TCG 2020 K

Maintenance schedule
5

Maintenance

Please note that the following maintenance schedule is a standard maintenance sched-
ule.
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 sili-

con, 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 operat-
ing 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.

! The intervals specified in the maintenance schedule are maximum values and assume
that installation, intended purpose and operating conditions comply with the specifica-
tions. 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 accord-
ing to TR 0199 - 99 - 3017 to avoid operating malfunctions and/or premature engine wear.

! 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 manu-
facturer documents supplied.
! The measures described must be carried out by technically skilled personnel or author-
ized specialists. The competencies are listed in the maintenance and service schedule
table.

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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 Carried out by

E10 Due once after commissioning and after Technically skilled personnel
E60 and E70 respectively
E20 Daily inspection round
E30 Periodic maintenance (small scope)
E40 Periodic maintenance (medium scope)
E50 Periodic maintenance (extended scope) Authorised specialists
E60 Intermediate overhaul
E70 General overhaul

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 accord-
ance with the engine's number of operating hours.
Arrange in advance the anticipated date with your service partner. When making the ap-
pointment, inform him of any irregularities in the engine.
If appropriate, draw up a maintenance contract with your service partner. All due mainte-
nance 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 con-
tract. Your local service partner will provide the details.

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Maintenance schedule
5

Definition of tasks in the maintenance schedule

Settings
Setting torques, dimensions, pressures etc.; extra work may be necessary to renew com-
ponents.

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 compo-
nents may be necessary.

Changing
Changing lube oil for example

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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 ex-
ceed 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 deter-
mined 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 5-1

5

Maintenance schedule

Valid for: Engine type: V12 and V16 engines

Speed: n = 1500 rpm

Combustion gas : Gas group 1

Performance abbreviations ICN

Type of application: Current generators

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

1x after 50 Oh
as specified

In accordance with Technical Bulletin 0199 - 99 - Gas engines - lubricating oil

2105 Lube oil analysis, lube oil change, etc.
In accordance with Technical Bulletin 0199 - 99 - Renew lube oil filter cartridge
2105
In accordance with Technical Bulletin 0199 - 99 - Engine coolant
2091 Engine coolant analysis, engine coolant change, etc.
In accordance with Technical Bulletin 0199 - 99 - Engine corrosion protection
2116 Engine corrosion protection, etc.
as required Renew intake air cleaner
- when low pressure limit value is reached (note main-
tenance indicator)
- if damaged (leakage)
- after 4000 oh at the latest
as required 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
as required Clean the engine
as required Replace or recondition the starter
Monthly Test run, if the engine was not run in operational read-
iness within a month
Monthly Service the battery, if the engine was not run in opera-
tional readiness within a month
every 4 months Carry out a gas analysis (according to Technical Bulle-
tin 0199 - 99 - 3017)
every 6 months Check engine coolant (according to Technical Bulletin
0199 - 99 - 2091)
every 6 months Check pressure drop of the gas filter
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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

every 12 months Check regulating devices, pressure setting and imper-

maebility of the gas control process
every 12 months Replace gas filter insert
After every 24 months Replace engine coolant
After maintenance work Run-in the engine (after e.g. replacing pistons, cylin-
der liners, etc.)
According to manufacturer specifications Service the generator
According to manufacturer specifications Service the clutch
According to manufacturer specifications Service spring elements (underframe)
According to manufacturer specifications Service intermediate gearbox
- only 60 Hz applications
x x x x x x Test and function run
x x x x x x Check and set inlet and exhaust valve clearance
x x x x x x Check valve lag (cylinder head fitted)
x Visual inspection of the system
x x x x x Maintaining the battery
x x x x x Check throttle body
x x x x x Check speed governor linkage
x Check the spark plugs, renew if necessary
x x x x Replace spark plugs
x x x x Check ignition time
x x x x 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
x x x x Auxiliary units test by TEM system
x x Check combustion chambers with endoscope
x Check, clean turbocharger
- Observe manufacturer's documentation
x Overhaul the exhaust gas turbocharger
- Observe manufacturer's documentation
x x x Check engine mounting
x x x Check starter pinion and gear rim on the flywheel
x x x Check exhaust line
x Check mixture cooler (using a bore scope)
x x Clean mixture cooler
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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 Cleaning the gas-air mixer

x Overhauling the gas-air mixer
x Check rubber compensators
x Renew rubber compensators
x x Renew viscosity rotary vibration dampers
x x Check vibration dampers, hoses and flexible lines
x x Check fittings and control units on engine side
x x Check electric cabling, cable set plug and sensor sys-
tem
x Check crankshaft axial clearance
x Check camshaft, axial clearance
x Check small end bushings
x x Renew big end bearing
x x Renew cylinder liners
x x Check crankcase, collar rest of cylinder liners and
water chambers
x Check piston bolt
x Renew piston rings
x Check the piston
x Renew pistons (complete)
x x Renew valve tappet
x Visually check camshaft (camshaft installed)
x Check camshaft
x Renew camshaft bearing
x Renew valve actuator
x Check conrod
x Renew connecting rods
x Renew crankshaft sealing ring on the drive side
x Renew crankshaft sealing ring on the free side
x Check crankshaft
x Renew main bearing and axial bearing or stop rings
x Check and clean gear drive
x Renew lubricating oil pump

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Maintenance schedule 5-1

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 Renew lubricating oil pressure limiting valve

x Renew exhaust gas compensators
x Recondition actuator

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

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