MTU_ValueService

Technical Documentation

Diesel Engine
V 396 TE94
Application Group 1DS

Maintenance Schedule
M050705/03E
applicable for ...

12V396TE94
16V396TE94
8V396TE94

Printed in Germany
© 2010 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, microfilming 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.
 Preface 01

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 average values based on
operational experience and are therefore to be regarded as guidelines only. Special operating conditions and technical
requirements may require additional maintenance work and/or modification of the maintenance intervals. 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 oper-
ation 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 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 approved 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:
Battery maintenance depends on the level of use and the ambient conditions. The battery
manufacturer’s instructions must be obeyed.
The relevant manufacturer’s instructions apply with respect to the maintenance of any components
which do not appear in this maintenance schedule.
This Maintenance Schedule may include components which are not installed on your engine; 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
1DS Continuous operation, variable, low load

Load profile
Load factor 100% 70% <10%
TIM ID: 0000000001 – 001

Corresponding operating time 10% 70% 20%

M050705/03E 2010-06 © MTU

02 Maintenance schedule matrix

2 Maintenance schedule matrix

0-5.250 Operating hours

Item Operating hours [h]

1.000
1.250
1.500
1.750
2.000
2.250
2.500
2.750
3.000
3.250
3.500
3.750
4.000
4.250
4.500
4.750
5.000
5.250
Limit

Daily
250
500
750
Engine operation - X
Engine oil filter 2a

Emergency air shut-off flaps 1a X X X X X X X X X X X X X X X X X X X X X

Engine oil edge-type filter 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 1a X X X X X X X X X X X X X X X X X X X X X

Valve gear 18 a X X X X X X X X X X

Air filters 1a X X X X X X X X X X

Lubrication points 1a X X X X X X X X X X

Fuel filter 2a X X X X X X X X X X

Starter 18 a X X X

Fuel injectors 18 a X X X
Battery charging generator 18 a X X X
Engine coolant circuit 18 a X X X

Combustion chambers 18 a X X X

Engine mounts 2a X X X

Air filters 3a X X X

Turbochargers 18 a X
Turbocharger control system 18 a X
Component maintenance 18 a X
Battery charging generator 18 a X
Cylinder heads 18 a X

Turbocharger control system 18 a

Extended component maintenance 18 a
w = weeks
m = months
a = years
TIM ID: 0000000002 – 001

M050705/03E 2010-06 © MTU

 Maintenance schedule matrix 03

5.500-6.000 Operating hours

Item Operating hours [h]

5.500
5.750
6.000
Limit
Engine operation -

Engine oil filter 2a

Emergency air shut-off flaps 1a X X X

Engine oil edge-type filter 1a X X X

Centrifugal oil filter 1a X X X

Valve gear 18 a X X
Air filters 1a X X

Lubrication points 1a X X
Fuel filter 2a X X

Starter 18 a X

Fuel injectors 18 a X
Battery charging generator 18 a X
Engine coolant circuit 18 a X

Combustion chambers 18 a X

Engine mounts 2a X

Air filters 3a X

Turbochargers 18 a X
Turbocharger control system 18 a X
Component maintenance 18 a X

Battery charging generator 18 a X

Cylinder heads 18 a X

Turbocharger control system 18 a X

Extended component maintenance 18 a X
w = weeks
m = months
a = years
TIM ID: 0000000002 – 001

M050705/03E 2010-06 © MTU

04 Maintenance tasks

3 Maintenance tasks

Qual- Inter- Limit Item Maintenance tasks Task

ifica- val
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

QL1 - 2a Engine oil filter Drain off oil sludge and test for metallic residues. Fit new filter inserts W1096
when the oil is changed or at the latest when the time limit has been
reached.
QL1 250 1a Emergency air shut-off flaps Check operation of emergency air shut-off flaps (electrical) . W1024

QL1 250 1a Engine oil edge-type filter Actuate ratchet lever several times. W1080

QL1 250 1a Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve (if fitted) . W1009

QL1 500 18 a Valve gear Check valve clearance . W1002

QL1 500 1a Air filters Clean air filter(s) . W1173

QL1 500 1a Lubrication points Apply lubricant at lubrication points. W1053

QL1 500 2a Fuel filter Fit new fuel filter or new fuel filter insert . W1001

QL1 1500 18 a Starter Starter: Inspect carbon brushes. W1061

QL1 1500 18 a Fuel injectors Remove fuel injectors, inspect them and fit new sealing rings. W1060

QL1 1500 18 a Battery charging generator Battery-charging generator: Inspect carbon brushes and coupling . W1174

QL1 1500 18 a Engine coolant circuit Clean strainers in coolant return line . W1189

QL1 1500 18 a Combustion chambers Inspect cylinder chambers using endoscope . W1011

QL1 1500 2a Engine mounts Check buffer clearance of resilient mounts Check proper seating of W1026
securing screws .
QL1 1500 3a Air filters Fit new air filters . W1005

QL3 3000 18 a Turbochargers Overhaul turbochargers (MTU-ZR-turbocharger). W1038

QL3 3000 18 a Turbocharger control Overhaul exhaust flaps, air flaps, actuating cylinders and solenoids. W1131
system

QL3 3000 18 a Component maintenance Before starting maintenance work, drain the coolant and flush the W2000
cooling systems .

Clean air ducting . W2002

Clean intercooler and inspect for leakage . W2003

Inspect centrifugal oil filter for wear (if fitted) . W2009

Clean engine coolant cooler and, if possible, inspect it for leaks . W2017
TIM ID: 0000000003 – 001

Check engine alignment . W2036

Starting air distributor: Inspect components. Check settings. Adjust if W2041

necessary .

Overhaul engine coolant pump . W2110

w = weeks
m = months
a = years

M050705/03E 2010-06 © MTU

 Maintenance tasks 05

Qual- Inter- Limit Item Maintenance tasks Task

ifica- val
tion
level [h]

Overhaul raw-water pump . W2111

Overhaul bilge pump (if fitted) . W2112

Exhaust line: Clean housing and hot components and check for W2113
cracks .

Fuel injection pumps: Check basic setting of injection timing . W2105

Fit new seals/sealing materials for all disassembled components . W2062

QL3 3000 18 a Battery charging generator Overhaul battery-charging generator. W1043

QL3 3000 18 a Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear W1063
pattern on cylinder liner running surfaces .

QL4 6000 18 a Turbocharger control Overhaul exhaust flaps, air flaps, actuating cylinders and solenoids. W1131
system

QL4 6000 18 a Extended component Completely disassemble the engine.Inspect engine components W3000
maintenance as per assembly instructions and repair or fit new components as
required .
Replace all elastomeric parts and seals with new ones . W3001
Fit new conrod bearings . W3003

Fit new crankshaft bearings . W3004

Fit new oil separator for crankcase breather system . W3009

Fit new fuel delivery pump . W3010

Fit new exhaust flap bearings . W3013

Remove pistons. Inspect skirts and crowns. Fit new piston rings . W3015
Inspect gear train for cracks. Inspect bearings . W3017

Fit new camshaft bearings and camshaft thrust bearings . W3018

Remove and inspect vibration damper. Repair if necessary . W3019

Re-hone cylinder liners or fit new ones if necessary . W3061

Overhaul fuel injection pump. W3071

w = weeks
m = months
a = years
TIM ID: 0000000003 – 001

M050705/03E 2010-06 © MTU