MTU 10V1600C Series User manual

Operating Instructions
Diesel Engine
10V1600Cx0
12V1600Cx0
MS150100/06E

Engine model kW/cyl. Application group
10V1600C60 57 kW/cyl. 5B, continuous operation, variable
10V1600C70 61 kW/cyl. 5B, continuous operation, variable
12V1600C50 53 kW/cyl. 5B, continuous operation, variable
12V1600C60 57 kW/cyl. 5B, continuous operation, variable
12V1600C70 61 kW/cyl. 5B, continuous operation, variable
Table 1: Applicability
© 2017 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 C&I and O&G, application 1600 – Intended
use 7
1.3 Personnel and organizational requirements 8
1.4 Safety regulations for initial start-up and
operation 9
1.5 Safety regulations for assembly,
maintenance, and repair work 11
1.6 Fire and environmental protection, fluids
and lubricants 15
1.7 Standards for warning notices in the text
and highlighted information 17
2 Transport
2.1 Transportation 18
2.2 Lifting requirements 21
3 General Information
3.1 Engine side and cylinder designations 22
3.2 Engine – Overview 23
3.3 Sensors and actuators – Overview 25
4 Technical Data
4.1 Engine data 10V1600C60 / 10V1600C70,
US EPA Nonroad Tier 4 (40 CFR 1039),
emissions-optimized 30
4.2 Engine data 10V1600C60 / 10V1600C70,
US EPA Nonroad Tier 4 (40 CFR 1039)
compliant, emissions-optimized 34
4.3 Engine data 12V1600C50 / 12V1600C60 /
12V1600C70, US EPA Nonroad Tier 4 (40
CFR 1039), emissions-optimized 38
4.4 Engine data 12V1600C50 / 12V1600C60 /
12V1600C70, US EPA Nonroad Tier 4 (40
CFR 1039) compliant, emissions-optimized 42
4.5 Firing order 46
4.6 Engine – Main dimensions 47
5 Operation
5.1 Putting the engine into operation after
scheduled out-of-service-period 49
5.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 50
5.3 Engine – Starting 51
5.4 Operational checks 52
5.5 Emission label – Check 53
5.6 Engine shutdown 54
5.7 After stopping the engine 55
5.8 Plant – Cleaning 56
6 Maintenance
6.1 Maintenance task reference table [QL1] 57
7 Troubleshooting
7.1 Troubleshooting 58
7.2 Engine Control Unit ECU9 – Fault messages 61
8 Task Description
8.1 Engine 102
8.1.1 Engine – Barring manually 102
8.1.2 Engine – Test run 103
8.2 Valve Drive 104
8.2.1 Valve clearance – Check and adjustment 104
8.2.2 Cylinder head cover – Removal and
installation 107
8.3 Fuel System 110
8.3.1 Fuel system – Venting 110
8.4 Fuel Filter 113
8.4.1 Fuel filter – Replacement 113
8.4.2 Fuel prefilter – Draining 115
8.4.3 Fuel prefilter – Filter element replacement 116
8.5 Air Filter 117
8.5.1 Air filter – Replacement 117
8.6 Air Intake 118
8.6.1 Service indicator – Check 118
8.7 Exhaust Gas Recirculation 119
8.7.1 Exhaust flaps – Overview 119
8.7.2 EGR shutoff flaps – Coupling rod function and
play check 120
8.7.3 EGR shutoff flaps – Coupling rod replacement 121
8.7.4 Bypass flap – Coupling rod function and play
check 124
8.7.5 Bypass flaps – Coupling rod replacement 126
8.7.6 EGR cooler – Check 129
8.7.7 EGR cooler – Replacement 130
8.8 Lube Oil System, Lube Oil Circuit 132
8.8.1 Engine oil level – Check 132
8.8.2 Engine oil – Change 135
8.9 Oil Filtration / Cooling 137
8.9.1 Engine oil filter – Replacement 137
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8.10 Coolant Circuit, General, High-Temperature
Circuit 139
8.10.1 Engine coolant – Level check 139
8.10.2 Engine coolant – Change 140
8.10.3 Engine coolant – Draining 141
8.10.4 Engine coolant – Filling 143
8.10.5 Engine coolant pump – Relief bore check 145
8.11 Low-Temperature Circuit 146
8.11.1 Charge-air coolant level – Check 146
8.11.2 Charge-air coolant – Change 147
8.11.3 Charge-air coolant – Draining 148
8.11.4 Charge-air coolant – Filling 149
8.11.5 Charge-air coolant pump – Relief bore check 151
8.12 Belt Drive 152
8.12.1 Drive belt – Condition check 152
8.12.2 Drive belt – Replacement 153
8.13 Battery-Charging Generator 155
8.13.1 Battery-charging generator – Cleaning 155
8.14 Drive Systems, Driving End and Free End
(Coupling) 156
8.14.1 Coupling – Checking radial/axial play 156
8.15 Wiring (General) for Engine/Gearbox/Unit 157
8.15.1 Engine cabling – Check 157
8.16 Accessories for (Electronic) Engine
Governor / Control System 158
8.16.1 Engine governor and connector – Cleaning 158
8.16.2 Engine governor – Checking plug-in
connections 159
8.16.3 NOx sensor – Replacement 160
8.16.4 Lambda sensor – Replacement 162
9 Appendix A
9.1 Abbreviations 164
9.2 MTU Contact/Service Partners 167
10 Appendix B
10.1 Special Tools 168
10.2 Index 174
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1 Safety
1.1 Important provisions for all products
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
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission-related components must only be serviced, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these specifications will invalidate the design type approval or certification issued by
the emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 7).
Emission certification applicable to engines with EPA Nonroad Tier 4 emission
certification in accordance with 40 CFR 1039
Extract from the standard:
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
Extract from the standard:
If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.
When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This
paragraph described the process for requesting and fitting the label, the documentation obligations and stor-
age obligations for the required documents.
Replacing components with emission labels
On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
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Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Emission labels shall not be transferred from the replaced part to the spare part.
• The emission labels must be removed from the replaced part and destroyed.
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1.2 C&I and O&G, application 1600 – Intended use
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• The Assembly Instructions must be available and be observed
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
The engine is not designed for operation in a potentially explosive atmosphere.
• The engine or electronic engine management system can produce electric sparks, which can ignite com-
bustible gases in the surrounding area.
• There is also a risk of the engine drawing in combustible gases, thus resulting in uncontrolled operation.
Neither can the possibility of components being ejected suddenly from the engine be excluded.
• The engine can generate sparks or flames in the exhaust system that can ignite combustible gases in the
surrounding area.
It is the responsibility of the operating company to install and operate the engine a safe distance from a dan-
ger source. Any existing safety regulations or recommendations must be observed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
The engine can shut down or continue operating at reduced power. If the engine is used for safety-related
tasks, or if this behavior compromises safety, corresponding backup solutions must be implemented by the
OEM or operating company.
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment
Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorisation and restriction of CHemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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1.4 Safety regulations for initial start-up and operation
Safety regulations for initial start-up
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• The product must be free of any damage, this applies in particular to lines and cabling.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/urea solution line, sup-
ply/return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• inform supervisor(s) in charge,
• analyze the message,
• respond by taking any necessary emergency action, e.g. emergency stop.
Contact Service if the root cause of the malfunction cannot be clearly identified.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
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The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.
Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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1.5 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch of the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Before working on the exhaust gas treatment system close the shutoff valve on the urea solution tank. Take
into consideration that the urea solution pumps continue to run for a certain period when the engine is stop-
ped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work
Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Setting down, lifting and climbing
Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down.
Assume a safe standing position when performing assembly work.
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Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Removing, installing and cleanliness
Pay particular attention to cleanliness at all times.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Miscellaneous
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-
ing on exhaust components. Wear protective gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). 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 sheet.
Safety regulations after performing assembly, maintenance, and repair work
Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
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Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working with batteries
Observe the safety instructions of the manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
ESD: Work on electrostatically endangered components which could be damaged by electrostatic discharge
(ESD) must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically con-
ductive work surfaces or antistatic wristbands.
Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
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Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular. The functional check of the emergency stop, during which the
voltage supply of the ECU is switched off, must only be carried out when the product is cold.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)
Working with laser equipment
Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to type
and application.
Measuring component dimensions
Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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1.6 Fire and environmental protection, fluids and lubricants
Fire prevention and fire
Fire, naked light and smoking are prohibited.
The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.
The operating company must install and operate the product a safe distance away from danger sources and
observe any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-
tion do not constitute such as danger.
After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Fuel or oil on hot components can cause fires – therefore always
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.
Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Ensure that suitable extinguishing agents (fire extinguishers) are always available and that staff are familiar
with their correct handling.
A fire can result in the creation of toxic substances. Always wear protective gloves when handling compo-
nents and wear additional personal protective equipment is necessary.
Noise
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.
Environmental protection and disposal
Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Operating fluids and auxiliary materials
Process materials can also be or contain hazardous or toxic substances. When using process materials and
other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained
from the relevant manufacturer or from MTU.
Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi-
cations must be used. The most recent respective version must be requested from the manufacturer.
Contamination of process materials with urea solution (e.g. AdBlue®, DEF): Store process materials in sepa-
rate containers and their own drip trays. Even extremely small amounts of urea solution contamination can
result in malfunctions in sensors and other components.
Used oil contains combustion residues that are harmful to health.
When handling used oil, protective gloves must be used.
Wash relevant areas after contact with used oil.
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Registration, evaluation, approval and restriction of chemicals (REACH
ordinance)
Particularly hazardous substances used with our products are named in a list:
www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products
Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away chips.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
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 which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing a compressed air device from the supply line. To depressurize
compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out a leak test in the specified manner.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. 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 for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that the working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (e.g. 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 cloth-
ing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After skin contact, wash affected body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean mains water. Consult a doctor as soon as possible.
Contamination of urea solution with other process materials: Store urea solution in separate containers
and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the exhaust
aftertreatment system.
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1.7 Standards for warning notices in the text and highlighted
information
DANGER In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
CAUTION In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.
NOTICE In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.
Warning notices
1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.
Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
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2 Transport
2.1 Transportation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80092479 1
DANGER Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
DANGER Engine tips over if unstable.
Risk of crushing body or limbs!
• Check whether the engine may be set down on the oil pan.
• The engine must be appropriately secured to prevent it tipping over when it is set down on the oil
pan.
Transportation
1. Install the locking screws for the engine mounts prior to engine transportation. Remove resilient mounts.
2. Transport the engine by the lifting eyes provided (→ Page 21).
3. Use suitable transport and lifting gear only.
4. Transport the engine in the installation position only: max. admissible diagonal pull 10° (→ Page 21).
5. Remove any loose parts on the engine.
6. Raise and lower the engine slowly. Lifting cables/chains must not touch the engine or any of its component
parts when lifting. Readjust lifting gear as necessary.
7. For special packaging with aluminum foil: Suspend the engine by the lifting eyes on the bearing pedestal or
transport by means of handling equipment (forklift truck) capable of bearing the load.
8. Secure the engine against tipping during transportation. Secure such as to preclude slipping and tipping
when driving up or down inclines and ramps.
Setting down an engine with standard oil pan after transportation
Note: The engine may only be set down on the oil pan in exceptional cases and then by trained and qualified per-
sonnel only.
1. Set down engine with standard oil pan (→ Page 47) on a firm, level surface only. The surface beneath the oil
pan must be free of any foreign bodies.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Setting down an engine with mid sump oil pan after transportation
Note: The engine may only be set down on the oil pan in exceptional cases and then by trained and qualified per-
sonnel only.
1. Set down engine with mid sump oil pan (→ Page 47) on a firm, level surface only. The surface beneath the
oil pan must be free of any foreign bodies.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Set the engine down on the oil pan. Do not remove the lifting chains!
4. Secure the engine by placing suitable wooden chocks under the engine mounting brackets leaving no clear-
ance (→ Page 19). During this procedure the engine must stand fully on the oil pan leaving the lifting chains
tensioned as a safety measure.
5. The lifting chains may be removed once the engine has been secured such as to prevent it toppling over.
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Position of the wooden chocks (view of driving end)
Position of the wooden chocks on an engine with 4-point mounting (free end
and side view)
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Position of the wooden chocks on an engine with 3-point mounting (free end
and side view)
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