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MTU 10V1600 B40S, Operating Instructions Manual

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MTU 10V1600 B40S Operating Instructions Manual Download Page 124

7.13.2

Engine governor – Checking plug connections

Preconditions

☑

Engine is stopped and starting disabled.

Checking engine governor plug
connections

1.

Check firm seating of all connectors on the
engine governor. Ensure that the clips (1)
are engaged.

2.

Check firm seating of all screws (2) on en-
gine governor cable clamps. Make sure
that cable clamps are not defective.

MS150076/05E 2014-02

| Task Description | 123

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Summary of Contents for 10V1600 B40S

Page 1: ...12 V 1600 G40F G50F 8 10 12 V 1600 G40F G50F 8 10 12 V 1600 G70F G80F 8 10 12 V 1600 G70F G80F 8 12 V 1600 B30S 8 12 V 1600 B30S 8 10 V 1600 B40S B50F 8 10 V 1600 B40S B50F 12 V 1600 B40S 12 V 1600 B4...

Page 2: ...iedrichshafen GmbH This restriction also applies to copyright distribution translation mi copyright distribution translation mi crofilming and storage or processing on electronic crofilming and storag...

Page 3: ...iedrichshafen GmbH This restriction also applies to copyright distribution translation mi copyright distribution translation mi crofilming and storage or processing on electronic crofilming and storag...

Page 4: ...mi iz ze ed d 6 69 9 3 16 3 16 10V 160 10V 1600 B50F e 0 B50F engine ngine data o data optimi ptimized fu zed fuel el c co on ns su um mp pt ti io on n 7 72 2 3 17 3 17 10V 16 10V 1600 B5 00 B50F eng...

Page 5: ...lant pump Relief bore check 114 7 11 Belt Drive 115 7 11 1 Drive belt Adjustment 115 7 11 2 Drive belt Condition check 116 7 11 3 Drive belt Tension check 117 7 11 4 Drive belt Replacement 119 7 12 Wi...

Page 6: ...tion approved by the manufacturer in writ ing including engine control parameters In compliance with all safety regulations and in adherence with all warning notices in this manual In accordance with...

Page 7: ...r around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training C...

Page 8: ...kaging 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 e...

Page 9: ...o not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device Observe the safety data sheet Safety regu...

Page 10: ...rehand Hydraulic installation and removal Check satisfactory function and safe operating condition of tools jigs and fixtures to be used Use only the specified jigs and fixtures for hydraulic removal...

Page 11: ...eature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched for repa...

Page 12: ...are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncomplian...

Page 13: ...or before device or tool is to be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in area...

Page 14: ...f a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Ma...

Page 15: ...ankcase 12 Engine mounting 13 Exhaust turbocharger 14 Oil dipstick 15 Oil pan 16 Fuel filter 17 Flywheel 18 Flywheel housing Engine model designation Key to the engine model designation 8 10 12V 1600...

Page 16: ...and side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at the driving end The numbering of...

Page 17: ...oolant temperature 3 B48 2 HP fuel B side 4 XY39 B1 XY39 B2 Injectors B side 5 B9 Charge air temperature 6 B10 Charge air pressure 7 XY39 A1 XY39 A2 Injectors A side 8 B48 1 HP fuel A side 9 B5 Lube o...

Page 18: ...toring of 1 M8 1 Fuel pump HDP A time measurement unit 2 M8 2 Fuel pump HDP B time measurement unit 3 B1 Camshaft TDC 4 B13 Crankshaft speed MS150076 05E 2014 02 General Information 17 T I M I D 0 0 0...

Page 19: ...B 3B 3B Intake air temper ature C 25 25 25 25 25 25 Barometric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are...

Page 20: ...Charge air pres sure before cylin der DL R bar abs 2 9 3 0 2 65 2 92 3 0 3 4 COOLANT SYSTEM HT circuit Number of cylin ders 8 8 10 10 12 12 Coolant tempera ture at engine connection outlet to cooling...

Page 21: ...TEM Number of cylin ders 8 8 10 10 12 12 Fuel pressure at engine inlet con nection min when engine is starting L bar 0 5 0 5 0 5 0 5 0 5 0 5 Fuel pressure at engine inlet con nection max when engine i...

Page 22: ...dard oil system Op tion max operat ing inclinations L Liters 43 43 53 53 64 64 WEIGHTS MAIN DIMENSIONS Number of cylin ders 8 8 10 10 12 12 Engine weight dry basic engine configuration acc to scope of...

Page 23: ...ric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylin ders 8 8 1...

Page 24: ...a ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off e...

Page 25: ...pm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 120 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engine side without cooling equip ment R Liters 50 50 60 60 6...

Page 26: ...49 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhaust noise un silenced DL sound power lev el LW ISO 6798 3dB A tol erance R dB A 121 121 121 122 121 122 Engine surface noise with attenu...

Page 27: ...c pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylin ders 8 8 10...

Page 28: ...ra ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off...

Page 29: ...pm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 120 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engine side without cooling equip ment R Liters 50 50 60 60 6...

Page 30: ...49 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhaust noise un silenced DL sound power lev el LW ISO 6798 3dB A tol erance R dB A 121 121 121 122 121 122 Engine surface noise with attenu...

Page 31: ...e power as per ISO 3046 Number of cylinders 8 8 10 12 12 Rated engine speed A rpm 1800 1800 1800 1800 1800 Continuous power ISO 3046 10 overload capability de sign power DIN 6280 ISO 8528 A kW 371 408...

Page 32: ...mpera ture before engine to R C 100 100 101 101 101 Lube oil operating pressure before engine from R bar 4 5 4 5 4 5 4 5 4 5 Lube oil operating pressure before engine to R bar 5 4 5 4 5 4 5 4 5 4 FUEL...

Page 33: ...tandard oil sys tem Option max operating inclinations L Liters 43 43 53 64 64 WEIGHTS MAIN DIMENSIONS Number of cylinders 8 8 10 12 12 Engine weight dry basic en gine configuration acc to scope of sup...

Page 34: ...5 25 25 25 25 25 Barometric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Nu...

Page 35: ...a ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off e...

Page 36: ...at ing case A R C 20 20 20 20 20 20 Firing speed from R rpm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 120 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engi...

Page 37: ...of cylin ders 8 8 10 10 12 12 Engine weight dry basic engine configuration acc to scope of supply specification R kg 1444 1444 1749 1749 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhau...

Page 38: ...25 25 25 25 25 25 Barometric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046...

Page 39: ...a ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off e...

Page 40: ...at ing case A R C 20 20 20 20 20 20 Firing speed from R rpm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 120 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engi...

Page 41: ...of cylin ders 8 8 10 10 12 12 Engine weight dry basic engine configuration acc to scope of supply specification R kg 1444 1444 1749 1749 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhau...

Page 42: ...LATED DATA power ratings are net brake power as per ISO 3046 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 GENERAL CONDITIONS...

Page 43: ...bar 5 4 5 4 5 4 5 4 FUEL SYSTEM Number of cylinders 8 8 10 10 Fuel pressure at engine inlet connection min when engine is starting L bar 0 5 0 5 0 5 0 5 Fuel pressure at engine inlet connection max w...

Page 44: ...ONS Number of cylinders 8 8 10 10 Engine weight dry basic engine configu ration acc to scope of supply specifica tion R kg 1444 1444 1749 1749 ACOUSTICS Number of cylinders 8 8 10 10 Exhaust noise uns...

Page 45: ...DATA power ratings are net brake power as per ISO 3046 Number of cylinders 8 8 12 12 Rated engine speed A rpm 1800 1800 1800 1800 Fuel stop power ISO 3046 A kW 408 408 613 613 GENERAL CONDITIONS for...

Page 46: ...ar 5 4 5 4 5 4 5 4 FUEL SYSTEM Number of cylinders 8 8 12 12 Fuel pressure at engine inlet connection min when engine is starting L bar 0 5 0 5 0 5 0 5 Fuel pressure at engine inlet connection max whe...

Page 47: ...ONS Number of cylinders 8 8 12 12 Engine weight dry basic engine configu ration acc to scope of supply specifica tion R kg 1444 1444 2022 1950 ACOUSTICS Number of cylinders 8 8 12 12 Exhaust noise uns...

Page 48: ...5 25 25 25 Barometric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number o...

Page 49: ...a ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off e...

Page 50: ...at ing case A R C 20 20 20 20 20 20 Firing speed from R rpm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 120 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engi...

Page 51: ...of cylin ders 8 8 10 10 12 12 Engine weight dry basic engine configuration acc to scope of supply specification R kg 1444 1444 1749 1749 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhau...

Page 52: ...5 25 25 25 25 25 Barometric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Nu...

Page 53: ...a ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off e...

Page 54: ...pm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 10 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engine side without cooling equip ment R Liters 50 50 60 60 65...

Page 55: ...49 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhaust noise un silenced DL sound power lev el LW ISO 6798 3dB A tol erance R dB A 121 121 121 122 121 122 Engine surface noise with attenu...

Page 56: ...C 25 25 25 25 25 25 Barometric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 304...

Page 57: ...a ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off e...

Page 58: ...pm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 120 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engine side without cooling equip ment R Liters 50 50 60 60 6...

Page 59: ...49 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhaust noise un silenced DL sound power lev el LW ISO 6798 3dB A tol erance R dB A 121 121 121 122 121 122 Engine surface noise with attenu...

Page 60: ...LATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 8 8 10 10 Rated engine speed A rpm 1500 1500 1500 1500 Fuel stop power ISO 3046 A kW 394 394 448 493 GENERAL CONDITIONS...

Page 61: ...4 5 4 5 4 5 Lube oil operating pressure before engine to R bar 5 4 5 4 5 4 5 4 FUEL SYSTEM Number of cylinders 8 8 10 10 Fuel pressure at engine inlet connection min when engine is starting L bar 0 5...

Page 62: ...ating inclinations L Liters 43 43 53 53 WEIGHTS MAIN DIMENSIONS Number of cylinders 8 8 10 10 Engine weight dry basic engine configu ration acc to scope of supply specifica tion R kg 1444 1444 1749 1...

Page 63: ...over load capability design power DIN 6280 load capability design power DIN 6280 ISO 8528 ISO 8528 A k A kW W 3 32 25 5 3 37 71 1 5 52 24 4 5 56 61 1 F Fu ue el l s st to op p p po ow we er r I IS SO...

Page 64: ...nd de er rs s 8 8 8 8 1 12 2 1 12 2 Fuel pressure at engine inlet Fuel pressure at engine inlet connection connection min when engine is starting min when engine is starting L L b ba ar r 0 0 5 5 0 0...

Page 65: ...98 3dB A toler ance ance R R d dB B A A 1 12 21 1 1 12 23 3 1 12 21 1 1 12 20 0 Exhaust noise unsilenced BL Exhaust noise unsilenced BL free field free field sound pressure level Lp 1m distance ISO so...

Page 66: ...es sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylin ders 8 8 10 10 1...

Page 67: ...ra ture after engine warning R C 105 105 105 105 105 105 Coolant tempera ture after engine shutdown L C 109 109 109 109 109 109 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off...

Page 68: ...pm 80 80 80 80 80 80 Firing speed to R rpm 120 120 120 120 120 120 CAPACITIES Number of cylin ders 8 8 10 10 12 12 Engine coolant capacity engine side without cooling equip ment R Liters 50 50 60 60 6...

Page 69: ...49 2022 2022 ACOUSTICS Number of cylin ders 8 8 10 10 12 12 Exhaust noise un silenced DL sound power lev el LW ISO 6798 3dB A tol erance R dB A 121 121 121 122 121 122 Engine surface noise with attenu...

Page 70: ...A power ratings are net brake power as per ISO 3046 Number of cylinders 10 Rated engine speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 448 GENERA...

Page 71: ...ar 0 5 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 GENERAL OPERATING DATA Number of cylinders 10 Cold start capability air temperature w o start aid w o preheating c...

Page 72: ...ACOUSTICS Number of cylinders 10 Exhaust noise unsilenced DL sound power level LW ISO 6798 3dB A toler ance R dB A 122 MS150076 05E 2014 02 Technical Data 71 T I M I D 0 0 0 0 0 2 0 1 7 5 0 0 2...

Page 73: ...DATA power ratings are net brake power as per ISO 3046 Number of cylinders 10 Rated engine speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 448 GEN...

Page 74: ...ar 0 5 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 GENERAL OPERATING DATA Number of cylinders 10 Cold start capability air temperature w o start aid w o preheating c...

Page 75: ...ACOUSTICS Number of cylinders 10 Exhaust noise unsilenced DL sound power level LW ISO 6798 3dB A toler ance R dB A 122 74 Technical Data MS150076 05E 2014 02 T I M I D 0 0 0 0 0 2 0 1 7 9 0 0 2...

Page 76: ...TA power ratings are net brake power as per ISO 3046 Number of cylinders 10 Rated engine speed A rpm 1500 Continuous power ISO 3046 10 overload capability design power DIN 6280 ISO 8528 A kW 448 GENER...

Page 77: ...ar 0 5 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 GENERAL OPERATING DATA Number of cylinders 10 Cold start capability air temperature w o start aid w o preheating c...

Page 78: ...ACOUSTICS Number of cylinders 10 Exhaust noise unsilenced DL sound power level LW ISO 6798 3dB A toler ance R dB A 122 MS150076 05E 2014 02 Technical Data 77 T I M I D 0 0 0 0 0 2 0 1 8 5 0 0 2...

Page 79: ...V 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 78 Techn...

Page 80: ...8 V 10 V 12 V approx approx 1470 mm approx 1620 mm Width B 8 V 10 V 12 V approx 1240 mm approx 1240 mm approx 1240 mm Height C 8 V 10 V 12 V approx 1185 mm approx 1185 mm approx 1185 mm MS150076 05E 2...

Page 81: ...Represervation Specifications A001070 Lube oil system Check engine oil level Page 106 Fuel system Vent Page 99 Engine coolant circuit If engine is out of service for more than one year change engine c...

Page 82: ...Task Lube oil system Check engine oil level Page 106 Coolant system Check engine coolant level Page 109 Monitoring equipment Carry out lamp test see manufacturer s documentation Engine generator contr...

Page 83: ...e switch if fitted Change to manual mode Starting the engine Item Action Switchgear cabinet control panel etc depending on manufacturer Press start button Automatic starting sequence is performed Engi...

Page 84: ...pushbutton is provided Safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown criteria an...

Page 85: ...d Visually inspect engine for leaks and general condition Check for abnormal running noises and vibration Check exhaust color Page 91 Air filter Check signal ring position of service indicator Page 10...

Page 86: ...ne ed d a al ll lo ow w t th he e e en ng gi in ne e t to o c co oo ol l d do ow wn n by running it idle for approx 5 minutes by running it idle for approx 5 minutes Stop engine Stop engine I It te e...

Page 87: ...is stopped by disconnecting the power supply to the Engine is stopped by disconnecting the power supply to the ECU ECU signalization e g by horn flashing lamp is signalization e g by horn flashing lam...

Page 88: ...er stopping the engine I It te em m A Ac ct ti io on n Engine generator pump Engine generator pump control control Select operating mode e g MANUAL AUTOMATIC OPERATION Select operating mode e g MANUAL...

Page 89: ...it Drain engine coolant Page 111 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 tem pe...

Page 90: ...k 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 condi tion...

Page 91: ...ilter or fuel filter element Page 100 Replace fuel prefilter or filter element of fuel prefilter Page 101 Check cooler elements externally for dirt Check drive belt condition and tension replace if ne...

Page 92: ...rred 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 manufac turer s docum...

Page 93: ...Air supply Air filter clogged Check signal ring position of service in dicator Page 104 Exhaust turbocharger Defective Contact Service Exhaust gas black Component Probable Cause Task Air supply Air f...

Page 94: ...lled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Engine Barring with starting system 1 Press pushbutton Bar engine without starti...

Page 95: ...sons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 82 2 Perform test run...

Page 96: ...key set 2 10 mm F30453050 1 Barring gear F6790714 1 Preparatory steps 1 Remove cylinder head cover Page 98 2 Remove cover on the bottom of flywheel housing A side 3 Install barring gear at opening 4...

Page 97: ...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...

Page 98: ...pecified torque using a torque wrench holding adjusting screw 2 firm with Al len key 5 mm Name Size Type Lubricant Value Standard Nut M10 x 1 Tightening torque 43 Nm 4 Nm 5 Check if the feeler gauge j...

Page 99: ...1 Remove screws 2 Remove cylinder head cover 3 Clean mating faces 4 Check condition of profile gasket and re place if required 5 Fit cylinder head cover and tighten screws with torque wrench to the s...

Page 100: ...ignition sources Do not smoke Venting fuel system 1 Unlock fuel priming pump screw out han dle 2 2 Loosen nut 1 on banjo union Note Catch emerging fuel with a suitable cloth 3 Operate the pump with th...

Page 101: ...els are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing fuel filter 1 Remove easy change filter using the filter wrench 2 Clean s...

Page 102: ...ssure escaping under high pressure Ope Open tan n tank sl k slowl owly y Wear g Wear goggl oggles or s es or safety afety mask mask NOTICE NOTICE Contamination of components Contamination of component...

Page 103: ...Spare Parts Catalog Spare Parts Catalog Air filter Replacement Air filter Replacement 1 1 Rem Remove ove air air fil filter ter and and ins instal tall n l new ew one one P Page age 103 103 2 2 Res Re...

Page 104: ...m connecting flange of intake housing 3 connecting flange of intake housing 3 3 3 Ve Veri rify fy th that at th ther ere a e are re no no ob obje ject cts i s in t n the he flange of the intake housin...

Page 105: ...gnal 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 102 2 After installation of new filter press reset but...

Page 106: ...onditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 121 MS150076 05E 2014 02...

Page 107: ...arks 4 If necessary top up to max mark Page 107 5 Insert oil dipstick 1 in guide tube up to the stop Checking oil level after engine is stopped 1 5 minutes after stopping the engine remove oil dipstic...

Page 108: ...gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Draining oil at drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug 2 and drain...

Page 109: ...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 press ing...

Page 110: ...ounterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visi ble at the lower edge of the ca...

Page 111: ...al tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 111 2 Fill with engine coolant Page 112 110 Task Description MS150076 05E 2014 02 T...

Page 112: ...lve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off separated corrosion i...

Page 113: ...d coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 of coolant expan sion ta...

Page 114: ...ps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 109 top up with coolant if required MS150076 05E 2014 02 Task Description 113 T I M I D 0 0 0 0 0 0 0 9 0...

Page 115: ...nning Risk of damage to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore 1 for coolant discharge Permissible engine coolant discharge Up to 0 1 ml per hour respect...

Page 116: ...belt tension for compliance with specifications Page 117 Engine coolant pump drive Belt tension adjustment engine with mechanical belt tensioner 1 Slacken off screws 1 and locknut 3 2 Screw in adjusti...

Page 117: ...bled Checking condition Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Fit new part Page 119 Drive belt C Chunking Drive belt Fouling by oil overhea...

Page 118: ...below Application Measured value Initial assembly Measured value Operating tension after 1 hour Measured value Minimum operating tension Fan drive belt 2250 N 1620 N 1080 N 7 If the measured values de...

Page 119: ...hour Measured value Minimum operating tension Fan drive belt 1000 N 720 N 480 N 7 If the measured values deviate from the specifications above adjust drive belt tension Page 115 8 Install protective...

Page 120: ...d 6 Fit new drive belt 7 The fan bearing mount must be in contact with the retainer 2 to allow belt tension ing 8 Adjust and check drive belt tension Page 115 9 Install fan 10 Install protective cover...

Page 121: ...sting screw 2 on mechanical belt tensioner 4 and take off drive belt Note When placing the drive belt in the grooves no force must be applied 5 Fit new drive belt 5 and tighten adjusting screw 2 on me...

Page 122: ...freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Contacts Soc...

Page 123: ...se dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or repla...

Page 124: ...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 en gine governor cable clamps Make...

Page 125: ...n as possible 2nd function Read out fault codes CCT Circuit CLS Coolant level sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant pressure sensor Monitors coolant p...

Page 126: ...maximum limit HT High Temperature IDM Interface Data Module Memory module for interface data IIG Initiale Injektorgleichstellung Initial input of injector code with DiaSys in engine governor INJ Injec...

Page 127: ...odes SID System Identifier SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety System Security Shutdown Safety system alarm TBS Turbocharger Boost Sensor Monitors charge air pressure TCI Turbo C...

Page 128: ...in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541 907777...

Page 129: ...ce Check and adjustment Page 95 Barring gear Part No F6790714 Qty Used in 1 7 2 1 Valve clearance Check and adjustment Page 95 Belt tension tester 1300 3100 N Part No Y20097431 Qty Used in 1 7 11 3 Dr...

Page 130: ...1 Valve clearance Check and adjustment Page 95 Feeler gauge Part No Y20098771 Qty Used in 1 7 2 1 Valve clearance Check and adjustment Page 95 Filter wrench Part No F30379104 Qty Used in 1 7 4 1 Fuel...

Page 131: ...1 7 9 1 Engine oil filter Replacement Page 108 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 7 2 2 Cylinder head cover Removal and installation Page 98 Qty Used in 1 7 9 1 Engine oil filter...

Page 132: ...d 51 8 10 12V 1600 G40F G50F optimized fuel consump tion 55 8 10 12V 1600 G70F G80F emissions optimized 33 8 10 12V 1600 G70F G80F optimized fuel consump tion 37 8 10 12V 1600 G80S EPA Tier 2 3 47 8 1...

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