Maintenance Schedule

Diesel Engine
V 2000 Gx5
Application Group 3B

MS50002/06E
Engine model kW/cyl. Application group *
12V2000G25 48.3 kW/cyl. 3B
12V2000G25-TB 48.3 kW/cyl. 3B
12V2000G45 59.2 kW/cyl. 3B
12V2000G45-TB 59.2 kW/cyl. 3B
12V2000G65 57.9 kW/cyl. 3B
12V2000G65-TB 57.9 kW/cyl. 3B
12V2000G85 67.5 kW/cyl. 3B
12V2000G85-TB 67.5 kW/cyl. 3B
16V2000G25 50.6 kW/cyl. 3B
16V2000G25-TB 50.6 kW/cyl. 3B
16V2000G45 57.2 kW/cyl. 3B
16V2000G45-TB 57.2 kW/cyl. 3B
16V2000G65 55.6 kW/cyl. 3B
16V2000G65-TB 55.6 kW/cyl. 3B
16V2000G85 63.1 kW/cyl. 3B
16V2000G85-TB 63.1 kW/cyl. 3B
18V2000G65 55.6 kW/cyl. 3B
18V2000G65-TB 55.6 kW/cyl. 3B
18V2000G85 66.2 kW/cyl. 3B
18V2000G85-TB 66.2 kW/cyl. 3B
*
3B Continuous operation, variable load, ICXN
Table 1: Applicability

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

© Copyright Rolls-Royce Solutions

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of Rolls-Royce Solutions. This particularly applies to its reproduction, distribution, editing, translation, microfilming
and storage and/or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. Rolls-Royce Solutions re-
serves the right to change, delete or supplement the information provided as and when required.
 1 Maintenance Schedule
1.1 Preface
This manual provides instructions for your product from the manufacturer Rolls-Royce Solutions.

Maintenance concept
The maintenance system for Rolls-Royce Solutions products is based on a preventive maintenance concept.
Preventive maintenance facilitates advance operational planning and ensures a high level of equipment avail-
ability. The maintenance intervals as well as the required scopes of maintenance tasks are based on opera-
tional experience and therefore to be considered as recommendations. Additional maintenance work and/or
changes to the maintenance intervals may be required in the case of difficult operational and ambient condi-
tions.
Adherence to the specified maintenance intervals is essential to maintain product safety.
The intervals according to which the maintenance tasks have to be carried out are specified as operating
hours and time limits. Whichever value is reached first shall apply.
The maintenance intervals are determined and verified by the load profile. Load profiles can be evaluated by
the Service Partner of Rolls-Royce Solutions. Reading out load profile data is recommended for the first time
after between 500 and 1000 operating hours depending on the application concerned, or after changing the
duty profile or operating area.
The individual maintenance intervals are assigned to the qualification levels QL1 to QL4.
QL1: Operational monitoring and maintenance work which does not require disassembly of the product.
QL2: Exchange of components and parts in case of repair (corrective only, not part of the maintenance
schedule).
QL3: Maintenance work which requires partial disassembly of the product.
QL4: Maintenance work which requires complete disassembly of the product.

Additional notes on maintenance and preservation:

The relevant component manufacturer's instructions apply with respect to the maintenance of any compo-
nents which do not appear in this maintenance schedule.
For the change intervals of fluids and lubricants, refer to the corresponding Fluids and Lubricants Specifica-
tions.
If the product is to remain out of service for a longer time period, Rolls-Royce Solutions recommends to carry
out a monthly test run until engine operating temperature is reached. If the engine is scheduled to remain
out of service for > 1 month, carry out engine preservation procedures in accordance with the Preservation
and Represervation Specifications
The latest version of the specifications is available at http://www.mtu-solutions.com.
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MS50002/06E 2021-06 | Maintenance Schedule | 3

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

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 1.3 Load profile
Load profile
Power 90% 75% 50% 20%
Corresponding operating time 5% 40% 50% 5%
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MS50002/06E 2021-06 | Maintenance Schedule | 5

 1.4 Maintenance schedule matrix
0 to 10,000 Operating hours
Task Operating hours [h]

10,000
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
Limit

Daily
500

W0500 - X
W0501 - X
W0502 - X
W0503 - X
W0505 - X
W0506 - X
W0507 - X
W0508 - X
W0534 1m
W1008 2a
W1001 2a X X X X X X X X X X X X X X X X X X X X
W1002 - X X X X X X X X X X X X X X X X X X X X
W1010 1a X X X X X X X X X X X X X X X X X X X X
W1006 - X X X
W1178 - X X X
W1003 2a X X X
W1005 3a X X X
W1011 4a X X X
W1007 - X
W1388 - X
W2000 - X
W2002 - X
W2003 - X
W2014 - X
W2017 - X
W2036 - X
W2072 - X
W2073 - X
W2074 - X
W2062 - X
W1063 - X
W1056 - X
W3000 18 a X
W3001 18 a X
W3002 18 a X
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W3003 18 a X
W3004 18 a X
W3005 18 a X
W3010 18 a X
W3041 18 a X
W3042 18 a X
W3108 18 a X
w = weeks
m = months
a = years

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 1.5 Maintenance tasks
Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
QL1 Daily - Engine operation Check engine oil level. W0500
Carry out visual inspection of engine for general condition and leaks. W0501
Inspect intercooler drain system. X W0502
Inspect service indicator of air filter. W0503
Check relief bores of coolant pump(s). W0505
Check for abnormal running noises, exhaust gas color and vibration. W0506
Drain off water and contamination from fuel prefilter. X W0507
Check differential pressure gauge of fuel prefilter. X W0508
QL1 - 1m Engine operation Test run at not below 1/3 load and at least until steady-state tem- W0534
perature is reached (monthly).
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at W1008
the latest, on expiry of the time limit (given in years).
QL1 500 2a Fuel filter Fit new fuel filter or new fuel filter insert. W1001
QL1 500 - Valve gear Check valve clearance, adjust if necessary. W1002
QL1 500 1a Engine coolant cooler Check cooling elements for external contamination. W1010
QL1 3000 - Fuel injectors Replace fuel injectors. W1006
QL1 3000 - Pressure pipe neck (bayonet) Fit new pressure pipe neck (bayonet) in cylinder head. W1178
QL1 3000 2a Belt drive Check belt condition and tension Fit new belt(s) if necessary. W1003
QL1 3000 3a Air filters Fit new air filters. W1005
QL1 3000 4a Combustion chambers Inspect cylinder chambers using endoscope. W1011
QL1 6000 - Fuel injection pumps Fit new fuel injection pump(s). W1007
QL3 10000 - Turbochargers Overhaul turbocharger. If Garrett turbocharger, fit new. W1388
QL3 10000 - 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
Fit new diaphragms for crankcase breathers. W2014
Clean engine coolant cooler and inspect it for leaks. W2017
Check engine alignment. W2036
Fit new engine coolant pump. W2072
Fit new thermal actuator in coolant thermostat. W2073
Inspect rocker arms, valve bridges, pushrods and ball joints for W2074
wear.
Fit new seals/sealing materials for all disassembled components. W2062
QL3 10000 - Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear W1063
pattern on cylinder liner running surfaces.
QL4 10000 - Fuel pressure maintaining Fit new fuel pressure maintaining valve. W1056
valve
QL4 10000 18 a Extended component mainte- Completely disassemble the engine. Inspect engine components as W3000
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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
w = weeks
m = months
a = years

MS50002/06E 2021-06 | Maintenance Schedule | 7

Qualifi- Interval Limit Item Maintenance tasks

Option
Task
cation [h]
level
Overhaul starter. W3041
Overhaul battery-charging generator. W3042
Check vibration damper, fit new one if necessary. W3108
w = weeks
m = months
a = years

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8 | Maintenance Schedule | MS50002/06E 2021-06