Maintenance Schedule V 4000

Maintenance Schedule
Diesel Engine
V 4000 Mx0
V 4000 Mx1
Application Group 1B
MS50126/00E
Engine model
kW/cyl.
Application group
8V4000M70
145 kW/cyl.
1B, continuous operation, variable, high load factors
12V4000M70
140 kW/cyl.
1B, continuous operation, variable, high load factors
12V4000M70
145 kW/cyl.
1B, continuous operation, variable, high load factors
12V4000M71
154 kW/cyl.
1B, continuous operation, variable, high load factors
16V4000M70
140 kW/cyl.
1B, continuous operation, variable, high load factors
16V4000M70
145 kW/cyl.
1B, continuous operation, variable, high load factors
16V4000M71
154 kW/cyl.
1B, continuous operation, variable, high load factors
Table 1: Applicability
Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Maintenance Schedule
Preface
Allocation matrix for application group 1B
Maintenance schedule matrix 24,000h
Maintenance tasks 24,000h
Maintenance schedule matrix 21,000h
4
6
8
11
13
Maintenance tasks 21,000h
Maintenance schedule matrix 18,000h
Maintenance tasks 18,000h
Maintenance schedule matrix 15,000h
Maintenance tasks 15,000h
15
17
19
21
23
DCL-ID: 0000026452 - 002
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
MS50126/00E 2013-10 | Table of Contents | 3
1 Maintenance Schedule
1.1 Preface
MTU maintenance concept
The following applies in the case of engines which are subject to emissions regulations:
Emissions regulations prohibit alteration, removal or addition of any mechanical or electronic component or calibration that could affect the emissions characteristics of the engine. Maintenance, replacement, or repair of emissions control devices, sensors, cylinder heads, injectors and exhaust flaps, for
example, can only be performed using MTU approved components or equivalents.
Failure to adhere to these guidelines could result in violation of legal requirements.
MTU Maintenance Schedules must be adhered to during the full life of the engine. In the case of engines which are not subject to any emissions regulations, the time intervals at which the maintenance
work is to be carried out and the relevant checks and tasks involved are average values based on operational experience and are therefore to be regarded as guidelines only.
The maintenance system for MTU products is based on a preventive maintenance concept. Preventive
maintenance facilitates advance planning and ensures a high level of equipment availability.
The maintenance schedule is based on the load profile / load factor specified below. Special operating
conditions and technical requirements may require additional maintenance work and/or modification of
the maintenance intervals. The intervals according to which the maintenance tasks have to be carried
out are specified as operating hours and time limits. The limit which occurs first is applicable. In order
to be authorized to carry out the individual maintenance jobs, maintenance personnel must have achieved a level of training and qualification appropriate to the complexity of the task in hand. The various
Qualification Levels QL1 to QL4 reflect the levels of training offered in MTU courses and the contents of
the tool kits required:
QL1: Operational monitoring and maintenance which can be carried out during a break in operation
without disassembling the engine.
QL2: Component exchange (corrective only).
QL3: Maintenance work which requires partial disassembly of the engine.
QL4: Maintenance work which requires complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. Following
this, maintenance work is to be continued at the intervals indicated.
The numbers stated in the list of jobs provide a reference to the scope of parts required.
Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and
lists of recommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001061 and in the fluids and lubricants specifications produced by the component manufacturers. They are therefore not included in the maintenance schedule (exception: deviations from the Fluids
and Lubricants Specifications). All fluids and lubricants used must meet MTU specifications and be approved by the relevant component manufacturer.
4 | Maintenance Schedule | MS50126/00E 2013-10
TIM-ID: 0000042536 - 001
Notes on maintenance
Amongst other items, the operator/customer must carry out the following additional maintenance
work:
• Protect components made of rubber or synthetic material from oil. Never treat them with organic detergents. Wipe with a dry cloth only.
• Fuel prefilter:
The maintenance interval depends on how dirty the fuel is. The paper inserts in fuel prefilters must
be changed every two years at the latest (Task 9998).
• Battery:
Battery maintenance depends on the level of use and the ambient conditions. The battery manufacturer's instructions must be obeyed.
The relevant manufacturer's instructions apply with respect to the maintenance of any components
which do not appear in this maintenance schedule.
This Maintenance Schedule may include components which are not included in the MTU supply scope;
these may be disregarded.
Out-of-service periods
TIM-ID: 0000042536 - 001
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures in accordance with the Preservations and Represervations Specifications, MTU Publication No.
A001070/...
MS50126/00E 2013-10 | Maintenance Schedule | 5
1.2 Allocation matrix for application group 1B
—
80 (65-80)
—
65 (50-65)
10
50 (30-50)
—
30 (5-30)
5
Idle (0-5)
50
110 (100-110)
—
100 (90-100)
35
90 (80-90)
10
80 (65-80)
—
65 (50-65)
10
50 (30-50)
—
30 (5-30)
10
Idle (0-5)
35
110 (100-110)
—
100 (90-100)
40
90 (80-90)
10
80 (65-80)
—
65 (50-65)
15
50 (30-50)
—
30 (5-30)
10
Idle (0-5)
25
110 (100-110)
—
100 (90-100)
55
90 (80-90)
5
80 (65-80)
—
65 (50-65)
10
50 (30-50)
—
30 (5-30)
15
Idle (0-5)
15
0 - 46
≤ 36
24,000
21,000
—
—
47 - 55
≤ 39
21,000
18,000
—
—
56 - 63
≤ 44
18,000
15,000
—
—
64 - 71
≤ 57
15,000
15,000
—
—
Table 2: Allocation matrix for application group 1B
6 | Maintenance Schedule | MS50126/00E 2013-10
TIM-ID: 0000042022 - 001
35
90 (80-90)
—
100 (90-100)
—
—
146 - 154 kW/cyl.
110 (100-110)
140 - 145 kW/cyl.
Time
%
Load indicator %
Load %
Load factor %
V 4000 Mx0/Mx1
Load profile
110 (100-110)
—
100 (90-100)
60
90 (80-90)
—
80 (65-80)
20
65 (50-65)
—
50 (30-50)
—
30 (5-30)
10
Idle (0-5)
10
—
—
146 - 154 kW/cyl.
Time
%
140 - 145 kW/cyl.
Load %
Load indicator %
Load profile
Load factor %
V 4000 Mx0/Mx1
Standard
72 - 80
≤ 63
15,000
15,000
—
—
TIM-ID: 0000042022 - 001
Table 3: Allocation matrix for application group 1B
MS50126/00E 2013-10 | Maintenance Schedule | 7
1.3 Maintenance schedule matrix 24,000h
0-10,500 Operating hours
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
10,000
10,500
Daily
Operating hours [h]
Limit
Item
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine operation
-
Fuel servicing plant
1a
X
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
Fuel filter
2a
X
X
X
X
X
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
X
X
X
X
X
Engine mounts
1a
X
X
X
Valve gear
2a
X
X
X
Turbochargers
2a
X
X
X
Air filters
3a
X
Battery charging alternator
9a
Crankcase breathers
9a
Fuel injectors
9a
X
Combustion chambers
9a
X
Turbochargers
9a
X
Cylinder heads
9a
X
Auxiliary PTO coupling
9a
Engine mounts
9a
Component maintenance
9a
Butterfly coupling
9a
Hose lines
6a
Rubber sleeves
6a
Extended component maintenance
18 a
Turbochargers
18 a
Oil priming pump
18 a
X
X
X
X
X
w = weeks
m = months
a = years
11,000-21,500 Operating hours
12,500
13,000
13,500
14,000
14,500
15,000
15,500
16,000
16,500
17,000
17,500
18,000
18,500
19,000
19,500
20,000
20,500
21,000
21,500
-
Fuel servicing plant
1a
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Fuel filter
2a
X
X
X
X
X
X
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
X
X
X
X
X
X
Engine mounts
1a
X
X
X
X
Valve gear
2a
X
X
X
X
w = weeks
m = months
a = years
8 | Maintenance Schedule | MS50126/00E 2013-10
TIM-ID: 0000042023 - 001
12,000
Engine operation
Limit
11,500
Operating hours [h]
11,000
Item
Turbochargers
2a
X
X
Air filters
3a
X
X
Battery charging alternator
9a
X
Crankcase breathers
9a
X
Fuel injectors
9a
X
Combustion chambers
9a
X
Turbochargers
9a
X
Cylinder heads
9a
Auxiliary PTO coupling
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Butterfly coupling
9a
X
Hose lines
6a
Rubber sleeves
6a
Extended component maintenance
18 a
Turbochargers
18 a
Oil priming pump
18 a
X
21,500
21,000
X
X
X
20,500
20,000
19,500
19,000
18,500
18,000
17,500
17,000
16,500
16,000
15,500
15,000
14,500
14,000
13,500
13,000
12,500
12,000
11,500
11,000
Operating hours [h]
Limit
Item
X
X
X
X
w = weeks
m = months
a = years
22,000-24,000 Operating hours
23,000
23,500
24,000
Engine operation
-
Fuel servicing plant
1a
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
X
X
X
X
X
Fuel filter
2a
X
X
X
Crankcase breathers
2a
X
X
X
Engine mounts
1a
X
Valve gear
2a
X
Turbochargers
2a
X
Air filters
3a
X
Battery charging alternator
9a
X
Crankcase breathers
9a
X
Fuel injectors
9a
X
Combustion chambers
9a
X
Turbochargers
9a
X
Cylinder heads
9a
X
Auxiliary PTO coupling
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Butterfly coupling
9a
X
Hose lines
6a
X
TIM-ID: 0000042023 - 001
Limit
22,500
Operating hours [h]
22,000
Item
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 9
Operating hours [h]
24,000
23,500
23,000
22,500
22,000
Limit
Item
Rubber sleeves
6a
X
Extended component maintenance
18 a
X
Turbochargers
18 a
X
Oil priming pump
18 a
X
TIM-ID: 0000042023 - 001
w = weeks
m = months
a = years
10 | Maintenance Schedule | MS50126/00E 2013-10
1.4 Maintenance tasks 24,000h
Interval
QL1
Daily
Limit
Item
Maintenance tasks
-
Engine operation
Check engine oil level.
W0500
Carry out visual inspection of engine for general condition and leaks.
W0501
Inspect intercooler drain system.
W0502
Inspect service indicator of air filter.
W0503
Check the inspection bores of the HP fuel pump.
W0504
Check relief bores of coolant pump(s).
W0505
[h]
Option
Qualification
level
Check for abnormal running noises, exhaust gas color and vibration.
QL1
-
1a
Fuel servicing plant
Task
W0506
Drain off water and contamination from fuel prefilter.
X
W0507
Check differential pressure gauge of fuel prefilter.
X
W0508
Check alarm function of differential pressure gauge.
X
W1245
Check pump capacity.
X
W1246
X
W1244
-
2a
Fuel servicing plant
Check function of bar electrode.
QL1
-
2a
Engine oil filter
Fit new engine oil filters each time the engine oil is changed or, at the
latest, on expiry of the time limit (given in years).
QL1
500
2a
Centrifugal oil filter
Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each time the engine oil is changed.
QL1
1000
2a
Fuel filter
Fit new fuel filter or new fuel filter insert.
QL1
1000
2a
Crankcase breathers
Crankcase breathers, 8V only: Fit new filters.
QL1
3000
1a
Engine mounts
Carry out visual inspection of engine mounts for general condition.
W1463
Check tightness of securing screws.
W1519
QL1
3000
2a
Valve gear
Check valve clearance, adjust if required. ATTENTION! First adjustment
after 1,000 hours.
W1207
QL1
3000
2a
Turbochargers
Clean compressor wheel.
QL1
3000
3a
Air filters
Fit new air filters.
X
W1005
QL1
4000
9a
Battery charging alternator
Check condition of coupling.
X
W1016
QL1
6000
9a
Crankcase breathers
Crankcase breathers, 12V/16V only: Fit new filters.
X
W1014
QL1
8000
9a
Fuel injectors
Replace fuel injectors.
W1006
QL1
8000
9a
Combustion chambers
Inspect cylinder chambers using endoscope.
W1011
QL3
8000
9a
Turbochargers
Overhaul turbochargers.
W1038
QL3
8000
9a
Cylinder heads
Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.
W1063
QL3
12000
9a
Auxiliary PTO coupling
Fit new rubber elements if damage occurs but no later than expiry of
service limit (stated in years).
QL3
12000
9a
Engine mounts
Check buffer clearance of resilient mounts Check proper seating of securing screws.
W1026
QL3
12000
9a
Component maintenance
Before starting maintenance work, carry out test run and record operating parameters. Then drain coolant and flush cooling systems.
W2012
Inspect rocker arms and valve bridge for wear. Insert an endoscope
through the pushrod bore to visually inspect swing followers and camshaft running surfaces.
W2001
Clean air ducting.
W2002
Clean intercooler and inspect for leakage.
W2003
Fit new high-pressure fuel sensor.
W2004
TIM-ID: 0000042024 - 002
QL1
W1008
X
W1009
X
W1012
W1001
W1076
X
W1191
Overhaul engine coolant preheating system.
X
W2008
Inspect centrifugal oil filter for wear.
X
W2009
Overhaul starter.
W2010
Inspect vibration damper.
W2011
Clean engine coolant cooler and, if possible, inspect it for leaks.
W2017
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 11
Limit
Item
Maintenance tasks
[h]
Clean engine oil cooler and inspect it for leaks.
Check operation of diverter valve.
Task
W2018
X
W2021
Check engine coolant thermostat and fit new thermal actuator.
W2006
Fit new seals/sealing materials for all disassembled components.
W2062
Overhaul engine coolant pump.
W2110
Overhaul raw-water pump.
W2111
Overhaul bilge pump.
X
W2112
QL3
12000
9a
Butterfly coupling
Check condition visually.
X
W1037
QL3
24000
6a
Hose lines
Replace all hose lines.
W1251
QL3
24000
6a
Rubber sleeves
Replace all rubber sleeves.
W1250
QL4
24000
18 a
Extended component maintenance
Completely disassemble the engine. Inspect engine components as
per assembly instructions and repair or fit new components as required.
W3000
Replace all elastomeric parts and seals with new ones.
W3001
Fit new piston rings.
W3002
Fit new conrod bearings.
W3003
Fit new crankshaft bearings.
W3004
Fit new cylinder liners.
Fit new antifriction bearings for auxiliary PTOs.
W3005
X
Fit new high-pressure fuel pump.
W3007
Fit new fuel delivery pump.
Fit new actuating cylinders for air flow control flaps.
W3006
W3010
X
W3011
Fit new actuator cylinders for exhaust flaps.
W3012
Fit new exhaust flap bearings.
W3013
Fit new camshaft bearings and camshaft thrust bearings.
W3018
Fit new pressure relief valve in high-pressure fuel system.
W3021
Overhaul battery-charging generator.
X
W3042
Fit new butterfly coupling.
X
W3035
Check gear train for cracks, replace bushings, check axles and replace
if necessary.
W3063
Fit new engine oil pump.
W3073
Fit new rubber elements of engine mounts.
W3100
Overhaul Geislinger coupling.
W3102
Replace swing followers and swing-follower shafts.
W3103
Check vibration damper, fit new one if necessary.
W3108
Replace wiring harnesses.
W3083
QL4
24000
18 a
Turbochargers
Fit new compressor wheels for turbochargers.
W1472
QL4
24000
18 a
Oil priming pump
Visually check oil priming pump.
W1605
Replace pump and coupling.
W1541
w = weeks
m = months
a = years
12 | Maintenance Schedule | MS50126/00E 2013-10
TIM-ID: 0000042024 - 002
Interval
Option
Qualification
level
1.5 Maintenance schedule matrix 21,000h
0-10,500 Operating hours
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
10,000
10,500
Daily
Operating hours [h]
Limit
Item
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine operation
-
Fuel servicing plant
1a
X
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
Fuel filter
2a
X
X
X
X
X
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
X
X
X
X
X
Engine mounts
1a
X
X
X
Valve gear
2a
X
X
X
Turbochargers
2a
X
X
X
Air filters
3a
X
X
Battery charging alternator
9a
X
Fuel injectors
9a
X
Combustion chambers
9a
X
Crankcase breathers
9a
X
Auxiliary PTO coupling
9a
X
Turbochargers
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Cylinder heads
9a
X
Butterfly coupling
9a
X
Hose lines
6a
Rubber sleeves
6a
Extended component maintenance
18 a
Turbochargers
18 a
Oil priming pump
18 a
X
w = weeks
m = months
a = years
11,000-21,000 Operating hours
12,000
12,500
13,000
13,500
14,000
14,500
15,000
15,500
16,000
16,500
17,000
17,500
18,000
18,500
19,000
19,500
20,000
20,500
21,000
Engine operation
-
Fuel servicing plant
1a
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Fuel filter
2a
X
X
X
X
X
X
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
X
X
X
X
X
X
Engine mounts
1a
X
X
X
X
Valve gear
2a
X
X
X
X
TIM-ID: 0000042025 - 001
Limit
11,500
Operating hours [h]
11,000
Item
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 13
21,000
20,500
20,000
19,500
19,000
18,500
18,000
17,500
17,000
16,500
16,000
15,500
15,000
14,500
14,000
13,500
13,000
12,500
12,000
11,500
11,000
Operating hours [h]
Limit
Item
Turbochargers
2a
X
X
X
X
Air filters
3a
X
Battery charging alternator
9a
X
X
X
X
X
Fuel injectors
9a
X
X
Combustion chambers
9a
X
X
Crankcase breathers
9a
X
X
Auxiliary PTO coupling
9a
X
Turbochargers
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Cylinder heads
9a
X
Butterfly coupling
9a
X
Hose lines
6a
X
Rubber sleeves
6a
X
Extended component maintenance
18 a
X
Turbochargers
18 a
X
Oil priming pump
18 a
X
TIM-ID: 0000042025 - 001
w = weeks
m = months
a = years
14 | Maintenance Schedule | MS50126/00E 2013-10
1.6 Maintenance tasks 21,000h
Interval
QL1
Daily
Limit
Item
Maintenance tasks
-
Engine operation
Check engine oil level.
W0500
Carry out visual inspection of engine for general condition and leaks.
W0501
Inspect intercooler drain system.
W0502
Inspect service indicator of air filter.
W0503
Check the inspection bores of the HP fuel pump.
W0504
Check relief bores of coolant pump(s).
W0505
[h]
Option
Qualification
level
Check for abnormal running noises, exhaust gas color and vibration.
QL1
-
1a
Fuel servicing plant
Task
W0506
Drain off water and contamination from fuel prefilter.
X
W0507
Check differential pressure gauge of fuel prefilter.
X
W0508
Check alarm function of differential pressure gauge.
X
W1245
Check pump capacity.
X
W1246
X
W1244
-
2a
Fuel servicing plant
Check function of bar electrode.
QL1
-
2a
Engine oil filter
Fit new engine oil filters each time the engine oil is changed or, at the
latest, on expiry of the time limit (given in years).
QL1
500
2a
Centrifugal oil filter
Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each time the engine oil is changed.
QL1
1000
2a
Fuel filter
Fit new fuel filter or new fuel filter insert.
QL1
1000
2a
Crankcase breathers
Crankcase breathers, 8V only: Fit new filters.
QL1
3000
1a
Engine mounts
Carry out visual inspection of engine mounts for general condition.
W1463
Check tightness of securing screws.
W1519
QL1
3000
2a
Valve gear
Check valve clearance, adjust if required. ATTENTION! First adjustment
after 1,000 hours.
W1207
QL1
3000
2a
Turbochargers
Clean compressor wheel.
QL1
3000
3a
Air filters
Fit new air filters.
X
W1005
QL1
7000
9a
Battery charging alternator
Check condition of coupling.
X
W1016
QL1
7000
9a
Fuel injectors
Replace fuel injectors.
W1006
QL1
7000
9a
Combustion chambers
Inspect cylinder chambers using endoscope.
W1011
QL1
7000
9a
Crankcase breathers
Crankcase breathers, 12V/16V only: Fit new filters.
X
W1014
QL3
10500
9a
Auxiliary PTO coupling
Fit new rubber elements if damage occurs but no later than expiry of
service limit (stated in years).
X
W1191
QL3
10500
9a
Turbochargers
Overhaul turbochargers.
W1038
QL3
10500
9a
Engine mounts
Check buffer clearance of resilient mounts Check proper seating of securing screws.
W1026
QL3
10500
9a
Component maintenance
Before starting maintenance work, carry out test run and record operating parameters. Then drain coolant and flush cooling systems.
W2012
Inspect rocker arms and valve bridge for wear. Insert an endoscope
through the pushrod bore to visually inspect swing followers and camshaft running surfaces.
W2001
Clean air ducting.
W2002
Clean intercooler and inspect for leakage.
W2003
TIM-ID: 0000042029 - 002
QL1
W1008
X
W1009
X
W1012
W1001
W1076
Fit new high-pressure fuel sensor.
W2004
Overhaul engine coolant preheating system.
X
W2008
Inspect centrifugal oil filter for wear.
X
W2009
Overhaul starter.
W2010
Inspect vibration damper.
W2011
Clean engine coolant cooler and, if possible, inspect it for leaks.
W2017
Clean engine oil cooler and inspect it for leaks.
W2018
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 15
Limit
Item
Maintenance tasks
Task
Check operation of diverter valve.
X
W2021
[h]
Check engine coolant thermostat and fit new thermal actuator.
W2006
Fit new seals/sealing materials for all disassembled components.
W2062
Overhaul engine coolant pump.
W2110
Overhaul raw-water pump.
Overhaul bilge pump.
W2111
X
W2112
QL3
10500
9a
Cylinder heads
Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.
QL3
10500
9a
Butterfly coupling
Check condition visually.
QL3
21000
6a
Hose lines
Replace all hose lines.
W1251
QL3
21000
6a
Rubber sleeves
Replace all rubber sleeves.
W1250
QL4
21000
18 a
Extended component maintenance
Completely disassemble the engine. Inspect engine components as
per assembly instructions and repair or fit new components as required.
W3000
Replace all elastomeric parts and seals with new ones.
W3001
Fit new piston rings.
W3002
Fit new conrod bearings.
W3003
Fit new crankshaft bearings.
W3004
Fit new cylinder liners.
W3005
Fit new antifriction bearings for auxiliary PTOs.
W1063
X
X
W1037
W3006
Fit new high-pressure fuel pump.
W3007
Fit new fuel delivery pump.
W3010
Fit new actuating cylinders for air flow control flaps.
X
W3011
Fit new actuator cylinders for exhaust flaps.
W3012
Fit new exhaust flap bearings.
W3013
Fit new camshaft bearings and camshaft thrust bearings.
W3018
Fit new pressure relief valve in high-pressure fuel system.
W3021
Overhaul battery-charging generator.
X
W3042
Fit new butterfly coupling.
X
W3035
Check gear train for cracks, replace bushings, check axles and replace
if necessary.
W3063
Fit new engine oil pump.
W3073
Fit new rubber elements of engine mounts.
W3100
Overhaul Geislinger coupling.
W3102
Replace swing followers and swing-follower shafts.
W3103
Check vibration damper, fit new one if necessary.
W3108
Replace wiring harnesses.
W3083
QL4
21000
18 a
Turbochargers
Fit new compressor wheels for turbochargers.
W1472
QL4
21000
18 a
Oil priming pump
Visually check oil priming pump.
W1605
Replace pump and coupling.
W1541
w = weeks
m = months
a = years
16 | Maintenance Schedule | MS50126/00E 2013-10
TIM-ID: 0000042029 - 002
Interval
Option
Qualification
level
1.7 Maintenance schedule matrix 18,000h
0-10,500 Operating hours
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
10,000
10,500
Daily
Operating hours [h]
Limit
Item
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine operation
-
Fuel servicing plant
1a
X
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
Fuel filter
2a
X
X
X
X
X
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
X
X
X
X
X
Engine mounts
1a
X
X
X
Valve gear
2a
X
X
X
Turbochargers
2a
X
X
X
Air filters
3a
X
X
X
Battery charging alternator
9a
X
Fuel injectors
9a
X
Combustion chambers
9a
X
Crankcase breathers
9a
X
Auxiliary PTO coupling
9a
X
Turbochargers
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Cylinder heads
9a
X
Butterfly coupling
9a
X
Hose lines
6a
Rubber sleeves
6a
Extended component maintenance
18 a
Turbochargers
18 a
Oil priming pump
18 a
w = weeks
m = months
a = years
11,000-18,000 Operating hours
12,000
12,500
13,000
13,500
14,000
14,500
15,000
15,500
16,000
16,500
17,000
17,500
18,000
Engine operation
-
Fuel servicing plant
1a
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Fuel filter
2a
X
X
X
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
X
X
X
Engine mounts
1a
X
X
X
Valve gear
2a
X
X
X
TIM-ID: 0000045998 - 001
Limit
11,500
Operating hours [h]
11,000
Item
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 17
18,000
17,500
17,000
16,500
16,000
15,500
15,000
14,500
14,000
13,500
13,000
12,500
12,000
11,500
11,000
Operating hours [h]
Limit
Item
Turbochargers
2a
X
X
X
Air filters
3a
X
X
X
Battery charging alternator
9a
X
X
Fuel injectors
9a
X
X
Combustion chambers
9a
X
X
Crankcase breathers
9a
X
X
Auxiliary PTO coupling
9a
X
Turbochargers
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Cylinder heads
9a
X
Butterfly coupling
9a
X
Hose lines
6a
X
Rubber sleeves
6a
X
Extended component maintenance
18 a
X
Turbochargers
18 a
X
Oil priming pump
18 a
X
TIM-ID: 0000045998 - 001
w = weeks
m = months
a = years
18 | Maintenance Schedule | MS50126/00E 2013-10
1.8 Maintenance tasks 18,000h
Interval
QL1
Daily
Limit
Item
Maintenance tasks
-
Engine operation
Check engine oil level.
W0500
Carry out visual inspection of engine for general condition and leaks.
W0501
Inspect intercooler drain system.
W0502
Inspect service indicator of air filter.
W0503
Check the inspection bores of the HP fuel pump.
W0504
Check relief bores of coolant pump(s).
W0505
[h]
Option
Qualification
level
Check for abnormal running noises, exhaust gas color and vibration.
QL1
-
1a
Fuel servicing plant
Task
W0506
Drain off water and contamination from fuel prefilter.
X
W0507
Check differential pressure gauge of fuel prefilter.
X
W0508
Check alarm function of differential pressure gauge.
X
W1245
Check pump capacity.
X
W1246
X
W1244
-
2a
Fuel servicing plant
Check function of bar electrode.
QL1
-
2a
Engine oil filter
Fit new engine oil filters each time the engine oil is changed or, at the
latest, on expiry of the time limit (given in years).
QL1
500
2a
Centrifugal oil filter
Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each time the engine oil is changed.
QL1
1000
2a
Fuel filter
Fit new fuel filter or new fuel filter insert.
QL1
1000
2a
Crankcase breathers
Crankcase breathers, 8V only: Fit new filters.
QL1
3000
1a
Engine mounts
Carry out visual inspection of engine mounts for general condition.
W1463
Check tightness of securing screws.
W1519
QL1
3000
2a
Valve gear
Check valve clearance, adjust if required. ATTENTION! First adjustment
after 1,000 hours.
W1207
QL1
3000
2a
Turbochargers
Clean compressor wheel.
QL1
3000
3a
Air filters
Fit new air filters.
X
W1005
QL1
6000
9a
Battery charging alternator
Check condition of coupling.
X
W1016
QL1
6000
9a
Fuel injectors
Replace fuel injectors.
W1006
QL1
6000
9a
Combustion chambers
Inspect cylinder chambers using endoscope.
W1011
QL1
6000
9a
Crankcase breathers
Crankcase breathers, 12V/16V only: Fit new filters.
X
W1014
QL3
9000
9a
Auxiliary PTO coupling
Fit new rubber elements if damage occurs but no later than expiry of
service limit (stated in years).
X
W1191
QL3
9000
9a
Turbochargers
Overhaul turbochargers.
W1038
QL3
9000
9a
Engine mounts
Check buffer clearance of resilient mounts Check proper seating of securing screws.
W1026
QL3
9000
9a
Component maintenance
Before starting maintenance work, carry out test run and record operating parameters. Then drain coolant and flush cooling systems.
W2012
Inspect rocker arms and valve bridge for wear. Insert an endoscope
through the pushrod bore to visually inspect swing followers and camshaft running surfaces.
W2001
Clean air ducting.
W2002
Clean intercooler and inspect for leakage.
W2003
TIM-ID: 0000045999 - 002
QL1
W1008
X
W1009
X
W1012
W1001
W1076
Fit new high-pressure fuel sensor.
W2004
Overhaul engine coolant preheating system.
X
W2008
Inspect centrifugal oil filter for wear.
X
W2009
Overhaul starter.
W2010
Inspect vibration damper.
W2011
Clean engine coolant cooler and, if possible, inspect it for leaks.
W2017
Clean engine oil cooler and inspect it for leaks.
W2018
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 19
Limit
Item
Maintenance tasks
Task
Check operation of diverter valve.
X
W2021
[h]
Check engine coolant thermostat and fit new thermal actuator.
W2006
Fit new seals/sealing materials for all disassembled components.
W2062
Overhaul engine coolant pump.
W2110
Overhaul raw-water pump.
Overhaul bilge pump.
W2111
X
W2112
QL3
9000
9a
Cylinder heads
Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.
QL3
9000
9a
Butterfly coupling
Check condition visually.
QL3
18000
6a
Hose lines
Replace all hose lines.
W1251
QL3
18000
6a
Rubber sleeves
Replace all rubber sleeves.
W1250
QL4
18000
18 a
Extended component maintenance
Completely disassemble the engine. Inspect engine components as
per assembly instructions and repair or fit new components as required.
W3000
Replace all elastomeric parts and seals with new ones.
W3001
Fit new piston rings.
W3002
Fit new conrod bearings.
W3003
Fit new crankshaft bearings.
W3004
Fit new cylinder liners.
W3005
Fit new antifriction bearings for auxiliary PTOs.
W1063
X
X
W1037
W3006
Fit new high-pressure fuel pump.
W3007
Fit new fuel delivery pump.
W3010
Fit new actuating cylinders for air flow control flaps.
X
W3011
Fit new actuator cylinders for exhaust flaps.
W3012
Fit new exhaust flap bearings.
W3013
Fit new camshaft bearings and camshaft thrust bearings.
W3018
Fit new pressure relief valve in high-pressure fuel system.
W3021
Overhaul battery-charging generator.
X
W3042
Fit new butterfly coupling.
X
W3035
Check gear train for cracks, replace bushings, check axles and replace
if necessary.
W3063
Fit new engine oil pump.
W3073
Fit new rubber elements of engine mounts.
W3100
Overhaul Geislinger coupling.
W3102
Replace swing followers and swing-follower shafts.
W3103
Check vibration damper, fit new one if necessary.
W3108
Replace wiring harnesses.
W3083
QL4
18000
18 a
Turbochargers
Fit new compressor wheels for turbochargers.
W1472
QL4
18000
18 a
Oil priming pump
Visually check oil priming pump.
W1605
Replace pump and coupling.
W1541
w = weeks
m = months
a = years
20 | Maintenance Schedule | MS50126/00E 2013-10
TIM-ID: 0000045999 - 002
Interval
Option
Qualification
level
1.9 Maintenance schedule matrix 15,000h
0-10,500 Operating hours
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
10,000
10,500
Daily
Operating hours [h]
Limit
Item
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine operation
-
Fuel servicing plant
1a
X
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
Fuel filter
2a
X
X
X
X
X
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
X
X
X
X
X
Engine mounts
1a
X
X
X
Valve gear
2a
X
X
X
Turbochargers
2a
X
X
X
Air filters
3a
X
X
Battery charging alternator
9a
X
Fuel injectors
9a
X
Combustion chambers
9a
X
Crankcase breathers
9a
X
Auxiliary PTO coupling
9a
X
Turbochargers
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Cylinder heads
9a
X
Butterfly coupling
9a
X
Hose lines
6a
Rubber sleeves
6a
Extended component maintenance
18 a
Turbochargers
18 a
Oil priming pump
18 a
X
w = weeks
m = months
a = years
11,000-15,000 Operating hours
12,000
12,500
13,000
13,500
14,000
14,500
15,000
Engine operation
-
Fuel servicing plant
1a
Fuel servicing plant
2a
Engine oil filter
2a
Centrifugal oil filter
2a
X
X
X
X
X
X
X
X
X
Fuel filter
2a
X
X
X
X
X
Crankcase breathers
2a
X
X
X
X
X
Engine mounts
1a
X
X
Valve gear
2a
X
X
TIM-ID: 0000046002 - 001
Limit
11,500
Operating hours [h]
11,000
Item
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 21
15,000
14,500
14,000
13,500
13,000
12,500
12,000
11,500
11,000
Operating hours [h]
Limit
Item
Turbochargers
2a
X
X
Air filters
3a
X
X
Battery charging alternator
9a
X
Fuel injectors
9a
X
Combustion chambers
9a
X
Crankcase breathers
9a
X
Auxiliary PTO coupling
9a
X
Turbochargers
9a
X
Engine mounts
9a
X
Component maintenance
9a
X
Cylinder heads
9a
X
Butterfly coupling
9a
X
Hose lines
6a
X
Rubber sleeves
6a
X
Extended component maintenance
18 a
X
Turbochargers
18 a
X
Oil priming pump
18 a
X
TIM-ID: 0000046002 - 001
w = weeks
m = months
a = years
22 | Maintenance Schedule | MS50126/00E 2013-10
1.10 Maintenance tasks 15,000h
Interval
QL1
Daily
Limit
Item
Maintenance tasks
-
Engine operation
Check engine oil level.
W0500
Carry out visual inspection of engine for general condition and leaks.
W0501
Inspect intercooler drain system.
W0502
Inspect service indicator of air filter.
W0503
Check the inspection bores of the HP fuel pump.
W0504
Check relief bores of coolant pump(s).
W0505
[h]
Option
Qualification
level
Check for abnormal running noises, exhaust gas color and vibration.
QL1
-
1a
Fuel servicing plant
Task
W0506
Drain off water and contamination from fuel prefilter.
X
W0507
Check differential pressure gauge of fuel prefilter.
X
W0508
Check alarm function of differential pressure gauge.
X
W1245
Check pump capacity.
X
W1246
X
W1244
-
2a
Fuel servicing plant
Check function of bar electrode.
QL1
-
2a
Engine oil filter
Fit new engine oil filters each time the engine oil is changed or, at the
latest, on expiry of the time limit (given in years).
QL1
500
2a
Centrifugal oil filter
Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each time the engine oil is changed.
QL1
1000
2a
Fuel filter
Fit new fuel filter or new fuel filter insert.
QL1
1000
2a
Crankcase breathers
Crankcase breathers, 8V only: Fit new filters.
QL1
3000
1a
Engine mounts
Carry out visual inspection of engine mounts for general condition.
W1463
Check tightness of securing screws.
W1519
QL1
3000
2a
Valve gear
Check valve clearance, adjust if required. ATTENTION! First adjustment
after 1,000 hours.
W1207
QL1
3000
2a
Turbochargers
Clean compressor wheel.
QL1
3000
3a
Air filters
Fit new air filters.
X
W1005
QL1
7500
9a
Battery charging alternator
Check condition of coupling.
X
W1016
QL1
7500
9a
Fuel injectors
Replace fuel injectors.
W1006
QL1
7500
9a
Combustion chambers
Inspect cylinder chambers using endoscope.
W1011
QL1
7500
9a
Crankcase breathers
Crankcase breathers, 12V/16V only: Fit new filters.
X
W1014
QL3
7500
9a
Auxiliary PTO coupling
Fit new rubber elements if damage occurs but no later than expiry of
service limit (stated in years).
X
W1191
QL3
7500
9a
Turbochargers
Overhaul turbochargers.
W1038
QL3
7500
9a
Engine mounts
Check buffer clearance of resilient mounts Check proper seating of securing screws.
W1026
QL3
7500
9a
Component maintenance
Before starting maintenance work, carry out test run and record operating parameters. Then drain coolant and flush cooling systems.
W2012
Inspect rocker arms and valve bridge for wear. Insert an endoscope
through the pushrod bore to visually inspect swing followers and camshaft running surfaces.
W2001
Clean air ducting.
W2002
Clean intercooler and inspect for leakage.
W2003
TIM-ID: 0000046003 - 002
QL1
W1008
X
W1009
X
W1012
W1001
W1076
Fit new high-pressure fuel sensor.
W2004
Overhaul engine coolant preheating system.
X
W2008
Inspect centrifugal oil filter for wear.
X
W2009
Overhaul starter.
W2010
Inspect vibration damper.
W2011
Clean engine coolant cooler and, if possible, inspect it for leaks.
W2017
Clean engine oil cooler and inspect it for leaks.
W2018
w = weeks
m = months
a = years
MS50126/00E 2013-10 | Maintenance Schedule | 23
Limit
Item
Maintenance tasks
Task
Check operation of diverter valve.
X
W2021
[h]
Check engine coolant thermostat and fit new thermal actuator.
W2006
Fit new seals/sealing materials for all disassembled components.
W2062
Overhaul engine coolant pump.
W2110
Overhaul raw-water pump.
Overhaul bilge pump.
W2111
X
W2112
QL3
7500
9a
Cylinder heads
Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.
QL3
7500
9a
Butterfly coupling
Check condition visually.
QL3
15000
6a
Hose lines
Replace all hose lines.
W1251
QL3
15000
6a
Rubber sleeves
Replace all rubber sleeves.
W1250
QL4
15000
18 a
Extended component maintenance
Completely disassemble the engine. Inspect engine components as
per assembly instructions and repair or fit new components as required.
W3000
Replace all elastomeric parts and seals with new ones.
W3001
Fit new piston rings.
W3002
Fit new conrod bearings.
W3003
Fit new crankshaft bearings.
W3004
Fit new cylinder liners.
W3005
Fit new antifriction bearings for auxiliary PTOs.
W1063
X
X
W1037
W3006
Fit new high-pressure fuel pump.
W3007
Fit new fuel delivery pump.
W3010
Fit new actuating cylinders for air flow control flaps.
X
W3011
Fit new actuator cylinders for exhaust flaps.
W3012
Fit new exhaust flap bearings.
W3013
Fit new camshaft bearings and camshaft thrust bearings.
W3018
Fit new pressure relief valve in high-pressure fuel system.
W3021
Overhaul battery-charging generator.
X
W3042
Fit new butterfly coupling.
X
W3035
Check gear train for cracks, replace bushings, check axles and replace
if necessary.
W3063
Fit new engine oil pump.
W3073
Fit new rubber elements of engine mounts.
W3100
Overhaul Geislinger coupling.
W3102
Replace swing followers and swing-follower shafts.
W3103
Check vibration damper, fit new one if necessary.
W3108
Replace wiring harnesses.
W3083
QL4
15000
18 a
Turbochargers
Fit new compressor wheels for turbochargers.
W1472
QL4
15000
18 a
Oil priming pump
Visually check oil priming pump.
W1605
Replace pump and coupling.
W1541
w = weeks
m = months
a = years
24 | Maintenance Schedule | MS50126/00E 2013-10
TIM-ID: 0000046003 - 002
Interval
Option
Qualification
level