Maintenance Schedule

Diesel Engine
10/12V1600G10F
10/12V1600G20F
10/12V1600G10S
10/12V1600G20S
10/12V1600B40S
12V1600B30S
12V1600G30F
12V1600G30S
Application group 3B

MS50053/06E
Engine model kW/cyl. Application group
10V1600B40S 44.8 / 51.1 kW/cyl. 3B, continuous operation, variable load, ICXN
10V1600G10F 40.7 kW/cyl. 3B, continuous operation, variable load, ICXN
10V1600G10S 46.5 kW/cyl. 3B, continuous operation, variable load, ICXN
10V1600G20F 44.8 kW/cyl. 3B, continuous operation, variable load, ICXN
10V1600G20S 51.1 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600B30S 43.7 / 46.8 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600B40S 48 / 50.7 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600G10F 43.7 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600G10S 46.8 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600G20F 48 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600G20S 50.7 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600G30F 56.1 kW/cyl. 3B, continuous operation, variable load, ICXN
12V1600G30S 55.3 kW/cyl. 3B, continuous operation, variable load, ICXN

Table 1: Applicability

Rolls-Royce Solutions refers to Rolls-Royce Solutions GmbH or an affiliated company pursuant to §15 AktG (German Stock
Corporation Act) or a controlled company (joint venture), and Rolls-Royce Solutions Ruhstorf GmbH.

© Copyright Rolls-Royce Solutions

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of Rolls-Royce Solutions. This particularly applies to its reproduction, distribution, editing, translation, microfilming
and storage and/or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. Rolls-Royce Solutions re-
serves the right to change, delete or supplement the information provided as and when required.
 Table of contents
1 Maintenance Schedule 1.4 Load profile 7
1.5 Maintenance Schedule Matrix 12000 HRS 8
1.1 Preface 4 1.6 Cyclical maintenance tasks 12000 HRS 9
1.2 Special conditions 5
1.3 Maintenance task tolerances 6
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 1 Maintenance Schedule
1.1 Preface
This manual provides instructions for your product from the manufacturer Rolls-Royce Solutions.

Maintenance concept
The maintenance system for Rolls-Royce Solutions products is based on a preventive maintenance concept.
Preventive maintenance facilitates advance operational planning and ensures a high level of equipment avail-
ability. The maintenance intervals as well as the required scopes of maintenance tasks are based on opera-
tional 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 condi-
tions.
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 and time limits. Whichever value is reached first shall apply.
The maintenance intervals are determined and verified by the load profile. Load profiles can be evaluated by
the Service Partner of Rolls-Royce Solutions. Reading out load profile data is recommended for the first time
after between 500 and 1000 operating hours depending on the application concerned, or after changing the
duty profile or operating area.
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 in case of repair (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:

The relevant component manufacturer's instructions apply with respect to the maintenance of any compo-
nents which do not appear in this maintenance schedule.
For the change intervals of fluids and lubricants, refer to the corresponding Fluids and Lubricants Specifica-
tions.
If the product is to remain out of service for a longer time period, Rolls-Royce Solutions recommends to carry
out a monthly test run until engine operating temperature is reached. If the engine is scheduled to remain
out of service for > 1 month, carry out engine preservation procedures in accordance with the Preservation
and Represervation Specifications
The latest version of the specifications is available at http://www.mtu-solutions.com.
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 1.2 Special conditions
Designation Value
Load factor ≤ 75%
Operating hours Unlimited hours
Time between major 12,000 h
overhaul

Table 2: Special conditions

Note 01:
The engines are certified for operation with the fuels approved in the Fluids and Lubricants Specifications.
For operation with a high sulfur content in the fuel, the following must be observed:
• The component TBO specified in the maintenance schedule refers to engine operation with diesel fuel
with a sulfur content < 15 ppm, e.g. EN 590 or ULSD.
If a fuel with a sulfur content > 15 ppm is used, the times specified in the maintenance schedule for compo-
nent TBO of the cylinder head may be shorter. For reduced TBOs, refer to the Fluids and Lubricants Specifi-
cations.
Engines with exhaust gas recirculation and/or exhaust gas aftertreatment must not be operated with ex-
cessive sulfur content in the fuel. The limit values in the Fluids and Lubricants Specifications apply.

Table 3: Special conditions

Note 02:
If the engine is used in an UPS unit with corresponding hardware, the exchange interval for the cylinder
heads is 500 h.

Table 4: Special conditions

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 1.3 Maintenance task tolerances
Maintenance tasks shall be completed within certain tolerances comprising a percentage and a maximum
value, whereby the smaller value shall apply. Taking full advantage of such tolerances does not influence the
scheduled timing of the ensuing maintenance task.
Interval (HRS)/limit Limit in % Limit max.
Operating hours ± 10% ± 500 hrs
Years ± 10% ± 30 days
Example 1 Task every 1000 hrs Between 900 hrs and 1100 hrs (10% of
1000 hrs)
Example 2 Task every 30000 hrs Between 29500 hrs and 30500 hrs (10% of
30000 hrs, but max. 500 hrs)

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 1.4 Load profile
Load profile
Load profile

Load indicator %

40 to 57 kW/cyl.
Load factor %

Time

—
Load %
%

110 (100-110) 1
100 (90-100) 5
90 (80-90) 3
80 (65-80) 78
0 to 75 ≤ 18 12,000 — — —
65 (50-65) —
50 (30-50) —
30 (5-30) 13
Idle Speed (0-5) —

Table 5: Load profile

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 1.5 Maintenance Schedule Matrix 12000 HRS
500 to 12000 Operating hours
Task Operating hours [HRS]

10000
10500
11000
11500
12000
Limit

1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
500

WM00285 1 DAY
WM00286 1 DAY
WM00287 1 DAY
WM00290 1 DAY
WM00321 1 DAY
WM00296 1 MON
WM00067 2 YR
WM00084 2 YR X X X X X X X X X X X X X X X X X X X X X X X X
WM00086 2 YR X X X X X X X X X X X X X X X X X X X X X X X X
WM01023 1 YR X X X X X X X X X X X X
WM00547 2 YR X X X X X X X X X X X X
WM01266 2 YR X X X X
WM01267 2 YR X X X X
WM00076 3 YR X X X X
WM00094 18 YR X X X X
WM01233 18 YR X
DAY = Days
MON = Months
YR = Years
HRS = Hours

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 1.6 Cyclical maintenance tasks 12000 HRS
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [HRS]
Engine
QL1 - 1 DAY ENGINE OPERATIONAL MONI- Check engine oil level WM00285
TORING
QL1 - 1 DAY ENGINE OPERATIONAL MONI- Visually inspect for leaks and general condition of engine WM00286
TORING
QL1 - 1 DAY ENGINE OPERATIONAL MONI- Check maintenance indicator of air filter WM00287
TORING
QL1 - 1 DAY ENGINE OPERATIONAL MONI- Drain water and contaminants from fuel prefilter X WM00290
TORING
QL1 - 1 DAY ENGINE OPERATIONAL MONI- Check condensate drain of intercooler X WM00321
TORING
QL1 - 1 MON ENGINE OPERATIONAL MONI- Perform test run, minimum duration: until operating temperature is WM00296
TORING reached, no less than 1/3 load
QL1 - 2 YR LUBE OIL SYSTEM Replace oil filter at every engine oil change, or when the time limit WM00067
(years) is reached, at the latest
QL1 500 2 YR FUEL SYSTEM (LOW PRES- Fuel prefilter, replace filter WM00084
SURE)
QL1 500 2 YR FUEL SYSTEM (LOW PRES- Replace easy-change fuel filter WM00086
SURE)
QL1 1000 1 YR FUEL COOLER Check cooler elements externally for contamination and leaks X WM01023
QL1 1000 2 YR AUXILIARY POWER TAKE-OFF Check belt condition and tension, replace belt if necessary WM00547
QL1 3000 2 YR AUXILIARY POWER TAKE-OFF Replace poly-vee belt WM01266
QL1 3000 2 YR AUXILIARY POWER TAKE-OFF Replace belt drive WM01267
QL1 3000 3 YR AIR SUPPLY SYSTEM Replace air filter WM00076
QL1 3000 18 YR VALVE GEAR Check valve clearance, adjust if necessary. ATTENTION! First adjust- WM00094
ment after 1,000 operating hours on a new engine and after 1,000
operating hours following each cylinder head overhaul.
QL4 12000 18 YR ENGINE, GENERAL Overhaul or replace engine WM01233
DAY = Days
MON = Months
YR = Years
HRS = Hours
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