Group D

Maintenance Schedule Subgroup 000

Page 01

Diesel Engines
V 4000 M 90
Maintenance Schedule
M050519/05E
MTU Motoren- und Turbinen-Union Friedrichshafen GmbH
88040 Friedrichshafen / Germany
Telephone (07541) 90-0
Telex 734 280-0 mt d
Telefax (07541) 90-3928

Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and
servicing being carried out in compliance with our specifications and instructions.
The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure trouble-
free engine operation at all times. For this purpose always:
- ensure that sufficient fuel is available,
- ensure that the combustion air is dry and clean,
- use only dry, clean compressed air,
- use only clean, filtered raw water.
Moreover, it is essential that:
- maintenance tasks be completed by trained personnel,
- suitable tools be used,
- genuine spare parts and fluids and lubricants as per the current MTU Fluids and Lubricants specifications must
be used.
Our Product Support Service will always be available should assistance be required.
Preventive maintenance instructions.
- Special care should be taken to keep the machinery plant in a clean and serviceable condition at all times to
facilitate early detection of possible leaks and prevent subsequent damage.
- Protect rubber and synthetic components from oil and fuel, never treat with organic detergents. Wipe with a dry
cloth only.
- Follow the manufacturer's maintenance instructions for components belonging to the power plant but not listed
in this Maintenance Schedule.
- Always replace all seals and gaskets.
MTU Maintenance Concept
The maintenance concept is a preventive maintenance concept and features the maintenance echelons W1 to
W6 as outlined below.
Preventive maintenance facilitates advance planning and ensures a high degree of equipment availability.
Main features of the maintenance echelons:
- W1: Operational checks
- W2, W3 and W4: Periodic maintenance tasks to be performed during out-of-service periods without the
need for engine disassembly.
- W5: This echelon requires partial engine disassembly.
- W6: Major overhaul. This echelon requires complete engine disassembly.
The time intervals according to which the W2 to W6 Maintenance Echelons and the relevant checks and tasks
involved are to be completed are based on operational experience. They have been determined so as to ensure
correct engine operation until the next scheduled maintenance echelon.
Oil change intervals to be determined according to the lube-oil analysis results. The oil filter is also to be changed.
Specific operational conditions may require modification of the Maintenance Schedule.
Note:
The codes on the following pages refer to the Section Nos. in Section G of the Operating Instructions.
This Maintenance Schedule may refer to parts which are not installed on your engine, these may be disregarded.

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Application Group
1DS: Fast vessels with low load factors
Maintenance Frequency Chart
Maintenance Echelon W1: Operational checks, daily X
W2: Operating hours 250
Limit, months 6
W3: Operating hours 750
Limit, year 1
W4: Operating hours 2 250
Limit, year(s) 2
W5: Operating hours 4 500
Limit, year(s) 6
W6: Operating hours 9 000
Limit, year(s) 18
Maintenance Task Schedule
Code No. One-time operations after the first 50 operating hours.
- With a new engine, after W5 maintenance echelon, or after W6 major overhaul
G055.050.01 Valve gear Check valve clearances
G073.051.07 HP fuel delivery pump Check relief bore for obstructions
G083.051.03 Fuel duplex filter Replace filter element
G083.101.09 Fuel pre-filter Replace filter element
G140.000.03 Exhaust system Check tightness of securing screws and nuts
G180.000.04 Engine oil Take sample and analyse
G202.051.01 Engine coolant pump Check relief bore for obstructions
G207.051.01 Raw water pump Check relief bore for obstructions
G368.051.01 Bilge pump Check relief bore for obstructions

Code No. Maintenance Echelon W1

- Operational Monitoring
G000.000.13 Engine operation Check speed
G000.000.15 Engine operation Check pressures (if gauges are provided)
G000.000.17 Engine operation Check temperatures (if gauges are provided)
G000.000.19 Engine operation Check running noises
G000.000.21 Engine operation Check engine and external pipework for leaks,
G083.101.03 Fuel pre-filter Drain water and contaminants
G083.101.17 Fuel pre-filter Check differential pressure
G111.051.01 Intercooler Check drain line for water discharge and obstructions
G121.052.01 Air filter Check contamination indicator
G140.000.05 Exhaust system Check exhaust gas colour
G140.000.11 Exhaust system Check (check drain line for obstructions, if provided)
G180.000.01 Engine oil Check level
G202.000.03 Engine coolant Check level
G510.070.01 Monitoring system Carry out lamp test

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Code No. Maintenance Echelons W 2 3 4 5

G083.101.05 Fuel pre-filter Flush out
G120.000.03 Intake air line Check air ducting for leaks and damage
G123.051.01 Air-flow control flap(s) Check air-flap ease-of-movement
G144.051.01 TC control Check exhaust-flap ease-of-movement
G180.000.04 Engine oil Take sample and analyse
G180.000.05 Engine oil Change
- with oil category 1, with centrifugal oil filter
every 2nd W2 maintenance echelon = 500 operating hours
- with oil category 2, with centrifugal oil filter
every 4th W2 maintenance echelon = 1 000 operating hours
G183.052.03 Engine oil filter Replace
- accomplish when changing the oil
G183.101.01 Centrifugal oil filters Clean, check thickness of oil sludge layer
Replace paper sleeve
G530.000.01 LOP Carry out test procedures
G055.050.01 Valve gear Check valve clearances
G083.051.03 Fuel duplex filter Replace filter element
G083.101.09 Fuel pre-filter Replace filter element
G202.000.05 Engine coolant Take sample and analyze, change if necessary
(see MTU Fluids and Lubricants Specification A001061)
G202.051.01 Engine coolant pump Check relief bore for obstructions
G207.051.01 Raw water pump Check relief bore for obstructions
G252.051.01 Torsionally resilient coupling Check condition (visual inspection)
G309.001.05 Battery Check charge state, electrolyte level and specific gravity
G368.051.01 Bilge pump Check relief bore for obstructions
G018.101.02 Crankcase ventilation Replace filter inserts (only 8V)
Check and clean filter inserts (only 12V and 16V)
G073.051.07 HP fuel delivery pump Check relief bore for obstructions
G075.051.05 Fuel injector(s) Replace
G121.051.01 Air filter Replace filter elements
G172.051.09 Starter Check condition (visual inspection)
G213.051.01 Charging generator Check condition of coupling
G231.051.01 Engine mounts Check tightness of securing screws and nuts
G231.051.03 Engine mounts Check condition of resilient mounts
G231.051.11 Engine mounts Check buffer clearances
G500.000.09 Engine wiring: Check
G500.000.10 LOP Check (visual inspection)
G500.000.11 LOP Clean LOP and connectors
G508.000.01 ECU Check (visual inspection)
G508.000.02 ECU Clean
G510.000.01 Monitoring system Check function of monitoring units
Prior to commencing W5 maintenance, drain engine coolant and flush cooling system!
Valve gear Remove and check rocker arms (pushrod driven) and valve bridges
Check rocker arms (camshaft driven), and rocker bearings for wear
Cylinder heads Remove,
Check inlet valve guides, replace exhaust valve guides
Recondition valves and valve seats
Replace O-rings on the protective sleeves
Replace gaskets
Crankcase Check cylinder liner wear pattern
Vibration damper Remove, inspect, recondition if necessary
Turbocharger Remove, disassemble, clean, check components, measure bearing clearances and
compressor wheels
Air ducting Remove, clean and replace seals
Intercooler Remove, clean, leak test, replace seals
Sequential control valve Check function
HP fuel delivery pump Replace
HP fuel delivery-pump sensor Replace
Engine coolant pump Disassemble, check parts, replace bearing and seals
Raw water pump Disassemble, check parts, replace bearing and seals
Bilge pump Disassemble, check parts, replace bearing and seals
Engine coolant cooler Clean and leak test
Engine coolant thermostat Check, replace if necessary

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Engine coolant preheating Overhaul
Engine oil heat exchanger Remove, clean, leak test and replace seals
Centrifugal oil filters Check, replace bearings if necessary

Maintenance Echelon W6
Requires complete engine disassembly to facilitate repair/overhaul of all relevant components.
The decisive factor is the component condition or the actual dimensions, referenced to the Tolerances and Wear
Limits List.
Out-of-Service Periods
Carry out tasks specified in the Engine Operating Manual

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