Maintenance Booklet

Diesel Engine
R 1600 Gx0 x
V 1600 Gx0 x
Application Group 3D

MSE50055/00E
Engine model kW/cyl. Application group
6R1600G70F 45.7 kW/cyl. 3D, Standby operation with variable load
6R1600G70S 52 kW/cyl. 3D, Standby operation with variable load
6R1600G80F 50.2 kW/cyl. 3D, Standby operation with variable load
6R1600G80S 57.2 kW/cyl. 3D, Standby operation with variable load
8V1600G7 0F 44. kW/cyl. 3D, Standby operation with variable load
8V1600G70S 51 kW/cyl. 3D, Standby operation with variable load
8V1600G80F 49,3 kW/cyl. 3D, Standby operation with variable load
8V1600G80S 56 kW/cyl. 3D, Standby operation with variable load
10V1600G70F 44,8 kW/cyl. 3D, Standby operation with variable load
10V1600G70S 51,1 kW/cyl. 3D, Standby operation with variable load
10V1600G80F 49.3 kW/cyl. 3D, Standby operation with variable load
10V1600G80S 56.1 kW/cyl. 3D, Standby operation with variable load
12V1600G70F 48 kW/cyl. 3D, Standby operation with variable load
12V1600G70S 51.1 kW/cyl. 3D, Standby operation with variable load
12V1600G80F 52.8 kW/cyl. 3D, Standby operation with variable load
12V1600G80S 55.7 kW/cyl. 3D, Standby operation with variable load

Table 1: Applicability

Printed in Germany
© 2013 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 Maintenance booklet 1.4.3.1 Maintenance schedule matrix 9
1.4.3.2 Maintenance tasks 10
1.1 Engine data 4
1.2 Introduction 5 1.5 Confirmation of 1st to 4th maintenance
1.3 Fluids and lubricants 6 services 11
1.4 MTU Maintenance Schedule 7 1.6 Confirmation of 5th to 8th maintenance
1.4.1 Preface 7 services 12
1.4.2 Restrictions 8 1.7 Confirmation of 9th to 12th maintenance
1.4.3 Maintenance Tasks 9 services 13
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MSE50055/00E 2013-11 | Table of Contents | 3

 1 Maintenance booklet
1.1 Engine data
Model Engine No.

Delivery date Commissioning

date

Owner Address

Use as Date, stamp, sig-

nature

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 1.2 Introduction
This Maintenance Booklet serves as a guideline for maintenance of your engine / genset.
Regular performance of the specified maintenance tasks in a timely manner provides a basis for opera-
tional reliability of your engine / genset.
The scope and frequency of the maintenance tasks is based primarily on the various operating condi-
tions.
Always have maintenance tasks performed by Service support center personnel qualified for this work.
They have the necessary specialist skills and tools to perform the activities required.

Confirmation
Performed maintenance activities are confirmed by the respective Service support center in this Main-
tenance Booklet.

Initial operation

Prior to initial operation of the engine / genset, read the section "Putting the engine into operation" of
the Operating Instructions for your engine.

Engine oil level

Coolant level

Safety instructions and warning notices

Familiarize yourself with the safety instructions and warning notices before working on the engine /
genset and read the relevant technical documentation, e.g. Operating Instructions.
When performing all tasks, the generally applicable country-specific legislation and other compulsory
regulations regarding accident prevention and environmental protection must be observed.

Warranty
Claims can be submitted to MTU Friedrichshafen GmbH with regard to defects of quality based on the
purchase contract.
If, during the warranty period, specified maintenance tasks are not carried out regularly, or in good
time, or in unqualified workshops, the validity of a claim based on defects of quality can only be decided
following preparation of examination findings by the manufacturer.
The use of fluids and lubricants not approved by MTU Friedrichshafen GmbH may reduce the validity of
claims due to defects of quality.
Special additives are not required in lubricants. This could have a negative effect on the properties of
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the fluids and lubricants and result in damage to the engines / gensets. The use of special additives
may reduce the validity of claims due to defects of quality.

MSE50055/00E 2013-11 | Maintenance booklet | 5

 1.3 Fluids and lubricants
Fluids and lubricants are decisive and integral design elements with regard to the operation and service
life of the engine / genset. They must therefore be continuously adapted to the current technical quali-
ty standard of the engine / genset.
Fluids and lubricants include:

• Lubricants (oils, greases)

• Coolants

• Fuels

Only use engine oils of MTU oil category 2 or 3.

The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a
list of approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications
A001063/..and in the fluids and lubricants specifications of the component manufacturers. They are
therefore not included in the maintenance schedule (exception: deviations from the Fluids and Lubri-
cants Specifications). All fluids and lubricants used must meet MTU specifications and be approved by
the relevant component manufacturer.
Prior to use, ensure that your copy of MTU Fluids and Lubricants Specifications A001063/.. is up to
date. The latest version is also available at: http://www.mtu-online.com/MTU/select English lan-
guage/Technical Info/Fluids and Lubricants Specifications ...

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 1.4 MTU Maintenance Schedule
1.4.1 Preface
The maintenance schedule is applicable to products certified in accordance with U.S. emissions regula-
tions and operated in the area of applicability of these regulations.
The following instructions must be observed for these products:
The maintenance schedule is an integral part of the emissions certification. Nonobservance of the main-
tenance instructions can result in violation of the statutory emission specifications. Modification or re-
moval of mechanical or electronic components or the installation of additional components as well as
the execution of calibration processes that might affect the emission characteristics of the product are
prohibited by emission regulations. Emission-related components, e.g. control units, sensors, cylinder
heads, injectors and exhaust flaps can only be serviced, replaced or repaired if components approved
by MTU or equivalent components are used.
The maintenance system for MTU products is based on a preventive maintenance concept. Preventive
maintenance facilitates advance operational planning and ensures a high level of equipment availabili-
ty.The maintenance intervals and the scope of required maintenance activities are the result of opera-
tional experience and therefore represent recommendations. Severe operating and ambient conditions
may require additional maintenance work and/or modification of the maintenance intervals.
Maintenance activities are specified with intervals based on hours in operation and time limits. Which-
ever value is reached first shall apply.
The individual maintenance intervals are classified in accordance with the qualification levels QL1 to
QL4.
QL1: Maintenance work which requires complete disassembly of the product.
QL2: Exchange of components and parts (corrective only, not part of the maintenance schedule).
QL3: Maintenance work which requires partial disassembly of the product.
QL4: Maintenance work which requires complete disassembly of the product.

Additional notes on maintenance and preservation:

For change intervals for fluids and lubricants as well as for preservation specifications, refer to the rele-
vant instructions of the component manufacturers and the MTU Fluids and Lubricants Specifications.
The latest version is also available at: http://www.mtu-online.com.
Components which are not listed in this maintenance schedule must be serviced in accordance with
Manufacturer's Instructions.

Application groups
MTU products are divided into the applications Industry, Rail, Marine, Oil & Gas and Power Gen. The
individual application areas are subdivided into application groups.
The intervals according to which the maintenance tasks are to be carried out are based on the respec-
tive application group (operating mode).
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Application group 3D (PowerGen)

Standby operation with variable load
Load factor: <85%

Useful life
Useful life: 8000h

MSE50055/00E 2013-11 | Maintenance booklet | 7

 1.4.2 Restrictions
The engine must not be used for peak shaving.

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 1.4.3 Maintenance Tasks

1.4.3.1 Maintenance schedule matrix

0-8,000 operating hours
Item Operating hours [h]

1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
Limit

Daily
500
Engine
Engine operation - X
Engine oil filter 2a
Fuel prefilter 2a X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X
Belt drive 2a X X X X X X X X
Valve gear - X X X X
Belt drive 2a X X
Belt drive 2a X X
Air filter 3a X X
Extended component maintenance 18 a X
w = weeks
m = months
a = years
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MSE50055/00E 2013-11 | Maintenance booklet | 9

 1.4.3.2 Maintenance tasks
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
Engine
QL1 Daily - Engine operation Check engine oil level. W0500
Visually inspect engine for leaks and general condition. W0501
Check signal ring position of service indicator, replace air filter if nec- W0521
essary.
QL1 - 2a Engine oil filter Replace engine oil filter when changing engine oil, or when the time W1008
limit (years) is reached, at the latest.
QL4 500 2a Fuel prefilter Replace fuel prefilter and clean housing. W1020
QL1 500 2a Fuel filter Replace fuel filter or fuel filter element. W1001
QL1 1000 2a Belt drive Check belt condition and tension, replace if necessary. W1003
QL1 2000 - Valve gear Check valve clearance, adjust if necessary. ATTENTION! First adjust- W1207
ment after 1,000 operating hours.
QL1 4000 2a Belt drive Replace drive belts of battery-charging generator and coolant pump. X W1505
QL1 4000 2a Belt drive Replace poly-Vee drive belt of fan. W1483
QL1 4000 3a Air filter Replace air filter. W1005
QL4 8000 18 a Extended component mainte- Overhaul or replace engine. W3148
nance
w = weeks
m = months
a = years

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 1.5 Confirmation of 1st to 4th maintenance services
1st service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

2nd service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

3rd service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

4th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________
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Company stamp of qualified service center

_________________________
Date/signature

Refer to Tasks section for details of maintenance scope

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 1.6 Confirmation of 5th to 8th maintenance services
5th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

6th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

7th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

8th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________
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Company stamp of qualified service center

_________________________
Date/signature

Refer to Tasks section for details of maintenance scope

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 1.7 Confirmation of 9th to 12th maintenance services
9th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

10th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

11th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________

Company stamp of qualified service center

_________________________
Date/signature

12th service
Due: _______ operating hours
Completed: _______ operating hours
Engine oil brand/viscosity: ____________________
Rep. order no.: ____________________
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Company stamp of qualified service center

_________________________
Date/signature

Refer to Tasks section for details of maintenance scope

Regular servicing ensures the operational availability of your engine. Please request a new maintenance
booklet from your MTU Service Center to continue documenting proof of maintenance.

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