4000 Series (post-2003)

Maintenance Schedule

Fuel Servicing Plant1a                      
Fuel Servicing Plant2a                      
Engine Oil Filter 2a                      
Engine Operation X                     
Centrifugal Oil Filter  X XXX XXX XXX XXX XXX
Crankcase Breathers   X X X X X X X  X X X 
Fuel Filter   X X X X X X X       
Turbochargers       X     X         
Valve Gear         X       X     
Air Filters         X       X     
Battery Charging Generator             X         
Component Maintenance             X         

Task Description

Fuel Servicing PlantCheck alarm function for differential pressure gauge. Check pump performance.
Engine Oil FilterFit new engine oil filters each time the engine oil is changed.
Engine OperationCheck engine oil level. Carry out visual inspection of engine for general condition and leaks. Inspect intercooler drain system. Inspect service indicator of air filter. Check the inspection bores of the HP fuel pump. Check relief bores of coolant pumps. Check for abnormal running noises, exhaust gas color and vibration. Drain off water and contamination from fuel pre filter. Check service indicator of fuel prefilter.
Air DuctingInspet air ducting between air filters and turbochargers for leaks and damage.
Centrifugal Oil FilterCheck thickness of oil residue layer. Clean. Fit new sleeve each time the engine oil is changed.
Crankcase Breathers8V only; fit new filters.
Fuel FilterFit new fuel filter or new fuel filter insert.
TurbochargersCheck condition of coupling.
Valve GearCheck valve clearance, adjust if required.
Battery Charging GeneratorCheck condition of coupling.
Component MaintenanceBefore starting maintenance work, carry out test run and record operating parameters. Then drain coolant and flush cooling systems. Inspect rocker arms and valve bridge for wear. Insert an endoscope through the pushrod bore to visually inspect swing followers and camshaft running surfaces. Inspect vibration damper. Clean air ducting. Clean intercooler and inspect for leakage. Fit new seals/sealing materials for all disassembled components. Fit new high-pressure fuel sensor. Clean engine coolant cooler and if possible, inspect it for leaks. Inspect centrifugal oil filter for air (if fitted). Disassemble Kusel coupling (if fitted). Check parts. Fit new friction rings and disks. Check adjustment at central buffer of engine mounts. Check operation of diverter valves (if fitted). Overhaul starts. Overhaul engine coolant pump. Overhaul raw water pump.