TCG 2020 K Maintenance schedule

5

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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OBJ_DOKU-17295-001.fm

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© MWM GmbH 01/2009

TCG 2020 K Maintenance schedule Maintenance and service schedules The operating hour-dependent maintenance measures are divided into maintenance and service schedules. Arrange in advance the anticipated date with your service partner.fm 8 © MWM GmbH 01/2009 . All due maintenance measures. draw up a maintenance contract with your service partner. Please note that maintenance and service schedules may be added or omitted depending on the speed and gas group. When making the appointment. and any repair measures depending on the agreement. 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. OBJ_DOKU-17295-001. If appropriate. Your local service partner will provide the details. depending on the speed and gas group. will then be planned and carried out properly by the service partner conformant as set out in the contract. All the listed measures are to be carried out carefully according to the maintenance schedule specifically defined for the engine. inform him of any irregularities in the engine. 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.

the cause must be determined and the nominal condition reinstated. replacement of cleaning components (e. If all criteria are not satisfied. Maintenance Maintenance according to job card. function blocks and liquids. Checking functions.TCG 2020 K Maintenance schedule 5 Definition of tasks in the maintenance schedule Settings Setting torques. extra work may be necessary to renew components. pressures etc. Checks Checks according to criteria in the job card. Visual inspection Visual inspection according to criteria in the job card.fm 9 © MWM GmbH 01/2009 . Changing Changing lube oil for example OBJ_DOKU-17295-001. If all criteria are not satisfied. Draining Draining condensation for example. Cleaning Cleaning by hand or machine (automatic). the cause must be determined and the nominal condition reinstated. air filter) may be necessary. rework or renewal of components. Replacing Replacement of components.. Reworking Material acceptance within the permissible tolerances to maintain a nominal condition.g. dimensions. reworking or renewal of components may be necessary. Overhauling Checking of function blocks.

also see Technical Bulletin 0199 99 . e. The combustion gasses are divided into three groups according to their wear properties.fm 10 © MWM GmbH 01/2009 . For more information. 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). OBJ_DOKU-17295-001. If necessary the maintenance intervals must be reduced accordingly.3017. for which the different normal maintenance plans are valid. the composition of the combustion gases must be determined at regular intervals by means of a comprehensive gas analysis.g. see Technical Bulletin 0199-99-3017. To ensure the required tool life. the maintenance intervals (TBO/Time Between Overhaul) have to be reduced because of the high level of abrasion. bio-gas after a desulphurisation treatment Maintenance interval If using combustion gases with a high pollutant load.TCG 2020 K Maintenance schedule Gas groups The maintenance intervals also depend on the quality of the combustion gases. Gas group 1 Natural gas Pit gas Liquefied gas such as propane.

3017) Check engine coolant (according to Technical Bulletin 0199 .99 . lube oil change.99 2105 In accordance with Technical Bulletin 0199 .2091) Check pressure drop of the gas filter 11 © MWM GmbH 01/2009 as required as required as required Monthly Monthly every 4 months every 6 months every 6 months OBJ_DOKU-17296-001.99 2105 In accordance with Technical Bulletin 0199 .when low pressure limit value is reached (note maintenance indicator) .after 4000 oh at the latest Overhaul cylinder heads . if the engine was not run in operational readiness within a month Carry out a gas analysis (according to Technical Bulletin 0199 . Engine corrosion protection Engine corrosion protection.99 .fm .TCG 2020 K Maintenance schedule 5-1 5 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 . engine coolant change. etc.if damaged (leakage) .99 2116 as required 1x after 50 Oh as specified Gas engines . etc.when the max. Renew lube oil filter cartridge Engine coolant Engine coolant analysis.lubricating oil Lube oil analysis. Renew intake air cleaner . if the engine was not run in operational readiness within a month Service the battery. etc.99 2091 In accordance with Technical Bulletin 0199 . 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.

Observe manufacturer's documentation x x x x x x x x x x x x x Overhaul the exhaust gas turbocharger .) Service the generator Service the clutch Service spring elements (underframe) Service intermediate gearbox .g. etc. cylinder liners. renew if necessary Replace spark plugs Check ignition time Maintain crankcase breather (model UPF) .fm .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.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 © MWM GmbH 01/2009 x x x x x x x OBJ_DOKU-17296-001.renew the inner filter (filter stage 1) every 8000 oh Auxiliary units test by TEM system Check combustion chambers with endoscope Check.TCG 2020 K 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 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. clean turbocharger .renew the outer filter (filter stage 2) every 4000 oh . replacing pistons. pressure setting and impermaebility of the gas control process Replace gas filter insert Replace engine coolant Run-in the engine (after e.

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 © MWM GmbH 01/2009 OBJ_DOKU-17296-001.fm . hoses and flexible lines Check fittings and control units on engine side Check electric cabling.TCG 2020 K Maintenance schedule 5-1 5 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 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. cable set plug and sensor system Check crankshaft axial clearance Check camshaft.

OBJ_DOKU-17296-001.TCG 2020 K 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 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.fm 14 © MWM GmbH 01/2009 .

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