Maintenance Schedule

Diesel Engine
Surface Mining
with MTU Series 4000 C13x/C23x Engines
Application Groups 5A, 5B

MS50096/02E
12V4000C13
12V4000C13L
12V4000C13R
12V4000C23
12V4000C23R
16V4000C13
16V4000C13L
16V4000C13R
16V4000C23
16V4000C23R
20V4000C13L
20V4000C23
20V4000C23L
Table 1: applicable for ...

Printed in Germany
© 2011 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, micro‐
filming 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 1.6 Maintenance schedule matrix TBO 18,000h 13
1.7 Maintenance tasks TBO 18,000h 14
1.1 Preface 4 1.8 Maintenance schedule matrix TBO 15,000h 16
1.2 Allocation matrix application group 5A 6 1.9 Maintenance tasks TBO 15,000h 17
1.3 Allocation matrix application group 5B 7 1.10 Maintenance schedule matrix TBO 12,000h 19
1.4 Maintenance schedule matrix TBO 21,000h 9 1.11 Maintenance tasks TBO 12,000h 20
1.5 Maintenance tasks TBO 21,000h 11
DCL-ID: 0000012596 - 003

MS50096/02E 2011-12 | Table of Contents | 3

 1 Maintenance Schedule
1.1 Preface
MTU maintenance concept
The following applies in the case of engines which are subject to emissions regulations:
Emissions regulations prohibit alteration, removal or addition of any mechanical or electronic component
or calibration that could affect the emissions characteristics of the engine. Maintenance, replacement, or
repair of emissions control devices, sensors, cylinder heads and exhaust flaps, for example, can only be
performed using MTU approved components or equivalents.
Failure to adhere to these guidelines could result in violation of legal requirements.
MTU Maintenance Schedules ensure the reliability and performance of MTU engines and must be ad‐
hered to during the full life of the engine. In the case of engines which are not subject to any emissions
regulations, the maintenance intervals cited are to be regarded as guideline values.

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 average
values based on operational experience and are therefore to be regarded as guidelines only. Special op‐
erating conditions and technical requirements may require additional maintenance work and/or modifica‐
tion 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 applicable. 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 vari‐
ous Qualification Levels QL1 to QL4 reflect the levels of training offered in MTU courses and the con‐
tents 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 Specifications
A001061 and in the fluids and lubricants specifications produced by the component manufacturers. They
TIM-ID: 0000032006 - 002

are therefore not included in the maintenance schedule (exception: deviations from the Fluids and Lubri‐
cants Specifications). All fluids and lubricants used must meet MTU specifications and be approved by
the relevant component manufacturer.

4 | Maintenance Schedule | MS50096/02E 2011-12

 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 deter‐
gents. 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:
Battery maintenance depends on the level of use and the ambient conditions. The battery manufactur‐
er'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.

Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
in accordance with the Fluids and Lubricants Specifications, MTU Publication No. A001061.

Application Group
5A Continuous operation, unrestricted
5B Continuous operation, variable
TIM-ID: 0000032006 - 002

MS50096/02E 2011-12 | Maintenance Schedule | 5

 1.2 Allocation matrix application group 5A
Allocation matrix: Excavator
Load profile 4000-03
Load factor %
Load % Time% ≤119 kW/cyl. / ≤159 bhp/cyl.
100 71
80 9
< 82 TBO 18,000
20 16
Idle 4

TIM-ID: 0000032007 - 003

6 | Maintenance Schedule | MS50096/02E 2011-12

 1.3 Allocation matrix application group 5B
Note:
TBO identifiable via cylinder power (shown on engine ID plate or in 'Engine Data' in Business Portal,
power/number of cylinder) and, where appropriate, contractually agreed load profile.

Allocation matrix: Haul truck

Load Profile Load V 4000-03
Time Fac‐ 93 kW/cyl. 109 kW/cyl. 117 kW/cyl. 126 kW/cyl. 140 kW/cyl. 150 kW/cyl.
Load% tor % 125 bhp/cyl. 146 bhp/cyl. 157 bhp/cyl. 169 bhp/cyl. 188 bhp/cyl. 204 bhp/cyl.
%
100 12
80 12
15-25 TBO 21,000 TBO 21,000 TBO 21,000 TBO 21,000 TBO 21,000 TBO 21,000
20 16
Idle 60
100 17
80 13
26-30 TBO 21,000 TBO 21,000 TBO 21,000 TBO 21,000 TBO 21,000 TBO 18,000
20 15
Idle 55
100 21
80 14
31-35 TBO 21,000 TBO 21,000 TBO 21,000 TBO 18,000 TBO 18,000 TBO 18,000
20 14
Idle 51
100 26
80 15
36-40 TBO 21,000 TBO 21,000 TBO 18,000 TBO 18,000 TBO 18,000 TBO 15,000
20 12
Idle 47
100 30
80 16
41-45 TBO 21,000 TBO 18,000 TBO 18,000 TBO 15,000 TBO 15,000 TBO 12,000
20 12
Idle 42
100 35
80 15
46-50 TBO 18,000 TBO 18,000 TBO 15,000 TBO 12,000 TBO 12,000 TBO 12,000
20 12
Idle 38
100 39
TIM-ID: 0000032017 - 002

80 15
51-55 TBO 18,000 TBO 15,000 TBO 12,000 NA NA NA
20 12
Idle 34

MS50096/02E 2011-12 | Maintenance Schedule | 7

 Allocation matrix: Wheel loader
Load Profile V 4000-03
Load Factor % 93 kW/cyl. 100 kW/cyl. 112 kW/cyl. 116 kW/cyl. 119 kW/cyl.
Load % Time %
125 bhp/cyl. 134 bhp/cyl. 150 bhp/cyl. 157 bhp/cyl. 160 bhp/cyl.
100 4
80 7
60 7
up to 30 TBO 18,000 TBO 18,000 TBO 18,000 TBO 18,000 TBO 18,000
40 16
20 32
Idle 34
100 5
80 8
60 8
>30-35 TBO 18,000 TBO 18,000 TBO 18,000 TBO 15,000 TBO 15,000
40 17
20 32
Idle 30
100 9
80 8
60 11
>35-40 TBO 18,000 TBO 18,000 TBO 15,000 TBO 15,000 TBO 15,000
40 20
20 30
Idle 22
100 14
80 8
60 11
>40-45 TBO 18,000 TBO 18,000 TBO 15,000 TBO 12,000 TBO 12,000
40 20
20 29
Idle 18
100 19
80 8
60 11
>45-50 TBO 18,000 TBO 18,000 TBO 12,000 TBO 12,000 NA
40 20
20 28
Idle 14
TIM-ID: 0000032017 - 002

100 27
80 8
60 11
>50-55 TBO 18,000 TBO 15,000 TBO 12,000 NA NA
40 15
20 26
Idle 13

8 | Maintenance Schedule | MS50096/02E 2011-12

 1.4 Maintenance schedule matrix TBO 21,000h
0-15,000 Operating hours
Item Operating hours [h]

10,000
10,500
11,000
12,000
13,000
13,750
14,000
15,000
1,000
2,000
2,750
3,000
4,000
5,000
5,250
5,500
6,000
7,000
8,000
8,250
9,000
Daily
Limit
Engine operation - X
Oil indicator filter 6m 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
Belt drive 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
Battery charging generator 1a X X X X X X X
Coolant filters 2a X X X X X
Flywheel 18 a X X X X X
Valve gear 2a X X
Fuel injectors 9a X X
Combustion chambers 9a X X
Engine governor 9a X X
Battery charging generator 9a X X
Turbochargers 18 a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Fuel delivery pump 9a X
HP fuel pump 9a X
Auxiliary PTO 9a X
Cylinder heads 9a
Hose lines 6a
Automatic engine oil filter 6a
Extended component maintenance 18 a
Turbochargers 18 a
Engine mounts 18 a
w = weeks
m = months
a = years

15,750-21,000 Operating hours

Item Operating hours [h]
15,750
16,000
16,500
17,000
18,000
19,000
19,250
20,000
21,000
Limit

Engine operation -
TIM-ID: 0000032062 - 002

Oil indicator filter 6m X X X X X X

Centrifugal oil filter 2a X X X X X X
Fuel filter 2a X X X X X X
Belt drive 2a X X X X X X
Flywheel 18 a X X X X X X
Battery charging generator 1a X X X
Coolant filters 2a X X
w = weeks
m = months
a = years

MS50096/02E 2011-12 | Maintenance Schedule | 9

Item Operating hours [h]

15,750
16,000
16,500
17,000
18,000
19,000
19,250
20,000
21,000
Limit
Flywheel 18 a X X
Valve gear 2a X X
Fuel injectors 9a X X
Combustion chambers 9a X X
Engine governor 9a X X
Battery charging generator 9a X
Turbochargers 18 a X
Engine mounts 5a X
Rubber sleeves 6a X
Component maintenance 9a X
Fuel delivery pump 9a X
HP fuel pump 9a X
Auxiliary PTO 9a X
Cylinder heads 9a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
Engine mounts 18 a X
w = weeks
m = months
a = years

TIM-ID: 0000032062 - 002

10 | Maintenance Schedule | MS50096/02E 2011-12

 1.5 Maintenance tasks TBO 21,000h
Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

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 (if fitted) 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 (if fitted) W0507
Check service indicator of fuel prefilter (if fitted) W0508
Inspect battery-charging generator for contamination and clean if necessary W0525
QL1 1000 6m Oil indicator filter Check and clean oil indicator filter W1047
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each W1009
time the engine oil is changed (if fitted)
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert W1001
QL1 1000 2a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjust tension W1241
QL1 1000 18 a Flywheel Check carbon brushes on flywheel (if fitted), replace if necessary W1697
QL1 2000 1a Battery charging generator Remove battery-charging generator and clean thoroughly with compressed W1209
air
QL1 2750 2a Coolant filters Fit new coolant filters W1036
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel (if fitted) W1698
QL1 5250 2a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment after W1207
1,000 hours!
QL1 5250 9a Fuel injectors Fit new fuel injectors W1006
QL1 5250 9a Combustion chambers Inspect cylinder chambers using endoscope W1011
QL1 5250 9a Engine governor Injector: reset drift compensation parameters (CDC) W1713
QL3 7000 9a Battery charging generator Overhaul battery-charging generator W1043
QL3 10500 18 a Turbochargers Overhaul turbochargers W1038
QL3 10500 5a Engine mounts Check tightness of securing screws W1519
QL3 10500 6a Rubber sleeves Replace all rubber sleeves W1250
QL3 10500 9a Component maintenance Before starting maintenance work, drain the coolant and flush the cooling sys‐ W2000
tems
Inspect rocker arms and valve bridge for wear. Insert an endoscope through W2001
the pushrod bore to visually inspect swing followers and camshaft 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
Inspect centrifugal oil filter for wear (if fitted) W2009
Overhaul starter W2010
TIM-ID: 0000032063 - 002

Overhaul charge-air coolant pump W2070

Fit new seals/sealing materials for all disassembled components W2062
Overhaul engine coolant pump W2110
QL3 10500 9a Fuel delivery pump Fit new fuel delivery pump W1051
QL3 10500 9a HP fuel pump Fit new high-pressure fuel pump W1058
QL3 10500 9a Auxiliary PTO Check function of drive (pulley) for add-on components, replace if necessary. W1696
Replace shaft seal.
w = weeks
m = months
a = years

MS50096/02E 2011-12 | Maintenance Schedule | 11

Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

QL3 21000 9a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on W1063
cylinder liner running surfaces
QL3 21000 6a Hose lines Replace all hose lines W1251
QL1 21000 6a Automatic engine oil filter Remove filter housing and clean, replace filter candles (if fitted) W1478
QL4 21000 18 a Extended component mainte‐ Completely disassemble the engine. Inspect engine components as per as‐ W3000
nance sembly instructions and repair or fit new components as required
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 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 if nec‐ W3063
essary
Fit new engine oil pump W3073
Replace wiring harnesses W3083
Fit new rubber elements of engine mounts W3100
Fit new turbine wheels for turbochargers W3101
Replace swing followers and swing-follower shafts W3103
Remove and inspect vibration damper. Repair if necessary W3019
Replace insulated flywheel W3139
QL4 21000 18 a Turbochargers Fit new compressor wheels for turbochargers W1472
QL4 21000 18 a Engine mounts Fit new Trunnion mount element W1124
w = weeks
m = months
a = years

TIM-ID: 0000032063 - 002

12 | Maintenance Schedule | MS50096/02E 2011-12

 1.6 Maintenance schedule matrix TBO 18,000h
0-18,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Daily
Limit
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
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
Belt drive 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
Battery charging generator 1a X X X X X X X X X
Coolant filters 2a X X X X X X
Flywheel 18 a X X X X X X
Valve gear 2a X X X X X X
Fuel injectors 9a X X X
Combustion chambers 9a X X X
Engine governor 9a X X X
Battery charging generator 9a X X X
Turbochargers 18 a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Component maintenance 9a X X
Fuel delivery pump 9a X X
HP fuel pump 9a X X
Auxiliary PTO 9a X X
Cylinder heads 9a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
Engine mounts 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000032070 - 002

MS50096/02E 2011-12 | Maintenance Schedule | 13

 1.7 Maintenance tasks TBO 18,000h
Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

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 (if fitted) 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 (if fitted) W0507
Check service indicator of fuel prefilter (if fitted) W0508
Inspect battery-charging generator for contamination and clean if necessary W0525
QL1 1000 6m Oil indicator filter Check and clean oil indicator filter W1047
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each W1009
time the engine oil is changed (if fitted)
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert W1001
QL1 1000 2a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjust tension W1241
QL1 1000 18 a Flywheel Check carbon brushes on flywheel (if fitted), replace if necessary W1697
QL1 2000 1a Battery charging generator Remove battery-charging generator and clean thoroughly with compressed W1209
air
QL1 3000 2a Coolant filters Fit new coolant filters W1036
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel (if fitted) W1698
QL1 3000 2a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment after W1207
1,000 hours!
QL1 6000 9a Fuel injectors Fit new fuel injectors W1006
QL1 6000 9a Combustion chambers Inspect cylinder chambers using endoscope W1011
QL1 6000 9a Engine governor Injector: reset drift compensation parameters (CDC) W1713
QL3 6000 9a Battery charging generator Overhaul battery-charging generator W1043
QL3 9000 18 a Turbochargers Overhaul turbochargers W1038
QL3 9000 5a Engine mounts Check tightness of securing screws W1519
QL3 9000 6a Rubber sleeves Replace all rubber sleeves W1250
QL3 9000 9a Component maintenance Before starting maintenance work, drain the coolant and flush the cooling sys‐ W2000
tems
Inspect rocker arms and valve bridge for wear. Insert an endoscope through W2001
the pushrod bore to visually inspect swing followers and camshaft 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
Inspect centrifugal oil filter for wear (if fitted) W2009
Overhaul starter W2010
TIM-ID: 0000032071 - 002

Overhaul charge-air coolant pump W2070

Fit new seals/sealing materials for all disassembled components W2062
Overhaul engine coolant pump W2110
QL3 9000 9a Fuel delivery pump Fit new fuel delivery pump W1051
QL3 9000 9a HP fuel pump Fit new high-pressure fuel pump W1058
QL3 9000 9a Auxiliary PTO Check function of drive (pulley) for add-on components, replace if necessary. W1696
Replace shaft seal.
w = weeks
m = months
a = years

14 | Maintenance Schedule | MS50096/02E 2011-12

 Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

QL3 18000 9a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on W1063
cylinder liner running surfaces
QL3 18000 6a Hose lines Replace all hose lines W1251
QL1 18000 6a Automatic engine oil filter Remove filter housing and clean, replace filter candles (if fitted) W1478
QL4 18000 18 a Extended component mainte‐ Completely disassemble the engine. Inspect engine components as per as‐ W3000
nance sembly instructions and repair or fit new components as required
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 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 if nec‐ W3063
essary
Fit new engine oil pump W3073
Replace wiring harnesses W3083
Fit new rubber elements of engine mounts W3100
Fit new turbine wheels for turbochargers W3101
Replace swing followers and swing-follower shafts W3103
Remove and inspect vibration damper. Repair if necessary W3019
Replace insulated flywheel W3139
QL4 18000 18 a Turbochargers Fit new compressor wheels for turbochargers W1472
QL4 18000 18 a Engine mounts Fit new Trunnion mount element W1124
w = weeks
m = months
a = years
TIM-ID: 0000032071 - 002

MS50096/02E 2011-12 | Maintenance Schedule | 15

 1.8 Maintenance schedule matrix TBO 15,000h
0-15,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
13,000
14,000
15,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,000
9,000
Daily
Limit
Engine operation - X
Oil indicator filter 6m 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
Belt drive 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
Battery charging generator 1a X X X X X X X
Coolant filters 2a X X X X X
Flywheel 18 a X X X X X
Valve gear 2a X X X
Fuel injectors 9a X X X
Combustion chambers 9a X X X
Engine governor 9a X X X
Battery charging generator 9a X X
Turbochargers 18 a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Auxiliary PTO 9a X X
Component maintenance 9a X
Fuel delivery pump 9a X
HP fuel pump 9a X
Cylinder heads 9a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
Engine mounts 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000032073 - 002

16 | Maintenance Schedule | MS50096/02E 2011-12

 1.9 Maintenance tasks TBO 15,000h
Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

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 (if fitted) 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 (if fitted) W0507
Check service indicator of fuel prefilter (if fitted) W0508
Inspect battery-charging generator for contamination and clean if necessary W0525
QL1 1000 6m Oil indicator filter Check and clean oil indicator filter W1047
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each W1009
time the engine oil is changed (if fitted)
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert W1001
QL1 1000 2a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjust tension W1241
QL1 1000 18 a Flywheel Check carbon brushes on flywheel (if fitted), replace if necessary W1697
QL1 2000 1a Battery charging generator Remove battery-charging generator and clean thoroughly with compressed W1209
air
QL1 3000 2a Coolant filters Fit new coolant filters W1036
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel (if fitted) W1698
QL1 5000 2a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment after W1207
1,000 hours!
QL1 5000 9a Fuel injectors Fit new fuel injectors W1006
QL1 5000 9a Combustion chambers Inspect cylinder chambers using endoscope W1011
QL1 5000 9a Engine governor Injector: reset drift compensation parameters (CDC) W1713
QL3 7500 9a Battery charging generator Overhaul battery-charging generator W1043
QL3 7500 18 a Turbochargers Overhaul turbochargers W1038
QL3 7500 5a Engine mounts Check tightness of securing screws W1519
QL3 7500 6a Rubber sleeves Replace all rubber sleeves W1250
QL3 7500 9a Auxiliary PTO Check function of drive (pulley) for add-on components, replace if necessary. W1696
Replace shaft seal.
QL3 15000 9a Component maintenance Before starting maintenance work, drain the coolant and flush the cooling sys‐ W2000
tems
Inspect rocker arms and valve bridge for wear. Insert an endoscope through W2001
the pushrod bore to visually inspect swing followers and camshaft 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
TIM-ID: 0000032074 - 002

Inspect centrifugal oil filter for wear (if fitted) W2009

Overhaul starter W2010
Overhaul charge-air coolant pump W2070
Fit new seals/sealing materials for all disassembled components W2062
Overhaul engine coolant pump W2110
QL3 15000 9a Fuel delivery pump Fit new fuel delivery pump W1051
QL3 15000 9a HP fuel pump Fit new high-pressure fuel pump W1058
w = weeks
m = months
a = years

MS50096/02E 2011-12 | Maintenance Schedule | 17

Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

QL3 15000 9a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on W1063
cylinder liner running surfaces
QL3 15000 6a Hose lines Replace all hose lines W1251
QL1 15000 6a Automatic engine oil filter Remove filter housing and clean, replace filter candles (if fitted) W1478
QL4 15000 18 a Extended component mainte‐ Completely disassemble the engine. Inspect engine components as per as‐ W3000
nance sembly instructions and repair or fit new components as required
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 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 if nec‐ W3063
essary
Fit new engine oil pump W3073
Replace wiring harnesses W3083
Fit new rubber elements of engine mounts W3100
Fit new turbine wheels for turbochargers W3101
Replace swing followers and swing-follower shafts W3103
Remove and inspect vibration damper. Repair if necessary W3019
Replace insulated flywheel W3139
QL4 15000 18 a Turbochargers Fit new compressor wheels for turbochargers W1472
QL4 15000 18 a Engine mounts Fit new Trunnion mount element W1124
w = weeks
m = months
a = years

TIM-ID: 0000032074 - 002

18 | Maintenance Schedule | MS50096/02E 2011-12

 1.10 Maintenance schedule matrix TBO 12,000h
0-12,000 Operating hours
Item Operating hours [h]

10,000
11,000
12,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Daily
Limit
Engine operation - X
Oil indicator filter 6m 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
Fuel filter 2a X X X X X X X X X X X X
Belt drive 2a 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
Battery charging generator 1a X X X X X X
Coolant filters 2a X X X X
Flywheel 18 a X X X X
Valve gear 2a X X X X
Fuel injectors 9a X X
Combustion chambers 9a X X
Engine governor 9a X X
Battery charging generator 9a X X
Turbochargers 18 a X X
Engine mounts 5a X X
Rubber sleeves 6a X X
Auxiliary PTO 9a X X
Component maintenance 9a X
Fuel delivery pump 9a X
HP fuel pump 9a X
Cylinder heads 9a X
Hose lines 6a X
Automatic engine oil filter 6a X
Extended component maintenance 18 a X
Turbochargers 18 a X
Engine mounts 18 a X
w = weeks
m = months
a = years
TIM-ID: 0000032075 - 002

MS50096/02E 2011-12 | Maintenance Schedule | 19

 1.11 Maintenance tasks TBO 12,000h
Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

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 (if fitted) 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 (if fitted) W0507
Check service indicator of fuel prefilter (if fitted) W0508
Inspect battery-charging generator for contamination and clean if necessary W0525
QL1 1000 6m Oil indicator filter Check and clean oil indicator filter W1047
QL1 1000 2a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each W1009
time the engine oil is changed (if fitted)
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert W1001
QL1 1000 2a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjust tension W1241
QL1 1000 18 a Flywheel Check carbon brushes on flywheel (if fitted), replace if necessary W1697
QL1 2000 1a Battery charging generator Remove battery-charging generator and clean thoroughly with compressed W1209
air
QL1 3000 2a Coolant filters Fit new coolant filters W1036
QL1 3000 18 a Flywheel Replace carbon brushes on flywheel (if fitted) W1698
QL1 3000 2a Valve gear Check valve clearance, adjust if required. ATTENTION! First adjustment after W1207
1,000 hours!
QL1 6000 9a Fuel injectors Fit new fuel injectors W1006
QL1 6000 9a Combustion chambers Inspect cylinder chambers using endoscope W1011
QL1 6000 9a Engine governor Injector: reset drift compensation parameters (CDC) W1713
QL3 6000 9a Battery charging generator Overhaul battery-charging generator W1043
QL3 6000 18 a Turbochargers Overhaul turbochargers W1038
QL3 6000 5a Engine mounts Check tightness of securing screws W1519
QL3 6000 6a Rubber sleeves Replace all rubber sleeves W1250
QL3 6000 9a Auxiliary PTO Check function of drive (pulley) for add-on components, replace if necessary. W1696
Replace shaft seal.
QL3 12000 9a Component maintenance Before starting maintenance work, drain the coolant and flush the cooling sys‐ W2000
tems
Inspect rocker arms and valve bridge for wear. Insert an endoscope through W2001
the pushrod bore to visually inspect swing followers and camshaft 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
TIM-ID: 0000032076 - 002

Inspect centrifugal oil filter for wear (if fitted) W2009

Overhaul starter W2010
Overhaul charge-air coolant pump W2070
Fit new seals/sealing materials for all disassembled components W2062
Overhaul engine coolant pump W2110
QL3 12000 9a Fuel delivery pump Fit new fuel delivery pump W1051
QL3 12000 9a HP fuel pump Fit new high-pressure fuel pump W1058
w = weeks
m = months
a = years

20 | Maintenance Schedule | MS50096/02E 2011-12

 Qualifica‐ Interval Limit Item Maintenance tasks Task
tion level [h]

QL3 12000 9a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on W1063
cylinder liner running surfaces
QL3 12000 6a Hose lines Replace all hose lines W1251
QL1 12000 6a Automatic engine oil filter Remove filter housing and clean, replace filter candles (if fitted) W1478
QL4 12000 18 a Extended component mainte‐ Completely disassemble the engine. Inspect engine components as per as‐ W3000
nance sembly instructions and repair or fit new components as required
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 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 if nec‐ W3063
essary
Fit new engine oil pump W3073
Replace wiring harnesses W3083
Fit new rubber elements of engine mounts W3100
Fit new turbine wheels for turbochargers W3101
Replace swing followers and swing-follower shafts W3103
Remove and inspect vibration damper. Repair if necessary W3019
Replace insulated flywheel W3139
QL4 12000 18 a Turbochargers Fit new compressor wheels for turbochargers W1472
QL4 12000 18 a Engine mounts Fit new Trunnion mount element W1124
w = weeks
m = months
a = years
TIM-ID: 0000032076 - 002

MS50096/02E 2011-12 | Maintenance Schedule | 21