MTU 6R1600M20x Operating Instructions Manual
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MTU 6R1600M20x Operating Instructions Manual

MTU 6R1600M20x Operating Instructions Manual

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Operating Instructions

Diesel engine
6R1600M20x
MS15029/01E

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Summary of Contents for MTU 6R1600M20x

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 6R1600M20x MS15029/01E...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 5 Maintenance 1.1 Important provisions for all products 5.1 Maintenance task reference table [QL1] 1.2 Personnel and organizational requirements 1.3 Safety regulations for startup and operation 6 Troubleshooting 1.4 Safety regulations for maintenance and 6.1 Troubleshooting repair work 6.2 Engine governor ECU9 –...
  • Page 4 7.14 Belt Drive 8 Appendix A 7.14.1 Drive belt – Condition check 8.1 Abbreviations 7.14.2 Belt tensioner – Check 8.2 MTU contact persons/service partners 7.14.3 Drive belt – Replacement 7.14.4 Belt tensioner – Tensioning element and tensioning roller replacement 9 Appendix B 7.15 Wiring (General) for Engine/Gearbox/Unit...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...
  • Page 6 Replacing components with emission labels Emission labels are attached to all MTU engines. These must remain on the engine throughout its op- erational life. Engines used exclusively in land-based, military applications other than by US government agencies are excepted from this proviso.

  • Page 7: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the user/manufacturer 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 it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 8: Safety Regulations For Startup And Operation

    1.3 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica- tions 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.
  • Page 9 Observe the warning information applicable to the devices. MS15029/01E 2015-06 | Safety | 9...

  • Page 10: Safety Regulations For Maintenance And Repair Work

    1.4 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 (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 11 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 retainers and dampers are installed correctly. Ensure that O-rings are not installed ina slanted/twisted condition.
  • Page 12 For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed on. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries.

  • Page 13: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials.

  • Page 14: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale lead vapors. • Wash relevant areas after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 15: Auxiliary Materials, Fire Prevention And Environmental Protection

    Only fuels of the specified quality required to achieve emission limits must be used. Dispose of used fluids, lubricants and filters in accordance with local regulations. Batteries can be returned within the EU to MTU FN / MTU Onsite Energy free of charge for correct recy- cling/disposal.
  • Page 16 Rub your hands with skin protection cream. Wash your hands after contact with used oil. Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Prevent the buildup of white powder of lead. •...

  • Page 17: Standards For Safety Notices In The Text

    1.7 Standards for safety notices in the text 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! •...

  • Page 18: Transport

    • Make sure that the consistency and load-bearing capacity of the ground or support surface is ade- quate. • Never set down engine onto the oil pan unless expressly permitted by MTU on an engine-specific base. • Only set down engine on a firm, level surface.

  • Page 19: General Information

    2 General Information 2.1 Engine side and cylinder designations 1 Engine free end in accord- 3 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite) 2 Right engine side 4 Left engine side For engine side designation (acc.

  • Page 20: Product Description

    2.2 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine, rotating counter-clockwise (viewed on driving end), with direct injection and charge air cooling. The engine is monitored by an engine control and monitoring system. The monitoring in the engine room is carried out by the engine control and monitoring unit.
  • Page 21 SOLAS – Fire safety requirements Fuel system, fuel lines with fuel pressure >1.8 bar SOLAS-compliant covers must be fitted to pipe joints according to MTU standard MTN5233 (→ Page 67). Lube oil system, oil lines with oil pressure >1.8 bar SOLAS-compliant covers must be fitted to pipe joints according to MTU standard MTN5233 (→...
  • Page 22 b) Plug-in pipe connection The sleeve (3) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (2) defect occurs. The connection is confirmed as compliant with SOLAS by DNV and GL. HP connections 1 Compensating disks 6 Not applicable...

  • Page 23: Engine Overview

    2.3 Engine overview 1 Engine lifting eyes 5 Raw water pump 9 Flywheel 2 Engine oil filter 6 Plate-core heat exchanger 10 Flywheel housing 3 Air filter 7 Crankcase breather KS Driving end 4 Exhaust turbocharger 8 Starter (pneumatic/elec- tric) MS15029/01E 2015-06 | General Information | 23...
  • Page 24 7 Oil pan 11 Coolant expansion tank 4 Engine mounting 8 Belt drive KGS Free end Engine model designation Key to the engine model designation 6R1600M20x Number of cylinders Cylinder arrangement: In-line engine 1600 Series Application (M = Marine) Application segment (1, 2, 4, 5, 7, 8)

  • Page 25: Sensors And Actuators - Overview

    2.4 Sensors and actuators – Overview Monitoring of Description B6.1 Engine coolant temperature at engine outlet B6.2 Coolant temperature at engine outlet for Engine coolant pressure B5.1 Lube oil pressure after filter Lube oil temperature MS15029/01E 2015-06 | General Information | 25...
  • Page 26 Monitoring of Description B48.1 Fuel high pressure B5.2 Lube oil pressure, redundant XY39.A2 Injector A2 Charge-air pressure Charge-air temperature XY39.A1 Injector A1 Fuel pump (HP) EMU - EIM connection Sensor connection to EMU EIM connection 26 | General Information | MS15029/01E 2015-06...
  • Page 27 Monitoring of Description Engine identification (Engine Ident Label EIL) Engine coolant level Camshaft speed Injector connection to governor ECU9 Connection to governor ECU9 Sensor connection to governor ECU9 B5.3 Lube oil pressure before filter B34.1 Fuel pressure after filter Fuel temperature Leak fuel level MS15029/01E 2015-06 | General Information | 27...
  • Page 28 Monitoring of Description Exhaust gas temperature B7.3 Lube oil temperature before turbocharger B5.8 Lube oil pressure before turbocharger Turbocharger speed B13.1 Crankshaft speed B13.2 Crankshaft speed for EMU 28 | General Information | MS15029/01E 2015-06...

  • Page 29: Technical Data

    3 Technical Data 3.1 Engine data 6R1600M20F, 6R1600M20S, engine-mounted heat exchanger, IMO Tier 2 Explanation Abbr. Meaning Ref. value: Continuous power. Continuously available power under standard conditions Ref. value: Fuel stop power. Maximum engine power. Not available continuously in some ap- plications (reserve for stabilization) Design value.
  • Page 30 Reference conditions Intake air temperature °C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level Raw water inlet temperature °C Performance data Rated engine speed 1500 1500 1800 1800 Continuous power ISO 3046 (10% over- load possible) (power range DIN 6280, ISO 8528) General conditions (for maximum power) Intake depression (new filter)
  • Page 31 Lube oil operating pressure upstream of engine, from Lube oil operating pressure before en- gine, to Fuel system Fuel pressure at engine inlet connection, -0.5 -0.5 -0.5 -0.5 min. (when engine is starting) Fuel pressure at engine inlet connection, -0.5 -0.5 -0.5 -0.5...
  • Page 32 Noise Exhaust noise, unsilenced - BL (free-field dB(A) sound-pressure level Lp, 1m distance, ISO 6798, +3dB(A) tolerance) Engine surface noise, without intake dB(A) noise - DL (free-field sound-pressure lev- el Lp, 1m distance, ISO 6798, +2dB(A) tolerance) 32 | Technical Data | MS15029/01E 2015-06...

  • Page 33: Engine Data 6R1600M20F, 6R1600M20S, Remote Heat Exchanger, Imo Tier

    3.2 Engine data 6R1600M20F, 6R1600M20S, remote heat exchanger, IMO Tier 2 Explanation Abbr. Meaning Ref. value: Continuous power. Continuously available power under standard conditions Ref. value: Fuel stop power. Maximum engine power. Not available continuously in some ap- plications (reserve for stabilization) Design value.
  • Page 34 Performance data Rated engine speed 1500 1500 1800 1800 Continuous power ISO 3046 (10% over- load possible) (power range DIN 6280, ISO 8528) General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model related data (basic design) Cylinder arrangement: V-angle Degrees (°)
  • Page 35 Fuel system Fuel pressure at engine inlet connection, -0.5 -0.5 -0.5 -0.5 min. (when engine is starting) Fuel pressure at engine inlet connection, -0.5 -0.5 -0.5 -0.5 min. (when engine is running) Fuel pressure at engine inlet connection, max. (when engine is starting) General operating data Firing speed, from Firing speed.

  • Page 36: Engine Data 6R1600M20S, Engine-Mounted Heat Exchanger, Epa Tier 3

    3.3 Engine data 6R1600M20S, engine-mounted heat exchanger, EPA Tier 3 Explanation Abbr. Meaning Ref. value: Continuous power. Continuously available power under standard conditions Ref. value: Fuel stop power. Maximum engine power. Not available continuously in some ap- plications (reserve for stabilization) Design value.
  • Page 37 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model related data (basic design) Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 1.75 1.75 Displacement, total Liters 10.5 10.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder Raw water circuit (open circuit) Raw water pump: Inlet pressure, min.
  • Page 38 Starting (electrical) Nominal starter voltage Starting (with compressed-air/hydraulic starter motor) Starting-air pressure before starter motor, min. Starting-air pressure before starter motor, max. Oil and coolant capacity Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (Option: Liters max.

  • Page 39: Engine Data 6R1600M20S, Remote Heat Exchanger, Epa Tier 3

    3.4 Engine data 6R1600M20S, remote heat exchanger, EPA Tier 3 Explanation Abbr. Meaning Ref. value: Continuous power. Continuously available power under standard conditions Ref. value: Fuel stop power. Maximum engine power. Not available continuously in some ap- plications (reserve for stabilization) Design value.
  • Page 40 Model related data (basic design) Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 1.75 1.75 Displacement, total Liters 10.5 10.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder Raw water circuit (open circuit) Raw water pump: Inlet pressure, min. Raw water pump: Inlet pressure, max.
  • Page 41 Starting (with compressed-air/hydraulic starter motor) Starting-air pressure before starter motor, min. Starting-air pressure before starter motor, max. Oil and coolant capacity Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (Option: Liters max.

  • Page 42: Firing Order

    3.5 Firing order Firing order Number of cylinders Firing order 2–4–1–5–3–6 42 | Technical Data | MS15029/01E 2015-06...

  • Page 43: Engine - Main Dimensions

    3.6 Engine – Main dimensions Engine – Main dimensions Height (C) Engine model Length (A) Width (B) 6R1600M20x approx. 1554 mm approx. 1193 mm approx. 1297 mm MS15029/01E 2015-06 | Technical Data | 43...

  • Page 44: Operation

    4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the PowerPack into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...

  • Page 45: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 95); Coolant circuit Check engine coolant level (→ Page 102). Monitoring system Carry out lamp test (see manufacturer's documentation).

  • Page 46: Engine Start In Manual Operation (Trials)

    4.3 Engine start in manual operation (trials) Preconditions ☑Generator is not connected to network. ☑External start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 47: Safety System - Override

    4.4 Safety system – Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! • Use override function only in hazardous situations to ensure full capability in the event of engine faults.

  • Page 48: Operational Checks

    4.5 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 49: Engine Stop In Manual Operation (Trials)

    4.6 Engine stop in manual operation (trials) Preconditions ☑Generator is not connected to network. ☑Engine is running in manual mode. Preparation Item Task Engine After the generator breaker has been opened, allow the engine to cool down by running it idle for approx. 5 minutes. Stop engine Item Task...

  • Page 50: Emergency Stop

    4.7 Emergency stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Item Action Emergency stop pushbutton Press pushbutton. • Engine is stopped by disconnecting the power supply to the ECU; •...

  • Page 51: After Stopping The Engine - Engine Remains Ready For Operation

    4.8 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control MS15029/01E 2015-06 | Operation | 51...

  • Page 52: After Stopping Engine - Putting Engine Out Of Operation

    Air intake and exhaust sys- Out-of-service-period > 1 week • Seal engine's air and exhaust sides. Engine Out-of-service-period > 1 month • Preserve engine (→ MTU Preservation and Represervation Specifications A001070/..). Engine/generator/pump Switch off. control 52 | Operation | MS15029/01E 2015-06...

  • Page 53: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a separate publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 54: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action u Charge or replace (→ manufacturer's documentation). Battery low or defective u Check cable connections for secure seating (→ manufacturer's Cable connections defective documentation). Starter: Engine cabling o starter u Check if cable connections are properly secured, contact defective Service.
  • Page 55 Engine governor defective u Contact Service. Charge-air temperature too high Cause Corrective action Incorrect coolant concentration u Check (→ MTU test kit). u Contact Service. Intercooler contaminated u Check fans and intake/exhaust lines. Engine room: Air-intake temperature too high Charge-air pressure too low...
  • Page 56 White exhaust gas Cause Corrective action Engine is not at operating u Run up to operating temperature. temperature Water in fuel u Check fuel system, at fuel prefilter (→ manufacturer's documentation). Drain water and contaminants from fuel prefilter (→ manufacturer's documentation). u Contact Service.

  • Page 57: Engine Governor Ecu9 - Fault Messages

    6.2 Engine governor ECU9 – Fault messages Possible engine reactions to yellow alarm: Warning, power limitation / reduction, speed limitation, engine stop Possible engine reactions to red alarm: Engine stop, power limitation / reduction, speed limitation, warning 5 – HI T-Charge Air Cause Corrective action The charge-air temperature at...
  • Page 58 25 – HI P-Diff-Lube Oil Cause Corrective action The differential oil pressure at 1. Replace engine oil filter (→ Page 98). sensors B5.1 and B5.3 has 2. Contact Service. exceeded limit value 1. The differential oil pressure is too high. 26 –...
  • Page 59 51 – HI T-Lube Oil Cause Corrective action The lube oil temperature at 1. Reduce power. sensor B7 has exceeded limit 2. Check operation of cooler and fan (plant side). value 1. Lube oil temperature is 3. Check engine coolant level (→ Page 102). too high.
  • Page 60 2. 3. Contact Service. 186 – AL CAN1 Bus Off Cause Corrective action Can bus 1 to MTU automation 1. Check plug connections to engine governor (→ Page 118). system (e. g. ECU/MAU/SAM) 2. Contact Service. is interrupted or defective.
  • Page 61 188 – AL CAN2 Bus Off Cause Corrective action Can bus 2 to plant-side 1. Check connection between plant-side automation and MTU automation system (e. g. automation. Murphy display) is interrupted or 2. Contact Service. defective.
  • Page 62 211 – SD P-Lube Oil Cause Corrective action Lube-oil pressure sensor after 1. Check engine wiring (→ Page 116). filter (B5.1) supplies incorrect 2. Contact Service. signal or no signal. 212 – SD P-Coolant Cause Corrective action Coolant pressure sensor after 1.
  • Page 63 229 – AL Stop Camshaft Sensor Defect Cause Corrective action Emergency stop following a u Contact Service. failure of crankshaft speed sensor (B13.1) and camshaft speed sensor (B1). 230 – SD Crankshaft Speed Cause Corrective action Crankshaft speed sensor 1. Check engine wiring (→ Page 116). (B13.1) supplies incorrect signal 2.
  • Page 64 322 – AL Wiring Cylinder A2 Cause Corrective action Short circuit in injector wiring of 1. Check wiring of the applicable injector (→ Page 116). cylinder A2 or injector defective. 2. Replace injector (→ Page 82). 3. Contact Service. 323 – AL Wiring Cylinder A3 Cause Corrective action Short circuit in injector wiring of...
  • Page 65 344 – AL Open Load Cylinder A4 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of the applicable injector (→ Page 116). cylinder A4. 2. Contact Service. 345 – AL Open Load Cylinder A5 Cause Corrective action Disruption fault in injector wiring 1.
  • Page 66 549 – AL Power Cut-Off detected Cause Corrective action ECU operating voltage was 1. If power supply has not been disconnected manually, check switched off while the engine engine wiring (→ Page 116). was running. Disconnect power 2. Contact Service. supply only when the engine is at standstill.

  • Page 67: Task Description

    7 Task Description 7.1 SOLAS 7.1.1 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 69). Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not feasible (→ Page 70). When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→...
  • Page 68 Shields in oil system Comments Item Type of shielding Adhesive tape (not shown) Banjo union between oil module and charge- air pipe Right engine side Shields in exhaust system Comments Item Type of shielding Insulation (not shown) Exhaust elbow with ISOTHERM insulation Cooling jacket Carrier housing of exhaust turbocharger 68 | Task Description | MS15029/01E 2015-06...

  • Page 69: Solas Shielding As Per Mtn 5233 - Installation

    7.1.2 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A5 735233000101 SOLAS shielding – Installation Pinpoint installation location (→ Page 67). Install suitable shielding.

  • Page 70: Adhesive Tape For Solas Shielding - Application

    7.1.3 Adhesive tape for SOLAS shielding – Application Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Adhesive tape X00026424 Applying adhesive tape – gener- al information Note: Use the cable clamp to make a drainage channel.

  • Page 71: Engine

    7.2 Engine 7.2.1 Engine – Barring manually Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring gear F6790714 Adapter F30011619 Ratchet F30027340 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 72 Barring engine manually – Var- iant B Note: Barring gear (1) is installed on vibration damper on engine free end. Fit ratchet with extension on barring gear (1). Rotate crankshaft in engine direction of ro- tation. Apart from the normal compression resistance, there should be no resistance.

  • Page 73: Engine - Barring With Starting System

    7.2.2 Engine – Barring with starting system Preconditions ☑External pushbutton 'Bar engine without starting' is provided. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 74: Engine - Test Run

    7.2.3 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 75: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Fine oil mist separator replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet F30027340 Assembly compound (Kluthe Hakuform 30-15) X00067260 Oil mist fine separator (→...
  • Page 76 Oil mist fine separator – Instal- lation Apply assembly compound to new O- rings (4, 5). Note: • Make sure not to twist O-rings (4, 5) dur- ing installation. • The lug (6) of the oil mist fine separator (3) must be in the groove of the vent housing when installing the separator.

  • Page 77: Valve Drive

    7.4 Valve Drive 7.4.1 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Engine coolant temperature is max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 Torque wrench, 20–100 Nm F30026582...
  • Page 78 Valve clearance – Adjustment Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm (3). Readjust adjusting screw (2) with Allen key so that the feeler gauge just passes through the gap.

  • Page 79: Cylinder Head Cover - Removal And Installation

    7.4.2 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F30043446 Ratchet F30027340 Gasket (→ Spare Parts Catalog) Cylinder head cover – Removal and installation Remove screws (1).
  • Page 80 Remove gasket (1) with wiring. Check condition of gasket (1) and replace if required. Clean installation surface. Fit gasket (1). Tighten cabling (1) on injector. Name Size Type Lubricant Value/Standard Hex nut Tightening torque 1.5 Nm 80 | Task Description | MS15029/01E 2015-06...
  • Page 81 Fit cylinder head cover and tighten screws at positions 1 to 4 to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw with twin Preload torque 10 Nm collar Tighten screws at positions 1 to 18 to specified tightening torque using a torque wrench. Name Size Type...

  • Page 82: Injector

    7.5 Injector 7.5.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install a new one (→ Page 83). 82 | Task Description | MS15029/01E 2015-06...

  • Page 83: Injector - Removal And Installation

    7.5.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Alignment device F6791418 Puller F6790992 Puller F6796371 Installation device F6790085 Milling cutter F30454305 Torque wrench, 20-100 Nm F30026582 Ratchet F30027340...
  • Page 84 HP line – Removal Loosen union nuts (1, 3) and remove HP line (2) from HP accumulator and cylinder head. Remove injector Loosen union nut (2) and remove pressure pipe neck (1) with puller (F6796371). Remove hold-down clamp screw. Install puller (F6790992) (1) on hold-down clamp (3).
  • Page 85 Remove sealing ring (2) from injector or use wire hook to remove from cylinder head. Remove O-ring (1) from injector. Seal all openings with suitable covers. Installing injector Note: Use sealing rings, O-rings, hold-down clamp screws, pressure pipe neck, and HP lines only once.
  • Page 86 Install new hold-down clamp screw. Name Size Type Lubricant Value/Standard Screw Tightening torque 5 Nm Loosen hold-down clamp screws again to completely unload the injector. Use the alignment device to align the HP connection of the injector at the pressure pipe neck (1).
  • Page 87 Tighten union nut (1) of pressure pipe neck with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Union nut Tightening torque 50 Nm +5 Nm HP line – Installation Fit new HP line (2) and tighten union nuts (1, 3) hand-tight: •...

  • Page 88: Fuel System

    7.6 Fuel System 7.6.1 Fuel system – Venting Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Fuel system –...

  • Page 89: Fuel Filter

    7.7 Fuel Filter 7.7.1 Fuel filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Easy-change filter (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 90 Note: Filter replacement on a running engine is permissible only with a short-time cutout of the filter to be replaced. Turn three-way cock to setting (B) to cut out the filter (2) which is to be replaced: Result: Fuel filter (2) is cut out of the fuel circuit, but is still under pressure.
  • Page 91 Stop engine and disable engine start. Turn three-way cock to setting (B) to cut out the filter (1) which is to be replaced. Unscrew cut out easy-change filter (1) us- ing a filter wrench. Clean sealing surface on filter head. Lightly oil sealing ring of new easy-change filter.

  • Page 92: Air Filter

    7.8 Air Filter 7.8.1 Air filter ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter ‒ Replacement Remove air filter and install new one (→ Page 93). Reset signal ring of service indicator (→ Page 94). 92 | Task Description | MS15029/01E 2015-06...

  • Page 93: Air Filter - Removal And Installation

    7.8.2 Air filter – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Air filter – Removal and installa- tion Loosen clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3). Verify that there are no objects in the flange of the intake housing (3) and clean Place new air filter (1) with clamp (2) onto intake housing (3).

  • Page 94: Air Intake

    7.9 Air Intake 7.9.1 Service indicator – Signal ring position check Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position Replace air filter if the signal ring (2) is completely visible in the red area of the ob- servation window (3) (→...

  • Page 95: Lube Oil System, Lube Oil Circuit

    7.10 Lube Oil System, Lube Oil Circuit 7.10.1 Engine oil – Level check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING Hot oil.
  • Page 96 Checking engine oil level before engine start after extended out-of-service periods Note: Engine is stopped and starting disabled. Remove oil dipstick (1) from guide tube and wipe it. Insert oil dipstick (1) into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.

  • Page 97: Engine Oil - Change

    7.10.2 Engine oil – Change Preconditions ☑Engine is stopped and starting disabled. ☑Engine is at operating temperature. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Hot oil.

  • Page 98: Oil Filtration / Cooling

    7.11 Oil Filtration / Cooling 7.11.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Drain hose with quick-release coupling X57299100654 Torque wrench, 20–100 Nm F30026582 Ratchet F30027340 Vent hose X57299100655 Socket wrench 8-22 A/F F30452510 Socket wrench 17 A/F F30030450...
  • Page 99 Engine oil filter replacement with the engine running To cut out the filter to be replaced, set the three-way cock (2) to the corresponding position. a Both filters cut in (operating posi- tion) b Right-hand filter cut out c Left-hand filter cut out Result: The oil filter is isolated from the oil circuit but still under pressure.
  • Page 100 Remove central screw (1) with sealing ring (2). Remove filter bowl (3) with oil filter ele- ment (4) and O-ring (5). Insert new oil filter element (4) in filter bowl (3) with the front face with coil spring facing upwards. Position filter bowl (3) with new O-ring (5) on filter head.
  • Page 101 Engine oil filter replacement with the engine at standstill Stop engine and disable engine start. Set three-way cock (2) the position where both filters are cut-in: a Both filters cut in (operating posi- tion) b Right-hand filter cut out c Left-hand filter cut out Turn threaded vent plug (1) counterclock- wise by one revolution.

  • Page 102: Coolant System, General, High-Temperature Circuit

    7.12 Coolant System, General, High-Temperature Circuit 7.12.1 Engine coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 103: Engine Coolant – Change

    7.12.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 104). Fill with engine coolant (→ Page 105). MS15029/01E 2015-06 | Task Description | 103...

  • Page 104: Engine Coolant – Draining

    7.12.3 Engine coolant – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 105: Engine Coolant – Filling

    7.12.4 Engine coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 106 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 102), top up with coolant if required. 106 | Task Description | MS15029/01E 2015-06...

  • Page 107: Engine Coolant Pump – Relief Bore Check

    7.12.5 Engine coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 108: Low-Temperature Circuit

    7.13 Low-Temperature Circuit 7.13.1 Charge-air coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 109: Belt Drive

    7.14 Belt Drive 7.14.1 Drive belt – Condition check Preconditions ☑Engine is stopped and starting disabled. Checking condition Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Fit new part (→ Page 111) Drive belt C Chunking Drive belt...

  • Page 110: Belt Tensioner – Check

    7.14.2 Belt tensioner – Check WARNING Belt tensioner spring is pretensioned. Risk of hands being crushed! • Lock belt tensioner in position. • Only use specified tools and devices. Checking belt tensioner Item Findings Action Tensioner Rubber cracked on spring and Replace (→...

  • Page 111: Drive Belt – Replacement

    7.14.3 Drive belt – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ratchet F30006211 Drive belt (→ Spare Parts Catalog) WARNING Belt tensioner spring is pretensioned. Risk of hands being crushed! •...
  • Page 112 Belt drive with raw water pump – Drive belt replacement Note: A second person is required to carry out the following steps. Fit ratchet with extension in square hole (1) on belt tensioner (4). Turn belt tensioner (4) clockwise almost up to the stop against spring force.

  • Page 113: Belt Tensioner – Tensioning Element And Tensioning Roller Replacement

    7.14.4 Belt tensioner – Tensioning element and tensioning roller replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet F30027340 Torque wrench, 80-400 Nm F30027338 Ratchet F30027342 Tension element...
  • Page 114 Replacing tensioning element Remove screws (2, 3) and belt tensioner (1). Remove screw (1) and take off tensioning element (2). Fasten new tensioning element (2) with screw (1) by hand. Tighten screw (1) to specified torque using a torque wrench. Name Size Type...
  • Page 115 Fasten belt tensioner (1) with screws (2, 3) by hand. Tighten screw (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque 150 Nm Tighten screw (3) to specified torque using a torque wrench. Name Size Type...

  • Page 116: Wiring (General) For Engine/Gearbox/Unit

    7.15 Wiring (General) for Engine/Gearbox/Unit 7.15.1 Engine cabling – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.

  • Page 117: Accessories For (Electronic) Engine Governor / Control System

    7.16 Accessories for (Electronic) Engine Governor / Control System 7.16.1 Engine governor and connector – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! •...

  • Page 118: Engine Governor – Checking Plug-In Connections

    7.16.2 Engine governor – Checking plug-in connections Preconditions ☑Engine is stopped and starting disabled. Checking engine governor plug connections Check firm seating of all connectors on the engine governor. Ensure that the clips (1) are engaged. Check firm seating of all screws (2) on en- gine governor cable clamps.

  • Page 119: Engine Mounting / Support

    7.17 Engine Mounting / Support 7.17.1 Engine mounting – Check Preconditions ☑Engine is stopped and starting disabled. ☑Engine is filled with coolant and engine oil. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 80–400 Nm F30027338 Ratchet F30027342...
  • Page 120 Engine mounts – Resilient ele- ments check Inspect resilient element (1) for crack for- mation and deformation. Result: Have cracked resilient element (1) re- placed, contact Service. Wipe rubber surface with dry cloth, do not use organic detergents. Check reference dimension (A) of resilient element (1).

  • Page 121: Abbreviations

    American National Standards Institute Governing body for US American standards Exhaust turbocharger Baureihe (Series) Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-...
  • Page 122 Explanation Abbrevia- Meaning tion Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly Light Emitting Diode Local Monitoring Unit LOP subassembly Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit...

  • Page 123: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 124: Special Tools

    9 Appendix B 9.1 Special Tools Adapter Part No.: F30011619 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 71) Alignment device Part No.: F6791418 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 83) Barring gear Part No.: F6790714 Qty.:...
  • Page 125 Box wrench, 14 mm Part No.: F30028346 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 77) Crowfoot box wrench, 22 mm Part No.: F30027425 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 83) Crowfoot box wrench, 27 mm Part No.: F30029816...
  • Page 126 Feeler gauge Part No.: Y20010128 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 77) Filter wrench Part No.: F30379104 Qty.: Used in: 7.7.1 Fuel filter – Replacement (→ Page 89) Installation device Part No.: F6790085 Qty.: Used in: 7.5.2 Injector –...
  • Page 127 Puller Part No.: F6790992 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 83) Puller Part No.: F6796371 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 83) Ratchet Part No.: F30027340 Qty.: Used in: 7.2.1 Engine – Barring manually (→ Page 71) Qty.: Used in: 7.3.1 Crankcase breather –...
  • Page 128 Ratchet Part No.: F30006211 Qty.: Used in: 7.14.3 Drive belt – Replacement (→ Page 111) Ratchet Part No.: F30027342 Qty.: Used in: 7.14.4 Belt tensioner – Tensioning element and ten- sioning roller replacement (→ Page 113) Ratchet Part No.: F30027342 Qty.: Used in: 7.17.1 Engine mounting –...
  • Page 129 Socket wrench 8-22 A/F Part No.: F30452510 Qty.: Used in: 7.11.1 Engine oil filter – Replacement (→ Page 98) Torque wrench, 20-100 Nm Part No.: F30026582 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 83) Torque wrench, 20–100 Nm Part No.: F30026582 Qty.:...
  • Page 130 Torque wrench, 8-40 Nm Part No.: F30043446 Qty.: Used in: 7.4.2 Cylinder head cover – Removal and installation (→ Page 79) Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 83) Torque wrench, 80-400 Nm Part No.: F30027338 Qty.: Used in: 7.14.4 Belt tensioner –...

  • Page 131: Index

    9.2 Index Engine  – Barring   Abbreviations 121 – Manually  71 Actuators  – With starting system  73 – Overview  25 – Main dimensions  43 Adhesive tape for SOLAS shielding  – Putting engine out of operation  52 – Application  70 – Test run  74 After stopping the engine ...
  • Page 132  77 – Removal  83 – Replacement  82 Installation locations for SOLAS shielding 67 Maintenance schedule  – Task reference table [QL1]  53 MTU contact persons 123 Operational checks 48 Product description 20 Putting into operation  – After scheduled out-of-service-period  45 Relief bore  – Charge-air coolant pump check  108...

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