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Maintenance Schedule

Diesel Engine
V 2000 M72
Application Group 1B

MS50194/01E

Engine model

kW/cyl.

Application group

8V2000M72

90 kW/cyl.

1B, Cont. operation, variable, high load

10V2000M72

90 kW/cyl.

1B, Cont. operation, variable, high load

12V2000M72

90 kW/cyl.

1B, Cont. operation, variable, high load

16V2000M72

90 kW/cyl.

1B, Cont. operation, variable, high load

Table 1: Applicability

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Table of Contents
1 Maintenance Schedule
Preface
Allocation matrix application group 1B
Maintenance schedule matrix 18,000h
Maintenance tasks 18,000h
Maintenance schedule matrix 16,000h

4
5
6
11
13

Maintenance tasks 16,000h


Maintenance schedule matrix 14,000h
Maintenance tasks 14,000h
Maintenance schedule matrix 12,000h
Maintenance tasks 12,000h

18
20
23
25
28

DCL-ID: 0000006809 - 008

1.1
1.2
1.3
1.4
1.5

1.6
1.7
1.8
1.9
1.10

MS50194/01E 2015-06 | Table of Contents | 3

1 Maintenance Schedule
1.1 Preface
In the case of emission-certified products, nonobservance of the maintenance specifications can result
in a violation of the statutory emission regulations. Modification or removal of mechanical or electronic
components or the installation of additional components as well as the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations. Components relevant to emissions, e.g. control units, sensors, cylinder heads, injectors and exhaust flaps can only be serviced, replaced or repaired if components approved by MTU, or equivalent
components, are used.
The MTU maintenance system is based on a preventive maintenance concept. Preventive maintenance
facilitates advance planning and ensures a high degree of equipment availability. The maintenance intervals and required maintenance scopes are based on operational experience and must therefore be
regarded as recommendations. In the event of difficult operational and ambient conditions, additional
maintenance tasks and/or changes to the maintenance intervals may be necessary.
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.
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: Component replacement (corrective, and thus not an element of the maintenance schedule).
QL3: Maintenance work that requires partial disassembly of the product.
QL4: Maintenance work that requires complete disassembly of the product.

Supplementary information on maintenance and preservation:


Change intervals for fluids and lubricants and details on preservation can be obtained in the relevant
specifications of the component manufacturers and MTU Fluids and Lubricants Specifications. The latest version is available at: http://www.mtu-online.com.
Manufacturer's specifications shall apply to the maintenance of all components not listed in this maintenance schedule.

TIM-ID: 0000046281 - 003

This maintenance schedule does not apply to engines with an EPA/CARB emission certificate.

4 | Maintenance Schedule | MS50194/01E 2015-06

1.2 Allocation matrix application group 1B

TIM-ID: 0000058780 - 001

35

90 (80-90)

80 (65-80)

65 (50-65)

10

50 (30-50)

30 (5-30)

10

Idle (0-5)

45

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)

80 (65-80)

65 (50-65)

10

50 (30-50)

30 (5-30)

15

Idle (0-5)

15

110 (100-110)

100 (90-100)

75

90 (80-90)

80 (65-80)

65 (50-65)

50 (30-50)

30 (5-30)

10

Idle (0-5)

15

100 (90-100)

110 (100-110)

0 - 90 kW/cyl.

Time
%

Load indicator %

Load %

Load factor %

V 2000 M72
Load profile

0 - 47

36

18,000

48 - 63

44

16,000

64 - 71

57

14,000

Standard 1B

72 - 79

76

12,000

Table 2: Allocation matrix application group 1B

MS50194/01E 2015-06 | Maintenance Schedule | 5

1.3 Maintenance schedule matrix 18,000h


0-14,500 Operating hours
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

11,000

11,500

12,000

12,500

13,000

13,500

14,000

14,500

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

Daily

W1245

Limit

1,000

Operating hours [h]


500

Task

Engine

w = weeks
m = months
a = years

6 | Maintenance Schedule | MS50194/01E 2015-06

X
X
X

X
X
X

X
X

TIM-ID: 0000020449 - 004

9,000

9,500

10,000

10,500

11,000

11,500

12,000

12,500

13,000

13,500

14,000

14,500

24,000

24,500

25,000

25,500

26,000

26,500

27,000

27,500

28,000

28,500

29,000

29,500

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

8,500
23,500

W1009

18 a

8,000
23,000

18 a

W3043

7,500
22,500

W0508

18 a

W3042

7,000
22,000

W0507

W3041

6,500
21,500

18 a

6,000
21,000

W0506

18 a

W3013

5,500
20,500

W0505

18 a

W3012

5,000
20,000

W0503

W3011

4,500
19,500

18 a

4,000
19,000

W0502

18 a

W3007

3,500
18,500

W0501

W3006

3,000
18,000

W0500

18 a

2,500
17,500

2a

18 a

W3005

2,000
17,000

2a

W1008

18 a

W3004

1,500
16,500

W1244

W3003

1,000
16,000

1a

18 a

500

1a

W1246

W3002

Daily

W1245

Limit

15,500

Operating hours [h]

15,000

Task

w = weeks
m = months
a = years

15,000-29,500 Operating hours


Operating hours [h]
Limit

Task

TIM-ID: 0000020449 - 004

Engine

X
X
X
X

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 7

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

W3002

18 a

W3003

18 a

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

8 | Maintenance Schedule | MS50194/01E 2015-06

29,500

29,000

28,500

28,000

X
X

TIM-ID: 0000020449 - 004

w = weeks
m = months
a = years

27,500

27,000

26,500

26,000

25,500

25,000

24,500

24,000

23,500

23,000

22,500

22,000

21,500

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

Operating hours [h]


Limit

Task

30,000-36,000 Operating hours


31,000

31,500

32,000

32,500

33,000

33,500

34,000

34,500

35,000

35,500

36,000

W1245

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

W3002

18 a

W3003

18 a

Limit

30,500

Operating hours [h]


30,000

Task

TIM-ID: 0000020449 - 004

Engine

X
X

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 9

36,000

35,500

35,000

34,500

34,000

33,500

33,000

32,500

32,000

31,500

31,000

30,500

30,000

Operating hours [h]


Limit

Task

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

TIM-ID: 0000020449 - 004

w = weeks
m = months
a = years

10 | Maintenance Schedule | MS50194/01E 2015-06

Qualification
level

Interval

Limit

Item

Maintenance tasks

Option

1.4 Maintenance tasks 18,000h


Task

Check alarm function of differential pressure gauge.

W1245

[h]

Engine
QL1

1a

Fuel servicing plant

Check pump capacity.

W1246

QL1

2a

Fuel servicing plant

Check function of bar electrode.

W1244

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).

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.

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.

W0507

Check differential pressure gauge of fuel prefilter.

W0508

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.

W1009

QL1

500

2a

Fuel filter

Fit new fuel filter or new fuel filter insert.

QL1

500

2a

Fuel prefilter

Fit new fuel prefilter or new fuel prefilter insert.

W1675

QL1

2000

2a

Valve gear

Check valve clearance, adjust if required. ATTENTION! Initial adjustment after 1,000 operating hours and subsequently 1,000 operating
hours after each cylinder-head overhaul..

QL1

2000

2a

Belt drive

Check belt condition and tension Fit new belt(s) if necessary.

QL1

4500

2a

Coolant filters

Fit new coolant filters.

W1036

QL1

4500

3a

Air filters

Fit new air filters.

W1005

QL1

6000

9a

Fuel injectors

Replace fuel injectors.

W1006

QL1

6000

9a

Combustion chambers

Inspect cylinder chambers using endoscope.

W1011

QL1

9000

2a

Crankcase breathers

Fit new oil separators.

W1055

Clean wire meshes of crankcase breathers.

W1140

QL3

6000

18 a

Turbochargers

Overhaul turbochargers.

W1038

Fit new compressor wheels for turbochargers.

W1472

Before starting maintenance work, drain the coolant and flush the
cooling systems.

W2000

Clean air ducting.

W2002

Clean intercooler and inspect for leakage.

W2003

Check engine coolant thermostat and fit new thermal actuator.

W2006

9000

9a

Component maintenance

TIM-ID: 0000020450 - 008

QL3

QL3

18000

9a

Cylinder heads

W1001
W1207

W1003

Inspect centrifugal oil filter for wear.

W2009

Clean engine coolant cooler and inspect it for leaks.

W2017

Clean engine oil cooler and inspect it for leaks.

W2018

Check engine alignment.

W2036

Clean fuel cooler.

W2059

Fit new seals/sealing materials for all disassembled components.

W2062

Inspect rocker arms, valve bridges, pushrods and ball joints for wear.

W2074

Overhaul engine coolant pump.

W2110

Overhaul raw-water pump.

W2111

Overhaul bilge pump.

W2112

Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.

W1063

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 11

Interval

QL4

18000

Limit

Item

Maintenance tasks

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

[h]

Option

Qualification
level

Fit new cylinder liners.


Fit new antifriction bearings for auxiliary PTOs.

Task

W3005
X

W3006

Fit new high-pressure fuel pump.

W3007

Fit new actuating cylinders for air flow control flaps.

W3011

Fit new actuator cylinders for exhaust flaps.

W3012

Fit new exhaust flap bearings.

W3013

Overhaul starter.

W3041

Overhaul battery-charging generator.

W3042

Fit new fuel pressure relief valve.

W3043

Fit new wire meshes for crankcase ventilation system.

W3056

Fit new high-pressure fuel sensor.

W3057

Check vibration damper, fit new one if necessary.

W3108

QL4

18000

18 a

Exhaust pipe bellows

Replace exhaust pipe bellows.

W1331

QL4

36000

18 a

Engine oil pump

Fit new engine oil pump.

W1205

TIM-ID: 0000020450 - 008

w = weeks
m = months
a = years

12 | Maintenance Schedule | MS50194/01E 2015-06

1.5 Maintenance schedule matrix 16,000h


0-14,500 Operating hours
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

11,000

11,500

12,000

12,500

13,000

13,500

14,000

14,500

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

Daily

W1245

Limit

1,000

Operating hours [h]


500

Task

TIM-ID: 0000058786 - 002

Engine

X
X
X

X
X

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 13

9,000

9,500

10,000

10,500

11,000

11,500

12,000

12,500

13,000

13,500

14,000

14,500

24,000

24,500

25,000

25,500

26,000

26,500

27,000

27,500

28,000

28,500

29,000

29,500

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

8,500
23,500

W1009

18 a

8,000
23,000

18 a

W3043

7,500
22,500

W0508

18 a

W3042

7,000
22,000

W0507

W3041

6,500
21,500

18 a

6,000
21,000

W0506

18 a

W3013

5,500
20,500

W0505

18 a

W3012

5,000
20,000

W0503

W3011

4,500
19,500

18 a

4,000
19,000

W0502

18 a

W3007

3,500
18,500

W0501

W3006

3,000
18,000

W0500

18 a

2,500
17,500

2a

18 a

W3005

2,000
17,000

2a

W1008

18 a

W3004

1,500
16,500

W1244

W3003

1,000
16,000

1a

18 a

500

1a

W1246

W3002

Daily

W1245

Limit

15,500

Operating hours [h]

15,000

Task

w = weeks
m = months
a = years

15,000-29,500 Operating hours


Operating hours [h]
Limit

Task

w = weeks
m = months
a = years

14 | Maintenance Schedule | MS50194/01E 2015-06

TIM-ID: 0000058786 - 002

Engine

TIM-ID: 0000058786 - 002

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

W3002

18 a

W3003

18 a

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

29,500

29,000

28,500

28,000

27,500

27,000

26,500

26,000

25,500

25,000

24,500

24,000

23,500

23,000

22,500

22,000

21,500

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

Operating hours [h]


Limit

Task

X
X

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 15

30,000-32,000 Operating hours


31,000

31,500

32,000

W1245

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

W3002

18 a

W3003

18 a

Limit

30,500

Operating hours [h]


30,000

Task

Engine

X
X

w = weeks
m = months
a = years

16 | Maintenance Schedule | MS50194/01E 2015-06

TIM-ID: 0000058786 - 002

32,000

31,500

31,000

30,500

30,000

Operating hours [h]


Limit

Task

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

TIM-ID: 0000058786 - 002

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 17

Qualification
level

Interval

Limit

Item

Maintenance tasks

Option

1.6 Maintenance tasks 16,000h


Task

Check alarm function of differential pressure gauge.

W1245

[h]

Engine
QL1

1a

Fuel servicing plant

Check pump capacity.

W1246

QL1

2a

Fuel servicing plant

Check function of bar electrode.

W1244

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).

W1008

QL1

Daily

Engine operation

Check engine oil level.

W0500

Carry out visual inspection of engine for general condition and leaks.

W0501
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.

W0507

Check differential pressure gauge of fuel prefilter.

W0508

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.

W1009

QL1

500

2a

Fuel filter

Fit new fuel filter or new fuel filter insert.

QL1

500

2a

Fuel prefilter

Fit new fuel prefilter or new fuel prefilter insert.

W1675

QL1

2000

2a

Valve gear

Check valve clearance, adjust if required. ATTENTION! Initial adjustment after 1,000 operating hours and subsequently 1,000 operating
hours after each cylinder-head overhaul..

QL1

2000

2a

Belt drive

Check belt condition and tension Fit new belt(s) if necessary.

QL1

4000

2a

Coolant filters

Fit new coolant filters.

W1036

QL1

4000

3a

Air filters

Fit new air filters.

W1005

QL1

6000

9a

Fuel injectors

Replace fuel injectors.

W1006

QL1

6000

9a

Combustion chambers

Inspect cylinder chambers using endoscope.

W1011

QL1

8000

2a

Crankcase breathers

Fit new oil separators.

W1055

Clean wire meshes of crankcase breathers.

W1140

QL3

6000

18 a

Turbochargers

Overhaul turbochargers.

W1038

Fit new compressor wheels for turbochargers.

W1472

Before starting maintenance work, drain the coolant and flush the
cooling systems.

W2000

Clean air ducting.

W2002

Clean intercooler and inspect for leakage.

W2003

Check engine coolant thermostat and fit new thermal actuator.

W2006

QL3

QL3

8000

16000

9a

9a

Component maintenance

Cylinder heads

W1001
W1207

W1003

Inspect centrifugal oil filter for wear.

W2009

Clean engine coolant cooler and inspect it for leaks.

W2017

Clean engine oil cooler and inspect it for leaks.

W2018

Check engine alignment.

W2036

Clean fuel cooler.

W2059

Fit new seals/sealing materials for all disassembled components.

W2062

Inspect rocker arms, valve bridges, pushrods and ball joints for wear.

W2074

Overhaul engine coolant pump.

W2110

Overhaul raw-water pump.

W2111

Overhaul bilge pump.

W2112

Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.

w = weeks
m = months
a = years

18 | Maintenance Schedule | MS50194/01E 2015-06

W1063

TIM-ID: 0000058787 - 002

Inspect intercooler drain system.

Interval
[h]

QL4

16000

Limit

Item

Maintenance tasks

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

Option

Qualification
level

Fit new cylinder liners.


Fit new antifriction bearings for auxiliary PTOs.

Task

W3005
X

W3006

Fit new high-pressure fuel pump.

W3007

Fit new actuating cylinders for air flow control flaps.

W3011

Fit new actuator cylinders for exhaust flaps.

W3012

Fit new exhaust flap bearings.

W3013

Overhaul starter.

W3041

Overhaul battery-charging generator.

W3042

Fit new fuel pressure relief valve.

W3043

Fit new wire meshes for crankcase ventilation system.

W3056

Fit new high-pressure fuel sensor.

W3057

Check vibration damper, fit new one if necessary.

W3108

QL4

16000

18 a

Exhaust pipe bellows

Replace exhaust pipe bellows.

W1331

QL4

32000

18 a

Engine oil pump

Fit new engine oil pump.

W1205

TIM-ID: 0000058787 - 002

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 19

1.7 Maintenance schedule matrix 14,000h


0-14,500 Operating hours
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

11,000

11,500

12,000

12,500

13,000

13,500

14,000

14,500

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

Daily

W1245

Limit

1,000

Operating hours [h]


500

Task

Engine

w = weeks
m = months
a = years

20 | Maintenance Schedule | MS50194/01E 2015-06

X
X
X
X

X
X

TIM-ID: 0000058788 - 002

W3002

18 a

W3003

18 a

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

14,500

14,000

13,500

13,000

12,500

12,000

11,500

11,000

10,500

10,000

9,500

9,000

8,500

8,000

7,500

7,000

6,500

6,000

5,500

5,000

4,500

4,000

3,500

3,000

2,500

2,000

1,500

1,000

500

Daily

Operating hours [h]


Limit

Task

w = weeks
m = months
a = years

15,000-28,000 Operating hours


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

W1245

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1036

2a

W1005

3a

W1006

9a

W1011

9a

Limit

15,500

Operating hours [h]


15,000

Task

TIM-ID: 0000058788 - 002

Engine

X
X

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 21

28,000

27,500

27,000

26,500

26,000

25,500

25,000

24,500

24,000

W1055

2a

W1140

2a

W1038

18 a

W1472

18 a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1063

9a

W3000

18 a

W3001

18 a

W3002

18 a

W3003

18 a

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

w = weeks
m = months
a = years

22 | Maintenance Schedule | MS50194/01E 2015-06

TIM-ID: 0000058788 - 002

23,500

23,000

22,500

22,000

21,500

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

Operating hours [h]


Limit

Task

Qualification
level

Interval

Limit

Item

Maintenance tasks

Option

1.8 Maintenance tasks 14,000h


Task

Check alarm function of differential pressure gauge.

W1245

[h]

Engine
QL1

1a

Fuel servicing plant

Check pump capacity.

W1246

QL1

2a

Fuel servicing plant

Check function of bar electrode.

W1244

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).

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.

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.

W0507

Check differential pressure gauge of fuel prefilter.

W0508

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.

W1009

QL1

500

2a

Fuel filter

Fit new fuel filter or new fuel filter insert.

QL1

500

2a

Fuel prefilter

Fit new fuel prefilter or new fuel prefilter insert.

W1675

QL1

2000

2a

Valve gear

Check valve clearance, adjust if required. ATTENTION! Initial adjustment after 1,000 operating hours and subsequently 1,000 operating
hours after each cylinder-head overhaul..

QL1

2000

2a

Belt drive

Check belt condition and tension Fit new belt(s) if necessary.

QL1

3500

2a

Coolant filters

Fit new coolant filters.

W1036

QL1

3500

3a

Air filters

Fit new air filters.

W1005

QL1

6000

9a

Fuel injectors

Replace fuel injectors.

W1006

QL1

6000

9a

Combustion chambers

Inspect cylinder chambers using endoscope.

W1011

QL1

7000

2a

Crankcase breathers

Fit new oil separators.

W1055

Clean wire meshes of crankcase breathers.

W1140

QL3

6000

18 a

Turbochargers

Overhaul turbochargers.

W1038

Fit new compressor wheels for turbochargers.

W1472

Before starting maintenance work, drain the coolant and flush the
cooling systems.

W2000

Clean air ducting.

W2002

Clean intercooler and inspect for leakage.

W2003

Check engine coolant thermostat and fit new thermal actuator.

W2006

7000

9a

Component maintenance

TIM-ID: 0000058789 - 002

QL3

QL3

14000

9a

Cylinder heads

W1001
W1207

W1003

Inspect centrifugal oil filter for wear.

W2009

Clean engine coolant cooler and inspect it for leaks.

W2017

Clean engine oil cooler and inspect it for leaks.

W2018

Check engine alignment.

W2036

Clean fuel cooler.

W2059

Fit new seals/sealing materials for all disassembled components.

W2062

Inspect rocker arms, valve bridges, pushrods and ball joints for wear.

W2074

Overhaul engine coolant pump.

W2110

Overhaul raw-water pump.

W2111

Overhaul bilge pump.

W2112

Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.

W1063

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 23

Interval

QL4

14000

Limit

Item

Maintenance tasks

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

[h]

Option

Qualification
level

Fit new cylinder liners.


Fit new antifriction bearings for auxiliary PTOs.

Task

W3005
X

W3006

Fit new high-pressure fuel pump.

W3007

Fit new actuating cylinders for air flow control flaps.

W3011

Fit new actuator cylinders for exhaust flaps.

W3012

Fit new exhaust flap bearings.

W3013

Overhaul starter.

W3041

Overhaul battery-charging generator.

W3042

Fit new fuel pressure relief valve.

W3043

Fit new wire meshes for crankcase ventilation system.

W3056

Fit new high-pressure fuel sensor.

W3057

Check vibration damper, fit new one if necessary.

W3108

QL4

14000

18 a

Exhaust pipe bellows

Replace exhaust pipe bellows.

W1331

QL4

28000

18 a

Engine oil pump

Fit new engine oil pump.

W1205

TIM-ID: 0000058789 - 002

w = weeks
m = months
a = years

24 | Maintenance Schedule | MS50194/01E 2015-06

1.9 Maintenance schedule matrix 12,000h


0-14,500 Operating hours
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

11,000

11,500

12,000

12,500

13,000

13,500

14,000

14,500

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1005

3a

W1036

2a

W1055

2a

W1140

2a

W1006

9a

W1011

9a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1038

18 a

W1472

18 a

W1063

9a

W3000

18 a

W3001

18 a

Daily

W1245

Limit

1,000

Operating hours [h]


500

Task

TIM-ID: 0000058790 - 002

Engine

X
X

X
X

X
X

X
X

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 25

W3002

18 a

W3003

18 a

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

14,500

14,000

13,500

13,000

12,500

12,000

11,500

11,000

10,500

10,000

9,500

9,000

8,500

8,000

7,500

7,000

6,500

6,000

5,500

5,000

4,500

4,000

3,500

3,000

2,500

2,000

1,500

1,000

500

Daily

Operating hours [h]


Limit

Task

w = weeks
m = months
a = years

15,000-24,000 Operating hours


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

W1245

1a

W1246

1a

W1244

2a

W1008

2a

W0500

W0501

W0502

W0503

W0505

W0506

W0507

W0508

W1009

2a

W1001

2a

W1675

2a

W1207

2a

W1003

2a

W1005

3a

W1036

2a

W1055

2a

W1140

2a

Limit

15,500

Operating hours [h]


15,000

Task

X
X

X
X

w = weeks
m = months
a = years

26 | Maintenance Schedule | MS50194/01E 2015-06

X
X

TIM-ID: 0000058790 - 002

Engine

TIM-ID: 0000058790 - 002

24,000

23,500

23,000

22,500

22,000

21,500

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

Operating hours [h]


Limit

Task

W1006

9a

W1011

9a

W2000

9a

W2002

9a

W2003

9a

W2006

9a

W2009

9a

W2017

9a

W2018

9a

W2036

9a

W2059

9a

W2062

9a

W2074

9a

W2110

9a

W2111

9a

W2112

9a

W1038

18 a

W1472

18 a

W1063

9a

W3000

18 a

W3001

18 a

W3002

18 a

W3003

18 a

W3004

18 a

W3005

18 a

W3006

18 a

W3007

18 a

W3011

18 a

W3012

18 a

W3013

18 a

W3041

18 a

W3042

18 a

W3043

18 a

W3056

18 a

W3057

18 a

W3108

18 a

W1331

18 a

W1205

18 a

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 27

Qualification
level

Interval

Limit

Item

Maintenance tasks

Option

1.10 Maintenance tasks 12,000h


Task

Check alarm function of differential pressure gauge.

W1245

[h]

Engine
QL1

1a

Fuel servicing plant

Check pump capacity.

W1246

QL1

2a

Fuel servicing plant

Check function of bar electrode.

W1244

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).

W1008

QL1

Daily

Engine operation

Check engine oil level.

W0500

Carry out visual inspection of engine for general condition and leaks.

W0501
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.

W0507

Check differential pressure gauge of fuel prefilter.

W0508

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.

W1009

QL1

500

2a

Fuel filter

Fit new fuel filter or new fuel filter insert.

QL1

500

2a

Fuel prefilter

Fit new fuel prefilter or new fuel prefilter insert.

W1675

QL1

2000

2a

Valve gear

Check valve clearance, adjust if required. ATTENTION! Initial adjustment after 1,000 operating hours and subsequently 1,000 operating
hours after each cylinder-head overhaul..

QL1

2000

2a

Belt drive

Check belt condition and tension Fit new belt(s) if necessary.

QL1

3000

3a

Air filters

Fit new air filters.

W1005

QL1

4000

2a

Coolant filters

Fit new coolant filters.

W1036

QL1

6000

2a

Crankcase breathers

Fit new oil separators.

W1055

Clean wire meshes of crankcase breathers.

W1140

W1001
W1207

W1003

QL1

6000

9a

Fuel injectors

Replace fuel injectors.

W1006

QL1

6000

9a

Combustion chambers

Inspect cylinder chambers using endoscope.

W1011

QL3

6000

9a

Component maintenance

Before starting maintenance work, drain the coolant and flush the
cooling systems.

W2000

Clean air ducting.

W2002

Clean intercooler and inspect for leakage.

W2003

Check engine coolant thermostat and fit new thermal actuator.

QL3
QL3

6000
12000

18 a
9a

Turbochargers
Cylinder heads

W2006

Inspect centrifugal oil filter for wear.

W2009

Clean engine coolant cooler and inspect it for leaks.

W2017

Clean engine oil cooler and inspect it for leaks.

W2018

Check engine alignment.

W2036

Clean fuel cooler.

W2059

Fit new seals/sealing materials for all disassembled components.

W2062

Inspect rocker arms, valve bridges, pushrods and ball joints for wear.

W2074

Overhaul engine coolant pump.

W2110

Overhaul raw-water pump.

W2111

Overhaul bilge pump.

W2112

Overhaul turbochargers.

W1038

Fit new compressor wheels for turbochargers.

W1472

Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces.

W1063

w = weeks
m = months
a = years

28 | Maintenance Schedule | MS50194/01E 2015-06

TIM-ID: 0000058791 - 002

Inspect intercooler drain system.

Interval
[h]

QL4

12000

Limit

Item

Maintenance tasks

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

Option

Qualification
level

Fit new cylinder liners.


Fit new antifriction bearings for auxiliary PTOs.

Task

W3005
X

W3006

Fit new high-pressure fuel pump.

W3007

Fit new actuating cylinders for air flow control flaps.

W3011

Fit new actuator cylinders for exhaust flaps.

W3012

Fit new exhaust flap bearings.

W3013

Overhaul starter.

W3041

Overhaul battery-charging generator.

W3042

Fit new fuel pressure relief valve.

W3043

Fit new wire meshes for crankcase ventilation system.

W3056

Fit new high-pressure fuel sensor.

W3057

Check vibration damper, fit new one if necessary.

W3108

QL4

12000

18 a

Exhaust pipe bellows

Replace exhaust pipe bellows.

W1331

QL4

24000

18 a

Engine oil pump

Fit new engine oil pump.

W1205

TIM-ID: 0000058791 - 002

w = weeks
m = months
a = years

MS50194/01E 2015-06 | Maintenance Schedule | 29