Maintenance Schedule Page 01
Diesel Engines
8V 2000 M70 (BM 531.923)
12V 2000 M70 (BM 535.923)
16V 2000 M70 (BM 536.923)
Maintenance Schedule
M050540/02E
MTU Motoren- und Turbinen-Union Friedrichshafen GmbH
88040 Friedrichshafen / Germany
Telephone (07541) 90-0
Telex 734 280-0 mt d
Telefax (07541) 90-3928
Low operating and maintenance costs as well as operational reliability and availability depend on maintenance
and servicing being carried out in compliance with our specifications and instructions.
The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure
trouble-free engine operation at all times. For this purpose always:
− ensure that sufficient fuel is available,
− ensure that the combustion air is dry and clean,
− use only clean, filtered raw water.
Moreover, it is essential that:
− maintenance tasks be completed by trained personnel,
− suitable tools be used,
− genuine spare parts and fluids and lubricants as per the current DDC/MTU Fluids and Lubricants Specifications
be used.
Our Product Support Service will always be available should assistance be required.
Preventive maintenance instructions.
− Special care should be taken to keep the machinery plant in a clean and serviceable condition at all times to
facilitate early detection of possible leaks and prevent subsequent damage.
− Protect rubber and synthetic components from oil and fuel, never treat with organic detergents. Wipe with a dry
cloth only.
− Always replace all seals and gaskets.
DDC/MTU Maintenance System
The maintenance concept for DDC/MTU products is a preventive maintenance concept and features the
maintenance levels W1 to W6 as outlined below.
Preventive maintenance facilitates advance planning and ensures a high degree of equipment availability.
Main features of the maintenance levels:
− W1: Operational checks
− W2, W3 and W4: Periodic maintenance tasks to be performed during out-of-service periods without the need
for engine disassembly.
− W5: This level requires partial engine disassembly.
− W6: Major overhaul. This level requires complete engine disassembly.
The time intervals according to which the W2 to W6 Maintenance Levels and the relevant checks and tasks
involved are to be completed are based on operational experience. They have been confirmed so as to ensure
correct engine operation until the next scheduled maintenance echelon.
Specific operational conditions may require modification of the Maintenance Schedule.
NOTE:
The codes on the following pages refer to the groups and subgroups in Section G of the Engine Operation Manual.
This Maintenance Schedule may refer to parts which are not installed on your engine, these may be disregarded.
M050540/02E 05-04 © MTU
Page 02 Maintenance Schedule
Application Group
1B: Fast vessels with high load factors
Maintenance Frequency Chart
Maintenance Level W1: Operational checks, daily X
W2: Operating hours 250
Limit, year 1
W3: Operating hours 500
Limit, year 1
W4: Operating hours 2 000
Limit, year(s) 2
W5: Operating hours 3 500 - 4 000
Limit, year(s) 6
W6: Operating hours 7 000
Limit, year(s) 18
Maintenance Task Schedule -Overall System-
See page 4
Maintenance Task Schedule -Engine-
Code No. One-time operations after the first 50 operating hours.
− With a new engine, after W5 maintenance echelon, or after W6 major overhaul
G055.050.01 Valve gear Check valve clearances
G083.101.09 Fuel pre-filter Check, replace filter inserts if necessary
G140.000.03 Exhaust system Check tightness of securing screws and nuts
G202.051.01 Engine coolant pump Check relief bore for oil and coolant discharge and contamination
G207.051.01 Raw water pump Check relief bore for oil and coolant discharge and contamination
G213.051.01 Charging generator drive Check belt condition and tension
G231.051.01 Engine mounts Check tightness of securing screws and nuts
G250.000.01 Engine driving end Check tightness of securing screws and nuts
Code No. Maintenance Echelon W1:
− Operational checks
G000.000.13 Engine operation Check speed
G000.000.17 Engine operation Check temperatures (if gauges are provided)
G000.000.19 Engine operation Check running noises
G000.000.21 Engine operation Check engine and external pipework for leaks,
G000.003.15 Engine operation Check pressures (if gauges are provided)
G083.101.03 Fuel pre-filter Drain water and contaminants
G111.051.01 Intercooler Check drain line for water discharge and obstructions
G140.000.05 Exhaust system Check exhaust gas color
G180.000.01 Engine oil Check level
G202.000.03 Engine coolant Check level
M050540/02E 05-04 © MTU
Maintenance Schedule Page 03
Code No. Maintenance Levels W 2 3 4 5
G083.101.05 Fuel pre-filter Flush
G121.052.01 Air filter Check contamination indicator
G180.000.05 Engine oil Change
− with oil category 1, after every 250 operating hours
− with oil category 2, after every 500 operating hours
G183.052.03 Engine oil filter Replace
− accomplish when changing the oil
G202.000.05 Engine coolant Take sample and analyze
− every 2nd W2 maintenance level = 500 operating hours
− at least once a year
G213.051.01 Charging generator drive Check belt condition and tension
G530.000.01 LOP station Carry out test procedures
G055.050.01 Valve gear Check valve clearances
G083.051.03 Fuel duplex filter Replace filter
G083.101.09 Fuel pre-filter Replace filter elements
G123.051.01 Air-flow control flap(s) Check for ease of movement
G140.000.01 Exhaust system Check (visual inspection)
G144.051.01 Exhaust flow control flap(s) Check for ease of movement
G146.000.01 Exhaust system Check exhaust pipework security and insulation (shipside)
G202.051.01 Engine coolant pump Check relief bore for oil and coolant discharge and contamination
G207.051.01 Raw water pump Check relief bore for oil and coolant discharge and contamination
G309.001.01 Battery Check
G000.000.29 Engine Check hoses and hose connections
G075.051.03 Fuel injectors Replace
G077.050.01 Pressure pipe neck Replace pressure pipe neck in cylinder head
G111.051.03 Intercooler Clean drain line
G121.051.01 Air filter Replace
G231.051.01 Engine mounts Check tightness of securing screws and nuts
G231.051.03 Engine mounts Check condition of resilient mounts (visual inspection)
G500.000.09 Engine wiring Check
G500.000.10 LOP station Check (visual inspection)
G500.000.11 LOP station Clean LOP station and plugs
G508.000.01 ECU Check (visual inspection)
G508.000.02 ECU Clean
G510.000.01 Monitoring system Check function of monitoring units
Prior to commencing W5 maintenance, drain engine coolant and flush cooling system!
Valve gear Remove and check rocker arms and valve bridges
Check rocker-arm bearings, ball joints and pushrods for wear
Cylinder heads Remove, recondition valves and valve seats, check valve guides
Replace O-rings on the protective seals
Replace gaskets
Crankcase ventilation Oil pre-separator
− Clean inserts
Crankcase ventilation Oil separator
− Check insert and membrane, replace if necessary
Fuel injection pumps Replace
Exhaust turbocharger Check bearing clearance and check turbine rotor for easy movement, clean compressor
wheel and housing
Air-flow control flap(s) Replace air flap stop, air flap gasket and seals
Air-flow control flap(s) Check actuating lever bearings
Intercooler Remove, clean, leak test, replace seals
Engine coolant pump Disassemble, inspect parts visually and replace seals
Raw water pump Disassemble, inspect parts visually and replace seals
Charging generator Renew drive belt
Starter Check carbon brushes
M050540/02E 05-04 © MTU
Page 04 Maintenance Schedule
Maintenance Level W6
Requires complete engine disassembly to facilitate repair/overhaul of all relevant components.
The decisive factor is the component condition or the actual dimensions, referenced to the Tolerances and Wear
Limits List.
Out-of-Service Periods
Carry out maintenance tasks in accordance with the time limit schedule (see the Maintenance Frequency Chart).
In addition, the engine must be barred manually every month.
If the engine is to remain out of service for more than 1 month, carry out engine preservation in accordance with
Section K.
Maintenance Task Schedule -Overall System-
Code No.
G256.051.01 Universal shaft Lubricate
− after installation
− annually
−
M050540/02E 05-04 © MTU
