MTU 6R 1600 G10F User manual
Operating Instructions
Diesel engine
6R 1600 G10F, G20F
6R 1600 G40F, G50F
6R 1600 G70F, G80F
6R 1600 G10S, G20S
6R 1600 G70S, G80S
6R 1600 B30S, B40S
MS15022/03E
Printed in Germany
© 2014 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 Safety
1.1 Important provisions for all products 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety regulations for startup and operation 8
1.5 Safety regulations for maintenance and
repair work 9
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 12
1.7 Standards for safety notices in the text 14
2 General Information
2.1 Engine overview 15
2.2 Engine side and cylinder designations 17
2.3 Sensors and actuators 18
3 Technical Data
3.1 6R 1600 B30S 60Hz engine data, optimized
fuel consumption 20
3.2 6R 1600 B30S 50Hz engine data, optimized
fuel consumption 22
3.3 6R 1600 B40S 50Hz engine data, optimized
emissions 24
3.4 6R 1600 B40S 50Hz engine data, optimized
fuel consumption 26
3.5 6R 1600 B40S 60Hz engine data, optimized
emissions 28
3.6 6R 1600 B40S 60Hz engine data, optimized
fuel consumption 30
3.7 6R 1600 G10F , G20F engine data,
optimized fuel consumption 32
3.8 6R 1600 G10F , G20F engine data,
optimized exhaust emissions 35
3.9 6R 1600 G10S, G20S engine data, EPA stage
3 38
3.10 6R 1600 G10F, G20F engine data, Nonroad
stage III a 41
3.11 6R 1600 G40F , G50F engine data,
optimized fuel consumption 44
3.12 6R 1600 G40F , G50F engine data,
optimized exhaust emissions 47
3.13 6R 1600 G40F, G50F engine data, Nonroad
stage III a 50
3.14 6R 1600 G70F , G80F engine data,
optimized fuel consumption 53
3.15 6R 1600 G70F , G80F engine data,
optimized exhaust emissions 56
3.16 6R 1600 G70S, G80S engine data, EPA stage
3 59
3.17 6R 1600 G70F, G80F engine data, Nonroad
stage III a 62
3.18 Firing order 65
3.19 Engine – Main dimensions 66
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 67
4.2 Putting the engine into operation after
scheduled out-of-service-period 68
4.3 Engine start in manual operation (trials) 69
4.4 Safety system – Override 70
4.5 Operational checks 71
4.6 Engine stop in manual operation (trials) 72
4.7 Emergency stop 73
4.8 After stopping the engine – Engine remains
ready for operation 74
4.9 After stopping the engine – Putting the
engine out of operation 75
5 Maintenance
5.1 Maintenance and servicing 76
5.2 Maintenance task reference table 77
6 Troubleshooting
6.1 Troubleshooting 78
7 Task Description
7.1 Engine 80
7.1.1 Engine – Barring with starting system 80
7.1.2 Engine – Test run 81
7.2 Valve Drive 82
7.2.1 Valve clearance – Check and adjustment 82
7.2.2 Cylinder head cover – Removal and
installation 84
7.3 Fuel System 85
7.3.1 Fuel system – Venting 85
7.4 Fuel Filter 86
7.4.1 Fuel filter – Replacement 86
7.4.2 Fuel prefilter – Replacement 87
7.5 Air Filter 88
7.5.1 Air filter ‒ Replacement 88
7.5.2 Air filter – Removal and installation 89
7.6 Air Intake 90
MS15022/03E 2014-02 | Table of Contents | 3
DCL-ID: 0000005207 - 006
7.6.1 Service indicator – Signal ring position check 90
7.7 Starting Equipment 91
7.7.1 Starter – Condition check 91
7.8 Lube Oil System, Lube Oil Circuit 92
7.8.1 Engine oil level – Check 92
7.8.2 Engine oil – Change 93
7.9 Oil Filtration / Cooling 94
7.9.1 Engine oil filter – Replacement 94
7.10 Coolant Circuit, General, High-Temperature
Circuit 95
7.10.1 Engine coolant – Level check 95
7.10.2 Engine coolant – Change 96
7.10.3 Engine coolant – Draining 97
7.10.4 Engine coolant – Filling 98
7.10.5 Engine coolant pump – Relief bore check 100
7.11 Belt Drive 101
7.11.1 Drive belt – Adjustment 101
7.11.2 Drive belt – Condition check 102
7.11.3 Drive belt – Tension check 103
7.11.4 Drive belt – Replacement 104
7.12 Wiring (General) for Engine/Gearbox/Unit 105
7.12.1 Engine wiring – Check 105
7.13 Accessories for (Electronic) Engine
Governor / Control System 106
7.13.1 Engine governor and connectors – Cleaning 106
7.13.2 Engine governor – Checking plug connections 107
8 Appendix A
8.1 Abbreviations 108
8.2 MTU contact persons/service partners 111
9 Appendix B
9.1 Special Tools 112
9.2 Index 115
4 | Table of Contents | MS15022/03E 2014-02
DCL-ID: 0000005207 - 006
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.
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 exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• 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
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• 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 and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
MS15022/03E 2014-02 | Safety | 5
TIM-ID: 0000040530 - 003
1.2 Personnel and organizational requirements
Organizational measures of the operator
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.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
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
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment
Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
6 | Safety | MS15022/03E 2014-02
TIM-ID: 0000040531 - 002
1.3 Transport
Transport
Lift the engine only with the lifting eyes provided.
Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans-
port pallet or transport with equipment for heavy loads (forklift truck).
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
MS15022/03E 2014-02 | Safety | 7
TIM-ID: 0000000872 - 003
1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance the manufacturer's specifications
before putting the product into service.
Before the product is put into operation for the first time, all official authorizations must be available
and commissioning preconditions met.
When putting the product into operation, always ensure that
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All personnel is clear of the danger zone surrounding moving parts of the machine.
• The service room is adequately ventilated.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
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.
Safety regulations for equipment 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 cases of emergency, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is recognized or reported by the sys-
tem:
• Inform supervisor(s) in charge.
• Analyze the message.
• If required, carry out emergency operations e.g. 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 at all 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.
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
When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
8 | Safety | MS15022/03E 2014-02
TIM-ID: 0000040533 - 003
1.5 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 before starting maintenance work (risk of explosion
of oil vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers 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:
• 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.
Secure the product against unintentional starting, e.g. with start interlock.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock contactors.
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.
The following applies to starters with copper-beryllium alloy pinions:
• Wear breathing protection of filter class P3 during maintenance work. 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.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
MS15022/03E 2014-02 | Safety | 9
TIM-ID: 0000040535 - 003
Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths
and cable ties).
Safety regulations after completion of maintenance and repair work
Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding
in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Hydraulic installation and removal
Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal jig, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries
Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear goggles and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
10 | Safety | MS15022/03E 2014-02
TIM-ID: 0000040535 - 003
Other manuals for 6R 1600 G10F
1
This manual suits for next models
11
Table of contents
Other MTU Engine manuals
MTU
MTU 20 V 4000 M93 User manual
MTU
MTU 12 V 1600 R50 User manual
MTU
MTU 20 V 4000 M73 x User manual
MTU
MTU 12V2000M84 User manual
MTU
MTU 20 V 4000 G23 User manual
MTU
MTU 12 V 4000 M53 User manual
MTU
MTU MS15025/00E User manual
MTU
MTU 8V4000Lx4 User manual
MTU
MTU 12 V 2000 M86 User manual
MTU
MTU 20V4000G44F User manual
MTU
MTU 12 V 4000 G73 User manual
MTU
MTU 12V4000L32F User manual
MTU
MTU 8 V 2000 M40A User manual
MTU
MTU 8V 4000 Lx2 x User manual
MTU
MTU 8 V 2000 M50A User manual
MTU
MTU 12V4000Gx5S Series User manual
MTU
MTU 12 V 4000 M93 x User manual
MTU
MTU 12V4000M*3 series User manual
MTU
MTU 12 V 4000 L62 User manual
MTU
MTU 12V 4000 L32 F User manual
