20V4000G83L Maintenance Data

Maintenance ScheduleDiesel Engine12 V 4000 Gx316 V 4000 Gx3, 16 V 4000 Gx3x20 V 4000 Gx3, 20 V 4000 Gx3x Application Group 3D

MS50004/04E

12V4000G23

12V4000G43

12V4000G63

12V4000G83

16V4000G23

16V4000G43

16V4000G63

16V4000G83

16V4000G83L

20V4000G23

20V4000G43

20V4000G63

20V4000G63L

20V4000G83

20V4000G83L

Table 1: applicable for

2013 Copyright MTU Friedrichshafen GmbH

This Publication is protected by copyright and may not be used in any way whether in whole or in part without the priorwritten permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-crofilming and storage or processing on electronic systems including data bases and online services.

This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damageduring operation.

Subject to alterations and amendments.

1 Maintenance Schedule1.1

MS50004/04E 2013-02 | Maintenance Schedule | 3

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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 organic

detergents. 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 battery

manufacturer'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.

Application Group3D Short-time operation, fuel stop

Load profile

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1.2 Maintenance schedule matrix0-10,500 Operating hours

Item

Limit

Operating hours [h]

Daily

500

1,000

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

10,00

010

,500

Engine operation 1 m

Engine oil filter 2 a

Engine operation - 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 1 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

Rubber sleeves 6 a X X X

Hose lines 6 a X

Fuel injectors 9 a X

Combustion chambers 4 a X

Crankcase breathers 2 a X

Turbochargers 9 a X

Turbochargers 9 a X

Component maintenance 9 a X

Engine mounts 5 a X

Fuel delivery pump 9 a X

Cylinder heads 9 a X

Extended component maintenance 18 a X

Turbochargers 18 a

w = weeksm = monthsa = years

11,000-12,000 Operating hoursItem

Limit

Operating hours [h]

11,00

011

,500

12,00

0

Engine operation 1 m

Engine oil filter 2 a

Engine operation -

Centrifugal oil filter 2 a X X X

Fuel filter 2 a X X

Engine mounts 1 a X X

Belt drive 2 a X

Valve gear 2 a X

Air filters 3 a X

Rubber sleeves 6 a X

Hose lines 6 a X

Fuel injectors 9 a X

Combustion chambers 4 a X



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Item

Limit

Operating hours [h]

11,00

011

,500

12,00

0

Crankcase breathers 2 a X

Turbochargers 9 a X

Turbochargers 9 a X

Component maintenance 9 a X

Engine mounts 5 a X

Fuel delivery pump 9 a X

Cylinder heads 9 a X

Extended component maintenance 18 a X

Turbochargers 18 a X



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1.3 Maintenance tasksQualifi-cationlevel

Interval Limit Item Maintenance tasks

Optio

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 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 1 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

QL3 3000 6 a Rubber sleeves Replace all rubber sleeves. W1250

QL3 6000 6 a Hose lines Replace all hose lines. W1251

QL1 6000 9 a Fuel injectors Replace fuel injectors. W1006

QL1 6000 4 a Combustion chambers Inspect cylinder chambers using endoscope. W1011

QL1 6000 2 a Crankcase breathers Crankcase breathers: Fit new filters or filter inserts. W1046

QL3 6000 9 a Turbochargers X W1786

QL3 6000 9 a Turbochargers Overhaul exhaust turbocharger (MTU ZR turbocharger). X W1785

QL3 6000 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 6000 5 a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se-curing screws.

W1026

QL3 6000 9 a Fuel delivery pump Fit new fuel delivery pump. W1051

QL3 6000 9 a Cylinder heads Overhaul cylinder heads. W1134



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Replace exhaust turbocharger (Garrett turbocharger).

Qualifi-cationlevel

Interval Limit Item Maintenance tasks

Optio

n Task[h]

QL4 6000 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

Fit new pressure relief valve in high-pressure fuel system. W3021

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

W3063

Fit new engine oil pump. W3073

Fit new rubber elements of engine mounts. W3100

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

X W3101

Replace swing followers and swing-follower shafts. W3103

Remove and inspect vibration damper. Repair if necessary. W3019

Insulated flywheel: Check and repair if required. W3144

QL4 12000 18 a Turbochargers Replace compressor wheels of exhaust turbochargers (MTU ZR turbo-charger).

X W1472



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Maintenance Schedule1 Maintenance Schedule1.1 Preface1.2 Maintenance schedule matrix1.3 Maintenance tasks

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20V4000G83L Maintenance Data