TCG 2020 K Maintenance schedule

Maintenance
Please note that the following maintenance schedule is a standard maintenance schedule. A fixed definition of the maintenance intervals for all applications is not possible due to the various relations between ambient conditions, operating mode and quality of the fuels. A shortening of the given interval may be necessary under critical operating conditions. The normal maintenance plan is then to be adapted. Normally, the local operating conditions are already taken into account in the projection phase. Critical operating conditions are for example: contamination of the combustion gases by wear promoting constituents such as silicon, sulphur, chlorine, ... Frequent starts, e.g. less than 12 operating hours per start Multiple emergency stops increased load in the intake air

Talk to your service partner if in doubt.

General
This engine is built exclusively for the purpose set out in the scope of supply - defined by the equipment manufacturer (use for the intended purpose). Depending on the purpose, the engine is identified by a performance code or a type of gas code which is embossed on the rating plate. The rating plate is described in detail in chapter 2. The maintenance schedule lists the measures for maintaining the nominal condition and thus operational safety of the engine with the corresponding intervals. When the specified interval or operating hours have been reached, or if necessary, the work specified in the maintenance schedule must be carried out. The activities are described on job cards. The job cards are listed in chapter 9. The operating manual contains the job cards up to the maintenance and service schedule E40. The workshop manual lists the job cards up to the maintenance and service schedule E70. z The intervals specified in the maintenance schedule are maximum values and assume that installation, intended purpose and operating conditions comply with the specifications. It must be ensured that all running materials such as combustion gas, lube oil and coolant are of the prescribed quality.

It must be ensured especially that the gas quality meets the minimum requirements according to TR 0199 - 99 - 3017 to avoid operating malfunctions and/or premature engine wear. z The maintenance schedule only applies to the engine itself and the parts mounted on the engine. System parts must be serviced according to the times and instructions specified by the manufacturer. The appropriate information can be found in the manufacturer documents supplied. The measures described must be carried out by technically skilled personnel or authorized specialists. The competencies are listed in the maintenance and service schedule table.

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TCG 2020 K Maintenance schedule

Maintenance and service schedules

The operating hour-dependent maintenance measures are divided into maintenance and service schedules. All the listed measures are to be carried out carefully according to the maintenance schedule specifically defined for the engine. Please note that maintenance and service schedules may be added or omitted depending on the speed and gas group.

Maintenance and service schedules E10 E20 E30 E40 E50 E60 E70 Due once after commissioning and after E60 and E70 respectively Daily inspection round Periodic maintenance (small scope) Periodic maintenance (medium scope) Periodic maintenance (extended scope) Intermediate overhaul General overhaul

Carried out by Technically skilled personnel

Authorised specialists

Selection and installation

A suitable maintenance schedule is allocated for the engine, depending on the speed and gas group. The maintenance plan consists of several sections: Maintenance measures Data on the average service life of wear parts Master copy for proof of execution

Plan in plenty of time when the the maintenance and service schedules are due in accordance with the engine's number of operating hours. Arrange in advance the anticipated date with your service partner. When making the appointment, inform him of any irregularities in the engine. If appropriate, draw up a maintenance contract with your service partner. All due maintenance measures, and any repair measures depending on the agreement, will then be planned and carried out properly by the service partner conformant as set out in the contract. Your local service partner will provide the details.

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TCG 2020 K Maintenance schedule

Definition of tasks in the maintenance schedule

Settings Setting torques, dimensions, pressures etc.; extra work may be necessary to renew components. Draining Draining condensation for example. Replacing Replacement of components, function blocks and liquids. Reworking Material acceptance within the permissible tolerances to maintain a nominal condition. Checks Checks according to criteria in the job card. If all criteria are not satisfied, the cause must be determined and the nominal condition reinstated. Cleaning Cleaning by hand or machine (automatic), replacement of cleaning components (e.g. air filter) may be necessary. Visual inspection Visual inspection according to criteria in the job card. If all criteria are not satisfied, the cause must be determined and the nominal condition reinstated. Overhauling Checking of function blocks; rework or renewal of components. Maintenance Maintenance according to job card. Checking functions; reworking or renewal of components may be necessary. Changing Changing lube oil for example

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TCG 2020 K Maintenance schedule

Gas groups
The maintenance intervals also depend on the quality of the combustion gases. The combustion gasses are divided into three groups according to their wear properties, for which the different normal maintenance plans are valid, also see Technical Bulletin 0199 99 - 3017. Gas group 1 Natural gas Pit gas Liquefied gas such as propane, LNG (liquefied natural gas) Wellhead gas (petroleum gas) Gas group 2 Sewage gas Landfill gas Bio-gas Gas group 3 All gases in which the concentration of every single pollutant gas component does not exceed 20% of the permissible limit value (see limit value list). e.g. bio-gas after a desulphurisation treatment

Maintenance interval
If using combustion gases with a high pollutant load, the maintenance intervals (TBO/Time Between Overhaul) have to be reduced because of the high level of abrasion. To ensure the required tool life, the composition of the combustion gases must be determined at regular intervals by means of a comprehensive gas analysis. For more information, see Technical Bulletin 0199-99-3017. If necessary the maintenance intervals must be reduced accordingly.

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Maintenance schedule
Valid for: Engine type: Speed: Combustion gas : Performance abbreviations Type of application: Maintenance measures
E10 E20 E30 E40 E45 E50 E55 E60 E70 Description every 24 hours (daily) after every 12000 oh after every 16000 oh after every 24000 oh after every 32000 oh after every 64000 oh after every 2000 oh after every 4000 oh

V12 and V16 engines n = 1500 rpm Gas group 1 ICN Current generators

In accordance with Technical Bulletin 0199 - 99 2105 In accordance with Technical Bulletin 0199 - 99 2105 In accordance with Technical Bulletin 0199 - 99 2091 In accordance with Technical Bulletin 0199 - 99 2116 as required

1x after 50 Oh

as specified

Gas engines - lubricating oil Lube oil analysis, lube oil change, etc. Renew lube oil filter cartridge Engine coolant Engine coolant analysis, engine coolant change, etc. Engine corrosion protection Engine corrosion protection, etc. Renew intake air cleaner - when low pressure limit value is reached (note maintenance indicator) - if damaged (leakage) - after 4000 oh at the latest Overhaul cylinder heads - when the max. valve clearance is reached (according to Chapter 8) - after 32000 oh at the latest Further information can be found in Appendix A Clean the engine Replace or recondition the starter Test run, if the engine was not run in operational readiness within a month Service the battery, if the engine was not run in operational readiness within a month Carry out a gas analysis (according to Technical Bulletin 0199 - 99 - 3017) Check engine coolant (according to Technical Bulletin 0199 - 99 - 2091) Check pressure drop of the gas filter 11
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as required

as required as required Monthly Monthly every 4 months every 6 months every 6 months
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E10 E20 E30 E40 E45 E50 E55 E60 E70 Description every 24 hours (daily) after every 12000 oh after every 16000 oh after every 24000 oh after every 32000 oh after every 64000 oh after every 2000 oh after every 4000 oh

every 12 months every 12 months After every 24 months After maintenance work According to manufacturer specifications According to manufacturer specifications According to manufacturer specifications According to manufacturer specifications 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 x x x x x x x x x x x x x x x x x x

1x after 50 Oh

as specified

Check regulating devices, pressure setting and impermaebility of the gas control process Replace gas filter insert Replace engine coolant Run-in the engine (after e.g. replacing pistons, cylinder liners, etc.) Service the generator Service the clutch Service spring elements (underframe) Service intermediate gearbox - only 60 Hz applications Test and function run Check and set inlet and exhaust valve clearance Check valve lag (cylinder head fitted) Visual inspection of the system Maintaining the battery Check throttle body Check speed governor linkage Check the spark plugs, renew if necessary Replace spark plugs Check ignition time Maintain crankcase breather (model UPF) - renew the outer filter (filter stage 2) every 4000 oh - renew the inner filter (filter stage 1) every 8000 oh Auxiliary units test by TEM system Check combustion chambers with endoscope Check, clean turbocharger - Observe manufacturer's documentation x x x x x x x x x x x x x Overhaul the exhaust gas turbocharger - Observe manufacturer's documentation Check engine mounting Check starter pinion and gear rim on the flywheel Check exhaust line Check mixture cooler (using a bore scope) Clean mixture cooler 12
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x x x

x x

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E10 E20 E30 E40 E45 E50 E55 E60 E70 Description every 24 hours (daily) after every 12000 oh after every 16000 oh after every 24000 oh after every 32000 oh after every 64000 oh after every 2000 oh after every 4000 oh

1x after 50 Oh

as specified

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 x x x x x x x x x x

Cleaning the gas-air mixer Overhauling the gas-air mixer Check rubber compensators Renew rubber compensators Renew viscosity rotary vibration dampers Check vibration dampers, hoses and flexible lines Check fittings and control units on engine side Check electric cabling, cable set plug and sensor system Check crankshaft axial clearance Check camshaft, axial clearance Check small end bushings Renew big end bearing Renew cylinder liners Check crankcase, collar rest of cylinder liners and water chambers Check piston bolt Renew piston rings Check the piston Renew pistons (complete) Renew valve tappet Visually check camshaft (camshaft installed) Check camshaft Renew camshaft bearing Renew valve actuator Check conrod Renew connecting rods Renew crankshaft sealing ring on the drive side Renew crankshaft sealing ring on the free side Check crankshaft Renew main bearing and axial bearing or stop rings Check and clean gear drive Renew lubricating oil pump 13
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E10 E20 E30 E40 E45 E50 E55 E60 E70 Description every 24 hours (daily) after every 12000 oh after every 16000 oh after every 24000 oh after every 32000 oh after every 64000 oh after every 2000 oh after every 4000 oh

1x after 50 Oh

as specified

x x x

Renew lubricating oil pressure limiting valve Renew exhaust gas compensators Recondition actuator

All the filter elements of the crankcase breather must be renewed if coolant penetrates the lubricating oil system.

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