Attachment_2_Manufacturer_s_engine_Maintenance_Schedule_MS5010504E_2021-06.pdf
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- Attached to
- KAHO 6000 HOUR ENGINE MAINTENANCE Federal contract opportunity
- Solicitation number
- 140G0226Q0012
About this file
This is a Maintenance Schedule document for Rolls-Royce Solutions diesel engines (8V/12V/16V2000M61 models) in Application Group 1A. The document outlines a preventive maintenance system designed to facilitate advance operational planning and ensure high equipment availability. Maintenance intervals are specified in both operating hours and time limits, with the first-reached threshold governing scheduling. The schedule assigns maintenance tasks to four qualification levels (QL1 through QL4), ranging from operational monitoring requiring no disassembly (QL1) to complete engine disassembly work (QL4). Maintenance task tolerances allow for ±10% variance with maximum allowances of ±500 hours for operating hours and ±30 days for time-based intervals.
The maintenance schedule matrix covers 0 to 24,000 operating hours and specifies 30 distinct maintenance tasks with corresponding intervals. Daily operational checks include engine oil level verification, visual inspections for leaks and condition, and checks of intercooler drain systems and fuel prefilter readings. Routine maintenance tasks occur at 500, 1,000, and 3,000-hour intervals and include fuel filter replacement, valve clearance checks, and belt inspection. Major maintenance tasks scheduled at 6,000-hour intervals and beyond (9 to 18-year limits) encompass component overhauls, fuel injection system servicing, and extended maintenance requiring partial or complete engine disassembly. The document emphasizes that adherence to specified maintenance intervals is essential to maintain product safety, and notes that load profile data evaluation is recommended after 500-1,000 operating hours to verify appropriate interval scheduling for specific applications.
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Text version
Maintenance Schedule Diesel engine 8V/12V16V2000M61 Application group 1A
MS50105/04E
8V2000M61 12V2000M61 16V2000M61
Table 1: Applicability
Rolls-Royce Solutions refers to Rolls-Royce Solutions GmbH or an affiliated company pursuant to §15 AktG (German Stock Corporation Act) or a controlled company (joint venture), and Rolls-Royce Solutions Ruhstorf GmbH.
© Copyright Rolls-Royce Solutions
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-ten consent of Rolls-Royce Solutions. This particularly applies to its reproduction, distribution, editing, translation, microfilming and storage and/or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. Rolls-Royce Solutions re-serves the right to change, delete or supplement the information provided as and when required.
1 Maintenance Schedule
1.1 Preface
This manual provides instructions for your product from the manufacturer Rolls-Royce Solutions.
Maintenance concept The maintenance system for Rolls-Royce Solutions products is based on a preventive maintenance concept.
Preventive maintenance facilitates advance operational planning and ensures a high level of equipment avail-ability. The maintenance intervals as well as the required scopes of maintenance tasks are based on opera-tional experience and therefore to be considered as recommendations. Additional maintenance work and/or changes to the maintenance intervals may be required in the case of difficult operational and ambient condi-tions.
Adherence to the specified maintenance intervals is essential to maintain product safety.
The intervals according to which the maintenance tasks have to be carried out are specified as operating hours and time limits. Whichever value is reached first shall apply.
The maintenance intervals are determined and verified by the load profile. Load profiles can be evaluated by the Service Partner of Rolls-Royce Solutions. Reading out load profile data is recommended for the first time after between 500 and 1000 operating hours depending on the application concerned, or after changing the duty profile or operating area.
The individual maintenance intervals are assigned to the qualification levels QL1 to QL4.
QL1: Operational monitoring and maintenance work which does not require disassembly of the product.
QL2: Exchange of components and parts in case of repair (corrective only, not part of the maintenance schedule).
QL3: Maintenance work which requires partial disassembly of the product.
QL4: Maintenance work which requires complete disassembly of the product.
Additional notes on maintenance and preservation:
The relevant component manufacturer's instructions apply with respect to the maintenance of any compo-nents which do not appear in this maintenance schedule.
For the change intervals of fluids and lubricants, refer to the corresponding Fluids and Lubricants Specifica-tions.
If the product is to remain out of service for a longer time period, Rolls-Royce Solutions recommends to carry out a monthly test run until engine operating temperature is reached. If the engine is scheduled to remain out of service for > 1 month, carry out engine preservation procedures in accordance with the Preservation and Represervation Specifications
The latest version of the specifications is available at http://www.mtu-solutions.com.
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1.2 Maintenance task tolerances
Maintenance tasks shall be completed within certain tolerances comprising a percentage and a maximum value, whereby the smaller value shall apply. Taking full advantage of such tolerances does not influence the scheduled timing of the ensuing maintenance task.
Interval (HRS)/limit Limit in % Limit max.
Operating hours ± 10% ± 500 hrs Years ± 10% ± 30 days Example 1 Task every 1000 hrs Between 900 hrs and 1100 hrs (10% of
1000 hrs) Example 2 Task every 30000 hrs Between 29500 hrs and 30500 hrs (10% of
30000 hrs, but max. 500 hrs)
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1.3 Load profile
Load profile Power 100% 80% 60% <15% Corresponding operating time 10% 50% 20% 20%
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1.4 Maintenance schedule matrix
0 to 14,500 operating hours Task
Li m it
Operating hours [h]
Da ily
1, 1, 2, 2, 3, 3, 4, 4, 5, 5, 6, 6, 7, 7, 8, 8, 9, 9, ,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
Engine
W1008 2 a
W0500 - X
W0501 - X
W0502 - X
W0503 - X
W0505 - X
W0506 - X
W0507 - X
W0508 - X
W1140 2 a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W1001 2 a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W1009 2 a X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
W1002 2 a X X X X X X X X X X X X X X
W1003 2 a X X X X
W1005 3 a X X X X
W1006 9 a X X X
W1011 9 a X X X
W1178 9 a X X X
W1007 9 a X X
W2000 9 a X X
W2002 9 a X X
W2003 9 a X X
W2009 9 a X X
W2011 9 a X X
W2014 9 a X X
W2017 9 a X X
W2018 9 a X X
W2036 9 a X X
W2059 9 a X X
W2062 9 a X X
W2073 9 a X X
W2074 9 a X X
W2075 9 a X X
W2110 9 a X X
W2111 9 a X X
W2112 9 a X X
W1063 9 a X
W1056 18 a X
W3000 18 a
W3001 18 a
W3002 18 a
W3003 18 a w = weeks m = months a = years
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- 0 tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight tinderrieden Highlight
Task Li m it
Operating hours [h]
Da ily
1, 1, 2, 2, 3, 3, 4, 4, 5, 5, 6, 6, 7, 7, 8, 8, 9, 9, ,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
W3004 18 a
W3005 18 a
W3056 18 a
W3006 18 a
W3010 18 a
W3041 18 a
W3042 18 a w = weeks m = months a = years
15,000 to 24,000 operating hours Task
Li m it
Operating hours [h]
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
Engine
W1008 2 a
W0500 -
W0501 -
W0502 -
W0503 -
W0505 -
W0506 -
W0507 -
W0508 -
W1140 2 a X X X X X X X X X X X X X X X X X X X
W1001 2 a X X X X X X X X X X X X X X X X X X X
W1009 2 a X X X X X X X X X X X X X X X X X X X
W1002 2 a X X X X X X X X X X
W1003 2 a X X X X
W1005 3 a X X X X
W1006 9 a X X X
W1011 9 a X X X
W1178 9 a X X X
W1007 9 a X X
W2000 9 a X X
W2002 9 a X X
W2003 9 a X X
W2009 9 a X X
W2011 9 a X X
W2014 9 a X X
W2017 9 a X X
W2018 9 a X X
W2036 9 a X X
W2059 9 a X X
W2062 9 a X X
W2073 9 a X X w = weeks m = months a = years
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Task Li m it
Operating hours [h]
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
,5
,0
W2074 9 a X X
W2075 9 a X X
W2110 9 a X X
W2111 9 a X X
W2112 9 a X X
W1063 9 a X
W1056 18 a X
W3000 18 a X
W3001 18 a X
W3002 18 a X
W3003 18 a X
W3004 18 a X
W3005 18 a X
W3056 18 a X
W3006 18 a X
W3010 18 a X
W3041 18 a X
W3042 18 a X w = weeks m = months a = years
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1.5 Maintenance tasks
Qualifi-cation
Interval Limit Item Maintenance tasks
O pt io n Task
[h]
Engine
QL1 - 2 a Engine oil filter Replace engine oil filters each time the engine oil is changed or, at the latest, on expiry of the time limit (given in years).
W1008
QL1 Daily - Engine operation Check engine oil level. W0500
Visually inspect engine for general condition and leaks. W0501
Check intercooler drain system. X W0502
Check signal ring position of maintenance indicator on air filter. W0503
Check relief bores of coolant pump(s). W0505
Check for abnormal running noises, exhaust gas color and vibration. W0506
Drain water and contamination from fuel prefilter. X W0507
Check reading on service indicator of fuel prefilter. X W0508
QL1 500 2 a Crankcase ventilation Clean wire meshes of crankcase ventilation. W1140
QL1 500 2 a Fuel filter Replace fuel filter or fuel filter element. W1001
QL1 500 2 a Centrifugal oil filter Check layer thickness of oil residue, clean out and replace filter sleeve together with every oil change, at the latest.
X W1009
QL1 1000 2 a Valve gear Check valve clearance, adjust if necessary. W1002
QL1 3000 2 a Belt drive Check belt condition and tension, replace belt(s) if necessary. W1003
QL1 3000 3 a Air filters Replace air filters. W1005
QL1 4000 9 a Fuel injection valves / injec-tors
Replace fuel injection valves/injectors. W1006
QL1 4000 9 a Combustion chambers Inspect cylinder chambers using an endoscope. W1011
QL1 4000 9 a Pressure pipe neck Replace pressure pipe neck (bayonet) in cylinder head. W1178
QL1 6000 9 a Fuel injection pump(s) Replace fuel injection pump(s). W1007
QL3 6000 9 a Component maintenance Before starting maintenance work, drain coolant and flush coolant systems.
W2000
Clean air pipework. W2002
Clean intercooler and inspect for leaks. W2003
Inspect centrifugal oil filter for wear. X W2009
Inspect vibration damper. W2011
Replace diaphragm of crankcase ventilation. W2014
Clean engine coolant cooler and check for leaks. W2017
Clean engine oil heat exchanger and check for leaks. W2018
Check engine alignment. W2036
Clean fuel cooler. W2059
Replace sealing material for all disassembled components. W2062
Replace coolant thermal actuator. W2073
Check rocker arms, valve bridges, pushrods and ball joints for wear. W2074
Overhaul exhaust turbochargers. W2075
Overhaul engine coolant pump. W2110
Overhaul raw water pump. W2111
Overhaul bilge pump. X W2112
QL3 12000 9 a Cylinder head Overhaul cylinder heads, visually inspect piston crowns and running pattern of cylinder liners.
W1063
QL4 12000 18 a Fuel pressure maintaining valve
Replace fuel pressure maintaining valve. W1056
QL4 24000 18 a Extended component mainte-nance
Disassemble engine completely. Inspect engine components accord-ing to assembly instructions; repair or replace as necessary.
W3000 w = weeks m = months a = years
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Qualifi-cation
Interval Limit Item Maintenance tasks
O pt io n Task
[h]
Replace all elastomeric parts and seals. W3001
Replace piston rings. W3002
Replace conrod bearings. W3003
Replace crankshaft bearings. W3004
Replace cylinder liners. W3005
Replace wire meshes for crankcase ventilation system. W3056
Replace antifriction bearings for auxiliary PTOs. W3006
Replace fuel delivery pump. W3010
Overhaul starter. W3041
Overhaul battery-charging generator. W3042 w = weeks m = months a = years
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| Maintenance Schedule |
| 1 Maintenance Schedule |
| 1.1 Preface |
| 1.2 Maintenance task tolerances |
| 1.3 Load profile |
| 1.4 Maintenance schedule matrix |
| 1.5 Maintenance tasks |
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