6R 1600 G10F/G20F, 6R 1600 G40F/G50F, 6R 1600 G70F

Transcription

Operating Instructions
Diesel engine
6R 1600 G10F, G20F
6R 1600 G40F, G50F
6R 1600 G70F, G80F
6R 1600 G10S, G20S
6R 1600 G70S, G80S
6R 1600 B30S, B40S
MS15022/02E
Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety
1.1
1.2
1.3
1.4
1.5
General conditions
Personnel and organizational requirements
Transport
Safety regulations for startup and operation
Safety regulations for maintenance and
repair work
1.6 Auxiliary materials, fluids and lubricants,
fire prevention and environmental
protection
1.7 Conventions for safety instructions in the
text
5
6
7
8
9
12
14
2 General Information
2.1 Engine layout
2.2 Engine side and cylinder designations
2.3 Sensors and actuators
15
17
18
DCL-ID: 0000005207 - 005
3 Technical Data
3.1 6R 1600 B30S 60Hz engine data,
optimized fuel consumption
optimized emissions
optimized emissions
3.7 6R 1600 G10F , G20F engine data,
optimized exhaust emissions
3.9 6R 1600 G10S, G20S engine data, EPA
stage 3
3.10 6R 1600 G10F, G20F engine data,
Nonroad stage III a
Nonroad stage III a
20
23
3.16 6R 1600 G70S, G80S engine data, EPA
stage 3
Nonroad stage III a
3.18 Firing sequence
3.19 Engine – Main dimensions
54
57
60
63
66
67
4 Operation
4.1 Putting the engine into operation after
extended out-of-service-periods (>3
months)
4.2 Putting the engine into operation after
scheduled out-of-service-period
4.3 Engine start in manual operation (trials)
4.4 Safety system – Override
4.5 Operational checks
4.6 Engine stop in manual operation (trials)
4.7 Emergency engine shutdown
4.8 After stopping the engine – Engine remains
ready for operation
4.9 After stopping the engine – Putting the
engine out of operation
68
69
70
71
72
73
74
75
76
25
27
5 Maintenance
29
5.1 Maintenance and servicing
5.2 Maintenance task reference table
77
78
31
33
36
6 Troubleshooting
6.1 Troubleshooting
79
39
42
45
48
51
7 Task Description
7.1 Engine
81
7.2 Valve Drive
83
7.1.1 Engine – Barring with starting system
7.1.2 Engine – Test run
7.2.1 Valve clearance – Check and adjustment
7.2.2 Cylinder head cover – Removal and
installation
81
82
83
85
MS15022/02E 2012-04 | Table of Contents | 3
7.3 Fuel System
7.3.1 Fuel system – Venting
86
86
7.4 Fuel Filter
87
7.5 Air Filter
89
7.4.1 Fuel filter – Replacement
7.4.2 Fuel prefilter – Replacement
7.5.1 Air filter – Replacement
7.5.2 Air filter – Removal and installation
7.6 Air Intake
7.6.1 Service indicator – Signal ring position check
87
88
89
90
91
91
7.7 Starting Equipment
92
7.8 Lube Oil System, Lube Oil Circuit
93
7.7.1 Starter – Condition check
7.8.1 Engine oil level – Check
7.8.2 Engine oil – Change
7.9 Oil Filtration / Cooling
7.9.1 Engine oil filter – Replacement
7.10 Coolant Circuit, General, HighTemperature Circuit
Engine coolant – Level check
Engine coolant – Change
Engine coolant – Draining
Engine coolant – Filling
101
7.11 Belt Drive
102
7.12 Wiring (General) for Engine/Gearbox/Unit
106
7.13 Accessories for (Electronic) Engine
Governor / Control System
107
7.11.1
7.11.2
7.11.3
7.11.4
Drive belt – Adjustment
Drive belt – Condition check
Drive belt – Tension check
Drive belt – Replacement
7.12.1 Engine wiring – Check
7.13.1 Engine governor and connectors – Cleaning
7.13.2 Engine governor plug connections – Check
102
103
104
105
106
107
108
92
93
94
8 Appendix A
95
8.1 Abbreviations
8.2 MTU contacts/service partners
96
9 Appendix B
95
96
97
98
99
9.1 Special Tools
9.2 Index
109
112
113
116
DCL-ID: 0000005207 - 005
7.10.1
7.10.2
7.10.3
7.10.4
7.10.5 Engine coolant pump – Relief bore check
4 | Table of Contents | MS15022/02E 2012-04
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection 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
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged 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. MTU 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.
Reworking components
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Repair or engine overhaul must be carried out in workshops authorized by MTU.
MS15022/02E 2012-04 | Safety | 5
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 operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available 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 who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Working clothes and protective equipment
Wear proper protective clothing for all work.
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Use the necessary protective equipment for the given work to be done.
6 | Safety | MS15022/02E 2012-04
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 trans‐
port 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.
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Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
MS15022/02E 2012-04 | Safety | 7
1.4 Safety regulations for startup and operation
Safety requirements for initial operation
Prior to initial operation of the unit, install the assembly or unit according to the specifications and check
the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that nobody is in the danger area of moving machine parts.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the signaling and alarm systems work properly.
Safety requirements for operators
The procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard 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:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
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Observe the safety instructions for these devices.
8 | Safety | MS15022/02E 2012-04
1.5 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental 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 pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
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Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
MS15022/02E 2012-04 | Safety | 9
Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
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.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
10 | Safety | MS15022/02E 2012-04
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Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
TIM-ID: 0000000879 - 023
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
MS15022/02E 2012-04 | Safety | 11
1.6 Auxiliary materials, fluids and lubricants, fire prevention and
environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting 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.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal
Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emissionrelevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Auxiliary materials, fluids and lubricants
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
12 | Safety | MS15022/02E 2012-04
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Use only fluids and lubricants that have been tested and approved by MTU.
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 extraction system.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted 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 chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.
Paints and lacquers
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
•
•
•
•
•
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
Avoid body contact (eyes, hands).
Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
Make sure that working area is well ventilated.
Avoid all knocks and jars to the containers, fixtures or workpieces.
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Acids and alkaline solutions
• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and
protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water.
MS15022/02E 2012-04 | Safety | 13
1.7 Conventions for safety instructions in the text
DANGER
WARNING
CAUTION
NOTICE
Note:
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
Read and familiarize yourself with all safety notices before starting up or repairing the product.
Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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1.
2.
14 | Safety | MS15022/02E 2012-04
2 General Information
2.1 Engine layout
Lifting eye, driving end
Service indicator
Cylinder head
Exhaust elbow
5
6
7
8
Engine mounting
Exhaust turbocharger
Oil pan
Starter
9 Flywheel
10 Flywheel housing
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1
2
3
4
MS15022/02E 2012-04 | General Information | 15
1
2
3
4
Lifting eye, free end
Air filter
Air supply
Fuel filter
5
6
7
8
Crankcase
Oil pan
Engine governor
Oil filter
9 Thermostat housing (re‐
turn cooler)
10 Belt drive
Engine model designation
Key to the engine model designation 6R 1600 Gxyz
Number of cylinders
R
Cylinder arrangement: In-line engine
1600
Series
G
Application
x
Application segment (1, 2, 4, 5, 7, 8)
y
Design index
z
Frequency code (F = 50Hz, S = 60Hz)
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6
16 | General Information | MS15022/02E 2012-04
2.2 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
For cylinder identification (as per DIN ISO 1204), the individual cylinders of the in-line engine are num‐
bered. The cylinders are numbered starting with No. 1 on driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
3 KS = Engine driving end
4 Left engine side
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1 KGS = Engine free end
2 Right engine side
2.3 Sensors and actuators
Designation
Monitoring of
1
B1
Camshaft speed
2
B13
Crankshaft speed
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Item
18 | General Information | MS15022/02E 2012-04
Designation
Monitoring of
1
B48
High-pressure fuel
2
XY39.A2
Injectors
3
B10
Charge-air pressure
4
XY39.A1
Injectors
5
M8
Fuel pump HDP (time measurement unit)
6
B9
Charge-air temperature
7
B5
Lube oil pressure
8
B16
Coolant pressure
9
B6
Coolant temperature
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Item
3 Technical Data
3.1 6R 1600 B30S 60Hz engine data, optimized fuel
consumption
Explanation:
DL
BL
A
G
R
L
N
X
Ref. value: Continuous power
Ref. value: Fuel stop power
Design value
Guaranteed value
Guideline value
Limit value, up to which the engine can be operated, without change (e.g. of power setting)
Not yet defined value
Not applicable
Applicable
REFERENCE CONDITIONS
Engine model
6R1600B
30S
Application group
3B
Intake air temperature
°C
Barometric pressure
mbar
Site altitude above sea level
m
25
1000
100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders
6
Rated engine speed
A
rpm
1800
Continuous power ISO 3046 (10% overload capability, design power DIN
6280, ISO 8528)
A
kW
284
GENERAL CONDITIONS (for maximum power)
6
Intake depression (new filter)
A
mbar
25
Intake depression, max.
L
mbar
50
Exhaust overpressure
A
mbar
85
Exhaust overpressure, max.
L
mbar
150
MODEL RELATED DATA (basic design)
Number of cylinders
6
Number of cylinders
6
Standard housing connecting flange (engine main PTO)
Flywheel interface (DISC)
20 | Technical Data | MS15022/02E 2012-04
SAE
01
14"
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Number of cylinders
COMBUSTION AIR / EXHAUST GAS
Number of cylinders
6
Charge-air pressure before cylinder - DL
R
bar abs
3.6
COOLANT SYSTEM (HT circuit)
Number of cylinders
6
Coolant temperature (at engine connection: outlet to cooling system)
A
°C
95
Coolant temperature after engine, warning
R
°C
105
Coolant temperature after engine, shutdown
L
°C
109
Pressure loss in off-engine cooling system, max.
L
bar
0.7
LUBE OIL SYSTEM
Number of cylinders
6
Lube oil operating pressure before engine, warning
R
bar
3.2
Lube oil operating pressure before engine, shutdown
L
bar
3.0
FUEL SYSTEM
Number of cylinders
6
Fuel pressure at engine inlet connection, min. (when engine is starting)
L
bar
-0.5
Fuel pressure at engine inlet connection, max. (when engine is starting)
L
bar
0.5
GENERAL OPERATING DATA
Number of cylinders
6
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
Number of cylinders
6
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Engine coolant, engine-side (without cooling system)
R
Liters
45
Engine oil on initial filling (standard oil system) (Option: max. operating incli‐ R
nations)
Liters
46
Oil change quantity, max. (standard oil system) (Option: max. operating in‐
clinations)
R
Liters
45
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max.
operating inclinations)
L
Liters
36
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L
Liters
45
MS15022/02E 2012-04 | Technical Data | 21
ACOUSTICS
Number of cylinders
6
dB(A)
113
Engine surface noise with attenuated intake noise (filter) - DL (sound power R
level LW, ISO 6798+2dB(A) tolerance)
dB(A)
118
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Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3dB(A) R
tolerance)
consumption
Explanation:
DL
BL
A
G
R
L
N
X
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
6R1600B
30S
Application group
3B
°C
Barometric pressure
mbar
m
25
1000
100
Number of cylinders
6
Rated engine speed
A
rpm
1500
6280, ISO 8528)
A
kW
249
Number of cylinders
6
A
mbar
25
L
mbar
50
A
mbar
85
L
mbar
150
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Number of cylinders
6
Number of cylinders
6
Cylinder displacement
Liters
SAE
1.75
01
14"
Number of cylinders
6
R
bar abs
2.8
Number of cylinders
6
A
°C
95
R
°C
105
L
°C
109
Coolant antifreeze content, max.
L
%
50
L
bar
0.7
LUBE OIL SYSTEM
Number of cylinders
6
R
bar
2.6
L
bar
2.4
FUEL SYSTEM
Number of cylinders
6
L
bar
-0.5
L
bar
0.5
Number of cylinders
6
A)
R
°C
-20
Firing speed, from
R
rpm
80
Firing speed, to
R
rpm
120
CAPACITIES
6
R
Liters
45*
nations)
Liters
46
clinations)
R
Liters
45
L
Liters
36
Liters
45
ACOUSTICS
Number of cylinders
6
tolerance)
dB(A)
114
dB(A)
116
TIM-ID: 0000026205 - 001
Number of cylinders
3.3 6R 1600 B40S 50Hz engine data, optimized emissions
Explanation:
DL
BL
A
G
R
L
N
X
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
6R1600B
40S
Application group
3B
°C
Barometric pressure
mbar
m
25
1000
100
Number of cylinders
6
Rated engine speed
A
rpm
1500
6280, ISO 8528)
A
kW
274
Number of cylinders
6
A
mbar
25
L
mbar
50
A
mbar
85
L
mbar
150
TIM-ID: 0000026257 - 001
Number of cylinders
6
Number of cylinders
6
SAE
01
14"
Number of cylinders
6
A
°C
95
R
°C
105
L
°C
109
Number of cylinders
6
L
%
50
L
bar
0.7
LUBE OIL SYSTEM
Number of cylinders
6
R
bar
2.6
L
bar
2.4
FUEL SYSTEM
Number of cylinders
6
L
bar
-0.5
L
bar
0.5
Number of cylinders
6
A)
R
°C
-20
Firing speed, from
R
rpm
80
Firing speed, to
R
rpm
120
CAPACITIES
Number of cylinders
6
nations)
Liters
42
clinations)
R
Liters
42
L
Liters
33
Liters
41
ACOUSTICS
6
tolerance)
dB(A)
115
dB(A)
117
TIM-ID: 0000026257 - 001
Number of cylinders
consumption
Explanation:
DL
BL
A
G
R
L
N
X
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
6R1600B
40S
Application group
3B
°C
Barometric pressure
mbar
m
25
1000
100
Number of cylinders
6
Rated engine speed
A
rpm
1800
6280, ISO 8528)
A
kW
274
Number of cylinders
6
A
mbar
25
L
mbar
50
A
mbar
85
L
mbar
150
TIM-ID: 0000026274 - 001
Number of cylinders
6
Number of cylinders
6
SAE
01
14"
Number of cylinders
6
A
°C
95
R
°C
105
Number of cylinders
6
L
°C
109
L
%
50
L
bar
0.7
LUBE OIL SYSTEM
Number of cylinders
6
R
bar
2.6
L
bar
2.4
FUEL SYSTEM
Number of cylinders
6
L
bar
-0.5
L
bar
0.5
Number of cylinders
6
A)
R
°C
-20
Firing speed, from
R
rpm
80
Firing speed, to
R
rpm
120
CAPACITIES
Number of cylinders
6
R
Liters
45*
nations)
Liters
42
clinations)
R
Liters
42
L
Liters
33
Liters
41
ACOUSTICS
6
tolerance)
dB(A)
115
dB(A)
117
TIM-ID: 0000026274 - 001
Number of cylinders
3.5 6R 1600 B40S 60Hz engine data, optimized emissions
Explanation:
DL
BL
A
G
R
L
N
X
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
6R1600B
40S
Application group
3B
°C
Barometric pressure
mbar
m
25
1000
100
Number of cylinders
6
Rated engine speed
A
rpm
1800
6280, ISO 8528)
A
kW
312
Number of cylinders
6
A
mbar
25
L
mbar
50
A
mbar
85
L
mbar
150
TIM-ID: 0000026275 - 001
Number of cylinders
6
Number of cylinders
6
SAE
01
14"
Number of cylinders
6
A
°C
95
R
°C
105
L
°C
109
Number of cylinders
6
L
%
50
L
bar
0.7
LUBE OIL SYSTEM
Number of cylinders
6
R
bar
3.2
L
bar
3.0
FUEL SYSTEM
Number of cylinders
6
L
bar
-0.5
L
bar
0.5
Number of cylinders
6
A)
R
°C
-20
Firing speed, from
R
rpm
80
Firing speed, to
R
rpm
120
CAPACITIES
Number of cylinders
Fuel, engine side
6
R
Liters
3*
nations)
Liters
46
clinations)
R
Liters
45
L
Liters
36
Liters
45
ACOUSTICS
6
tolerance)
dB(A)
113
dB(A)
118
TIM-ID: 0000026275 - 001
Number of cylinders
consumption
Explanation:
DL
BL
A
G
R
L
N
X
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
6R1600B
40S
Application group
3B
°C
Barometric pressure
mbar
m
25
1000
100
Number of cylinders
6
Rated engine speed
A
rpm
1800
6280, ISO 8528)
A
kW
312
Number of cylinders
6
A
mbar
25
L
mbar
50
A
mbar
85
L
mbar
150
TIM-ID: 0000026300 - 001
Number of cylinders
6
Number of cylinders
6
SAE
01
14"
Number of cylinders
6
R
bar abs
3.5
Number of cylinders
6
A
°C
95
R
°C
105
L
°C
109
L
%
50
L
bar
0.7
LUBE OIL SYSTEM
Number of cylinders
6
Lube oil operating temperature after engine, to
R
°C
114
R
bar
3.2
L
bar
3.0
FUEL SYSTEM
Number of cylinders
6
L
bar
-0.5
L
bar
0.5
Number of cylinders
6
A)
R
°C
-20
Firing speed, from
R
rpm
80
Firing speed, to
R
rpm
120
CAPACITIES
6
nations)
Liters
46
clinations)
R
Liters
45
L
Liters
36
Liters
45
ACOUSTICS
Number of cylinders
6
tolerance)
dB(A)
113
dB(A)
118
TIM-ID: 0000026300 - 001
Number of cylinders
3.7 6R 1600 G10F , G20F engine data, optimized fuel
consumption
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Limit value, up to which the engine can be operated, without change (e.g. of power settings).
Not applicable
Applicable
Data not yet available when at time of publication
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G10F
G20F
3B
3B
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
Continuous power ISO 3046 (10% overload capability, design
power DIN 6280, ISO 8528)
A
kW
249
274
6
6
TIM-ID: 0000010803 - 001
Number of cylinders
A
mbar
25
25
L
mbar
50
50
Exhaust gas overpressure
A
mbar
85
85
Exhaust gas overpressure, max.
L
mbar
150
150
Number of cylinders
6
6
Cooling method: conditioned water
X
X
Direction of rotation: c.c.w. (facing driving end)
X
X
SAE
01
01
Flywheel interface
DISC
14"
14"
Number of cylinders
R
bar abs
6
6
3.0
3.2
6
6
Number of cylinders
Coolant temperature (at engine connection: outlet to cooling
equipment)
A
°C
95
95
Coolant temperature after engine, alarm
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
Lube-oil operating temperature before engine, from
R
°C
*
*
Lube-oil operating temperature before engine, to
R
°C
*
*
Lube-oil temperature before engine, alarm
R
°C
-
-
Lube-oil temperature before engine, shutdown
L
°C
-
-
Lube-oil operating pressure before engine, from
R
bar
*
*
Lube-oil operating pressure before engine, to
R
bar
*
*
Lube-oil operating pressure before engine, warning (speed-de‐
pendent value, consult MTU)
R
bar
Lube-oil operating pressure before engine, shutdown (speeddependent value, consult MTU)
L
bar
6
6
FUEL SYSTEM
Number of cylinders
Fuel pressure at engine inlet connection, min. (when engine is
starting)
L
bar
-0.5
-0.5
Fuel pressure at engine inlet connection, max. (when engine is
starting)
L
bar
0.0
0.0
6
6
Number of cylinders
Cold start capability: air temperature (w/o start aid, w/o preheat‐ R
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
TIM-ID: 0000010803 - 001
CAPACITIES
Number of cylinders
6
6
Engine coolant capacity, engine side (without cooling equip‐
ment)
R
Liters
45
45
Total engine oil capacity for initial filling (standard oil system)
R
Liters
-
-
Oil change capacity, max. (standard oil system)
R
Liters
-
-
Oil change quantity, max. (standard oil system) (Option: max.
R
Liters
45
45
Oil pan capacity at dipstick mark “min.” (standard oil system)
(Option: max. operating inclinations)
L
Liters
36
36
Oil pan capacity at dipstick mark “max.” (standard oil system)
L
Liters
45
45
6
6
1150
1150
6
6
WEIGHTS / MAIN DIMENSIONS
Number of cylinders
Engine weight, dry (basic engine configuration acc. to scope of
delivery specification)
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
114
115
Engine surface noise with attenuated intake noise (filter) - DL
(sound power level LW, ISO 6798)
R
dB(A)
116
116
TIM-ID: 0000010803 - 001
Exhaust noise, unsilenced - DL (sound power level LW, ISO
6798)
3.8 6R 1600 G10F , G20F engine data, optimized exhaust
emissions
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G10F
G20F
3B
3B
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
A
kW
249
274
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
SAE
01
01
Flywheel interface
DISC
14"
14"
TIM-ID: 0000010845 - 001
Number of cylinders
R
bar abs
6
6
3.0
3.3
6
6
Number of cylinders
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
*
R
°C
*
*
R
°C
-
-
L
°C
-
-
R
bar
*
*
R
bar
*
*
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
TIM-ID: 0000010845 - 001
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
CAPACITIES
Number of cylinders
6
6
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
114
115
R
dB(A)
116
117
TIM-ID: 0000010845 - 001
6798)
3.9 6R 1600 G10S, G20S engine data, EPA stage 3
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
6R 1600
6R 1600
G10S
G20S
3B
3B
°C
*
25
Barometric pressure
mbar
*
1000
m
*
100
6
6
Number of cylinders
Rated engine speed
A
rpm
1800
1800
A
kW
284
312
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
TIM-ID: 0000010881 - 001
SAE
01
01
Flywheel interface
DISC
14"
14"
6
6
3.0
3.5
Number of cylinders
R
bar abs
Number of cylinders
6
6
equipment)
A
°C
*
95
R
°C
*
105
L
°C
109
109
L
%
*
50
L
bar
*
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
*
R
°C
*
*
R
°C
-
-
L
°C
-
-
R
bar
*
*
R
bar
*
*
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
*
-0.5
starting)
L
bar
*
0.0
6
6
Number of cylinders
ing) - (case A)
°C
*
-20
Firing speed, from
R
rpm
*
80
Firing speed, to
R
rpm
*
120
6
6
CAPACITIES
Number of cylinders
ment)
R
Liters
*
45
R
Liters
-
-
R
Liters
-
-
R
Liters
*
45
TIM-ID: 0000010881 - 001
Number of cylinders
6
6
L
Liters
*
36
L
Liters
*
45
6
6
*
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
113
113
R
dB(A)
118
118
TIM-ID: 0000010881 - 001
6798)
3.10 6R 1600 G10F, G20F engine data, Nonroad stage III a
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G10F
G20F
3B
3B
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
A
kW
249
274
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
SAE
01
01
Flywheel interface
DISC
14"
14"
6
6
3.0
3.2
Number of cylinders
R
bar abs
TIM-ID: 0000010904 - 001
Number of cylinders
6
6
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
*
R
°C
*
*
R
°C
-
-
L
°C
-
-
R
bar
*
*
R
bar
*
*
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
TIM-ID: 0000010904 - 001
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
6
6
CAPACITIES
Number of cylinders
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
Number of cylinders
6
6
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
114
115
R
dB(A)
116
116
TIM-ID: 0000010904 - 001
6798)
consumption
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G40F
G50F
3C
3C
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
Fuel stop power ISO 3046
A
kW
274
301
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
TIM-ID: 0000010921 - 001
SAE
01
01
Flywheel interface
DISC
14"
14"
Number of cylinders
R
bar abs
6
6
3.0
3.2
6
6
Number of cylinders
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
85
R
°C
*
100
R
°C
-
-
L
°C
-
-
R
bar
*
*
R
bar
*
*
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
TIM-ID: 0000010921 - 001
CAPACITIES
Number of cylinders
6
6
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
114
115
R
dB(A)
116
116
TIM-ID: 0000010921 - 001
6798)
emissions
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G40F
G50F
3C
3C
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
A
kW
274
301
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
SAE
01
01
Flywheel interface
DISC
14"
14"
TIM-ID: 0000010935 - 001
Number of cylinders
R
bar abs
6
6
3.0
3.3
6
6
Number of cylinders
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
*
R
°C
*
+
R
°C
-
-
L
°C
-
-
R
bar
*
*
R
bar
*
*
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
TIM-ID: 0000010935 - 001
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
CAPACITIES
Number of cylinders
6
6
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
114
115
R
dB(A)
116
117
TIM-ID: 0000010935 - 001
6798)
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G40F
G50F
3C
3C
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
A
kW
274
301
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
TIM-ID: 0000010948 - 001
SAE
01
01
Flywheel interface
DISC
14"
14"
6
6
3.0
3.2
Number of cylinders
R
bar abs
Number of cylinders
6
6
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
85
R
°C
*
100
R
°C
-
-
L
°C
-
-
R
bar
*
*
R
bar
*
*
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
Number of cylinders
Cold start capability: air temperature (w/o start aid. w/o preheat‐ R
ing) - (case A)
°C
-20
-20
Firing speed. from
R
rpm
80
80
Firing speed. to
R
rpm
120
120
6
6
CAPACITIES
Number of cylinders
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
TIM-ID: 0000010948 - 001
Number of cylinders
6
6
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
114
115
R
dB(A)
116
116
TIM-ID: 0000010948 - 001
6798)
consumption
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G70F
G80F
3D
3D
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
A
kW
274
301
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
SAE
01
01
Flywheel interface
DISC
14"
14"
TIM-ID: 0000010958 - 001
Number of cylinders
Charge-air pressure before cylinder - BL
R
bar abs
6
6
3.2
3.4
6
6
Number of cylinders
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
88
R
°C
*
94
R
°C
-
-
L
°C
-
-
R
bar
*
4.2
R
bar
*
4.8
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
TIM-ID: 0000010958 - 001
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
CAPACITIES
Number of cylinders
6
6
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
115
115
Engine surface noise with attenuated intake noise (filter) - BL
R
dB(A)
116
116
TIM-ID: 0000010958 - 001
Exhaust noise, unsilenced - BL (sound power level LW, ISO
6798)
emissions
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G70F
G80F
3D
3D
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
A
kW
274
301
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
TIM-ID: 0000010966 - 001
SAE
01
01
Flywheel interface
DISC
14"
14"
Number of cylinders
R
bar abs
6
6
3.3
3.4
6
6
Number of cylinders
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
85
88
R
°C
100
94
R
°C
-
-
L
°C
-
-
R
bar
*
4.2
R
bar
*
4.8
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
TIM-ID: 0000010966 - 001
CAPACITIES
Number of cylinders
6
6
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
115
116
R
dB(A)
117
116
TIM-ID: 0000010966 - 001
6798)
3.16 6R 1600 G70S, G80S engine data, EPA stage 3
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G70S
G80S
3D
3D
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1800
1800
A
kW
312
343
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
SAE
01
01
Flywheel interface
DISC
14"
14"
6
6
3.5
3.6
Number of cylinders
R
bar abs
TIM-ID: 0000010973 - 001
Number of cylinders
6
6
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
*
88
R
°C
*
94
R
°C
-
-
L
°C
-
-
R
bar
*
5.7
R
bar
*
6.0
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
TIM-ID: 0000010973 - 001
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
6
6
CAPACITIES
Number of cylinders
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
Number of cylinders
6
6
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
113
117
R
dB(A)
118
117
TIM-ID: 0000010973 - 001
6798)
Explanation:
DL
BL
A
G
R
L
N
X
*
Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Engine model
Application group
°C
Barometric pressure
mbar
m
6R 1600
6R 1600
G70F
G80F
3D
3D
25
25
1000
1000
100
100
Number of cylinders
6
6
Rated engine speed
A
rpm
1500
1500
A
kW
274
301
6
6
Number of cylinders
A
mbar
25
25
L
mbar
50
50
A
mbar
85
85
L
mbar
150
150
Number of cylinders
6
6
X
X
X
X
TIM-ID: 0000010979 - 001
SAE
01
01
Flywheel interface
DISC
14"
14"
6
6
3.2
3.4
Number of cylinders
R
bar abs
Number of cylinders
6
6
equipment)
A
°C
95
95
R
°C
105
105
L
°C
109
109
L
%
50
50
L
bar
0.7
0.7
6
6
LUBE-OIL SYSTEM
Number of cylinders
R
°C
85
88
R
°C
100
94
R
°C
-
-
L
°C
-
-
R
bar
*
4.2
R
bar
*
4.8
R
bar
L
bar
6
6
FUEL SYSTEM
Number of cylinders
starting)
L
bar
-0.5
-0.5
starting)
L
bar
0.0
0.0
6
6
Number of cylinders
ing) - (case A)
°C
-20
-20
Firing speed, from
R
rpm
80
80
Firing speed, to
R
rpm
120
120
6
6
CAPACITIES
Number of cylinders
ment)
R
Liters
45
45
R
Liters
-
-
R
Liters
-
-
R
Liters
45
45
TIM-ID: 0000010979 - 001
Number of cylinders
6
6
L
Liters
36
36
L
Liters
45
45
6
6
1150
1150
6
6
Number of cylinders
R
kg
ACOUSTICS
Number of cylinders
R
dB(A)
115
115
R
dB(A)
116
116
TIM-ID: 0000010979 - 001
6798)
3.18 Firing sequence
Firing sequence
2–4–1–5–3–6
TIM-ID: 0000010707 - 001
6R
3.19 Engine – Main dimensions
Engine – Main dimensions
approx. 1630 mm
Width (B)
approx. 920 mm
Height (C)
approx. 1185 mm
TIM-ID: 0000010029 - 001
Length (A)
4 Operation
4.1 Putting the engine into operation after extended out-ofservice-periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.
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 93).
Fuel system
Vent (→ Page 86).
Coolant circuit
If engine is out of service for more than one year, change engine coolant
(→ Page 97).
Coolant circuit
Check engine coolant level (→ Page 96).
Engine governor
Check plug-in connections (→ Page 108).
Monitoring equipment
Carry out lamp test (see manufacturer's documentation).
Engine/generator control
system
Switch ON;
TIM-ID: 0000000864 - 001
select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
68 | Operation | MS15022/02E 2012-04
4.2 Putting the engine into operation after scheduled out-ofservice-period
Preconditions
Startup
Item
Task
Lube oil system
Coolant system
Check engine coolant level (→ Page 96).
Monitoring equipment
Carry out lamp test (see manufacturer's documentation).
Engine/generator control
system
Switch ON;
TIM-ID: 0000000876 - 001
select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
MS15022/02E 2012-04 | Operation | 69
4.3 Engine start in manual operation (trials)
Preconditions
☑ Generator is not connected to network.
☑ External start interlock is not activated.
DANGER
WARNING
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• 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!
• Wear ear protectors.
Preparation
Item
Task
Operating mode selector
switch (if provided)
Change to manual mode.
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.
manufacturer)
Apply full load only after engine has reached operating temperature (cool‐
ant temperature approx. 60 °C).
TIM-ID: 0000000865 - 001
Engine
70 | Operation | MS15022/02E 2012-04
4.4 Safety system – Override
CAUTION
CAUTION
Safety functions and engine shutdown alarms will be disregarded.
Serious damage to plant!
• Initiate emergency start only in emergency situations.
Inadmissible operational condition.
Major material damage!
• Use override function only in hazardous situations to ensure full capability in case of engine mal‐
functions.
Preparation
Note:
This function is only available when a pushbutton is provided.
Bypassing the safety system (Override)
Item
Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
• Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
(→ Page 70).
manufacturer)
Control and display panels
During operation, check the displayed operational data (speed, tempera‐
ture, pressures).
TIM-ID: 0000000984 - 002
Constantly monitor plant limit values.
MS15022/02E 2012-04 | Operation | 71
4.5 Operational checks
DANGER
WARNING
• Take special care when working on a running engine.
Operational checks
Item
Action
Engine under load,
Visually inspect engine for leaks and general condition;
engine at nominal speed
Check for abnormal running noises and vibration;
Check exhaust color (→ Page 79).
Air filter
Check signal ring position of service indicator (→ Page 91).
Replace air filter (→ Page 89), if the signal ring is completely visible in the
service indicator control window.
Check relief bore for oil and coolant discharge and contamination
(→ Page 101).
Engine oil
Check engine oil level (→ Page 93)
TIM-ID: 0000000866 - 002
Engine coolant pump
72 | Operation | MS15022/02E 2012-04
4.6 Engine stop in manual operation (trials)
Preconditions
☑ Generator is not connected to network.
☑ Engine is running in manual mode.
Preparation
Item
Task
Engine
After the generator breaker has been opened, allow the engine to cool
down by running it idle for approx. 5 minutes.
Stop engine
Item
Task
TIM-ID: 0000000867 - 001
Switchgear cabinet, control Press stop button.
• Automatic stopping sequence is performed;
manufacturer)
• engine is stopped.
MS15022/02E 2012-04 | Operation | 73
4.7 Emergency engine shutdown
CAUTION
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Emergency engine shutdown
Item
Task
Emergency stop pushbut‐
ton
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
TIM-ID: 0000000868 - 001
Switchgear cabinet, control Press pushbutton for alarm acknowledgement.
• Audible and visual signalization stops.
manufacturer)
74 | Operation | MS15022/02E 2012-04
4.8 After stopping the engine – Engine remains ready for
operation
After stopping the engine
Action
Engine/generator/pump
control
Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
TIM-ID: 0000000983 - 002
Item
MS15022/02E 2012-04 | Operation | 75
4.9 After stopping the engine – Putting the engine out of
operation
Preconditions
After stopping the engine
Task
Coolant circuit
Drain engine coolant (→ Page 98) if:
• the engine room is not heated;
• the engine coolant is not maintained at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40°C.
Engine/generator/pump
control
Switch OFF.
TIM-ID: 0000000877 - 001
Item
76 | Operation | MS15022/02E 2012-04
5 Maintenance
5.1 Maintenance and servicing
Preface
Low operating and maintenance costs as well as operational reliability and availability depend on mainte‐
nance 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 en‐
sure trouble-free engine operation at all times. For this purpose always:
• ensure that sufficient fuel of approved quality is provided,
• ensure that the combustion air is dry and clean.
Notes on maintenance:
• Special care should be taken to keep the machinery plant in a clean and serviceable condition at all
times to facilitate detection of possible leaks and prevent consequential damage.
• Protect rubber and synthetic components from oil and fuel, never treat with organic detergents. Wipe
with a dry cloth only.
• Always replace all seals and gaskets. Our Product Support Service will always be available should
assistance be required.
MTU maintenance concept
The maintenance system for MTU products is based on preventive maintenance concept.
Preventive maintenance permits advance operational planning and increases availability. The mainte‐
nance 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 opera‐
tional 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 Mainte‐
nance Booklet. Exchange parts (reliabilt®) are available for components to be replaced.
Note:
The maintenance schedule matrix finishes with extended component maintenance. Following this, main‐
tenance work must then be continued at the specified intervals.
TIM-ID: 0000000869 - 003
The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a
list of approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications
A001063/.. Use only fluids and lubricants which comply with the MTU Fluids and Lubricants Specifica‐
tions.
The user/customer must perform the following additional maintenance tasks:
• Fuel prefilter:
The maintenance interval depends on how dirty fuel is. The filter elements of the fuel prefilters must
be replaced every 2 years at the latest.
• Battery:
Battery maintenance depends on duty and ambient conditions. The specifications of the battery manu‐
facturer apply.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
according to the Fluids and Lubricants Specifications, MTU Publication No. A001063/... .
MS15022/02E 2012-04 | Maintenance | 77
5.2 Maintenance task reference table
The maintenance tasks and intervals for this product are defined in the Maintenance Booklet. The Main‐
tenance Booklet is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Booklet.
Task
Check engine oil level
(→ Page 72)
Visually inspect engine for leaks and general con‐
dition
(→ Page 72)
Check signal ring position of service indicator, re‐
place air filter if necessary
(→ Page 72)
Replace fuel filter or fuel filter element
(→ Page 87)
Replace fuel prefilter or filter element of fuel prefil‐
ter
(→ Page 88)
Check cooler elements externally for dirt
Check drive belt condition and tension, replace if
necessary
(→ Page 105)
Replace air filter
(→ Page 89)
Replace engine oil filter at each oil change or
(→ Page 95)
when the time limit (years) is reached, at the latest
Check valve clearance, adjust if necessary. Atten‐
tion!First adjustment after 1,000 operating hours!
(→ Page 83)
Replace poly-vee belt of fan
(→ Page 105)
Replace drive belt of battery-charging generator (if (→ Page 105)
fitted) and coolant pump
TIM-ID: 0000023912 - 003
Table 1: Maintenance task reference table [QL1]
78 | Maintenance | MS15022/02E 2012-04
6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated
Component
Probable Cause
Task
Battery
Low or defective
Charge or replace (see manufacturer's
documentation).
Cable connections defective
Check whether cable connections are
properly secured (see manufacturer's
documentation).
Starter
Engine wiring or starter defective
Check whether cable connections are
properly secured, contact Service.
Engine wiring
Defective
Check (→ Page 106).
Engine/generator
control system
Secure seating of assemblies or con‐
nectors not provided
Perform visual inspection (see manu‐
facturer's documentation).
Engine governor
Plug-in connections are loose
Check plug-in connections
(→ Page 108).
Engine
Running gear blocked (engine cannot
be barred manually)
Contact Service.
Engine turns but does not fire
Component
Probable Cause
Task
Starter
Poor rotation by starter: Battery low or
defective
Charge or replace battery (see manu‐
facturer's documentation).
Engine wiring
Defective
Fuel system
Not vented
Vent fuel system (→ Page 86).
Engine governor
Defective
Contact Service.
TIM-ID: 0000000871 - 001
Engine fires unevenly
Component
Probable Cause
Task
Fuel injection equip‐
ment
Injector defective
Contact Service.
Engine wiring
Defective
Fuel system
Not vented
Engine governor
Defective
Contact Service.
Engine does not reach nominal speed
Component
Probable Cause
Task
Fuel supply
Easy-change fuel filter clogged
Replace (→ Page 87).
Air supply
Air filter clogged
Check signal ring position of service in‐
dicator (→ Page 91).
ment
Injector defective
Contact Service.
MS15022/02E 2012-04 | Troubleshooting | 79
Component
Probable Cause
Task
Engine wiring
Defective
Engine
Overload
Contact Service.
Engine speed not steady
Component
Probable Cause
Task
ment
Injector defective
Contact Service.
Speed sensor
Defective
Contact Service.
Fuel system
Not vented
Engine governor
Defective
Contact Service.
Charge-air temperature too high
Component
Probable Cause
Task
Engine room
Air-intake temperature too high
Check fans and air supply / ventilation
ducts.
Charge-air pressure too low
Component
Probable Cause
Task
Air supply
Air filter clogged
Exhaust turbocharger Defective
Contact Service.
Exhaust gas black
Component
Probable Cause
Task
Air supply
Air filter clogged
ment
Injector defective
Contact Service.
Engine
Overload
Contact Service.
Component
Probable Cause
Task
Engine oil
Too much oil in engine
Drain engine oil (→ Page 94).
Exhaust gas blue
Contact Service.
Exhaust gas white
Component
Probable Cause
Task
Engine
Not at operating temperature
Run up to operating temperature.
80 | Troubleshooting | MS15022/02E 2012-04
TIM-ID: 0000000871 - 001
Exhaust turbocharg‐ Defective
er, cylinder head, pis‐
ton rings, cylinder lin‐
er
7 Task Description
7.1 Engine
7.1.1
Engine – Barring with starting system
Preconditions
☑ External pushbutton “Bar engine without starting” is provided.
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.
Engine – Barring with starting system
Press pushbutton “Bar engine without starting” and keep depressed.
Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.
Repeat this procedure after approx. 20 seconds if required.
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2.
3.
MS15022/02E 2012-04 | Task Description | 81
7.1.2
DANGER
WARNING
Engine – Test run
• Before barring or starting the engine, make sure that nobody is in the danger zone.
Engine – Test run
Start engine (→ Page 70).
Perform test run not below 1/3 load and at least until steady-state temperature is reached.
Carry out operational checks (→ Page 72).
Stop engine (→ Page 73).
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2.
3.
4.
82 | Task Description | MS15022/02E 2012-04
7.2 Valve Drive
7.2.1
Valve clearance – Check and adjustment
Preconditions
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.
Special tools, Material, Spare parts
Designation / Use
Part No.
Qty.
Feeler gauge
Y20010128
1
Torque wrench, 20-200 Nm
F30451339
1
Box wrench, 14 mm
F30028346
1
Allen key, 5 mm
F30002815
1
Preparatory steps
1.
2.
Remove cylinder head cover (→ Page 85).
Bar engine manually in engine direction of rotation to bring the A1 piston to top dead center position.
Diagram: Two crankshaft positions
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1
2
E
A
Cylinder A1 is in firing TDC
Cylinder A1 is in overlap TDC
Inlet valve
Exhaust valve
Checking valve clearance at two crankshaft positions
1.
2.
3.
4.
5.
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.
Check valve clearance with cold engine:
• Inlet = 0.3 mm;
• Exhaust = 0.6 mm.
Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
per diagram.
Use feeler gauge to determine the distance between valve bridge and rocker arm.
If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance
1.
2.
3.
4.
5.
Result:
Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
Insert feeler gauge between valve bridge
and rocker arm (3).
Readjust adjusting screw (2) so that the
feeler gauge just passes through the gap.
Tighten locknut (1) with torque wrench to specified torque, holding adjusting screw (2) firm with Allen
screw.
Name
Size
Type
Nut
M10 x 1
Tightening torque
Lubricant
Value/Standard
43 Nm +4 Nm
Check if the feeler gauge just passes through between valve bridge and rocker arm (3).
If not, adjust valve clearance.
Final steps
Install cylinder head cover (→ Page 85).
Install plug.
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1.
2.
7.2.2
Cylinder head cover – Removal and installation
Preconditions
Cylinder head cover – Removal
and installation
1.
2.
3.
4.
Remove screws.
Remove cylinder head cover.
Clean installation surface.
Check condition of profile gasket and re‐
place if required.
5.
Fit cylinder head cover and tighten screws with torque wrench to specified tightening torque.
Size
Type
Screw with twin
collar
M8
Preload torque
Lubricant
Value/Standard
10 Nm
Tighten screws to specified torque using a torque wrench.
Name
Size
Type
Screw with twin
collar
M8
Tightening torque
Lubricant
Value/Standard
20 Nm ±2 Nm
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6.
Name
7.3 Fuel System
7.3.1
Fuel system – Venting
Preconditions
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Fuel system – Venting
1.
2.
Note:
3.
Catch emerging fuel with a suitable cloth.
Operate the pump with the handle (1) until
bubble-free fuel emerges.
Tighten nut (2) on banjo union.
Lock fuel priming pump, screw in handle
(1).
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4.
5.
Unlock fuel priming pump, screw out handle
(1).
Loosen nut (2) on banjo union.
7.4 Fuel Filter
7.4.1
Fuel filter – Replacement
Preconditions
Designation / Use
Filter wrench
Engine oil
Easy-change filter
WARNING
Part No.
Qty.
F30379104
1
(→ Spare Parts Catalog)
1
• Do not smoke.
Fuel filter – Replacement
1.
2.
3.
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4.
Remove easy-change filter using the filter
wrench.
Clean the sealing surface of the filter head.
Slightly lubricate seal on the easy-change
filter.
Screw on easy-change filter by hand until
the seal makes contact and then tighten by
hand.
7.4.2
Fuel prefilter – Replacement
Preconditions
☑ System is not under pressure.
Designation / Use
Filter wrench
Engine oil
Easy-change filter
WARNING
WARNING
CAUTION
Part No.
Qty.
F30379104
1
1
• Do not smoke.
Tank is pressurized.
Risk of injury!
• Allow pressure to escape slowly.
• Wear goggles or facial protection.
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanness.
Fuel prefilter – Replacement
1.
2.
3.
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4.
Remove easy-change filter (2) with filter
wrench.
Clean sealing surface on filter head (1).
Slightly lubricate seal on the easy-change
filter (2).
Screw on easy-change filter (2) by hand un‐
til the seal makes contact with the filter
head and tighten manually.
7.5 Air Filter
7.5.1
Air filter – Replacement
Designation / Use
Air filter
Part No.
Qty.
Air filter – Replacement
Remove air filter and install new one (→ Page 90).
Reset signal ring of service indicator (→ Page 91).
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2.
7.5.2
Air filter – Removal and installation
Preconditions
Air filter – Removal and installation
1.
2.
3.
4.
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5.
Release clamp (2).
Remove air filter (3) and clamp (2) from
flange of intake housing (1).
Verify that there are no objects in the flange
of the intake housing (1) and clean it.
Place new air filter (3) with clamp (2) onto
intake housing (1).
Tighten clamp (2).
7.6 Air Intake
7.6.1
Service indicator – Signal ring position check
Preconditions
Checking signal ring position
1.
2.
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Result:
Replace air filter, if the signal ring (2) is
completely visible in the red area of the
service indicator control window (3)
(→ Page 89).
After installation of new filter, press reset
button (1).
Signal ring returns to initial position.
7.7 Starting Equipment
7.7.1
Starter – Condition check
Preconditions
Checking starter condition
Check securing screws of starter for secure seating and tighten if required.
Check wiring (→ Page 106).
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2.
7.8 Lube Oil System, Lube Oil Circuit
7.8.1
Engine oil level – Check
Preconditions
Checking engine oil level prior to
engine start
1.
2.
3.
4.
5.
Remove oil dipstick (1) from guide tube and
wipe it.
Insert oil dipstick (1) into guide tube up to
the stop, withdraw after approx. 10 seconds
and check oil level.
Oil level must be between “min.” and “max.”
marks.
Top up with oil to the “max.” mark as neces‐
sary (→ Page 94).
Insert oil dipstick (1) in guide tube up to the
stop.
Oil level check after the engine is stopped
1.
2.
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3.
4.
5.
5 minutes after stopping the engine, remove oil dipstick (1) from the guide tube and wipe it.
Insert oil dipstick (1) into guide tube up to the stop, withdraw after approx. 10 seconds and check oil lev‐
el.
Oil level must be between “min.” and “max.” marks.
Top up with oil to the “max.” mark as necessary (→ Page 94).
Insert oil dipstick (1) in guide tube up to the stop.
7.8.2
Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
Designation / Use
Part No.
Qty.
Engine oil
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
1.
2.
Provide a suitable container in which to col‐
lect the oil.
Remove drain plug(s) (2) and drain oil.
3.
Insert drain plug (2) and use torque wrench to tighten to specified tightening torque.
Name
Size
Drain plug
4.
Type
Lubricant
Value/Standard
Tightening torque
(Engine oil)
100 Nm ±10 Nm
Replace engine oil filter (→ Page 95)
Filling with new oil
1.
2.
3.
4.
Open cap (1) on cylinder head cover.
Fill with oil, oil filling capacity (→ Product Summary - Technical Data).
Close cap (1) on cylinder head cover.
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Draining oil at drain plug on oil pan
7.9 Oil Filtration / Cooling
7.9.1
Engine oil filter – Replacement
Preconditions
Designation / Use
WARNING
Part No.
Qty.
F30510423
1
Ratchet adapter
F30027340
1
Socket, 32 mm
F30006120
1
Engine oil
Oil filter element
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Engine oil filter – Replacement
1.
2.
3.
4.
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5.
6.
7.
8.
Unscrew the oil filter covers (1) approx. 3 to
4 revolutions.
Wait 10 minutes until the oil has drained
from the filter housings.
Remove cover (1) with oil filter element (3)
and remove oil filter element (3) by pressing
on the bottom edge from the side.
Check condition of sealing ring (2) on cov‐
er.
Replace sealing ring (2) if damaged.
Coat sealing ring (2) with oil.
Insert new oil filter element (3) in cover (1)
and press in until it locks in place.
Screw on cover (1) with oil filter element (3) and tighten to the specified torque with a torque wrench.
Name
Cover
9.
10.
Size
Type
Lubricant
Value/Standard
Tightening torque
(Engine oil)
35 Nm
Replace further oil filters in the same way.
Check oil level (→ Page 93)
7.10 Coolant Circuit, General, High-Temperature Circuit
7.10.1
Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Coolant-level check at filler neck:
1.
2.
3.
4.
5.
6.
Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
Continue to turn breather valve counter‐
clockwise and remove.
Check coolant level (coolant must be visible
at the lower edge of the cast-in eye or at
the marking plate).
Top up with treated coolant as necessary
(→ Page 99).
Check breather valve (visual inspection)
and clean if necessary.
Place breather valve on filler neck and
close.
Coolant-level check by means of level sensor:
Switch on engine control system and check readings on the display.
Top up with treated coolant as necessary (→ Page 99).
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2.
7.10.2
Engine coolant – Change
Designation / Use
Part No.
Qty.
Engine coolant
Changing engine coolant
Drain engine coolant (→ Page 98).
Fill with engine coolant (→ Page 99).
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2.
7.10.3
Preconditions
Designation / Use
Part No.
Engine oil
Sealing ring
WARNING
Qty.
Preparatory steps
1.
2.
Provide an appropriate container to drain the coolant into.
Switch off preheater, if installed.
1.
4.
Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
Remove drain plug (1) and drain coolant.
5.
Insert drain plug with new sealing ring and use torque wrench to tighten to specified tightening torque.
2.
3.
Name
Size
Drain plug
6.
Type
Lubricant
Value/Standard
Tightening torque
(Engine oil)
70 Nm
Place breather valve on filler neck and close.
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7.10.4
Preconditions
Designation / Use
Part No.
Qty.
Engine coolant
WARNING
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1.
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2.
Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
1.
2.
3.
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.
Check proper condition of breather valve, clean sealing faces if required.
Fit breather valve and close it.
Final steps
Start the engine and operate it at idle speed for some minutes.
Check coolant level (→ Page 96), top up if required.
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2.
7.10.5
DANGER
WARNING
Engine coolant pump – Relief bore check
• Take special care when working on a running engine.
Engine coolant pump – Relief bore
check
1.
2.
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3.
Check relief bore (1) for engine coolant dis‐
charge.
• Permissible engine coolant discharge:
Up to 0.1 ml per hour respectively 100 ml
per 1,000 operating hours.
Stop engine (→ Page 73) and disable en‐
gine start.
If discharge exceeds the specified limits,
contact Service.
7.11 Belt Drive
7.11.1
Drive belt – Adjustment
Preconditions
Fan drive – Adjusting belt tension
1.
2.
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3.
4.
Slacken off screws (1).
Screw in nut (2) to set the required belt ten‐
sion.
Tighten screws (1).
Check drive belt tension for compliance
with specifications (→ Page 104).
7.11.2
Drive belt – Condition check
Preconditions
Checking belt condition
Findings
Action
Drive belt A
Singular cracks
None
Drive belt
Belt is oily, shows signs of over‐
heating
Fit new part (→ Page 105)
Drive belt B
Cracks on entire circumference
Drive belt C
Chunking
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Item
7.11.3
Drive belt – Tension check
Preconditions
Designation / Use
Part No.
Qty.
Tester
Y4345711
1
Belt tension tester, 500-1400 N
Y20097430
1
Y20097431
1
Fan drive – Checking belt tension
1.
2.
3.
4.
5.
6.
Remove protective cover.
Set belt tension tester onto the drive belt in
the middle between the belt pulleys (arrow).
Actuate pushbutton to press the tester uni‐
formly on the drive belt surface until the
spring disengages.
Do not press any further, otherwise the dis‐
play value will be falsified.
Take off tension tester without changing the
position of the display arm.
Read off measured value at the intersection
of display arm and "KG" scale. For specifi‐
cations, refer to table below.
Application
Fan drive belt
Measured value
Measured value
Initial assembly
Operating tension after
1 hour
Minimum operating ten‐
sion
2250 N
1620 N
1080 N
If the measured values deviate from the above specifications, readjust drive belt tension (→ Page 102).
Install protective cover.
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7.
8.
Measured value
7.11.4
Drive belt – Replacement
Preconditions
Designation / Use
Drive belt
Part No.
Qty.
Replacing fan drive belt
1.
2.
3.
4.
5.
Note:
6.
7.
8.
9.
10.
Remove protective cover from cooler.
Remove cooler.
Slacken off securing screws (1).
Screw out tension nut (2) as far as neces‐
sary to allow drive belt removal.
Check belt pulley on cooler bearing mount
and crankshaft for contamination and clean
if necessary.
When placing the drive belt in the grooves,
no force must be applied.
Fit new drive belt.
The fan bearing mount must be in contact
with the retainer (3) to allow belt tensioning.
Adjust and check belt tension
(→ Page 102).
Install fan.
Replacing drive belts of batterycharging generator and coolant
pump
1.
2.
3.
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Note:
4.
5.
6.
Remove protective cover.
Remove drive belt from fan drive
(→ Step 1).
Use appropriate tool to release the auto‐
matic belt tensioner at hexagon (1) and
take off drive belt (2).
When placing the drive belt in the grooves,
no force must be applied.
Fit new drive belt (2) and unload belt ten‐
sioner.
Install drive belt on fan drive (→ Step 1).
7.12 Wiring (General) for Engine/Gearbox/Unit
7.12.1
Engine wiring – Check
Preconditions
Designation / Use
Part No.
Qty.
Isopropyl alcohol
X00058037
1
Engine wiring – Check
1.
2.
3.
4.
5.
6.
Close male connectors that are not plugged in with the protective cap supplied.
Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
Ensure that all sensor connectors are securely engaged.
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Note:
7.
8.
Check securing screws of cable clamps on engine and tighten loose threaded connections.
Ensure that cables are fixed in their clamps and cannot swing freely.
Check that cable ties are firm, tighten loose cable ties.
Replace faulty cable ties.
Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
(→ Contact Service) if cable conductors are damaged.
7.13 Accessories for (Electronic) Engine Governor / Control
System
7.13.1
Engine governor and connectors – Cleaning
Preconditions
Note:
Designation / Use
Part No.
Qty.
Isopropyl alcohol
X00058037
1
Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
Engine governor and connectors – Cleaning
1.
2.
3.
Remove coarse dirt from housing surface with isopropyl alcohol.
Remove dirt from connector and cable surfaces with isopropyl alcohol.
Check legibility of cable labels. Clean or replace illegible labels.
Cleaning severely contaminated connectors on the engine governor
Seal unused connectors with the supplied protective cap.
Release the latch and pull off connectors.
Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
When connectors, sockets and all contacts are dry: Fit connectors and lock them.
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Note:
1.
2.
3.
7.13.2
Engine governor plug connections – Check
Preconditions
Checking engine governor plug
connections
1.
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2.
Check firm seating of all connectors on the
engine governor. Ensure that the clips (1)
are engaged.
Check firm seating of all screws (2) on en‐
gine governor cable clamps. Ensure that
cable clamps are not faulty.
8 Appendix A
8.1 Abbreviations
Abbreviation
Meaning
Explanation
A/D
Analog/Digital
Transformer: transforms sensor voltages into
numeric values
ADEC
Advanced Diesel Engine Controller
Engine management system
AFRS
Air Filter Restriction Sensor
ANSI
American National Standards Institute
Association of American standardization or‐
ganizations
ATL
Abgasturbolader
Exhaust turbocharger (ETC)
ATS
Air Temperature Sensor
BR
Baureihe
Series
BV
Betriebsstoffvorschrift
MTU Fluids and Lubricants Specifications,
Publication No. A01061/..
CAN
Controller Area Network
Data bus system, bus standard
CDC
Calibration Drift Compensation
Setting of drift compensation in engine gov‐
ernor with DiaSys
CEL
Stop Engine Light
1st function: Warning lamp (rectify fault as
soon as possible)
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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 Die‐
sel
DDL
Diagnostic Data Link
Diagnostic lines
DDR
Diagnostic Data Reader
Diagnostic unit
DIN
Deutsches Institut für Normung e. V.
At the same time identifier of German stand‐
ards (DIN = “Deutsche Industrie-Norm”)
DL
Default Lost
Alarm: Default CAN bus failure
DOC
Diesel Oxidation Catalyst
Oxidation catalyst upstream of the diesel
particulate filter
DPF
Diesel Particulate Filter
DT
Diagnostic Tool
Diagnostic unit
ECM
Electronic Control Module
Electronic control unit of the DDEC system
ECU
Engine Control Unit
Engine governor
EDM
Engine Data Module
Memory module for engine data
EEPROM
Electrically Erasable Programmable
Read Only Memory
EFPA
Electronic Foot Pedal Assembly
MS15022/02E 2012-04 | Appendix A | 109
Abbreviation
Meaning
EGR
Exhaust Gas Recirculation
EMU
Engine Monitoring Unit
ETK
Ersatzteilkatalog
EUI
Electronic Unit Injector
FPS
Fuel Pressure Sensor
FRS
Fuel - Differential Pressure Sensor
FTS
Fuel Temperature Sensor
Monitors fuel temperature
FWCP
Fire Water Control Panel
Control cabinet
GND
Ground
HD
Hochdruck
High Pressure (HP)
HI
High
Alarm: Measured value exceeds 1st maxi‐
mum limit
HIHI
High High
Alarm: Measured value exceeds 2nd maxi‐
mum limit value
HT
High Temperature
IDM
Interface Data Module
INJ
Injector
ISO
International Organization for Stand‐
ardization
International umbrella organization for all na‐
tional standardization institutes
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 mini‐
mum limit value
LOLO
Low Low
Alarm: Measured value lower than 2nd mini‐
mum limit value
LSG
Limiting Speed Governor
N/A
Not Applicable
LP
Low Pressure
OEM
Original Equipment Manufacturer
OI
Optimized Idle
OLS
Oil Level Sensor
Monitors oil level
OPS
Oil Pressure Sensor
Monitors oil pressure
OTS
Oil Temperature Sensor
Monitors oil temperature
OT
Oberer Totpunkt
Top Dead Center (TDC)
PAN
Panel
Control panel
PIM
Peripheral Interface Module
PWM
Modulated signal
P-xyz
Pressure-xyz
Pressure measuring point, xyz specifies the
measuring point designation
RL
Redundancy Lost
Alarm: Redundant CAN bus failure
110 | Appendix A | MS15022/02E 2012-04
Explanation
Spare Parts Catalog (SPC)
Monitors fuel pressure
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Memory module for interface data
Abbreviation
Meaning
Explanation
SAE
Society of Automotive Engineers
U.S. standardization organization
SD
Sensor Defect
Alarm: Sensor failure
SEL
Stop Engine Light
1st function: Warning lamp (stop engine and
rectify fault)
2nd function: Read out fault codes
SID
System Identifier
SRS
Synchronous Reference Sensor
TDC cylinder 1
SS
Safety System
Safety system alarm
TBS
Turbocharger Boost Sensor
Monitors charge-air pressure
TCI
Turbo Compressor Inlet
TCO
Turbo Compressor Outlet
TD
Transmitter Deviation
TPS
Throttle Position Sensor
TRS
Timing Reference Sensor
T-xyz
Temperature-xyz
Temperature measuring point, xyz specifies
the measuring point designation
UT
Unterer Totpunkt
Bottom Dead Center (BDC)
VNT
Variable Nozzle Turbine
VSG
Variable-Speed Governor
VSS
Vehicle Speed Sensor
WZK
Werkzeugkatalog
Alarm: Deviation in transmitter values
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Tool Catalog (TC)
MS15022/02E 2012-04 | Appendix A | 111
8.2 MTU contacts/service partners
Service
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
- either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
Spare parts service
Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
TIM-ID: 0000000873 - 013
Fax.: +49 7541 908121
112 | Appendix A | MS15022/02E 2012-04
9 Appendix B
9.1 Special Tools
Allen key, 5 mm
Part No.:
F30002815
Qty.:
Used in:
1
7.2.1 Valve clearance – Check and adjustment (→ Page
83)
Part No.:
Y20097431
Qty.:
Used in:
1
7.11.3 Drive belt – Tension check (→ Page 104)
Y20097430
Qty.:
Used in:
1
DCL-ID: 0000005207 - 005
Part No.:
MS15022/02E 2012-04 | Appendix B | 113
Box wrench, 14 mm
Part No.:
F30028346
Qty.:
Used in:
1
83)
Part No.:
Y20010128
Qty.:
Used in:
1
83)
Part No.:
F30379104
Qty.:
Used in:
1
7.4.1 Fuel filter – Replacement (→ Page 87)
Qty.:
Used in:
1
7.4.2 Fuel prefilter – Replacement (→ Page 88)
Part No.:
F30027340
Qty.:
Used in:
1
7.9.1 Engine oil filter – Replacement (→ Page 95)
Feeler gauge
Filter wrench
DCL-ID: 0000005207 - 005
Ratchet adapter
114 | Appendix B | MS15022/02E 2012-04
Socket, 32 mm
Part No.:
F30006120
Qty.:
Used in:
1
Part No.:
Y4345711
Qty.:
Used in:
1
Part No.:
F30510423
Qty.:
Used in:
1
Part No.:
F30451339
Qty.:
Used in:
1
83)
Tester
DCL-ID: 0000005207 - 005
MS15022/02E 2012-04 | Appendix B | 115
9.2 Index
A
Abbreviations 109
After stopping the engine – Engine remains ready for op‐
eration 75
Air filter
– Installation 90
– Removal 90
– Replacement 89
Auxiliary materials 12
Drive belt – Tension check 104
E
Engine
– Test run 82
– Wiring check 106
Engine coolant
– Change 97
Engine coolant pump
– Relief bore check 101
Engine coolant – Draining 98
Engine governor
– Cleaning 107
Engine layout 15
Engine oil filter – Replacement 95
Engine oil level – Check 93
Engine oil – Change 94
Engine side and cylinder designations 17
Engine wiring
– Check 106
Engine – Main dimensions 67
Environmental protection 12
F
Fire prevention 12
Firing sequence 66
Fluids and lubricants 12
Fuel filter – Replacement 87
Fuel prefilter – Replacement 88
Fuel system – Venting 86
G
General conditions 5
H
Hotline 112
M
Maintenance task reference table 78
Maintenance work
– Safety regulations 9
MTU contact persons 112
C
O
Connectors
– Cleaning 107
Contact persons 112
Cylinder head cover
– Installation 85
– Removal 85
Operation
Operational checks 72
D
R
Drive belt
– Condition check 103
Drive belt – Adjustment 102
Drive belt – Replacement 105
116 | Appendix B | MS15022/02E 2012-04
P
Personnel and organizational requirements 6
Relief bore
– Engine coolant pump – Check 101
Repair work
DCL-ID: 0000005207 - 005
6R 1600 B30S 50Hz engine data, optimized fuel con‐
sumption 23
sumption 20
6R 1600 B40S 50Hz engine data, optimized emissions 25
sumption 27
6R 1600 B40S 60Hz engine data, optimized emissions 29
sumption 31
6R 1600 G10F , G20F engine data, optimized exhaust
emissions 36
6R 1600 G10F , G20F engine data, optimized fuel con‐
sumption 33
6R 1600 G10F, G20F engine data, Nonroad stage III a 42
6R 1600 G10S, G20S engine data, EPA stage 3 39
emissions 48
sumption 45
emissions 57
sumption 54
6R 1600 G70S, G80S engine data, EPA stage 3 60
S
Safety instructions 14
Safety regulations 8, 9
Safety system
– Override 71
Sensors and actuators 18
Service partners 112
Spare parts service 112
Starter
– Condition check 92
Startup
V
Valve clearance – Check and adjustment 83
W
DCL-ID: 0000005207 - 005
Wiring - engine
– Check 106
MS15022/02E 2012-04 | Appendix B | 117

6R 1600 G10F/G20F, 6R 1600 G40F/G50F, 6R 1600 G70F

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