MTU 12V2000M91, Operating Instructions Manual

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Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Personnel and organizational requirements 7
1.3 Safety regulations for startup and operation 8
1.4 Safety precautions when working on the
engine 9
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
12
1.6 Standards for safety notices in the text 14
2 Transport
2.1 Transportation 15
2.2 Lifting requirements 16
3 General Information
3.1 Engine side and cylinder designations 20
3.2 Product description 21
3.3 Engine layout – 2000 M91 engines 29
4 Technical Data
4.1 12/16V 2000 M91 engine data 30
4.2 Firing order 33
4.3 Main engine dimensions 34
5 Operation
5.1 LOP controls (without Blue Line automation
system) 35
5.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 37
5.3 Putting the engine into operation after
scheduled out-of-service period 38
5.4 Engine start at LOP (without BlueLine
automation system) 39
5.5 Starting the engine at the BlueLine
automation system (control stand) 40
5.6 Engine emergency stop at BlueLine
automation system (control stand) 41
5.7 Operational checks 42
5.8 Coupling – Engaging from LOP 43
5.9 Coupling – Disengaging from LOP 44
5.10 Waterjet – Flushing from LOP (optional) 45
5.11 Engine shutdown at LOP (without BlueLine
automation system) 46
5.12 Stopping the engine at the BlueLine
automation system (control stand) 47
5.13 Emergency engine shutdown at LOP
(without BlueLine automation system) 48
5.14 After stopping the engine 49
5.15 Plant – Cleaning 50
6 Maintenance
6.1 Maintenance task reference table [QL1] 51
7 Troubleshooting
7.1 Troubleshooting 52
7.2 LOP fault messages 55
8 Task Description
8.1 Engine 64
8.1.1 Engine – Barring manually 64
8.1.2 Engine – Barring with starting system 65
8.2 Cylinder Liner 66
8.2.1 Cylinder liner – Endoscopic examination 66
8.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 68
8.3 Crankcase Breather 70
8.3.1 Crankcase breather – Cleaning oil pre-
separator element 70
8.3.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement
71
8.4 Valve Drive 73
8.4.1 Valve clearance – Check and adjustment 73
8.4.2 Cylinder head cover – Removal and
installation 76
8.5 Injection Pump / HP Pump 77
8.5.1 Injection pump – Replacement 77
8.5.2 Injection pump – Removal and installation 78
8.6 Injection Valve / Injector 81
8.6.1 Injector – Replacement 81
8.6.2 Injector – Removal and installation 82
8.7 Fuel System 85
8.7.1 HP fuel line – Pressure pipe neck replacement 85
8.7.2 Fuel – Draining 87
8.7.3 Fuel system – Venting 88
8.8 Fuel Filter 90
8.8.1 Fuel filter – Replacement 90
8.8.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 92
8.8.3 Fuel prefilter – Draining 93
8.8.4 Fuel prefilter – Flushing 95
8.8.5 Fuel prefilter – Filter element replacement 97
MW15409/04E 2015-08 | Table of Contents | 3
DCL-ID: 0000039398 - 002