3B Maintenance MS50005_04E

8/11/2019 3B Maintenance MS50005_04E

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Maintenance ScheduleDiesel EngineV 4000 G23, G23R

V 4000 G43V 4000 G63, G63LV 4000 G83, G83LApplication Group 3B

MS50005/04E



1 Maintenance Schedule

1.1 PrefaceMTU maintenance conceptThe maintenance system for MTU products is based on a preventive maintenance concept. Preventivemaintenance 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 intervalsat 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/ormodification of the maintenance intervals. The intervals according to which the maintenance tasks haveto 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 musthave achieved a level of training and qualification appropriate to the complexity of the task in hand. Thevarious Qualification Levels QL1 to QL4 reflect the levels of training offered in MTU courses and thecontents of the tool kits required:

QL1: Operational monitoring and maintenance which can be carried out during a break in operationwithout 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. Followingthis, 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 maintenanceSpecifications for fluids and lubricants, guideline values for their maintenance and change intervals andlists 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 Fluidsand 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 maintenancework:

• Protect components made of rubber or synthetic material from oil. Never treat them with organicdetergents. 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 batterymanufacturer's instructions must be obeyed.

The relevant manufacturer's instructions apply with respect to the maintenance of any componentswhich 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 periodsIf 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.

MS50005/04E 2013-02 | Maintenance Schedule | 3

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Application Group

3B Continuous operation, variable load

Note:TBO identifiable via cylinder power (shown on engine ID plate, power/number of cylinder)

Allocation matrix V4000Gx3x

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1.2 Maintenance schedule matrix TBO 10,000h (High Power)

0-10,500 Operating hoursItem

L i m i t

Operating hours [h]

D a i l y

5 0 0 1 , 0 0 0

1 , 5 0 0

2 , 0 0 0

2 , 5 0 0

3 , 0 0 0

3 , 5 0 0

4 , 0 0 0

4 , 5 0 0

5 , 0 0 0

5 , 5 0 0

6 , 0 0 0

6 , 5 0 0

7 , 0 0 0

7 , 5 0 0

8 , 0 0 0

8 , 5 0 0

9 , 0 0 0

9 , 5 0 0

1 0 , 0 0 0

1 0 , 5 0 0

Engine operation 1 m

Engine oil filter 2 a

Engine operation - X

Oil indicator filter 6 m X X X X X X X X X X X X X X X X X X X X X

Centrifugal oil filter 2 a X X X X X X X X X X X X X X X X X X X X X

Fuel filter 2 a X X X X X X X X X X

Engine mounts 2 a X X X X X X X X X X

Belt drive 2 a X X X X X X X

Valve gear 2 a X X X

Air filters 3 a X X X

Fuel injectors 9 a X X

Engine governor 9 a X X

Combustion chambers 4 a X X

Crankcase breathers 2 a X X

Rubber sleeves 6 a X X

Hose lines 6 a X

Turbochargers 18 a X

Component maintenance 9 a X

Engine mounts 5 a X

Fuel delivery pump 9 a XCylinder heads 9 a X

Automatic engine oil filter 6 a X

Extended component maintenance 18 a X

Turbochargers 18 a

w = weeksm = monthsa = years

11,000-20,000 Operating hoursItem

L i m i t

Operating hours [h]

1 1 , 0 0 0

1 1 , 5 0 0

1 2 , 0 0 0

1 2 , 5 0 0

1 3 , 0 0 0

1 3 , 5 0 0

1 4 , 0 0 0

1 4 , 5 0 0

1 5 , 0 0 0

1 5 , 5 0 0

1 6 , 0 0 0

1 6 , 5 0 0

1 7 , 0 0 0

1 7 , 5 0 0

1 8 , 0 0 0

1 8 , 5 0 0

1 9 , 0 0 0

1 9 , 5 0 0

2 0 , 0 0 0



Engine operation -

Oil indicator filter 6 m X X X X X X X X X X X X X X X X X X X

Centrifugal oil filter 2 a X X X X X X X X X X X X X X X X X X X



Belt drive 2 a X X X X X X


Air filters 3 a X X XFuel injectors 9 a X X



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Item

L i m i t

Operating hours [h]

1 1 , 0 0 0

1 1 , 5 0 0

1 2 , 0 0 0

1 2 , 5 0 0

1 3 , 0 0 0

1 3 , 5 0 0

1 4 , 0 0 0

1 4 , 5 0 0

1 5 , 0 0 0

1 5 , 5 0 0

1 6 , 0 0 0

1 6 , 5 0 0

1 7 , 0 0 0

1 7 , 5 0 0

1 8 , 0 0 0

1 8 , 5 0 0

1 9 , 0 0 0

1 9 , 5 0 0

2 0 , 0 0 0




Rubber sleeves 6 a X X

Hose lines 6 a X



Engine mounts 5 a X

Fuel delivery pump 9 a X

Cylinder heads 9 a X






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1.3 Maintenance tasks TBO 10,000h (High Power)Qualifi-cation

level

Interval Limit Item Maintenance tasks

O

p t i o n Task

[h]

QL1 - 1 m Engine operation Test run at not below 1/3 load and at least until steady-state tempera-ture is reached (monthly).

W0534

QL1 - 2 a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at thelatest, on expiry of the time limit (given in years).

W1008

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 6 m Oil indicator filter Check and clean oil indicator filter. X W1714

QL1 500 2 a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat-est, each time the engine oil is changed.

X W1009

QL1 1000 2 a Fuel filter Fit new fuel filter or new fuel filter insert. W1001

QL1 1000 2 a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463

QL1 1500 2 a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjusttension.

W1241

QL1 3000 2 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustmentafter 1,000 hours.

W1207

QL1 3000 3 a Air filters Fit new air filters. W1005

QL1 5000 9 a Fuel injectors Replace fuel injectors. W1006

QL1 5000 9 a Engine governor Injector: reset drift compensation parameters (CDC). W1713

QL1 5000 4 a Combustion chambers Inspect cylinder chambers using endoscope. W1011

QL1 5000 2 a Crankcase breathers Crankcase breathers: Fit new filters or filter inserts. W1046

QL3 5000 6 a Rubber sleeves Replace all rubber sleeves. W1250

QL3 10000 6 a Hose lines Replace all hose lines. W1251

QL3 10000 18 a Turbochargers Overhaul turbocharger (MTU-ZR-turbocharger) If Garrett turbocharger,fit new.

W1388

QL3 10000 9 a Component maintenance Before starting maintenance work, drain the coolant and flush thecooling systems.

W2000

Inspect rocker arms and valve bridge for wear. Insert an endoscopethrough the pushrod bore to visually inspect swing followers and cam-shaft running surfaces.

W2001

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

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 10000 5 a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se-curing screws.

W1026



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Qualifi-cationlevel


O p t i o n Task

[h]

Check for cracks. Measure cracks if necessary. Measure height of rub-ber elements.

W1462

QL3 10000 9 a Fuel delivery pump Fit new fuel delivery pump. W1051

QL3 10000 9 a Cylinder heads Overhaul cylinder heads. W1134

QL4 10000 6 a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478

QL4 10000 18 a Extended component mainte-nance

Completely disassemble the engine. Inspect engine components asper assembly instructions and repair or fit new components as re-quired.

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 high-pressure fuel pump. W3007

Fit new camshaft bearings and camshaft thrust bearings. W3018

Check gear train for cracks, replace bushings, check axles and replaceif necessary.

W3063

Fit new engine oil pump. W3073

Replace wiring harnesses. W3083

Fit new rubber elements of engine mounts. W3100

Replace turbine wheels of exhaust turbochargers (MTU ZR turbocharg-er).

W3101

Replace swing followers and swing-follower shafts. W3103

Check vibration damper, fit new one if necessary. W3108

Replace insulated flywheel. X W3140

QL4 20000 18 a Turbochargers Replace compressor wheels of exhaust turbochargers (MTU ZR turbo-charger).

W1472



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1.4 Maintenance schedule matrix TBO 15,000h (Low Power)

0-10,500 Operating hoursItem

L i m i t

Operating hours [h]

D a i l y

5 0 0 1 , 0 0 0

1 , 5 0 0

2 , 0 0 0

2 , 5 0 0

3 , 0 0 0

3 , 5 0 0

4 , 0 0 0

4 , 5 0 0

5 , 0 0 0

5 , 5 0 0

6 , 0 0 0

6 , 5 0 0

7 , 0 0 0

7 , 5 0 0

8 , 0 0 0

8 , 5 0 0

9 , 0 0 0

9 , 5 0 0

1 0 , 0 0 0

1 0 , 5 0 0



Engine operation - X

Oil indicator filter 6 m X X X X X X X X X X X X X X X X X X X X X

Centrifugal oil filter 2 a X X X X X X X X X X X X X X X X X X X X X










Rubber sleeves 6 a X

Hose lines 6 a

Turbochargers 18 a

Component maintenance 9 a

Engine mounts 5 a

Fuel delivery pump 9 aCylinder heads 9 a

Automatic engine oil filter 6 a

Extended component maintenance 18 a

Turbochargers 18 a



L i m i t

Operating hours [h]

1 1 , 0 0 0

1 1 , 5 0 0

1 2 , 0 0 0

1 2 , 5 0 0

1 3 , 0 0 0

1 3 , 5 0 0

1 4 , 0 0 0

1 4 , 5 0 0

1 5 , 0 0 0

1 5 , 5 0 0

1 6 , 0 0 0

1 6 , 5 0 0

1 7 , 0 0 0

1 7 , 5 0 0

1 8 , 0 0 0

1 8 , 5 0 0

1 9 , 0 0 0

1 9 , 5 0 0

2 0 , 0 0 0

2 0 , 5 0 0

2 1 , 0 0 0

2 1 , 5 0 0



Engine operation -

Oil indicator filter 6 m X X X X X X X X X X X X X X X X X X X X X X

Centrifugal oil filter 2 a X X X X X X X X X X X X X X X X X X X X X X

Fuel filter 2 a X X X X X X X X X X X

Engine mounts 2 a X X X X X X X X X X X


Valve gear 2 a X X X X

Air filters 3 a X X X XFuel injectors 9 a X X



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Item

L i m i t

Operating hours [h]

1 1 , 0 0 0

1 1 , 5 0 0

1 2 , 0 0 0

1 2 , 5 0 0

1 3 , 0 0 0

1 3 , 5 0 0

1 4 , 0 0 0

1 4 , 5 0 0

1 5 , 0 0 0

1 5 , 5 0 0

1 6 , 0 0 0

1 6 , 5 0 0

1 7 , 0 0 0

1 7 , 5 0 0

1 8 , 0 0 0

1 8 , 5 0 0

1 9 , 0 0 0

1 9 , 5 0 0

2 0 , 0 0 0

2 0 , 5 0 0

2 1 , 0 0 0

2 1 , 5 0 0




Rubber sleeves 6 a X

Hose lines 6 a X



Engine mounts 5 a X





Turbochargers 18 a



L i m i t

Operating hours [h]

2 2 , 0 0 0

2 2 , 5 0 0

2 3 , 0 0 0

2 3 , 5 0 0

2 4 , 0 0 0

2 4 , 5 0 0

2 5 , 0 0 0

2 5 , 5 0 0

2 6 , 0 0 0

2 6 , 5 0 0

2 7 , 0 0 0

2 7 , 5 0 0

2 8 , 0 0 0

2 8 , 5 0 0

2 9 , 0 0 0

2 9 , 5 0 0

3 0 , 0 0 0



Engine operation -Oil indicator filter 6 m X X X X X X X X X X X X X X X X X

Centrifugal oil filter 2 a X X X X X X X X X X X X X X X X X

Fuel filter 2 a X X X X X X X X X

Engine mounts 2 a X X X X X X X X X

Belt drive 2 a X X X X X X






Crankcase breathers 2 a X XRubber sleeves 6 a X X

Hose lines 6 a X



Engine mounts 5 a X








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1.5 Maintenance tasks TBO 15,000h (Low Power)Qualifi-cation

level


O

p t i o n Task

[h]

QL1 - 1 m Engine operation Test run at not below 1/3 load and at least until steady-state tempera-ture is reached (monthly).

W0534

QL1 - 2 a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at thelatest, on expiry of the time limit (given in years).

W1008

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 6 m Oil indicator filter Check and clean oil indicator filter. X W1714

QL1 500 2 a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat-est, each time the engine oil is changed.

X W1009

QL1 1000 2 a Fuel filter Fit new fuel filter or new fuel filter insert. W1001

QL1 1000 2 a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463

QL1 1500 2 a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjusttension.

W1241

QL1 3000 2 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustmentafter 1,000 hours.

W1207

QL1 3000 3 a Air filters Fit new air filters. W1005

QL1 5000 9 a Fuel injectors Replace fuel injectors. W1006

QL1 5000 9 a Engine governor Injector: reset drift compensation parameters (CDC). W1713

QL1 5000 4 a Combustion chambers Inspect cylinder chambers using endoscope. W1011

QL1 5000 2 a Crankcase breathers Crankcase breathers: Fit new filters or filter inserts. W1046

QL3 7500 6 a Rubber sleeves Replace all rubber sleeves. W1250

QL3 15000 6 a Hose lines Replace all hose lines. W1251

QL3 15000 18 a Turbochargers Overhaul turbocharger (MTU-ZR-turbocharger) If Garrett turbocharger,fit new.

W1388

QL3 15000 9 a Component maintenance Before starting maintenance work, drain the coolant and flush thecooling systems.

W2000

Inspect rocker arms and valve bridge for wear. Insert an endoscopethrough the pushrod bore to visually inspect swing followers and cam-shaft running surfaces.

W2001

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

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 15000 5 a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se-curing screws.

W1026



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0 0 0 0 0 2 0 0 9 3 -

0 0 3



Qualifi-cationlevel


O p t i o n Task

[h]

Check for cracks. Measure cracks if necessary. Measure height of rub-ber elements.

W1462

QL3 15000 9 a Fuel delivery pump Fit new fuel delivery pump. W1051

QL3 15000 9 a Cylinder heads Overhaul cylinder heads. W1134

QL4 15000 6 a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478

QL4 15000 18 a Extended component mainte-nance

Completely disassemble the engine. Inspect engine components asper assembly instructions and repair or fit new components as re-quired.

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 high-pressure fuel pump. W3007

Fit new camshaft bearings and camshaft thrust bearings. W3018

Check gear train for cracks, replace bushings, check axles and replaceif necessary.

W3063

Fit new engine oil pump. W3073

Replace wiring harnesses. W3083

Fit new rubber elements of engine mounts. W3100

Replace turbine wheels of exhaust turbochargers (MTU ZR turbocharg-er).

W3101

Replace swing followers and swing-follower shafts. W3103

Check vibration damper, fit new one if necessary. W3108

Replace insulated flywheel. X W3140

QL4 30000 18 a Turbochargers Replace compressor wheels of exhaust turbochargers (MTU ZR turbo-charger).

W1472


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3B Maintenance MS50005_04E

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