MTU 6R1600M20x Manuale utente
Operating Instructions
Diesel engine
6R1600M20x
MS15029/01E
Engine model kW/cyl. Hz rpm Application group
6R1600M20F 44.8 kW/cyl. 50 Hz 1500 3A, continuous operation, unrestricted
6R1600M20S 53.8 kW/cyl. 60 Hz 1800 3A, continuous operation, unrestricted
Table 1: Applicability
© 2015 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 consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
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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 Personnel and organizational requirements 7
1.3 Safety regulations for startup and operation 8
1.4 Safety regulations for maintenance and
repair work 10
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13
1.6 Auxiliary materials, fire prevention and
environmental protection 15
1.7 Standards for safety notices in the text 17
1.8 Transport 18
2 General Information
2.1 Engine side and cylinder designations 19
2.2 Product description 20
2.3 Engine overview 23
2.4 Sensors and actuators – Overview 25
3 Technical Data
3.1 Engine data 6R1600M20F, 6R1600M20S,
engine-mounted heat exchanger, IMO Tier 2 29
3.2 Engine data 6R1600M20F, 6R1600M20S,
remote heat exchanger, IMO Tier 2 33
3.3 Engine data 6R1600M20S, engine-mounted
heat exchanger, EPA Tier 3 36
3.4 Engine data 6R1600M20S, remote heat
exchanger, EPA Tier 3 39
3.5 Firing order 42
3.6 Engine – Main dimensions 43
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 44
4.2 Putting the engine into operation after
scheduled out-of-service-period 45
4.3 Engine start in manual operation (trials) 46
4.4 Safety system – Override 47
4.5 Operational checks 48
4.6 Engine stop in manual operation (trials) 49
4.7 Emergency stop 50
4.8 After stopping the engine – Engine remains
ready for operation 51
4.9 After stopping engine – Putting engine out
of operation 52
5 Maintenance
5.1 Maintenance task reference table [QL1] 53
6 Troubleshooting
6.1 Troubleshooting 54
6.2 Engine governor ECU9 – Fault messages 57
7 Task Description
7.1 SOLAS 67
7.1.1 Installation locations for SOLAS shielding 67
7.1.2 SOLAS shielding as per MTN 5233 –
Installation 69
7.1.3 Adhesive tape for SOLAS shielding –
Application 70
7.2 Engine 71
7.2.1 Engine – Barring manually 71
7.2.2 Engine – Barring with starting system 73
7.2.3 Engine – Test run 74
7.3 Crankcase Breather 75
7.3.1 Crankcase breather – Fine oil mist separator
replacement 75
7.4 Valve Drive 77
7.4.1 Valve clearance – Check and adjustment 77
7.4.2 Cylinder head cover – Removal and
installation 79
7.5 Injector 82
7.5.1 Injector – Replacement 82
7.5.2 Injector – Removal and installation 83
7.6 Fuel System 88
7.6.1 Fuel system – Venting 88
7.7 Fuel Filter 89
7.7.1 Fuel filter – Replacement 89
7.8 Air Filter 92
7.8.1 Air filter ‒ Replacement 92
7.8.2 Air filter – Removal and installation 93
7.9 Air Intake 94
7.9.1 Service indicator – Signal ring position check 94
7.10 Lube Oil System, Lube Oil Circuit 95
7.10.1 Engine oil – Level check 95
7.10.2 Engine oil – Change 97
7.11 Oil Filtration / Cooling 98
7.11.1 Engine oil filter – Replacement 98
7.12 Coolant System, General, High-Temperature
Circuit 102
7.12.1 Engine coolant – Level check 102
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7.12.2 Engine coolant – Change 103
7.12.3 Engine coolant – Draining 104
7.12.4 Engine coolant – Filling 105
7.12.5 Engine coolant pump – Relief bore check 107
7.13 Low-Temperature Circuit 108
7.13.1 Charge-air coolant pump – Relief bore check 108
7.14 Belt Drive 109
7.14.1 Drive belt – Condition check 109
7.14.2 Belt tensioner – Check 110
7.14.3 Drive belt – Replacement 111
7.14.4 Belt tensioner – Tensioning element and
tensioning roller replacement 113
7.15 Wiring (General) for Engine/Gearbox/Unit 116
7.15.1 Engine cabling – Check 116
7.16 Accessories for (Electronic) Engine
Governor / Control System 117
7.16.1 Engine governor and connector – Cleaning 117
7.16.2 Engine governor – Checking plug-in
connections 118
7.17 Engine Mounting / Support 119
7.17.1 Engine mounting – Check 119
8 Appendix A
8.1 Abbreviations 121
8.2 MTU contact persons/service partners 123
9 Appendix B
9.1 Special Tools 124
9.2 Index 131
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, 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 accompa-
nying specifications.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• 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)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• With maintenance work performed in accordance with 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
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use. 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.
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 au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
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Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions
regulation authorities. The manufacturer does not accept any liability for violations of the emission reg-
ulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of
the product.
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.
Please note the following when replacing components with emission labels:
• Appropriate emission labels must be affixed on spare parts.
• Emission labels may not be transferred from old components to new ones.
• Emission labels on old components must be removed and destroyed.
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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.
Personnel must receive instruction on product handling and maintenance on the basis of this manual
with a special emphasis on safety requirements and warnings.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction and electrical engi-
neering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Personnel must not be under the influence of alcohol, drugs or strong medication.
Work clothing and personal protective equipment
When working, always wear the necessary personal protective equipment (e.g. safety shoes, ear protec-
tors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
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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.
When putting the product into operation, always 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.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• Keep clear of the service room during the first operating hours. Hazardous gases may occur as a re-
sult of the combustion of paints or oils.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the controls and displays.
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 re-
gard to present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
The procedures for emergencies, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely neces-
sary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly in-
structed to do so following a written procedure.
Do not inhale the exhaust gases of the product.
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 binder
agent.
Operation of electrical equipment
During operation of electrical devices, certain elements of these devices are live/under high voltage.
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Observe the warning information applicable to the devices.
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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).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
Use special tools if they are specified for the relevant work.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be
painted. They may only be installed after painting the engine or must be covered before painting work is
carried out.
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 during maintenance and repair work
Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid
that components/tools fall down . Use the specified lifting equipment for all components.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Never work on
engines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
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