MTU_ValueService

Technical Documentation

Engine-generator sets
Prime Power Applications
with MTU Series 2000 Engines
Application Group 3B

System Maintenance Schedule

MS50047/01E
Printed in Germany
© 2010 Copyright MTU Onsite Energy Corp.
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 Onsite Energy Corp. 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.
 Preface 01

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

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 (all variants: duplex fuel prefilter, single fuel/water separator, dual fuel/water separator):
The maintenance interval depends on how dirty the fuel is. The 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 system maintenance schedule may include components which are not installed on your
engine-generator set; these may be disregarded.

Out-of-service periods
If the engine-generator set 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 and
also see the manufacturers instructions from the non-engine components.

Application Group
3B Continuous operation, variable load
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MS50047/01E 2010-02 © MTU Onsite Energy Corp.

02 Preface

Applicable engine-generator sets

System nomenclature Engine System nomenclature Engine

DP00640D6S 12V2000G45TD DP00930D6S 16V2000G85TD
DP00670D6S 12V2000G45TB DP00940D5S 16V2000G25TB
DP00700D6S 12V2000G85TD DP00960D6S 16V2000G85TB
DP00725D6S 12V2000G85TB DP01020D5S 16V2000G65TD
DP00800D5S 12V2000G65TD DP01045D5S 16V2000G65TB
DP00820D5S 12V2000G65TB DP01090D6S 18V2000G85TD
DP00835D6S 16V2000G45TD DP01130D6S 18V2000G85TB
DP00870D6S 16V2000G45TB DP01150D5S 18V2000G65TD
DP00925D5S 16V2000G25TD DP01170D5S 18V2000G65TB

All gensets are available with air charge - air cooling and water charge - air cooling.
All gensets are available with optional voltages. Ratings can vary. Please refer to the relevant specification sheet.

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MS50047/01E 2010-02 © MTU Onsite Energy Corp.

 Maintenance schedule matrix 03

2 Maintenance schedule matrix

0-10.000 Operating hours

Item Operating hours [h]

Limit, years

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
Daily
500
Engine-generator set operation
Engine-generator set operation - X
Engine-generator set operation 1
m
Engine
Engine oil filter 2
a
Fuel filter 2 X X X X X X X X X X X X X X X X X X X X
a
Valve gear - X X X X X X X X X X X X X X X X X X X X
Fuel injectors - X X X X
Pressure pipe neck (bayonet) - X X X X
Belt drive 2 X X X X
a
Air filters 3 X X X X
a
Combustion chambers 4 X X X X
a
Fuel pressure maintaining valve - X X
Fuel injection pumps - X X
Generator

Generator 1
m
Generator 1
a
Generator 1 X X X X
a
Automatic transfer switch
Automatic transfer switch 1
m
Automatic transfer switch 1
a
Jacket water heater
Jacket water heater 1
a
Jacket water heater 1
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a
Jacket water heater 1
a
Jacket water heater 5
a
Jacket water heater 10
a

MS50047/01E 2010-02 © MTU Onsite Energy Corp.

04 Maintenance schedule matrix

Item Operating hours [h]

Limit, years

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
Daily
500
Engine-generator set control panel
PP400/X20 3
a
DGC-2020 10
a
Radiator
Radiator 6 X X X X X X X X X X X X X X X X X X X X
m
Engine
Turbochargers - X
Component maintenance - X
Cylinder heads - X
Extended component maintenance 18 X
a
Generator

Generator 18 X
a

w = weeks
m = months
a = years

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MS50047/01E 2010-02 © MTU Onsite Energy Corp.

 Maintenance tasks 05

3 Maintenance tasks

Qual- Interval Item Maintenance tasks Task

ifica-
tion [h] [a]
level
Engine-generator set operation
QL1 Daily - Engine-generator set Check engine-generator set oil level . W0100
operation
Carry out visual inspection of engine-generator set for general W0101
condition 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 colour and vibration. W0106
.
Drain off water and contamination from single or dual fuel/water W0107
separator (if fitted). .
Check service indicator of dual fuel/water separator (if W0108
differential-pressure gauge is fitted). .
QL1 - 1m Engine-generator set Test run at not below 1/3 load and at least until steady-state W0134
operation temperature 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 500 2a Fuel filter Fit new fuel filter or new fuel filter insert. . W1001
QL1 500 - Valve gear Check valve clearance. . W1002
QL1 2500 - Fuel injectors Fit new fuel injectors. . W1006
QL1 2500 - Pressure pipe neck Fit new pressure pipe neck (bayonet) in cylinder head. . W1178
(bayonet)
QL1 2500 2a Belt drive Check belt condition and tension. Fit new belt(s) if necessary. . W1003
QL1 2500 3a Air filters Fit new air filters. . W1005
QL1 2500 4a Combustion chambers Inspect cylinder chambers using endoscope. . W1011
QL1 5000 - Fuel pressure maintaining Fit new fuel pressure maintaining valve. W1056
valve
QL1 5000 - Fuel injection pumps Fit new fuel injection pump(s). . W1007
Generator
QL1 - 1m Generator Carry out visual inspection of generator for general condition . W1445
QL1 - 1a Generator Inspect wiring for defects . W1446
QL1 2500 1a Generator Re-grease antifriction bearings . W1318
Automatic transfer switch
QL1 - 1m Automatic transfer switch Check function of the automatic transfer switch (if fitted) . W1448
QL1 - 1a Automatic transfer switch Inspect and clean automatic transfer switch (if fitted) . W1449
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Jacket water heater

QL1 - 1a Jacket water heater Check and tigthen electrical connections at the control box . W1450
QL1 - 1a Jacket water heater Check and tigthen electrical connections at element enclosure . W1451
QL1 - 1a Jacket water heater Check and clean heating element and tank . W1452
QL1 - 5a Jacket water heater Replace thermostat . W1453
QL1 - 10 a Jacket water heater Replace contactor . W1454

MS50047/01E 2010-02 © MTU Onsite Energy Corp.

06 Maintenance tasks

Qual- Interval Item Maintenance tasks Task

ifica-
tion [h] [a]
level
Engine-generator set control panel
QL1 - 3a PP400/X20 Replace backup battery (if fitted) . W1465
QL1 - 10 a DGC-2020 Replace backup battery (if fitted) . W1444
Radiator
QL1 500 6m Radiator Check cooling elements for external contamination . W1510
Engine
QL3 10000 - Turbochargers Overhaul turbocharger (MTU-ZR-turbocharger). If Garrett W1388
turbocharger, fit new. .
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 (if fitted) . W2148
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 wear. . W2074
Fit new seals/sealing materials for all disassembled components. . W2062
Fit new diaphragms for crankcase breathers. . W2014
QL3 10000 - Cylinder heads Overhaul cylinder heads. Visually inspect piston crowns and wear W1063
pattern on cylinder liner running surfaces. .
QL4 10000 18 a Extended component Completely disassemble the engine. Inspect engine components as W3000
maintenance per Maintenance Manual instructions and repair or fit new components
as required. .
Exchange all elastomeric parts and seals for new ones. . W3001
Fit new vibration damper W3053
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 synthetic fuel lines (if fitted).. W3081
Generator
QL4 10000 18 a Generator Overhaul generator. Inspect and clean components. Fit new diodes W1545
and bearings

w = weeks
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m = months
a = years

MS50047/01E 2010-02 © MTU Onsite Energy Corp.