@irs Generating sets OPERATING AND MAINTENANCE MANUAL MODEL: MP 600 M SERIAL NO.: G 2828 YEAR OF MANUFACTURE: 2021 TTS Martin, s.r.0., 038 42 Rakovo 92, Slovakia Tel.: 043-4294 466, service no, 0903 523 102, www.tts-martin.skTECHNICAL SPECIFICATION General information ‘Generating set model _ Year of manufacture / serial number Version / noise level MP 600M. 2021 / G 2828 Canopied/ 95 LWA Exhaust silencer REZIDENTIAL Type of operation STAND - BY 595 kVA/ 476 kW. Limited time power 655 KVA/ 524 kW Current 859 A Voltage 3x240/405V Phases 3 Power factor cos @ 08 Frequency 50 Hz Speed 1500 rpm Intermal manufacturer number Dimensions and Weight 7116-00-9002 Length 5235 mm Width 2245 mum Height 2245 mm Weight 6905 kg Engine Producer MTU Type T2V 1600 GIOF Speed regulation Electronic Performance class B Starting _ Electric Battery voltage 24V DC Battery capacity 2x 110 Ah Cooling system Water Coolant volume 991 Engine oil volume 721 Fuel Diesel Fuel tank capacity 10001 Fuel consumption Consumption at prime power T19 Th Consumption at 75% of prime power (information only) 93. Uh Consumption at 50% of prime power (information only) ~ 67h Consumption at 25% of prime power (information only) 39h ‘Synchronous alternator Producer MARELLI T, MIB 355 MAG ‘Voltage regulation Elektronie Voltage regulation precision 15% Protection level _ 1P 23 Insulation class Connection engine - alternator H SAE WdControl board Type MP AUTOMATIC Serial number 62828 Current 1000 A Control unit TL4 AMF9 Frequene 50 Hz | Voltage 3x 230/400 V Phases 3 Degree of protection against contact voltage STNEN 61 439-1 SIN EN 61439-2 Wiring diagram number 5020-65-2828 ‘Auxiliary circuits voltage 24V DC Protection degree TP 40/20 Control board Type MP ATS Serial number G 2828 Current 1000 A Control unit - Frequency 50 Hz Voltage 3x 230/400 V Phases 3 Degree of protection against contact voltage STNEN 61 439-1 STN EN 61439-2 Wiring diagram number 5020-65-2828 ‘Auxiliary circuits voltage 230 VAC Protection degree TP 55/00 Notes: Manufacturer reserves right to make modification by innovation and improving technical characteristics and safety of the products while keeping its functional characteristics. In case of any disbelieves in this operating and maintenance manual do not hesitate to contact our company Nominal environmental conditions See level 100m ‘Ambient temperature 25°C Max. ambient temperature 40°C Relative humidity 30%GENERAL DESCRIPTION AND SAFETY INSTRUCTIONS ‘An electric generating set (Gen-set) is a machine that is composed of: ~ combustion engine with its systems ( electric, fuel, exhaust, air inlet, cooling), ~ generator of electric energy, ~ common frame (that can be open or with a canopy), ~ electric panels (control, power, combined, ATS), A combustion engine is connected to a generator of electric energy and together their create 2 mono-block. Depending on the type of generator the engine - generator connection can be: ~ single bearing generator: solid connection by flange and coupling disc ~ double bearing generator: flexible connection by flange, shaft and flexible coupling The mono-block is mounted through flexible elements (silent-blocks) onto a common base frame. The gen-set frame usually includes electric panel(s), fuel tank and for additional surcharge also retention bath. Gen-set accessories: Electric panels: - MP MANUAL is a panel, that together with a basic gen-set creates a source of electric energy controlled manually by operator, but with automatic operation; it always includes a controlling section with an automatic control and can also include a power section, - MP AUTOMATIC is a panel that together with a basic gen-set creates an automatic source of electric energy; it always includes a controlling section with an automatic control and can also include a power section, - MP PARALLEL is a panel that together with a basic gen-set creates an automatic source of electric energy, which can operate according to design, either parallel with other gensets or with the mains; it always includes a controlling section with an automatic control and can also include a power section, ~ MP MAIN is a panel that includes power components of electricity output (if they are not included in other panels), - MP ATS is a panel that switches power supply of backup circuits between the mains and generator. ~ fuel tank of is situated under the gen-set and it is designed for approximately 8 hours (for surcharge 24 hours) of normal gen-set operation under average output of 75% PRP, - separate or integrated retention bath is a device that is situated under the gen-set and in the case of oil, fuel or coolant leaking from the gen-set, it is able to capture their full volume. TRANSPORTATION OF THE GEN-SET Transportation of the gen-set is possible by all standard transport vehicles. During the transport it is strongly recommended to anchor gen-set using its anchoring or lifting points. During the manipulation with the gen-set with a crane it is necessary to use the lifting eyes, which are constructed on the gen-set frame and respect its correct hoisting method (liftingcapacity of the device and its components including tackles and chains or slings, correct length of hoisting chains or straps, safety instructions according to valid regulations, etc.) The lifting openings are shown on the picture A. Depending on the gen-set design, according to attached specification, it is necessary to proceed according to the correct picture. The lifting openings are also marked on the machine by symbol according to picture B. Manipulation of the gen-set is possible also with help of lifting devices such as pallet jacks, forklifts, etc. INSTALLATION OF GEN-SETS Gen-set has to be installed on a flat horizontal hard reinforced pad (concrete base, concrete footing, paver blocks) while it does not need to be anchored. Anchoring is needed, if the gen-set is placed on a loose unsecured surface, or a surface with a small inclination (possibility of movement while the gen-set is operating). Installation of the gen-set must be performed only by sufficiently qualified personnel with the relevant license. After the installation only a person authorized by the manufacturer can put the device into operation. SAFETY COMPONENTS Clearly visible and marked safety components are installed on the gen-set (covers of rotating components, covers of exhaust manifold, etc.). These protect operating personnel from injuries. Safety components can be dismounted only in necessary events (repair) and before dismounting the gen-set must be secured to avoid its start. Under no circumstances can the gen-set be put into operation if the safety components are dismounted! Flawless condition of the safety components, their cleanness and fixation to the gen-set must be regularly inspected with every test mode. Placement of the safety components is marked on the drawing "ARRANGEMENT OF THE GEN-SET COMPONENTS". IMPORTANT WARNINGS Always follow "Instructions for operators" and "Operation manual", which are located in the engine room. The gen-set is an electric machine that consists of live and rotating components. That is the reason why entry to the engine room or canopy is allowed only to instructed personnel which is aware of impeding risks, which can be source of an accident, injury, illness or even death. Gen-set is a machine that is a source of noise, vibration and heat, because of that always use the recommended protective gear and tools, and at the same time follow instructions given at operators training. With the gen-set in operation, limit your stay in the engine room only for the time needed to execute an inspection and maintenance of the machine. While the gen-set is operating use an ear protection, because the level of noise exceeds limits allowed by the sanitary norms. This general description serves for a basic orientation and before executing any work or intervention on the machine the assigned operator is obliged to fully understand the relevant manuals for operation and maintenance of the engine, generator, automatic control and other components. These manuals are inseparable items of the machine and in case they are damaged or lost, they need to be acquired from the manufacturer the sameWay as any other spare part. In case of differences between this general description and the related manual for operation and maintenance of the engine, generator, automatic control, or other components, always follow the related manual instead of this general description, Pic, AZ Pic, A3 Pic. BPUTTING GEN-SETS INTO OPERATION Before starting the gen-set thoroughly read and respect warnings and rules that are contained in the manual for operation and maintenance of the gen-set. A The gen-set is equipped with an electric panel, that can give a signal to start. Due to that you have to secure the gen-set to switched off state on the control panel before any inspection of the gen-set. 1, Secure that operation switch of the gen-set or a start key is in the position “OFF” "SWITCHED OFF" and TOTAL STOP or MAIN SWITCH is pushed in. 2. Check levels of the engine oil, fuel and coolant. Electric generating sets MARTIN POWER (manufactured by TTS Martin, s.r.o.) are supplied with engines filled by lubricating oil type SAE 15W-40 (if not mentioned otherwise directly on the engine). Due to that you have to check before starting and after a short period of operation if the oil level reaches the upper mark on a level gauge. If the air cleaner is an oil bath type fill its bath up to the mark by the same type of oil. Also fill a case of the injection pump by the same type of oil (if itis required by a manufacturer of the engine according to the related operation and maintenance manual). Fill up the fuel tank by diesel fuel (lower heating value 10 000 kcal/kg) and then bleed air from the fuel filters and fuel lines (see the engine's Operation manual). Caution: if the fuel tank is filled by insufficient amount, then the control panel lights the warning signal for using the fuel reserve. A While filling the fuel tank, pay maximal attention to purity, so that impurities or unwanted liquid will not enter the fuel tank. It is strictly forbidden to smoke or use open flame near the fuel tank. At first filling of the engine with a coolant, open air bleeding vents located on the engine, place containers under them to catch any spillage and fill the system through related filling cap until the coolant starts to spili through the vents. After a short time of operating the engine, check if the level of the coolant has not decreased, because air bubbles could remain in cooling circuit during the first filling. If the coolant is decreased it is necessary to top it up. It is essential to use the cooling liquid specified by the manufacturer of the combustion engine (its type is listed in operation and maintenance manual of the engine).Never open cap on the radiator if the engine is hot because the system contains a hot liquid under pressure! Never overfill the cooling system, because that can cause an excessive leaking of the coolant through overflow hose. 3. Check the tension and condition of the V-belt on the alternator and the fan. Adjust or replace the belt (see operation and maintenance manual of the engine) if necessary. 4. Check the condition of the connecting pipes and if they are damaged or have signs of wear replace them immediately, 5. Check terminals of the accumulator batteries, especially their oxidation. If necessary, clean and protect them with petroleum jelly or other appropriate product. A To avoid an explosion during maintenance, do not smoke, neither use open flame nearby the accumulator batteries. 6. If the gen-set uses classic accumulator batteries regularly check their electrolyte level and if necessary top them up with distilled water (see operation and maintenance manual of the engine). The electrolyte level must not exceed more than 10 mm above plates. WN The accumulators contain highly corrosive sulphuric acid. While filling the accumulator batteries use safety gloves and glasses. This operation must be performed only by trained personnel. To avoid a possible explosion of the accumulator batteries do ‘not smoke, neither use open flame during any maintenance of the gen-set. ‘The MARTIN POWER GEN-SETS are currently supplied exclusively with maintenance free accumulator batteries, unless required otherwise by a customer. 7. Check the electric panel and the gen-set and if necessary clean of any dirt and dust. 8. Check if the air filter is not clogged (see operation and maintenance manual of the engine) and if it is necessary replace it. 9. To avoid difficulties during maintenance make sure that area surrounding the gen-set is clean and not obstructed. 10. Check visually if any leakage from the coolant, oil, fuel or exhaust system is present on the gen-set.Check if the exhaust system is not clogged or damaged, to avoid leakage of harmful exhaust gases into the engine room. 11. Check electric connections, fuses, signal lights and tightening of terminals. Electric connections must be connected to terminal boxes or directly to terminals of the contactors and breakers (according to the wiring diagram). rN The control panels are dedicated only for control and protection of the gen-set and because of that they are equipped with three pole or four pole breakers (in case of a three phase system) and one pole or two pole breakers (in case of a single phase system) dedicated to own protection of the generator. (If not mentioned otherwise directly in the gen-set wiring diagram). Each firmly connected consumption device or multiple consumption system must be equipped with its own protection, which is included in the consumption device (constructional, industrial, residential or other distributor). TTS Martin, s.r.o. is not in any way liable for damages on a connected de e, property or personal injuries that are caused by violation of work safety or general obligatory safety rules and directions for electric appliances. Design of gen-sets according mains syste! TT system: The point of the source is directly connected with ground, while the neutral conductor marked as N can be extended. All metal components (frames) of connected electric devices are grounded individually, in groups (local grounded protective connection) or all metal components (frames) are connected together by the individual protective conductor marked as PE, which is grounded at suitable location. This protective (connecting) conductor PE must not be connected anywhere with the neutral conductor N. The terminals marked as N and PE must be connected at the terminal board of the generator or the gen-set distributor, while the PE terminal is connected with a metal component (frame) of the gen-set and a relevant grounding terminal. ‘TN system: The point of the source is directly connected with ground. All metal components (frames) of connected electric devices in the TN-C system are connected directly on the combined protective neutral conductor marked as PEN. In the TN-S distribution system metal components (frames) of electric devices are connected with the point of the source indirectly through the individual protective conductor marked as PE. The neutral conductor (individual neutral service conductor) marked as N is led from the point of the source, or a specific place of the distribution system (TN-C-S) and it is insulated from the protective conductor. The individual protective conductor PE must not be connected anywhere with the extended neutral conductor N, except the point of the source (or a place of separation in TN-C-S system). The terminals marked as N and PE are connected at the terminal board of the generator or the gen-set distributor, while the PE terminal is connected with a metal component (frame) of the gen-set and a relevant grounding terminal.IT system: The point of the source is insulated or indirectly connected with ground through relevant impedance. All metal components (frames) of connected electric devices are Brounded individually, in groups (local grounded protective connection) or all metal Components (frames) are connected together by the individual protective conductor marked as PE, which is grounded at suitable location. This protective conductor PE must not be connected anywhere with the extended neutral conductor N. The terminals marked as N and PE are not connected at the terminal board of the generator or the gen-set distributor, while the PE terminal is connected with a metal component (frame) of the gen-set and a relevant grounding terminal. Use of the IT system is specified in particular cases, where an event of a power outage causes higher risks of injury, threats to health and life, great damages to property, etc because this type of distribution system can be temporarily safely operated with the first ground connection. On the assumption that the gen-set in the IT system supplies only distribution systems of smaller scale, where the reliability and safety of this protection is theoretically and practically verified - pic. 1. For supplying long and large temporary cable distributions on construction sites, installations in buildings, etc. this type of protection cannot be used due to a decrease in total insulating resistance of mains to ground and an increase in dangerous capacitive currents in the distribution system. When a second ground connection is created, the IT system is no longer safe due to a danger of high contact voltage, which can occur in metal components (frames) of electric devices - pic. 2. A reliable protection against a dangerous contact can be secured with residual-current circuit breakers (RCCB), which are connected in individual supplied branches (sub-circuits) - pic. 3. Use of a single residual-current circuit breaker for a whole distribution system is inconvenient and has a small effect, as shown on the pie. 4. The type of connection on the pie. 5, where metal components (frames) are connected to the point of the source (neutral conductor), which is insulated from ground, this is dangerous (incorrect connection of the TN system), because with the first ground connection of the phase conductor (for example in a supply cable) a person connected to ground is in danger also in case, when a device is not damaged. A residual-current circuit breaker with a high sensitivity (disconnecting residual current Id= 0.03 A) can solve a situation, but it is necessary to realize that the disconnecting current of the circuit breaker also passes through the stricken person. This type of protection is unsuitable and can be used only exceptionally-pic 6. BS "rr nl4) + | ope.s h oars = - I _ In particular cases the gen-set supplies individual distribution system located on a continuous metal construction (for example gen-set installed at a mobile device) and the only possible ground connection is onto the continuous metal construction - this is valid under the assumption, that no external devices are connected (for example through sockets) outside the reach of the continuous metal construction. In this case it is possible to use the type of protection in the distribution system according to the pie. 1, while occurrence of a dangerous situation according to the pie. 2 can be excluded. The IT distribution system with the insulated point of the source is safer even in case of a direct contact with a live part, considering its smaller range and low leakage currents of the distribution system. In order to utilize advantages of the IT distribution system the MARTIN POWER gen-sets are supplied also as versions with the insulated point. The point of the source (neutral terminal N) is accessible together with the protective terminal (PE), that allows to select the relevant connection of the distribution system. Metal components (frames) of the gen-set are electrically connected with a relevantly labelled external grounding (protective) terminal. Note: Appliances can be connected in the insulated IT system with the extended neutral conductor N and the protective conductor PE (label 3NPE,50Hz,230/400V, 7), in the system without the combined protective conductor PE (label 3N,SOHz,230/400V,IT) in the system without the connected neutral conductor N with the combined protective conductor PE (label PE,50Hz,400V,IT), or in the system without the protective conductor PE and the extended neutral conductor NV (label 3,50H2,400V,IT). ‘Metal components (frames) ofl. class appliances are in the IT system connected with the combined protective conductor, or they are grounded on the combined protective grounding conductor PE, or they are grounded individually. In the case of individual grounding of appliances without using the combined protective conductor PE (for example in system 3N,50H2,400V,IT) and at request for continual operation of insulated system with the first ground connection, itis possible to use a device guarding the insulated state, that will optically and acoustically signalize presence of the first ground connection.12. Check phase sequence. In automatic backup gen-sets, or manually controlled reserve gen-sets with external output it is necessary to check, if the phase sequence of the generator is corresponding with a phase sequence from an external source. It is necessary to avoid the inverted direction of rotation in electric engines. ENGINE RUN-IN -DOES NOT APPLY TO AUTOMATIC BACKUP GEN-SETS At the first start-up or after a long time of inactivity perform complete inspection of all the gen-set systems. oO ‘Anew engine requires a gradual running-in. It is not recommended to operate the engine for longer time at low load during the first hours of operation, because it could lead to an excessive consumption of the engine oil, accompanied with an excessive smoking and oil drops sputtering from exhaust pipes. This event is more obvious with air cooled engines, because the cooling of the cylinders is always the same, as at no load as it is at maximum load. That is why at no load the engine stays virtually cool. On the other side with water cooled engines, the cooling is maintained by a thermostatic valve, which vastly reduces the temperature range between none and full load. That secures the temperature balance of the engine also at low load. From the above- mentioned is apparent, that it is appropriate if the gen-set always operates at loads higher than 60%, not only during the run-in period. In other case, beside that you will be annoyed by already mentioned problems, the operation of the engine will be systematically in danger, so it will be less efficient, it will smoke more and it will be less reliable than the engine, that is used correctly. MAINTENANCE A Following actions must be executed only by authorized qualified personnel. Execution of periodical maintenance depends on the gen-set application. While executing inspection and maintenance follow instructions according to the operation and maintenance manuals of the engine and the generator, which are part of this manual and also according to operating instructions of the gen-set manufacturer - TTS Martin, s.t.0. PN a warning sign informing about maintenance works on the gen-set during the maintenance works. For securing long time failure-free operation of the gen-set and high usage level, it is necessary to thoroughly respect procedures stated in this operation and maintenance manual. It is absolutely necessary to keep a service book in which are listed operating hours,interventions, refuelings, maintenance works and performed repairs. Periodical maintenance and repairs must be executed only by authorized qualified personnel. Gen-set must be kept clean. When necessary, clean it with appropriate industrial cleaners; do not use flammable solvents. Any segments, components or spare parts that need to be changed must completely match the parts listed in the catalogue supplied by the gen-set manufacturer, AR instructions stated in this manual will lead to correct execution of the maintenance. Before executing any operation that is not stated in this manual, contact technical division of TTS Marti . In terms of applicable laws TTS Martin, s.r.0. is not liable for unauthorized interventions and incorrect use of the gen-set, which are not in compliance with operation manuals and which can cause failure of the device, personal injury or even death. When a failure occurs from above-mentioned causes, the right for warranty is automatically terminated. AR maintenance operations on the gen-set with automatic operation, except refueling and inspection of the accumulator batteries must be executed with the gen-set in the lockout state, i.e. pushed in TOTAL STOP, or MAIN SWITCH and automatic control is in OFF pos LONG TERM NON-OPERABLE STORAGE OF THE GEN-SET During a long term shutdown (time exceeding 3 months or the minimum period according to the operation and maintenance manual of the engine) and storage the gen-set must be situated on clean, dry and closed location, and must be covered by a water-proof sheet. Besides that, it is necessary to follow instructions for storing the combustion engine stated in its operation and maintenance manual. Regarding the generator, in case of a long term storage it is necessary to execute resistance test of the stator winding insulation to ground before putting it back into operation. Before executing this test, disconnect the voltage regulator according to instructions stated in chapter “Insulation tests" in operation and maintenance manual of the generator. If the test, which is performed by Megmet (insulation resistance measuring instrument) or other similar device, shows insulation resistance lower than the one stated by the generator manufacturer, dry the generator according to the instructions stated in its manual and then repeat the test. It is also recommended to measure total insulation resistance of the electric panel to ground, which must be at least 1 ma. WARRANTY PERIOD 1. Warranty period for the gen-set is 12 months since the day of delivery to buyer. Warranty period for the gen-set is 12 months since the commissioning but no more than 15 months since the day of delivery to purchaser. 3. Warranty period for the gen-set used as back-up power source with less than 300 annual running hours is 24 months since the commissioning but no more than 27 months since the day of delivery to purchaser. 10ComApp> InteliLite 4 AMF8/AMF9 Controller for single gen-set applications 1 Front panel elements... 2 Display screens and pages structure 3 Browsing alarms Login... S Logout 6 Production mode .. 7 Information screen 8 Language selection... Display contrast adjustment Copyright ®2021 Comapas. Wirtenby Jen ipa Prague, Czech Republic ComApas, U Urarie 1612/14a, 17000 Prague 7. C2ach Repubtc Tet: #420 246012111 Sarita mete Operator GuideSR Control buttons Position Picture ge 1.1 Operator int ce of InteliLite 4 AMF8/AMF9 Description LEFT button. Use this button to move left or to change the mode. The button ccan change the mode only if the main screen with the indicator of curently selected mode is displayed. Note: This button will not change the mode if the controller mode is forced by one of binary inputs listed in the Reference Guide — "Operating modes” chapter. RIGHT button. Use this button to move right orto change the mode. The button can change the mode only if the main screen with the indicator of currently selected mode is displayed. Note: This button will not change the mode if the controller mods is forced by (one of binary inputs listed in the Reference Guide ~ "Operating modes” chapter. HORN RESET button, Use this button to deactivate the hom output without acknowledging the alarms.6® 66600 6 © ComApp FAULT RESET button. Use this button to acknowledge alarms and deactivate the hom output. Inactive alarms will disappear immediately ang, status of active alarms will be changed to “confirmed” so they will disappear ‘as soon as their reasons dismiss. UP button. Use this button to move up or increase value. PAGE button. Use this button to switch over display pages, 6 5 4 DOWN button. Use this button to move down or decrease value. ENTER button. Use this button to finish editing a setpoint or moving right in the history page, ‘START button. Works in MAN mode only. Press this button to initiate the start sequence of the engine. Sequence of the Gen-set. Repeated pressing of button will cancel current phase of stop sequence (ike cooling) and next phase will continue. DB ‘STOP button. Works in MAN mode only. Press this button tointiate the stop GCB button. Works in MAN mode only. Press this button to open orclose the cece, | 8 MCB button. Works in MAN mode only. Press this button to open or close the i A) Mcp. Indicators and others Position Description GENERATOR status indicator. There are two states ~ Gen-set OK (indicatoris green) and Gen-set failure (indicators red). Green LED is onif the generator voltage and frequency is present and within limits. Red LED starts flashing when Gen-set failure occurs. After FAULT RESET button is pressed, Red LED goes to steady light (fan alarm is still active) ors off (f no alarm is active). MAINS status indicator. There are two states ~Mains OK (indicators green) and Mains. failure (indicators red). Green LED is on, if mains is present and within limits, Red LED starts blinking when the mains failure is detected and after the Gen-set has started and Connected to the load it lights permanently until the mains failure disappears. Graphic BIW display, 132 x 64 px, GCB Status. Green LED is on if GCB is closed. Itis driven by GCB CLOSE/OPEN output or by GCB feedback signal MCB Status. Green LED is on if MCB is closed. It is driven by MCB CLOSE/OPEN output or by MCB feedback signal InolLte 4 AMF8-AMF9 Operator GuideComApp> 2, Dis ay screens and pages structur ‘The displayed information is structured into "pages" and "screens”. Use PAGE button to switch over the pages > The page Measurement consists of screens which display measured values like voltages, current, cil pressure etc., computed values like i.e. gen-set power, statistic data and the alarm list on the last Screen. > The page Setpoints contains all setpoints organized to groups and also a special group for entering password, > The page History log shows the history login the order that the ast record is displayed fist. 2.1 Main Screen Mode selector Symbols {Engine status) A Breaker status (“optional {Optional Current process | 2.1.1 Symbols > Padlock —active when LBI Access Lookis active > R-active when there is active remote connection to controller > Exclamation mark —active when there is any alarm in alarmist 2.2 Measurement Screens Note: Use Up and Down button to move between measurement pages. iveiLtes MFS+AMF9 Operator Guideberet | LIN 230 LIL2 490U LzN 23aU L2L3 4o0y L3N 230U L3L1 4o0y Benerator Fres 50.@Hz ‘Note: Use Up and Down button to move between measurement pages. ‘Note: Use Up and Down button to move between measurement pages. = 230U LiL2 490U BIE Note: Use Up and Down button to move between measurement pages. il Pressure #HHHHHEBar Colant Temp ##HHHHE TC Fuel Level HEHEHE Seed ‘Note: Use Up and Down button to move between measurement pages. ComApf>Note: Use Up and Down button to move between measurement pages. easee08 1 Input 6 2 Ineut So 3 Ineut 8 4 Ineut 8 5S_Ineut 6 ! | | ‘Note: Use Up and Down button to move between measurement pages. eseeeea Note: Use Up and Down button to move between measurement pages. evens 4 ANE S=8i eepeweeEe) | Q 8 a 8 8 Note: Use Up and Down button to move between measurement pages. goeceo! Outeut 9 @ Outeut Q 8 Outeut eo Note: Use Up and Down button to move between measurement pages. @OAR 09161616 Earth Fault Input Not Used OUT: Outeut Note: Use Up and Down button to move between measurement pages. | Note: Available only with plug-in module Incl 26-4 AMF3+AMF9 Overator Gude ComApf>ComApp> 0101010 IN? Input 8 QUT: Outeut 1 OUT! Outeut a OUT! Ourteut 1 OUT? Outer a ‘Note: Uso Up and Down button ta move between measurement pages Note: Available only with plugein module. Note: Use Up and Down button to move between measurement pages. Note: Use Up and Down button to move between measurement pages.ComApp Num E-Stors 8 Shurtdowns: @ Naintenancel Rhrs a Maintenance! Days 8 MaintenanceZ Rhrs a Maintenance Days a og ‘Note: Use Up and Down button ta move between measurement pages. intenance 3 RH Q heireenanee 3 Int a I PAddr 123.123.123.123 Note: Use Up and Down button to move between measurement pages. Note: Available only with plug-in module, = aur Latitu 8.1234 Lena tide 6, 1234 HomePosDis: 12Z3km Active Satellites q Note: Use Up and Down button to move between measurement pages. Note: Available anly with plug-in module, Inveltee 4 AtIFS+ AMPS Overator GudeCurrent IP Address | 123.123.123.123, ETH Interface Status Connected ‘Note: Use Up and Down button to move between measurement pages. Note: Available only with plugein module. Note: Use Up and Down button to move between measurement pages. Note: Available only with plug-in module. Note: Use Up and Down button to move between measurement pages. Note: Available only with ECU supported by TIER4FComAp 7 Slot A:Disabled | Module | ‘Note: Use Up and Down button to move between measurement pages, ‘Note: Use Up and Down button to move between measurement pages. ‘Note: From all of hese pages itis possible to switch seamlessly to the setpoint group page by pressing Page button, Note: There can be some additional screens and also some screens can be hidden. Sereen's visibility ‘depends on actual configuration (usage of extension or communication modules, ECU etc.) 2.3 Setpoint Screens s MAN AUTO TEST GRE EnerctManual << | fins B03 — Note: From all measurement pages we can fluently yo to the setpoint group page by pressing Page button. AUIFS AMP Operator GideComAp p> Down button to select required go Basic Settinas. ommunication Settins: Engine Settines Maintenance Timers Generator Settinas _____ Protections 2 Note: Use Enter button to enter selected setpoint group. Note: Use Up and Down button to select required setpoint Note: Use Left and Right button to select required setpoint. Note: Use Enter button to enter selected setpoint. Note: Use Up and Down button to set required value of selected setpoint. Note: Use Page button to discard changes, to set setpoint to previous value and to retum to the ist of setpoints of selected group.ComApp 2.4 History Log MAN AUTO TEST aR? EmereManual 2 pene 8:68 Note: Use Up and Down button to select required alarm reason. Note: Use Up and Down button to select required alarm reason. Note: Use Enter button to move to the next page of history log. inte t AMFS+AMFS Onerator GideComAp}> 15.9 15.8 Note: Use Up and o Down button to 15.8 ‘select required 5. alarm reason, Note: Use Enter button to move to the next page of history log. Note: Use Up and Down button to select required alarm reason. Note: Use Up and Down button to select required alarm reason, Note: Use Up and Down button to seleat required alarm reason, Note: Use Enter button to mave to the next page of history log.Note: Use Up and Down button to select required alarm reason. Note: Use Up and Down button to select required alarm reason, Note: Use Up and Down button to select required alarm reason. Note: Use Up and Down button to select required alan reason. Note: Use Enter button to move to the next page of history logComAp [> Note: Use Up and Down button to select required alarm reason, Note: Use Up and Down button to select required alarm reason. Note: Use Up and CHIE: Down button to @19900 a1101000 select rquied 1980011 81910108 Geer Note: Use Enter button to move to the next page of history fog. Note: Use Up and Down button to select required alarm reason Note: Use Enter button to move to the first page of history log, | IMPORTANT: The records are numbered in reverse order, i.e. the latest (newest) record is "0" and older records have "-1", ".2" etc.ComApp ‘Note: This is only basic history record. There can be some aduitional screens in case that in controller is extension module or ECU is configured. Also it depends on connection type. © back to Display screens and pages structure Intel 4 AMF8¥AMF9 Overator GuideComApp 3 Browsing alarms Gi MAN AUTO TEST oR? > Active alarms are displayed as white text on black background. It means the alarm is still active, ie. the appropriate alarm conditions are still present. > Inactive alarms are displayed as black text on white background. It means the alam is no more active, i.e. the appropriate alarm conditions are gone. > Not confirmed alarms are displayed with an asterisk. It means the alarm is stil not acknowledged (confirmed). > ECU alarms: SPN/FMIOCISC ‘© SPN—Suspect parameter number «© FMI—type of protection © OC ~number of erors © SC—source of error Number of alarms Active unconfirmed alarm {Inactive unconfirmed atarm {Active confirmed alarm ECU alarm inteiLte 4 AMFa+AMFS Operator GuideComApp 3.1 User access management alarms ‘The controller comes to the customer with tumed on Production mode, the default administrator password and with no filed email address for password reset. Due to the security reasons following user access management ‘alarms appear. Detailed description of situation when the alarms are active are described below: > Wm Production Mode is present in the alarm lst all the time while production mode is tumed on. To tum. Off the Production mode go to User management and uncheck the checkbox Production made or go to Production Mode display screen and select disable. > Wm Default Password appears in alarmlist when the default administrator password is set and Communication module is plugged in the controller. The purpose of alarm is to inform that the controller might bbe oris connected to the untrusted interface and cybersecurity rules are not fulfilled due to default ‘administrator password. > Wm Password reset e-mail addr is not set appears in alarmlist when there is no email address set and the administrator password is not the default one. The purpose of alarm is to inform that there is possibility ‘that the controller might not be accessible by administrator password due to forgotten password reason, Password reset procedure cannot be performed without filed email address. To fill out email address, the ‘administrator password is required. © back to Browsing alarms Intell 4 AMF8*AMF9 Operator GudeComApp> os c GG MAN AUTO TEST GRT Note: Use Up and Down button to select setpoint group Login. Note: Use Up and Down Button to select Login. Note: Use Enter button to enter Login. Intel te 4 AMF+AME9 OoerComApp UserlD Edit Note: Use Up and Down Button to g change the digit. Note: Use Enter button to confirm the UseriD or Page button to cancel entering Login. PIN Edit ao | Note: Use Up and Down Button to go change the digit Note: Use Left and Right button to move between digits. iiel.te 4 AMFB*AMF9 Operator GuteUserID PIN Note: Use Enter button to confirm the PIN and Loging or Page button to cancel entering the Login. Wrone Credentials Note: Incase that invalid UsertD or PIN are entered, the controller shows Wrong Credentials screen. Use Enter button to enter Login again or Page Button to go back to menu. 4.1 Account break protection The controllers protecting the user accounts against breaking by abrte-force attack, i.e against breaking into the controller by fast repeating attempts to login with credentials generated from the range of al possible combinations, Ifthe account break protection detects a possible attack and biocks an account or interface the alam eo is activated The alarm canbe used o send an active message (e.g. emai to inform about tha situation The detailed behavior ofthe controler depends on situation. 4.1.1 PIN protection If an user performs ten consecutive attempts to login using UIDIPIN, providing correct UID but incorrect PIN, the user account is permanently blacked fo login using UIDIPIN. The user must login with usemame!password and change the PIN to unblock this login method again. 4.2 Reset accounts to factory default ‘If credentials (usemame and/or password) for administrator account are lost, it is possible to reset all user accounts tothe factory default state. For more information see Resetting the administrator password on page 1 Aterreset procedure user accounts ae in factory default state Wim Default Password appears in alarmist when the default administrator passwords set and communication modules plaguedin the controler. The purpose of alam i to inform tha the controller might be oris connected tothe untrusted interface and cybersecurity ues are ot filed cause theres default administrator password Intllite4 AMEB+AMES Operator GudeNote: Use Enter button to enter Login. _ UserID PIN Note: Use Enter button to accept the inputs Intellite 4 AMF8 ANS Oc Note: Use Up and Down button to select setpoint group Login. Note: Use Up and Down Button to select Login. Note: Use wrong credentials — wrong UsertD or PIN,Wrons Credentials ‘Note: Use Page button to retum to the Main screen. © back to Logout Intelte 4 AME8+AMES Operator GuideComApp 6 Production mode (ia MAN AUTO TEST aR? wd Pberabela> 6 ‘Note: From all measurement pages we can fluently go to the setpaint group page by pressing Page button. Note: Use Up and Down Button to select Production Mode ‘Note: Use Enter button to enter Production Mode. intellte 4 AMFB+ANF9 Operator Guideise Up and Down Button to change to disabled Note: Use Enter button to aisable the Production Mode. eae Note: Once Disabled is confirmed by Enter button the option Enabled is no longer an the screen and therefore it fs not possible to enable Production mode by HMI display screen. Use inteliContig to enable the Production mode. back to Production mode IntelLte 4 AMES +409 OperatorComApp> 7 Information screen MAN AUTO TEST aR? 1 ‘Note: On Main measurement screen press Enter and Page button together. Enter button has to be pressed first. | InteliLite Ww. ComaP—control.com | Note: Use Page button to move to the next page. InteliLite ComAr InteliLite lication: ie Note: Use Page button to move to the next page. Version: 1,0.0.89 Version: 1.6 ial: 12345678, 1234 Note: Use Up button to move back to main measurement screen, InteLite 4 AMES+AMES Operator GudeComAp p> © back to information screen Intollte 4 AMFS~AMF9 Operator GuideComApp> 8 Language selection a oer aR? a "e ki Fist Note: On Main measurement screen press Enter and Page button together. Enter button has to be pressed first. InteliLite ComAr }-comaP—control.com ed Note: Use Page button to move to the next page. InteliLite Replication: Note: Use Page button to move to the next page. Intl 4 AMF8+AMF9 Operator GuideComAp}>> FB reeertoan down button to Laneuasez select required Laneuase3 | go language. ‘Note: Use Enter button to confirm selected language. © back to Language sel Intoltte 4 AMF8*AMF9 Operator GuideComAp p> Display contrast adjustment ae MAN AUTO TEST aR? ine eat Be ol ec 5.8 5.0 ‘Note: On any measurement screen press Enterand Note: On any measurement screen press Enter and Up button together for higher contrast. ‘Down button together for lower contrast. © ‘Note: After setting a contrast, no another action is needed. © back to Display contrast adjustment Intllite 4 AMFB+AMES Operator Guide\ 4Operating Instructions Diesel engine 8, 10, 12 V 1600 G10F, G20F 8, 10, 12 V 1600 G40F, G50F 8, 10, 12 V 1600 G70F, G80F 8, 12 V 1600 B30S 8, 10 V 1600, B40S, BSOF 12 V 1600, B40S 8, 10, 12 V 1600 G10S, G20S 8, 10, 12 V 1600 G70S, G80S MS150076/05EPrinted in Germany © 2014 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming 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 11 Important provisions for all products 1.2 Personnel and organizational requirements 1.3 Transport 1.4 Safety regulations for maintenance and repair work 15 Fite prevention and environmental protection, fluids and lubricants, auxiliary materials 1.6 Standards for safety notices in the text 2 General Information 2.1 Engine layout 2.2 Engine side and cylinder designations 23 Sensors and actuators - Overview 3 Technical Data 34 8/10/12 1600 G10F/G20F engine data, emissions optimized 3.2 BV/LOV/12V 1600 G10F/G20F engine data, optimized fuel consumption 3.3. BV/10V/12V 1600 G10F/G20F engine data, EU Nonroad Stage Ill A 3.4 BV/10V/12V 1600 G10S/G20S engine dala, EPA Tier 2,3 35 8/10/12V 1600 G7OF/G8OF engine data, emissions optimized 3.6 10/12V 1600 G708/G8OF engine data, optimized fuel consumption 3.7 /10V 1600 G7OF/GAOF engine data, EU Nonroad Stage IIT A 3.8 8/12V 1600 G70S engine data, EPA Tior 2, 3 3.9 8/10/12V 1600 G80S engine data, EPA Tier 23 3.10 8/10/12V 1600 G4OF/G5OF engine data, emissions optimized 3.11 8/10/12V 1600 G40F/GSOF engine data, optimized fuel consumption 3.12 8/10V 1600 G4OF/G5OF engine data, EU Nonroad Stage ill A 3.13 8/12V 1600 B30S engine data 3.14 8/10/12V 1600 B40S engine data, switchable frequency 3.15 10V 1600 BSOF engine data, emissions- optimized 10V 1600 BSOF engine data, optimized fuel consumption 316 1 13 rr 15 16 18 2 26 30 33 9 al “4 a7 5 55 59 62 65 } 72 3.17 10V 1600 BSOF engine data, EU Nonroad Stage TIA 3.18 Firing order 3.19 Engine - Main dimensions 4 Operation 4.1. Putting the engine into operation after extended outofservice periods (°3 months) 4.2 Putting the engine into operation after scheduled outofservice-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 stop 4.8 After stopping the engine - Engine remains ready for operation 4.9 After stopping the engine ~ Putting the ‘engine out of operation 5 Maintenance 5.1 Maintenance and servicing 5.2 Maintenance task reference table 6 Troubleshooting, 6.1 Troubleshooting 7 Task Description 7.1 Engine 7A.L Engine ~ Baring with starting system, 74.2 Engine - Test un 7.2 Valve Drive 721 Valve clearance - Check and adjusiment 72.2 Cylinder head cover - Removal and instalation 7.3 Fuel System 734 Fuel system ~ Venting 74 Fuel Filter 74.4 Fuel iter ~ Replacement 742 Fuel profiler Replacement 78 Air Filter 74. Ait filter ~ Replacement 752 Ate flter ~ Removal and installation 76 Air Intake 7.64 Service indicator - Signal sing position check 8180076 /OSE 2014-02 | Table of Contents 75 78 79 80 81 22. 83 84 85 86 87 88 89 90. oe 93 93 o 95 98 8 9 % 100 100 101 102 102 103 104 104 137.7 Starting Equipment ‘774. Slarter~ Condition check 7.8 Lube Oil System, Lube Oil Circuit 784 Eg 782 Engine oll - Change 1 Level check 79 Oil Filtration / Cooling 79.41 Engine ol filter ~ Replacement 7.10 Coolant Circuit, General, High-Temperature Gircuit 710.1 Engine colant- Level check 7302 Engine colent - Change 7.108 Engine coolant - Draining 7104 Engine coolant - Filing 7105 Engine coolant pump - elit bore check TAL Belt Drive ‘TALL Drive belt - Adjustment 712 Drive belt - Condition check 109 109 no ut 12 i 115 us us 4 | Table of Contents | MS150076/05E 2014-02 741 Dive belt ~ Tension check ‘7ALA.Daive belt - Replacement 7.12 Wiring (General) for Engine/Gearbox/Unit TARA. Engine wring ~ Check. 7.13 Accessories for (Electronic) Engine Governor / Control System 7481. Engine governor and connectors ~ Cleaning 74132 Engine govern ~ Checking pug connections 8 Appendix A 8.1 Abbreviations 8.2 MTU contact persons/service partners 9 Appendix B 9.1. Special Tools 92 Index 17 19 121 12 122 12 12a 124 127 128 131Lt Safety Important provisions for all products Nameplate The product is identitied by nameplate, model designation or serial number and must match with the information on the ttle page of this manual. Nameplate, model designation or serial number can be found on the product, General information This product may pose a risk of injury or damage in the following cases: * Incorrect use *+ Operation, maintenance and repair by unqualified personnel + Modifications or conversions + Noncompliance with the safety instructions and warning notices Correct use ‘The product is intended exclusively for the application specified in the contract or defined at the time of delivery. This means thatthe equipment must be operated: + Within the permissible operating parameters in accordance with the (- Technical data) + With fluids and lubricants approved by the manufacturer in accordance withthe (~ Fluids and Lubri- cants Specifications of the manufacturer) + With spare parts approved by the manufacturer in accordance with the (~ Spare Parts Catalog/MTU contact/Servce partner) + In the original es-delivered configuration or in a configuration approved by the manufacturer in writ- ing (including engine control/paramaters) In compliance with all safety regulations and in adherence with all warning notices in this manual In accordance with the maintenance requirements over the entice service life of the product (-+ Main- tenance Schedule) + In compliance with the maintenance and repair instructions contained in this manual, n particular with regard tothe specified tightening torques *+ With the exclusive use of technical personnel trained in commissioning, operation, maintenance and repair + By contracting only workshops authorized by the manufacturer to carry out repair and overhaul Any other use is considered improper use and increases the risk of personnel injury or material damage in product operation. The manufacturer will accept no liability for such damage. Modifications or conversions Unauthorized modifications to the product compromise safety The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions, jarts must be used to replace components or assemblies, The manufacturer will accept no liability or warranty claims for any damage caused by the use of other spare parts. MS 150076/0SE 20144 2 | Safety 151.2 6 | Safety Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion, Keep this manual handy in the vicinity of the product such that itis accessible to operating, mainte- nance, repair and transport personnel at all times. Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe- ‘y-relevant instructions, in particular, must be read and understood, This is particularly important in the case of personnel who only occasionally perform work on or around the product. This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only + Training at the Training Center of the manufacturer * Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation, maintenance, re- pair and transport. Working clothes and personal protective equipment Wear proper protective clothing for all work. When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec tive gloves, goggles, breathing protection). Observe the information on personal protective equipment in the respective activity description, 1 Ms150076/05E 2014-02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 foll, suspend the engine on the lifting eyes of the trans- ort pallet or transport with equipment for heavy loads (forklift truck). Setting the engine down after transport Place the engine only on an even, firm surfa Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so. MS150076/05E 2014-02 | Safety | 714 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use suitable containers of adequate capacity to catch fluids and lubricants When changing the oil or working on the fuel system, ensure that the service room is adequately venti- late. Never carry out maintenance and repair work with the product in operation, unless: + Expressly permitted to do so following a written procedure. + The product is running in the low load range and only for as long as absolutely necessary. Secure the product against unintentional starting, e.g. with start interlock. Attach “Do not operate” sign in the operating area or to control equipment. Disconnect the battery, Lock contactors. Clase the main valve on the compressed-air system and vent the compressed-air line when pneumatic starters are fitted, Disconnect the control equipment from the product. ‘The following applies to starters with copper-berylium alloy pinions: + Wear breathing protection of filter class P3 during maintenance work, Do not blow out the interior of the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction device, + Observe the safety data sher Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the product. Cover the screw or plug with 2 rag to prevent fluids escaping under pressure. ‘Take care when draining hot fluids and lubricants (risk of burning). Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis- assembly. Carry out work only on assemblies or plants which are properly secured. Never use lines for climbing, Keep fuel injection lines and connections clean Always seal connections with caps or covers if a line is removed or opened. Take care not to damage lines, in particular fuel lines, during maintenance and repair work. Ensure that all retainers and dampers are installed correctly. Ensure that all uel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components. Do not place fuel or ol lines near hot components. Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop- erly protected, Note cooling time for components which are heated for installation or removal (isk of burning). When working high on the equipment, always use sultable ladders and work platforms. Make sure com ponents or assemblies are placed on stable surfaces. 8 | Safety | Ms150076/05E 2014-02Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths and cable ties), Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product, Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the product (in particular, the barring tool) Welding work Welding operations on the product or mounted units are not permitted, Cover the product when welding inits vicinity Before starting welding work: + Switch off the power supply master switch, * Disconnect the battery + Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on. Risk of explosion or fire due to oll vapors and highly flammable fluids and lubricants. Do not use product as ground terminal Never position the welding power supply cable adjacent to, or crassing wiring harnesses of the produ: The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system, Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand. Hydraulic installation and removal Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the specified jigs and fixtures for hydraulic removal /installation procedures. Observe the max. permissible force-on pressure specified for the jig fixture. Do not attempt to bend or apply force to lines. Before starting work, pay attention to the following + Vent the hydraulic installation /removal jig, the pumps and the lines at the relevant points for the equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs). * For hydraulic installation, screw on the jig with the piston retracted. * For hydraulic removal, screw on the jig with the piston extended. For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft ‘end until correct sealing is established. During hydraulic installation and removal, ensure that nobody is standing inthe immediate vicinity of the component to be installed /removed. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases emanating from the battery are explosive, Avoid sparks and naked flames. Do not allow electrolyte to come in contact with skin or clothing Wear gogsles and protective gloves Never place tools on the battery. Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. MS180076/OSE 2014-02 | Safety | 910 | Safety Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work cr switching off any part of the electronic system required to do so. Devenergize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged dur- ing 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 nat use cable straps to secure cables. ‘Always use connector pliers to tighten union nuts on connectors, Subject the device as well as the product to @ function check on completion of all repair work. In partic- Ular, chack the function of the engine emergency stop feature. ‘Store spare parts properly prior to replacement, ie. protect them against moisture in particular. Pack defective lectronic components and assemblies in @ suitable manner when dispatched for repair, ie. protected, in particular, against moisture and impact and wrapped in antistatic fol if necessary. Working with laser equipment When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi- ly focused radiation}, Laser equipment must be equipped with the protective devices necessary for safe operation according to type and application. For conducting light-beam procedures and measurement work, only the following laser devices must be used: * Laser devices of classes 1, 2 oF 3A. * Laser devices of class 38, which have maximum output in the visible wavelength range (400 to 700 rim), @ maximum output of § mW, and in which the beam axis and surface are designed to prevent any risk to the eyes. I Msis1.5 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials Fire prevention Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires - therefore ak ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product. Do not store combustible materials near the product. Do nat carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity ofthe battery, connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their use. Noise Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals, ‘warning calls or noises indicating danger Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A). Environmental protection and disposal Modification or removal of any mechanical/electronic components or the installation of additional com- ponents including the execution of calibration processes that might affect the emission characteristics Of the product are prohibited by emission regulations. Emission control units/systems may only be maintained, exchanged or repaired if the components used for this purpose are approved by the manu- facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the emissions regulation authorities. The manufacturer does not accept any liability for violations of the emission regulations. The maintenance schedules of the manufacturer must be observed over the entire lite cycle of the product. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly sycled, Consumable fluids and materials The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera- tion, make sure that the latest version is used. The latest version can be found on the website on the "Technical nfo or "Spare Parts and Service" tabs at http:/ /www.mtu-online.com. Consumable fiuids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product. Take spe- cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them coming into contact with ignition sources and do not smoke. Used oil Used oil contains combustion residues that are harmful to health, Rub barrier cream into hands. Wash hands after contact with used oil. MS150076/05E 2014-02 | Safety | 11Lead ‘+ Adopt suitable measures to avoid the formation of lead dust. + Switch on extraction system. + When working with lead or pastes that contain lead, avoid direct contact with the skin, Do not inhale lead vapors. + Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed ar: + Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class Al, All and B) out of containers, risks causing an explosion + Wear goggles when blowing dirt off workpieces or blowing away swarr. * Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or lass) for drying purposes or to check for leaks risks bursting them, + Pay special attention to the pressure in the compressed air system or pressure vessel ‘+ Assemblies or products to be connected must either be designed for that pressure, or, if the permis- sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to the permissible pressure) must be connected between the assemblies /products and the system, + Hose couplings and connections must be securely attached. * Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). * First shut off compressed air lines before compressed air device is disconnected from the supply line, or before device or tool is to be replaced. * Carry out leak test in accordance with the specifications. Paints and varnishes Observe the relevant safety data sheet for all materials. ‘When painting in areas other than spray booths equipped with extractors, ensure good ventilation. Make sure that neighboring work areas are not adversely affected. There must be no naked flames in the vicinity. No smoking, Observe fire prevention regulations. Always wear a mask providing protection against paint and solvent vapors. Liquid nitrogen Observe the relevant safety data sheet forall materials. * Store liquid nitrogen only in small quantities and always in regulation containers (\ caps) + ‘void body contact (eyes, hands). + Wear protective clothing, protective gloves, closed shoes and safety goggles. + Make sure that working area is well ventilated. + Avoid knocking or jolting the containers, valves and fittings or workpieces in any way. jut gasctight Acids/alkaline solutions/urea (AdBlue®, DEF) + Observe the relevant safety data sheet for all materials. + When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective clothing, Do nat inhale vapors. If urea solution is swallowed, rinse out mouth and drink plenty of water. If spilled onto clothing, remove the affected clothing immediately. ‘After contact with skin, rinse affected parts of the body with plenty of water. Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi- ble. 12 | Safety | MS150076/05€1.6 Standards for safety notices in the text = ~ in the event of immediate danger. Consequences: Death eelous or permanen A Premetit action In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! BD Remedial action In the event of a situation involving potential danger. Consequences: Minor or moderate injuries! A + Remedial action In the event ofa situation involving potentially adverse effects on the product. Consequences: Material damage! ‘+ Remedial action + Additional product information. Safety notices This manual with all safety instructions and safety notices must be issued to all personnel involved in operation, maintenance, repair or transportation, MS 150076 /05E 2014-02 | Safety | 132 General Information 2.1 Engine layout 1 Airfilter 7 Thermostat housing (re ‘13. Exhaust turbocharger, 2 Lifting equipment, driving. turn cooler) 14 Oil dipstick end 8 Belt drive 15 Oil pan 3 Engine governor 9 Cylinder head 16 Fuel fiter 4 Air supply 10 Exhaust elbow 17 Flywh 5 Oil filter 11 Grankease 18 Flywheel housing 6 Lifting equipment, free end 12 Engine mounting. Engine model designation Key to the engine model designation 8/ 10/12V 1600 Gxyz 12 Number of eylinders Vv ylinder arrangement: V engine [1600 Series iG Application x Application segment (1, 2, 4, 5, 7,8) y Design index 2 Frequency code (F = 50Hz, $= 60H) 14 | General Information | MS150076 /O5E 2014-022.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4) For designation ofthe cylinders (to DIN ISO 1204) the letter "A* (1) is used to refer to the cylinders on the leftthand 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 atthe driving end. The numbering of other engine components also starts with no. 1 at the driving end, 0001555 1 Leftchand side of engine 3 Right-hand side of engine 2 Free end 4 Driving end MS150076/05E 2014-02 | General Information | 152.3 Sensors and actuators - Overview Sensors on engine free end - Overview Hlustration applies in the same way to TOV 1600 Gx0. a Sensors on engine driving end - Overview Illustration applies in the same way to 10V 1600 Gx0. 16 | General Information | MS1S0076/0SE 2014-02oseonsta6 1 MB. Fuel pump HOP A (time measurement unit) 2 Ma.2 Fuel pump HOP & (time measurement unit) 3 BI Camshaft TDC 4 Bia Crankshaft speed MS150076/05E 2014-02 | General Information | 173 Technical Data 3.1. 8/10/12V 1600 G10F/G20F engine data, emissions-optimized Explanation: DL Ref. value: Continuous power A Design value G Guaranteed value R Guideline value LL Limit value, up to wihich the engine can be operated, without change (e.g. of power settings). N Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS pur Gt 38 tr ag 38 Pra) ctr 38 s2v1600] 12v1600 G10F my 38 Application group 3B, 3B Intake air tomper- 25 25 25 25 25 25 ature | Barometric pres- | [mbar 1000] 1000} 1000/1000, 1000/1000 ‘Site altitude ™ i) 100 100 100. 100 100 ‘above sea level Rated engine [A |rpm 1500 speed 1500 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) eens eS ‘Continuous power |_| kW 325 150 3046 (10% overload capabil- ty) (design power DIN 6280, ISO 8528) 358 GENERAL CONDITIONS (for maximum. ‘Number of cylin- ders Intake depression |A | mbar | 25 (cow fier) Intake depres [L_|mbar 50 sion, mat. 18 | Technical Data | MS150076/05E 2014-02eens ders ibe ee Exhaust overpres- mbar 85 85, 85 85 sre | Exhaust overpres- L | mbar 160) 150,~—~=«50| aso) 1800 sure, ax | MODEL-RELATED DATA (basic design) frerrerieset et Standard housing | | SAE ot connecting flange (engine main PT) Flywheel interface A AIR / EXHAUST Perera 3 dors Chargeairpres- | bar abs 29/30) 265) 292, 3.0 sure before cylin. der-DL I | COOLANT SYSTEM (HT circuit) reentry et “Coolant tempera ture (at engine | conrettion: outlet to cooling equi | ment) Coolant tempera (R|°C 105) 105) ~~=«105/ 105) === ture after engine, warning Coolant tempera~ L | °C 109 109 109 109 109 109 ‘ure after engine, shutdown | | Goclant aniveeze L% 50) 80, 80/ —-80)~—~«50,~SCO ‘content, max, Pressure lossin |L bar | 07 07 07, O7 1 1 oftengine cooling | “system, max. MS150076/05E 2014-02 | Technical Data | 19LUBE-OIL SYSTEM Lube oll operating temperature be- fore engine, from | ae Go a ee ee ae R "6 rr) 87 Lube oil operating |R [°C | 100 100) temperature be- | ore engine, to 100 100 101 10 Lube oil operating [R | bar 45 45 pressure before engine, from 45 45 40 40 ‘Lube oil operating |R [bar 54 54 pressure before engine, to BA 54 52 50 FUEL SYSTEM Fuel pressure at engine inlet con- nection, min. (when engine is starting) “05, 05 | 05) Fuel pressure at |L [bar Os 05 engine inlet con- nection, max. (when engine is starting) 0s 08 05 GENERAL OPERATING DATA ‘Cold start R °C “ity: air tempera- ture (w/o start | aid, w/o preheat- ing) ~ (case A) ‘Firing speed, from |R_|rpm 80 80 80 20. 80 80 Firing speed, to [R [rpm 120 120 120 120 120 120) 20 | Technical Data | MS150076/05E 2014-02CAPACITIES fees der "Engine coolant “capaciy, engine side (uthout “cooling equip: rent) | Liters R 50° re GE SE Oil change quanti- /R [users ty, max, (standard ol system) (Op- tion: max. operat- ng inclinations) Oil pan capacity || Liters {at dipstick mark “min.” (standard ‘ll system) (Op- tion: max. operat~ ing inclinations) | 36 Oil pan capacity |L Liters 43 a 53 53 64 64 ener fos Engine welght, dry (basic engine configuration acc. “to scope of supply _ specification) 1444 t4ea) 1749/1749) 2022/2022) Exhaust noise, silenced - DL (sound power lev- el LW, ISO. | 6798436814) tok erance) 08(4) 121 122 121 122 Engine surface = /R |dB(A) noise with attenu- ‘ated intake noise | (filter) - DL (sound power level LW, 150 6798+2a8 (A) ltolerance) ‘| 4 a 120. 122 MS180076/05E 2014-02 | Technical Data | 213.2 8V/10V/12V 1600 G10F/G20F engine data, optimized fuel consumption Explanation: DL Ref. value BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value LL Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS: Perera ‘v1600] 8vi600] 101600] tov1600 Co oF} G20 s2vi6oo] s2v16 Cty mos 3B, 38 ‘Application group Intake air temper- | [°C 25 25 28 25) 25 25 ature | Barometric pres- | | mbar rooo] 1000} t000| 1000) 1000/1000 ‘sure ‘Site altitude ™ 100 100) 100, 100 100 100 above sea level POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) overload capabil- 'y) (design power DIN 6280, 180 8528) ‘Number of cylin 2 2 ders Rated engine |A. rpm 1500) 1500, 1500/1500 18001500 speed | ‘Continuous power |A_ [kW 325] 358) 407|—aas| 524) 876 150 3046 (10% | Intake depression |A | mbar 25 GENERAL CONDITIONS (for maximum power) 25 25 25 25 25 sure, max, | rewttey | ake deroz [ar se] 88] 53] 80] 50) sone Exhaust overpres- [A | mbar 85 85 85 85 85 85 ‘sure | Ete eee | [mbar wo] 180] 80} 80] ao] 22 | Technical Data | MS150076/0SE 2014-02MODEL-RELATED DATA (basic design) eereerrror tas ders Standard housing | oot connecting ange | (engine main PTO) | Fiywheclintefce| OSC) AIR / EXHAUST irs 10 fo Chargesicpres- | [bar abs 26/28) 2.30 sue before oye | er-DL | COOLANT SYSTEM (HT circuit) er ders Coolanttempera: A |*C OS 95, 95 95, 95 95; ture (at engine connection: outlat to cooling equip- ment) [Coolant tempere- [R °C vos; 105/105) 105/105) 108) ture ater engine, | [warning Coolant tempera |L | *C 109) 109/109) ~—~«109)-~=«t09| 109) ture after engine, | shutdown | Coolant antifreeze |L|% 7 80 50 50 50 50) content, max. Pressurelossin|L_ [bar o7|o7| a7] or 1 1 offengine cooling system, max, ory 50 LUBE-OIL SYSTEM Lube oil operating temperature be- | fore engine, trom | ‘Lube oil operating |R/°C wool 100/100, 100/101) 107 temperature be- fore engine, to Lube oi operating |R bar 45) 45) asf 48) ~~) pressure belore engin, trom | Lube ol operating |R bar sal 4) bal SASSO) SC«* pressure before | engin to | NS180076/0SE 2014-02 | Technical Data | 23FUEL SYSTEM freee? ders Fuel pressure at |L_ |bar engine inlet con nection, min, “(when engine is | starting) ‘Fuel pressure atk “engine inlet con- | nection, max. | (when engine is starting) 08 08 | 05) 05 GENERAL OPERATING DATA ery Cold start capabil-/R °C ty: air tempera- ture (w/o start aid, w/o preneat- ing) - (ease A) fee ed ac ae -20 iene] x “20 -20 Firing speed, rom |R_|rpm 30 80 30 | 80 80 80 Firing speed, to |R [rpm 120 120 120) 120 120) 120 CAPACITIES eer cs R Engine cool Liters pacity, engine side (without ‘cooling equip- ment) rr 60" ‘Oil change quant |R Liters ty, max, (standard il system) (Op- tion: max. operat- ing inclinations) 43 a 53 53 64 il pan capacity |L Liters at dipstick mark min." (standard | cll system) (Op | tion: max. operat- ng inclinations) 36 46 46 56 56 (il pan capacity |L Liters 23t dipstick mark max." (standard il system) (Op- ton: max. operat- ng inclinations) 43 53 53 6a 64 24 | Technical Data | MS150076/05E 2014-02,WEIGHTS / MAIN DIMENSIONS eens cs Engine weight, |R kg “enous engine contigo ae coccope tay | |spectean) | 1484 ae ie oe) i 1464 1749 1749-2022 2022 ACOUSTICS Exhaust noise, un- silenced - DL (sound power lev- el LW, ISO 6798+3dB(4) tok erance) pressrr co R dBA) 121 121 121 Engine surface | aB(A) nates wit atten fed intake nose | {filter) - DL (sound: owe evel Li, 150 6798¢208 (4) tolerance) 4 7 7 120 122 M$180076/0SE 2014.02 | Technical Data | 253.3 8V/10V/12V 1600 G10F/G20F engine data, EU Nonroad Stage mA Explanation: DL Ret. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L. Limit value, upto which the engine can be operated, without change (e.g. of power settings). IN Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS. Eero) ‘8vi600] 8v1600] 10v1600] sovi600] 12V1600 Gior} G20F| —Gi0F}_—_Gzor|__Gi0F ‘Application group 3B 38 38 38 38 38 Intake air temper | |°C ] 25 8 28 25 25 25) we | Barometric pres- | mbar tooo; 1900-1000) 1000/1000] 1000 sure | {site attitude ™ | 100} 00 100 100, 100 100 above sea level POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) prereset. 10 10 cS ‘A rpm Reted engine 1500/1500 1500) 1500, 1500/1500, speed | | Continuous power |A | KW 35a) 388) 407| «ab, 2t] «876, 180 3046 (10% | | | ‘overload capabil- | ‘y) (design power | | | DIN 6280, [SO | 3528) | GENERAL CONDITIONS (for maximum power) bese i ES ae ed Intake depression | A | mbar 25) 25) 15 18) 25 {new filter), ‘Intake depres |[L__ mbar 50 50 50 50 50 son moe | Exhaust overpres- [A | mbar 85 85 30 30 85 sure | I | Ease Ce af a, | et [seems 26 | Technical Data | MS150076/0SE 2014.02MODEL-RELATED DATA (basic design) ene Standard housing ‘connecting flange [engine main PTO) rr rT) rr ders SAE 01 01 or ot 1 on Flywheel interface | wee te) ae) 1a AIR / EXHAUST. fey tc Charge-air pres~ sure before oylin- [der-DL 304 at2| 265) 2.92. 3.0 34 COOLANT SYSTEM Coolant tempera- A ture {at engine connection: outlet to cooling equip- ment) (HT circu 95 95 95 95 95 95 Coolant tempera- | ture after engine, warning °C 105 105 105 105 105) 105 “Coolant tempera- | L “ture after engine, | shutdown °C 109,109) ——«109 109/109 109 Coolant antifreeze | L content, max. 50 50 50 50 50, 50, Pressure loss in |L off-engine cooling “system, max. O7 o7 07 oF) 1 LUBE-OIL SYSTEM ees co Lube oil operating ‘temperature be fore engine, from ‘Lube oil operating |R temperature be- fore engine, to °C 100, 100 100 100. 101 vor Lube oil operating | pressure before | engine, from 45 45 45048 40 40 Lube oil operating |R pressure before “engine, to 54 Ba 34 5a 52) 50 MS 150076 /O5E 2014-02 | TechnicFUEL SYSTEM reer ders Fuel pressure at Lar ‘engine inlet con- rection, min, when engine is starting) | “05 Fuel pressure at |L|bar engine inlet con ‘nection, max. (when engine is starting) 08 05 O85 GENERAL OPERATING DATA. ture (w/o start aid, w/o preheat- ing) - (case 4) Firing speed, from |R_ rpm 80 80 80 80 80 Firing speed, to [Rpm 120 120 120 120 120 120 CAPACITIES re Engine coolant ‘capacity, engine side (without ‘cooling equip- | ment} | or ate 60" 65 65 Oi change quanti | Litere ‘ty, max, (standard oil system) (Op. tion: max. operat ing inclinations) 43 53 53 66 64 [Oilpan capacity |L Liters “min” (standard ‘il system) (Op- tion: max. operat- ing inclinations) 36 46 36 il pan capacity |L Liters: at dipstick mark “max.” (standard ‘ll system) (Op- tion: max. operat- Ling inclinations) | 43 3 53 583 of 28 | Technical Data | MS150076/05E 2014-02WEIGHTS / MAIN DIMENSIONS Engine weight, | kg dry (basic engine configuration acc. | “10 scope of supply “spectication) | Exhaust noise, un- | | dB(A) wt) wat) t2t) ta) tata jlenced -DL (sound power lev 21 LW, 180 6798+348(4) tok erance) | | | Engine surface |R 3(A) = 7 3 noise with attenu- ated intake noise | ffiter|~DL (sound | | “power level LW, 14441444) 1749) 1749) 2022) 2022) ACOUSTICS 120 122 1s 6798+24B (A) tolerance) MS150076/0SE 2014-02 | Technical Data | 293.4 8V/10V/12V 1600 G10S/G20S engine data, EPA Tier 2, 3 Explanation: DL Ref. value: Cantinuous power BL Ref, value: Fuel stop power A Design value Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). 'N Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS rr ‘8v1600] sv1600] 10v1600| 12v1600] 12v1600 ios} cz0s| c20s| ios} Gos ‘Application group 3838) B, 88) 8B Intake air temperature °c 228) 3 Barometis pressure [ [moar 7000, 1000/1000) 1000] 1000 ‘Sit altitude above sea level = 10100) 100/100] 100, POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) oe ee ee Rated engine speed 1800/1800 1800) 1800] 1800 ‘Continuous power ISO 3046 [A | kW avi, -408)—=Si1| S610 (10% overload capability) (de- | ‘sign power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) aa el a a Intake depression [new fer) |_| mbar 25) 25 25 23) 2 [Intake depression, max. |L__ mbar 50) 50 50 50) 50 Exhaust overpressure ‘A mbar 85 85 85 35 | 85 Exhaust overpressure, max L_mbar 150,150 150) ~—~150)~—~—=T80) MODEL-RELATED DATA (basic design) CE De a ‘Standard housing connecting | | SAE 01 01 o1) Ot 1 flange (engine main PTO) Flywheel interface 7 [ose 7 AIR / EXHAUST A TA ‘Charge-air pressure before bar abs 31] 277) 277 a1 3M ‘cylinder - DL | | 30 | Technical Data | MS150076/05E 2014-02COOLANT SYSTEM (HT circuit) ‘Coolant temperature (aten- |A °C | gine connection: outlet to 98) 95 95, 95 98 | | cooling equipment) | L | | Coolant temperature afteren- |R °C 105 | 105, 105, 105 105, sine, waring | [coolant temperature after ex [L_|* io) 109) 109) 09,109) |gine, shutdown: [Coolant antieeze conten, Ue so) 80)~«~SO]S«SO SS max | Pressure loss in off-engine L |bar O7 07 07 [cooing system, max LUBE-OIL SYSTEM a Es before engine, to Lube ol operating temper rr rr ture before engine, fom | ‘Lube oil operating tempera» R= |°C. 100 100 tor 101) 101 tue boone engine, | Lube oil oparatng pressure Rar rr rc bofore engine, rom | | | Lube oil operating pressure |R | bar 54 54 54 54 | 34 FUEL SYSTEM Simos Fuel pressure at engine inlet connection, min. (when en- | gine is starting) Fuel pressure at engine inlet |L_|bar connection, max. when en- “gine is starting) 08 Os os 08 GENERAL OPERATING DATA a “Cold start capability: air tem- c erature (w/o start aid, w/o preheating) -(case A) | Firing speed, from R [pm 80 80 80 20 80) Firing speed, to R [pm 120 vo] 120) ~—«120/~=~=«120 M$150076/0SE 2014-02 | Technical Data | 31CAPACITIES a a a Engine coolant capacity, en- |R_Lters 65, ine sie (without cooling | | equipment) | | [standard ol system) (Option: [oitchange quantiy, max Rites a) ae 64 Oil pan capacity at dipstick = L_ Liters, | 36, 36 46 36 nak mi. (Standard ol sys tem) (Option: max. operating inclinations) 56 Oil pan capacity at dipstick —|L Liters 3B a 53 64 mark "max.” (standard ol sys- |tem) (Option: max. operating | Linctinations) LI 64 WEIGHTS / MAIN DIMENSIONS ea [Engine weight, dry (basic en- | | kg vasa] tage) 1749/1950 sine configuration ace. to [scope of supply specification) | Acoustics Seo tenuated intake noise iter) - DL (sound power level LW, 180 6798+208 (A) tolerance) Exhaust noise, unsilenced ~ dB(A) 121 121 iat 120 121 DL (sound power level LW, 180 6798+3dB(A) tolerance) Engine surface noise with at- R |dB(A) A | 7 123 122 32 | Technical Data | MS150076/05 2014.023.5 8/10/12V 1600 G70F/G80F engine data, emissions-optimized Explan: ion: DL. Ref, value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value . Limit value, up to which the engine can be operated, without change (e.g. of power settings N Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS ‘v1600] 8v1600] 10V1600] 10 Prager) PTET G70F| Gaor| —G70F| _G8CF|_G70F| GeoF. 30 30 Application group 3D 3D 30 3D, Intake air temper- °C 25 25 25 5 25 25 ature “Barometric pres- ‘mbar ¥o00] 1000/1000) 1900/1000) 1900) sure l Site altitude m | 100] 100) ~~ 100/100 100) “above sea level POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) baal Tea s Rated engine 1500) 1500/1500, 1500, “speed | | | ‘Fuel stop power A [kW 358 394 448 493 576 638 Iso 3046 | | GENERAL CONDITIONS (for maximum power) ens ders Intake depression |A. | mbar 25 (new fiter Intake depres- [mbar | —-50)—<80 50 30) «80 50 _slon, max. | | | Exhaust overpres- /A_| mbar oO aol 90) 85 sure | [Exhaust overpres- |_| mbar 150] 150 —150|—=«150)~—~=«50/—=—«180 sure, max, | MS150076/05E 2014-02 | Technical Data | 33MODEL-RELATED DATA (basic design) ry ‘Standard nousing | | SAE on “connecting flange “{engine main PTO) o1 “Flywheel interface | DISC i) a AIR / EXHAUST Charge-air pres- /R | bar abs 3.0 sure before cylin. der-BL 2.92 34 34 COOLANT SYSTEM (HT circuit) eeeery (Coolant temper A |*C 95 ture (at engine connection: outlet | to cooling equi- ment) fl is 95 ‘Coolant tempera |R | °C 105 ture after engine, warning 105 105 105 105 108 Coolant tempera |L ture after engin | shutdown | 109 109 109 109 109 109 ‘Coolant antifreeze | % 50 50 50 50 Preasurelossin | [Bor 07 errengine cooing | | ystems max |_| o7 o7 o7 LUBE-OIL SYSTEM Lube oll operating temperature be- fore engine, from roads Wh eS Slew 87 87 87, 87 temperature be- ‘Lube ol operating [R_| °C. 100 creme | | 100 100 100 101 tor Lube oil operating |R pressure before engine, from 45 45 40 40 Lube olf operating |R [= ar) Pressure before engine, to | 54 54 54 82 5.0 34 | Technical Data | MS150076/05E 2014-02FUEL SYSTEM errr ders “Fuel pressure at ‘engine inlet con- nection, min. (when engine is starting) | Fuel pressure at engine inlet con- nection, max. (when engine is starting) bar GENERAL OPERATING DATA aay Cold start capabil-| R ity: air temper ture (w/o start aid, w/o preheat- ing) - [case A) § -20 20/20 -20 -20 Firing speed, from 3/8 Firing speed, to 120 [120 120 120) 120. 120) CAPACITIES Seen co “Engine coolant capacity, engine side (without cooling equip- ment) Liters 50" 50° 60" 65 65 Engine oll total, |R Liters or initial filling (standard oll sys- tem) (option: ‘max. operating in linations) | 46 4%) (605) 605/725) «728 Oi change quanti- {Livers ty, max. (standard a 53 53 64 64, MS150076/05E 2014-02 | Technical Data | 35eeseerrmerrey ders Ol pan capacity |L_|Litors at dipstick mark min” (standard system) (Op tion: max. operat- ing inclinations) | Oil pan capacity L [Liters a at dipstick mark max” (standard || cil system) (Op- tion: max. operat- ing incinations) 43 53 53 64 WEIGHTS / MAIN DIMENSIONS Engine weight, |R |kg 1484 dry (basic engine ‘configuration acc. to scape of supply 1444 1749 2022 2022 specification) ACOUSTICS reer ders Exhaust noise, un-|R |dB(A) 109 silenced - BL. (feee-tield sound pressure level Lp, ‘im distance, ISO 6798, +-3d8(4) {tolerance} 109 109 110. Exhaust noise, un-|R | dB(A) 122 silenced - BL (sound power lev- el LW, ISO. 6798+348)A) tol erance) 122 122 123 123 123 36 | Technical Data | 1MS150076/05E 2014-023.6 10/12V 1600 G70F/G80F engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value |. Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS [Application group ‘8v1600] svieoo] tov1600] 10v1600 Prat) G70F| caor| G70F| —GaoF Ca ED 30 3D 30 3D 30 25 25 Barometric pres- mbar | 1000 1000 1000 1000 1000 | 1000 “Site altitude m 100 100 | 100) 100) 100 100 eee mo POWER-RELATED DATA (power ratings are net brake power as per ISO ie Seer ders Rated engine 1500/1500) 1500/1500, ie (speed | Fuel stop power [A KW 358 304 448) 493, 638 Iso 3046 GENERAL CONDITIONS (for maximum power) Number of cylin- rr] 2 C Intake depression 2 28 25 25 [new iter) | | Intake depres- Ls [mbar 50 50) 50, 50 50, 50 sion, max. | | Exhaust verpres- |_| mbar 3 BBs a5 5 a5 sure | | ‘Exhaust overpres- |L_ | mbar 150) 150 150 150 150 150 sure, max. | I | | MS180076/0SE 2014-02 | TechniMODEL-RELATED DATA (basic design) eer Standard housing | connecting flange “(engine main PTO) SAE 01 or fies a or 01 1 |Fhuheslinceiace |_| DISG 14" Ty cg 1" AIR / EXHAUST R | barabs ‘sure before cylin der-BL COOLANT SYSTEM (HT circuit) (Coolant tempera A |°C ture (at engine ‘connection: outlet to cooling equip- ment) Number of cylin- ders Charge-air ores 29 29 peers ee 95 95 s 95, Coolant tempera /R |*C ture after engine, warning | 105 105 105 108 105 105 (Coolant tempera- | |*C ture after engine, shutdown 109 108 109 108 109 109 (Coolant antifreeze |L ‘content, max. 50 50 50 50 50 Pressure loss in |L | bar offengine cooling system, max. o7 o7 o7 07 LUBE-OIL SYSTEM Number of cylin: cS Lube oil operating emperature be- fore engine, from | 87 Cape of opening JF />C temperate |" | fowermnesto |_| 100100 100) 100 101 tor Lube oll operating |R-_ bar pressure before engine, from 45 45 40 42 | Lube oil operating |R bar pressure before ‘engine, to 38 | Technical Data | MS180076/0SE 2014-02 Ba 54 BtFUEL SYSTEM crereery cea Fuel pressure at ‘engin inlet con- neation, mi {when engine is starting) | Fuel pressure at | L engine inlet con- | “nection, max. (when engine starting) bar os 08 os 08 08 GENERAL OPERATII frerery co Cold start capabil-|® ity: air tempera- ture (w/o start ‘aid, w/o preheat- ing) - (case A) ING DATA, Nort Firing speed, from | [rom 80 80 80 20, 80 Firing speed, to R |m 120 120 120 120 ‘20 | CAPACITIES Engine coolant | R. capacity, engine side (without ‘cooling equip~ ment) Liters 50° Engine oll, total, | or initial iting {standard oil sys- tem) (option: ‘max. operating in- “clinations) titers 46 46) (605 605 725 | 725 Oil change quanti- | ty, max, (standard, “al system) (Op- tion: max. operat- ing inclinations) Liters: 53 MS180076/05E 2014-02 | Technical Data | 39Oil pan capacity Liters 46] {3t dipstick mark “min.” (standard cil system) (Op- ‘ion: max. operat- ing inclinations) i | Oil pan capacity |L (Liters a 3 53 33 oe 6a at dipstick mark max." (standard oil system) (Op- tion: max, operat: | ing incinations) |_| | WEIGHTS / MAIN DIMENSIONS Engine weight, dry (basic engine ‘configuration ace. ‘to scope of supply specification) 1444] 1444) 1749) 1749 2022/2022, ACOUSTICS eres rr ee Exhaust noise, un-|R | (A) 109) 109) 109,110) 109) 110 silenced - BL (freefield sound pressure level Lp, ‘im distance, ISO 6798, +308(4) tolerance) | ‘Exhaust noise, uv-|R | 8(A) vez] i) ~=—t22| =, | St silenced - BL {sound power lev- el LW, ISO (6798"34B)A) tok erance) | 40 | Technical Data | M5150076/05E 2014-023.7 8/10V 1600 G70F/G80F engine data, EU Nonroad Stage III A Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value . Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value ~ Not applicable X Applicable REFERENCE CONDITIONS errr rT 0V1600] 10V1600 ey ey ‘Application group l [| 90) aD) aD Inte air temperature [fe | 8) 28| asf as [Barometric pressure [mbar 1000" 1000/1000 1000 [Ste atitude above sea level im | 100) 100, 100) 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) [Se en Rated engine speed 1500) 1500, ‘1500/1500, Fuel stop power 180 3046 cm 358,98) aaa) a8, GENERAL CONDITIONS (for maximum power) LL ET] Intake depression (new filter) ‘A | mbar: 25 25 25) [Intake depression, max [L [mbar | 50 50 30) Exhaust overpressure TA [mbar 88] as) Exhaust overpressure, max, [Limba | 180,50, ~=«SD|~=CSD. MODEL-RELATED DATA (basic design) SET ED EL Standard housing connecting flange (en | SAE) OT 0 on o1 gine main PTO) | | Fiywheel interface Disc |) we) ee AIR / EXHAUST o 3.27 barabs | 3.12 ‘Charge-ir pressure before cylinder -8L MS 180076/05E 2014-02 | Technical Data | 41COOLANT SYSTEM (HT circuit) es ee a ree ea ‘Coolant temperature (at engine comnec- | |*C 95 95 95; 95 tion: outlet to coating equipment) | [Coolant temperature after engine, warning |R_| °C 108 105 105 105 Coolant temperature after engine, shut |L_|°C to9) 109/109) 109 down | [Coolant antifreeze content, max L |x 50 50 50 50, [Pressure oss in offengine cooing sy Lb 07, o7|o7| on tem, max. LUBE-OIL SYSTEM aT) Lube oll operating temperature before en- JR |°C a7 87 a7 87 sine, trom ‘Lube oi operating temperature before en- | [°C 100] 100/100) 100 Bin, to Lube ol operating pressure before engine, [R | bor 45| 43/48) 48 from Lube ol erating pressure before engine, [R | bar sa 84) sa) Ba) to | FUEL SYSTEM Fuel pressure at engine inlet connection, in, (when engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) GENERAL OPERATING DATA fiero Cold start capabiity: air temperature (w/o start aid, w/o preheating) - (case A) Firing speed, rom R lee so) 80) Firing speed, to a ) CAPACITIES TT (without cooling equipment) Engine oil, total, for initial filing (standard |R [Liters 46 46 60.5) a0] pee oar mag read tions) aeRO er | eae ne nea tions) 42 | Technical Data | MS150076/05E 2014-02eer ll pan capacity at diastick mark “min, (standard oil system (Option: max. oper ating inclinations) (il pan capacity at dipstick mark “max.” {standard oil system) (Option: max, oper- ating inclinations) WEIGHTS / MAIN DIMENSIONS ton) | Engine weight, dry (basic engine configu R |kg. “ration acc. to scope of supply specifica- i ty | ESS a ED Ve Utes % 36S) a Liters a 43 53 53, 1749 ACOUSTICS Pee Exhaust noise, unsilenced - BL (free-fiald ‘sound pressure level Lp, 1m distance, ISO |6798, +2dB(A) tolerance) Sa e8() 109) 109) 109) 110 Exhaust noise, unsilenced BL (sound power level LW, 180 6798-348 toler ance) | TR /aBiay 122 122 122 123 MS180076/0SE 2014.02 | Technical Data | 433.8 8/12V 1600 G70S engine data, EPA Tier 2, 3 Explanation: DL Ref. value: Continuous power BL Ref, value: Fuel stop power A Design value G Guaranteed value R Guideline value LL Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS LU BU TT) EST oe 0s] 670s Application group 5) aE) SE) Intake air temperature °C 25] 2s) a8] 8 Barometric pressure 1 [mbar ooo] 1000) 1000) 1000, St alitude above sea level im 100) 100,100] 100) POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) a Rated engine speed 14 |r 1800) 1800) 1800, Fuel stop power IO 3046 A kW 408408) «68 oll GENERAL CONDITIONS (for maximum power) a Intake depression (ew filter) Amar 525) |Itoke depression, max [mbar 30,80, ~<50|—~=SO Exhaust overpressure —_ [Ambar 8588 35 85 Exhaust overpressure, max. mbar 160/150 150/150; MODEL-RELATED DATA (basic design) Po 7 Standard housing connecting flange (en ‘SAE or oF or ot sine main PTO) | | Flywheel interface DISC 14° 14" cl AIR / EXHAUST Number of eylindrs a es Charger pressure before ayinger-BL | bar abs Bu 8) a2) 44 | Technical Data | MS150076/05E 2014-02COOLANT SYSTEM (HT circuit) ‘Coolant temperature (at engine connec- tem, max, outlet to cooling equipment) Coolant temperature after arning R °C 105) 108,~=~=«105) =n Coolant temperature after engine, shut- °C. 109) 109) 109) 109 “aown | | | ‘Coolant antifreeze content, max ule 50 50 50 50, Pressure lossinoffengine cooling ye |L bar ==) SCOT 1 1 LUBE-OIL SYSTEM Sern Lube oil operating temperature before en- gine, from i 87 87 SS a7, 87 Lube oil operating temperature before en- [R |°C 100 100) 101 101 gine, to _ Lube oll operating pressure before engine, |R | bar 45 45 45 45 {from | Lube oil operating pressure before engine, |R_ | bar | 54 54 54 54 ls FUEL SYSTEM (Enero “Fuel pressure at engine inlet connection, | | bar 05) 05 05 “0.5 min, (when engine is starting) | | Fuel pressure at engine inlet connection, |L | bar 05 08 08 os ‘max. {when engine is starting) GENERAL OPERATING DATA a ee ee Cold start capability: air temperature (w/o R | °C 20 start aid, w/o preheating) - (case A) Firing speed, from Firing speed, to CAPACITIES _Engine coolant capacity, engi ‘side 65 [age cnn cach Sea mame ena os Oil change quantity, max, (standard oll Liters, @ 8 64 64 ene | aes | MS150076/05E 2014-02 | Technical Data | 45eT Se [Oil pan capacity at dipstick mark “min” Liters 3) 5s 56. (standard ol system) (Option: max. oper- _ating inclinations) | “Oitpan capacity at dipstick mark“max* |L Liters a oe (standard oil system) (Option: max. oper- ating inclinations) 43 | of WEIGHTS / MAIN DIMENSIONS fines Engine weight, dry (basic engine configu- ration acc. to scope of supply specitica- tion) Ro kg 1444 “| 2022 1950 ACOUSTICS fiero Exhaust noise, unsilenced - BL ree-field ‘sound pressure level Lp, 1m distance, ISO 6798, +3d8(8) tolerance) R | dBKA) 109 109 [Exhaust nose, unsilenced BL (sound power level LW, ISO 6798+308\A)toler- | ance) R | aBiA) 122 122 122) Data | MS150076/05E 2014-023.9 8/10/12V 1600 G80S engine data, EPA Tier 2, 3 Explanation: DL. Ref. value: Continuous power BL Ref. value: Fuel stop power ‘A Design value G Guaranteed value R Guideli value LL Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value = Not applicable X Applicable REFERENCE CONDITIONS fv1609] s0v1600] t0v3400) 123600 ry Ges es ded Pe co Application group 30 =| Intake air temper- 3 25 25 25 25 25 ature Barometric pres. | (mbar 1000 —-1000/ 1000/1000, 1000/1000) sure | | Site altitude m woo. 100/100) ~—~100/-~—~*100) 400 above sea level | fresno ders POWER-RELATED DATA (power rating: e net brake power as per ISO 3046) Rated engine pm 1800/ 1800/1800) 1800/1800, -—«1800 speed Fuel stop power |A [kW 448 448 561 561 668 668 180 3046 GENERAL CONDITIONS (for maximum power) eens 10 cs ‘sure, max. Intake depression |A | mbar 3) 25) 2528 25 (new fier Intake depres: |L_| mbar so] 60/80) ~<80) ~~ =s0)—=s0 |slon, max | | Exhaust overpres- A [mbar wes) s] SS) Exhaust overpres-[L_|mbar 150) 150/150) —~—*150/—150/ ~—150 | MS150076/05E 2014-02 | Technical Data | 47MODEL-RELATED DATA (basic design) Number of ders Standardhousing | SAE connecting ange | (engine main PTO) | Fhyheelinterface | DISC ol iti oF ir 18 o1 14" AIR / EXHAUST Charge-airpres- |R | bar abs sure before cylin [der-BL | 30 3.0 ea a 2.93 COOLANT SYSTEM (HT circuit) Coolant tempera- ‘ture (at engine connection: outlet ‘to cooling equip- ment) 95, Coolant tempera- JR [°C ture after engine, warning, 105 105 105 105 105 ‘Coolant tempera- |L | °C ture after engine, shutdown 109 109 109 109 109 109 Coolant antifreeze |L | % content, max. { 50 50 50 50 50) 50 Pressure loss in |L | bar off-engine cooling 07 o7 o7 o7 system, max. LUBE-OIL SYSTEM ‘Lube oil operating ‘temperature be- fore engine, from Lube oil operating |R [°C ‘temperature be- {ore engine, to 100 100 tor 101 tor Lube oil operating | R [bar pressure before engine, from 45 45 45 a8 45 a5 Lube oil operating |R [bar pressure before engine, to Ba 54 54 54 54) 54 48 | Technical Data | MS150076/05E 2014-02,FUEL SYSTEM ere ders “Fuel pressure at engine inlet con- “nection, in, (when engine is ane | | | Fuolpressueat [Lib 05/05) engine inlet con- nection, max. | {when engine is starting) | 05 05 GENERAL OPERATING DATA erent co Cold start capabil- ity: air tempera- ture (w/o start aid, w/o preheat- ing) (case A) Firing speed, from R rpm 80 80 80 80 80 Firing speed,to_|R [rpm 120 120 120 120 120 120| CAPACITIES rent co “Engine coolant capacity, engine | side (without cooling equip: ment) | Engine oll total, |R liters | 46/46) _——-605| 608] 728 ~—«728 fornia filing [standard oi ys- tem) (option: | max, operating in- | clnations) Oitchange quanti-|R [Lites | 43) == sa) 88 o | 65 “yy max. (standard “oil system) (Op | tion: max. operat- | ing inclinations) MS150076/05E 2014-02 | Technical Data | 49eee fo (Oil pan capacity (L_|Liters 36 ‘t dipstick mark min,” (standard cil system) (Op- tion: max. operat- ing inclinations) 36 46 46. 56 56 [Ollpon capacity Liters a at dipstick mark max” (standard cil system) (Op- tion: max. operat ing inclinations} 43 53 53 64 64 WEIGHTS / MAIN DIMENSIONS ks eer ders Engine weight, dry (basic engine configuration acc. to scope of supply. specification) 1444 1448 1749 1749 2022: 2022 ACOUSTICS Reon ders | Exhaust noise, un- dBA) 109 “silenced BL | free-field sound pressure level Lp, ‘im distance, iSO 6798, +3dB(A) tolerance) 109 110 i) 110 Exhaust noise, un-|R dB(A) 122 silenced - BL (sound power lev- el LW, ISO 6798+348(A) tol- ‘erance) 122 123 123 123 123 50 | Technical Data | MS150076/05¢ 2014-02