installation and commissioning engine mtu series 6r1600

8/18/2019 Installation and Commissioning Engine MTU Series 6R1600

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Technical Documentation

Diesel Engines12 V 1600 Gx0.10 V 1600 Gx0.8 V 1600 Gx0.

6R 1600 Gx0.

Installation Guidelines

September, 2010


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Table of Content Page

1 Introduction ...............................................................................................................12

2 General.......................................................................................................................13

2.1 Abstract.......................................................................................................................13

2.2 Foreword.....................................................................................................................13

2.3 Safety Precautions ......................................................................................................14

2.3.1 Stands.........................................................................................................................14 2.3.2 Glasses.......................................................................................................................14 2.3.3 Welding.......................................................................................................................14

2.3.4 Work Place..................................................................................................................15 2.3.5 Clothing.......................................................................................................................16 2.3.6 Electric Tools...............................................................................................................16 2.3.7 Air ...............................................................................................................................16 2.3.8 Fluids and Pressure ....................................................................................................17 2.3.9 Batteries......................................................................................................................17 2.3.10 Fire..............................................................................................................................18 2.3.11 Paint............................................................................................................................18 2.3.12 Fluoroelastomer (VITON) ............................................................................................18 2.3.13 Hot Surface Components ............................................................................................18

3 Transport and Storage..............................................................................................18

3.1 Transport.....................................................................................................................19

3.2 Storage .......................................................................................................................19

3.3 Installation Check........................................................................................................19

3.4 Initial Operation...........................................................................................................19

4 Engine-Generator Set Room ....................................................................................21

4.1 General .......................................................................................................................21

4.2 Genset Foundation......................................................................................................21

4.2.1 Responsibilities ...........................................................................................................21 4.2.2 Construction................................................................................................................21

4.3 Loads into the Foundation ...........................................................................................21

4.3.1 Static Load..................................................................................................................21


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Installation Manual Series 1600

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4.3.2 Dynamic Load.............................................................................................................22 4.3.2.1 General .......................................................................................................................22 4.3.2.2 Single Resilient Mounting............................................................................................22 4.3.2.3 Double Resilient Mounting...........................................................................................23 4.3.3 Generator Short-Circuit Torque ...................................................................................23

4.4 Ventilation System.......................................................................................................24

4.4.1 Ventilation Overview....................................................................................................24 4.4.2 Natural Ventilation.......................................................................................................24 4.4.3 Forced Ventilation - Depression Ventilation System ....................................................24 4.4.3.1 Definition.....................................................................................................................24 4.4.3.2 Depression Ventilation ................................................................................................25 4.4.3.3 Forced Ventilation - Overpressure Ventilation System.................................................26 4.4.3.4 Determining Air Requirement ......................................................................................27 4.4.3.5 Guidelines an Data Source..........................................................................................28 4.4.4 Components................................................................................................................28

4.4.4.1 Louvers .......................................................................................................................28 4.4.4.2 Manually Controlled Louvers.......................................................................................29 4.4.4.3 Gravity Louvers...........................................................................................................29 4.4.4.4 Fixed Louvers..............................................................................................................29 4.4.4.5 Electrically Controlled Louvers ....................................................................................29

5 Diesel Engine Series 1600 ........................................................................................30

5.1 Engine Component Identification.................................................................................30

5.1.1 Engine Serial Number Identification ............................................................................30

5.1.2 Series 1600 Serial Number Identification.....................................................................30

5.2 Engine Application Code Designation .........................................................................31

5.3 Engine Cylinder Labeling.............................................................................................31

5.4 Sound data..................................................................................................................32

5.4.1 Explanation of the Sound Spectra ...............................................................................32 5.4.2 Engine Surface Noise (Mean Free-Field Spectrum) ....................................................32

5.4.3 Undamped Exhaust Noise...........................................................................................32 5.4.4 Engine Specific Noise Data and Spectra.....................................................................32

5.5 Air Inlet System...........................................................................................................32

5.6 Installation Requirements............................................................................................33

5.6.1 General Air Filter System ............................................................................................33 5.6.2 Air Cleaners ................................................................................................................34 5.6.3 Inlet Screens...............................................................................................................34 5.6.4 Rain Caps and Inlet Hoods..........................................................................................34

5.6.5 Inlet Silencers..............................................................................................................35 5.6.6 Restriction / Maintenance Indicator .............................................................................35 5.6.7 Pipe Work ...................................................................................................................35 5.6.7.1 Pipe work material specifications.................................................................................36


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5.6.7.2 Diffusers......................................................................................................................36 5.6.8 Hose Connections.......................................................................................................36 5.6.9 Closed Crankcase Breather System............................................................................37

5.7 Design Guidelines .......................................................................................................37

5.7.1 Maximum Inlet Air Flow...............................................................................................37

5.7.2 Air Inlet System Restriction .........................................................................................37 5.7.2.1 Restriction / Maintenance Indicator .............................................................................37 5.7.2.2 Air inlet restriction calculation ......................................................................................38 5.7.3 Inlet Location...............................................................................................................39 5.7.4 Pipe Work ...................................................................................................................39 5.7.5 Flexible Connection.....................................................................................................39

5.8 Testing Requirements .................................................................................................39

5.8.1 Instrumentation ...........................................................................................................40 5.8.1.1 Temperature Measurement.........................................................................................40 5.8.1.2 Restriction Measurement.............................................................................................40 5.8.2 Test.............................................................................................................................40

6 Exhaust System ........................................................................................................41

6.1 Exhaust System Description........................................................................................41

6.2 Turbocharger...............................................................................................................41

6.3 Exhaust System Design Requirements and Guidelines...............................................43

6.3.1 Sizing Guidelines ........................................................................................................43 6.3.2 Back Pressure.............................................................................................................44 6.3.3 Flexible Connection / Exhaust Bellows........................................................................44 6.3.4 Pipework .....................................................................................................................48 6.3.5 Exhaust Insulation.......................................................................................................48 6.3.6 Noise...........................................................................................................................49 6.3.7 Outlet Location............................................................................................................49 6.3.8 Drainage .....................................................................................................................49 6.3.9 Exhaust Silencer Location...........................................................................................50 6.3.10 Spark Arresters ...........................................................................................................50

6.4 Testing ........................................................................................................................50

6.4.1 Requirement................................................................................................................50 6.4.2 Instrumentation ...........................................................................................................51 6.4.3 Exhaust Temperature Measurement ...........................................................................51 6.4.4 Exhaust Back Pressure Measurement.........................................................................51

6.5 Test.............................................................................................................................52

7 Cooling System.........................................................................................................54

7.1 Function description ....................................................................................................54


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7.2 Cooling System Overview ...........................................................................................54

7.3 Radiator Cooling System.............................................................................................54

7.3.1 Types of Radiator Cooling System ..............................................................................54 7.3.2 Rapid Warm-Up Radiator ............................................................................................54 7.3.3 Conventional Radiator.................................................................................................54

7.4 Cooling System Configuration.....................................................................................54

7.4.1 Series 1600 configuration............................................................................................54 7.4.2 Engine Coolant / Jacket Water Circuit .........................................................................55 7.4.3 Charge-Air Cooling......................................................................................................55

7.5 Cooling System Performance and Installation Requirements ......................................55

7.5.1

System Components ...................................................................................................55 7.5.2 Maximum Coolant Temperatures ................................................................................56

7.5.3 System Fill ..................................................................................................................56 7.5.4 System Drain...............................................................................................................56 7.5.5 De-Aeration.................................................................................................................56 7.5.6 System Coolant Capability ..........................................................................................57 7.5.7 Drawdown Capacity ....................................................................................................59 7.5.8 Cooling System Pressurization, Expansion , and Contraction .....................................59 7.5.9 Water Pump Inlet Pressure .........................................................................................61 7.5.10 Maximum Static Height ...............................................................................................61 7.5.11 Coolant Flow Rate / External Pressure Drop ...............................................................61 7.5.12 Minimum Coolant Temperature ...................................................................................62

7.5.13 Coolant Selection........................................................................................................62 7.5.14 End-Product Questionnaire (EPQ) ..............................................................................62 7.5.15 Heat Rejection.............................................................................................................62 7.5.16 Maximum Ambient Capability ......................................................................................62 7.5.17 System Deterioration or Degradation...........................................................................62 7.5.18 Auxiliary Air-Cooled Cooler Cores...............................................................................62 7.5.19 Coolant Heaters ..........................................................................................................63

7.6 Cooling System Design Considerations.......................................................................63

7.6.1 General Considerations...............................................................................................63 7.6.2 Design Temperature Requirements.............................................................................64

7.6.2.1 Engine Operating Temperature ...................................................................................64 7.6.2.2 Charged Air Intake Manifold Temperature...................................................................64 7.6.3 Heat Rejection and Coolant Flow................................................................................64 7.6.3.1 Engine Heat Rejection.................................................................................................64 7.6.3.2 Additional Heat Loads .................................................................................................64 7.6.3.3 Coolant Pump Flow.....................................................................................................65 7.6.3.4 Heat Transfer Capability..............................................................................................65 7.6.3.5 Coolant Type...............................................................................................................65 7.6.4 Environmental Effects and Operating Conditions ........................................................ 65 7.6.4.1 Ambient.......................................................................................................................66 7.6.4.2 Altitude........................................................................................................................66 7.6.4.3 Space Constraints.......................................................................................................66

7.6.4.4 Enclosures ..................................................................................................................66 7.6.4.5 Ground Effects ............................................................................................................67 7.6.4.6 Noise Limits.................................................................................................................67


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7.6.4.7 Tilt Operations.............................................................................................................67 7.6.5 Cooling System Components ......................................................................................67 7.6.5.1 Coolant Plumbing........................................................................................................67 7.6.5.2 Flexible Connections...................................................................................................67 7.6.5.3 Vent Lines ...................................................................................................................69 7.6.5.4 Fill Lines......................................................................................................................69 7.6.5.5 Expansion Tank Design ..............................................................................................69

7.6.5.6 Water Cooled Exhaust Systems..................................................................................70 7.6.5.7 Water Pumps ..............................................................................................................70 7.6.6 Radiator ......................................................................................................................70 7.6.6.1 MTU Radiator..............................................................................................................70 7.6.6.2 Radiator Selection.......................................................................................................70 7.6.6.3 Radiator Design Data..................................................................................................71 7.6.6.4 Homologation and Qualification of Third Party Radiators.............................................71 7.6.7 Fan Drive Selection.....................................................................................................71 7.6.7.1 Belt Driven Engine Cooling Fan...................................................................................72 7.6.7.2 Fan Drive Belt .............................................................................................................72 7.6.7.3 Air Re-circulation Baffles .............................................................................................72 7.6.7.4

Series 1600 TD or A/AC..............................................................................................72

7.6.8 Coolant Heaters ..........................................................................................................72 7.6.9 Severe Duty Cycle.......................................................................................................72 7.6.10 Cooling System or Duty Cycle Changes......................................................................72

7.7 Cooling System Evaluation Tests................................................................................72

7.7.1 System Description .....................................................................................................73 7.7.2 Instrumentation ...........................................................................................................73 7.7.3 Test Preparations........................................................................................................75 7.7.4 Types of Tests.............................................................................................................76

7.8 Cooling System Diagnostics and Troubleshooting Guide ............................................83

7.8.1 Engine Overheat .........................................................................................................83 7.8.2 Cold Running Engine (Overcooling) ............................................................................85

8 Fuel System...............................................................................................................89

8.1 Engine Fuel System Description..................................................................................89

8.2 Fuel System Description..............................................................................................89

8.3 Design and Installation Guidelines ..............................................................................90

8.3.1 Fuel Lines ...................................................................................................................90 8.3.2 Fuel Filter Configuration..............................................................................................91 8.3.3 Fuel restriction.............................................................................................................91 8.3.4 Water Separation ........................................................................................................91 8.3.5 Fuel Coolers................................................................................................................91 8.3.6 Fuel Heater .................................................................................................................92 8.3.7 Fuel tank .....................................................................................................................92 8.3.7.1 Fuel tank material........................................................................................................92

8.3.7.2 Fuel tank design..........................................................................................................92 8.3.7.3 Fuel tank sizing ...........................................................................................................93

8.4 Fuel Specifications ......................................................................................................94


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8.5 Testing requirements...................................................................................................95

8.5.1 Instrumentation ...........................................................................................................95 8.5.2 Test.............................................................................................................................95

9 Lubrication System...................................................................................................97

9.1 General .......................................................................................................................97

9.2 Description ..................................................................................................................97

9.2.1 System Description .....................................................................................................97 9.2.2 Operational Description...............................................................................................97

9.3 Oil Lines ......................................................................................................................97

9.4 Lube Oil Heating Aids..................................................................................................97

9.5 Oil Filter Configuration.................................................................................................98

9.6 Oil Level Measurement ...............................................................................................98

9.6.1 General Possibilities....................................................................................................98 9.6.2 Oil Level Dipstick.........................................................................................................98 9.6.3 Electrical Level Monitor ...............................................................................................99 9.6.4 Oil Pan Sight Gage......................................................................................................99

9.7 Oil Replenishment Unit................................................................................................99

9.8 Tilt Operation.............................................................................................................100

9.9 Priming......................................................................................................................100

9.10 Crankcase Venting....................................................................................................100

9.11 Fluid Specifications and Recommendations ..............................................................100

9.12 Testing Requirements ...............................................................................................100

10 Electrical and Starting Systems.............................................................................101

10.1 Electrical System Description....................................................................................101

10.2 Cranking requirements..............................................................................................101


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13.1 ADEC System Description.........................................................................................114

13.1.1 Components..............................................................................................................114 13.1.2 Location of Sensors...................................................................................................114 13.1.3 SAM for Genset Application ......................................................................................114

13.1.4 Harness.....................................................................................................................114

13.2 Installation Requirements..........................................................................................115

13.3 Message Format .......................................................................................................115

13.4 ADEC Power Requirements......................................................................................115

13.5 Welding Precautions .................................................................................................115

13.6 Engine Protection......................................................................................................115

13.7 Normal Engine Start ..................................................................................................116

13.8 Diagnostics and Service............................................................................................116

14 Flywheel Housing and Generator...........................................................................116

14.1 Flywheel Housing and Flywheel ................................................................................117

14.1.1 Generator Alignment .................................................................................................117 14.1.1.1 General .....................................................................................................................117 14.1.1.2 Angular Alignment.....................................................................................................118 14.1.1.3 Unbalanced mass .....................................................................................................118 14.1.1.4 Proper seating of the Drive disc.................................................................................118 14.1.1.5 Flywheel radial run out ..............................................................................................119 14.1.1.6 Drive disc concentricity..............................................................................................119 14.1.2 Flywheel Housing Venting.........................................................................................119 14.1.3 Forces on Crankshaft ................................................................................................119

14.2 Alternators and Couplings .........................................................................................119

14.2.1 Alternator Configurations / Designs...........................................................................119 14.2.2 Single Bearing Alternator...........................................................................................120 14.2.2.1 Description ................................................................................................................120 14.2.2.2 Installation requirements ...........................................................................................120 14.2.3 Dual Bearing Alternator (Close-Coupled) ..................................................................120 14.2.3.1 Description ................................................................................................................120 14.2.3.2 Installation requirements ...........................................................................................120 14.2.4 Dual Bearing Alternator (Remote) .............................................................................120

14.2.4.1 Description ................................................................................................................120 14.2.4.2 Installation requirements ...........................................................................................120 14.2.5 Couplings ..................................................................................................................121 14.2.5.1 Torsional and bending vibration analysis...................................................................121


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14.2.5.2 Coupling (between engine and rotor) ........................................................................121 14.2.5.3 Single bearing alternator couplings ...........................................................................121 14.2.5.4 Close-coupled dual-bearing alternator couplings.......................................................122 14.2.5.5 Remote mounted dual bearing alternator couplings...................................................122 14.2.5.6 Requirements for the axial endplay of the crankshaft and the alternator shaft...........122 14.2.6 Standby Gensets with Permanent Inducing of Vibration and Forces .........................123 (No Break Gensets).....................................................................................................................123


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PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of Cali-fornia to cause cancer, birth defects, and other reproductive harm.

• Always start and operate an engine in a well ventilated area.• If operating an engine in an enclosed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system or emission control sys-tem.


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1 Introduction

Symbols

The symbols used in the safety instructions are explained in the chapter “Safety instructions”.

This symbol indicates cross–references to other manuals.

This symbol refers to notes about special MTU/ recommendations.

This symbol refers to notes concerning personal safety.

Figures and References

Details in figures are provided with reference numbers and reference lines if necessary.

If reference is made in the text to a detail provided with a reference number, the figure number and,separated by an oblique, the reference number of the detail is written in brackets. Example: (5/2) refersto fig. 5, reference number 2.


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2 General

2.1 Abstract

This manual discusses the proper installation and application of the MTU/ Series 1600 Oil & Gas and

Generator Set Engines. This manual contains the following information:

• General information on safety precautions, performance curves, and installation drawings

• Specific component and accessory information on various production models

• Information on the electrical, fuel, exhaust, lubrication, cooling, and air inlet systems

2.2 Foreword

This document is a guideline for qualified personnel as an aid to the project planner, plant and generatorset constructor and also for assembly companies that plan and carry out installation of MTU/ diesel en-

gines. It is intended to be used by equipment manufacturers and contains MTU/ ’s recommendations forthe ancillary systems supporting the MTU/ engines covered by this document. The aim of these installa-tion guidelines is to ensure that the generator set is properly installed. The equipment manufacturer isresponsible for developing, designing, manufacturing and installing these systems, including componentqualification. The equipment manufacturer is also responsible for furnishing complete service and safetyinformation for these systems to equipment users. MTU/ make no representations or warranties regard-ing the information contained in this document and disclaim all liability or other responsibility for the de-sign, manufacture or installation of these ancillary systems, or the preparation or distribution to equip-ment users of appropriate information regarding these systems. The installation guidelines do not relievethose in charge of the system from their responsibility to perform accurate work and proper inspectionsby skilled and qualified personnel. All valid laws, ordinances, and regulations must be observed.

The information contained in this document may not be complete and is subject to change without no-tice.

Performance of the required maintenance work contributes to operational dependability, reliability, and along service life. Easy access for operating, maintenance and repair personnel must therefore be guar-anteed when planning and installing the engine.

In addition to the installation guidelines, the following current technical documents should be consulted:

• Engine installation drawings

• Schematic diagrams

• Sound spectra

• Technical engine data• Accessory drawings etc.

• De-rating table

• Operating instructions

Exclusion of Liability

MTU/ will not accept liability for damage caused to the engine due to the customer’s installation if the installationrequirements stated in this manual are not followed


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2.3 Safety Precautions

General safety instructions, accident prevention regulations, and those safety precautions defined by lawmust be observed.

This documentation contains specially highlighted safety instructions. These safety instructions must beobserved and followed in order to prevent injury and material damage.

Adherence to the following safety measures is essential when installing MTU/ Series 1600 engines.

PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of Cali-fornia to cause cancer, birth defects, and other reproductive harm.

• Always start and operate an engine in a well ventilated area.

• If operating an engine in an enclosed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system or emission control sys-tem.

2.3.1 Stands

Use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on either the jack or the hoistto carry the load.

2.3.2 Glasses

Select appropriate safety glasses for the job. Safety glasses must be worn when using tools such ashammers, chisels, pullers and punches.

2.3.3 Welding

Consider the consequences of welding.

NOTICE:When welding, the following must be done to avoid damage to the ADEC electronic controls andthe engine:

• Both the positive (+) and negative (-) battery leads must be disconnected before weld-ing.

• The ground cable must be in close proximity to welding location. (less than 60 cm or 24

inches).

• The engine must never be used as a grounding point. This may cause burn and scorch

marks on mounts, which could lead to pitting of the mounts.

• Never lay the welding cable over or in the vicinity of any cables of the engine /generator

set. Welding currents could be induced into the cables, which may cause damage to the

engine/generator set.

• If welding must be carried out on parts connected to the engine (e.g. exhaust pipe),

these parts must be removed from the engine prior to welding.

• Welding on the engine or engine mounted components is NEVER recommended.


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Wear welding goggles and gloves when welding or using an acetylene torch.

NOTICE:Cover the engine when welding in its vicinity

PERSONAL INJURYTo avoid injury from arc welding, gas welding, or cutting, wear required safetyequipment such as an arc welder's face plate or gas welder's goggles, weldinggloves, protective apron, long sleeve shirt, head protection, and safety shoes. Al-ways perform welding or cutting operations in a well ventilated area. The gas in oxy-gen/acetylene cylinders used in gas welding and cutting is under high pressure. If acylinder should fall due to careless handling, the gage end could strike an obstruc-tion and fracture, resulting in a gas leak leading to fire or an explosion. If a cylinder

should fall resulting in the gage end breaking off, the sudden release of cylinderpressure will turn the cylinder into a dangerous projectile. Observe the followingprecautions when using oxygen/acetylene gas cylinders:

• Always wear required safety shoes.

• Do not handle tanks in a careless manner or with greasy gloves or slipperyhands.

• Use a chain, bracket, or other restraining device at all times to prevent gascylinders from falling.

• Do not place gas cylinders on their sides, but stand them upright when inuse.

• Do not drop, drag, roll, or strike a cylinder forcefully.

• Always close valves completely when finished welding or cutting.

FIRE To avoid injury from fire, check for fuel or oil leaks before welding or carrying anopen flame near the engine.

Insure that a metal shield separates the acetylene and oxygen that must be chained to a cart.

2.3.4 Work Place

Never put lines to any use other than that for which they are intended.Never use lines for climbing .

Organize your work area and keep it clean.

PERSONAL INJURY To avoid injury from slipping and falling, immediately clean up any spilled liquids.

Eliminate the possibility of a fall by:• Wiping up oil spills

• Keeping tools and parts off the floor


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A fall could result in a serious injury.

After installation of the engine is complete:

To avoid injury from rotating belts and fans, do not remove and discard safetyguards.

Never put lines to any use other than that for which they are intended.Never use lines for climbing.

• Reinstall all safety devices, guards or shields

• Check to be sure that all tools and equipment used to install the engine are removed from the engine

2.3.5 Clothing

Wear work clothing that fits and is in good repair. Work shoes must be sturdy and rough-soled. Barefeet, sandals or sneakers are not acceptable foot-wear when installing an engine.

PERSONAL INJURY To avoid injury when working near or on an operating engine, remove loose items ofclothing and jewellery. Tie back or contain long hair that could be caught in anymoving part causing injury.

2.3.6 Electric Tools

Improper use of electrical equipment can cause severe injury.

To avoid injury from electrical shock, use care when connecting battery cables. Themagnetic switch studs are at battery voltage.

Check power tools before using.

2.3.7 AirUse proper shielding to protect everyone in the work area.

EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eyeprotection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) airpressure.


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2.3.8 Fluids and Pressure

Be extremely careful when dealing with fluids under pressure.

HOT COOLANT To avoid scalding from the expulsion of hot coolant, never remove the cooling sys-tem pressure cap while the engine is at operating temperature. Wear adequate pro-tective clothing (face shield, rubber gloves, apron, and boots). Remove the capslowly to relieve pressure.

Fluids under pressure can have enough force to penetrate the skin.

To avoid injury from penetrating fluids, do not put your hands in front of fluid underpressure. Fluids under pressure can penetrate skin and clothing.

These fluids can infect a minor cut or opening in the skin. See a doctor at once, if injured by escapingfluid. Serious infection or reaction can result without immediate medical treatment.

To avoid injury from battery explosion or contact with battery acid, work in a well-ventilated area, wear protective clothing, and avoid sparks or flames near the bat-

tery. Always establish correct polarity before connecting cables to the battery orbattery circuit. If you come in contact with battery acid: • Flush your skin with water.

• Apply baking soda or lime to help neutralize the acid.

• Flush your eyes with water.

• Get medical attention immediately.

2.3.9 Batteries

Electrical storage batteries give off highly flammable hydrogen gas when charging and continue to do sofor some time after receiving a steady charge.

Always disconnect the battery cable before working on the ADEC system.

Electrical Shock To avoid injury from electrical shock, use care when connecting battery cables. Themagnetic switch studs are at battery voltage.


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2.3.10 Fire

Keep a charged fire extinguisher within reach. Be sure you have the correct type of extinguisher for thesituation. The correct fire extinguisher types for specific working environments are listed in Table 0-1.

Fire Extinguisher Work EnvironmentType A Wood, Paper, Textile and Rubbish

Type B Flammable Liquids

Type C Electrical Equipment

Table 0-1 The Correct Type of Fire Extinguisher

2.3.11 Paint

Mask off the ECM and EFC, prior to applying any paint.

NOTICE:Do not apply paint to the ECM or EFC. The application of paint may affect the performance of theECM and EFC.

2.3.12 Fluoroelastomer (VITON)

Fluor rubber (Viton) parts such as O-rings and seals are perfectly safe to handle under normal designconditions.

To avoid injury from degraded flouro-elastomer parts, wear eye protection (gogglesand faceplate) and neoprene or PVC gloves when handling fluoro-elastomer O-ringsor seals, which have been degraded by excess heat. Do not handle engine parts untilthey have cooled. Wash equipment and parts well with lime water (calcium hydrox-ide solution) before reusing if hydrogen fluoride condensate is expected. Discardgloves after handling degraded fluoro-elastomer.

A potential hazard may occur if these components are raised to a temperature above 600_F (316_C) (ina fire for example). Fluoro-elastomer will decompose (indicated by charring or the appearance of a black,sticky mass) and produce hydrofluoric acid. This acid is extremely corrosive and, if touched by bare skin,may cause severe burns (the symptoms could be delayed for several hours).

2.3.13 Hot Surface Components

NOTICE:Hot-surface components, which will be installed by third parties and which are not part of thecore engine (i.e. exhaust piping), need to be installed and/or insulated in a way, that neither dur-ing engine operation, nor during engine stop, non-metallic fuel line surface temperatures don’t

exceed 100°C / 212°F.

3 Transport and Storage


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3.1 Transport

The following information should be considered before transporting the engine:

• Lift the engine only with suitable lifting equipment.

• The engine should only be lifted by utilizing the factory supplied lifting eyes - see installation draw-ings.

• Centre of gravity is shown in the engine installation drawings.

• In the case of special packing (e.g. with aluminium foil), lift the engine by the lifting eyes of the en-gine-shipping skid or transport it with a forklift truck.

• The lifting eyes installed on the engine are intended for lifting the engine only, not a complete gen-erator package. The lifting eyes are designed for the engine weight only.

• Lift the engine/generator set only using the provided lifting eyes on the generator set frame.

• Transport generator set only when utilizing the crankshaft lock and when the engine vibrationmounts are blocked (if vibration isolators are included).

3.2 Storage

The following information should be considered before preserving the engine:

• Preserve the engine/generator set in accordance with the preservation procedures outlined in theoperator’s manual and Fluids an Lubricants documentation unless special procedures are applica-ble.

• Store the engine/generator set in a dry room on the original wooden frame or other suitable frame,and cover with an oil resistant cover.

• If seaworthy packing (vacuum sealed air tight aluminium foil) is used, do not use additional coveringand monitor the moisture indicator regularly.

For detailed instructions on proper preservation of the engine refer to Service Publication Fluidsand Lubricants Specification (A001063/0xE).

3.3 Installation Check

All documents to do a proper installation check are provided in the MTU Business Portal (BP). They arelisted within a table in chapter “Commissioning Tools”.

3.4 Initial Operation

The plant may only be commissioned under the supervision of a qualified specialist in plant construction.Before the plant is put into operation, the following conditions must be satisfied first:

• All work on the plant must be completed

• All work has been performed correctly

• All safety equipment (protective grilles etc.) must be in place.

• There should be no tools or foreign parts in the genset’s area of operation.

• The section entitled “Initial Operation” in the Engine Operation Manual and in the Governor Manualare read and followed.


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• Fluids and lubricants (such as fuel, oils, greases, corrosion inhibitor oil and antifreeze) approved bythe MTU Fluids and Lubricants Specification are used.

• The engine governor is checked and optimized in accordance with MTU setting instructions.


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4 Engine-Generator Set Room

4.1 General

The engine room should be

• Equipped with a lifting gear, load-bearing capacity of which is designed to accommodate the heavi-est individual component.

• The engine room should be configured in such a way that the appropriate components and the fill-ing/draining points are freely accessible for maintenance and repair work.

• With approved non-crack, oil-resistant paint to the surface of the foundation .

4.2 Genset Foundation

4.2.1 Responsibilities

Structural design and construction of the foundation or the floor surface are not included in MTU scopeof supply. The foundation and floor should be designed by an experienced supporting-framework plannerin accordance with applicable regulations

4.2.2 Construction

The foundation or the floor surface should be manufactures from a single piece of reinforced concrete(without a layer of concrete or flooring). Appropriate action must be taken to even out foundation irregu-larities in the area of the genset contact surfaces so as to ensure a distortion-free setup. The base skipcan be secured to the foundation by means of dowels or bonding.

4.3 Loads into the Foundation

4.3.1 Static Load

The static load is the sum of the weights of all components like e.g.:

• Engine (filled with oil, coolant and fuel)

• Alternator

• Radiator (filled with coolant)

• Piping (filled with coolant, fuel …)

• Skid

• Coupling

• Accessories


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Figure 4-1

4.3.2 Dynamic Load

4.3.2.1 General

Although MTU engines theoretically demonstrate complete mass balancing, dynamic loads are createdby tolerance-conditioned free inertia forces and moments and by the dynamic share of the indicated en-gine speed moment. These dynamic loads are introduced to the foundation via the base skid.

The extent of this load is dependent on the resilient mounting configuration. The overall foundation iscalculated from the total of individual loads.

Special load types such as e.g. shock and earthquake load transmissions cannot be dealt with here.

4.3.2.2 Single Resilient Mounting

Figure 4-2


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4.3.2.3 Double Resilient Mounting

Figure 4-3

4.3.3 Generator Short-Circuit Torque

Short-circuit torque M depends on

• Alternator manufacturer• Alternator model

Figure 4-4


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A value of 6 to10 times engine rated torque can be estimated as the short-circuit torque.

This load acts with 50 or 60 Hz alternately on both sides of the base skid in vertical direction and diesdown after approx. 0.5 s.

Additional transverse forces of approx. 20% of static load.

4.4 Ventilation System

4.4.1 Ventilation Overview

Engine-generator set room ventilation is critical to provide adequate air volume to dissipate heat radiatedfrom:

• The engine

• The cooling system

• The CAC system

• The generator

• The exhaust pipe

The ventilation provides the adequate air volume

• To dissipate harmful emissions

• For engine combustion

• For a safe working environment

• To ensure applicable regulatory requirements are observed

For MTU Onsite Energy radiator mounted cooling systems, the engine-generator set room depression as

measured between the inside and outside of the room must not exceed -0.12 kPa (-0.5 in. H2O).Performance of the engine-generator set may be impaired if air circulation or cooling is inadequate.

Engine-generator set room ventilation methods are as follows:

• Natural

• Forced

4.4.2 Natural Ventilation

Engine -generator set rooms without forced ventilation devices relying totally an natural ventilation arenot recommended by MTU Onsite Energy and therefore not covered in this manual.

4.4.3 Forced Ventilation - Depression Ventilation System

4.4.3.1 Definition

Forced ventilation of the engine-generator set room is realized by engine mounted and electrically-drivenfans.

Depression ventilation is the simplest solution in this case. Depression is created when warm air is ex-tracted from the engine room; this in turn ensures a relatively steady supply of fresh air to the engineroom.

It is advisable to route the flow of air past the generator first and then the engine. The air inlets and out-lets should be arranged in such a manner to achieve the best possible degree of room ventilation withoutany so-called dead corners.


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4.4.3.2 Depression Ventilation

Figure 4-5 : Depression ventilation system by means of a front-end cooler system

1 Engine 5 Noise attenuation 9 Weather + rodent guard

2 Generator 6 Adjustable louvers 10 Adjustable louvers

3 Cooling + combustion air 7 Noise attenuation 11 Outlet air volume corresponding

4 Weather + rodent guard 8 Outlet air to cooling air volume


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Figure 4-6 : Depression ventilation system by means of electrically-driven fans

1 Engine 5 Noise attenuation 9 Weather + rodent guard

2 Generator 6 Adjustable louvers 10 Adjustable louvers

3 Cooling + combustion air 7 Noise attenuation 11 Fan arrangement corresponding

4 Weather + rodent guard 8 Outlet air to calculated air volumes

4.4.3.3 Forced Ventilation - Overpressure Ventilation System

The pressure in a force-ventilated engine-generator set room is marginally higher than atmosphericpressure. This ventilation method is usually used in cases where:

• Filtering of the engine room inlet air is required.

• Fresh air is drawn in from a dust-free area.

In this case, the fans are located on the air inlet side, for example, between the filter and the engine-generator set room and create overpressure in the room. The overpressure in the room corresponds tothe pressurized air resistance.


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Figure 4-7 : Forced feed ventilation system

1 Engine 5 Noise attenuation 9 Outlet air

2 Generator 6 Adjustable louvers 10 Weather + rodent guard

3 Cooling + combustion air 7 Fan arrangement 11 Adjustable louvers

4 Weather + rodent guard 8 Noise attenuation

4.4.3.4 Determining Air Requirement

The calculations and guidelines provided below are approximate. Finalized values require recalculationtaking on-site conditions into consideration.

The air requirement needed for adequate ventilation of the engine room can be calculated as follows:


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4.4.3.5 Guidelines an Data Source

Please refer to the MTU engine TVU data for guidelines and data required to determine the combustionair volume.

The data can be found in the MTU Business Portal or obtained from the local MTU Onsite Energy au-thorized distributor/dealer.

4.4.4 Components

4.4.4.1 Louvers

The air inlets and outlets must feature louvers to allow fresh air into the engine-generator set room whenthe engine-generator set is operating and to prevent air flow when the engine-generator set is not in op-eration. Furthermore, louvers afford the ventilation system good protection against intrusion from water,foliage and small animals.

The air resistance of the louvers depends on the size of the clear opening, air speed and the shape ofthe slats and must be specified separately by the louver supplier. Louvers are generally installed inopenings in the masonry or on the inside.


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Figure 4-8

4.4.4.2 Manually Controlled Louvers

Louvers which are opened and closed manually may be installed for engine-generator sets which arestarted manually.

4.4.4.3 Gravity Louvers

Gravity louvers are often used in engine-generator set rooms. The slats of the louver are kept open bythe flow of air when the engine-generator set is running. The slats close by their own weight when theengine-generator set is not operating. Gravity louvers afford the ventilation system good protection in theclosed position against intrusion from water, foliage and small animals. This louver variant requires care-ful installation in the right position taking the direction of air f low into consideration.

4.4.4.4 Fixed Louvers

Fixed louvers afford the ventilation system good protection against intrusion from water, foliage andsmall animals.

4.4.4.5 Electrically Controlled Louvers

All functions on fully-automated engine-generator sets are controlled by an automatic control system. Inthis case, electrically-controlled louvers may be installed which are actuated by electrical servomotors.There are two types of systems:

• Powered open - servomotor opens louvers when active. The louvers must open when the engine-generator set starts.

• Powered closed - servomotor closes louvers when active. The powered closed louver system is the

MTU Onsite Energy preferred method. Louvers open at any power interruption.

All electrically-controlled louvers may also be controlled by a room air thermostat.


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5 Diesel Engine Series 1600

5.1 Engine Component Identification

This section explains the methods of engine identification used for the Series 1600 engines. The follow-

ing representative engine configurations can be found in the Business Portal (Installation Drawings):

• 6R Series 1600 G

• 8V Series 1600 G



5.1.1 Engine Serial Number Identification

There are serial number formulas assigned to the Series 1600 engines. The eleven-digit serial number

designates whether the engine is:• A Series 1600 engine built in Detroit (DT)

• A Series 1600 engine built in Friedrichshafen (FN)

• A Series 1600 engine built in Suzhou

5.1.2 Series 1600 Serial Number Identification

The first two digits of every series 1600 engine are sixteen (16). After this

Number of cylinders and

arrangement

Description Production plant Location

3 6R 01 Friedrichshafen

5 8V 02 Detroit

6 10V 03 Suzhou

7 12V …

…

Series Number of cylinders andarrangement

Production plant Sequential buildnumber

1600 10V FN

16 6 01 000005

This means that an engine with the serial number 16601000005 is the fifth 10V engine that was pro-

duced in Friedrichshafen.


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5.2 Engine Application Code Designation

The next figure shows the diesel engine application code designation system.

Application

Group

Application

Code

Definition

Gen SetPrimePower

3B

This type of rating applies to heavy-duty diesel generator sets when used as autility power source. It is subject to normal varying load conditions, with anintermittent overload capability of 10% for no more than 1 hour in every 12hours operation. When averaged over a 24-hour period, the average loadfactor must not exceed 75% of the prime power rating. Under these conditionsthe generator set may be operated for an unlimited number of hours per year.

Gen SetLimitedRunning

Time Power

3C

This type of rating applies to heavy-duty diesel generator sets when used as autility power source that will deliver rated power for up to 1000 hours per year.Normal varying load factors and/or constant dedicated loads must not exceed75% of the limited running time power rating.

Gen SetStandbyPower

3D

This type of rating applies to heavy-duty diesel generator sets when used in

the event of a utility power failure. The generator set may operated at ratedpower for the duration of the utility outage. The generator set will operate withan average load factor of less then 85% of the rated power and will operate upto 500 hours over the course of a year.

Figure 5-1 Diesel Engine Application Code System

5.3 Engine Cylinder Labeling

The Series 1600 cylinder labeling follows the ISO1204 nomenclature. For cylinder labeling, the viewpoint

is taken from the rear of the engine looking forward.From this position, the cylinder bank on the left is the A bank and the closest cylinder to the viewer onthat bank is named A1. The right cylinder bank is the B bank and the closest cylinder to the viewer isnamed B1. The cylinder block access covers are labelled A1 for left rear and B1 for right rear; thus theA1 access cover is found directly below the A1 cylinder.

Figure 5-2 Cylinder labelling


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5.4 Sound data

5.4.1 Explanation of the Sound Spectra

Third-octave and octave spectra are shown. The reference variable is 2 x 10-5 Pa. This sound pressurespectrum (in contrast to a sound output spectrum with the reference variable 1 x 10-12 W). The spectraare shownin accordance with the standard unweighted in dB.

Tolerance: +5 dB for single 1/3-octave bands+2 dB for mean excess

Note: Some engine manufacturers publish A-weighted spectra. When comparing with MTUEngines, it is essential to ensure that the spectra are available in the same form.

The right-band column of the spectrum is headed “LA” and “LIN”. The cross bars shown underneath

identify the sum level, also referred as the “total level”. LA stands for the weighted-sum level in db(A).LIN stands for the unweighted (shown spectrally in the diagram), i.e. merely logarithmically added uplevel of the spectrum in dB.

5.4.2 Engine Surface Noise (Mean Free-Field Spectrum)

The spectra shown are energetically averaged spectra from a number of measuring points that dependon the size of the engine. The measuring distance, i.e. the distance of the microphone from the engineereference surface during the measurement, is 1 m. The term free-field noise means that the level calcu-lated in the test bay is reduced by the proportion of background noise (if present) as well as by the pro-portion reflected by the test bay walls. Only in this way is it possible to compare such spectra of of differ-ent engine manufacturers.

The spectra are based on measurements with MTU standard air filters, i.e. the measured values alreadyinclude the intake noise. This normally corresponds to the standard setting-up conditions of gensets. Ifother air filters are useed, deviations are possible in the entire engine noise spectrum.

Note: Some engine manufacturers determine the engine surface noise without the intake noise(suction intake from outside). This produces lower levels. This must be taken into accountin the comparison with MTU engines and in the project configuration.

5.4.3 Undamped Exhaust Noise

Since measurement of the exhaust noise (without silencer) takes place outside of the test bay, i.e. out-

doors, there is no room level correction. The free-field noise is recorded already. The spectrum is ener-getically averaged from measured values at 2 points at a distance of 1 m from the pipe outer edge underan angle of 90° to the pipe centre line.

5.4.4 Engine Specific Noise Data and Spectra

All engine specific noise data and sound spectra are published in the MTU Business Portal.

5.5 Air Inlet System

An internal combustion engine must receive an adequate supply of air for combustion to develop fullrated power and burn fuel efficiently. The performance of the engine is affected by the following factors:

• Combustion air volume

• Ambient air temperature


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• Barometric pressure

The function of the air inlet system is to furnish to the engine cylinders an adequate supply of clean, dry,cool air for proper fuel combustion. There are two main components to the application of an air inlet sys-tem: the air cleaner and the ducting (piping). The design of the air inlet system has a direct effect on theengine power output, fuel consumption, exhaust emissions, and engine life.

The complete engine air inlet system consists of the following components:

• Air cleaner and associated pipe work

• Turbochargers

• Charge air cooler piping

• Charge air cooler (CAC)

• Intake manifolds

The intake air enters the turbochargers after passing through the air cleaner. The turbochargers supply

air under pressure to the intake manifolds. Power to drive the turbochargers is extracted from energy inthe engine exhaust gases. The expanding exhaust gases turn a single stage turbocharger wheel, whichdrives an impeller, thus pressuring intake air. This charge air is then cooled by a charge air cooler (CAC)for improved combustion efficiency prior to entering the engine intake manifolds. All series 1600 engineshave:

• Air to Air Charge Cooling (A/AC) – This features charge air connections on the engine that are con-nected to and from a radiator (air to air cooling).

The pressurized intake charge is routed from the discharge side of the turbochargers, through the CACto the intake manifolds, which directs the air to ports in the cylinder heads, through two intake valves percylinder, and into the cylinders. At the beginning of the compression stroke, each cylinder is filled withclean air.

5.6 Installation Requirements

The combustion air intake system should be designed to:

• Prevent preheating of intake air

• Prevent exhaust gas re-circulation

• Ensure service friendly filter position

• Minimize debris ingress during filter element change

• Prevent water ingress

• Ensure the turbocharger does not support the weight of the air intake system• Ensure the intake duct is isolated from engine vibrations in the case of remote installation

5.6.1 General Air Filter System

The air inlet system has a direct effect on engine output, fuel consumption, exhaust emissions, and en-gine life. MTU/ diesel engines must be fitted with combustion air filters. Only dry paper air filters with afilter efficiency > 99.9 % may be used. The parts and materials must be designed to withstand the work-ing environment that applies to the system. The efficiency of the filter system, including pre-filters, mustbe adapted to environmental conditions. These filters must satisfy allowable inlet restriction require-ments. The ducting between the air cleaner and turbocharger inlet should be airtight.

Tests to determine the service life of an air cleaner are usually performed in accordance with SAE J726-C and/or ISO 5011.


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The filter configuration also influences the engine noise level. Noise spectrum data on TVU is based onmeasurement with the factory supplied single stage dry air cleaners.

5.6.2 Air Cleaners

The air cleaners protect the engine from abrasive airborne contaminants, which cause excessive engine

wear. Materials that contain rust, mill scale or other deposits should not be used in the air intake systemsince they may cause excessive engine wear.

Heavy duty dry paper element type cleaners are recommended for use on MTU/ engines. In the case ofshort operating times, (e.g. emergency power operation) single stage filters are normally sufficient.

Dry paper element air cleaners must meet the following requirements:

• Sufficient filter efficiency

• Good structural integrity and quality workmanship

• Sufficient service life

• Easily accessible for maintenance with adequate space provided for replacement of the element.

The choice of air cleaner depends upon the engine type, application, operating environment, and desiredservice life. The service life is proportional to the dust holding capacity of the air cleaner. Safety elementis recommended in 3A and 3B applications.

Choose an appropriate air cleaner as follows:

1. Determine the maximum engine airflow requirement and the clean and dirty restriction limitationsfrom TVU.

2. Determine total air intake system restriction.

3. Determine desired service life.

4. Define operating environment (e.g. dusty, moisture, saline atmosphere, etc.)

5. Select the appropriate cleaner from the manufacturer’s recommendations.

The service life of the filters can be increased by using dry air cleaners with pre–separation (centrifugalaction pre-cleaners). In this case, the intake air is rotated by guide blades arranged at an angle, with thecoarser dust particles being separated out first. This may be necessary in dusty environments or in conjunction with continuous operation.

MTU/ recognize that oil bath air cleaners may be necessary in locations where dry type air cleaners arenot readily available. In those cases, oil-bath type air cleaners are acceptable when used according tothe air cleaner manufacturer’s guidelines and MTU/ air system requirements.

If any further questions remain regarding air cleaner selection, including the need for oil-bath air clean-ers, contact MTU/ Series 1600 Application Engineering.

5.6.3 Inlet Screens

An inlet screen may be used with an air cleaner when larger airborne material is encountered in an op-erating environment. An inlet screen will prevent large airborne material from blocking air passagethrough the air cleaner elements. The inlet screen should be inspected frequently and cleaned as neces-sary.

5.6.4 Rain Caps and Inlet Hoods

The entrance to the air cleaner must be designed to ensure that no water or snow can enter the aircleaner. Rain caps or inlet hoods are required for applications that expose the engine air inlet to rain orsnow.


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Figure 5-3 Rain Cap and Inlet Hood

5.6.5 Inlet Silencers

Appreciable reductions in noise levels can sometimes be achieved with the use of inlet silencers. Inletsilencers operate on the same principle as exhaust silencers. The installer should consult the supplier forspecific recommendations. Care should be taken to ensure that the intake restriction is not raised above

the allowable limit for clean air cleaners. Refer to TVU for maximum allowed intake air restriction.

5.6.6 Restriction / Maintenance Indicator

A restriction/maintenance indicator must be installed in the air system to indicate when air cleaner sys-tem maintenance is required.

Air inlet restriction is an important parameter of the air inlet system. High inlet restriction may cause in-sufficient air for combustion. Factors contributing to high inlet restriction include:

• Small intake pipe diameter

• Excessive number of sharp bends in system

• Long pipe between the air cleaner and turbocharger compressor inlet

• High air cleaner resistance

Air inlet restriction that is too high may result in:

• Reduced power

• Poor fuel economy

• High combustion temperature

• Over-heating

• Reduced engine life

5.6.7 Pipe Work


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Give careful attention to the pipe work and associated fittings used in the inlet system in order to mini-mize restriction and maintain reliable sealing.

Keep piping lengths short and minimize the number of bends and restriction incurred in the system. Usesmooth bend elbows with a bend radius to tube diameter (R/D) ratio of at least 2.0 and preferably 4.0.

Keep air ducts away from heat sources such as exhaust manifolds, etc. Use appropriate insulation orshielding to minimize radiated heat from these sources to the inlet system.

Give careful attention to accessibility to service related parts (i.e., rocker covers, oil spinner filter, etc.).

5.6.7.1 Pipe work material specifications

Aluminium or aluminized steel seamless tubing should be used. The tube ends require a 2.3 mm (0.09in.) minimum bead to retain hose and clamp connections.

Stainless steel piping is recommended in environments that have saline atmospheres or high concentra-tions of salt.

Fibreglass piping between the air cleaner and the turbocharger compressor inlet is also acceptable.

MTU/ does not recommend the use of metered elbows of less than five sections.

5.6.7.2 Diffusers

Make any necessary cross-sectional changes in the piping diameter gradually rather than using suddenexpansions or contractions (see Figure 5-2).

Figure 5-4 Diffuser Configurations

5.6.8 Hose Connections

Use the following for hose connections:

• Plain (non reinforced) hose sections to connect items of rigid pipe work, which are in line and closetogether, or have little relative motion.

• A short section of reinforced hose between the ductwork sections where significant relative motion ormisalignment occurs. High quality “Hump" hose is capable of meeting these requirements.

• Constant torque clamps to provide positive clamping and to prevent piping separation.• Minimum number of hose connections to reduce risk of leaks that may allow ingress of unfiltered air

• MTU/ does not approve the use of hoses with internal coil spring insertions.


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• Hoses used in the inlet system must be of adequate specification to withstand service conditions.

• Hoses must be resistant to fuel, lube oil, depression up to 12.5 kPa (50” H2O) and temperatures ofup to 150°C (302°F ).

5.6.9 Closed Crankcase Breather System

A closed crankcase breather system is standard for the Series 1600 engines. Closed crankcase breathersystems vents crankcase vapour back into the air inlet stream of the engine.

The vapour that is discharged from the crankcase breather on the valve covers is routed through an oilseparator that routes the oil to the pan and the air to the inlet of the turbocharger.

5.7 Design Guidelines

The installed inlet system must be designed in accordance with the technical guidelines outlined in Sec-tion 4.1.

Important: For closed engine room applications adequate engine room ventilation must be provided foran environment, which allows both equipment and operating personnel to function effectively. Addition-ally, the temperature rise inside the engine room must remain low with respect to the outside air. If this isnot possible to a sufficient degree, the combustion air must be taken from outside the engine room.

The main design criteria for the air inlet system includes:

• Maximum inlet air flow

• Air intake restriction

• Inlet location

• Temperature rise from ambient to turbo inlet

Refer to the TVU data of the specific engine rating for limits on each of these criteria.

5.7.1 Maximum Inlet Air Flow

The first step in the design of the air inlet system is to determine the maximum airflow requirement forthe engine. Refer to TVU for maximum airflow values.

5.7.2 Air Inlet System Restriction

5.7.2.1 Restriction / Maintenance Indicator

The restriction/maintenance indicator should be located in a straight section of tubing as close to theturbocharger compressor inlet as practical, but no closer than 127 mm (5 in.). The restriction indicatorshould be placed perpendicular to the plane of the bend where measurement on a bend is unavoidable.The fittings should be at right angles to the tube and flush with the inside of the tube.


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Figure 5-5 Static Pressure Tap

The operating setting of the indicator should correspond to the maximum permissible inlet restriction forsystems with dirty filters, provided that it is connected to a tapping point close to the turbocharger inlet.Refer to TVU for permissible air inlet restriction values.

5.7.2.2 Air inlet restriction calculation

The restriction of the air inlet system is equal to the sum of the individual restrictions in the system.These include rain caps, inlet hoods, air cleaners, and piping.

Figure 5-6 Air Inlet Restriction Calculation

For the initial sizing of the air inlet system use the turbo inlet diameter. Increase the pipe size or modifythe piping configuration if the air intake restriction exceeds the maximum limit. When silencers, cleaners,

Air Inlet Restriction Calculation

Rain Cap or Inlet Hood Restriction ________________ mbar (“H2O)

Pre-cleaner Restriction + ________________ mbar (“H2O)

Air Cleaner Restriction + ________________ mbar (“H2O)

Piping Restriction + ________________ mbar (“H2O)

Other ___________________ + ________________ mbar (“H2O)

Total Air Inlet Restriction = ________________ mbar (“H2O)


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piping and engine room air inlets are insufficiently sized, engine air restriction is increased. To keep therestriction within specifications, properly sized components must be installed and maintained. The airintake system should be designed with a minimum number of bends, obstructions and lengths of pipe.

5.7.3 Inlet Location

Position the air inlet such that it will:

• Supply lowest available temperature level into air intake system

• Minimize inlet air temperature rise from ambient to turbo inlet

• Prevent exhaust fumes from being drawn into the air inlet system

• Minimize the ingress of dust and moisture

• Prevent the ingress of water and snow

5.7.4 Pipe Work

• Consider the following when designing an air inlet system:• Limit the use of bends or elbows.

• Use long radius elbows rather than metered joints when an elbow is required.

• Use the most direct route for piping to minimize the pipe length.

• Isolate off-engine air piping from the engine to allow for engine torque-over, engine displacement,and thermal expansion.

• All air inlet connections should be securely fastened.

• Installing elbows back-to-back can result in higher losses than estimates would indicate.

• Protect air inlet piping from all sources of heat.

5.7.5 Flexible Connection

The purpose of flexible piping in the air inlet system is to allow for engine torque-over, engine displace-ment, thermal expansion, and facilitate alignment of the engine with the off-engine piping. Typically arubber "hump" hose is used before the compressor inlet to provide isolation. The rubber material mustbe capable of withstanding temperatures up to 150°C (302°F ).

NOTICE:Nitrile rubber is not an acceptable material for a flexible connection to the turbochargercompressor inlet. Nitrile rubber becomes brittle and cracks under high temperature

Premature failure of the turbocharger, charge air piping, or joints could occur if flexible piping is not em-ployed.

5.8 Testing Requirements

• A thorough evaluation of the air inlet system will include:

• Complete descriptions and documentation of the system in the End Product Questionnaire (EPQ)form

• Adequate instrumentation

• Proper test preparation


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• Accurate tests

• Data analysis and documentation

• Diagnostics (troubleshooting) and corrective action (if necessary)

These tests must be run on all new installations, engine repowers, or whenever modifications have beenmade to the engine, air inlet system, engine load, duty cycle, or environmental operating conditions.

The appropriate section of the EPQ form must be completed for documentation of these tests.

5.8.1 Instrumentation

5.8.1.1 Temperature Measurement

Use a precision thermocouple and an appropriate read-out device to measure temperatures. Thermo-couples should be located downstream of the pressure taps. Refer to Figure 4-12 for the location of thethermocouples.

5.8.1.2 Restriction Measurement

Use a precision gauge or a water manometer capable of reading a minimum of 5.0 kPa (20 in. H2O).Take the measurement from the air restriction gauge port located in front of each turbo inlet. Refer to theengine installation drawing for the location of the air restriction gauge port.

5.8.2 Test

Thorough preparations prior to testing will e

installation and commissioning engine mtu series 6r1600

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