Documente Academic
Documente Profesional
Documente Cultură
2012
Training presentation
Series
1600
Genset engine
Hardy Pfaff
MTU Training Center
Notes
Specified torques and procedures are correct at the time of writing but must be checked before use.
Commercial exploitation and use of any kind requires the prior written consent of
MTU Friedrichshafen GmbH.
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Series 1600
8 V 1600 10 V 1600
6 R 1600 12 V 1600
6 R 1600
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8 V 1600
10 V 1600
3
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12 V 1600
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Bore/Stroke: 122/150 mm
Cylinder capacity 1.75 ltr
Compression ratio: 17.5 : 1
Max. ignition pressure: 200 bar
Single-stage turbocharging: 1 x Garrett GT 35 on 6 R 1600 G
2 x Garrett GT 42 on 8+10 V 1600 G
2 x Garrett GT 45 on 12 V 1600 G
Emissions: > 560 KW EPA Tier 2/EU IIIA
TA Luft 1500 mg NOx
< 560 KW EPA Tier 3/EU IIIB
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Application
Additional information
Design index
Application
Series
Cylinder configuration V = Vee engine, R = Inline engine
H = Horizontal engine
Number of cylinders
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Additional information
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A1-A6
B1-B6
This standard applies to dynamically unstressed set-screws to MMN 384, DIN 912, EN 24014 (DIN 931-1), EN 24017
(DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to stud bolts to DIN 833, DIN 835, DIN 836, DIN 938,
DIN 939 and the matching nuts.
It does not apply to heat-resistant bolts in the hot components zone.
The tightening torques specified are MA ratings for strength class 8.8 (surface finish bare, phosphated or galvanized) and
10.9 (surface finish bare or phosphated).
The figures in the table are based on a frictional coefficient of µtot. = 0.125. Requirement: threads and contact faces of the
nuts and bolts must be lubricated with engine oil before fitting.
When tightening by hand (defined tightening), a fitting tolerance of +10% is permissible to allow for the unavoidable
divergence of the tightening torques from the table figures, e.g. due to inaccurate reading and overtightening when fitting.
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Tightening torques for plug bolts to DIN 908, DIN 910 and DIN 7604A (with short threaded end)
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This standard applies to banjo bolts to standards MMN 223 and N 15011 with DIN 7603 Cu sealing washer.
The tightening torques specified are MA ratings for banjo bolts made of steel (St) with a phosphated and oiled or galvanized
protective surface finish and made of copper-aluminum alloys.
Threads and contact faces under the head must be lubricated with engine oil before fitting.
A fitting tolerance of +10% of the table figure is permissible to allow for the unavoidable divergence of the tightening torques
from the table figures, e.g. due to inaccurate reading and overtightening when fitting.
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1 Sleeve nut
2 Union body
3 O-ring
4 Ball sleeve
Sleeve nut: when fitting the ball sleeve, the sleeve nut should be hand tightened (to perceptible increase in resistance)
and then tightened a further ¼ turn (90°) beyond that point.
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B09 B48.2
B10
M8.2 B01 Camshaft speed
M8.1 B13 Crankshaft speed
B09 Boost air temp
B10 Boost air pressure
B48.2 B rail pressure
M8.1 Metering unit A
M8.2 Metering unit B
XY 39B2 XY 39B1 Injector B1 connector
B13
B01 XY 39B1 XY 39B2 Injector B2 connector
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X2
PWM (pulse width modulation signal)
X1
M8.1 Metering unit, A-bank pump
M8.2
M8.1
M8.2 Metering unit, B-bank pump
Voltage: 24 V
Current: 3A
Frequency: < 500 Hz
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1.
2.
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Functions of ECU-8
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19
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Low-pressure indicator
1. Reset button
2. Indicator ring
3. Viewing window with scale
1. Connection socket
2. Clip
3. Air filter
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1. Service cover
2. Snap fastener
3. Coarse dirt valve
4. Filter insert
5. Filter element
6. Filter housing
7. Clean air outlet
8. Low-pressure indicator connection
9. Air inlet
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1. Remove the air intake duct from the air filter and plant
exhaust system.
2. Remove the crankcase vent pipe and
oil supply and return pipes from the turbocharger
3. Undo the 4 hexagonal nuts (50) and remove these
together with the turbocharger.
4. Remove the gasket and seal openings with suitable
covers.
5. Clean the sealing faces and check for damage.
6. When fitting a new turbocharger, the position of the compressor
and bearing housing has to be rotated on the right-hand side of the engine. 10 Turbocharger
20 Gasket
30 Stud bolt
To do so proceed as follows: 40 Washer
50 Hexagonal nut
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Checking the condition of the drive belts for the fan and
alternator/water pump
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Testing point
Application Initial assembly Measured value for operating Measured value for minimum
measured value voltage after 1 hour operating voltage
Drive belt – fan 2250 N 1620 N 1080 N
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Testing point
Application Initial assembly Measured value for operating Measured value for minimum
measured value voltage after 1 hour operating voltage
Drive belt – fan 1000 N 720 N 480 N
1
at the bottom of the flywheel housing on A-side.
4. Lock the crankshaft with the locking tool
and loosen the fixing bolts.
5. Unscrew the 2 fixing bolts and screw in
3 the two F30452741 guide bolts (3)
7. Unscrew the remaining bolts.
8. Remove the flywheel using the
lifting bracket (1).
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28
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30
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To radiator
To crankcase
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190
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2
4
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Fuel system:
Low pressure system Fuel system diagram: XZ57507000001
3
4 10
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Fuel system:
Low pressure system
Replacing the fuel filter: (replace every 500 hours of duty or at least every 2 years).
F30379104
Fuel system:
Low-pressure system
Bleeding the fuel system
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Fuel system:
High-pressure system Fuel system diagram: XZ57507000001
3
(1) High-pressure pumps identical on A-side and B-side 2
6 R 1600 1 High-pressure pump
8 V 1600 2 High-pressure pumps
10 V 1600 2 High-pressure pumps
12 V 1600 2 High-pressure pumps
4
(2) Fuel rails identical on A-side and B-side
6
(3) 12 CRIN 3 fuel injectors (6 fuel outlet jets)
(4) 12 high-pressure fuel lines
(5) 12 high-pressure connecting spigots 7
(6) A-side high-pressure fuel line
(7) B-side high-pressure fuel line
1 5
Fuel system:
Common rail fuel injector for Series 1600 genset engine
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Fuel system:
Removing the high-pressure system
1. Remove the cylinder head cover and disconnect the
wiring.
2. Disconnect and remove the high-pressure fuel lines (1).
3. Remove the high-pressure fuel line from the high-pressure pump
to the fuel rail on A-side and B-side.
4. Undo the sleeve nut (2) and remove the high-pressure connecting
spigot (3).
5. Undo the shackle and unscrew the bolt then remove the fuel injector
using the extractor tool F6790992 (4).
6. If the same fuel injectors are to be reused, then the sealing
ring between the cylinder head and the fuel injector and
the O-ring for sealing off the low-pressure system must be replaced.
If new fuel injectors are to be used, new items of those components
are supplied.
7. Remove the sealing ring from the fuel injector or
use a self-fashioned wire hook to remove it from
4
the cylinder head.
Fuel system:
Removing the high-pressure system
8. Remove the O-rings from the fuel injector.
9. Seal off the openings with suitable covers. Fuel rail:
10. Unplug the wiring from the fuel pressure sensor B48.1 (A-side)
Single-wall design
and B48.2 (B-side).
Safety valve integrated in rail
11. Undo the pipe brackets and remove the fuel rail.
12. If necessary, use the milling tool F30452390 (5) Opening pressure 1950 (-100) bar
to remove oil coking from the rail bore.
Note: Shackle bolt, high-pressure connecting spigot,
high-pressure fuel lines and injector seal should only
be used once.
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Fuel system:
Refitting the high-pressure system
13. Before fitting the components, remove all covers.
14. If a used injector is to be refitted, fit
a new O-ring on the injector
and fit a new sealing ring.
15. Apply a coat of grease (Kluthe Hakuform 30-10/Emulsion)
to the O-ring on the injector and use
fitting paste 40477 (Optimoly Paste White T) to hold
the sealing ring on the injector.
16. Slide the injector and shackle together into the
cylinder head.
Caution: pay attention to the installation position of
injector (port/rounded side facing upwards)
17. Fit the injector into the cylinder head using the fitting tool
F6790085 (6), lubricate the new shackle bolt with engine oil
6
and screw in by hand.
Fuel system:
Refitting the high-pressure system
18. Apply a coat of engine oil to the conical sealing face at
the tip and the contact face of the new high-pressure
connecting spigot.
19. Lubricate the O-ring on the high-pressure connecting
spigot (3) with grease (Kluthe Hakuform 30-10/Emulsion)
and press the high-pressure connecting spigot by hand
into the hole facing the right way round (key).
20. Coat the sleeve nut (2) with engine oil on the thread
and sealing face and screw on by hand.
21. Using the torque wrench, tighten the sleeve nut (2)
to the specified pretightening torque of
15 Nm +5 Nm.
Result: the injector should be fixed in position.
22. Tighten the new shackle bolt using
the torque wrench to the specified
tightening torque of 18 Nm +2 Nm and
then turn a further 90°+5°.
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Fuel system:
Refitting the high-pressure system
23. Tighten the sleeve nut (2) on the high-pressure connecting spigot
to the specified tightening torque of 45 Nm +5 Nm.
24. Fix the fuel rail to the cylinder head using the pipe brackets (3).
25. Apply a coat of engine oil to the sealing faces of the new
high-pressure fuel lines (1) and screw on by hand.
26. Lubricate the new high-pressure fuel lines (4) from the 2
Fuel system:
Removing/refitting the high-pressure pump
Nut tightening torque 105 Nm ±5 Nm.
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Fuel system:
Removing/refitting the high-pressure pump
• Refit the high-pressure pump with the new O-ring
and tighten to a torque of 30 Nm ±5 Nm.
• High-pressure lines from the high-pressure pump to
the fuel rail on A-side and B-side must be replaced.
• Tightening torque for high-pressure line connection to the rail
and high-pressure pump 30 Nm ±3 Nm.
Note:
The low-pressure fuel pump (1) is mounted on the
high-pressure pump and both are driven by
a common pump shaft. 1
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Y4347481
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Overall view:
Rockers, camshaft and cylinder head
52 Cylinder head
60 Bearing shell
70 Valve yoke
80 Camshaft
130 Cylinder head gasket
135 Bolt
360 Rocker pedestal
Features:
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14. Undo the cylinder head bolts in reverse order of the specified
tightening sequence and unscrew all except
two bolts.
15. Fit the lifting beam T80092463 and attach it to the crane.
16. Unscrew the last two cylinder head bolts.
17. Lift the cylinder head off the crankcase with the aid of
lifting beam T80092463 and a crane.
18. Seal off all openings by suitable means.
1. Remove all sealing caps and adhesive tape from the openings.
2. Clean the crankcase mating surface.
3. Place the new cylinder head gasket in position (gaskets identical on both sides).
4. Screw the two F30451398 guide bolts into crankcase.
5. Lower the cylinder head on to the crankcase using the lifting beam T80092463.
6. Check that the cylinder head bolt length is within the maximum limit (282 mm).
7. Lubricate the cylinder head bolt threads and contact faces with engine oil.
8. Screw in the cylinder head bolts by hand.
9. Remove the lifting beam from the cylinder head and unscrew the guide bolts.
10. Screw in the missing cylinder head bolts.
11. Tighten the fixing bolts in the specified sequence from A-Z.
12. Cylinder head bolt tightening specifications:
pretighteing torque: 300 +30 Nm
Then turn a further: 180°
13. Special tool F6790757 is recommended for applying the additional turn.
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4 3 14
2 6 5 8 7 9
10 12 11
1 13
17
15
18
16
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Lubrication system
Lubrication system diagram: XZ57518000003
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Lubrication system
Oil supply to camshaft bearings and valve gear
Lubrication system
Oil module
Oil filter Manufacturer of oil module: MAHLE
Filters
Oil filter
Oil separators
Crankcase venting
Oil cooler
Oil pressure sensor
Bypass valve for
Oil
Filter
cooler
Oil cooler
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Lubrication system:
Oil module and attached components
10 Oil module
20 Gasket
30 External Torx head bolt
Lubrication system
Removing and refitting the oil module
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Lubrication system
Oil module and bypass valves
Bypass valve for oil cooler 2.5 bar
Lubrication system:
Oil supply to turbocharger
Single-stage turbocharging:
1 x Garrett GT 35 on 6R 1600 G
2 x Garrett GT 42 on 8+10 V 1600 G
2 x Garrett GT 45 on 12 V 1600 G
Return
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Lubrication system
Plastic sump
Oil pump
To oil module
Lubrication system
Plastic sump
Plastic sump:
Manufacturer: HUMMEL-Formen GmbH
Material: Ultramid
Standing the engine on the sump
is not allowed!
Follow the specified tightening sequence.
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Lubrication system
Removing and refitting the sump
1. Drain off the engine oil
2. Remove the dipstick
3. Loosen the sump bolts and
unscrew them.
4. Clean the sealing face with easy
cleaner (Loctite 7061).
5. Check the sealing face and molding
and if necessary
replace the molding.
6. At the junctions
apply silicon rubber
(Loctite 5970).
7. Fit four F30452998 guide pins
in and place the sump in position.
8. Tighten the bolts 1-16 in order
to a torque of 10 Nm ±1.5 Nm.
Lubrication system
Removing and refitting the sump
9. Unscrew the four guide pins from the
positions marked 2.
10. Screw in the remaining bolts
and similarly tighten to
a torque of 10 Nm ±1.5 Nm.
11. Tighten all bolts in the specified sequence
to a torque of 21 Nm ±2 Nm.
12. Refit the attached components in reverse
order of removal.
13. Refill the engine with oil (oil capacity as per
data sheet, oil quality to
consumables specifications A001063/00D).
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Lubrication system
Changing the oil
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• 2-stage turbocharging
• Minimized exhaust emissions achieved by EGR system on V10 and V12 models.
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Series 1600
Assembly line in Überlingen
Production process:
1) Assembly line
2) Test bench
C A
E 3) Paintshop
B
1 2
3 D B
Logistics:
A) Goods inwards
B) Warehouse
C) Engine dispatch
Assembly line
D) Customer Service
E) Offices Truck route
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