Maintenance Schedule

Diesel Engine
12 V 4000 Gx3
16 V 4000 Gx3, 16 V 4000 Gx3x
20 V 4000 Gx3, 20 V 4000 Gx3x
Application Group 3D

MS50004/04E
12V4000G23
12V4000G43
12V4000G63
12V4000G83
16V4000G23
16V4000G43
16V4000G63
16V4000G83
16V4000G83L
20V4000G23
20V4000G43
20V4000G63
20V4000G63L
20V4000G83
20V4000G83L

Table 1: applicable for

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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, mi-
crofilming 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.
 1 Maintenance Schedule
1.1 Preface
MTU maintenance concept
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. The time intervals
at which the maintenance work is to be carried out and the relevant checks and tasks involved are aver-
age values based on operational experience and are therefore to be regarded as guidelines only. Spe-
cial 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 applica-
ble. 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.

Notes on maintenance
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 Specifica-
tions A001061 and in the fluids and lubricants specifications produced by the component manufactur-
ers. 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 ap-
proved by the relevant component manufacturer.
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 pre-
filters 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.
TIM-ID: 0000000002 - 001

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
If the engine is to remain out of service for more than 1 month, carry out engine preservation proce-
dures in accordance with the Fluids and Lubricants Specifications, MTU Publication No. A001061.

MS50004/04E 2013-02 | Maintenance Schedule | 3

 Application Group
3D Short-time operation, fuel stop

Load profile

TIM-ID: 0000000002 - 001

4 | Maintenance Schedule | MS50004/04E 2013-02

 1.2 Maintenance schedule matrix
0-10,500 Operating hours
Item Operating hours [h]

10,000
10,500
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 operation 1m
Engine oil filter 2a
Engine operation - X
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
Engine mounts 1a X X X X X X X X X X
Belt drive 2a X X X X X X X
Valve gear 2a X X X
Air filters 3a X X X
Rubber sleeves 6a X X X
Hose lines 6a X
Fuel injectors 9a X
Combustion chambers 4a X
Crankcase breathers 2a X
Turbochargers 9a X
Turbochargers 9a X
Component maintenance 9a X
Engine mounts 5a X
Fuel delivery pump 9a X
Cylinder heads 9a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

11,000-12,000 Operating hours

Item Operating hours [h]
11,000
11,500
12,000
Limit

Engine operation 1m
Engine oil filter 2a
Engine operation -
Centrifugal oil filter 2a X X X
Fuel filter 2a X X
Engine mounts 1a X X
TIM-ID: 0000000003 - 001

Belt drive 2a X
Valve gear 2a X
Air filters 3a X
Rubber sleeves 6a X
Hose lines 6a X
Fuel injectors 9a X
Combustion chambers 4a X
w = weeks
m = months
a = years

MS50004/04E 2013-02 | Maintenance Schedule | 5

Item Operating hours [h]

11,000
11,500
12,000
Limit
Crankcase breathers 2a X
Turbochargers 9a X
Turbochargers 9a X
Component maintenance 9a X
Engine mounts 5a X
Fuel delivery pump 9a X
Cylinder heads 9a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years

TIM-ID: 0000000003 - 001

6 | Maintenance Schedule | MS50004/04E 2013-02

 1.3 Maintenance tasks
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
QL1 - 1m Engine operation Test run at not below 1/3 load and at least until steady-state tempera- W0534
ture is reached (monthly).
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the 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 intercooler drain system. X W0502
Inspect service indicator of air filter. 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- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1500 2a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjust W1241
tension.
QL1 3000 2a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 3a Air filters Fit new air filters. W1005
QL3 3000 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 6000 6a Hose lines Replace all hose lines. W1251
QL1 6000 9a Fuel injectors Replace fuel injectors. W1006
QL1 6000 4a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 6000 2a Crankcase breathers Crankcase breathers: Fit new filters or filter inserts. W1046
QL3 6000 9a Turbochargers Replace exhaust turbocharger (Garrett turbocharger). X W1786
QL3 6000 9a Turbochargers Overhaul exhaust turbocharger (MTU ZR turbocharger). X W1785
QL3 6000 9a Component maintenance Before starting maintenance work, drain the coolant and flush the W2000
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.
Clean air ducting. W2002
Clean intercooler and inspect for leakage. W2003
Fit new high-pressure fuel sensor. W2004
Check engine coolant thermostat and fit new thermal actuator. W2006
Check charge-air coolant thermostat and fit new thermal actuator. W2007
Overhaul engine coolant preheating system. X W2008
Inspect centrifugal oil filter for wear. X W2009
TIM-ID: 0000000004 - 001

Overhaul starter. W2010

Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Overhaul engine coolant pump. W2110
QL3 6000 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 6000 9a Fuel delivery pump Fit new fuel delivery pump. W1051
QL3 6000 9a Cylinder heads Overhaul cylinder heads. W1134
w = weeks
m = months
a = years

MS50004/04E 2013-02 | Maintenance Schedule | 7

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
QL4 6000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 high-pressure fuel pump. W3007
Fit new camshaft bearings and camshaft thrust bearings. W3018
Fit new pressure relief valve in high-pressure fuel system. W3021
Check gear train for cracks, replace bushings, check axles and replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Replace turbine wheels of exhaust turbochargers (MTU ZR turbocharg- X W3101
er).
Replace swing followers and swing-follower shafts. W3103
Remove and inspect vibration damper. Repair if necessary. W3019
Insulated flywheel: Check and repair if required. W3144
QL4 12000 18 a Turbochargers Replace compressor wheels of exhaust turbochargers (MTU ZR turbo- X W1472
charger).
w = weeks
m = months
a = years

TIM-ID: 0000000004 - 001

8 | Maintenance Schedule | MS50004/04E 2013-02