Maintenance Schedule

Gas engine-generator set

MTU 8V4000 GS - 8V4000L64 / 8V4000L64FNER
MTU 12V4000 GS - 12V4000L64 / 12V4000L64FNER
MTU 16V4000 GS - 16V4000L64 / 16V4000L64FNER
MTU 20V4000 GS - 20V4000L64 / 20V4000L64FNER
Natural gas interval: 3,000 hrs - 63,000 hrs
Application group 3A

MS50202/05E
System designation Engine model Application group
Product name Model number
MTU 8V4000 GS GG08V4000A1 8V4000L64 3A, continuous operation, un-
restricted
MTU 8V4000 GS GG08V4000A1/A2 8V4000L64FNER 3A, continuous operation, un-
restricted
MTU 12V4000 GS GG12V4000A1 12V4000L64 3A, continuous operation, un-
restricted
MTU 12V4000 GS GG12V4000A1/A2 12V4000L64FNER 3A, continuous operation, un-
restricted
MTU 16V4000 GS GG16V4000A1 16V4000L64 3A, continuous operation, un-
restricted
MTU 16V4000 GS GG16V4000A1/A2 16V4000L64FNER 3A, continuous operation, un-
restricted
MTU 20V4000 GS GG20V4000A1 20V4000L64 3A, continuous operation, un-
restricted
MTU 20V4000 GS GG20V4000A1/A2 20V4000L64FNER 3A, continuous operation, un-
restricted

Table 1: Applicability

© 2019 MTU Onsite Energy GmbH, Augsburg

The original document was created in the German language.
This publication including all of its parts is protected by copyright. Each instance of use requires the prior written consent of
MTU Onsite Energy GmbH. This applies in particular to duplication, dissemination, editing, translation, microfilming, and stor-
age and/or processing in electronic systems, including databases and online services.
All of the information presented in this publication was current and up-to-date at the time of publishing. MTU Onsite Energy
GmbH reserves the right to make changes to, delete, or supplement the provided information and data as needed.
 Table of Contents
1 Maintenance Schedule 1.3 Checks by the operator 6
1.4 Acyclic maintenance tasks 9
1.1 Preface 4 1.5 Maintenance schedule matrix 63000 HRS 10
1.2 Additional notes on the maintenance of gas 1.6 Cyclic maintenance tasks 63000 HRS 19
systems 5
DCL-ID: 0000034255 - 006

MS50202/05E 2019-04 | 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, time limits and if required as number of starts. 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: 0000085714 - 001

4 | Maintenance Schedule | MS50202/05E 2019-04

 1.2 Additional notes on the maintenance of gas systems
General information
The maintenance schedule matrix normally finishes with extended component maintenance or with engine
overhaul. Following this, maintenance work is to be continued at the intervals indicated.
The numbers stated in the task list serve as a reference for the scope of parts required.
Repairs tasks on the gas system, for which the gas-conducting area is opened, and leak or
stress tests must only be carried out by specialized companies. As a rule these are companies
that are approved for the gas industry with qualified personnel who have been trained for tech-
nical gas applications.

The fluids and lubricants specifications, the guidelines for maintenance and fluid and lubricant
change as well as a list of recommended fluids and lubricants are contained in the Fluids and
Lubricants Specifications of MTU Onsite Energy as well as in the fluids and lubricants specifica-
tions of the component manufacturers. They are therefore not included in the maintenance
schedule (exception: deviations from the Fluids and Lubricants Specifications). Use only fluids
and lubricants which comply with the Fluids and Lubricants Specifications of MTU Onsite Ener-
gy or which are approved by the relevant component manufacturer.
Among 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 deter-
gents. Wipe with a dry cloth only.
• Gas filter:
The maintenance interval depends on gaseous fuel quality (purity). Fuel filters upstream of the engine
must be regularly cleaned and renewed if necessary.
• Battery:
Battery maintenance depends on duty and ambient conditions. The specifications of the battery manufac-
turer apply.
Items listed in this maintenance schedule but which are not included in the scope of delivery of MTU On-
site Energy may be disregarded.

Generator maintenance
Refer to the Operating Instructions provided by the manufacturer for the intervals for these maintenance
tasks.

Generator circuit breaker maintenance

Refer to the Operating Instructions provided by the manufacturer for the intervals for these maintenance
tasks.

Maintenance of non-MTU components

Refer to the Operating Instructions provided by the relevant manufacturer for the intervals for these mainte-
TIM-ID: 0000085431 - 001

nance tasks.

Maintenance tasks
The respective maintenance tasks to be carried out are based on operating hours (see the following pages).

Number of starts
In general, each engine start is to be counted for the number of engine starts.

MS50202/05E 2019-04 | Maintenance Schedule | 5

 1.3 Checks by the operator
Always observe the safety instructions.

Non-observance of these instructions may lead to damage to the system!

When using the unit supplied in a foreign country or in special regions, MTU Onsite Energy is
not responsible for the adherence to the legal or other regulations / standards at the place of
use.

Recommended daily checks – System

• Check exhaust gas piping for condensate leaks (visual inspection)
• Check condensate collecting tank downstream of condensate drain (if fitted)
• Carry out visual inspection of engine and plant for leaks / damage (bellows, hoses etc.)
• Check gas supply / gas system for damage (visual inspection)
Only for 60 Hz transmission units
• Oil temperature
• Storage temperature
• Oil pressure
• Oil contamination indicator
• Leaks
• Oil level
• Noise, vibrations

Recommended daily checks – Control system

The following measured values and functions are monitored by the control system to protect the plant. These
messages can also be called up via remote access (option) and can be monitored by the customer in the
display.
• Electric power
• Lube oil level
• Lube oil pressure
• Coolant temperature
• Coolant pressure
• Oxygen sensor voltage (option)
• Battery voltage
• Smooth running of engine
• Exhaust gas temperature
• Heating water supply and return temperature (option)
• Oil bleed system function (option)

Recommended weekly checks

TIM-ID: 0000052185 - 001

• Lube oil consumption or content of fresh oil tank

• Engine room temperature
• Check of operating hours
• Check of number of starts
• Check of speed control for stability of regulator and the linkage (if installed)
• General visual inspection of module / engine-generator set
Only for 60 Hz transmission units

6 | Maintenance Schedule | MS50202/05E 2019-04

 • Transmission mounting
• Outer condition of transmission (contamination, oil deposits)
• Visual condition of the transmission oil

Additional checks
The operator's gas installation (upstream of twin solenoid valve) must be inspected for leaks at the following
intervals:
• Every year for engines with turbocharger
• Every six months for aspirated engines
The following checks are to be carried out at appropriate intervals, depending on the degree of contamina-
tion:
• Check room air fan and fresh air filter for contamination
• Check filter or air-conditioning unit for control cabinet for contamination
• Check recooler for contamination

Electrical systems
Electrical systems and operating equipment must be checked prior to initial commissioning, after repairs,
prior to re-commissioning and at regular intervals. The intervals are to be so arranged that defects, which are
to be expected, are detected at an early stage.
Here, among others, the following requirements apply:
• Accident prevention regulations BGV A3 "Electrical Systems and Operating Equipment"
• Technical rules for operational safety TRBS 2131 "Electrical Hazards"
• Industrial Safety Directive (BetrSichV)
• DIN VDE 0701/0702 Repairs, modifications and testing of electrical equipment/repeat tests on electrical
units
• DIN EN 60204-1 Safety of machinery - Electrical equipment of machines
The operating company has the responsibility to see that these tests are carried out correctly. Electrical sys-
tems and fixed electrical operating equipment must be tested at appropriate intervals by a qualified electri-
cian for their correct condition. The test is to include the following:
• Visual inspection and testing of protective equipment
• Testing of protective conductor resistance, insulation resistance, leakage current replacement, protective
conductor current and differential current
• Carrying out fault diagnoses
• Preparation of test reports and inspection stickers
The industrial safety regulations, the technical rules for operational safety and the BGV A3 are fundamental
with regard to adherence to the protective measures for "Electric Plants and Operating Equipment". The op-
erating company is accordingly obligated to care for the safety of electrical systems and operating equip-
ment.

Designation
DIN Deutsches Institut für Normung (Federal German Standards Institute)
EN Europäische Normung (European Standards)
TIM-ID: 0000052185 - 001

ISO International Standards Organization

VDE Verband der Elektrotechnik, Elektronik und Informationstechnik (Association for
electrical engineering, electronics and information technology)
BGV Berufsgenossenschaftliche Vorschriften (Trade association regulations)
TRBS Technische Regeln für Betriebssicherheit (Technical rules for operational safety)

Table 2: Designations for standards and regulations

MS50202/05E 2019-04 | Maintenance Schedule | 7

 These regulations are contained in the manufacturers' instructions, legal requirements and
technical guidelines valid in the individual countries. Since there can be major differences from
country to country, it is not possible to provide a universally applicable statement on the rules
to be observed within the framework of this maintenance schedule.
The user of the product mentioned herein is obligated to inform him-/herself about the provi-
sions applicable in his/her country. MTU Onsite Energy does not accept any liability whatsoev-
er for improper or unlawful use of the electric plant it has approved.

TIM-ID: 0000052185 - 001

8 | Maintenance Schedule | MS50202/05E 2019-04

 1.4 Acyclic maintenance tasks

Option
No. Qual- Task Maintenance tasks Reference Off- Value Unit
ifica- task set
tion
0010 QL1 WM00490 Oil change. Important! Initial 0 500 HRS
change after 500 operating hours
0020 QL1 WM00825 Clean oil filter, replace if necessa- 0 500 HRS
ry. Initial cleaning after 500 oper-
ating hours
0030 QL1 WM00094 Check valve clearance and adjust 0 1000 HRS
as necessary. IMPORTANT! Initial
setting after 1,000 operating hours
and every overhaul of cylinder
heads after 1,000 operating hours
Reference task: Name of maintenance task to which the offset relates.
Offset: Interval of a maintenance activity depending on another interval.
Value: Fixed value for performance of the maintenance activity.
TIM-ID: 0000085715 - 001

MS50202/05E 2019-04 | Maintenance Schedule | 9

 1.5 Maintenance schedule matrix 63000 HRS
0 to 20000 operating hours
Task Operating hours [HRS]

10000
10500
11000
12000
13000
13500
14000
15000
15750
16000
16500
17000
18000
19000
19500
20000
Limit

Daily

1000
1500
2000
3000
4000
4500
5000
6000
7000
7500
8000
9000
500

Engine-generator plant operational monitoring

WM00338 1 MON
WM00465 - X X X X X X
WM00472 - X X X X X X
WM00480 - X X X X X X
WM00486 - X X X X X X
WM00488 - X X X X X X
WM00489 - X X X X X X
WM00492 - X X X X X X
WM00457 1 YR X X X X X X
WM00496 1 YR X X X X X X
WM00461 1 YR
WM00930 8 YR
Engine
WM00050 1 YR
WM00136 1 YR
WM00286 - X
WM00426 - X
WM00427 - X
WM00931 18 YR X X X X X X X X X X X X X X X X X X X X
WM00779 18 YR X X X X X X X X X X
WM00511 1 YR X X X X X X
WM00067 2 YR X X X X X X
WM00509 2 YR X X X X X X
WM00510 3 YR X X X X X X
WM00822 3 YR X X X X X X
WM00150 6 YR X X X X X X
WM00094 18 YR X X X X X X X
WM00434 18 YR X X X X X X
WM00780 18 YR X X X X X X
WM00433 3 YR X X X
WM00098 18 YR X X
WM00573 3 YR X
WM00442 18 YR X
WM00447 4 YR
TIM-ID: 0000085716 - 001

WM00508 4 YR
WM00431 2000
NOS
WM00431 18 YR
WM00823 10000
NOS
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

10 | Maintenance Schedule | MS50202/05E 2019-04

 Task Operating hours [HRS]

10000
10500
11000
12000
13000
13500
14000
15000
15750
16000
16500
17000
18000
19000
19500
20000
Limit

Daily

1000
1500
2000
3000
4000
4500
5000
6000
7000
7500
8000
9000
500
WM00823 18 YR
WM00783 4 YR
WM00005 18 YR
WM00082 18 YR
WM00093 18 YR
WM00099 18 YR
WM00108 18 YR
WM00430 18 YR
WM00443 18 YR
WM00444 18 YR
WM00782 18 YR
WM00842 18 YR
WM00922 18 YR
WM00126 5 YR
WM00008 6 YR
WM00096 18 YR
WM00439 18 YR
WM00007 6 YR
WM00097 18 YR
WM00505 18 YR
WM00001 18 YR
WM00002 18 YR
WM00070 18 YR
WM00092 18 YR
WM00095 18 YR
WM00103 18 YR
WM00104 18 YR
WM00111 18 YR
WM00127 18 YR
WM00137 18 YR
Lube oil tank
WM00428 1 WK
Generator
WM00483 6 MON X X X X X X X X X X X X X
WM00468 - X X X X X X
WM00469 - X X X X X X
WM00467 1 YR X X X X X X
WM00484 1 YR X X X X X X
WM00458 1 YR X X
TIM-ID: 0000085716 - 001

WM00466 18 YR
WM00504 18 YR
Coupling
WM00482 1 YR X X X
WM00481 4 YR
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

MS50202/05E 2019-04 | Maintenance Schedule | 11

Task Operating hours [HRS]

10000
10500
11000
12000
13000
13500
14000
15000
15750
16000
16500
17000
18000
19000
19500
20000
Limit

Daily

1000
1500
2000
3000
4000
4500
5000
6000
7000
7500
8000
9000
500
Gearbox
WM00471 1 YR X X X X X X
WM00473 1 YR X X X X X X
WM00500 1 YR X X X X X X
WM00490 2 YR X X X X
WM00818 2 YR X X X
WM00819 2 YR X X X
WM00825 2 YR X X X X
WM00512 3 YR X
WM00487 1 YR X X X
WM00498 1 YR X X X
WM00820 -
WM00821 -
Exhaust system
WM00919 14000
NOS
WM00453 1 YR X X X X X X
WM00454 1 YR X X X X X X
WM00476 1 YR X X X X X X
WM00813 2 YR X X X X X X
WM00456 2 YR X
WM00501 18 YR
WM00475 2 YR X
Cooling system
WM00485 1 YR X X X
WM00495 1 YR X X X
WM00817 1 YR X X X
WM00494 1 YR
WM00497 18 YR
Control cabinet
WM00491 30 MON
WM00506 10 YR
WM00462 1 YR X X X X X X
WM00463 1 YR X X X X X X
WM00470 1 YR X X X X X X
WM00477 1 YR X X X X X X
WM00478 1 YR X X X X X X
Gas supply
WM00814 2 YR X X X X X X
WM00499 1 YR X X X
TIM-ID: 0000085716 - 001

WM00816 3 YR X X
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

12 | Maintenance Schedule | MS50202/05E 2019-04

 21000 to 43000 operating hours
Task Operating hours [HRS]

21000
22000
22500
23000
24000
25000
25500
26000
27000
28000
28500
29000
30000
31000
31500
32000
33000
34000
34500
35000
36000
37000
37500
38000
39000
40000
40500
41000
42000
43000
Limit

Engine-generator plant operational monitoring

WM00338 1 MON
WM00465 - X X X X X X X X
WM00472 - X X X X X X X X
WM00480 - X X X X X X X X
WM00486 - X X X X X X X X
WM00488 - X X X X X X X X
WM00489 - X X X X X X X X
WM00492 - X X X X X X X X
WM00457 1 YR X X X X X X X X
WM00496 1 YR X X X X X X X X
WM00461 1 YR
WM00930 8 YR
Engine
WM00050 1 YR
WM00136 1 YR
WM00286 -
WM00426 -
WM00427 -
WM00931 18 YR X X X X X X X X X X X X X X X X X X X X X X X
WM00779 18 YR X X X X X X X X X X X
WM00511 1 YR X X X X X X X X
WM00067 2 YR X X X X X X X X
WM00509 2 YR X X X X X X X X
WM00510 3 YR X X X X X X X X
WM00822 3 YR X X X X X X X X
WM00150 6 YR X X X X X X X X
WM00094 18 YR X X X X X X X X
WM00434 18 YR X X X X X X X X
WM00780 18 YR X X X X X X X X
WM00433 3 YR X X X X
WM00098 18 YR X X
WM00573 3 YR X X X
WM00442 18 YR X X X
WM00447 4 YR X X
WM00508 4 YR X X
WM00431 2000
NOS
TIM-ID: 0000085716 - 001

WM00431 18 YR
WM00823 10000
NOS
WM00823 18 YR X X
WM00783 4 YR X X
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

MS50202/05E 2019-04 | Maintenance Schedule | 13

Task Operating hours [HRS]

21000
22000
22500
23000
24000
25000
25500
26000
27000
28000
28500
29000
30000
31000
31500
32000
33000
34000
34500
35000
36000
37000
37500
38000
39000
40000
40500
41000
42000
43000
Limit

WM00005 18 YR X X
WM00082 18 YR X X
WM00093 18 YR X X
WM00099 18 YR X X
WM00108 18 YR X X
WM00430 18 YR X X
WM00443 18 YR X X
WM00444 18 YR X X
WM00782 18 YR X X
WM00842 18 YR X X
WM00922 18 YR X X
WM00126 5 YR X
WM00008 6 YR X
WM00096 18 YR X
WM00439 18 YR X
WM00007 6 YR
WM00097 18 YR
WM00505 18 YR
WM00001 18 YR
WM00002 18 YR
WM00070 18 YR
WM00092 18 YR
WM00095 18 YR
WM00103 18 YR
WM00104 18 YR
WM00111 18 YR
WM00127 18 YR
WM00137 18 YR
Lube oil tank
WM00428 1 WK
Generator
WM00483 6 MON X X X X X X X X X X X X X X X
WM00468 - X X X X X X X X
WM00469 - X X X X X X X X
WM00467 1 YR X X X X X X X X
WM00484 1 YR X X X X X X X X
WM00458 1 YR X X
WM00466 18 YR X
WM00504 18 YR
TIM-ID: 0000085716 - 001

Coupling
WM00482 1 YR X X X X
WM00481 4 YR X X
Gearbox
WM00471 1 YR X X X X X X X X
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

14 | Maintenance Schedule | MS50202/05E 2019-04

 Task Operating hours [HRS]

21000
22000
22500
23000
24000
25000
25500
26000
27000
28000
28500
29000
30000
31000
31500
32000
33000
34000
34500
35000
36000
37000
37500
38000
39000
40000
40500
41000
42000
43000
Limit

WM00473 1 YR X X X X X X X X
WM00500 1 YR X X X X X X X X
WM00490 2 YR X X X X
WM00818 2 YR X X X X
WM00819 2 YR X X X X
WM00825 2 YR X X X X
WM00512 3 YR X
WM00487 1 YR X X X X
WM00498 1 YR X X X X
WM00820 - X
WM00821 -
Exhaust system
WM00919 14000
NOS
WM00453 1 YR X X X X X X X X
WM00454 1 YR X X X X X X X X
WM00476 1 YR X X X X X X X X
WM00813 2 YR X X X X X X X X
WM00456 2 YR X X X
WM00501 18 YR
WM00475 2 YR X
Cooling system
WM00485 1 YR X X X X
WM00495 1 YR X X X X
WM00817 1 YR X X X X
WM00494 1 YR
WM00497 18 YR X X
Control cabinet
WM00491 30 MON
WM00506 10 YR
WM00462 1 YR X X X X X X X X
WM00463 1 YR X X X X X X X X
WM00470 1 YR X X X X X X X X
WM00477 1 YR X X X X X X X X
WM00478 1 YR X X X X X X X X
Gas supply
WM00814 2 YR X X X X X X X X
WM00499 1 YR X X X X
WM00816 3 YR X X
NOS = Number of starts
TIM-ID: 0000085716 - 001

YR = Years
MON = Months
HRS = Hours
WK = Weeks

MS50202/05E 2019-04 | Maintenance Schedule | 15

 43500 to 63000 operating hours
Task Operating hours [HRS]
43500
44000
45000
46000
46500
47000
47250
48000
49000
49500
50000
51000
52000
52500
53000
54000
55000
55500
56000
57000
58000
58500
59000
60000
61000
61500
62000
63000
Limit

Engine-generator plant operational monitoring

WM00338 1 MON
WM00465 - X X X X X X X
WM00472 - X X X X X X X
WM00480 - X X X X X X X
WM00486 - X X X X X X X
WM00488 - X X X X X X X
WM00489 - X X X X X X X
WM00492 - X X X X X X X
WM00457 1 YR X X X X X X X
WM00496 1 YR X X X X X X X
WM00461 1 YR
WM00930 8 YR
Engine
WM00050 1 YR
WM00136 1 YR
WM00286 -
WM00426 -
WM00427 -
WM00931 18 YR X X X X X X X X X X X X X X X X X X X X
WM00779 18 YR X X X X X X X X X X
WM00511 1 YR X X X X X X X
WM00067 2 YR X X X X X X X
WM00509 2 YR X X X X X X X
WM00510 3 YR X X X X X X X
WM00822 3 YR X X X X X X X
WM00150 6 YR X X X X X X X
WM00094 18 YR X X X X X X X
WM00434 18 YR X X X X X X X
WM00780 18 YR X X X X X X X
WM00433 3 YR X X X
WM00098 18 YR X X X
WM00573 3 YR X X
WM00442 18 YR X X
WM00447 4 YR X
WM00508 4 YR X
WM00431 2000 X
NOS
TIM-ID: 0000085716 - 001

WM00431 18 YR X
WM00823 10000
NOS
WM00823 18 YR X
WM00783 4 YR X
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

16 | Maintenance Schedule | MS50202/05E 2019-04

 Task Operating hours [HRS]

43500
44000
45000
46000
46500
47000
47250
48000
49000
49500
50000
51000
52000
52500
53000
54000
55000
55500
56000
57000
58000
58500
59000
60000
61000
61500
62000
63000
Limit

WM00005 18 YR X
WM00082 18 YR X
WM00093 18 YR X
WM00099 18 YR X
WM00108 18 YR X
WM00430 18 YR X
WM00443 18 YR X
WM00444 18 YR X
WM00782 18 YR X
WM00842 18 YR X
WM00922 18 YR X
WM00126 5 YR X
WM00008 6 YR X
WM00096 18 YR X
WM00439 18 YR X
WM00007 6 YR X
WM00097 18 YR X
WM00505 18 YR X
WM00001 18 YR X
WM00002 18 YR X
WM00070 18 YR X
WM00092 18 YR X
WM00095 18 YR X
WM00103 18 YR X
WM00104 18 YR X
WM00111 18 YR X
WM00127 18 YR X
WM00137 18 YR X
Lube oil tank
WM00428 1 WK
Generator
WM00483 6 MON X X X X X X X X X X X X X X
WM00468 - X X X X X X X
WM00469 - X X X X X X X
WM00467 1 YR X X X X X X X
WM00484 1 YR X X X X X X X
WM00458 1 YR X X X
WM00466 18 YR X
WM00504 18 YR X
TIM-ID: 0000085716 - 001

Coupling
WM00482 1 YR X X X
WM00481 4 YR X
Gearbox
WM00471 1 YR X X X X X X X
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

MS50202/05E 2019-04 | Maintenance Schedule | 17

Task Operating hours [HRS]

43500
44000
45000
46000
46500
47000
47250
48000
49000
49500
50000
51000
52000
52500
53000
54000
55000
55500
56000
57000
58000
58500
59000
60000
61000
61500
62000
63000
Limit

WM00473 1 YR X X X X X X X
WM00500 1 YR X X X X X X X
WM00490 2 YR X X X
WM00818 2 YR X X X
WM00819 2 YR X X X
WM00825 2 YR X X X
WM00512 3 YR X
WM00487 1 YR X X X
WM00498 1 YR X X X
WM00820 -
WM00821 - X
Exhaust system
WM00919 14000
NOS
WM00453 1 YR X X X X X X X
WM00454 1 YR X X X X X X X
WM00476 1 YR X X X X X X X
WM00813 2 YR X X X X X X X
WM00456 2 YR X X
WM00501 18 YR X
WM00475 2 YR X X
Cooling system
WM00485 1 YR X X X
WM00495 1 YR X X X
WM00817 1 YR X X X
WM00494 1 YR
WM00497 18 YR X
Control cabinet
WM00491 30 MON
WM00506 10 YR
WM00462 1 YR X X X X X X X
WM00463 1 YR X X X X X X X
WM00470 1 YR X X X X X X X
WM00477 1 YR X X X X X X X
WM00478 1 YR X X X X X X X
Gas supply
WM00814 2 YR X X X X X X X
WM00499 1 YR X X X
WM00816 3 YR X X X
NOS = Number of starts
TIM-ID: 0000085716 - 001

YR = Years
MON = Months
HRS = Hours
WK = Weeks

18 | Maintenance Schedule | MS50202/05E 2019-04

 1.6 Cyclic maintenance tasks 63000 HRS
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [HRS]
Engine-generator plant operational monitoring
QL1 - 1 MON Engine-generator set opera- Carry out test run, minimum duration: until steady-state temperature WM00338
tional monitoring is reached, no less than 1/3 load
QL1 3000 - Operating data Check mixture temperature WM00465
QL1 3000 - Operating data Check heating water supply and return temperature WM00472
QL1 3000 - Operating data Check stability of coolant temperature in high-temperature and low- WM00480
temperature circuit
QL1 3000 - Operating data Check mains voltage WM00486
QL1 3000 - Operating data Check oil pressure and oil level WM00488
QL1 3000 - Operating data Check oil temperature WM00489
QL1 3000 - Operating data Check cooling water supply and return temperature WM00492
QL1 3000 1 YR VALVE GEAR Check shutdown criteria in peripheral equipment WM00457
QL1 3000 1 YR EXTERNAL ELECTRIC POWER Check starter and backup batteries WM00496
SUPPLY
QL3 - 1 YR COMPONENTS SAFETY TECH- Maintenance tasks / checks to be carried out by the qualified per- WM00461
NOLOGY son
QL3 - 8 YR COMPONENTS SAFETY TECH- Replace fire and smoke detectors X WM00930
NOLOGY
Engine
QL1 - 1 YR ENGINE MOUNTING Check general condition of rubber mounts (visual inspection) WM00050
QL1 - 1 YR ENGINE MOUNTING Check securing screws for firm seating WM00136
QL1 24 - ENGINE, GENERAL Carry out visual inspection of engine for general condition and leaks WM00286
QL1 24 - ENGINE, GENERAL Check operating room for smell of gas WM00426
QL1 24 - ENGINE, GENERAL Check for abnormal running noises and vibrations WM00427
QL1 1000 18 YR AIR FILTER Replace prefilter WM00931
QL1 2000 18 YR IGNITION SYSTEM (FOR GAS Replace spark plugs during operation with 250 mg NOx and sealing X WM00779
ENGINES) in spark plug connector
QL1 3000 1 YR ENGINE, GENERAL Check emissions values, adjust if necessary. Observe local emissions WM00511
standards
QL1 3000 2 YR OIL FILTRATION/COOLING Replace oil filter at each oil change or when the time limit (years) is WM00067
reached, at the latest
QL1 3000 2 YR IGNITION SYSTEM (FOR GAS If spark plug is replaced: Clean and check spark plug connector, re- WM00509
ENGINES) place as necessary
QL1 3000 3 YR CRANKCASE BREATHER Check crankcase pressure control and adjust if necessary WM00510
QL1 3000 3 YR AIR FILTER Check air filter, replace if necessary. WM00822
QL1 3000 6 YR SENSOR TECHNOLOGY COM- Replace NOx sensor WM00150
PONENTS
QL1 3000 18 YR VALVE DRIVE Check valve clearance and adjust as necessary. IMPORTANT! Initial WM00094
setting after 1,000 operating hours and every overhaul of cylinder
heads after 1,000 operating hours
QL1 3000 18 YR ENGINE, GENERAL Check ignition timing, adjust as necessary WM00434
TIM-ID: 0000085719 - 001

QL1 3000 18 YR IGNITION SYSTEM (FOR GAS Replace spark plugs during operation with >250 mg NOx and sealing X WM00780
ENGINES) in spark plug connector
QL1 6000 3 YR GAS PIPING (FOR GAS EN- Check gas lines for leaks, seal as necessary WM00433
GINES)
QL1 9000 18 YR CYLINDER HEAD Measure valve protrusion WM00098
QL1 10500 3 YR CRANKCASE BREATHER Replace fine filter WM00573
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

MS50202/05E 2019-04 | Maintenance Schedule | 19

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [HRS]
QL1 10500 18 YR EXHAUST TURBOCHARGER, Clean exhaust turbocharger WM00442
GENERAL OR HP TURBO-
CHARGER
QL1 21000 4 YR CRANKCASE BREATHER Replace coarse filter (coalescence filter) WM00447
QL1 21000 4 YR COOLANT CIRCUIT GENERAL, Replace flexible hose in coolant line (8/12/16V only) WM00508
IF APPLICABLE HIGH-TEMPER-
ATURE CIRCUIT
QL1 63000 2000 ELECTRIC STARTER Replace starter WM00431
NOS
QL1 63000 18 YR ELECTRIC STARTER Replace starter WM00431
QL3 - 10000 EXHAUST LINES AFTER CYLIN- Replace exhaust pipe bellows and Vee-belt clamps WM00823
NOS DER HEAD
QL3 21000 18 YR EXHAUST LINES AFTER CYLIN- Replace exhaust pipe bellows and Vee-belt clamps WM00823
DER HEAD
QL3 21000 4 YR ACCESSORIES FOR ENGINE Replace humidity sensor WM00783
GOVERNOR (ELECTR.) / CON-
TROL SYSTEM
QL3 21000 18 YR ENGINE, GENERAL Replace rubber bellows WM00005
QL3 21000 18 YR EXHAUST TURBOCHARGER, Overhaul exhaust turbocharger WM00082
GENERAL OR HP TURBO-
CHARGER
QL3 21000 18 YR VALVE DRIVE Check rocker arm and valve bridge for wear. Visually inspect swing WM00093
follower with endoscope through pushrod bore
QL3 21000 18 YR CONROD Replace conrod bearings WM00099
QL3 21000 18 YR CRANKCASE Replace cylinder liners WM00108
QL3 21000 18 YR PISTON Replace pistons WM00430
QL3 21000 18 YR GAS MIXTURE COOLING (FOR Check for contamination and leaks, clean if necessary WM00443
GAS ENGINES)
QL3 21000 18 YR CONROD Replace conrods WM00444
QL3 21000 18 YR AIR SUPPLY TO CYLINDERS Check for contamination, clean if necessary. X WM00782
QL3 21000 18 YR COOLANT CIRCUIT GENERAL, Replace O-rings in plug connections of connecting lines to mixture WM00842
IF APPLICABLE HIGH-TEMPER- cooler.
ATURE CIRCUIT
QL3 21000 18 YR EXHAUST SYSTEM AFTER TUR- Check exhaust pipe bellows, replace if necessary. WM00922
BOCHARGER
QL3 31500 5 YR ENGINE MOUNTING Measure height of rubber element WM00126
QL3 31500 6 YR ENGINE, GENERAL Replace rubber sleeve WM00008
QL3 31500 18 YR CAMSHAFT Visually inspect camshaft running surface with endoscope through WM00096
pushrod bore
QL3 31500 18 YR CRANKSHAFT PTO, FREE END Replace vibration damper WM00439
QL3 63000 6 YR ENGINE, GENERAL Replace hose WM00007
QL3 63000 18 YR CYLINDER HEAD Overhaul cylinder head WM00097
QL3 63000 18 YR ENGINE MOUNTING Replace dome mounts WM00505
QL4 63000 18 YR ENGINE, GENERAL Replace elastomer parts and seals and gaskets WM00001
QL4 63000 18 YR ENGINE, GENERAL Disassemble engine completely. Inspect engine components as per WM00002
assembly instructions; repair or replace if necessary
TIM-ID: 0000085719 - 001

QL4 63000 18 YR LUBE OIL PUMP WITH DRIVE Check pump and replace if necessary WM00070
QL4 63000 18 YR VALVE DRIVE Replace swing followers and swing-follower shafts WM00092
QL4 63000 18 YR CAMSHAFT Replace thrust bearing flange WM00095
QL4 63000 18 YR CRANKSHAFT WITH BEARING Replace crankshaft bearings WM00103
QL4 63000 18 YR GEARCASE, FREE END Check tooth flanks in gear train for wear (visual inspection), replace WM00104
bushings
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

20 | Maintenance Schedule | MS50202/05E 2019-04

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [HRS]
QL4 63000 18 YR CRANKCASE Replace camshaft bearings WM00111
QL4 63000 18 YR ENGINE MOUNTING Replace rubber element of rubber mounts WM00127
QL4 63000 18 YR WIRING, GENERAL, FOR EN- Replace wiring harness WM00137
GINE/GEARBOX/PLANT
Lube oil tank
QL1 - 1 WK ENGINE, GENERAL Check engine oil level in storage tank WM00428
Generator
QL1 1500 6 MON DRIVE, ELECTRIC POWER AND Lubricate bearings according to instruction plate, check bearing tem- WM00483
SAFETY SYSTEMS perature and winding temperature
QL1 3000 - DRIVE, ELECTRIC POWER AND Check generator power and generator operating data WM00468
SAFETY SYSTEMS
QL1 3000 - DRIVE, ELECTRIC POWER AND Check generator voltage in idle mode WM00469
SAFETY SYSTEMS
QL1 3000 1 YR DRIVE, ELECTRIC POWER AND Clean generator intake grill WM00467
SAFETY SYSTEMS
QL1 3000 1 YR MAJOR DOCUMENTATION Replace air filter if required X WM00484
QL3 9000 1 YR DRIVE, ELECTRIC POWER AND Check power cable connections in terminal box, tighten if required WM00458
SAFETY SYSTEMS
QL3 31500 18 YR DRIVE, ELECTRIC POWER AND Check generator and replace generator bearings WM00466
SAFETY SYSTEMS
QL4 63000 18 YR DRIVE, ELECTRIC POWER AND Repair generator WM00504
SAFETY SYSTEMS
Coupling
QL1 6000 1 YR MAIN AND AUXILIARY PTO Check coupling element WM00482
SYSTEMS (COUPLINGS)
QL3 21000 4 YR MAIN AND AUXILIARY PTO Replace coupling element WM00481
SYSTEMS (COUPLINGS)
Gearbox
QL1 3000 1 YR DRIVE SYSTEM Check gearbox housing temperature and bearing temperature X WM00471
QL1 3000 1 YR DRIVE SYSTEM Check internal condition and function of gearbox and oil circulation X WM00473
system
QL1 3000 1 YR DRIVE SYSTEM Check gearbox oil level and take oil sample X WM00500
QL1 6000 2 YR DRIVE SYSTEM Oil change. Important! Initial change after 500 operating hours X WM00490
QL1 6000 2 YR DRIVE SYSTEM Replace ring gear oil pump X WM00818
QL1 6000 2 YR DRIVE SYSTEM Clean gearbox inside and clean oil circulation system X WM00819
QL1 6000 2 YR DRIVE SYSTEM Clean oil filter, replace if necessary. Initial cleaning after 500 operat- X WM00825
ing hours
QL1 18000 3 YR DRIVE SYSTEM Replace oil filter. X WM00512
QL3 6000 1 YR DRIVE SYSTEM Check surface condition and contact pattern of tooth flanks. X WM00487
QL3 6000 1 YR MOUNTING SYSTEM Check shaft alignment. X WM00498
QL4 42000 - DRIVE SYSTEM Overhaul gearbox (12/20V4000L64FNER) X WM00820
QL4 63000 - DRIVE SYSTEM Overhaul gearbox (8/16V4000L64FNER) X WM00821
Exhaust system
QL1 - 14000 Exhaust system Check unions on all exhaust components after engine, replace seals WM00919
TIM-ID: 0000085719 - 001

NOS and screws if necessary

QL1 3000 1 YR Exhaust system Check function of exhaust flap and inspect for leaks X WM00453
QL1 3000 1 YR Exhaust system Check exhaust temperature and exhaust backpressure before and X WM00454
after exhaust heat exchanger
QL1 3000 1 YR Exhaust system Check condensate neutralization system and flush condensate line X WM00476
with condensate collecting tank
QL1 3000 2 YR Exhaust system Check exhaust back pressure before and after catalytic converter X WM00813
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

MS50202/05E 2019-04 | Maintenance Schedule | 21

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [HRS]
QL1 10500 2 YR Exhaust system Check exhaust heat exchanger, clean if required X WM00456
QL1 63000 18 YR Exhaust system Check exhaust gas heat exchanger, clean or replace if necessary X WM00501
QL3 15750 2 YR Exhaust system Check catalytic converter, replace if required X WM00475
Cooling system
QL1 6000 1 YR Cooling system Lubricate motor bearings acc. to the specifications of the manufac- WM00485
turer
QL1 6000 1 YR Cooling system Check rubber bellows, hoses and coolant pump (visual inspection) WM00495
QL1 6000 1 YR Cooling system Visually inspect coolant pumps WM00817
QL3 - 1 YR Cooling system Check safety valve X WM00494
QL3 21000 18 YR Cooling system Replace thermostat valve element WM00497
Control cabinet
QL1 - 30 MON Control cabinet Replace buffer battery in central processing unit (CPU of the PC) X WM00491
QL1 - 10 YR Control cabinet Replace safety switching device X WM00506
QL1 3000 1 YR Control cabinet Check filter fans for contamination WM00462
QL1 3000 1 YR Control cabinet Check noise generation of filter fans WM00463
QL1 3000 1 YR Control cabinet Checking noise generation of compressor and fans X WM00470
QL1 3000 1 YR Control cabinet Check cooling function of cooling unit X WM00477
QL1 3000 1 YR Control cabinet Check cooling fins for contamination, clean if required X WM00478
Gas supply
QL1 3000 2 YR FUEL SUPPLY SYSTEM Check differential pressure at gas filter WM00814
QL1 6000 1 YR FUEL SUPPLY SYSTEM Check function of valve-leak control and check shut-off equipment WM00499
QL1 9000 3 YR FUEL SUPPLY SYSTEM Replace gas filter WM00816
NOS = Number of starts
YR = Years
MON = Months
HRS = Hours
WK = Weeks

TIM-ID: 0000085719 - 001

22 | Maintenance Schedule | MS50202/05E 2019-04