Plan de Manteniemiento m53 mtu

8/18/2019 Plan de Manteniemiento m53 mtu

1/9

MTU_ ValueServiceTechnical Documentation

Diesel Engine8 V 4000 M53R Application Group 1A

Maintenance ScheduleMS50062/00E


2/9

applicable for ...

8V4000M53R

Printed in Germany© 2010 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole or in part without theprior 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.


3/9

Preface 01

1 Preface

MTU maintenance conceptEmission 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.

MTU Maintenance Schedules ensure the reliability and performance of MTU engines and must beadhered to during the full life of the engine.

The maintenance system for MTU products is based on a preventive maintenance concept. Preventive maintenancefacilitates advance planning and ensures a high level of equipment availability.

The maintenance schedule is based on the load profile / load factor specified below. Special operating conditions andtechnical requirements may require additional maintenance work and/or modification of the maintenance intervals. Inorder to be authorized to carry out the individual maintenance jobs, maintenance personnel must have achieved a levelof training and qualification appropriate to the complexity of the task in hand. The various Qualification Levels QL1 toQL4 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 maintenanceSpecifications 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 thefluids and lubricants specifications produced by the component manufacturers. They are therefore not included in themaintenance schedule (exception: deviations from the Fluids and Lubricants Specifications). All fluids and lubricantsused 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 prefiltersmust be changed every two years at the latest (Task 9998).

• Battery:Battery maintenance depends on the level of use and the ambient conditions. The batterymanufacturer’s instructions must be obeyed.

The relevant manufacturer’s instructions apply with respect to the maintenance of any componentswhich 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 periodsIf the engine is to remain out of service for more than 1 month, carry out engine preservation procedures in accordancewith the Fluids and Lubricants Specifications, MTU Publication No. A001061.

Application Group

1A Continuous operation, unrestricted

Load profile

Load factor 100% 90%


4/9

02 Maintenance schedule matrix


0-10.500 Operating hours

Operating hours [h]Item

L i m i t

D a i l y

5 0 0

1 . 0

0 0

1 . 5

0 0

2 . 0

0 0

2 . 5

0 0

3 . 0

0 0

3 . 5

0 0

4 . 0

0 0

4 . 5

0 0

5 . 0

0 0

5 . 5

0 0

6 . 0

0 0

6 . 5

0 0

7 . 0

0 0

7 . 5

0 0

8 . 0

0 0

8 . 5

0 0

9 . 0

0 0

9 . 5

0 0

1 0 . 0

0 0

1 0 . 5

0 0

Fuel servicing plant 1 a


Engine oil fi lter 2 a

Engine operation - X

Air ducting - X X X X X X X X X X X X X X X X X X X X X

Centrifugal oil fi lter - X X X X X X X X X X X X X X X X X X X X X

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

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

Fuel prefilter 2 a X X X X X X X X X X

Primary fuel fi lter 2 a X X X X X X X X X X

Engine mounts 1 a X X X X X X X X X X

Turbochargers - X X X X X

Coolant fi lters - X X X

Air filters 3 a X X X

Battery charging generator - X X

Fuel injectors -

X XCombustion chambers - X X

Turbochargers - X

Component maintenance -

Oil replenishment pump -

Oil-level regulating pump -

Engine mounts 5 a

Rubber sleeves 6 a

Cylinder heads -

HP fuel pumps -

Hose lines 6 a

Extended component maintenance 18 a

Elastomer coupling (main PTO) 18 a

w = weeksm = monthsa = years

MS50062/00E 2010-02 © MTU

T I M

I D : 0 0 0 0 0 0 0 0 0 2 – 0 0 1


5/9

Maintenance schedule matrix 03

11.000-21.500 Operating hours


L i m i t

1 1

. 0 0 0

1 1

. 5 0 0

1 2

. 0 0 0

1 2

. 5 0 0

1 3

. 0 0 0

1 3

. 5 0 0

1 4

. 0 0 0

1 4

. 5 0 0

1 5

. 0 0 0

1 5

. 5 0 0

1 6

. 0 0 0

1 6

. 5 0 0

1 7

. 0 0 0

1 7

. 5 0 0

1 8

. 0 0 0

1 8

. 5 0 0

1 9

. 0 0 0

1 9

. 5 0 0

2 0

. 0 0 0

2 0

. 5 0 0

2 1

. 0 0 0

2 1

. 5 0 0




Engine operation -

Air ducting - X X X X X X X X X X X X X X X X X X X X X X

Centrifugal oil fi lter - X X X X X X X X X X X X X X X X X X X X X X

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

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

Fuel prefilter 2 a X X X X X X X X X X X

Primary fuel fi lter 2 a X X X X X X X X X X X

Engine mounts 1 a X X X X X X X X X X X


Coolant fi lters - X X X X

Air filters 3 a X X X X


Fuel injectors - X X

Combustion chambers - X X

Turbochargers - X

Component maintenance - X

Oil replenishment pump - X

Oil-level regulating pump - X

Engine mounts 5 a X

Rubber sleeves 6 a X

Cylinder heads - X

HP fuel pumps - X

Hose lines 6 a

Extended component maintenance 18 a

Elastomer coupling (main PTO) 18 a


MS50062/00E 2010-02 © MTU

T I M

I D : 0 0 0 0 0 0 0 0 0 2 – 0 0 1


6/9


22.000-30.000 Operating hours


L i m i t

2 2

. 0 0 0

2 2

. 5 0 0

2 3

. 0 0 0

2 3

. 5 0 0

2 4

. 0 0 0

2 4

. 5 0 0

2 5

. 0 0 0

2 5

. 5 0 0

2 6

. 0 0 0

2 6

. 5 0 0

2 7

. 0 0 0

2 7

. 5 0 0

2 8

. 0 0 0

2 8

. 5 0 0

2 9

. 0 0 0

2 9

. 5 0 0

3 0

. 0 0 0




Engine operation -

Air ducting - X X X X X X X X X X X X X X X X X

Centrifugal oil fi lter - X X X X X X X X X X X X X X X X X

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

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

Fuel prefilter 2 a X X X X X X X X X

Primary fuel fi lter 2 a X X X X X X X X X

Engine mounts 1 a X X X X X X X X X


Coolant fi lters - X X X

Air filters 3 a X X X


Fuel injectors - X X

Combustion chambers - X X

Turbochargers - X

Component maintenance - X

Oil replenishment pump - X

Oil-level regulating pump - X

Engine mounts 5 a X

Rubber sleeves 6 a X

Cylinder heads - X

HP fuel pumps - X

Hose lines 6 a X

Extended component maintenance 18 a X

Elastomer coupling (main PTO) 18 a X


MS50062/00E 2010-02 © MTU

T I M

I D : 0 0 0 0 0 0 0 0 0 2 – 0 0 1


7/9

Maintenance tasks 05

3 Maintenance tasks

Inter-val

Qual-ifica-tion

level [h]

Limit Item Maintenance tasks Task

QL1 - 1 a Fuel servicing plant Check alarm function for differential pressure gauge. W1245

Check pump performance. W1246

QL1 - 2 a Fuel servicing plant Check function of rod electrode. W1244

QL1 - 2 a Engine oil fi lter Fit new engine oil filters each time the engine oil is changed or, at thelatest, on expiry of the time limit (given in years) .

W1008

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 fi lter . W0503

Check the inspection bores of the HP fuel pump . W0504

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 500 - Air ducting Inspect air ducting between air fi lters and turbochargers for leaksand damage.

W1029

QL1 500 - Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve (if fitted) . W1009

QL1 1000 - Valve gear Check valve clearance . W1002

QL1 1000 2 a Fuel fi lter Fit new fuel fi lter or new fuel fi lter insert . W1001

QL1 1000 2 a Fuel prefilter Depending on the degree of contamination but at the latest beforeexpiry of the time limit (in years), fit new filter insert and sealing ring (if fitted) .

W1494

QL1 1000 2 a Primary fuel filter Fit new primary fuel fi lter or primary fuel filter insert (if fitted) . W1495

QL1 1000 1 a Engine mounts Carry out visual inspection of engine mounts for general condition . W1463

QL1 2000 - Turbochargers Turbocharger: Clean compressor wheel . W1076

QL1 3000 - Coolant fi lters Fit new coolant filters . W1036

QL1 3000 3 a Air filters Fit new air fi lters . W1005

QL1 5000 - Battery charging generator Battery-charging generator: Check condition of coupling . W1016

QL1 5000 - Fuel injectors Fit new fuel injectors . W1006

QL1 5000 - Combustion chambers Inspect cylinder chambers using endoscope . W1011

QL3 10000 - Turbochargers Overhaul turbochargers. W1038

Fit new aluminum compressor wheels on secondary turbochargers . W1493

QL3 15000 - Component maintenance Before starting maintenance work, carry out test run and recordoperating parameters. Then drain coolant and flush cooling systems .

W2012

Inspect rocker arms and valve bridge for wear. Insert an endoscopethrough the pushrod bore to visually inspect swing followers andcamshaft running surfaces .

W2001

Clean air ducting . W2002

Clean intercooler and inspect for leakage . W2003

Fit new high-pressure fuel sensor . W2004


MS50062/00E 2010-02 © MTU

T I M

I D : 0 0 0 0 0 0 0 0 0 3 – 0 0 1


8/9

06 Maintenance tasks

Inter-val

Qual-ifica-tionlevel [h]


Check engine coolant thermostat and fit new thermal actuator . W2006

Inspect centrifugal oil fi lter for wear (if fitted) . W2009

Overhaul starter . W2010

Clean engine coolant cooler (if fitted) and, if possible, inspect it for leaks .

W2149

Clean engine oil cooler and inspect it for leaks . W2018

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

Overhaul engine coolant pump . W2110

Overhaul raw-water pump (if fi tted) . W2150

Overhaul bilge pump (if fitted) . W2112

Check operation of diverter valve . W2151

QL3 15000 - Oil replenishment pump Check for wear (if fitted) . W1513

QL3 15000 - Oil-level regulating pump Check for wear (if fitted) . W1514

QL3 15000 5 a Engine mounts Check buffer clearance of resilient mounts Check proper seating of securing screws .

W1026

Check for cracks. Measure cracks if necessary. Measure height of rubber elements .

W1462

QL3 15000 6 a Rubber sleeves Replace all rubber sleeves . W1250

QL3 15000 - Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear pattern on cylinder liner running surfaces .

W1063

QL3 15000 - HP fuel pumps Fit new HP fuel pumps. W1058

QL3 30000 6 a Hose lines Replace all hose lines . W1251

QL4 30000 18 a Extended componentmaintenance

Completely disassemble the engine.Inspect engine componentsas per assembly instructions and repair or fit new components asrequired .

W3000

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

Fit new actuating cylinders for air flow control flaps . W3011

Fit new actuator cylinders for exhaust flaps . W3012

Fit new exhaust flap bearings . W3013

Fit new camshaft bearings and camshaft thrust bearings . W3018

Fit new pressure relief valve in high-pressure fuel system . W3021

Overhaul battery-charging generator . W3042

Check gear train for cracks, replace bushings, check axles andreplace if necessary .

W3063

Fit new engine oil pump. W3073

Replace wiring harnesses. W3083


MS50062/00E 2010-02 © MTU

T I M

I D : 0 0 0 0 0 0 0 0 0 3 – 0 0 1


9/9

Maintenance tasks 07

Inter-val

Qual-ifica-tionlevel [h]


Fit new rubber elements of engine mounts . W3100

Replace swing followers and swing-follower shafts . W3103

Fit new oil replenishment pump (if fitted) . W3106

Fit new oil-level regulating pump (if fitted) . W3107

Check vibration damper, fit new one if necessary . W3108

QL4 30000 18 a Elastomer coupling (mainPTO)

Fit new elastomer components (if fitted) . W1544


MS50062/00E 2010-02 © MTU

T I M

I D : 0 0 0 0 0 0 0 0 0 3 – 0 0 1

Documents

Plan de Manteniemiento m53 mtu