Maintenance Schedule

Diesel Engine
16V4000M73
Application Group 1B

MS50241/00E
Engine model kW/cyl. Application group
16V4000M73 160 kW/cyl. (with SCR (bridging)) 1B, continuous operation, variable, high load

Table 1: Applicability

© 2016 Copyright MTU Friedrichshafen GmbH

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All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
 Table of Contents
1 Maintenance Schedule 1.4 Maintenance tasks 24,000 h 14
1.5 Maintenance schedule matrix 21,000 h 17
1.1 Preface 4 1.6 Maintenance tasks 21,000 h 25
1.2 Allocation matrix application group 1B, 1DS 5
1.3 Maintenance schedule matrix 24,000 h 6
DCL-ID: 0000044523 - 001

MS50241/00E 2016-11 | Table of Contents | 3

 1 Maintenance Schedule
1.1 Preface
In the case of emission-certified products, nonobservance of the maintenance instructions can result in viola-
tion of the statutory specifications. Modification or removal of mechanical or electronic components or the
installation of additional mechanical or electronic components as well as the execution of calibration proc-
esses that might affect the emission characteristics of the engine are prohibited by emission regulations.
Components relevant to emissions may only be serviced, replaced or repaired if components approved by
MTU are used. Components relevant to emissions include e.g. control units, data records, sensors, injectors,
exhaust flaps and all components of exhaust after-treatment systems.
The maintenance system for MTU products is based on a preventive maintenance concept. Preventive main-
tenance facilitates advance operational planning and ensures a high level of equipment availability. The main-
tenance intervals as well as the required scopes of maintenance tasks are based on operational experience
and therefore to be considered as recommendations. Additional maintenance work and/or changes to the
maintenance intervals may be required in the case of difficult operational and ambient conditions.
Adherence to the specified maintenance intervals is essential to maintain product safety.
The intervals according to which the maintenance tasks have to be carried out are specified as operating
hours and time limits. Whichever value is reached first shall apply.
The individual maintenance intervals are assigned to the qualification levels QL1 to QL4.
QL1: Operational monitoring and maintenance work which does not require disassembly of the product.
QL2: Exchange of components and parts (corrective only, not part of the maintenance schedule).
QL3: Maintenance work which requires partial disassembly of the product.
QL4: Maintenance work which requires complete disassembly of the product.

Additional notes on maintenance and preservation:

For the change intervals for fluids and lubricants and for information on preservation, refer to the relevant
specifications of the component manufacturers and the MTU Fluids and Lubricants Specifications. The latest
version for drive systems is available at: http://www.mtu-online.com, for power generation at: http://
www.mtuonsiteenergy.com.
Components which are not listed in this maintenance schedule must be serviced in accordance with Manu-
facturer's Instructions.
This maintenance schedule does not apply to engines with an EPA/CARB emissions certificate. TIM-ID: 0000046281 - 006

4 | Maintenance Schedule | MS50241/00E 2016-11

 1.2 Allocation matrix application group 1B, 1DS
16V4000M73
Load profile

Load indicator %

0 to 160 kW/cyl.
Load factor %

Time

—
Load %
%

110 (100-110) — Relevant load profile for engines with exhaust af-
100 (90-100) 1 tertreatment

90 (80-90) —
80 (65-80) 4
0 to 21 ≤2 24,000 — — —
65 (50-65) —
50 (30-50) 5
30 (5-30) 40
Idle Speed (0-5) 50
110 (100-110) —
100 (90-100) 35
90 (80-90) —
80 (65-80) —
0 to 47 ≤ 36 21,000 — — —
65 (50-65) 10
50 (30-50) —
30 (5-30) 10
Idle Speed (0-5) 45

Table 2: Allocation matrix application group 1B, 1DS

TIM-ID: 0000072839 - 001

MS50241/00E 2016-11 | Maintenance Schedule | 5

 1.3 Maintenance schedule matrix 24,000 h
0 to 14,500 Operating hours
Task Operating hours [h]

10,000
10,500
11,000
11,500
12,000
12,500
13,000
13,500
14,000
14,500
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
Limit

Daily
500

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 - X
W0501 - X
W0503 - X
W0505 - X
W0506 - X
W0507 - X
W0508 - X
W1009 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W1864 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4172 1a X X X X X X X X X X X X X X
W1519 1a X X X X X X X X X X X X X X
W1001 2a X X X X X X X X X X X X X X
W1675 2a X X X X X X X X X X X X X X
W1005 3a X X X X
W1296 3a X X X X
W1207 18 a X X X X X
W1689 18 a X X X X
W1055 6a X X
W1016 18 a X
W1006 18 a X
W1713 18 a X
W1011 18 a X
W1477 18 a
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
TIM-ID: 0000072777 - 001

W2006 18 a X
W2009 18 a X
W2010 18 a X
W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
w = weeks
m = months
a = years

6 | Maintenance Schedule | MS50241/00E 2016-11

 Task Operating hours [h]

10,000
10,500
11,000
11,500
12,000
12,500
13,000
13,500
14,000
14,500
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
Limit

Daily
500
W2111 18 a X
W2112 18 a X
W1251 6a
W1134 18 a
W1478 6a X
W1058 18 a X
W4146 18 a
W4171 18 a
W4147 18 a
W1485 18 a
W1331 18 a
W4173 18 a
W1476 18 a
W3000 18 a
W3001 18 a
W3002 18 a
W3003 18 a
W3004 18 a
W3005 18 a
W3010 18 a
W3011 18 a
W3012 18 a
W3013 18 a
W3018 18 a
W3021 18 a
W3042 18 a
W3057 18 a
W3182 18 a
W3177 18 a
W3103 18 a
W3106 18 a
W3108 18 a
W1493 36 a
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4180 2a X X X X X X X X X X X X X X
W4181 9a X X X X X X X X X X X X X X
TIM-ID: 0000072777 - 001

W1769 6a X X X
W4182 9a X
W1767 18 a
W1768 18 a
W4183 18 a
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 7

 15,000 to 29,500 Operating hours
Task Operating hours [h]
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
22,000
22,500
23,000
23,500
24,000
24,500
25,000
25,500
26,000
26,500
27,000
27,500
28,000
28,500
29,000
29,500
Limit

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 -
W0501 -
W0503 -
W0505 -
W0506 -
W0507 -
W0508 -
W1009 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W1864 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4172 1a X X X X X X X X X X X X X X X
W1519 1a X X X X X X X X X X X X X X X
W1001 2a X X X X X X X X X X X X X X X
W1675 2a X X X X X X X X X X X X X X X
W1005 3a X X X X X
W1296 3a X X X X X
W1207 18 a X X X X X X
W1689 18 a X X X X X
W1055 6a X X
W1016 18 a X X
W1006 18 a X X
W1713 18 a X X
W1011 18 a X X
W1477 18 a X
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
W2006 18 a X
W2009 18 a X
W2010 18 a X
TIM-ID: 0000072777 - 001

W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
W2111 18 a X
W2112 18 a X
w = weeks
m = months
a = years

8 | Maintenance Schedule | MS50241/00E 2016-11

 Task Operating hours [h]

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
22,000
22,500
23,000
23,500
24,000
24,500
25,000
25,500
26,000
26,500
27,000
27,500
28,000
28,500
29,000
29,500
Limit
W1251 6a X
W1134 18 a X
W1478 6a X
W1058 18 a X
W4146 18 a X
W4171 18 a X
W4147 18 a X
W1485 18 a X
W1331 18 a X
W4173 18 a X
W1476 18 a X
W3000 18 a X
W3001 18 a X
W3002 18 a X
W3003 18 a X
W3004 18 a X
W3005 18 a X
W3010 18 a X
W3011 18 a X
W3012 18 a X
W3013 18 a X
W3018 18 a X
W3021 18 a X
W3042 18 a X
W3057 18 a X
W3182 18 a X
W3177 18 a X
W3103 18 a X
W3106 18 a X
W3108 18 a X
W1493 36 a
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4180 2a X X X X X X X X X X X X X X X
W4181 9a X X X X X X X X X X X X X X X
W1769 6a X X X X
W4182 9a X X
TIM-ID: 0000072777 - 001

W1767 18 a X
W1768 18 a X
W4183 18 a X
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 9

 30,000 to 44,500 Operating hours
Task Operating hours [h]
30,000
30,500
31,000
31,500
32,000
32,500
33,000
33,500
34,000
34,500
35,000
35,500
36,000
36,500
37,000
37,500
38,000
38,500
39,000
39,500
40,000
40,500
41,000
41,500
42,000
42,500
43,000
43,500
44,000
44,500
Limit

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 -
W0501 -
W0503 -
W0505 -
W0506 -
W0507 -
W0508 -
W1009 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W1864 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4172 1a X X X X X X X X X X X X X X X
W1519 1a X X X X X X X X X X X X X X X
W1001 2a X X X X X X X X X X X X X X X
W1675 2a X X X X X X X X X X X X X X X
W1005 3a X X X X X
W1296 3a X X X X X
W1207 18 a X X X X X
W1689 18 a X X X X X
W1055 6a X X X
W1016 18 a X X
W1006 18 a X X
W1713 18 a X X
W1011 18 a X X
W1477 18 a
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
W2006 18 a X
W2009 18 a X
W2010 18 a X
TIM-ID: 0000072777 - 001

W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
W2111 18 a X
W2112 18 a X
w = weeks
m = months
a = years

10 | Maintenance Schedule | MS50241/00E 2016-11

 Task Operating hours [h]

30,000
30,500
31,000
31,500
32,000
32,500
33,000
33,500
34,000
34,500
35,000
35,500
36,000
36,500
37,000
37,500
38,000
38,500
39,000
39,500
40,000
40,500
41,000
41,500
42,000
42,500
43,000
43,500
44,000
44,500
Limit
W1251 6a
W1134 18 a
W1478 6a X
W1058 18 a X
W4146 18 a
W4171 18 a
W4147 18 a
W1485 18 a
W1331 18 a
W4173 18 a
W1476 18 a
W3000 18 a
W3001 18 a
W3002 18 a
W3003 18 a
W3004 18 a
W3005 18 a
W3010 18 a
W3011 18 a
W3012 18 a
W3013 18 a
W3018 18 a
W3021 18 a
W3042 18 a
W3057 18 a
W3182 18 a
W3177 18 a
W3103 18 a
W3106 18 a
W3108 18 a
W1493 36 a
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4180 2a X X X X X X X X X X X X X X X
W4181 9a X X X X X X X X X X X X X X X
W1769 6a X X X X
W4182 9a X X
TIM-ID: 0000072777 - 001

W1767 18 a
W1768 18 a
W4183 18 a
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 11

 45,000 to 48,000 Operating hours
Task Operating hours [h]
45,000
45,500
46,000
46,500
47,000
47,500
48,000
Limit

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 -
W0501 -
W0503 -
W0505 -
W0506 -
W0507 -
W0508 -
W1009 2a X X X X X X X
W1864 2a X X X X X X X
W4172 1a X X X X
W1519 1a X X X X
W1001 2a X X X X
W1675 2a X X X X
W1005 3a X X
W1296 3a X X
W1207 18 a X X
W1689 18 a X X
W1055 6a X
W1016 18 a X
W1006 18 a X
W1713 18 a X
W1011 18 a X
W1477 18 a X
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
W2006 18 a X
W2009 18 a X
W2010 18 a X
TIM-ID: 0000072777 - 001

W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
W2111 18 a X
W2112 18 a X
w = weeks
m = months
a = years

12 | Maintenance Schedule | MS50241/00E 2016-11

 Task Operating hours [h]

45,000
45,500
46,000
46,500
47,000
47,500
48,000
Limit
W1251 6a X
W1134 18 a X
W1478 6a X
W1058 18 a X
W4146 18 a X
W4171 18 a X
W4147 18 a X
W1485 18 a X
W1331 18 a X
W4173 18 a X
W1476 18 a X
W3000 18 a X
W3001 18 a X
W3002 18 a X
W3003 18 a X
W3004 18 a X
W3005 18 a X
W3010 18 a X
W3011 18 a X
W3012 18 a X
W3013 18 a X
W3018 18 a X
W3021 18 a X
W3042 18 a X
W3057 18 a X
W3182 18 a X
W3177 18 a X
W3103 18 a X
W3106 18 a X
W3108 18 a X
W1493 36 a X
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X
W4180 2a X X X X
W4181 9a X X X X
W1769 6a X
W4182 9a X
TIM-ID: 0000072777 - 001

W1767 18 a X
W1768 18 a X
W4183 18 a X
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 13

 1.4 Maintenance tasks 24,000 h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 1a Fuel servicing plant Check alarm function of differential pressure gauge. X W1245
Check pump capacity. X W1246
QL1 - 2a Fuel servicing plant Check function of bar electrode. X W1244
Fit new filter element. X W1380
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
QL1 Daily - Engine operation Check engine oil level. W0500
Carry out visual inspection of engine for general condition and leaks. W0501
Inspect service indicator of air filter. X W0503
Check relief bores of coolant pump(s). W0505
Check for abnormal running noises, exhaust gas color and vibration. W0506
Drain off water and contamination from fuel prefilter. X W0507
Check differential pressure gauge of fuel prefilter. X W0508
QL1 500 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- W1009
est, each time the engine oil is changed.
QL1 500 2a Automatic engine oil filter Check and clean oil indicator filter. X W1864
QL1 1000 1a Engine mounts Check general condition of resilient mount (visual inspection). X W4172
Check tightness of securing screws. X W1519
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Fuel prefilter Fit new fuel prefilter or new fuel prefilter insert. X W1675
QL1 3000 3a Air filters Fit new air filters. X W1005
QL1 3000 3a Coolant expansion tank Replace valve. X W1296
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! Initial adjust- W1207
ment after 1,000 operating hours and subsequently 1,000 operating
hours after each cylinder-head overhaul..
QL1 3000 18 a Cylinder heads Measure valve stem end to cylinder head top distance. W1689
QL1 6000 6a Crankcase breathers Fit new oil separators. W1055
QL1 8000 18 a Battery charging alternator Check condition of coupling. X W1016
QL1 8000 18 a Fuel injectors Replace fuel injectors. W1006
QL1 8000 18 a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 8000 18 a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 24000 18 a Preheater / Jacket water heat- Overhaul preheater / jacket water heater. X W1477
er
QL3 12000 5a Engine mounts Measure height of rubber element. X W4150
Measure buffer clearance, adjust if needed. X W4170
QL3 12000 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 12000 18 a Turbochargers Overhaul turbochargers. W1038
QL3 12000 18 a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
TIM-ID: 0000072778 - 001

ating parameters. Then drain coolant and flush cooling systems.

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
Check engine coolant thermostat and fit new thermal actuator. W2006
Inspect centrifugal oil filter for wear. W2009
Overhaul starter. X W2010
Overhaul air starter. X W2143
w = weeks
m = months
a = years

14 | Maintenance Schedule | MS50241/00E 2016-11

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Clean engine coolant cooler and inspect it for leaks. W2017
Check operation of diverter valve. W2021
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 24000 6a Hose lines Replace all hose lines. W1251
QL3 24000 18 a Cylinder heads Overhaul cylinder heads. W1134
QL4 12000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 12000 18 a HP fuel pump Fit new high-pressure fuel pump. W1058
QL4 24000 18 a Flexible/torsional resilient Replace rubber element. X W4146
coupling
QL4 24000 18 a Shaft misalignment coupling Replace diaphragm. X W4171
QL4 24000 18 a Steel-spring coupling Check coupling, replace if necessary. X W4147
QL4 24000 18 a Turbochargers Fit new turbine wheels for turbochargers. W1485
QL4 24000 18 a Exhaust pipe bellows Replace exhaust pipe bellows. W1331
QL4 24000 18 a Engine mounts Replace rubber element of resilient mounts. X W4173
QL4 24000 18 a Preheater / Jacket water heat- Replace circulating pump. X W1476
er
QL4 24000 18 a Extended component mainte- Completely disassemble the engine.Inspect engine components as per W3000
nance assembly instructions and repair or fit new components as required.
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 fuel delivery pump. W3010
Fit new actuating cylinders for air flow control flaps. 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 high-pressure fuel sensor. W3057
Gear train: Check tooth flanks for wear (visual inspection), replace W3182
bearing bushings.
Check engine oil pump, replace if necessary. W3177
Replace swing followers and swing-follower shafts. W3103
Replace oil replenishment pump. X W3106
Check vibration damper, fit new one if necessary. W3108
QL4 48000 36 a Turbochargers Fit new aluminum compressor wheels on secondary turbochargers. W1493
TIM-ID: 0000072778 - 001

SCR system
QL1 - 3a SCR supply unit Replace filter insert. X W1765
QL1 - 6a SCR system Replace reducing agent lines. X W1766
QL1 500 - SCR system Carry out visual inspection of insulation of housing and bypass, re- X W4179
place if necessary.
QL1 1000 2a SCR system Replace filter on pre-feed module. X W4180
QL1 1000 9a SCR system Check measuring lines of exhaust pressure sensor, clean if necessary. X W4181
QL1 4000 6a SCR NOx sensor Fit new sensor. X W1769
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 15

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
QL1 8000 9a SCR system Replace SCR-GECANNT insert. X W4182
QL1 24000 18 a SCR dosing unit Replace dosing unit. X W1767
QL1 24000 18 a SCR supply unit Replace supply unit. X W1768
QL1 24000 18 a SCR system Replace pre-feed module. X W4183
w = weeks
m = months
a = years

TIM-ID: 0000072778 - 001

16 | Maintenance Schedule | MS50241/00E 2016-11

 1.5 Maintenance schedule matrix 21,000 h
0 to 12,600 Operating hours
Task Operating hours [h]

10,000
10,500
11,000
11,500
12,000
12,500
12,600
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,200
4,500
5,000
5,250
5,500
6,000
6,500
7,000
7,500
8,000
8,400
8,500
9,000
9,500
Limit

Daily
500

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 - X
W0501 - X
W0503 - X
W0505 - X
W0506 - X
W0507 - X
W0508 - X
W1009 2a X X X X X X X X X X X X X X X X X X X X X X X X X
W1864 2a X X X X X X X X X X X X X X X X X X X X X X X X X
W4172 1a X X X X X X X X X X X X
W1519 1a X X X X X X X X X X X X
W1001 2a X X X X X X X X X X X X
W1675 2a X X X X X X X X X X X X
W1005 3a X X X X
W1296 3a X X X X
W1207 18 a X X X X X
W1689 18 a X X X X
W1055 6a X X
W1016 18 a X
W1006 18 a X
W1713 18 a X
W1011 18 a X
W1477 18 a
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
TIM-ID: 0000072779 - 001

W2006 18 a X
W2009 18 a X
W2010 18 a X
W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 17

Task Operating hours [h]

10,000
10,500
11,000
11,500
12,000
12,500
12,600
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,200
4,500
5,000
5,250
5,500
6,000
6,500
7,000
7,500
8,000
8,400
8,500
9,000
9,500
Limit

Daily
W2111 18 a 500 X
W2112 18 a X
W1251 6a
W1134 18 a
W1478 6a X
W1058 18 a X
W4146 18 a
W4171 18 a
W4147 18 a
W1485 18 a
W1331 18 a
W4173 18 a
W1476 18 a
W3000 18 a
W3001 18 a
W3002 18 a
W3003 18 a
W3004 18 a
W3005 18 a
W3010 18 a
W3011 18 a
W3012 18 a
W3013 18 a
W3018 18 a
W3021 18 a
W3042 18 a
W3057 18 a
W3182 18 a
W3177 18 a
W3103 18 a
W3106 18 a
W3108 18 a
W1493 36 a
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X X X X X X X X X X X X X X X X X X X
W4180 2a X X X X X X X X X X X X
W4181 9a X X X X X X X X X X X X
TIM-ID: 0000072779 - 001

W4182 9a X X X
W1769 6a X X X
W1767 18 a
W1768 18 a
W4183 18 a
w = weeks
m = months
a = years

18 | Maintenance Schedule | MS50241/00E 2016-11

 13,000 to 26,000 Operating hours
Task Operating hours [h]

13,000
13,500
14,000
14,500
15,000
15,500
15,750
16,000
16,500
16,800
17,000
17,500
18,000
18,500
19,000
19,500
20,000
20,500
21,000
21,500
22,000
22,500
23,000
23,500
24,000
24,500
25,000
25,200
25,500
26,000
Limit

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 -
W0501 -
W0503 -
W0505 -
W0506 -
W0507 -
W0508 -
W1009 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X
W1864 2a X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4172 1a X X X X X X X X X X X X X X
W1519 1a X X X X X X X X X X X X X X
W1001 2a X X X X X X X X X X X X X X
W1675 2a X X X X X X X X X X X X X X
W1005 3a X X X X
W1296 3a X X X X
W1207 18 a X X X X X
W1689 18 a X X X X
W1055 6a X X
W1016 18 a X X
W1006 18 a X X
W1713 18 a X X
W1011 18 a X X
W1477 18 a X
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
W2006 18 a X
W2009 18 a X
W2010 18 a X
TIM-ID: 0000072779 - 001

W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
W2111 18 a X
W2112 18 a X
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 19

Task Operating hours [h]

13,000
13,500
14,000
14,500
15,000
15,500
15,750
16,000
16,500
16,800
17,000
17,500
18,000
18,500
19,000
19,500
20,000
20,500
21,000
21,500
22,000
22,500
23,000
23,500
24,000
24,500
25,000
25,200
25,500
26,000
Limit

W1251 6a X
W1134 18 a X
W1478 6a X
W1058 18 a X
W4146 18 a X
W4171 18 a X
W4147 18 a X
W1485 18 a X
W1331 18 a X
W4173 18 a X
W1476 18 a X
W3000 18 a X
W3001 18 a X
W3002 18 a X
W3003 18 a X
W3004 18 a X
W3005 18 a X
W3010 18 a X
W3011 18 a X
W3012 18 a X
W3013 18 a X
W3018 18 a X
W3021 18 a X
W3042 18 a X
W3057 18 a X
W3182 18 a X
W3177 18 a X
W3103 18 a X
W3106 18 a X
W3108 18 a X
W1493 36 a
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X X X X X X X X X X X X X X X X X X X X X
W4180 2a X X X X X X X X X X X X X X
W4181 9a X X X X X X X X X X X X X X
W4182 9a X X X X
W1769 6a X X X
TIM-ID: 0000072779 - 001

W1767 18 a X
W1768 18 a X
W4183 18 a X
w = weeks
m = months
a = years

20 | Maintenance Schedule | MS50241/00E 2016-11

 26,250 to 38,500 Operating hours
Task Operating hours [h]

26,250
26,500
27,000
27,500
28,000
28,500
29,000
29,400
29,500
30,000
30,500
31,000
31,500
32,000
32,500
33,000
33,500
33,600
34,000
34,500
35,000
35,500
36,000
36,500
36,750
37,000
37,500
37,800
38,000
38,500
Limit

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 -
W0501 -
W0503 -
W0505 -
W0506 -
W0507 -
W0508 -
W1009 2a X X X X X X X X X X X X X X X X X X X X X X X X X
W1864 2a X X X X X X X X X X X X X X X X X X X X X X X X X
W4172 1a X X X X X X X X X X X X
W1519 1a X X X X X X X X X X X X
W1001 2a X X X X X X X X X X X X
W1675 2a X X X X X X X X X X X X
W1005 3a X X X X
W1296 3a X X X X
W1207 18 a X X X X
W1689 18 a X X X X
W1055 6a X X X
W1016 18 a X X
W1006 18 a X X
W1713 18 a X X
W1011 18 a X X
W1477 18 a
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
W2006 18 a X
W2009 18 a X
W2010 18 a X
TIM-ID: 0000072779 - 001

W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
W2111 18 a X
W2112 18 a X
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 21

Task Operating hours [h]

26,250
26,500
27,000
27,500
28,000
28,500
29,000
29,400
29,500
30,000
30,500
31,000
31,500
32,000
32,500
33,000
33,500
33,600
34,000
34,500
35,000
35,500
36,000
36,500
36,750
37,000
37,500
37,800
38,000
38,500
Limit

W1251 6a
W1134 18 a
W1478 6a X
W1058 18 a X
W4146 18 a
W4171 18 a
W4147 18 a
W1485 18 a
W1331 18 a
W4173 18 a
W1476 18 a
W3000 18 a
W3001 18 a
W3002 18 a
W3003 18 a
W3004 18 a
W3005 18 a
W3010 18 a
W3011 18 a
W3012 18 a
W3013 18 a
W3018 18 a
W3021 18 a
W3042 18 a
W3057 18 a
W3182 18 a
W3177 18 a
W3103 18 a
W3106 18 a
W3108 18 a
W1493 36 a
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X X X X X X X X X X X X X X X X X X X
W4180 2a X X X X X X X X X X X X
W4181 9a X X X X X X X X X X X X
W4182 9a X X X X
W1769 6a X X X
TIM-ID: 0000072779 - 001

W1767 18 a
W1768 18 a
W4183 18 a
w = weeks
m = months
a = years

22 | Maintenance Schedule | MS50241/00E 2016-11

 39,000 to 42,000 Operating hours
Task Operating hours [h]

39,000
39,500
40,000
40,500
41,000
41,500
42,000
Limit

Engine
W1245 1a
W1246 1a
W1244 2a
W1380 2a
W1008 2a
W0500 -
W0501 -
W0503 -
W0505 -
W0506 -
W0507 -
W0508 -
W1009 2a X X X X X X X
W1864 2a X X X X X X X
W4172 1a X X X X
W1519 1a X X X X
W1001 2a X X X X
W1675 2a X X X X
W1005 3a X X
W1296 3a X X
W1207 18 a X X
W1689 18 a X X
W1055 6a X
W1016 18 a X
W1006 18 a X
W1713 18 a X
W1011 18 a X
W1477 18 a X
W4150 5a X
W4170 5a X
W1250 6a X
W1038 18 a X
W2012 18 a X
W2001 18 a X
W2006 18 a X
W2009 18 a X
W2010 18 a X
TIM-ID: 0000072779 - 001

W2143 18 a X
W2017 18 a X
W2021 18 a X
W2062 18 a X
W2110 18 a X
W2111 18 a X
W2112 18 a X
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 23

Task Operating hours [h]

39,000
39,500
40,000
40,500
41,000
41,500
42,000
Limit

W1251 6a X
W1134 18 a X
W1478 6a X
W1058 18 a X
W4146 18 a X
W4171 18 a X
W4147 18 a X
W1485 18 a X
W1331 18 a X
W4173 18 a X
W1476 18 a X
W3000 18 a X
W3001 18 a X
W3002 18 a X
W3003 18 a X
W3004 18 a X
W3005 18 a X
W3010 18 a X
W3011 18 a X
W3012 18 a X
W3013 18 a X
W3018 18 a X
W3021 18 a X
W3042 18 a X
W3057 18 a X
W3182 18 a X
W3177 18 a X
W3103 18 a X
W3106 18 a X
W3108 18 a X
W1493 36 a X
SCR system
W1765 3a
W1766 6a
W4179 - X X X X X X X
W4180 2a X X X X
W4181 9a X X X X
W4182 9a X
W1769 6a X
TIM-ID: 0000072779 - 001

W1767 18 a X
W1768 18 a X
W4183 18 a X
w = weeks
m = months
a = years

24 | Maintenance Schedule | MS50241/00E 2016-11

 1.6 Maintenance tasks 21,000 h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 1a Fuel servicing plant Check alarm function of differential pressure gauge. X W1245
Check pump capacity. X W1246
QL1 - 2a Fuel servicing plant Check function of bar electrode. X W1244
Fit new filter element. X W1380
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
QL1 Daily - Engine operation Check engine oil level. W0500
Carry out visual inspection of engine for general condition and leaks. W0501
Inspect service indicator of air filter. X W0503
Check relief bores of coolant pump(s). W0505
Check for abnormal running noises, exhaust gas color and vibration. W0506
Drain off water and contamination from fuel prefilter. X W0507
Check differential pressure gauge of fuel prefilter. X W0508
QL1 500 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- W1009
est, each time the engine oil is changed.
QL1 500 2a Automatic engine oil filter Check and clean oil indicator filter. X W1864
QL1 1000 1a Engine mounts Check general condition of resilient mount (visual inspection). X W4172
Check tightness of securing screws. X W1519
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Fuel prefilter Fit new fuel prefilter or new fuel prefilter insert. X W1675
QL1 3000 3a Air filters Fit new air filters. X W1005
QL1 3000 3a Coolant expansion tank Replace valve. X W1296
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! Initial adjust- W1207
ment after 1,000 operating hours and subsequently 1,000 operating
hours after each cylinder-head overhaul..
QL1 3000 18 a Cylinder heads Measure valve stem end to cylinder head top distance. W1689
QL1 5250 6a Crankcase breathers Fit new oil separators. W1055
QL1 7000 18 a Battery charging alternator Check condition of coupling. X W1016
QL1 7000 18 a Fuel injectors Replace fuel injectors. W1006
QL1 7000 18 a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 7000 18 a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 21000 18 a Preheater / Jacket water heat- Overhaul preheater / jacket water heater. X W1477
er
QL3 10500 5a Engine mounts Measure height of rubber element. X W4150
Measure buffer clearance, adjust if needed. X W4170
QL3 10500 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 10500 18 a Turbochargers Overhaul turbochargers. W1038
QL3 10500 18 a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
TIM-ID: 0000072780 - 001

ating parameters. Then drain coolant and flush cooling systems.

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
Check engine coolant thermostat and fit new thermal actuator. W2006
Inspect centrifugal oil filter for wear. W2009
Overhaul starter. X W2010
Overhaul air starter. X W2143
w = weeks
m = months
a = years

MS50241/00E 2016-11 | Maintenance Schedule | 25

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Clean engine coolant cooler and inspect it for leaks. W2017
Check operation of diverter valve. W2021
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 21000 6a Hose lines Replace all hose lines. W1251
QL3 21000 18 a Cylinder heads Overhaul cylinder heads. W1134
QL4 10500 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 10500 18 a HP fuel pump Fit new high-pressure fuel pump. W1058
QL4 21000 18 a Flexible/torsional resilient Replace rubber element. X W4146
coupling
QL4 21000 18 a Shaft misalignment coupling Replace diaphragm. X W4171
QL4 21000 18 a Steel-spring coupling Check coupling, replace if necessary. X W4147
QL4 21000 18 a Turbochargers Fit new turbine wheels for turbochargers. W1485
QL4 21000 18 a Exhaust pipe bellows Replace exhaust pipe bellows. W1331
QL4 21000 18 a Engine mounts Replace rubber element of resilient mounts. X W4173
QL4 21000 18 a Preheater / Jacket water heat- Replace circulating pump. X W1476
er
QL4 21000 18 a Extended component mainte- Completely disassemble the engine.Inspect engine components as per W3000
nance assembly instructions and repair or fit new components as required.
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 fuel delivery pump. W3010
Fit new actuating cylinders for air flow control flaps. 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 high-pressure fuel sensor. W3057
Gear train: Check tooth flanks for wear (visual inspection), replace W3182
bearing bushings.
Check engine oil pump, replace if necessary. W3177
Replace swing followers and swing-follower shafts. W3103
Replace oil replenishment pump. X W3106
Check vibration damper, fit new one if necessary. W3108
QL4 42000 36 a Turbochargers Fit new aluminum compressor wheels on secondary turbochargers. W1493
TIM-ID: 0000072780 - 001

SCR system
QL1 - 3a SCR supply unit Replace filter insert. X W1765
QL1 - 6a SCR system Replace reducing agent lines. X W1766
QL1 500 - SCR system Carry out visual inspection of insulation of housing and bypass, re- X W4179
place if necessary.
QL1 1000 2a SCR system Replace filter on pre-feed module. X W4180
QL1 1000 9a SCR system Check measuring lines of exhaust pressure sensor, clean if necessary. X W4181
QL1 3500 9a SCR system Replace SCR-GECANNT insert. X W4182
w = weeks
m = months
a = years

26 | Maintenance Schedule | MS50241/00E 2016-11

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
QL1 4200 6a SCR NOx sensor Fit new sensor. X W1769
QL1 21000 18 a SCR dosing unit Replace dosing unit. X W1767
QL1 21000 18 a SCR supply unit Replace supply unit. X W1768
QL1 21000 18 a SCR system Replace pre-feed module. X W4183
w = weeks
m = months
a = years
TIM-ID: 0000072780 - 001

MS50241/00E 2016-11 | Maintenance Schedule | 27