Design index
z Frequency code (F = 50Hz, S = 60Hz)
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Product Summary 21
2.2 Engine Side and Cylinder Designations

2.2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving 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.
The numbering of engine components is also from the driving end, starting with No. 1.
1 KGS = Free end 3 KS = Driving end

2 Right side 4 Left side
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22 Product Summary
2.3 Main Engine Dimensions

2.3.1 Engine – Main dimensions
Engine – Main dimensions
Length (A) 8V approx. –

10 V approx. 1470 mm
Width (B) 8V approx. 1240 mm
Height (C) 8V approx. 1185 mm
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Product Summary 23
2.4 Firing Sequence

2.4.1 Firing order
Firing order
8V A1–B4–A4–A2–B3–A3–B2–B1
10 V A1–B4–A4–B3–A3–B2–A2–B5–A5–B1
12 V A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6
Direction of rotation
Direction of rotation (as viewed on driving end) c.c.w., not reversible
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24 Product Summary
2.5 Technical Data

2.5.1 8V/10V/12V 1600 G10F/G20F engine data, emissions-optimized
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 8V1600G1 8V1600G2 10V1600G 10V1600G 12V1600G 12V1600G

0F 0F 10F 20F 10F 20F
Application group 3B 3B 3B 3B 3B 3B
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
Site altitude above m 100 100 100 100 100 100
sea level
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of 8 8 10 10 12 12
cylinders
Rated engine A rpm 1500 1500 1500 1500 1500 1500
speed
Continuous power A kW 325 358 407 448 524 576
ISO 3046 (10%
overload capability,
design power DIN
6280, ISO 8528)
GENERAL CONDITIONS (for maximum power)
Number of 8 8 10 10 12 12
cylinders
Intake depression A mbar 25 25 15 15 25 25
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(new filter)
Intake depression, L mbar 50 50 50 50 50 50
max.
Exhaust gas A mbar 85 85 30 30 85 85
overpressure

Product Summary 25
Number of 8 8 10 10 12 12
cylinders
Exhaust gas L mbar 150 150 150 150 150 150
overpressure, max.
MODEL RELATED DATA (basic design)
Number of 8 8 10 10 12 12
cylinders
Standard flywheel SAE 01 01 01 01 01 01
housing flange
(engine main PTO)
Flywheel interface DISC 14" 14" 14" 14" 14" 14"
COMBUSTION AIR / EXHAUST GAS
Number of 8 8 10 10 12 12
cylinders
Charge-air R bar abs 2.9 3.0 2.65 2.92 3.0 3.4
pressure before
cylinder - DL
COOLANT SYSTEM (HT circuit)
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
Coolant antifreeze L % 50 50 50 50 50 50
content, max.
Pressure loss in off- L bar 0.7 0.7 0.7 0.7 1 1
engine cooling
system, max.
TIM ID: 0000020173 - 001

26 Product Summary
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
Lube oil operating R °C 87 87 87 87 87 87
temperature before
engine, from
Lube-oil operating R °C 100 100 100 100 101 101
temperature before
engine, to
Lube-oil operating R bar 4.5 4.5 4.5 4.5 4.0 4.0
pressure before
engine, from
Lube oil operating R bar 5.4 5.4 5.4 5.4 5.2 5.0
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
Fuel pressure at L bar -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
engine inlet
connection, min.
(when engine is
starting)
Fuel pressure at L bar 0.5 0.5 0.5 0.5 0.5 0.5
engine inlet
connection, max.
(when engine is
starting)
GENERAL OPERATING DATA
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
Firing speed, from R rpm 80 80 80 80 80 80
TIM ID: 0000020173 - 001
Firing speed, to R rpm 120 120 120 120 120 120

Product Summary 27
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
Engine coolant R Liters 50* 50* 60* 60* 65 65
capacity, engine
side (without
cooling equipment)
Oil change quantity, R Liters 43 43 53 53 64 64
max. (standard oil
system) (Option:
max. operating
inclinations)
Oil pan capacity at L Liters 36 36 46 46 56 56
dipstick mark “min.”
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
“max.” (standard oil
system) (Option:
max. operating
inclinations)
WEIGHTS / MAIN DIMENSIONS
Number of 8 8 10 10 12 12
cylinders
Engine weight, dry R kg 1444 1444 1749 1749 2022 2022
(basic engine
configuration acc.
to scope of delivery
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
Exhaust noise, R dB(A) 121 121 121 122 121 122
unsilenced - DL
(sound power level
LW, ISO
6798+3dB(A)
TIM ID: 0000020173 - 001
tolerance)

28 Product Summary
Number of 8 8 10 10 12 12
cylinders
Engine surface R dB(A) - - - - 120 122
noise with
attenuated intake
noise filter) - DL
(sound power level
LW, ISO 6798+2dB
(A) tolerance)
TIM ID: 0000020173 - 001

Product Summary 29
2.5.2 8V/10V/12V 1600 G10F/G20F engine data, optimized fuel consumption

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

0F 0F 10F 20F 10F 20F
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
ISO 3046 (10%
design power DIN
6280, ISO 8528)
Number of 8 8 10 10 12 12
cylinders
(new filter)
TIM ID: 0000020187 - 001
max.
overpressure
overpressure, max.

30 Product Summary
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - DL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020187 - 001
temperature before
engine, from
temperature before
engine, to

Product Summary 31
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020187 - 001
side (without
cooling equipment)

32 Product Summary
Number of 8 8 10 10 12 12
cylinders
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - DL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
noise with
attenuated intake
noise filter) - DL
TIM ID: 0000020187 - 001
(sound power level

LW, ISO 6798+2dB
(A) tolerance)

Product Summary 33
2.5.3 8V/10V/12V 1600 G10F/G20F engine data, EU Nonroad Stage III A

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

0F 0F 10F 20F 10F 20F
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
ISO 3046 (10%
design power DIN
6280, ISO 8528)
Number of 8 8 10 10 12 12
cylinders
(new filter)
TIM ID: 0000020186 - 001
max.
overpressure
overpressure, max.

34 Product Summary
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - DL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020186 - 001
temperature before
engine, from
temperature before
engine, to

Product Summary 35
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020186 - 001
side (without
cooling equipment)

36 Product Summary
Number of 8 8 10 10 12 12
cylinders
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - DL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
noise with
attenuated intake
noise filter) - DL
TIM ID: 0000020186 - 001
(sound power level

LW, ISO 6798+2dB
(A) tolerance)

Product Summary 37
2.5.4 8V/10V/12V 1600 G10S, G20S engine data, EPA Tier 2, 3

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V1600G 8V1600G 10V1600 12V1600 12V1600

10S 20S G20S G10S G20S
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100 100
Number of cylinders 8 8 10 12 12
Rated engine speed A rpm 1800 1800 1800 1800 1800
Continuous power ISO 3046 A kW 371 408 511 561 608
(10% overload capability, design
power DIN 6280, ISO 8528)
Intake depression (new filter) A mbar 25 25 25 25 25
Intake depression, max. L mbar 50 50 50 50 50
Exhaust gas overpressure A mbar 85 85 85 85 85
Exhaust gas overpressure, max. L mbar 150 150 150 150 150
Standard flywheel housing SAE 01 01 01 01 01
TIM ID: 0000020188 - 001
flange (engine main PTO)

Flywheel interface DISC 14" 14" 14" 14" 14"

38 Product Summary
Charge-air pressure before R bar abs 3.1 2.77 2.77 3.1 3.1
cylinder - DL
Coolant temperature (at engine A °C 95 95 95 95 95
connection: outlet to cooling
equipment)
Coolant temperature after R °C 105 105 105 105 105
engine, warning
Coolant temperature after L °C 109 109 109 109 109
engine, shutdown
Coolant antifreeze content, max. L % 50 50 50 50 50
Pressure loss in off-engine L bar 0.7 0.7 0.7 1 1
cooling system, max.
LUBE-OIL SYSTEM
Lube oil operating temperature R °C 87 87 87 87 87
before engine, from
Lube-oil operating temperature R °C 100 100 101 101 101
before engine, to
Lube-oil operating pressure R bar 4.5 4.5 4.5 4.5 4.5
before engine, from
Lube oil operating pressure R bar 5.4 5.4 5.4 5.4 5.4
before engine, to
FUEL SYSTEM
Fuel pressure at engine inlet L bar -0.5 -0.5 -0.5 -0.5 -0.5
connection, min. (when engine is
starting)
Fuel pressure at engine inlet L bar 0.5 0.5 0.5 0.5 0.5
connection, max. (when engine
is starting)
TIM ID: 0000020188 - 001

Product Summary 39
Cold start capability: air R °C -20 -20 -20 -20 -20
temperature (w/o start aid, w/o
preheating) - (case A)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120
CAPACITIES
Engine coolant capacity, engine R Liters 50* 50* 60* 65 65
side (without cooling equipment)
Oil change quantity, max. R Liters 43 43 53 64 64
(standard oil system) (Option:
max. operating inclinations)
Oil pan capacity at dipstick mark L Liters 36 36 46 56 56
“min.” (standard oil system)
(Option: max. operating
inclinations)
Oil pan capacity at dipstick mark L Liters 43 43 53 64 64
“max.” (standard oil system)
(Option: max. operating
inclinations)
Engine weight, dry (basic engine R kg 1444 1444 1749 1950 2022
configuration acc. to scope of
delivery specification)
ACOUSTICS
Exhaust noise, unsilenced - DL R dB(A) 121 121 121 120 121
(sound power level LW, ISO
6798+3dB(A) tolerance)
Engine surface noise with R dB(A) - - - 123 122
attenuated intake noise filter) -
DL (sound power level LW, ISO
TIM ID: 0000020188 - 001
6798+2dB (A) tolerance)

40 Product Summary
2.5.5 8/10/12V 1600 G70F, G80F engine data, emissions-optimized

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

0F 0F 70F 80F 70F 80F
Application group 3D 3D 3D 3D 3D 3D
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
Fuel stop power A kW 358 394 448 493 576 634
ISO 3046
Number of 8 8 10 10 12 12
cylinders
(new filter)
max.
TIM ID: 0000020199 - 001
overpressure
overpressure, max.

Product Summary 41
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - BL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020199 - 001
temperature before
engine, from
temperature before
engine, to

42 Product Summary
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020199 - 001
side (without
cooling equipment)

Product Summary 43
Number of 8 8 10 10 12 12
cylinders
Engine oil, total, for R Liters 46 46 60.5 60.5 72.5 72.5
initial filling
(standard oil
system) (option:
max. operating
inclinations)
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - BL
(free-field sound
pressure level Lp,
TIM ID: 0000020199 - 001
1m distance, ISO
6798, +3dB(A)
tolerance)

44 Product Summary
Number of 8 8 10 10 12 12
cylinders
unsilenced - BL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
TIM ID: 0000020199 - 001

Product Summary 45
2.5.6 8/10/12V 1600 G70F, G80F engine data, optimized fuel consumption
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

0F 0F 70F 80F 70F 80F
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
ISO 3046
Number of 8 8 10 10 12 12
cylinders
(new filter)
max.
TIM ID: 0000020200 - 001
overpressure
overpressure, max.

46 Product Summary
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - BL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020200 - 001
temperature before
engine, from
temperature before
engine, to

Product Summary 47
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020200 - 001
side (without
cooling equipment)

48 Product Summary
Number of 8 8 10 10 12 12
cylinders
initial filling
(standard oil
system) (option:
max. operating
inclinations)
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - BL
(free-field sound
pressure level Lp,
TIM ID: 0000020200 - 001
1m distance, ISO
6798, +3dB(A)
tolerance)

Product Summary 49
Number of 8 8 10 10 12 12
cylinders
unsilenced - BL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
TIM ID: 0000020200 - 001

50 Product Summary
2.5.7 8/10V 1600 G70F, G80F engine data, EU Nonroad Stage III A
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V1600G 8V1600G 10V1600 10V1600

70F 80F G70F G80F
Application group 3D 3D 3D 3D
Intake air temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
Number of cylinders 8 8 10 10
Rated engine speed A rpm 1500 1500 1500 1500
Fuel stop power ISO 3046 A kW 358 394 448 493
Intake depression (new filter) A mbar 25 25 25 25
Intake depression, max. L mbar 50 50 50 50
Exhaust gas overpressure A mbar 85 85 85 85
Exhaust gas overpressure, max. L mbar 150 150 150 150
Standard flywheel housing flange (engine SAE 01 01 01 01
main PTO)
Flywheel interface DISC 14" 14" 14" 14"
TIM ID: 0000020229 - 001
Charge-air pressure before cylinder - BL R bar abs 3.12 3.27 3.12 3.27

Product Summary 51
Coolant temperature (at engine connection: A °C 95 95 95 95
outlet to cooling equipment)
Coolant temperature after engine, warning R °C 105 105 105 105
Coolant temperature after engine, shutdown L °C 109 109 109 109
Coolant antifreeze content, max. L % 50 50 50 50
Pressure loss in off-engine cooling system, L bar 0.7 0.7 0.7 0.7
max.
LUBE-OIL SYSTEM
Lube oil operating temperature before engine, R °C 87 87 87 87
from
Lube-oil operating temperature before engine, R °C 100 100 100 100
to
Lube-oil operating pressure before engine, R bar 4.5 4.5 4.5 4.5
from
Lube oil operating pressure before engine, to R bar 5.4 5.4 5.4 5.4
FUEL SYSTEM
Fuel pressure at engine inlet connection, min. L bar -0.5 -0.5 -0.5 -0.5
(when engine is starting)
Fuel pressure at engine inlet connection, max. L bar 0.5 0.5 0.5 0.5
Cold start capability: air temperature (w/o start R °C -20 -20 -20 -20
aid, w/o preheating) - (case A)
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120
CAPACITIES
TIM ID: 0000020229 - 001
Engine coolant capacity, engine side (without R Liters 50* 50* 60* 60*
cooling equipment)
Engine oil, total, for initial filling (standard oil R Liters 46 46 60.5 60.5
system) (option: max. operating inclinations)

52 Product Summary
Oil change quantity, max. (standard oil R Liters 43 43 53 53
system) (Option: max. operating inclinations)
Oil pan capacity at dipstick mark “min.” L Liters 36 36 46 46
(standard oil system) (Option: max. operating
inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 43 43 53 53
inclinations)
Engine weight, dry (basic engine configuration R kg 1444 1444 1749 1749
acc. to scope of delivery specification)
ACOUSTICS
Exhaust noise, unsilenced - BL (free-field R dB(A) 109 109 109 110
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
Exhaust noise, unsilenced - BL (sound power R dB(A) 122 122 122 123
level LW, ISO 6798+3dB(A) tolerance)
TIM ID: 0000020229 - 001

Product Summary 53
2.5.8 8/12V 1600 G70S engine data, EPA Tier 2, 3

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V1600G7 8V1600G7 12V1600G 12V1600G

0S 0S 70S 70S
Application group 3D 3D 3D 3D
main PTO)
TIM ID: 0000020196 - 001
Charge-air pressure before cylinder - BL R bar abs 3.1 3. 3.2 3.1

54 Product Summary
Pressure loss in off-engine cooling system, L bar 0.7 0.7 1 1
max.
LUBE-OIL SYSTEM
from
to
from
FUEL SYSTEM
CAPACITIES
TIM ID: 0000020196 - 001
Engine coolant capacity, engine side (without R Liters 50* 50* 65 65
cooling equipment)
Engine oil, total, for initial filling (standard oil R Liters 46 46 72.5 72.5
system) (option: max. operating inclinations)

Product Summary 55
inclinations)
inclinations)
ACOUSTICS
Exhaust noise, unsilenced - BL (free-field R dB(A) 109 109 109 109
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
Exhaust noise, unsilenced - BL (sound power R dB(A) 122 122 122 122
TIM ID: 0000020196 - 001

56 Product Summary
2.5.9 8/10/12V 1600 G80S engine data, EPA Tier 2, 3

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

0S 0S 80S 80S 80S 80S
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
ISO 3046
Number of 8 8 10 10 12 12
cylinders
(new filter)
max.
TIM ID: 0000020197 - 001
overpressure
overpressure, max.

Product Summary 57
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - BL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020197 - 001
temperature before
engine, from
temperature before
engine, to

58 Product Summary
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020197 - 001
side (without
cooling equipment)

Product Summary 59
Number of 8 8 10 10 12 12
cylinders
initial filling
(standard oil
system) (option:
max. operating
inclinations)
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - BL
(free-field sound
pressure level Lp,
TIM ID: 0000020197 - 001
1m distance, ISO
6798, +3dB(A)
tolerance)

60 Product Summary
Number of 8 8 10 10 12 12
cylinders
unsilenced - BL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
TIM ID: 0000020197 - 001

Product Summary 61
2.5.10 8/10/12V 1600 G40F, G50F engine data, emissions-optimized

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V1600G 8V1600G 10V1600 10V1600 12V1600 12V1600

40F 50F G40F G50F G40F G50F
Application group 3C 3C 3C 3C 3C 3C
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
ISO 3046
Number of 8 8 10 10 12 12
cylinders
(new filter)
max.
TIM ID: 0000020189 - 001
overpressure
overpressure, max.

62 Product Summary
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - DL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020189 - 001
temperature before
engine, from
temperature before
engine, to

Product Summary 63
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020189 - 001
side (without
cooling equipment)

64 Product Summary
Number of 8 8 10 10 12 12
cylinders
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - DL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
noise with
attenuated intake
noise filter) - DL
TIM ID: 0000020189 - 001
(sound power level

LW, ISO 6798+2dB
(A) tolerance)

Product Summary 65
2.5.11 8/10/12V 1600 G40F, G50F engine data, optimized fuel consumption
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

0F 0F 40F 50F 40F 50F
Application group 3C 3C 3C 3C 3C 3C
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
ISO 3046
Number of 8 8 10 10 12 12
cylinders
(new filter)
max.
TIM ID: 0000020190 - 001
overpressure
overpressure, max.

66 Product Summary
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - DL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020190 - 001
temperature before
engine, from
temperature before
engine, to

Product Summary 67
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020190 - 001
side (without
cooling equipment)

68 Product Summary
Number of 8 8 10 10 12 12
cylinders
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - DL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
noise with
attenuated intake
noise filter) - DL
TIM ID: 0000020190 - 001
(sound power level

LW, ISO 6798+2dB
(A) tolerance)

Product Summary 69
2.5.12 8/10V 1600 G40F, G50F engine data, EU Nonroad stage III A
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V1600G4 8V1600G5 10V1600G 10V1600G

0F 0F 40F 50F
Application group 3C 3C 3C 3C
main PTO)
TIM ID: 0000020193 - 001
Charge-air pressure before cylinder - DL R bar abs 2.43 3.12 3.04 3.12

70 Product Summary
Pressure loss in off-engine cooling system, L bar 0.7 0.7 0.7 0.7
max.
LUBE-OIL SYSTEM
from
to
from
FUEL SYSTEM
CAPACITIES
TIM ID: 0000020193 - 001
Engine coolant capacity, engine side (without R Liters 50* 50* 60* 60*
cooling equipment)

Product Summary 71
inclinations)
inclinations)
ACOUSTICS
Exhaust noise, unsilenced - DL (sound power R dB(A) 121 121 121 122
TIM ID: 0000020193 - 001

72 Product Summary
2.5.13 8/10//12V 1600 B40S engine data, switchable frequency

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V1600B 8V1600B 10V1600 10V1600 12V1600 12V1600

40S 40S B40S B40S B40S B40S
Intake air °C 25 25 25 25 25 25
temperature
Barometric mbar 1000 1000 1000 1000 1000 1000
pressure
sea level
Number of 8 8 10 10 12 12
cylinders
speed
ISO 3046 (10%
design power DIN
6280, ISO 8528)
Number of 8 8 10 10 12 12
cylinders
(new filter)
TIM ID: 0000020172 - 001
max.
overpressure
overpressure, max.

Product Summary 73
Number of 8 8 10 10 12 12
cylinders
housing flange
(engine main PTO)
Number of 8 8 10 10 12 12
cylinders
pressure before
cylinder - DL
Number of 8 8 10 10 12 12
cylinders
Coolant A °C 95 95 95 95 95 95
temperature (at
engine connection:
outlet to cooling
equipment)
Coolant R °C 105 105 105 105 105 105
temperature after
engine, warning
Coolant L °C 109 109 109 109 109 109
temperature after
engine, shutdown
content, max.
engine cooling
system, max.
LUBE-OIL SYSTEM
Number of 8 8 10 10 12 12
cylinders
TIM ID: 0000020172 - 001
temperature before
engine, from
temperature before
engine, to

74 Product Summary
Number of 8 8 10 10 12 12
cylinders
pressure before
engine, from
pressure before
engine, to
FUEL SYSTEM
Number of 8 8 10 10 12 12
cylinders
engine inlet
connection, min.
(when engine is
starting)
engine inlet
connection, max.
(when engine is
starting)
Number of 8 8 10 10 12 12
cylinders
Cold start R °C -20 -20 -20 -20 -20 -20
capability: air
temperature (w/o
start aid, w/o
preheating) - (case
A)
CAPACITIES
Number of 8 8 10 10 12 12
cylinders
capacity, engine
TIM ID: 0000020172 - 001
side (without
cooling equipment)

Product Summary 75
Number of 8 8 10 10 12 12
cylinders
max. (standard oil
system) (Option:
max. operating
inclinations)
(standard oil
system) (Option:
max. operating
inclinations)
dipstick mark
system) (Option:
max. operating
inclinations)
Number of 8 8 10 10 12 12
cylinders
(basic engine
configuration acc.
specification)
ACOUSTICS
Number of 8 8 10 10 12 12
cylinders
unsilenced - DL
(sound power level
LW, ISO
6798+3dB(A)
tolerance)
noise with
attenuated intake
noise filter) - DL
TIM ID: 0000020172 - 001
(sound power level

LW, ISO 6798+2dB
(A) tolerance)

76 Product Summary
2.5.14 10V 1600 B50F engine data, emissions-optimized

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 10V1600B

50F
Application group 3B
Intake air temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100
Number of cylinders 10
Rated engine speed A rpm 1500
Continuous power ISO 3046 (10% overload capability, design power DIN 6280, ISO A kW 448
8528)
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 50
Exhaust gas overpressure A mbar 30
Exhaust gas overpressure, max. L mbar 150
Standard flywheel housing flange (engine main PTO) SAE 01
Flywheel interface DISC 14"
TIM ID: 0000020175 - 001
Charge-air pressure before cylinder - DL R bar abs 2.92

Product Summary 77
Coolant temperature (at engine connection: outlet to cooling equipment) 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 before engine, from R °C 87
Lube-oil operating temperature before engine, to R °C 100
Lube-oil operating pressure before engine, from R bar 4.5
Lube oil operating pressure before engine, to R bar 5.4
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 0.0
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
CAPACITIES
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 Liters 46
inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. operating L Liters 53
TIM ID: 0000020175 - 001
inclinations)
Engine weight, dry (basic engine configuration acc. to scope of delivery specification) R kg 1749

78 Product Summary
ACOUSTICS
Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798+3dB(A) tolerance) R dB(A) 122
TIM ID: 0000020175 - 001

Product Summary 79
2.5.15 10V 1600 B50F engine data, optimized fuel consumption

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

50F
8528)
TIM ID: 0000020179 - 001

80 Product Summary
LUBE-OIL SYSTEM
FUEL SYSTEM
CAPACITIES
inclinations)
TIM ID: 0000020179 - 001
inclinations)

Product Summary 81
ACOUSTICS
TIM ID: 0000020179 - 001

82 Product Summary
2.5.16 10V 1600 B50F engine data, EU Nonroad Stage IIIA

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable

50F
8528)
TIM ID: 0000020185 - 001

Product Summary 83
LUBE-OIL SYSTEM
FUEL SYSTEM
CAPACITIES
inclinations)
TIM ID: 0000020185 - 001
inclinations)

84 Product Summary
ACOUSTICS
TIM ID: 0000020185 - 001

Operation 85
3 Operation
3.1 Putting the engine into operation after extended out-of-service-
periods (>3 months)
Preconditions
• Engine is stopped and starting disabled.
• MTU Fluids and Lubricants Specifications (A001063/..) are available.
Procedure
Putting the engine into operation after extended out-of-service-periods (>3 months)
Item Task
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001063/..).
Lube oil system Check engine oil level (→ Page 114).
Fuel system Vent (→ Page 108).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 120).
Coolant circuit Check engine coolant level (→ Page 119).
Engine governor Check plug-in connections (→ Page 136).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
TIM ID: 0000000864 - 001

86 Operation
3.2 Putting the engine into operation after scheduled out-of-service-

period
Preconditions
Procedure
Startup
Item Task
Lube oil system Check engine oil level (→ Page 114).
Coolant system Check engine coolant level (→ Page 119).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
TIM ID: 0000000876 - 001

Operation 87
3.3 Engine start in manual operation (trials)

Preconditions
• Generator is not connected to network.
• External start interlock is not activated.
Cautions
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
DANGER • Before barring or starting the engine, make sure that nobody is in the danger zone.
Engine noise above 85 dB (A).

Risk of damage to hearing!
WARNING • Wear ear protectors.
Procedure
Preparation
Item Task
Operating mode selector Change to manual mode.
switch (if provided)
Starting the engine
Item Task
Switchgear cabinet, control Press start button.
panel etc. (depending on • Automatic starting sequence is performed;
manufacturer) • 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 Task
Switchgear cabinet, control Close the generator circuit breaker.
panel etc. (depending on
manufacturer)
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 60 °C).
TIM ID: 0000000865 - 001

88 Operation
3.4 Bypassing the safety system (Override)

Cautions
Safety functions and engine shutdown alarms will be disregarded.
Serious damage to plant!
CAUTION • Initiate emergency start only in emergency situations.
Inadmissible operational condition.

Major material damage!
CAUTION • Use override function only in hazardous situations to ensure full capability in case of
engine malfunctions.
Procedure
Preparation
Note: This function is only available when a pushbutton is provided.
Bypassing the safety system (Override)
Item Task
Switching cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence see Engine start (→ Page 87).
panel etc. (depending on
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM ID: 0000000984 - 001

Operation 89
3.5 Operational checks

Cautions
DANGER • Take special care when working on a running engine.

Procedure
Operational checks
Item Task
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 97).
Air filter Check signal ring position of service indicator (→ Page 112).
Replace air filter (→ Page 110), if the signal ring is completely visible in the service
indicator control window.
Coolant pump Check relief bore for escaping oil and coolant, check for dirt (→ Page 125).
TIM ID: 0000000866 - 001

90 Operation
3.6 Engine stop in manual operation (trials)

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

Operation 91
3.7 Emergency engine shutdown

Cautions
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
CAUTION • Initiate emergency stop only in emergency situations.
Procedure
Emergency engine shutdown
Item Task
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.
After emergency shutdown
Item Task
Switchgear cabinet, control Press pushbutton for alarm acknowledgement.
panel etc. (depending on • Audible and visual signalization stops.
manufacturer)
TIM ID: 0000000868 - 001

92 Operation
3.8 After stopping the engine – engine remains ready for operation
Procedure
After stopping the engine
Item Task
Engine/generator/pump Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
controller
TIM ID: 0000000983 - 001

Operation 93
3.9 After stopping the engine – Putting the engine out of operation
Preconditions
Procedure
After stopping the engine
Item Task
Coolant circuit Drain engine coolant (→ Page 121) 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 Switch OFF.
control
TIM ID: 0000000877 - 001

94 Operation
TIM ID: 0000000877 - 001

Maintenance 95
4 Maintenance
4.1 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 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.
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/... 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.
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: 0000000869 - 001

96 Maintenance
TIM ID: 0000000869 - 001

Troubleshooting 97
5 Troubleshooting
5.1 Troubleshooting
Procedure
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 134).
Engine/generator Secure seating of assemblies or connectors Perform visual inspection (see
control system not provided manufacturer's documentation).
Engine governor Plug-in connections are loose Check plug-in connections (→ Page 136).
Engine Running gear blocked (engine cannot be Contact Service.
barred manually)
Engine turns but does not fire

Starter Poor rotation by starter: Battery low or Charge or replace battery (see
defective manufacturer's documentation).
Fuel system Not vented Vent fuel system (→ Page 108).
Engine governor Defective Contact Service.
TIM ID: 0000000871 - 001

98 Troubleshooting
Engine fires unevenly

Fuel injection Injector defective Contact Service.
equipment
Engine does not reach nominal speed

Fuel supply Easy-change fuel filter clogged Replace (→ Page 109).
Air supply Air filter clogged Check signal ring position of service
indicator (→ Page 112).
equipment
Engine Overload Contact Service.
Engine speed not steady

equipment
Speed sensor Defective Contact Service.
Charge-air temperature too high

TIM ID: 0000000871 - 001
Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts.

Troubleshooting 99
Charge-air pressure too low

Exhaust turbocharger Defective Contact Service.
Exhaust gas black

equipment
Engine Overload Contact Service.
Exhaust gas blue

Engine oil Too much oil in engine Drain engine oil (→ Page 115).
Exhaust turbocharger, Defective Contact Service.
cylinder head, piston
rings, cylinder liner
Exhaust gas white

Engine Not at operating temperature Run up to operating temperature.
TIM ID: 0000000871 - 001

100 Troubleshooting
TIM ID: 0000000871 - 001

Task Description 101
6 Task Description
6.1 Engine
6.1.1 Engine – Barring with starting system
Preconditions
• External pushbutton “Bar engine without starting” is provided.
Cautions
DANGER • 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.
Procedure
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: 0000000013 - 001

102 Task Description
6.1.2 Engine test run

Cautions
DANGER • Before barring or starting the engine, make sure that nobody is in the danger zone.

Procedure
Engine test run
1. Start engine (→ Page 87).

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 89).
4. Stop engine (→ Page 90).
TIM ID: 0000000870 - 001

6.2 Valve Drive

6.2.1 Valve clearance – Check and adjustment
Preconditions
• Engine coolant temperature is max. 40 °C.
• Valves are closed.
Special tools
Designation / Use Part No. Qty.
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
Procedure
Preparatory steps
1. Remove cylinder head cover (→ Page 107).

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.
Diagram for 8V engines

TIM ID: 0000000899 - 002

• Two crankshaft positions
1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

TIM ID: 0000000899 - 002

I Inlet valve
X Exhaust valve


I Inlet valve
X Exhaust valve
Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder A1:

• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet = 0.3 +/- 0.05 mm;
• Exhaust = 0.6 +/- 0.05 mm.
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram.
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: 0000000899 - 002

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. Remove barring device.

2. Install cover.
3. Install cylinder head cover (→ Page 107).
TIM ID: 0000000899 - 002

6.2.2 Cylinder head cover – Removal and installation

Preconditions
Procedure
Cylinder head cover – Removal and installation
Note: 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
torque 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
TIM ID: 0000000900 - 002

6.3 Fuel System

6.3.1 Fuel system – Venting
Preconditions
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Procedure
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: 0000000901 - 001

6.4 Fuel Filter

6.4.1 Fuel filter – Replacement
Preconditions
Special tools
Filter wrench F30379104 1
Material
Engine oil
Spare parts
Easy-change filter 1
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Procedure
Replacing the fuel filter
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.
TIM ID: 0000000902 - 001

6.5 Air Filter

6.5.1 Air filter replacement
Spare parts
Air filter
Procedure
Remove air filter and install new one (→ Page 111).
Reset signal ring of service indicator (→ Page 112).
TIM ID: 0000000903 - 001

6.5.2 Air filter – Removal and installation

Preconditions
Procedure
Air filter – Removal and installation
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).
TIM ID: 0000000904 - 003

6.6 Air Intake

6.6.1 Service indicator – Signal ring position check
Preconditions
Procedure
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 110).
2. After installation of new filter, press reset button (1).
Result: Signal ring returns to initial position.
TIM ID: 0000000985 - 001

6.7 Starting Equipment

6.7.1 Starter – Condition check
Preconditions
Procedure
Starter – Condition check
1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 134).
TIM ID: 0000000905 - 003

6.8 Lube Oil System, Lube Oil Circuit

6.8.1 Engine oil level – Check
Preconditions
Procedure
Checking engine oil level 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. Top up with oil to the “max.” mark as necessary
(→ Page 115).
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. Top up with oil to the “max.” mark as necessary (→ Page 115).
5. Insert oil dipstick (1) in guide tube up to the stop.
TIM ID: 0000000907 - 001

6.8.2 Engine oil – Change

Preconditions
• Engine is at operating temperature.
Material
Engine oil
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid cobtact with skin.
• Do not inhale oil vapor.
Procedure
Draining oil at drain plug on oil pan
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
TIM ID: 0000000906 - 001
4. Replace engine oil filter (→ Page 117)

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 114).
TIM ID: 0000000906 - 001

6.9 Oil Filtration / Cooling

6.9.1 Engine oil filter – Replacement
Preconditions
Special tools
Torque wrench, 10-60 Nm F30510423 1
Ratchet adapter F30027340 1
Socket, 32 mm F30006120 1
Material
Engine oil
Spare parts
Oil filter element
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
• Avoid cobtact with skin.
• Do not inhale oil vapor.
TIM ID: 0000000908 - 001

Procedure
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.

Cover Tightening torque Engine oil 35 Nm
9. Replace further oil filters in the same way.

10. Check oil level (→ Page 114).
TIM ID: 0000000908 - 001

6.10 Coolant Circuit, General, High-Temperature Circuit

6.10.1 Engine coolant – Level check
Preconditions
Cautions
Coolant is hot and under pressure.
Risk of injury and scalding!
WARNING • Let the engine cool down.
Procedure
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 123).
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 123).
TIM ID: 0000000911 - 001

6.10.2 Engine coolant – Change

Material
Engine coolant
Procedure
Drain engine coolant (→ Page 121).
Fill with engine coolant (→ Page 123).
TIM ID: 0000000036 - 004

6.10.3 Engine coolant – Draining

Preconditions
Material
Engine oil
Spare parts
Sealing ring
Cautions
Procedure
Preparatory steps
1. Provide an appropriate container to drain the coolant into.

2. Switch off preheater, if installed.
Draining engine coolant
1. Turn breather valve of filler neck on coolant

expansion tank counterclockwise to first stop and
allow pressure to escape.
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
torque wrench to tighten to specified tightening
torque.
TIM ID: 0000000910 - 001

Drain plug Tightening torque Engine oil 100 Nm

6. Place breather valve on filler neck and close.
TIM ID: 0000000910 - 001

6.10.4 Engine coolant – Filling

Preconditions
Material
Engine coolant
Cautions

Cold coolant in hot engine can cause thermal stress.

Formation of cracks in components!
CAUTION • Fill / top up coolant only into cold engine.
Procedure
Preparatory steps
1. Turn breather valve of filler neck on coolant

expansion tank counterclockwise to first stop and
allow pressure to escape.
and remove.
TIM ID: 0000000909 - 001

Engine 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, clean sealing faces if required.
3. Fit breather valve and close it.
Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 119), top up if required.
TIM ID: 0000000909 - 001

6.10.5 Coolant pump – Relief bore check

Cautions
DANGER • Take special care when working on a running engine.

Procedure
Coolant pump – checking relief bore
1. Check relief bore (1) for oil and coolant discharge.

• Permissible coolant discharge: up to 10
drops/hour
• Permissible oil discharge: up to 5 drops per
hour
2. Stop engine (→ Page 90) and disable engine start.
3. If discharge exceeds the specified limits, contact
Service.
TIM ID: 0000000912 - 001

6.11 Belt Drive

6.11.1 Drive belt – Adjustment
Preconditions
Procedure
Fan drive – Adjusting belt tension
1. Slacken off 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 128).
Coolant pump drive – Adjusting belt tension (engine with mechanical belt tensioner)
1. Slacken off screws (1) and locknut (3).

2. Screw in adjusting screw to set the required drive
belt tension.
3. Tighten screws (1) and locknut (3).
4. Check drive belt tension for compliance with
specifications (→ Page 128). TIM ID: 0000000895 - 001

6.11.2 Drive belt – Condition check

Preconditions
• Protective cover is removed.
Procedure
Item Findings Task

Drive belt A Singular cracks None
Drive belt Belt is oily, shows signs of Replace (→ Page 130)
overheating
Drive belt B Cracks on entire circumference
Drive belt C Chunking
TIM ID: 0000000896 - 001

6.11.3 Drive belt – Tension check

Preconditions
Special tools
Tester Y4345711 1
Belt tension tester, 500-1400 N Y20097430 1
Belt tension tester, 1300-3100 N Y20097431 1
Procedure
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 Measured Measured value Measured value

value Operating tension after 1 hour Minimum operating tension
Initial
assembly
Fan drive belt 2250 N 1620 N 1080 N
7. If the measured values deviate from the above specifications, readjust drive belt tension (→ Page 126).
TIM ID: 0000000897 - 001
8. Install protective cover.

Checking coolant pump drive belt tension – Engine with mechanical belt tensioner

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 Measured Measured value Measured value

value Operating tension after 1 hour Minimum operating tension
Initial
assembly
Fan drive belt 1000 N 720 N 480 N
7. If the measured values deviate from the above specifications, readjust drive belt tension (→ Page 126).
TIM ID: 0000000897 - 001

6.11.4 Drive belt – Replacement

Preconditions
Spare parts
Drive belt
Procedure
Replacing fan drive belt
1. Remove protective cover from cooler.

2. Remove cooler.
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
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 (3) to allow belt tensioning.
8. Adjust and check belt tension (→ Page 126).
9. Install fan.
TIM ID: 0000000898 - 001

Replacing drive belts of battery-charging generator and coolant pump

2. Remove drive belt from fan drive (→ Step 1.).
3. Remove brace (2).
4. Use appropriate tool to release the automatic belt
tensioner at hexagon (3) and take off drive belt (1).

5. Fit new drive belt (1) and unload belt tensioner.

6. Install drive belt on fan drive (→ Step 1.).
Replacing drive belt of coolant pump (mechanical belt tensioner)

2. Remove drive belt from fan drive (→ Step 1.).
3. Slacken off screws (1) and locknut (3).
4. Release adjusting screw (2) on mechanical belt
tensioner (4) and take off drive belt.

5. Fit new drive belt (5) and tighten adjusting screw

(2) on mechanical belt tensioner to set the required
tension (→ Page 126).
6. Install drive belt on fan drive (→ Step 1.).
TIM ID: 0000000898 - 001

6.12 Wiring (General) for Engine/Gearbox/Unit

6.12.1 Sensors and actuators
Item Designation Monitoring of

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
TIM ID: 0000000815 - 001
7 XY39.A1 Injectors, A side

XY39.A
8 B48.1 HP fuel, A side
9 B5 Lube oil pressure

Item Designation Monitoring of

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
TIM ID: 0000000815 - 001

6.12.2 Engine wiring – Check

Preconditions
• Engine shut down and starting disabled.
Material
Isopropyl alcohol 46181 1
Procedure
Checking engine wiring
1. Check securing screws of cable clamps 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. Inspect electrical components visually for damage:
• Connector housing
• Contacts
• Sockets
• Cable and connection terminals
• Terminal contacts
6. (→ Contact Service) if cable conductors are damaged.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all connecting plugs of the sensors are correctly engaged.
TIM ID: 0000000029 - 003

6.13 Accessories for (Electronic) Engine Governor / Control System

6.13.1 Engine governor and connectors – Cleaning
Preconditions
Material
Isopropyl alcohol 46181 1
Procedure
Engine governor and connectors – Cleaning
1. Remove coarse dirt on housing surface using isopropyl alcohol.

2. Remove dirt from connector and cable surfaces using isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.
Cleaning severely contaminated connectors on engine governor
1. Release latches of connectors and withdraw connectors.

2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches.
TIM ID: 0000000047 - 002

6.13.2 Engine governor plug connections – Check

Preconditions
Procedure
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. Ensure that cable clamps
are not faulty.
TIM ID: 0000000913 - 001

Appendix A 137
7 Appendix A
7.1 Abbreviations
Abbreviation Meaning Explanation
A/D Analog/Digital Transformer: transforms sensor voltages into
numeric values
AFRS Air Filter Restriction Sensor
ANSI American National Standards Institute
ATL Abgasturbolader Exhaust turbocharger
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)
2nd function: Read out fault codes
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
TIM ID: 0000000858 - 002
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

138 Appendix A

FRS Fuel - Differential Pressure Sensor
FTS Fuel Temperature Sensor Monitors fuel temperature
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
Standardization
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 Pressure measuring point xyz
TIM ID: 0000000858 - 002
RL Redundancy Lost Alarm: Redundant CAN bus failure

SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure

Appendix A 139

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 Alarm: Sensor-comparison failure
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
TIM ID: 0000000858 - 002

140 Appendix A
7.2 MTU contact person / service partner

Service
We provide immediate attention through fast and direct access to our worldwide sales and service network.
On-site service
Skilled product experts will assist you with knowledge and experience and thus contribute to your business success.
For further information on our on-site service, visit: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during
operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for
spare parts supply.
Your contact in our headquarters: Service-support@mtu-online.com
Spare parts service
Fast, straightforward and accurate identification of spare parts for your drive plant or vehicle fleet. The right spare part
at the right time, at the right place.
With this aim in mind, we can call on a globally networked spares logistics system,
- a central warehouse at headquarters and on-site stores at our subsidiary companies, agencies and service
workshops.
Your contact in our headquarters:
E-mail: spare.parts@mtu-online.com
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM ID: 0000000873 - 003

Appendix B 141
8 Appendix B
8.1 Special Tools
Designation / Use Part No. Qty. Used in
Feeler gauge Y20010128 1 6.2.1 Valve clearance – Check and adjustment
(→ Page 103)
Torque wrench, 20-200 Nm F30451339 1 6.2.1 Valve clearance – Check and adjustment
(→ Page 103)
Box wrench, 14 mm F3625502 1 6.2.1 Valve clearance – Check and adjustment
(→ Page 103)
Allen key, 5 mm F30002815 1 6.2.1 Valve clearance – Check and adjustment
(→ Page 103)
Barring device F6790714 1 6.2.1 Valve clearance – Check and adjustment
(→ Page 103)
Filter wrench F30379104 1 6.4.1 Fuel filter – Replacement (→ Page 109)
Torque wrench, 10-60 Nm F30510423 1 6.9.1 Engine oil filter – Replacement (→ Page 117)
Ratchet adapter F30027340 1 6.9.1 Engine oil filter – Replacement (→ Page 117)
Socket, 32 mm F30006120 1 6.9.1 Engine oil filter – Replacement (→ Page 117)
Tester Y4345711 1 6.11.3 Drive belt – Tension check (→ Page 128)
Belt tension Y20097430 1 6.11.3 Drive belt – Tension check (→ Page 128)
tester, 500-1400 N
Belt tension Y20097431 1 6.11.3 Drive belt – Tension check (→ Page 128)
tester, 1300-3100 N

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User guide and maintenance

MTU Friedrichshafen GmbH

Please use block capitals!

Motornr.: Auftragsnr.: Commissioning

Eingebaut in: Schiffstyp / Schiffshersteller:

1.1 General conditions 9

1.2 Personnel and organizational requirements 10

1.4 Safety requirements when working on the engine 12

1.5 Auxiliary materials, fire prevention and environmental protection 15

1.6 Conventions for safety instructions in the text 17

2.1 Engine Layout 19

2.2 Engine Side and Cylinder Designations 21

2.3 Main Engine Dimensions 22

2.4 Firing Sequence 23

2.5 Technical Data 24

3.2 Putting the engine into operation after scheduled out-of-service-period 86

3.3 Engine start in manual operation (trials) 87

3.4 Bypassing the safety system (Override) 88

3.5 Operational checks 89

3.6 Engine stop in manual operation (trials) 90

MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

3.7 Emergency engine shutdown 91

4.1 Maintenance and servicing 95

6 Task Description 101

6.1 Engine 101

6.2 Valve Drive 103

6.3 Fuel System 108

6.4 Fuel Filter 109

6.5 Air Filter 110

6.6 Air Intake 112

6.7 Starting Equipment 113

6.9 Oil Filtration / Cooling 117

6.10 Coolant Circuit, General, High-Temperature Circuit 119

6.11 Belt Drive 126

© MTU Friedrichshafen GmbH 2010-09 MS150076/01E

6.11.4 Drive belt – Replacement 130

6.12 Wiring (General) for Engine/Gearbox/Unit 132

6.13 Accessories for (Electronic) Engine Governor / Control System 135

7.1 Abbreviations 137

7.2 MTU contact person / service partner 140

8.1 Special Tools 141

MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

© MTU Friedrichshafen GmbH 2010-09 MS150076/01E

MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

1.2 Personnel and organizational requirements

TIM ID: 0000000874 - 004

© MTU Friedrichshafen GmbH 2010-09 MS150076/01E

MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

1.4 Safety requirements when working on the engine

© MTU Friedrichshafen GmbH 2010-09 MS150076/01E

MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

© MTU Friedrichshafen GmbH 2010-09 MS150076/01E

1.5 Auxiliary materials, fire prevention and environmental protection

neighboring work areas are not impaired.

MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

TIM ID: 0000000880 - 003

© MTU Friedrichshafen GmbH 2010-09 MS150076/01E

1.6 Conventions for safety instructions in the text

In the event of possibly dangerous situations.

In the event of dangerous situations.

MS150076/01E 2010-09 © MTU Friedrichshafen GmbH

TIM ID: 0000000881 - 005

© MTU Friedrichshafen GmbH 2010-09 MS150076/01E