MTU 12/16/18V 2000 — Repair Procedure

For the MTU 12/16/18V 2000.

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Procedure

1. 13.
2. 14.
3. 15.
4. 16.
5. Please mark all filed amendments here.
6. Please use block capitals!
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8. Table of Contents
9. 1 – I
10. 1
11. Safety
12. 1.1
13. General conditions
14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15. 1 – 01
16. 1.2
17. Personnel and organizational requirements
18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19. 1 – 02
20. 1.3
21. Transport
22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23. 1 – 03
24. 1.4
25. Safety precautions when working on the engine
26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27. 1 – 04
28. 1.5
29. Auxiliary materials, fire prevention and environmental protection
30. . . . . . . . . . . . . . . . . . .
31. 1 – 07
32. 1.6
33. Standards for warning notices in the publication
34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35. 1 – 09
36. M015560/00E
37. 03-05
38. © MTU
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40. 1 – II
41. Table of Contents
42. M015560/00E
43. 03-05
44. © MTU
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46. Safety
47. 1 – 01
48. 1.1
49. General conditions
50. General
51. In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
52. regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
53. with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
54. • Incorrect use
55. • Operation, maintenance and repair by unqualified personnel
56. • Modifications or conversions
57. • Non-compliance with the Safety Instructions
58. Correct use
59. The engine is intended exclusively for the application specified in the contract or defined at the time
60. of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
61. any resultant damage. The responsibility is borne by the user alone.
62. Correct use also includes observation of and compliance with the maintenance specifications.
63. Modifications or Conversions
64. Modifications made by the customer to the engine may affect safety.
65. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
66. Spare parts
67. Only genuine MTU spare parts must be used to replace components or assemblies. In the
68. event of any damage caused by the use of other spare parts, no liability nor warranty claims
69. vis-à-vis the engine manufacturer will be accepted.
70. M015560/00E
71. 03-05
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74. 1 – 02
75. Safety
76. 1.2
77. Personnel and organizational requirements
78. Personnel
79. Work on the engine must only be carried out by properly qualified and instructed personnel.
80. The specified legal minimum age must be observed.
81. Responsibilities of the operating, maintenance and repair personnel must be specified.
82. Organization
83. This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
84. It must be kept at hand near the engine and accessible at any time to all personnel involved
85. in operation, maintenance, repair or transportation.
86. The personnel must be instructed on engine operation and repair by means of this publication,
87. and in particular the safety instructions must be explained.
88. This is especially important for personnel who work on the engine only on an occasional basis.
89. Such personnel must be given instructions repeatedly.
90. Working clothes and protective equipment
91. Wear proper work clothing for all work.
92. Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
93. Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
94. Do not wear jewelry (e.g. rings, chains etc.).
95. M015560/00E
96. 03-05
97. © MTU
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99. Safety
100. 1 – 03
101. 1.3
102. Transport
103. Transport
104. Lift the engine only with the lifting eyes provided.
105. Use only the transport and lifting equipment approved by MTU.
106. Take note of the engine center of gravity.
107. The engine must only be transported in installation position, max. permissible diagonal pull 10 .
108. In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the
109. transport pallet or transport with equipment for heavy loads (forklift truck).
110. Prior to transporting the engine, it is imperative to install transportation locking
111. devices for crankshaft and engine mounts.
112. Secure the engine against tilting during transport. The engine must be especially secured against
113. slipping or tilting when going up or down inclines and ramps.
114. Setting the engine down after transport
115. Place the engine only on an even, firm surface.
116. Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
117. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.
118. M015560/00E
119. 03-05
120. © MTU
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122. 1 – 04
123. Safety
124. 1.4
125. Safety precautions when working on the engine
126. Engine operation
127. When the engine is running, always wear ear protectors.
128. Ensure that the engine room is well ventilated.
129. Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
130. Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
131. hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
132. During engine operation, do not touch battery terminals, generator terminals or cables.
133. Inadequate protection of electrical components can lead to electric shocks and serious injuries.
134. When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
135. Maintenance and repair
136. Compliance with maintenance and repair specifications is an important safety factor.
137. Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure
138. the engine against inadvertent starting. With electric starter, disconnect the battery. With pneumatic starter, close
139. main shut-off valve of compressed-air system and release pressure from compressed-air supply line. Attach sign
140. "Do not operate" in operating area or to control equipment. Persons not involved must keep clear.
141. Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
142. required. Maintenance and repair work must only be carried out by authorized, qualified personnel.
143. Use only proper, calibrated tools.
144. Do not work on engines or components which are only held by lifting equipment or crane.
145. Always support these components in accordance with regulations on suitable frames or stands
146. before beginning any maintenance or repair work.
147. Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check
148. that all guards have bee

Source: manual:1b6a37.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.