Maintenance information

TCG 2016 C
2013-07
0299 9393 EN

1800 min-1, Low Gas Quality

This documentation is a component of the operating manual in accordance with the Machinery Directive
2006/42/EC.

This is the English translation. All translations are based on the German original.
Maintenance information

Technical modifications required to improve our gensets are reserved with regard to specification data and
other technical information contained in this documentation. No parts of this document may be reproduced
in any form or by any means without our written approval.

This maintenance information contains information that is necessary for maintenance and repair work on
the genset.
When carrying out the work listed in the maintenance schedule, only original parts or parts and operating
media approved by MWM may be used.

Masthead:
MWM GmbH
Servicedokumentation
Carl-Benz-Str. 1
68167 Mannheim
Germany
Tel.: +49 621 384-0
Fax: +49 621 384-8841
www.mwm.net
Printed in Germany
All rights reserved
Issued on:
2013-07
Order number
0299 9393

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Contents

Contents

1 Maintenance
General information ............................................................................................................................ 7
Operating media regulations as separate documentation .................................................................. 7
Selection and structure ....................................................................................................................... 8
Maintenance interval........................................................................................................................ 8
Maintenance levels .......................................................................................................................... 9
Maintenance work............................................................................................................................ 9
Definition of the maintenance work................................................................................................... 10
Gas qualities ..................................................................................................................................... 10

2 Maintenance schedule
Valid for:............................................................................................................................................ 13
General information .......................................................................................................................... 13
Maintenance interval schedule ......................................................................................................... 14
Maintenance work............................................................................................................................. 15

3 Templates
Maintenance work independent on operating hours ......................................................................... 22
Maintenance work dependent on operating hours............................................................................ 23
Operational control log...................................................................................................................... 24

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Contents

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Maintenance

General information

The following maintenance schedule is a regular maintenance schedule.

A fixed definition of the maintenance intervals for all applications is not possible due to the
diverse interactions between the ambient conditions, operating modes and quality of the fu-
els.
It may be necessary to shorten a given maintenance interval under critical operating condi-
tions. The regular maintenance schedule is then to be adapted. Normally, the local operat-
ing conditions are already taken into account in the projection phase.
The following are examples of critical operating conditions:

 Loading of combustion gases with abrasive components, e.g. silicon, sulfur, chlorine,
...
 frequent starts, e.g. less than 8 continuous operating hours per start. Except for com-
missioning, maintenance and repair work.
 multiple emergency stops
 contaminated intake air
Please contact the responsible Service Partner if you have any queries.

The product is built exclusively for the purpose in the scope of delivery - as defined by the
manufacturer (intended use). Depending on its intended use, the engine is marked with a
power code, engraved in the rating plate. The rating plate is described in detail in the genset
operating instructions.
To maintain the genset's required condition, and thus its operational safety, the mainte-
nance schedule contains the maintenance work together with the relevant maintenance in-
tervals.

 The maintenance intervals indicated in the maintenance schedule are maximum val-
ues, and it is presupposed that the installation, intended use and operating conditions
comply with all regulations stated.
 The described maintenance work must be performed by the operating personnel and/
or service personnel. For the competencies, please refer to the table Maintenance Lev-
els.
 In order to avoid any operating faults and/or premature wear, make sure that all oper-
ating media comply with the required specification. The operating media are specified
in the operating media regulations. The figures mentioned therein are binding unless
otherwise specified in the engine or system-specific contracts.

Operating media regulations as separate documentation

For further information on the operating media regulations, see

 Operating Manual  General  Operating media regulations

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Selection and structure

The maintenance work indicated in the maintenance schedule must be performed once the
indicated maintenance intervals (months, operating hours or when required) have been
reached.

A specific maintenance schedule is assigned to the engine depending on speed and gas
quality.
The maintenance schedule consists of several sections, which are valid in parallel to each
other.

 The maintenance work independent on operating hours

Here, the maintenance work is listed, which must be performed once the indicated
maintenance intervals in months have been reached.
The maintenance work for which the time intervals (when necessary and/or as
specified) are determined by an analysis are also listed.
 The maintenance work dependent on operating hours
Here, the maintenance work is listed, which must be performed once the indicated
maintenance intervals in operating hours (maintenance levels) have been
reached.

Maintenance interval
Maintenance intervals may be added or dropped depending on the speed and gas quality.
To ensure the required service lives, the composition of the combustion gas must be deter-
mined at regular intervals by means of a comprehensive gas analysis.
The maintenance intervals may need to be shortened correspondingly.

Plan the due date of the maintenance intervals in good time according to the number of op-
erating hours of your genset.
You should arrange the expected appointments early on with your responsible Service
Partner. When you arrange the appointments, report any malfunction which might have oc-
curred on your genset.
If necessary, conclude a service contract with your Service Partner. All due maintenance
work and any repair work depending on the agreement will then be planned and carried out
properly by the Service Partner as set out in the contract. Your responsible Service Partner
will be pleased to provide you with more detailed information.

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Maintenance levels
Maintenance work which takes place depending on the number of operating hours is divid-
ed into maintenance levels.
All the maintenance work listed must be carefully performed according to the maintenance
schedule specific to the genset.

Maintenance levels
Operating personnel
E10 due once after commissioning and after replacement of the cylinder heads re-
spectively
E20 daily inspection round
E30 periodic maintenance (small scale)
E40 periodic maintenance (medium scale)
Service personnel
E50 periodic maintenance (extended scale)
E60 Interim overhaul
E70 Major overhaul

Maintenance work
The maintenance work is described in job cards. The genset operating instructions contain
the job cards up to maintenance level E40. The workshop manual contains the job cards
up to maintenance level E70.

It is imperative that the assembly, maintenance and repair work is carried out.
The work may be carried out by personnel that meet the following minimum requirements:

B are maintenance activities for which the personnel must have the minimum require-
ment CC1
W are maintenance and repair activities for which the personnel must have the mini-
mum requirement CC2
Q are assembly and repair activities for which the personnel must have the minimum
requirement for qualified specialist personnel.

For further information on specialists, see

 Operating Manual  General  Safety specifications

- Personnel - Qualifications and Duties

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Definition of the maintenance work

Adjusting
Adjusting torques, dimensions, pressures etc.; additional work for replacing components
may be necessary.

Draining
Draining condensation, for example.

Replacing
Replacing components.

Reworking
Material removal within the permitted tolerances for maintaining a required condition.

Checking
Checking according to criteria in the job card. If one or more criteria are not satisfied, the
cause must be determined and the required condition reinstated.

Cleaning
Cleaning manually or mechanically (automatically); it may be necessary to replace com-
ponents (e.g. air filters) being cleaned.

Visually inspecting
Visual inspection according to criteria in the job card. If one or more criteria are not satis-
fied, the cause must be determined and the required condition reinstated.

Overhauling
Checking of components and systems; rework or renewal of components.

Maintaining
Maintaining according to job card. Checking of functions; rework or renewal of components
may be necessary.

Changing
Changing operating media such as lubricating oil.

Gas qualities
The maintenance intervals depend on the quality of the combustion gases, among other
things.
The combustion gases are classified into various gas quality groups by their accompanying
substances and their effects on the wear.

For more information on the gas qualities and limit values of the combustion gases, see

 Operating Manual  General  Operating media regulations

- TR 0199-99-03017 Specification for combustion gas

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Maintenance schedule

Valid for:

Engine type: TCG 2016 C

Speed: 1800 rpm

Gas quality: Low

Power code: ICN

Application: Power supply unit

General information
The maintenance schedule consists of several sections, which are valid in parallel to each
other.

 The maintenance work independent on operating hours

Here, the maintenance work is listed, which must be performed once the indicated
maintenance intervals in months have been reached.
The maintenance work for which the time intervals (when necessary and/or as
specified) are determined by an analysis are also listed.
 The maintenance work dependent on operating hours
Here, the maintenance work is listed, which must be performed once the indicated
maintenance intervals in operating hours (maintenance levels) have been
reached.

The maintenance schedules of the genset components (e.g. generator, clutch, gas control
line) and system components (e.g. recooler, plate heat exchanger, coolant pumps) are in-
cluded in the system specific customer documentation.

Replacement parts such as cylinder heads and crankcase, in original manufacturer quality
with manufacturer guarantee, can be purchased from your Service Partner.
Your responsible Service Partner will be pleased to provide you with more detailed infor-
mation.

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Maintenance interval schedule

Maintenance work independent on operating hours
 on demand
 as specified
 Monthly
 after 4 months
 after 6 months
 after 24 months
 after repair work

Maintenance work dependent on operating hours

oh E10 E30 E40 E50 E60 E70
50 X
1 500 X
3 000 X
4 500 X
6 000 X
7 500 X
9 000 X
10 500 X
12 000 X
12 050 X
13 500 X
15 000 X
16 500 X
18 000 X
19 500 X
21 000 X
22 500 X
24 000 X
24 050 X
25 500 X
27 000 X
28 500 X
30 000 X
31 500 X
33 000 X
34 500 X
36 000 X
36 050 X
37 500 X
39 000 X
40 500 X
42 000 X
43 500 X
45 000 X
46 500 X
48 000 X
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Maintenance work

Maintenance work independent on operating hours

AK No.

after repair work

Maintenance work

after 24 months
after 4 months

after 6 months
as specified
on demand

monthly

B Clean engine B 0-3-6

W Replace or overhaul starter W 13-3-2
B Lubricating oil for gas engines (lubricating oil analysis, lu-
bricating oil change etc.)
- according to TR 0199-99-02105
B Replace the lubricating oil filter cartridges
- according to TR 0199-99-02105
B Coolant for engines and systems (coolant analysis, cool-
ant change etc.)
- according to TR 0199-99-02091
B Corrosion protection of engines, (corrosion protection, re-
application of corrosion protection, removal of corrosion
protection)
- according to TR 0199-99-02116
B Maintenance of crankcase breather (model UPF) B 3-1-9
- Carry out measurement of limit values every 2000 oh
- Renew after 16000 oh at the latest
A control measurement must be carried out after replace-
ment of the filter inserts
B Replace intake air filter B 6-3-6
- when low pressure limit value is reached (note mainte-
nance indicator)
- in case of damage to the surface (leakages)
- after 4000 operating hours at the latest
Q Overhaul exhaust turbocharger (model TPS 44 - with wa-
ter cooling)
- Standard overhaul every 16000 oh
- Major overhaul every 48000 oh
Q Overhaul exhaust turbocharger (model TPS 48 - without
water cooling)
- Standard overhaul every 12000 oh
- Major overhaul every 48000 oh
B Test run B 0-1-4
- if the engine was not run in operational readiness within
a month

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Maintenance work independent on operating hours

AK No.

after repair work

Maintenance work

after 24 months
after 4 months

after 6 months
as specified
on demand

monthly

B Service battery B 13-4-1

- if the engine was not run in operational readiness within
a month
B Sampling and gas analysis B 7-18-1
- according to TR 0199-99-03017
B Check coolant B 9-1-1
- according to TR 0199-99-02091
B Replace coolant B 9-0-4
- according to TR 0199-99-02091
B Run in engine (after e.g. replacing pistons, cylinder liners, W 0-1-3
etc.)

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Maintenance work independent on operating hours

E10 E20 E30 E40 E50 E60 E70
after every 24 h (daily)

Maintenance work AK No.

after every 12000 oh

after every 24000 oh

after every 48000 oh

after every 1500 oh

after every 3000 oh

1x after 50 oh

B B B B B B Test and functioning run B 0-1-7

B B B B B B Check and adjust inlet and outlet valve clearance B 1-1-1
B B B B B Check valve recession (mounted on cylinder head) B 1-7-10
B Visual inspection of the system B 0-1-5
B B B B B Auxiliary units test with TEM System B 0-1-6
B B B B B Check throttle valve B 7-23-3
B B B B B Service battery B 13-4-1
B Check spark plugs B 13-5-6
B B B B B Check ignition time B 13-5-3
W W W W Check pollutant emission in the exhaust gas W 0-1-9
B B B B Replace spark plugs B 13-5-4
W W W Overhaul cylinder heads W 1-4-6
W Visually inspect cylinder liners (cylinder liners dismantled) W 3-3-9
W W W Check engine mount W 3-7-1
W W W Visually inspect exhaust line (exhaust line dismantled) W 6-1-1
W Check mixture cooler (using an endoscope) W 6-4-11
W W Clean gas/air mixer W 7-22-4
W W W Check starter pinion and gear ring on the flywheel W 12-6-4
W W Check vibration dampers, hose lines and flexible lines W 0-3-4
W W Check valves and regulating devices on the engine side W 0-3-5
W Check crankshaft, axial clearance W 2-1-4
W Check con rod bushings W 2-3-7
W W Replace con rod bearing W 2-5-3
W W Replace piston (complete) W 2-9-8
W W Check cylinder liners W 3-3-2
W Visually inspect the valve tappet (valve tappet installed) W 4-2-3
W Visually check camshaft (camshaft installed) W 4-5-8
W W Clean mixture cooler W 6-4-7
W W Replace flexible lubricating oil lines of the pre-lubricating W 8-80-1
system
W W Check electric cabling, cable set plug and sensor system W 13-1-4
W W Replace viscosity torsional damper W 12-1-4
W Check rubber compensators W 12-3-1

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Maintenance work independent on operating hours

E10 E20 E30 E40 E50 E60 E70
after every 24 h (daily)

Maintenance work AK No.

after every 12000 oh

after every 24000 oh

after every 48000 oh

after every 1500 oh

after every 3000 oh

1x after 50 oh

W Check crankshaft W 2-1-7

W Replace crankshaft sealing ring of the drive side W 2-2-2
W Replace crankshaft sealing ring of the free side W 2-2-4
W Replace con rods W 2-3-6
W Replace main bearing and thrust bearing W 2-4-1
W Replace camshaft bearing W 4-1-1
W Replace valve tappets W 4-2-3
W Replace camshaft W 4-5-5
W Check and clean valve train (complete) W 4-2-5
W Check and clean gear drive W 4-4-15
Q Recondition actuator
W Replace exhaust compensators W 6-1-11
W Overhaul gas/air mixer W 7-22-3
W Replace lubricating oil pump W 8-4-5
W Replace lubricating oil pressure-limiting valve W 8-11-16
W Replace rubber compensators W 12-3-3

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Templates
The proper execution of maintenance and repair work is to be documented.
The following templates are attached:

 Maintenance work independent on operating hours

- Here, the performance log will document the date, the genset operating hours and
signature independent on the operating hours.
 Maintenance work dependent on operating hours
- Here, the performance log will document the genset and signature according to
maintenance levels.
 Operational control log for repair work
- The repair work is documented in the operational control log.
- All irregularities (warnings, faults) are recorded as well. On the one hand, this al-
lows for a simpler overview of maintenance work due and, on the other hand, ir-
regularities can be fully documented for the Service Partner.
- In case of warning or fault messages, the measurement values from the TEM sys-
tem are documented.

Risk of destruction of components

If the plant is still operated when a warning message has been given, or is started after a
fault

 Find and remove the cause of the warning or fault

 Acknowledge warning/error messages

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Maintenance work independent on operating hours

System: Genset No.:

Engine type Engine No.: Sheet:

Maintenance work Oh - actual Date Signature

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Maintenance work dependent on operating hours

System: Genset No.:

Engine type Engine No.:

Oh - target E10 E30 E40 E50 E60 E70 Oh - actual Date Signature
50 X
1 500 X
3 000 X
4 500 X
6 000 X
7 500 X
9 000 X
10 500 X
12 000 X
12 050 X
13 500 X
15 000 X
16 500 X
18 000 X
19 500 X
21 000 X
22 500 X
24 000 X
24 050 X
25 500 X
27 000 X
28 500 X
30 000 X
31 500 X
33 000 X
34 500 X
36 000 X
36 050 X
37 500 X
39 000 X
40 500 X
42 000 X
43 500 X
45 000 X
46 500 X
48 000 X
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Operational control log

If the system is restarted without the cause of the warning or fault being rectified, there is
no warranty claim against the manufacturer.

System: Genset No.:

Engine type Engine No.: Sheet:

Date Module Occurrence Signature

Time Operating hours Action

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