Technical Documentation

Diesel Engine
12 V 2000 Gx2, Gx3
16 V 2000 Gx2. Gx3
18 V 2000 Gx2, Gx3
Application group 3B TAL

Maintenance Schedule
M050620/07E
Printed in Germany
© 2007 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.
 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
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 "Task" numbers stated in the list of jobs to be done/action to be taken indicate the relevant maintenance item. They
provide a reference to the scope of parts required and appear on the labels of the appropriate replacement parts.

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.

Applicationgroup

3B Continuous operation, variable load

Load profile

Load factor 110% 100% 70%

Corresponding operating time 1% 9% 90%

M050620/07E 07-09 © MTU

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2 Maintenance schedule matrix

0-5.250 Operating hours

Item Operating hours [h]

Limit, years

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
250
500
750
Engine operation - X

Engine oil filter 2

Engine oil - X X X X X X X X X X X X X X X X X X X X X

Crankcase breathers - X X X X X X X X X X X X X X X X X X X X X

Crankcase breathers - X X X X X X X X X X

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

Valve gear - X X X X X X X X X X

Engine coolant cooler 1 X X X X X X X X X X

Belt drive 2 X

Air filters 3 X

Fuel injectors - X

Combustion chambers 4 X

Pressure pipe neck (bayonet) -

Fuel injection pumps -

HP fuel lines -

Fuel pressure maintaining valve -

Component maintenance -

Cylinder heads -

Extended component maintenance 18

M050620/07E 07-09 © MTU

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5.500-10.000 Operating hours

Item Operating hours [h]

Limit, years

10.000
5.500
5.750
6.000
6.250
6.500
6.750
7.000
7.250
7.500
7.750
8.000
8.250
8.500
8.750
9.000
9.250
9.500
9.750
Engine operation -

Engine oil filter 2

Engine oil - X X X X X X X X X X X X X X X X X X X

Crankcase breathers - X X X X X X X X X X X X X X X X X X X

Crankcase breathers - X X X X X X X X X X

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

Valve gear - X X X X X X X X X X

Engine coolant cooler 1 X X X X X X X X X X

Belt drive 2 X X

Air filters 3 X X

Fuel injectors - X X

Combustion chambers 4 X X

Pressure pipe neck (bayonet) - X

Fuel injection pumps - X

HP fuel lines - X

Fuel pressure maintaining valve - X

Component maintenance - X

Cylinder heads - X

Extended component maintenance 18 X

M050620/07E 07-09 © MTU

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3 Maintenance tasks

Qual- Interval Item Maintenance tasks Task

ifica-
tion [h] [a]
level

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 water pump(s). . W0505

Check for abnormal running noises, exhaust gas colour and vibration. W0506
.

Drain off water and contamination from fuel prefilter (if fitted). . W0507

Check service indicator of fuel prefilter (if fitted). . W0508

QL1 - 2 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 250 - Engine oil Change engine oil. . W1000

QL1 250 - Crankcase breathers Fit new paper or woven insert (if fitted) for fine separator for oil mist.. W1139

QL1 500 - Crankcase breathers Clean wire meshes for crankcase ventilation system.. W1140

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

QL1 500 - Valve gear Check valve clearance. . W1002

QL1 500 1 Engine coolant cooler Engine coolant cooler: Check cooler elements for external W1010
contamination..

QL1 3000 2 Belt drive Check belt condition and tension. Fit new belt(s) if necessary. . W1003

QL1 3000 3 Air filters Fit new air filters. . W1005

QL1 3000 - Fuel injectors Fit new fuel injectors. . W1006

QL1 3000 4 Combustion chambers Inspect cylinder chambers using endoscope. . W1011

QL1 6000 - Pressure pipe neck Fit new pressure pipe neck (bayonet) in cylinder head. . W1178
(bayonet)

QL1 6000 - Fuel injection pumps Fit new fuel injection pump(s). . W1007

QL1 6000 - HP fuel lines Replace HP fuel lines . W1298

QL1 6000 - Fuel pressure maintaining Fit new fuel pressure maintaining valve. W1056
valve

QL3 10000 - Component maintenance Before starting maintenance work, drain the coolant and flush the W2000
cooling systems. .

Inspect rocker arms, valve bridges, pushrods and ball joints for wear. . W2074

Overhaul turbochargers. . W2075

Inpect vibration damper. . W2011

Clean air ducting. . W2002

Clean intercooler and inspect for leakage. . W2003

Fit new diaphragms for crankcase breathers. . W2014

M050620/07E 07-09 © MTU

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Qual- Interval Item Maintenance tasks Task

ifica-
tion [h] [a]
level

Fit new engine coolant pump. . W2072

Clean engine coolant cooler and, if possible, inspect it for leaks. . W2017

Fit new thermal actuator in coolant thermostat. . W2073

Check engine alignment. . W2036

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 18 Extended component Completely disassemble the engine. Inspect engine components W3000
maintenance as per Maintenance Manual instructions and repair or fit new
components as required. .

Exchange all elastomeric parts and seals for 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

Overhaul starter . W3041

Overhaul battery-charging generator. . W3042

Fit new wire meshes for crankcase ventilation system. . W3056

Fit new synthetic fuel lines (if fitted).. W3081

M050620/07E 07-09 © MTU