Maintenance Schedule

Diesel Engine
V 4000 Rx3 x
Application Group 2A

MS50140/00E
Engine model kW/cyl. Application group
8V4000R43 125 kW/cyl. 2A, continuous operation, unlimited
12V4000R43 125 kW/cyl. 2A, continuous operation, unlimited
16V4000R43 138 kW/cyl. 2A, continuous operation, unlimited
20V4000R43 135 kW/cyl. 2A, continuous operation, unlimited
8V4000R43L 150 kW/cyl. 2A, continuous operation, unlimited
12V4000R43L 150 kW/cyl. 2A, continuous operation, unlimited
16V4000R43L 150 kW/cyl. 2A, continuous operation, unlimited
20V4000R43L 150 kW/cyl. 2A, continuous operation, unlimited
16V4000R43R 125 kW/cyl. 2A, continuous operation, unlimited
20V4000R53 158 kW/cyl. 2A, continuous operation, unlimited

Table 1: Applicability

Printed in Germany
© 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 prior
written 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 damage
during operation.
Subject to alterations and amendments.
 Table of Contents
1 Maintenance Schedule 1.9 Maintenance schedule matrix 24,000h 24
1.10 Maintenance tasks 24,000h 27
1.1 Preface 4 1.11 Maintenance schedule matrix 21,000h 29
1.2 Allocation matrix application group 2A 6 1.12 Maintenance tasks 21,000h 32
1.3 Maintenance schedule matrix 36,000h 8 1.13 Maintenance schedule matrix 18,000h 34
1.4 Maintenance tasks 36,000h 12 1.14 Maintenance tasks 18,000h 36
1.5 Maintenance schedule matrix 30,000h 14 1.15 Maintenance schedule matrix 15,000h 38
1.6 Maintenance tasks 30,000h 17 1.16 Maintenance tasks 15,000h 40
1.7 Maintenance schedule matrix 27,000h 19
1.8 Maintenance tasks 27,000h 22
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MS50140/00E 2013-08 | Table of Contents | 3

 1 Maintenance Schedule
1.1 Preface
MTU maintenance concept
The maintenance system for MTU products is based on a preventive maintenance concept. Preventive
maintenance 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 intervals
at 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/or
modification of the maintenance intervals. 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 applica-
ble. In order to be authorized to carry out the individual maintenance jobs, maintenance personnel must
have achieved a level of training and qualification appropriate to the complexity of the task in hand. The
various Qualification Levels QL1 to QL4 reflect the levels of training offered in MTU courses and the
contents of the tool kits required:
QL1: Operational monitoring and maintenance which can be carried out during a break in operation
without 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. Following
this, 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 maintenance
Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and
lists 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 Fluids
and 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 maintenance
work:
• 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 prefilters must
be changed every two years at the latest (Task 9998).
• Battery:
TIM-ID: 0000035566 - 004

Battery maintenance depends on the level of use and the ambient conditions. The battery manufac-
turer's instructions must be obeyed.
The relevant manufacturer's instructions apply with respect to the maintenance of any components
which 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.

4 | Maintenance Schedule | MS50140/00E 2013-08

 Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation proce-
dures in accordance with the MTU Preservation and Represervation Specifications A001070/...
TIM-ID: 0000035566 - 004

MS50140/00E 2013-08 | Maintenance Schedule | 5

 1.2 Allocation matrix application group 2A
V 4000 Rx3 x
Load profile

126 - 138 kW/cyl.

139 - 150 kW/cyl.

151 - 158 kW/cyl.

Load indicator %

0 - 125 kW/cyl.
Load factor %

Time
Load %
%

110 (100-110) —
Shunter
100 (90-100) 5
90 (80-90) 5
80 (65-80) —
0 - 18 ≤7 36,000 36,000 30,000 27,000
65 (50-65) 5
50 (30-50) —
30 (5-30) 5
Idle (0-5) 80
110 (100-110) —
Multi Purpose
100 (90-100) 5
90 (80-90) 10
80 (65-80) 10
19 - 26 ≤ 10 36,000 30,000 27,000 24,000
65 (50-65) —
50 (30-50) —
30 (5-30) —
Idle (0-5) 75
110 (100-110) —
Standard Loco
100 (90-100) 10
90 (80-90) 15
80 (65-80) 15
27 - 38 ≤ 17 30,000 27,000 24,000 21,000
65 (50-65) —
50 (30-50) —
30 (5-30) —
Idle (0-5) 60
110 (100-110) —
High Speed
100 (90-100) 20
90 (80-90) 10
80 (65-80) 5
39 - 46 ≤ 25 27,000 24,000 21,000 18,000
65 (50-65) —
50 (30-50) —
TIM-ID: 0000044604 - 001

30 (5-30) 40
Idle (0-5) 25

Table 2: Allocation matrix application group 2A

6 | Maintenance Schedule | MS50140/00E 2013-08

 V 4000 Rx3 x
Load profile

126 - 138 kW/cyl.

139 - 150 kW/cyl.

151 - 158 kW/cyl.

Load indicator %

0 - 125 kW/cyl.
Load factor %
Time
Load %
%

110 (100-110) —
High Load
100 (90-100) 30
90 (80-90) 12
80 (65-80) —
47 - 56 ≤ 35 24,000 21,000 18,000 15,000
65 (50-65) —
50 (30-50) 10
30 (5-30) 30
Idle (0-5) 18

Table 3: Allocation matrix application group 2A

TIM-ID: 0000044604 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 7

 1.3 Maintenance schedule matrix 36,000h
0-21,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
21,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Limit

Daily
Engine
Engine oil filter 2a
Engine operation - X
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X
Engine governor 9a X X
Combustion chambers 9a X X
Turbochargers 18 a X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a
Automatic engine oil filter 6a
Extended component maintenance 18 a
Turbochargers 18 a
w = weeks
m = months
a = years

22,000-43,000 Operating hours

TIM-ID: 0000044605 - 001

Item Operating hours [h]

22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
37,000
38,000
39,000
40,000
41,000
42,000
43,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X X X
w = weeks
m = months
a = years

8 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
37,000
38,000
39,000
40,000
41,000
42,000
43,000
Limit
Air filters 6m X X X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X X
Fuel injectors 9a X X
Engine governor 9a X X
Combustion chambers 9a X X
Turbochargers 18 a X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

44,000-65,000 Operating hours

Item Operating hours [h]
44,000
45,000
46,000
47,000
48,000
49,000
50,000
51,000
52,000
53,000
54,000
55,000
56,000
57,000
58,000
59,000
60,000
61,000
62,000
63,000
64,000
65,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X X X X
TIM-ID: 0000044605 - 001

Engine mounts 1a X X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
w = weeks
m = months
a = years

MS50140/00E 2013-08 | Maintenance Schedule | 9

Item Operating hours [h]

44,000
45,000
46,000
47,000
48,000
49,000
50,000
51,000
52,000
53,000
54,000
55,000
56,000
57,000
58,000
59,000
60,000
61,000
62,000
63,000
64,000
65,000
Limit
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a
Automatic engine oil filter 6a
Extended component maintenance 18 a
Turbochargers 18 a
w = weeks
m = months
a = years

66,000-72,000 Operating hours

Item Operating hours [h]
66,000
67,000
68,000
69,000
70,000
71,000
72,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X
Air filters 6m X X X X X X X
Engine mounts 1a X X X X X X X
Centrifugal oil filter 2a X X X X X X X
Fuel filter 2a X X X X X X X
Intermediate fuel filter 2a X X X X X X X
Fuel prefilter 2a X X X X X X X
Flywheel 18 a X X X X X X X
Turbochargers 2a X X X
Valve gear 18 a X X X
TIM-ID: 0000044605 - 001

Flywheel 18 a X X X
Air filters 3a X X
Fuel injectors 9a X
Engine governor 9a X
Combustion chambers 9a X
Turbochargers 18 a X
Crankcase breathers 6a X
w = weeks
m = months
a = years

10 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

66,000
67,000
68,000
69,000
70,000
71,000
72,000
Limit
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000044605 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 11

 1.4 Maintenance tasks 36,000h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
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 the inspection bores of the HP fuel pump. W0504
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 1000 6m Oil indicator filter Check and clean oil indicator filter. X W1047
QL1 1000 6m Air filters Clean air filter(s) Empty dust collector box. X W1027
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Intermediate fuel filter Replace intermediate fuel filter of filter element of intermediate fuel fil- W1481
ter.
QL1 1000 2a Fuel prefilter Replace filter element of fuel prefilter and sealing ring depending on W1164
the degree of contamination, when the limit (years) is reached, at the
latest.
QL1 1000 18 a Flywheel Check carbon brushes on flywheel, replace as necessary. X W1697
QL1 3000 2a Turbochargers Clean compressor wheel. W1076
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel. X W1698
QL1 6000 3a Air filters Fit new air filters. X W1005
QL1 9000 9a Fuel injectors Replace fuel injectors. W1006
QL1 9000 9a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 9000 9a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 9000 18 a Turbochargers Check turbine housing for cracks (externally by visual inspection and W1577
internally by endoscopic examination), replace if necessary..
QL1 18000 6a Crankcase breathers Fit new oil separators. W1055
QL3 18000 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 18000 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 18000 9a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
ating parameters. Then drain coolant and flush cooling systems.
TIM-ID: 0000044612 - 001

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
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
w = weeks
m = months
a = years

12 | Maintenance Schedule | MS50140/00E 2013-08

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Inspect centrifugal oil filter for wear. X W2009
Overhaul starter. W2010
Clean engine oil cooler and inspect it for leaks. W2018
Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Auxiliary PTO coupling: Check rubber elements (visual inspection), re- W2106
place parts if necessary.
Overhaul engine coolant pump. W2110
QL3 18000 18 a Turbochargers Overhaul turbochargers. W1038
QL4 18000 5a Elastomer coupling (main PTO) Fit new elastomer components . X W1544
QL3 18000 9a HP fuel pump Fit new high-pressure fuel pump. W1058
QL3 18000 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pat- W1063
tern on cylinder liner running surfaces.
QL3 36000 6a Hose lines Replace all hose lines. W1251
QL4 36000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 36000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 fuel delivery pump. W3010
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 replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Fit new turbine wheels for turbochargers. W3101
Overhaul Geislinger coupling. X W3102
Replace swing followers and swing-follower shafts. W3103
Check vibration damper, fit new one if necessary. W3108
Insulated flywheel: Check and repair if required. W3145
Torsionally resilient coupling. Check parts. Fit new friction rings and X W3136
disks.
Overhaul battery-charging generator. X W3042
QL4 72000 18 a Turbochargers Fit new compressor wheels for turbochargers. W1472
w = weeks
m = months
a = years
TIM-ID: 0000044612 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 13

 1.5 Maintenance schedule matrix 30,000h
0-20,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,000
9,000
Limit

Daily
Engine
Engine oil filter 2a
Engine operation - X
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X
Valve gear 18 a X X X X X X
Flywheel 18 a X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X
Engine governor 9a X X
Combustion chambers 9a X X
Turbochargers 18 a X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a
Automatic engine oil filter 6a
Extended component maintenance 18 a
Turbochargers 18 a
w = weeks
m = months
a = years

21,000-40,000 Operating hours

TIM-ID: 0000044606 - 001

Item Operating hours [h]

21,000
22,000
22,500
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
37,000
37,500
38,000
39,000
40,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X
w = weeks
m = months
a = years

14 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

21,000
22,000
22,500
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
37,000
37,500
38,000
39,000
40,000
Limit
Air filters 6m X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

41,000-60,000 Operating hours

Item Operating hours [h]
41,000
42,000
43,000
44,000
45,000
46,000
47,000
48,000
49,000
50,000
51,000
52,000
52,500
53,000
54,000
55,000
56,000
57,000
58,000
59,000
60,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X X
TIM-ID: 0000044606 - 001

Engine mounts 1a X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
w = weeks
m = months
a = years

MS50140/00E 2013-08 | Maintenance Schedule | 15

Item Operating hours [h]

41,000
42,000
43,000
44,000
45,000
46,000
47,000
48,000
49,000
50,000
51,000
52,000
52,500
53,000
54,000
55,000
56,000
57,000
58,000
59,000
60,000
Limit
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
HP fuel pump 9a X X
Cylinder heads 18 a X X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years

TIM-ID: 0000044606 - 001

16 | Maintenance Schedule | MS50140/00E 2013-08

 1.6 Maintenance tasks 30,000h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
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 the inspection bores of the HP fuel pump. W0504
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 1000 6m Oil indicator filter Check and clean oil indicator filter. X W1047
QL1 1000 6m Air filters Clean air filter(s) Empty dust collector box. X W1027
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Intermediate fuel filter Replace intermediate fuel filter of filter element of intermediate fuel fil- W1481
ter.
QL1 1000 2a Fuel prefilter Replace filter element of fuel prefilter and sealing ring depending on W1164
the degree of contamination, when the limit (years) is reached, at the
latest.
QL1 1000 18 a Flywheel Check carbon brushes on flywheel, replace as necessary. X W1697
QL1 3000 2a Turbochargers Clean compressor wheel. W1076
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel. X W1698
QL1 6000 3a Air filters Fit new air filters. X W1005
QL1 7500 9a Fuel injectors Replace fuel injectors. W1006
QL1 7500 9a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 7500 9a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 7500 18 a Turbochargers Check turbine housing for cracks (externally by visual inspection and W1577
internally by endoscopic examination), replace if necessary..
QL1 15000 6a Crankcase breathers Fit new oil separators. W1055
QL3 15000 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 15000 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 15000 9a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
ating parameters. Then drain coolant and flush cooling systems.
TIM-ID: 0000044613 - 001

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
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
w = weeks
m = months
a = years

MS50140/00E 2013-08 | Maintenance Schedule | 17

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Inspect centrifugal oil filter for wear. X W2009
Overhaul starter. W2010
Clean engine oil cooler and inspect it for leaks. W2018
Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Auxiliary PTO coupling: Check rubber elements (visual inspection), re- W2106
place parts if necessary.
Overhaul engine coolant pump. W2110
QL3 15000 18 a Turbochargers Overhaul turbochargers. W1038
QL4 15000 5a Elastomer coupling (main PTO) Fit new elastomer components . X W1544
QL3 15000 9a HP fuel pump Fit new high-pressure fuel pump. W1058
QL3 15000 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pat- W1063
tern on cylinder liner running surfaces.
QL3 30000 6a Hose lines Replace all hose lines. W1251
QL4 30000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 30000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 fuel delivery pump. W3010
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 replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Fit new turbine wheels for turbochargers. W3101
Overhaul Geislinger coupling. X W3102
Replace swing followers and swing-follower shafts. W3103
Check vibration damper, fit new one if necessary. W3108
Insulated flywheel: Check and repair if required. W3145
Torsionally resilient coupling. Check parts. Fit new friction rings and X W3136
disks.
Overhaul battery-charging generator. X W3042
QL4 60000 18 a Turbochargers Fit new compressor wheels for turbochargers. W1472
w = weeks
m = months
a = years
TIM-ID: 0000044613 - 001

18 | Maintenance Schedule | MS50140/00E 2013-08

 1.7 Maintenance schedule matrix 27,000h
0-19,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
13,500
14,000
15,000
16,000
17,000
18,000
19,000
1,000
2,000
3,000
4,000
5,000
6,000
6,750
7,000
8,000
9,000
Limit

Daily
Engine
Engine oil filter 2a
Engine operation - X
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X
Valve gear 18 a X X X X X X
Flywheel 18 a X X X X X X
Air filters 3a X X
Fuel injectors 9a X X
Engine governor 9a X X
Combustion chambers 9a X X
Turbochargers 18 a X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a
Automatic engine oil filter 6a
Extended component maintenance 18 a
Turbochargers 18 a
w = weeks
m = months
a = years

20,000-39,000 Operating hours

TIM-ID: 0000044607 - 001

Item Operating hours [h]

20,000
20,250
21,000
22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
33,750
34,000
35,000
36,000
37,000
38,000
39,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X
w = weeks
m = months
a = years

MS50140/00E 2013-08 | Maintenance Schedule | 19

Item Operating hours [h]

20,000
20,250
21,000
22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
33,750
34,000
35,000
36,000
37,000
38,000
39,000
Limit
Air filters 6m X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

40,000-54,000 Operating hours

Item Operating hours [h]
40,000
40,500
41,000
42,000
43,000
44,000
45,000
46,000
47,000
47,250
48,000
49,000
50,000
51,000
52,000
53,000
54,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X
TIM-ID: 0000044607 - 001

Engine mounts 1a X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X
w = weeks
m = months
a = years

20 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

40,000
40,500
41,000
42,000
43,000
44,000
45,000
46,000
47,000
47,250
48,000
49,000
50,000
51,000
52,000
53,000
54,000
Limit
Valve gear 18 a X X X X X
Flywheel 18 a X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
HP fuel pump 9a X X
Cylinder heads 18 a X X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000044607 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 21

 1.8 Maintenance tasks 27,000h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
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 the inspection bores of the HP fuel pump. W0504
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 1000 6m Oil indicator filter Check and clean oil indicator filter. X W1047
QL1 1000 6m Air filters Clean air filter(s) Empty dust collector box. X W1027
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Intermediate fuel filter Replace intermediate fuel filter of filter element of intermediate fuel fil- W1481
ter.
QL1 1000 2a Fuel prefilter Replace filter element of fuel prefilter and sealing ring depending on W1164
the degree of contamination, when the limit (years) is reached, at the
latest.
QL1 1000 18 a Flywheel Check carbon brushes on flywheel, replace as necessary. X W1697
QL1 3000 2a Turbochargers Clean compressor wheel. W1076
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel. X W1698
QL1 6750 3a Air filters Fit new air filters. X W1005
QL1 6750 9a Fuel injectors Replace fuel injectors. W1006
QL1 6750 9a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 6750 9a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 6750 18 a Turbochargers Check turbine housing for cracks (externally by visual inspection and W1577
internally by endoscopic examination), replace if necessary..
QL1 13500 6a Crankcase breathers Fit new oil separators. W1055
QL3 13500 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 13500 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 13500 9a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
ating parameters. Then drain coolant and flush cooling systems.
TIM-ID: 0000044614 - 001

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
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
w = weeks
m = months
a = years

22 | Maintenance Schedule | MS50140/00E 2013-08

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Inspect centrifugal oil filter for wear. X W2009
Overhaul starter. W2010
Clean engine oil cooler and inspect it for leaks. W2018
Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Auxiliary PTO coupling: Check rubber elements (visual inspection), re- W2106
place parts if necessary.
Overhaul engine coolant pump. W2110
QL3 13500 18 a Turbochargers Overhaul turbochargers. W1038
QL4 13500 5a Elastomer coupling (main PTO) Fit new elastomer components . X W1544
QL3 13500 9a HP fuel pump Fit new high-pressure fuel pump. W1058
QL3 13500 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pat- W1063
tern on cylinder liner running surfaces.
QL3 27000 6a Hose lines Replace all hose lines. W1251
QL4 27000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 27000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 fuel delivery pump. W3010
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 replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Fit new turbine wheels for turbochargers. W3101
Overhaul Geislinger coupling. X W3102
Replace swing followers and swing-follower shafts. W3103
Check vibration damper, fit new one if necessary. W3108
Insulated flywheel: Check and repair if required. W3145
Torsionally resilient coupling. Check parts. Fit new friction rings and X W3136
disks.
Overhaul battery-charging generator. X W3042
QL4 54000 18 a Turbochargers Fit new compressor wheels for turbochargers. W1472
w = weeks
m = months
a = years
TIM-ID: 0000044614 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 23

 1.9 Maintenance schedule matrix 24,000h
0-21,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
21,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Limit

Daily
Engine
Engine oil filter 2a
Engine operation - X
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a
Automatic engine oil filter 6a
Extended component maintenance 18 a
Turbochargers 18 a
w = weeks
m = months
a = years

22,000-43,000 Operating hours

TIM-ID: 0000044608 - 001

Item Operating hours [h]

22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
37,000
38,000
39,000
40,000
41,000
42,000
43,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X X X
w = weeks
m = months
a = years

24 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
37,000
38,000
39,000
40,000
41,000
42,000
43,000
Limit
Air filters 6m X X X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X X
Fuel injectors 9a X X X X
Engine governor 9a X X X X
Combustion chambers 9a X X X X
Turbochargers 18 a X X X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
HP fuel pump 9a X X
Cylinder heads 18 a X X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

44,000-48,000 Operating hours

Item Operating hours [h]
44,000
45,000
46,000
47,000
48,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X
Air filters 6m X X X X X
TIM-ID: 0000044608 - 001

Engine mounts 1a X X X X X
Centrifugal oil filter 2a X X X X X
Fuel filter 2a X X X X X
Intermediate fuel filter 2a X X X X X
Fuel prefilter 2a X X X X X
Flywheel 18 a X X X X X
Turbochargers 2a X X
w = weeks
m = months
a = years

MS50140/00E 2013-08 | Maintenance Schedule | 25

Item Operating hours [h]

44,000
45,000
46,000
47,000
48,000
Limit
Valve gear 18 a X X
Flywheel 18 a X X
Air filters 3a X
Fuel injectors 9a X
Engine governor 9a X
Combustion chambers 9a X
Turbochargers 18 a X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Cylinder heads 18 a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years

TIM-ID: 0000044608 - 001

26 | Maintenance Schedule | MS50140/00E 2013-08

 1.10 Maintenance tasks 24,000h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
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 the inspection bores of the HP fuel pump. W0504
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 1000 6m Oil indicator filter Check and clean oil indicator filter. X W1047
QL1 1000 6m Air filters Clean air filter(s) Empty dust collector box. X W1027
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Intermediate fuel filter Replace intermediate fuel filter of filter element of intermediate fuel fil- W1481
ter.
QL1 1000 2a Fuel prefilter Replace filter element of fuel prefilter and sealing ring depending on W1164
the degree of contamination, when the limit (years) is reached, at the
latest.
QL1 1000 18 a Flywheel Check carbon brushes on flywheel, replace as necessary. X W1697
QL1 3000 2a Turbochargers Clean compressor wheel. W1076
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel. X W1698
QL1 6000 3a Air filters Fit new air filters. X W1005
QL1 6000 9a Fuel injectors Replace fuel injectors. W1006
QL1 6000 9a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 6000 9a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 6000 18 a Turbochargers Check turbine housing for cracks (externally by visual inspection and W1577
internally by endoscopic examination), replace if necessary..
QL1 12000 6a Crankcase breathers Fit new oil separators. W1055
QL3 12000 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 12000 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 12000 9a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
ating parameters. Then drain coolant and flush cooling systems.
TIM-ID: 0000044615 - 001

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
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
w = weeks
m = months
a = years

MS50140/00E 2013-08 | Maintenance Schedule | 27

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Inspect centrifugal oil filter for wear. X W2009
Overhaul starter. W2010
Clean engine oil cooler and inspect it for leaks. W2018
Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Auxiliary PTO coupling: Check rubber elements (visual inspection), re- W2106
place parts if necessary.
Overhaul engine coolant pump. W2110
QL3 12000 18 a Turbochargers Overhaul turbochargers. W1038
QL4 12000 5a Elastomer coupling (main PTO) Fit new elastomer components . X W1544
QL3 12000 9a HP fuel pump Fit new high-pressure fuel pump. W1058
QL3 12000 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pat- W1063
tern on cylinder liner running surfaces.
QL3 24000 6a Hose lines Replace all hose lines. W1251
QL4 24000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 24000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 fuel delivery pump. W3010
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 replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Fit new turbine wheels for turbochargers. W3101
Overhaul Geislinger coupling. X W3102
Replace swing followers and swing-follower shafts. W3103
Check vibration damper, fit new one if necessary. W3108
Insulated flywheel: Check and repair if required. W3145
Torsionally resilient coupling. Check parts. Fit new friction rings and X W3136
disks.
Overhaul battery-charging generator. X W3042
QL4 48000 18 a Turbochargers Fit new compressor wheels for turbochargers. W1472
w = weeks
m = months
a = years
TIM-ID: 0000044615 - 001

28 | Maintenance Schedule | MS50140/00E 2013-08

 1.11 Maintenance schedule matrix 21,000h
0-18,000 Operating hours
Item Operating hours [h]

10,000
10,500
11,000
12,000
13,000
14,000
15,000
15,750
16,000
17,000
18,000
1,000
2,000
3,000
4,000
5,000
5,250
6,000
7,000
8,000
9,000
Limit

Daily
Engine
Engine oil filter 2a
Engine operation - X
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X
Valve gear 18 a X X X X X X
Flywheel 18 a X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Hose lines 6a
Cylinder heads 18 a
Automatic engine oil filter 6a
Extended component maintenance 18 a
Turbochargers 18 a
w = weeks
m = months
a = years

19,000-37,000 Operating hours

TIM-ID: 0000044609 - 001

Item Operating hours [h]

19,000
20,000
21,000
22,000
23,000
24,000
25,000
26,000
26,250
27,000
28,000
29,000
30,000
31,000
31,500
32,000
33,000
34,000
35,000
36,000
36,750
37,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X
w = weeks
m = months
a = years

MS50140/00E 2013-08 | Maintenance Schedule | 29

Item Operating hours [h]

19,000
20,000
21,000
22,000
23,000
24,000
25,000
26,000
26,250
27,000
28,000
29,000
30,000
31,000
31,500
32,000
33,000
34,000
35,000
36,000
36,750
37,000
Limit
Air filters 6m X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X
Valve gear 18 a X X X X X X
Flywheel 18 a X X X X X X
Air filters 3a X X X X
Fuel injectors 9a X X X X
Engine governor 9a X X X X
Combustion chambers 9a X X X X
Turbochargers 18 a X X X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
HP fuel pump 9a X X
Hose lines 6a X
Cylinder heads 18 a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

38,000-42,000 Operating hours

Item Operating hours [h]
38,000
39,000
40,000
41,000
42,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X
Air filters 6m X X X X X
TIM-ID: 0000044609 - 001

Engine mounts 1a X X X X X
Centrifugal oil filter 2a X X X X X
Fuel filter 2a X X X X X
Intermediate fuel filter 2a X X X X X
Fuel prefilter 2a X X X X X
Flywheel 18 a X X X X X
Turbochargers 2a X X
w = weeks
m = months
a = years

30 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

38,000
39,000
40,000
41,000
42,000
Limit
Valve gear 18 a X X
Flywheel 18 a X X
Air filters 3a X
Fuel injectors 9a X
Engine governor 9a X
Combustion chambers 9a X
Turbochargers 18 a X
Crankcase breathers 6a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Turbochargers 18 a X
Elastomer coupling (main PTO) 5a X
HP fuel pump 9a X
Hose lines 6a X
Cylinder heads 18 a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000044609 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 31

 1.12 Maintenance tasks 21,000h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
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 the inspection bores of the HP fuel pump. W0504
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 1000 6m Oil indicator filter Check and clean oil indicator filter. X W1047
QL1 1000 6m Air filters Clean air filter(s) Empty dust collector box. X W1027
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Intermediate fuel filter Replace intermediate fuel filter of filter element of intermediate fuel fil- W1481
ter.
QL1 1000 2a Fuel prefilter Replace filter element of fuel prefilter and sealing ring depending on W1164
the degree of contamination, when the limit (years) is reached, at the
latest.
QL1 1000 18 a Flywheel Check carbon brushes on flywheel, replace as necessary. X W1697
QL1 3000 2a Turbochargers Clean compressor wheel. W1076
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel. X W1698
QL1 5250 3a Air filters Fit new air filters. X W1005
QL1 5250 9a Fuel injectors Replace fuel injectors. W1006
QL1 5250 9a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 5250 9a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 5250 18 a Turbochargers Check turbine housing for cracks (externally by visual inspection and W1577
internally by endoscopic examination), replace if necessary..
QL1 10500 6a Crankcase breathers Fit new oil separators. W1055
QL3 10500 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 10500 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 10500 9a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
ating parameters. Then drain coolant and flush cooling systems.
TIM-ID: 0000044616 - 001

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
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
w = weeks
m = months
a = years

32 | Maintenance Schedule | MS50140/00E 2013-08

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Inspect centrifugal oil filter for wear. X W2009
Overhaul starter. W2010
Clean engine oil cooler and inspect it for leaks. W2018
Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Auxiliary PTO coupling: Check rubber elements (visual inspection), re- W2106
place parts if necessary.
Overhaul engine coolant pump. W2110
QL3 10500 18 a Turbochargers Overhaul turbochargers. W1038
QL4 10500 5a Elastomer coupling (main PTO) Fit new elastomer components . X W1544
QL3 10500 9a HP fuel pump Fit new high-pressure fuel pump. W1058
QL3 21000 6a Hose lines Replace all hose lines. W1251
QL3 21000 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pat- W1063
tern on cylinder liner running surfaces.
QL4 21000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 21000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 fuel delivery pump. W3010
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 replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Fit new turbine wheels for turbochargers. W3101
Overhaul Geislinger coupling. X W3102
Replace swing followers and swing-follower shafts. W3103
Check vibration damper, fit new one if necessary. W3108
Insulated flywheel: Check and repair if required. W3145
Torsionally resilient coupling. Check parts. Fit new friction rings and X W3136
disks.
Overhaul battery-charging generator. X W3042
QL4 42000 18 a Turbochargers Fit new compressor wheels for turbochargers. W1472
w = weeks
m = months
a = years
TIM-ID: 0000044616 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 33

 1.13 Maintenance schedule matrix 18,000h
0-21,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
21,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Limit

Daily
Engine
Engine oil filter 2a
Engine operation - X
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X X
Valve gear 18 a X X X X X X X
Flywheel 18 a X X X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
Hose lines 6a X
HP fuel pump 9a X
Cylinder heads 18 a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

22,000-36,000 Operating hours

TIM-ID: 0000044610 - 001

Item Operating hours [h]

22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X X X X X X
w = weeks
m = months
a = years

34 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
31,000
32,000
33,000
34,000
35,000
36,000
Limit
Air filters 6m X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X
Valve gear 18 a X X X X X
Flywheel 18 a X X X X X
Air filters 3a X X X
Fuel injectors 9a X X X
Engine governor 9a X X X
Combustion chambers 9a X X X
Turbochargers 18 a X X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
Hose lines 6a X
HP fuel pump 9a X
Cylinder heads 18 a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000044610 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 35

 1.14 Maintenance tasks 18,000h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
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 the inspection bores of the HP fuel pump. W0504
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 1000 6m Oil indicator filter Check and clean oil indicator filter. X W1047
QL1 1000 6m Air filters Clean air filter(s) Empty dust collector box. X W1027
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Intermediate fuel filter Replace intermediate fuel filter of filter element of intermediate fuel fil- W1481
ter.
QL1 1000 2a Fuel prefilter Replace filter element of fuel prefilter and sealing ring depending on W1164
the degree of contamination, when the limit (years) is reached, at the
latest.
QL1 1000 18 a Flywheel Check carbon brushes on flywheel, replace as necessary. X W1697
QL1 3000 2a Turbochargers Clean compressor wheel. W1076
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel. X W1698
QL1 6000 3a Air filters Fit new air filters. X W1005
QL1 6000 9a Fuel injectors Replace fuel injectors. W1006
QL1 6000 9a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 6000 9a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 6000 18 a Turbochargers Check turbine housing for cracks (externally by visual inspection and W1577
internally by endoscopic examination), replace if necessary..
QL1 9000 6a Crankcase breathers Fit new oil separators. W1055
QL3 9000 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 9000 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 9000 9a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
ating parameters. Then drain coolant and flush cooling systems.
TIM-ID: 0000044618 - 001

Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
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
w = weeks
m = months
a = years

36 | Maintenance Schedule | MS50140/00E 2013-08

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Inspect centrifugal oil filter for wear. X W2009
Overhaul starter. W2010
Clean engine oil cooler and inspect it for leaks. W2018
Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Auxiliary PTO coupling: Check rubber elements (visual inspection), re- W2106
place parts if necessary.
Overhaul engine coolant pump. W2110
QL3 9000 18 a Turbochargers Overhaul turbochargers. W1038
QL4 9000 5a Elastomer coupling (main PTO) Fit new elastomer components . X W1544
QL3 18000 6a Hose lines Replace all hose lines. W1251
QL3 18000 9a HP fuel pump Fit new high-pressure fuel pump. W1058
QL3 18000 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pat- W1063
tern on cylinder liner running surfaces.
QL4 18000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 18000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 fuel delivery pump. W3010
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 replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Fit new turbine wheels for turbochargers. W3101
Overhaul Geislinger coupling. X W3102
Replace swing followers and swing-follower shafts. W3103
Check vibration damper, fit new one if necessary. W3108
Insulated flywheel: Check and repair if required. W3145
Torsionally resilient coupling. Check parts. Fit new friction rings and X W3136
disks.
Overhaul battery-charging generator. X W3042
QL4 36000 18 a Turbochargers Fit new compressor wheels for turbochargers. W1472
w = weeks
m = months
a = years
TIM-ID: 0000044618 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 37

 1.15 Maintenance schedule matrix 15,000h
0-20,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,000
9,000
Limit

Daily
Engine
Engine oil filter 2a
Engine operation - X
Oil indicator filter 6m X X X X X X X X X X X X X X X X X X X X
Air filters 6m X X X X X X X X X X X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X X X X X X X X X X X
Turbochargers 2a X X X X X X
Valve gear 18 a X X X X X X
Flywheel 18 a X X X X X X
Air filters 3a X X X X
Fuel injectors 9a X X X X
Engine governor 9a X X X X
Combustion chambers 9a X X X X
Turbochargers 18 a X X X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
Hose lines 6a X
HP fuel pump 9a X
Cylinder heads 18 a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a
w = weeks
m = months
a = years

21,000-30,000 Operating hours

TIM-ID: 0000044611 - 001

Item Operating hours [h]

21,000
22,000
22,500
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
Limit

Engine
Engine oil filter 2a
Engine operation -
Oil indicator filter 6m X X X X X X X X X X
w = weeks
m = months
a = years

38 | Maintenance Schedule | MS50140/00E 2013-08

 Item Operating hours [h]

21,000
22,000
22,500
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
Limit
Air filters 6m X X X X X X X X X X
Engine mounts 1a X X X X X X X X X X
Centrifugal oil filter 2a X X X X X X X X X X
Fuel filter 2a X X X X X X X X X X
Intermediate fuel filter 2a X X X X X X X X X X
Fuel prefilter 2a X X X X X X X X X X
Flywheel 18 a X X X X X X X X X X
Turbochargers 2a X X X X
Valve gear 18 a X X X X
Flywheel 18 a X X X X
Air filters 3a X X
Fuel injectors 9a X X
Engine governor 9a X X
Combustion chambers 9a X X
Turbochargers 18 a X X
Crankcase breathers 6a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Turbochargers 18 a X X
Elastomer coupling (main PTO) 5a X X
Hose lines 6a X
HP fuel pump 9a X
Cylinder heads 18 a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000044611 - 001

MS50140/00E 2013-08 | Maintenance Schedule | 39

 1.16 Maintenance tasks 15,000h
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the X W1008
latest, on expiry of the time limit (given in years).
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 the inspection bores of the HP fuel pump. W0504
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 1000 6m Oil indicator filter Check and clean oil indicator filter. X W1047
QL1 1000 6m Air filters Clean air filter(s) Empty dust collector box. X W1027
QL1 1000 1a Engine mounts Carry out visual inspection of engine mounts for general condition. W1463
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the lat- X W1009
est, each time the engine oil is changed.
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 1000 2a Intermediate fuel filter Replace intermediate fuel filter of filter element of intermediate fuel fil- W1481
ter.
QL1 1000 2a Fuel prefilter Replace filter element of fuel prefilter and sealing ring depending on W1164
the degree of contamination, when the limit (years) is reached, at the
latest.
QL1 1000 18 a Flywheel Check carbon brushes on flywheel, replace as necessary. X W1697
QL1 3000 2a Turbochargers Clean compressor wheel. W1076
QL1 3000 18 a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment W1207
after 1,000 hours.
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel. X W1698
QL1 5000 3a Air filters Fit new air filters. X W1005
QL1 5000 9a Fuel injectors Replace fuel injectors. W1006
QL1 5000 9a Engine governor Injector: reset drift compensation parameters (CDC). W1713
QL1 5000 9a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 5000 18 a Turbochargers Check turbine housing for cracks (externally by visual inspection and W1577
internally by endoscopic examination), replace if necessary..
QL1 7500 6a Crankcase breathers Fit new oil separators. W1055
QL3 7500 5a Engine mounts Check buffer clearance of resilient mounts Check proper seating of se- W1026
curing screws.
QL3 7500 6a Rubber sleeves Replace all rubber sleeves. W1250
QL3 7500 9a Component maintenance Before starting maintenance work, carry out test run and record oper- W2012
ating parameters. Then drain coolant and flush cooling systems.
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Inspect rocker arms and valve bridge for wear. Insert an endoscope W2001
through the pushrod bore to visually inspect swing followers and cam-
shaft running surfaces.
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
w = weeks
m = months
a = years

40 | Maintenance Schedule | MS50140/00E 2013-08

 Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Inspect centrifugal oil filter for wear. X W2009
Overhaul starter. W2010
Clean engine oil cooler and inspect it for leaks. W2018
Fit new seals/sealing materials for all disassembled components. W2062
Overhaul charge-air coolant pump. W2070
Auxiliary PTO coupling: Check rubber elements (visual inspection), re- W2106
place parts if necessary.
Overhaul engine coolant pump. W2110
QL3 7500 18 a Turbochargers Overhaul turbochargers. W1038
QL4 7500 5a Elastomer coupling (main PTO) Fit new elastomer components . X W1544
QL3 15000 6a Hose lines Replace all hose lines. W1251
QL3 15000 9a HP fuel pump Fit new high-pressure fuel pump. W1058
QL3 15000 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pat- W1063
tern on cylinder liner running surfaces.
QL4 15000 6a Automatic engine oil filter Remove filter housing and clean. Fit new filter candles. X W1478
QL4 15000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
nance per assembly instructions and repair or fit new components as re-
quired.
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 fuel delivery pump. W3010
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 replace W3063
if necessary.
Fit new engine oil pump. W3073
Fit new rubber elements of engine mounts. W3100
Fit new turbine wheels for turbochargers. W3101
Overhaul Geislinger coupling. X W3102
Replace swing followers and swing-follower shafts. W3103
Check vibration damper, fit new one if necessary. W3108
Insulated flywheel: Check and repair if required. W3145
Torsionally resilient coupling. Check parts. Fit new friction rings and X W3136
disks.
Overhaul battery-charging generator. X W3042
QL4 30000 18 a Turbochargers Fit new compressor wheels for turbochargers. W1472
w = weeks
m = months
a = years
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MS50140/00E 2013-08 | Maintenance Schedule | 41