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MTU_ValueService

Technical Documentation

Engine-generator sets
Stand By Power Applications
with MTU 12V/16V 4000 Gx3x Engines
Application Group 3D

Maintenance Schedule
MS50061/03E
System nomenclature Engine System nomenclature Engine
DS01650D5S 12V4000G23 DS02185D6S 16V4000G43
DS01665D6S 12V4000G43 DS02285D5S 16V4000G23
DS01815D6S 12V4000G83 DS02400D6S 16V4000G83
DS01880D5S 12V4000G23 DS02595D5S 16V4000G63
DS02085D5S 12V4000G63
All gensets are available with water charge-air cooling.
All gensets are available with optional voltages. Ratings can vary. Please refer to the relevant specification sheet.

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 MS50061/03E

1 Maintenance Schedule 5

1.1 Preface 5

1.2 Maintenance schedule matrix 6

1.3 Maintenance tasks 9

© MTU Friedrichshafen GmbH 2011-05 3


MS50061/03E Table of Contents

4 2011-05 © MTU Friedrichshafen GmbH


Maintenance Schedule MS50061/03E

1 Maintenance Schedule
1.1 Preface
MTU maintenance concept
Emission 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 emission control devices
and systems can only be performed using MTU approved components or equivalents. Failure to adhere to these guidelines
may be a violation of the Clean Air Act.
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.
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 operation without disassem‐
bling the engine-generator set.
QL2: Component exchange (corrective only).
QL3: Maintenance work which requires partial disassembly of the engine-generator set.
QL4: Maintenance work which requires complete disassembly of the engine-generator set.
The maintenance schedule matrix normally finishes with extended component maintenance. Following this, maintenance
work is to be continued at the intervals indicated.
The "Task" numbers specified in the measures list identify the respective maintenance item.
Notes on maintenance
Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and lists of recom‐
mended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001064 and in the fluids and
lubricants specifications produced by the component manufacturers. They are, therefore, not included in the system
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 or fuel/water separator:
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 system maintenance schedule.
This system maintenance schedule may include components which are not included in the MTU Onsite Energy supply
scope; these may be disregarded.
Out-of-service periods
TIM ID: 0000022689 - 002

If the engine-generator set is to remain out of service for more than one month, carry out engine preservation procedures
in accordance with the Fluids and Lubricants Specifications, MTU Publication No. A001064 and also see the manufacturers
instructions from the non-engine components.
Application Group
3D Short-time operation, fuel stop

© MTU Friedrichshafen GmbH 2011-05 5


MS50061/03E Maintenance Schedule

1.2 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
Daily
Limit

250
500
750
Engine-generator set operation
Engine-generator set operation - X
Engine-generator set operation 1m
Engine
Engine oil filter 2a
Valve gear 2a X X X X X
Fuel filter 2a X X X X X
Fuel prefilter 2a X X X X X
Belt drive 2a X X X X X
Air filters 3a X
Rubber sleeves 6a X
Fuel injectors 9a
Combustion chambers 4a
Crankcase breathers 2a
Turbochargers 18 a
Component maintenance 9a
Cylinder heads 9a
Extended component maintenance 18 a
Generator
Generator 1m
Generator 1a
Generator 1a X
Generator 18 a
Automatic transfer switch
Automatic transfer switch 1m
Automatic transfer switch 1a
Preheater / Jacket water heater
Preheater / Jacket water heater 1a
Preheater / Jacket water heater 1a
Preheater / Jacket water heater 1a
Preheater / Jacket water heater 5a
Preheater / Jacket water heater 10 a
Preheater / Jacket water heater 9a
Engine-generator set control panel
Power Panel 3a
DGC-2020 10 a
Cooler
Radiator 2a
Radiator - X X X X X X X X X X X X X X X X X X X X X
TIM ID: 0000022690 - 002

Radiator 6m X X X X X X X X X X
Fuel cooler 6m X X X X X X X X X X
Radiator 2a X X X X X
Radiator 18 a X X
Radiator 18 a
Fuel cooler 18 a
Engine generator set
Rubber sleeves 6a X
w = weeks
m = months
a = years

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Maintenance Schedule MS50061/03E

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
Daily
Limit

250
500
750
Hose lines 6a
w = weeks
m = months
a = years

5.500-6.000 Operating hours


Item Operating hours [h]

5.500
5.750
6.000
Engine-generator set operation Limit
Engine-generator set operation -
Engine-generator set operation 1m
Engine
Engine oil filter 2a
Valve gear 2a X
Fuel filter 2a X
Fuel prefilter 2a X
Belt drive 2a X
Air filters 3a X
Rubber sleeves 6a X
Fuel injectors 9a X
Combustion chambers 4a X
Crankcase breathers 2a X
Turbochargers 18 a X
Component maintenance 9a X
Cylinder heads 9a X
Extended component maintenance 18 a X
Generator
Generator 1m
Generator 1a
Generator 1a X
Generator 18 a X
Automatic transfer switch
Automatic transfer switch 1m
Automatic transfer switch 1a
Preheater / Jacket water heater
Preheater / Jacket water heater 1a
Preheater / Jacket water heater 1a
Preheater / Jacket water heater 1a
Preheater / Jacket water heater 5a
Preheater / Jacket water heater 10 a
Preheater / Jacket water heater 9a X
TIM ID: 0000022690 - 002

Engine-generator set control panel


Power Panel 3a
DGC-2020 10 a
Cooler
Radiator 2a
Radiator - X X X
Radiator 6m X X
Fuel cooler 6m X X
w = weeks
m = months
a = years

© MTU Friedrichshafen GmbH 2011-05 7


MS50061/03E Maintenance Schedule

Item Operating hours [h]

5.500
5.750
6.000
Limit
Radiator 2a X
Radiator 18 a X
Radiator 18 a X
Fuel cooler 18 a X
Engine generator set
Rubber sleeves 6a X
Hose lines 6a X
w = weeks
m = months
a = years

TIM ID: 0000022690 - 002

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Maintenance Schedule MS50061/03E

1.3 Maintenance tasks


Qualifi‐ Interval Limit Item Maintenance tasks Task
cation
level [h]
Engine-generator set operation
QL1 Daily - Engine-generator set opera‐ Check engine-generator set oil level W0100
tion
Carry out visual inspection of engine-generator set for general condition W0101
and leaks
Inspect intercooler drain system (if fitted) W0102
Inspect service indicator of air filter W0103
Check relief bores of water pump(s) W0105
Check for abnormal running noises, exhaust gas color and vibration W0106
Drain off water and contamination from single or dual fuel/water sepa‐ W0107
rator (if fitted)
Check reading on differential pressure gauge of dual fuel/water separa‐ W0108
tor (if differential pressure gauge fitted)
QL1 - 1m Engine-generator set opera‐ Test run at not below 1/3 load and at least until steady-state temperature W0134
tion is reached (monthly)
Engine
QL1 - 2a Engine oil filter Fit new engine oil filters each time the engine oil is changed or, at the W1008
latest, on expiry of the time limit (given in years)
QL1 1000 2a Valve gear Check valve clearance W1002
QL1 1000 2a Fuel filter Fit new fuel filter or new fuel filter insert W1001
QL1 1000 2a Fuel prefilter Depending on the degree of contamination but at the latest before expiry W1164
of the time limit (in years), fit new filter insert and sealing ring
QL1 1000 2a Belt drive Inspect condition of drive belts and fit new ones if necessary. Adjust W1241
tension
QL1 3000 3a Air filters Fit new air filters W1005
QL1 3000 6a Rubber sleeves Replace all rubber sleeves W1250
QL1 6000 9a Fuel injectors Fit new fuel injectors W1006
QL1 6000 4a Combustion chambers Inspect cylinder chambers using endoscope W1011
QL1 6000 2a Crankcase breathers Crankcase breathers: Fit new filters or filter inserts W1046
QL3 6000 18 a Turbochargers Fit new turbochargers W1041
QL3 6000 9a Component maintenance Before starting maintenance work, drain the coolant and flush the cooling W2000
systems
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
Inspect centrifugal oil filter for wear (if fitted) W2009
Overhaul starter W2010
Inspect vibration damper W2011
Fit new seals/sealing materials for all disassembled components W2062
Overhaul charge-air coolant pump W2070
Overhaul engine coolant pump W2110
TIM ID: 0000022691 - 002

QL3 6000 9a Cylinder heads Overhaul cylinder heads W1134


QL4 6000 18 a Extended component mainte‐ Completely disassemble the engine. Inspect engine components as per W3000
nance assembly 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 antifriction bearings for auxiliary PTOs W3006
w = weeks
m = months
a = years

© MTU Friedrichshafen GmbH 2011-05 9


MS50061/03E Maintenance Schedule

Qualifi‐ Interval Limit Item Maintenance tasks Task


cation
level [h]

Fit new high-pressure fuel pump W3007


Fit new fuel delivery pump W3010
Overhaul battery-charging generator W3042
Generator
QL1 - 1m Generator Carry out visual inspection of generator for general condition W1445
QL1 - 1a Generator Inspect wiring for defects W1446
QL1 3000 1a Generator Re-grease antifriction bearings W1318
QL4 6000 18 a Generator Overhaul generator. Inspect and clean components. Fit new diodes and W1545
bearings
Automatic transfer switch
QL1 - 1m Automatic transfer switch Check function of the automatic transfer switch (if fitted) W1448
QL1 - 1a Automatic transfer switch Clean and inspect automatic transfer switch (if fitted) W1449
Preheater / Jacket water heater
QL1 - 1a Preheater / Jacket water Check and tighten electrical connections at the control box W1450
heater
QL1 - 1a Preheater / Jacket water Check and tighten electrical connections at element enclosure W1451
heater
QL1 - 1a Preheater / Jacket water Check and clean heating element and tank W1452
heater
QL1 - 5a Preheater / Jacket water Replace thermostat W1453
heater
QL1 - 10 a Preheater / Jacket water Replace contactor W1454
heater
QL3 6000 9a Preheater / Jacket water Overhaul preheater W1477
heater
Engine-generator set control panel
QL1 - 3a Power Panel Replace backup battery (if fitted) W1465
QL1 - 10 a DGC-2020 Replace backup battery (if fitted) W1444
Cooler
QL1 - 2a Radiator Lubricate belt tensioner (if fitted) W1678
QL1 250 - Radiator Lubricate fan wheel bearing and belt pulley W1676
QL1 500 6m Radiator Check cooler elements externally for contamination and leaks W1510
QL1 500 6m Fuel cooler Check cooler elements externally for contamination and leaks W1682
QL1 1000 2a Radiator Check poly V-belt (if fitted), replace if necessary W1677
QL3 2000 18 a Radiator Clean radiator cores and, if possible, replace if necessary W1679
QL4 6000 18 a Radiator Replace electric motor (if fitted) W1680
QL4 6000 18 a Fuel cooler Replace electric motor W1681
Engine generator set
QL3 3000 6a Rubber sleeves Replace all rubber sleeves W1250
QL3 6000 6a Hose lines Replace all hose lines W1251
w = weeks
m = months
a = years
TIM ID: 0000022691 - 002

10 2011-05 © MTU Friedrichshafen GmbH