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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