Maintenance (J J245-EN) - 1 PDF

JGS 620 GS-N.
L
Maintenance
Generator set
DADU ENERGY 1 - 6
J J245
Engine number: _______
Module number: _______
2012-02
© GE Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach (Austria)
www.gejenbacher.com
Revision history
Index Date Description/Revision summary Creator
Auditor
1 30.01.2012 Delivery ➔ Footer
Kecht
Original operating instructions
GE proprietary information: CONFIDENTIAL

The information contained in this document is General Electric Company proprietary information and is dis-
closed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without
the express written consent of GE. This includes but not limited to use for the creation, manufacture, develop-
ment or derivation of any repairs, modifications, spare parts, designs or configuration changes, or for obtain-
ing government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this
notice and the notice set forth on each page of this document shall appear in any such reproduction in whole
or in part.
© GE Jenbacher GmbH & Co OG, 2012-01

Identification Table
Password Module type Module number Module number engine number
DADU ENERGY 1 - 6 JGS 620 GS-N.L J J245 1022345 1022346
Table of contents
User Instructions ......................................................................................................................................................................... 1

Sections of the GE Jenbacher Product Documentation ................................................................................................................ 1.1
Key to Symbols .................................................................................................................................................................................................. 1.2
Type Plate and Type Designation of GE Jenbacher Products ..................................................................................................... 1.3
Web portal .......................................................................................................................................................................................................... 1.4
Your Opinion Counts! ..................................................................................................................................................................................... 1.5
Service and Sales partners .......................................................................................................................................................................... 1.6
Imprint ................................................................................................................................................................................................................... 1.7
General conditions ...................................................................................................................................................................... 2

Designated Use ................................................................................................................................................................................................. 2.1
Declaration of Conformity ..................................................................................................................................................................................
General conditions - Operation and Maintenance ................................................................................................... TA 1100-0111
Boundary conditions for GE Jenbacher gas engines ............................................................................................... TA 1100-0110
Safety instructions .................................................................................................................................................................... TA 2300-0005
Maintenance plan ........................................................................................................................................................................ 3

Maintenance plan - specific intervals .................................................................................................................................................... 3.1
Maintenance plan - operating hours intervals .................................................................................................................................. 3.2
Inspection and maintenance work ........................................................................................................................................... 4

Inspection/maintenance work .................................................................................................................................................................. 4.1
Inspection .................................................................................................................................................................................................. I 0103 6
Daily inspection round ......................................................................................................................................................................... I 9003 0
Lubricating oil/oil filter cartridge ........................................................................................................................................... IW 0101 M6
Ignition voltage check / Spark plugs .................................................................................................................................... IW 0309 M0
In-line air filter - Type 6 F/ engines ........................................................................................................................................ IW 8040 A6
Pre-combustion chamber gas compressor ......................................................................................................................... IW 8046 0
Leak testing of all pipes and components carrying fuel gas and mixtures .......................................................... IW 8049 0
Flexibly-mounted coupling housing ...................................................................................................................................... IW 8079 A6
Condensate removal in the fuel-gas system .................................................................................................................... IW 8090 A0
Exhaust gas system condensate drain line ....................................................................................................................... IW 8095 A0
Control rod assembly/throttle valve/actuator ............................................................................................................. W 0200 M6ef
Engine cooling water pump ........................................................................................................................................................ W 0203 A6
Ignition ................................................................................................................................................................................................. W 0303 M0
Valve clearance ............................................................................................................................................................................... W 0400 M6
Pre-combustion chamber / pre-combustion chamber gas valve ........................................................................... W 0501 M6
Crankcase ventilation system ................................................................................................................................................... W 0509 M6
Vibration damper ............................................................................................................................................................................ W 0601 M0
Gas quantity controller ................................................................................................................................................................. W 0705 M0
Maintenance after initial commissioning ............................................................................................................................... W 1000 6
Overhaul .............................................................................................................................................................................................. W 2100 M0
Exhaust gas turbocharger .......................................................................................................................................................... W 8026 M6
Generator ............................................................................................................................................................................................ W 8030 A0
GE Jenbacher - switch cabinets ............................................................................................................................................... W 8031 A0
Starter ................................................................................................................................................................................................... W 8032 M0
Elastomer components ................................................................................................................................................................... W 8034 6
Oil filter cartridge ............................................................................................................................................................................ W 8038 M6
Plate-type heat exchanger .......................................................................................................................................................... W 8043 A0
Gas pressure control system ...................................................................................................................................................... W 8045 A6
Piston/Piston cooling ..................................................................................................................................................................... W 8047 M6
Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Module type: JGS 620 GS-N.L Engine version: F 101
Author: Responsible: Release date: 01.02.2012
Index: 1 Page No.: 1 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Table of contents
Cylinder liner ..................................................................................................................................................................................... W 8049 M6

Main crankshaft bearing/thrust bearing ............................................................................................................................. W 8050 M6
Exhaust gas manifold/exhaust gas lagging ....................................................................................................................... W 8051 M0
Replacing the cylinder head ...................................................................................................................................................... W 8053 M6
Pre-lubricating pump .................................................................................................................................................................... W 8054 M0
Combustion chamber ................................................................................................................................................................... W 8056 M0
Engine – cooling water circuit / Mixture recirculating water ...................................................................................... W 8080 A0
Maintenance protocol Module 1 ............................................................................................................................................... 5

Maintenance protocol ................................................................................................................................................................................... 5.1
Registration of operational data Module 1 ............................................................................................................................. 6

Operational data booklet ............................................................................................................................................................................. 6.1
Operational data – Engine lubricating oil ..................................................................................................................................... E 0101
Operational data - Heat exchanger mixture/water ............................................................................................................ E 0103 a
Operational data Pre-combustion chamber gas differential pressure ...................................................................... E 0103 d
Operational data - crankcase ventilation system ................................................................................................................. E 0103 f
Operational data - Flame trap Mixture cooler ....................................................................................................................... E 0103 g
Operational data – spark plugs ......................................................................................................................................................... E 0309
Operational data - Valve-stem projection ................................................................................................................................... E 0400
Operational data on leak test for pipes and components carrying fuel gas and mixtures .................................. E 8049
Data collection for flexibly-mounted coupling housing .................................................................................................... E 8079 6

Registration of operational data Module 2 ............................................................................................................................. 8

Operational data booklet ............................................................................................................................................................................. 8.1

Registration of operational data Module 3 ........................................................................................................................... 10

Operational data booklet ........................................................................................................................................................................... 10.1
Table of contents
Maintenance protocol Module 4 ............................................................................................................................................. 11

Maintenance protocol ................................................................................................................................................................................. 11.1





Initial commissioning data sheet ........................................................................................................................................... 17

Initial commissioning data sheet ........................................................................................................................................................... 17.1

1 User Instructions
1.1
Sections of the GE Jenbacher Product Documentation
Description – Operation
▪ Operation of the system

▪ Fault rectification
▪ Description of the engine and the system
▪ Choice of fuels
▪ Technical instructions
Maintenance
▪ What inspection work and maintenance work needs to be car-

ried out?
▪ When should the work be carried out?
▪ How should the work be carried out?
▪ Gathering operational data
Spare parts list
▪ Selecting the required spare part

▪ Ordering spare parts
▪ Allocating spare parts

Author: Doku./Schartner Responsible: Dokumentation Release date: 05.11.2009
1.2
Key to Symbols
The following symbols are used to highlight certain text passages in your GE Jenbacherproduct documen-
tation.
Caution
Follow these instructions to avoid risk of personal injury or risk of damaging engine or sys-
tem components.
Disassemble
Disassemble the component as described.
Assembling
Assemble the component as described.
Inspection
Inspect the components or operating materials as described.
Tightening torque
Tighten the nut or bolt to the specified tightening torque.
Clean
Clean the component as described.
Lubricate
Lubricate or grease the component as described.
Reference
Reference to a document or a section of the product documentation. Important informa-
tion or important note.
Info
Important information or important note.

Author: Doku./Schatz Responsible: Dokumentation Release date: 21.07.2011
1.3
Type Plate and Type Designation of GE Jenbacher Prod-
ucts
1 Type plate
1.1 Engine type plate

The engine type plate is located on the crankcase.
Engine type plate
1.2 System type plate

The system type plate is located on the left-hand longitudinal member of the frame (viewed looking towards
the flywheel).

1.3
ucts
System type plate
Type Type Max. ambient Max. ambient temperature:

temperature (in-
take air)
Serial No. Serial No. Rated frequency Rated frequency
Year of manu- Year of manufacture Rated voltage Rated voltage
facture
Rated power Rated power Rated current Rated current
Rated power Rated power factor Mass Weight
factor
Maximum site Maximum installation site altitude Performance Performance class
altitude of in- class
stallation
2 Type designation
2.1 Engine type designation

Term Abbreviation Key to abbreviation e.g.
Manufacturer Y GE Jenbacher J 320 GS C05
Engine type 2 J 320 GS C05
3
4
6
9
No. of cylinders 8 8 cylinder in-line engine J 320 GS C05
12 12-cylinder V-engine

1.3
ucts

Mode of operation (e.g.) GS Gas engine, turbocharged J 320 GS C05
GSH Gas engine, tur-
bocharged and hot cooled
Design A First design J 320 GS C05
B, C, D, E ... Modified designs
Version (e.g.) 02 Natural gas; ½ TA-Luft J 320 GS C05
05 Natural gas; TA-Luft
27 Biogas; TA-Luft
Engine type designation
① Manufacturer ④ Mode of operation

② Engine type ⑤ Design
③ No. of cylinders ⑥ Version
2.2 Module type designation

Manufacturer Y GE Jenbacher JMS 320 GS-N.LC
Unit type (e.g.) M co-generation plant JMS 320 GS-N.LC
G generator set
C compressor set
Installation type S stationary JMS 320 GS-N.LC
C In container
Engine type 2 JMS 320 GS-N.LC
3
4
6
9
No. of cylinders 08 8 cylinder in-line engine JMS 320 GS-N.LC

1.3
ucts

Mode of operation (e.g.) GS Gas engine, turbocharged JMS 320 GS-N.LC
GSH Gas engine, tur-
bocharged and hot cooled
Type of fuel gas N Natural gas JMS 320 GS-N.LC
B Biogas
L Landfill gas
P propane gas
S Special gas
N/B Natural gas /biogas (2-
gas operation)
Exhaust gas purification L LEANOX engine JMS 320 GS-N.LC
LC LEANOX engine with oxi-
dation-type catalytic con-
verter
C 3-way catalytic converter
Plant type designation
① Installation type ⑥ Mode of operation

② Unit type ⑦ Type of fuel gas
③ Manufacturer ⑧ Alternative type of fuel gas
④ Engine type ⑨ Exhaust gas purification
⑤ No. of cylinders

1.4
Web portal
The web portal contains the latest online information on our products, drawings, Service Bulletins, SPATSL (the
digital spare parts catalogue), background knowledge concerning gas engine technology etc. You can also down-
load interesting documents to your PC via the web portal. The web portal’s URL is:
http://information.jenbacher.com
When you first visit the web portal, you will find general information on GE Jenbacher. Since you are a GE Jen-
bachercustomer, we are offering you the possibility of increased access rights for which you only need to regis-
ter online.
Registration:
Click on "registrieren" (Registration) and fill in the requested personal data. It is very important to also fill in your
regular GE Jenbachercontact person, as he or she is responsible for granting you the increased access rights.
Once you have registered, you will immediately be sent an e-mail containing the web portal link. You will then
be able to enter the required password. At this stage, you do not have increased access rights yet as your GE
Jenbacher contact person needs to confirm your application. This might take a few days.
Subsequently, you may change your password and personal data. Click on "know-how login" to enter your per-
sonal profile, which you may edit yourself.
As soon as your increased access rights have been confirmed, you can enter the increased access web portal
below:

Author: Doku./Velik Responsible: VSB/Steinberger Release date: 25.05.2010
1.4
Web portal
Menu bullets – Tips:

"Produkte +Service" (Products and Service) menu -> "Produkte 50/60 Hz" (50/60 Hz products)
Viewing and downloading drawings and diagrams for various engine types and applications.
"Produkte + Service" (Products and Service) menu -> "Service" -> "Service Datenbank" (Service database)
Online access to all published Service Bulletins and therefore access to all service-related changes and innova-
tions.
"Expert know-how" menu
Comprehensive information on co-generation, fuel gas conditioning, exhaust gas treatment, etc.
For security reasons, you must change your password every 6 months. You will be sent an e-mail reminder
containing a link to your personal profile. To extend your increased access rights for another 6 months, just
overwrite your existing password in your "know-how profile", repeat the password and click on "absenden" (send).

1.4
Web portal
After you have registered, you will receive a regular Newsletter. If you do not wish to receive it, click on "Nein" (No).
If you have any questions, please contact your regular GE Jenbachercontact person.

1.5
Your Opinion Counts!
Dear readers,
The purpose of this product documentation is twofold. Firstly, it should ensure risk-free operation and mainte-
nance of your GE Jenbachersystem.
Secondly, this product documentation should serve as a reference manual covering technical data, require-
ments and descriptions of engine and system components, and can also be used for troubleshooting and train-
ing purposes.
Please help us to meet these aims by sharing your work experiences with us.
Subject: Rating Comments

How well do you think our documentation
is structured?
How easy is it to locate information?
What do you think about our technical vo-

cabulary?
Is the documentation comprehensive?

(Have all of the necessary topics been cov-
ered to an appropriate extent?)
Any additional comments:
Rating: 1 = very good 2 = good 3 = satisfactory 4= adequate 5= inadequate
Please send the completed feedback form to: GE Jenbacher GmbH & Co OG
Documentation Department
Achenseestraße 1-3
A-6200 Jenbach (Austria)
+43 5244 600 566

robert.pichler@ge.com

Author: Doku./Velik Responsible: Documentation Release date: 21.07.2011
1.6
Service and Sales partners
GE Jenbacher GmbH & Co OHG

Achenseestraße 1 - 3, A-6200 Jenbach
Tel.: +43 5244 600-0, Telefax: +43 5244 600 548
e-mail: info@gejenbacher.com
GE Jenbacher
Servicecenter Wien
Am Concorde-Park 1/D2, A-2320 Schwechat
Tel.: +43 1 707 95 10, Telefax: +43 1 707 93 28
e-mail: jes.wien@gejenbacher.com
GE Jenbacher
Servicecenter Villach
Magdalener Straße 81, 9506 Villach
Tel.: +43 4242 431 124, Telefax: +43 4242 431 124 5
e-mail: markus.appenzeller@gejenbacher.com
Industrias Juan F Secco SA

Juan Pablo II 5665
Av. Circunvalacion y Av. Urib
Santa Fe
2000 Rosario, Argentinia
Tel.: + 54-341 4094097
e-mail: rosario@ifsecco.com.ar
CLARKE ENERGY AUSTRALIA Pty.Ltd.

Building 1, 2-4 Stirling Street
Thebarton SA 5031
Tel.: +61 (0)8 8290 2100, Telefax: +61 (0)8 8443 5848
e-mail: gregc@clarke-energy.com
www: www.clarke-energy.com
Orient Energy Systems Ltd.

Author: Doku./Lechner Responsible: Dokumentation Release date: 01.02.2012
1.6
11th floor,
Land View Building,
28, Gulshan 2,
1212 Dhaka
Tel.: +88 02 9898837, +88 02 9899268, Telefax: +88 02 8826530
e-mail: info.bd@orient-power.com
Sales Representative
Ecogen Energy Systems bvba
Vaart Rechteroever 225
B-9800 Deinze
Tel.: +32 938 64860, Telefax: + +32 938 61134
e-mail: jd@ecogen.be
Filter EOOD
87 Aleksander Malinov Blvd.
1715 Sofia
P: +359 2 9745085
F: +359 2 9745087
e-mail: filter@filter.bg
www: www.filter.bg
Sales - Jenbacher gas engines

Rod. Jornalista Frco. Aguirre Proenca s/n Km 3,8 - Boa Vista
13064-654 Campinas-SP, Brazil
Tel.: +55 19 2104 6996, Telefax: +55 19 2104 6999
e-mail: gustavo.nielsen@ge.com
Distributor/Service Provider
Filter SZAO
Logoisky Tract and MCAD Crossing, Minsky district,
Administrative Bldg., Office 501
223053 Minsk, Republic of Belarus

1.6
Tel.: +375 (172) 95 04 03, Telefax: +375 172 95 96 18

e-mail: Evgeny.Shakovets@filter.by
Integrated Distribution Systems Limited Partnership, dba Detroit Diesel-Allison Canada East
(Ontario, Quebec, New Brunswick, Nova Scotia)
1 Moyal Court
Concord, Ontario L4K 4R8
Tel.(Sales): +1 416 804 2203, Tel.(Service): +1 514 636 0680 Telefax: +1 416 352 5868
e-mail: sales@ddace.com
Waterous Power Systems (British Columbia, Alberta, Sask. Manitoba)
10025-51 Avenue Edmonton
Alberta T6E 0A8
Tel.: +1 780 437 8271, Telefax: +1 780 504 0255
e-mail: Sales contacts: gbailey@waterouspower.com and mmcelligott@waterouspower.com
Marketing & Communications contact: Ischur@waterouspower.com
IWK Integrierte Wärme und Kraft AG (Sales)

Aspstrasse 11, CH-8472 Oberohringen / Seuzach, Schweiz
Tel.: + 41 52 320 00 00, Telefax: + 41 52 320 00 01
e-mail: joachim.maier@iwk.ch
www: www.iwk.ch
MPD Trade
Carli Caplina 7,
11060 Beograd, Serbia, SCG
Tel.: +381 11 32 93 795 Telefax: +381 11 32 93 600
e-mail: info@kogeneracija.rs
www: kogeneracija.rs; www: biogas.rs
International Office & Packaging Operation

GE Energy (Hangzhou) Co. Ltd.

1.6
288 Hongxing Rd., South Bridge

Xiaoshan Economic & Tech. Development Zone
Hangzhou, 311231, P.R. China
Tel.: +86 571 8369 9888, Telefax: +86 571 8286 9107
e-mail: jenbacher.china@ge.com
International Office
GE Energy
Jenbacher Sales China
18/F., Kerry Center , 1 Guanghua Road , Chaoyang District , Beijing 100020
Tel.: +8610 5822 3821, Telefax: +8610 8529 6283
e-mail: jenbacher.china@ge.com
Jebsen & Co. (China) Ltd.
30/F., Lee Garden Two, 28 Yun Ping Road,
Causeway Bay, Hong Kong, China
Tel.: +852 2923 8668, Telefax: +852 2882 1588
e-mail: raymondlkchan@jebsen.com
Tel.: +852 2923 8718, Telefax: +852 2882 1588
e-mail: puiwingleung@jebsen.com
www: www.jebsen.com
Clarke Energy Equipment Trading (Beijing) Co. Ltd.
Rm 1802
Chaowai SOHO, Chaoyang District
Beijing 100020
Tel.: + 86 10 5900 0561, Telefax: + 86 01 5900 0562, Mobile: +86 13910 575857
e-mail: ian.wang@clarke-energy.com
Distributor/Service
Shenyang WeiLiDa Engineering Equipment Co. Ltd.
Jiahuan Building No. 39, RM 1306, Heping nan street
Shenyang, Liaoning 110003
Tel.: +86 24 23254011, Fax: +86 24 83251066
e-mail: reader_song@126.com

1.6
Klor GmbH
Manesova 92, 12000 Praha 2
Tel.: +420 2 22 72 00 46, or -534, Telefax: +420 2 22 71 23 85
e-mail: polak.klor@jenbacher.cz
www: www.jenbacher.cz
JMP (Service)
Plynarenska 1, 65702 Brno
Tel.: +420 545 548 263, Telefax: +420 545 548 263
e-mail: jaroslav.hruska@rwe-jmp.cz
www: www.jmpas.cz
Jenbacher GmbH
Carl-Benz-Straße 25
D-67227 Frankenthal (Pfalz)
Tel.: +49 (0) 6233 5110-0, Telefax: +49 (0) 6233 5110-170
Service Hotline: 07000 – 536 - 2224
e-mail: jes.mannheim@gejenbacher.com
GE Jenbacher Denmark
Samsøvej 10
DK-8382 Hinnerup
Tel.: +45 86966788, Telefax: +45 86967072
e-mail: jenbacher.scandinavia@ge.com
Dominikanische Republik
Sales Representative / Service Provider
The Power Service Group, S.A.
Door Power Service S.A.
Calle Vicente Celestino Duarte 2
Zona Colonial , DN
Santo Domingo

1.6
Tel.: +1 809 285 0016, Telefax: +1 809 285 0017

e-mail: info@carpsg.com
Algeria
Distributor / Service Provider
Amimer Energie SARL
za Adha Seddouk, 06500 W. Bejaia, Algeria
Tel.: 00 213 34323154, Telefax.: 00 213 34323135
e-mail: amarboukheddami@amimer.com
AS Filter
Läike tee 9, Peetri küla, Rae vald
75312 Harjumaa
Tel.: +372 606 6666, Telefax: +372 606 6650
e-mail: filter@filter.ee
www: www.filter-group.com
GE International Inc.
54 Lebanon Street,
El Mohandessin, Floor 13
Cairo
Tel.: + 20 2 3301 8000
e-mail: jenbacher.egypt@ge.com
Sakr Power Systems

South Kattamyia, Sokhna old road, New Cairo
Third district, Block # 12
Tel.: +20 10 50 239 47, Telefax: +20 10 17 246 18
e-mail: egypt@sakr.com
Clarke Energy Ltd.

Power House, Senator Point, South Boundary Road,

1.6
Knowsley Industrial Park

Liverpool L33 7RR
Tel.: + 44 151 546 4446, Telefax: +44 151 545 5714
e-mail: alanf@clarke-energy.com
GE Jenbacher Spain and Portugal

Avda. del Camino de lo Cortao, 34 - Nave 8
E-28703 San Sebastián de los Reyes (Madrid)
Tel.: +34 91 658 6800, Telefax: +34 91 652 2616
e-mail: jenbacher.iberica@ge.com
GE Jenbacher Spain and Portugal

Ctra. de Hospitalet, 147-149 | Cityparc - Ed. Roma
E-08940 Cornellà de Llobregat (Barcelona)
Tel.: +34 93 475 1300, Telefax: +34 93 475 1301
e-mail: jes.barcelona@gejenbacher.com
Höyrytys Oy
Palokorvenkatu 2
FIN-04261 Kerava
Tel.: +358 468 508 070, Telefax: +358 941 746 100
e-mail: jorgen.barlund@hoyrytys.fi
Clarke Energy France SAS

Z.A. de la Malle
RD 6
13320 Bouc Bel Air
Frankreich
Tel.: +33 442 907 575, Telefax: +33 442 907 576
e-mail: info.michels@clarke-energy.com

1.6
International Office & Packaging Operation

GE Energy Jenbacher Hungary (Service)
Kisret ut1
H-2112 Veresegyhaz
Tel.: + 36 2858 7376 , Telefax: + 0036 2858 7491
e-mail: jenbacher.hungary@ge.com
TZV Gredelj d.o.o. (Service)

Trnjanska Cesta 1, HR-10000 Zagreb
Tel.: +385 1 6111 311, Telefax: +385 1 6110 121
e-mail: ozbolt@tzv-gredelj.hr
Sales Representative
GETES d.o.o.
Fantovo 15
51414 Icici
Tel.: + 00385 51 704620, Telefax: + 00385 51 704620
e-mail: mail@getes.hr
Navigat Energy Pte. Ltd.

139 Cecil Street, 04-02 Cecil House,
Singapore 069539, Rep. of Singapore
Tel.: +62 21 572 4944, Telefax: +62 21 572 7614
e-mail: nils@navigat.com
Clarke Energy Ltd.
Power House, Senator Point, South Boundary Road,
Knowsley Industrial Park, Liverpool L33 7RR
Telephone: + 44 151 546 4446, Fax: + 44 151 545 5714
e-mail: alanf@clarke-energy.com

1.6
Clarke Energy Ireland Ltd.

1 Stokes Place, St. Stephens Green, Dublin 2, Ireland
Tel.: +353 879 804002
e-mail: johnc@clarke-energy.com
Madei Taas Industrial Controls Ltd.

2 Hacharoshet st., Kfar-Saba 44641
Tel.: +972 9 7669903, Telefax: +972 9 7669904
e-mail: elimatz@madeitaas.co.il
www: www.madeitaas.co.il
Clarke Energy India Private Limited

"Shivkiran", Lane no. 4, Dahanukar Colony, Kothrud
Pune 411 038
Tel.: +91 20 30241777
Telefax: +91 20 30241800
e-mail: deodatta.bhishikar@clarke-energy-india.com
www: www.clarke-energy-india.com
GE India Industrial Pvt. Ltd.
A-1, 2nd Floor, Golden Enclave
Corporate Towers, Airport Road
560 017 Bangalore
Tel.: +91 80 4150 1406, Telefax: +91 80 2520 3860
e-mail: jenbacher.india@ge.com
Trinidad & Tobago

Water Tech Limited
10 Nelson Road
Freeport
Trinidad, West Indies
Tel.: +868 673 5453, +868 673 2061, Telefax: +868 673 1620
e-mail: sudesh@watertech-ltd.com
1.6
Navigat Energy Pte. Ltd.
139 Cecil Street, 04-02 Cecil House, Singapore 069539,
Rep. of Singapore, Indonesia
Tel.: +62 21 5724944, Telefax: +62 21 5727614
e-mail: nils@navigat.com
GE Jenbacher Italy
Via Crocioni, 46 / H, Casella Postale n. 41 Aperta
I-37012 Bussolengo (VR)
Tel.: +39 045 6760211, Telefax: +39 045 6766322
e-mail: jes.verona@gejenbacher.com

Sakr Power Systems SAL
Kartaba Road, Industrial Area
Halata (Jbeil), Lebanon
Tel.: +961 9 444888, Telefax: +961 3 811108
e-mail: info@sakr.com
www: www.sakr.com
Hitachi Engineering & Services Co., Ldt.

2-2 Kandatacho Chiyoda-ku
Tokyo 101-0046
Tel.: +81 3 5297 0514, Telefax: +81 3 5297 0517
e-mail: osamu.fukunaga.ux@hitachi.hes.com
Hitachi Engineering & Services Co., Ldt.

15-1, Higashionuma-cho, 1-chome
Hitachi-shi
Ibaraki-ken, 316-0023
Tel.: +81 294 36 7996, Telefax: +81 294 36 9637

1.6
e-mail: shigehisa.sugita.yp@hitachi-hes.com
Osaka Gas Engineering Co., Ldt.

1-4-100, Hokuko, Konohana-Ku
Osaka 554-0033
Tel.: +81 6 4804 2600, Telefax: +81 6 4804 2601
e-mail: t-joh@oge.co.jp

Halata (Jbeil), Lebanon
Tel.: +961 9 444888, Telefax: +961 3 811108
www: www.sakr.com
RNP Enterprise Ltd.

Room 301, Chung Won Bldg. 170-3
Bang - I - Dong
Song Pa-Ku, Seoul 138-050, Korea
Tel.: +82 2 412 3700, Telefax: +82 2 412 3044
e-mail: rnp@rnp-ent.co.kr
Turkuaz Machinery Ltd.

Rayimbek ave. 160A,
50016 Almaty
Tel.: +7 727 273 19 95, Telefax: +7 727 273 15 68
e-mail: machinery@turkuaz.kz
www: turkuazmachinery.kz
Promelectronika-K TOO
Bogenbay batyra str 132, Office 113.105
050026 Almaty.
Tel.: +77 272 965560

1.6
Fax.: +77 272 721983

e-mail: aponomarev@intma.ru
www: www.intma.kz
Abdulaziz Abdulmoshin Al-Rashed Sons Co. WLL

Building No. 225-227, Block 2, next to Al-Watan TV,
Afdiya, Kuwait
Tel: 00965-24376740
Fax: 00965-24339291
Email: info@al-rashed.com
www: www.al-rashedholdings.com

Halata (Jbeil)
Tel.: +961 9 444888, Telefax: +961 3 811108
www: www.sakr.com
IWK Integrierte Wärme und Kraft AG (Sales)

Aspstrasse 11, CH-8472 Oberohringen / Seuzach, Schweiz
Tel.: + 41 52 320 00 00, Telefax: + 41 52 320 00 01
e-mail: joachim.maier@iwk.ch
www: www.iwk.ch
UAB Filter
Draugystes Str. 19, 3031 Kaunas
Tel.: +37 037 400 380, Telefax: +370 0872 1399
e-mail: filter@filter.lt
www: www.filter.lt

1.6
ENERGOLUX S.A.
12, rue de Bitbourg, L-1273 Luxembourg-Hamm
Tel.: +352 43 42 43-1, Telefax: +352 43 68 33
e-mail: enerlux@pt.lu
SIA Filter
21 Aizkraukles street, 1006 Riga
Tel.: + 371 7 556765, Telefax: + 371 70550224
e-mail: filter@filter.lv
www: www.filter-group.com
JD Energy Systems Sd. Bhd.

Sector 1, No 1
Jalan Lada Hitam Satu 16/12A
Shah Alam, Selangor Darul Ehsan
Malaysia 40200
Tel.: +603 5569 1000, Telefax: +603 556 92660
e-mail: chanhh@jdgroup.com.my
Clarke Energy Nigeria Ltd.
13 B Obanta Street, Apapa, Lagos, Nigeria
Tel.: +234 181 56723
e-mail: patrick.nzekwe@clarke-energy.com
GE Jenbacher Netherlands
Kelvinring 58
NL-2952 BG ALBLASSERDAM
Tel.: +31 (0) 88 0019700, Telefax: +31 (0) 88 0019701
e-mail: jenbacher.netherlands@ge.com

1.6
Desco Incorporated
Laguna International Industrial Park
Lot 2 Block 3, Interstar Street
Barangay Mamplasan, City of Binan
Laguna, Philippines 4024
Tel.: +632 520 8149 to 50
www: www.deco.ph
ORIENT Energy System Ltd.

Plot # 16, Sector 24,
Korangi Industrial Area,
Karachi 75950, Pakistan
Tel.: +92 21 507 2091-4(four lines), Telefax: +92 21 507 2095
e-mail: m.saeed@orient-power.com
KWE - Technika Energetyczna Sp.z o.o.

Ul. Miedziana 38
43-305 Bielsko-Biała, Polen
Tel.: +48 338 215 093, Telefax: +48 338 216 562
e-mail: kwe@kwe.com.pl
www: www.kwe.pl
ECOPOWER – EQUIP. SERV. ENERGIA, UNIPESSOAL, LDA.

ATT: Raul Assunção
Carregado Park, Arm. D,
Lugar da Torre,
2580-512 Carregado
LISBOA – PORTUGAL
e-mail: ecocogen@ecopower.pt
www: www.ecopower.pt
SC Total Eurobusiness S.A.

Str. Calea Rahovei nr. 266-268 Corp D

1.6
Etaj 3; Sector 5
050912 Bucharest
Tel.: +40 21 408 08 80 221, Telefax: +40 21 423 23 15
e-mail: office@teb.com.ro
International Offices
GE Energy Russia
27, Electrozavodskaya Street, bld. 8, floor 5
107023 Moscow, Russia
Tel.: +7 495 937 11 11; +7 495 9 81 13 13, Telefax: +7 495 937 11 12
e-mail: jenbacher.russia@ge.com
ZAO Sigma Services (Service)

h. 15. bld. 33, M. Kaluzhskaya str.
117071 Moscow
Tel.: +7 095 935 7835, Telefax: +7 095 935 7888
e-mail: skoff@sigmat.ru
ZAO VADO International GUS (Sales)

Krasnaja Presnja 28
123022 Moskau - Russische Föderation
Tel.: +7 095 363 95 05, Telefax: +7 095 363 9509
e-mail: info@vado.ru
www: www.vado.biz
Focused on the North West Region

Vapor CJSC
B. Moskovskaya 8/2 Letter A,
191002 Saint – Petersburg
T: + 7 812 448 00 70
Email: spb.office@vapor.ru
Web: www.vapor.ru
Focused on the South Ural Region

Intma CJSC

1.6
2-nd Kabelnaya str., 2, bld. 9,

111024 Moscow
T: +7 495 974 1295
Email: d_glushich@intma.ru
Web: www.intma.ru
Focused on the South Region

Max Motors LLC
19/4, Kurortniy prospect
354000 Sochi, RUSSIA
Tel.: +7(8622) 62-77-99(multichannel), Telefax: +7(8622) 62-61-16
Call center 8(800)505-77-99(calls are free of charge for Russian Federation customers!)
e-mail: info@max-motors.ru
www: www.max.motors.ru
Ali A. Tamimi Trading Company

2nd Industrial City
Al Baqaiq Street
Khobar, 31952
Tel.: +966 3 868 1037 ext. 100
Fax.: +966 3 868 2733
e-mail: DTCO@tco.com.sa
www: www.al-tamimi.com
GE Jenbacher Denmark
Industrivej 19, DK-8881 Thorsø
Tel.: + 45 8 6966788, Telefax: + 45 8 6967072
e-mail: jenbacher.scandinavia@ge.com
GE Pacific Pte Ltd.
240 Tanjong Pagar Road,
# 11-00 GE Tower

1.6
Singapore 088540
Tel.: +65 6326 3659, Telefax: +65 6326 3623
e-mail: jenbacher.singapore@ge.com
IMP Inzeniring d.d.

Dunajska cesta 7, SLO-1113 Ljubljana
Tel.: +386 1300 9024, Telefax: +386 1300 9060
e-mail: borut.jurca@imp.si
www: www.imp.si
TES d.o.o.
Gregorciceva 3, Maribor 2000
Tel.: +386 2 229 4726, Telefax: +386 2 229 4727
e-mail: borut.bencic@tes.si or sasa.rodosek@tes.si
www: www.tes.si
EMES s.r.o
Trieda SNP 75
974 01 Banska Bystrica
Slovakia
Tel.: +421 48 4145183, Telefax: +421 48 4145183
e-mail: emes@bb.psg.sk
Italthai Industrial Co., Ltd.

2013 New Petchburi Road
Bangkapi, Huay Kwang
10310 Bangkok / THAILAND
Tel.: +662 3191031-40, Telefax: +662 3182654
e-mail: sarayuth@italthai.co.th; gasengine@italthai.co.th
www: www.italthai.co.th
Topkapi Endüstri Mallari Ticaret A.S.

Pazartekke, Millet Cad. No.180-184

1.6
Topkapi
34104, Istanbul
Tel.: +90 212 534 04 10, Telefax: +90 212 524 58 46
e-mail: info@topkapigroup.com.tr
www: www.topkapigroup.com.tr
Clarke Energy Tunisie SARL
Immeuble Sarra Bb Principle, Les Berges du Lac
Tunis
Tel.: +216 71 96 52 99, Fax: +216 25 39 04 90
e-mail: Ali.Hjaiej@clarke-energy.com
Sinapse
7, Vanda Vasilevskaya Str.
03055 Kiev
Tel.: +38 044 238 0967 or +38 044 2380966, Telefax: +38 044 2380967 or +38 044 2380970
e-mail: lvm@sinapse.ua, oksana@sinapse.ua, www.sinapse.ua; www.cogeneration.com.ua
GE Energy
Jenbacher Sales and Service USA
5244 N. Sam Houston Parkway East,
Houston, TX 77032
Tel.: +1 832 295 5600
e-mail: jenbacher.us@ge.com
Northeast Energy Systems, a division of Penn Detroit Diesel Allison
(ME, VT, NH, MA, PA, NY, CT, DE, NJ, RI, OH) Corporate Headquater
8330 State Road, Philadelphia PA 19136
Telephone: +1 215 335 5010, Fax: +1 215 335 2163
e-mail: aclark@neesys.com or ffarrand@neesys.com
www: www.neesys.com

1.6
Northeast Energy Systems, a division of Penn Detroit Diesel Allison

(ME, VT, NH, MA, PA, NY, CT, DE, NJ, RI, OH)
86 Finnell Drive, Units 13 and 14
Weymouth, Massachusetts 02188
Telephone: + 1 781 340 9640, Fax: + 1 781 340 9649
e-mail: aclark@neesys.com or ffarrand@neesys.com
www: www.neesys.com
Western Energy Systems, a division of Penn Detroit Diesel Allison
(AK, CA, HI, OR)
499 Nibus Street, Brea, California 92821
Telephone: +1 714 529 9700
e-mail: aclark@weesys.com or ffarrand@neesys.com
Inland Power Group. (MN, MI, WI, IA, IL, IN)

13015 W. Custer Avenue,
Butler, WI 53007
Tel.: +1 262 781 7100, Telefax: +1 262 783 8974
e-mail: jgoing@inlandpowergroup.comor tpalmer@inlandpowergroup.com
www: www.inlandpowergroup.com
Smith Power Products (WA, MT, ID, WY, NV, UT, AZ, CO, KS, MO, NE, NM, ND, OK, SD, TX)
3065 West California Ave.
Salt Lake City, UT 84104
Tel.: +1 801 415 5000, Telefax: +1 801 415 5700
e-mail: mhayes@smithdda.com
www: smithpowerproducts.com
GENEVA LLC, DBA Nixon Power Services Company

(AR, LA, MS, TN, AL, GA, KY, FL, SC, NC, VA, WV, MD)
5038 Thoroghbred Lane
Brentwood, TN 37027
Tel.: +1 615 309 5823
e-mail: msiebert@nixonpower.com

1.6
Dome Trading and Contracting Company LTD

Villa Nr. 18, Street Nr. 38 (off Hadda Rd.)
Sana'a. PO Box 16187
YEMEN
Tel Office: +9671414023
Fax: +9671414044
e-mail: azizdaer@dome.com.ye
www: www.domeint.com
South Afrika/Botswana/Lesotho/Mozambique/Swaziland
Sales Representative/Service Provider
Agaricus Trading cc
P O Box 1535
Linkhills
3652
Kwazulu-Natal
South Africa
Tel.: + 27 31 7633222, Telefax: + 27 31 7633041
e-mail: paul@agaricus.co.za
www: www.agaricus.co.za

1.7
Imprint
This GE Jenbacher Product Documentation consisting of :

▪ Description – Operation
▪ Maintenance
▪ spare parts list
was created by the Technical Documentation Department of GE Jenbacher.
If you have any questions, problems or suggestions regarding this Product Documentation, please contact us.
Address: GE Jenbacher GmbH & Co OG

A-6200 Jenbach | Austria
Telephone: +43 | 5244| 600-3064
Fax: +43 | 5244| 600-566
E-mail: robert.pichler@ge.com

2 General conditions
2.1
Designated Use
1 Designated use ............................................................................................................................................... 1

2 Foreseeable misuse ....................................................................................................................................... 1
1 Designated use
The designated use is the use of the engine which must be applied as described in the operating instructions.
GE Jenbacherco-generation plants and generator modules are designed for decentralised production of electri-
cal energy.
For this purpose a gas engine is used to power a high-voltage or low-voltage three-phase generator.
Co-generation plants also utilise the thermal energy from engine cooling water, engine oil, mixtures and ex-
haust gases.
Any use not described in the operating or maintenance instructions is not considered a designated use. GE Jen-
bacher accepts no liability for the consequences of any non-designated use.
GE Jenbacher systems are designed individually to the customer’s specifications. These specific requirements
also clearly define the designated use of the system and its proper operating conditions. Any subsequent
changes to the system must therefore always be approved by GE Jenbacher.
① Gas engine ③ Heat exchanger

② Generator
2 Foreseeable misuse
A reasonably foreseeable misuse is any use of the engine which may arise in a way not intended in the operat-
ing instructions but can arise from easily foreseeable human behaviour.
In order to prevent a reasonably foreseeable misuse, GE Jenbacher has carried out a risk analysis as described
in DIN EN 14121.

Author: Doku./Velik Responsible: Dokumentation Release date: 25.05.2010
2.1
Designated Use
The residual risks and possible misuses revealed in these analyses have been reduced to a minimum on the
basis of the PREVENT-PROTECT-WARN principle. For risks which cannot be constructively prevented, you will
find hazard signs on the plant and appropriate warnings in the operating instructions.
Misuses constitute a danger to operators, third parties and the plant itself.
You will find information on how to deal with the residual risks to prevent health and safety from being compro-
mised in the safety instructions TI 2300-0005, work instructions and your operating instructions.
Examples of residual risks include hot surfaces, electrical hazards (high voltage), poisonous gases, liquids under
pressure, heavy components, risk of trapping fingers, incorrect behaviour in the event of an alarm, fall from
height, danger of slipping, failure to follow lock-out/tag-out procedures and working on unsecured plant while
still running.
Unqualified staff are prohibited from operating or working on GE Jenbacher plants or entering the engine room.
Familiarise yourself with the requirements in TI 2300-0001 “Employee protection”, TI 1100-0111 “General condi-
tions – Operation and maintenance”, official regulations on safety at work and the relevant parts of the safety
instructions.
Never operate GE Jenbacher plants outside their operational design constraints for and technical specifications.
Familiarise yourself with the requirements in TI 1100-0110 “Boundary conditions for GE Jenbacher gas en-
gines”, the specified maintenance plan and the technical data recorded for your plant (e.g. performance, gas
quality, gas type, explosive environment, temperature, ventilation, monitoring, program and software versions,
etc.).
While the plant is operating, all safety devices and monitors specified by GE Jenbacher and official bodies must
be functional and should not be bypassed or removed.
Use only operating fluids, tools and spare parts approved by GE Jenbacher and official bodies for operation,
maintenance, servicing and cleaning. Familiarise yourself with the requirements in TI 1100-0111 "Operation
and maintenance", the official regulations and the approved operating fluids (engine oil, cooling-water addi-
tives, lubricants, etc.) as stated in your operating instructions.
GE Jenbacher plants must be installed in accordance with GE Jenbacher specifications. Familiarise yourself
with the requirements in the arrangement plan, the technical diagram, the circuit diagram, the interface list,
the technical specification for the control system and information in the technical instructions for installation,
lifting and setting up.
Familiarise yourself with the disposal requirements and the special handling needed for hazardous materials or
materials subject to mandatory disposal.
You should also familiarise yourself with the requirements in safety guidelines TI 2300-0005, all statutory regu-
lations and the danger and disposal information on the product concerned.

Author: Doku./Velik Responsible: Dokumentation Release date: 25.05.2010
Declaration of Conformity
Declaration of Conformity - ORIGINAL

in accordance with Appendix II, 1.A of the Machinery Directive, 2006/42/EC
We,
GE Jenbacher GmbH & Co OG
Achenseestraße 1 – 3
A-6200 Jenbach
herewith declare, on our responsibility, that the follow-
ing equipment
Generator set : JGS 620 GS-N.L
Generator No.: _______
together with accessory electrical plant, lifting gear and all electrical and mechanical equipment supplied
and directly associated with it
to which this Declaration refers, conforms to the relevant fundamental safety objectives of EC Directives 2006/42/
EC (Machinery Directive), 2004/108/EC (Electromagnetic Compatibility), 2006/95/EC (Low-Voltage Directive -
electrical units, to be used within specific voltage limits) and 97/23/EC (Pressure Equipment).
The following standards and technical specifications, among others, have been taken into account in order to
properly satisfy the requirements specified in the EC Directives:
EN ISO 14121-1:2007 Safety of machinery – Risk assessment

EN ISO 12100-1:2009 Safety of Machinery: Basic Concepts, General Principles for Design - Part 1: Basic
terminology, methodology
EN ISO 12100-2:2009 Safety of Machinery: Basic Concepts, General Principles for Design - Part 2: Techni-
cal principles
EN 12601:2010 Reciprocating Internal Combustion Engine Driven Generating Sets - Safety.
EN 60204-1:2006 +A1:2009 The safety of basic machine terms, - electric equipment of machines.
EN 60439-1:1999 +A1:2004 Combinations of low-voltage switchgear.
DVGW Gas appliances are CE-DVGW-certified (EC Type-Examination Certificate in accor-
dance with the EC Gas Appliance Directive 90/396/EEC) and the fuel gas lines and
controlled gas pressure system on the module have been leak-tested in accor-
dance with DVGW- TRGI 1986 – Work Sheet G600 (Technical Guidelines for Gas In-
stallations issued by the German Technical and Scientific Association for Gas and
Water).
EN 61000-6-1:2007 Electromagnetic compatibility (EMC) – Part 6-1: Generic standards - immunity for
residential, commercial and light industrial environments
EN 61000-6-4:2007 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards - Generic stan-
dard interference emission for industrial environment.

Author: Doku./Provin Responsible: Dokumentation Release date: 21.12.2011
Declaration of Conformity
Dr. Volker Schulte Documentation Officer: Country: PAK

General Manager Robert Pichler, Documentation Manager Date: 2012-01
Technology GE Jenbacher GmbH & Co OG Language:
Achenseestraße 1-3, 6200 Jenbach,Austria
is authorised to compile technical documents

Author: Doku./Provin Responsible: Dokumentation Release date: 21.12.2011
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance
1 General conditions - Operation and maintenance .................................................................................. 1

1.1 Basic conditions ................................................................................................................................................................ 1
1.2 Cooler/heat exchanger (GE Jenbacher scope of supply) ............................................................................... 1
1.3 Interfaces/limits of supply ............................................................................................................................................ 1
1.4 Maintenance staff ............................................................................................................................................................ 1
1.5 Safety instructions ........................................................................................................................................................... 2
1.6 Risk assessment ................................................................................................................................................................ 2
1.7 Start-up conditions .......................................................................................................................................................... 2
1.8 Failures .................................................................................................................................................................................. 2
1.9 Recording operational data, maintenance record sheet ............................................................................. 4
1.10 Spare parts .......................................................................................................................................................................... 4
1.11 Lubricating oil ..................................................................................................................................................................... 4
1.12 Spark plugs .......................................................................................................................................................................... 5
1.13 Elastomer components ................................................................................................................................................. 5
1.14 Decommissioning the plant ......................................................................................................................................... 5
1.15 Welding work on the module ...................................................................................................................................... 5
1.16 Components coming into contact with exhaust gas ...................................................................................... 5
1.17 Fuels ........................................................................................................................................................................................ 5
1.18 Fuel gas quality ................................................................................................................................................................. 6
1.19 J624 TSTC turbocharger unit ...................................................................................................................................... 6
1 General conditions - Operation and maintenance
1.1 Basic conditions

The boundary conditions for GE Jenbacher gas engines as specified in Technical Instruction No. 1100-0110
must be observed. The work specified in the operational-data sheet must be carried out and this sheet must be
filled in correctly. All specified maintenance work must be performed regularly, expertly and on schedule. Knock-
free operation must be guaranteed.
1.2 Cooler/heat exchanger (GE Jenbacher scope of supply)

When integrated into the hot water system, appropriate measures must be taken to prevent dirt or sediment
building up in these components on the water side.
Refer to technical diagram and technical instructions for settings.
1.3 Interfaces/limits of supply

The conditions specified must be fulfilled and the equipment to be supplied for each specific system in accor-
dance with the boundary conditions, the technical diagram, the schematic diagram, the interface list and the
technical specification for the control system must be available within the limits of supply/interfaces. Failure to
comply with these requirements may have an adverse effect on the characteristics of the product and on its
reliability of operation and, in the end, restrict or invalidate warranty claims.
1.4 Maintenance staff

Work on the plant may only be carried out by specialist staff who have received relevant electrical and mechan-
ical training. It is possible to conclude service contracts with GE Jenbacher, withGE Jenbachersubsidiaries or
authorised specialist contractors. The intervals stated in the maintenance plan are average empirical values.
Where there is a lack of proper operation and maintenance (such as defective oil care, large accumulations of

Author: Doku./Bilek Responsible: Dokumentation Release date: 04.01.2012
dust or other problematic circumstances), maintenance operations have to be carried out before the specified
intervals.
The above can only be judged by the operator. If irregularities are found during the daily inspection, especially
during the warranty period (abnormal sounds or noises, etc.), the operator must take action to minimise any
damage (e.g. by immediately switching off the engine, investigating the cause of the irregularity and rectifying
it, and/or notifying the GE Jenbacher customer service department).
Upcoming maintenance work must be carried out before the maintenance interval is reached to ensure
smooth operation or to avoid interruptions in operation, for example, during the heating season. Maintenance
intervals may not be extended to avoid downtime during the heating season.
1.5 Safety instructions

Always follow the safety instructions in the operator's manual. Statutory safety regulations and accident preven-
tion rules must be observed. Before performing any maintenance work on the plant, the customer must make
sure that the relevant safety instructions are being followed. For work which may only be carried out when the
engine has been shut down, the system must be shut down as specified in TI 1100-0106 and measures taken
to ensure that it cannot be started accidentally.
1.6 Risk assessment

The plant operator (employer) is required to undertake a risk assessment to determine the measures necessary
to effect the safe availability and use of the plant and equipment and to comply with all official and quasi-
official safety rules and laws governing the operation of the plant. The employer must take the necessary mea-
sures to ensure that employees are only provided with equipment which is suitable for the conditions pertain-
ing at the workplace and guarantees their health and safety if used properly.
The risk assessment will cover approval, planning, assembly, commissioning, operation, maintenance, servicing
and shutting down.
The risk assessment to be performed by the plant operator and the official and quasi-official safety rules and
laws may give rise to acceptance tests, inspections and maintenance operations which are not included in the
Maintenance Plan. It is the operator’s responsibility to implement and enforce these additional measures.
1.7 Start-up conditions

All GE Jenbacherengines are fitted with a preheating system for the engine cooling water. Only preheated en-
gines with a cooling water temperature of >55°C may be started, loaded and operated at full-load, otherwise
engine damage may result.
1.8 Failures
When a failure results in the engine automatically being switched off by the module control, the cause of the
failure should be remedied first before the module is started again! It is not permissible simply to reset a failure
and then restart the engine, as critical or wear-induced damage could possibly result in premature replace-
ment of various components.
Remote resetting: Based on the risk category selected by the customer (0-4), failures resulting in the installation
being switched off can be reset using remote access to the visualisation system (max. 5 times every 6 hours'
running under load).

Failures: Diane No.: National Risk category

restrictions
Misfiring 1047, 3005 - 3024 0
Cooling water temperature maximum 1021 * 0
Engine room temperature maximum 1135 * 0
Failure of auxiliary equipment 1129 0
Synchronising failure 1039 0
Supply water temperature maximum 1063 0
Missing engine running conditions 1025 1
Starting failure 1023 * 1
gas pressure MINIMUM Controlled gas system 1 1028 * 1
gas pressure MINIMUM Controlled gas system 2 1030 * 1
Mixture temperature maximum 1040
oil temperature maximum 1043 1
ADMISSIBLE CONTROL DEVIATION OF LEANOX controller 1080 1
EXCEEDED
engine cooling water pump FAILURE 1090 1
Generator frequency too low 1110 1
Actual value measuring signal failure 1113 1
Engine speed measurement signal failure 1120 1
TecJet GAS QUANTITY JUMP 3099 1
ENGINE Oil level MINIMUM 1018 2
GENERATOR reverse power 1038 2
Cylinder exhaust gas temperature Deviation from maxi- 1044 2
mum average value
Cylinder exhaust gas temperature Maximum excess 1049 2
over absolute value
Cooling water pressure maximum 1050 2
Mixture temperature fluctuation speed maximum 1105 2
Generator exciter failure 1109 2
Neutral current maximum 1112 2
Engine oil level minimum 1018 2
Generator reverse power 1038 2
Cylinder exhaust gas temperature Deviation from maxi- 1044 2
mum average value
Cylinder exhaust gas temperature Maximum excess 1049, 2001 – 2020 2
over absolute value
Cooling water pressure maximum 1050 2
Mixture temperature fluctuation speed maximum 1105 2
Generator exciter failure 1109 2
Neutral current maximum 1112 2
cylinder 1 maximum excess over absolute value 2001 2
cylinder x deviation from average value, Maximum posi- 2021 – 2040 2
tive deviation

Failures: Diane No.: National Risk category

restrictions
Cylinder x deviation from average value, Maximum neg- 2041 – 2060 2
ative deviation
Gas proportioning valve CAN link failed 3093 2
Oil pressure minimum 1017 3
Missing power signal 1041 3
Oil filter differential pressure maximum 1059 3
Gas mixer control faulty 1083 3
Backfire protection 1128 3
All other risk categories not listed in risk categories 0 – 3. 4
Due to national restrictions, risks listed in category 0 and 1 may be promoted to category 4 risks.
Single or multiple resetting of all other trip-generating failures without remedying the cause first will result in a
considerable potential risk of injury or damage. The customer (or the party responsible for the remote resetting)
will be entirely liable for such injury or damage.
1.9 Recording operational data, maintenance record sheet

It is mandatory for all operational data to be recorded and all out-of-the-ordinary events to be described.
Please note:
It is not enough merely to record the facts in writing. The data should be compared with the commissioning
data and be checked for plausibility. In case of deviations, abnormal noises etc. the cause must be investigated
and rectified. If you cannot find the cause, the GE Jenbachercustomer-service department should be notified
immediately.
It is in the operator's best interests to maintain and record operational data (maintenance record sheet, opera-
tional data journal, data recorded in the "Maintenance file"). Properly maintained operational data journals and
data record sheets are important documents, enabling analysis and support in case of failures. Moreover,
these documents are also important when deciding on warranty claims.
1.10 Spare parts

Only original GE Jenbacherspare parts (e.g. oil filters!) should be used. Warranty claims in respect of defects
and damage will be invalidated by the use of non-original spare parts.
Important: In order to avoid unscheduled downtimes it is strongly recommended that a stock of spare parts be
held.
1.11 Lubricating oil

No specific maintenance interval is specified for lubricating oil. It is the operator's responsibility to take all nec-
essary measures to ensure the protection and safe operation of the plant and guarantee the plant's availability.
The oil service life (depending on gas quality, mean pressure, engine type, oil consumption, oil temperature and
oil type) can be prolonged by fitting an additional oil tank. If premature wear is claimed, the results of the lubri-
cating oil analysis, subject to the limit levels laid down in Technical Instruction No. 1000-0099B, must be present-
ed in full, even after the warranty period has expired.

1.12 Spark plugs

No specific maintenance interval is specified for spark plugs. It is the operator's responsibility to take all neces-
sary measures to ensure the protection and safe operation of the plant and guarantee the plant's availability.
Spark plug service life depends on the boundary conditions of the plant (e. g. type of spark plugs, gas type,
mean pressure, gas mixing temperature, ignition system, emission limits).
1.13 Elastomer components

Elastomer components age and become brittle, even when engines are not operational. That is why the service
life of these components does not depend solely on the length of time for which the module has been in ser-
vice, the cooling water temperature and pressure, etc. With a normal running time of 5,000-6,000 operating
hours annually and a maximum cooling water temperature of 90°C, all elastomer components are replaced at
the normal intervals as described in the maintenance plan. If this number of operating hours is not reached,
the elastomer components (e.g. O-rings on cylinder liners, flexible coupling, etc.) should still be replaced as a
precautionary measure after a maximum of 5 years.
1.14 Decommissioning the plant

When prolonged scheduled or unscheduled downtimes occur, such as after the heating season in the case of
power plants, the engine systems must be prepared (preserve, change old lubricating oil, close off the flue-gas
connection, etc.) for their downtime according to their geographical location (climate, proximity to the sea, gas
type, etc.)
As conditions can vary enormously, we recommend that you consult a suitable specialist firm concerning the
measures to be taken or contract it to carry out the work.
Of course, before recommissioning the plant, you must make sure that it has been restored to its normal opera-
tional condition.
1.15 Welding work on the module

Always make sure to attach the negative pole as close as possible to the weld location when carrying out weld-
ing work on the module – not on the mass connection (earth cable) though.
1.16 Components coming into contact with exhaust gas

All parts that come into contact with exhaust gas are state-of-the-art materials with a specified service life.
Due to the different operating modes and different fuel gas content (including traces of harmful substances),
no binding guarantee can be given on the service life of components such as the exhaust manifold, etc. Where
silencers are situated in the open air without external heat insulation, condensate (acid, water) can occur even
in installations without heat exchangers (hot exhaust gases) and shorten the service life. This also applies to
silencers with internal insulation, where the temperature in the rock wool insulation can fall below the dew point.
1.17 Fuels
The service life and safe operation of the plant depend to a considerable extent on the operating materials
used. Only use operating materials such as fuel gas, engine cooling water, warm water, anti-freeze agent, anti-
corrosive agent, lubricating oil, etc. as specified in the respective GE JenbacherTechnical Instructions.

1.18 Fuel gas quality

The operator is obliged to check the quality of the fuel gas in terms of thermal value, methane number and
content of harmful substances at regular intervals. If these values differ from the values stipulated in the con-
tract, immediate measures must be taken by agreement with the GE Jenbachercustomer service department.
If the content of harmful substances increases (e.g. sewage gas, landfill gas) the lubricating oil can become
heavily acidified within a fraction of the normal oil change interval and acute or irreparable damage and in-
creased wear occur all of a sudden, for example on cylinder liners and bearings and/or oil consumption increases.
If the methane number fluctuates downwards (within the range stipulated in the contract) the engine is protect-
ed against harmful knock operation by the control system (automatic ignition point adjustment, power reduction).
Note:
During the commissioning process the engine is adjusted to the optimum setting for the methane number giv-
en at that time.
If the methane number increases after commissioning (for a prolonged period or a major part of the plant's
operating time) the engine setting should be adjusted so as to optimise operational efficiency. This task must
be carried out by specialist staff.
1.19 J624 TSTC turbocharger unit

This pressure equipment is part of the generating set and may only be used in the intended manner. The entire
engine and generating set documentation therefore applies in addition to these Instructions and must be taken
into account as well.
Use of the pressure equipment is only permissible if the stated limits are observed.
Connection information:
▪ The operator must arrange for the recurrent tests required by the law of the country of operation.
▪ The introduction of additional loads (lifting, pushing) is prohibited.
▪ No welding, heat treatment or metal-cutting machining may be carried out on the cast parts.
▪ The bolted joints between the cast parts must never be touched in any way, unless instructed in the mainte-
nance instructions.
Since these are open pressure equipment items, static overpressures are not possible. However, to avoid ex-
ceeding the design pressures during engine operation, bypass valves and pressure sensors are fitted, which
must be fully functional.
Safety cannot be assured in the event of improper use.

Boundary conditions for GE Jenbacher gas engines
1 Tips .................................................................................................................................................................... 1
2 Potentially explosive atmospheres ............................................................................................................. 1
3 EMERGENCY STOP .......................................................................................................................................... 1
4 Minimum clearance to be left around the module for maintenance work ......................................... 2
5 Gas and smoke alarm installation .............................................................................................................. 4
5.1 Exhaust, breather and air-bleed lines in the fuel-gas system ..................................................................... 5
6 Fuel gas ............................................................................................................................................................ 6
6.1 Condensate removal in the fuel-gas system ...................................................................................................... 6
6.2 Underrunning the minimum methane value ....................................................................................................... 8
7 Intake air .......................................................................................................................................................... 9
7.1 Engine room ........................................................................................................................................................................ 9
7.2 Cooling air generator ................................................................................................................................................... 11
8 Engine cooling water circuit ...................................................................................................................... 11
9 Cooling water for the mixture and oil ...................................................................................................... 12
10 Raw water, warm water, hot water .......................................................................................................... 14
11 When operating with a steam boiler ........................................................................................................ 14
12 Lubricating oil ............................................................................................................................................... 15
13 Exhaust gas ................................................................................................................................................... 15
14 Electrical conditions .................................................................................................................................... 15
15 Operation and maintenance ...................................................................................................................... 16
16 Pipelines (pickling and cleaning) ............................................................................................................... 17
17 Connections (GE Jenbacher's limits of supply) ....................................................................................... 17
18 Refer to the TIs listed below ....................................................................................................................... 17
1 Tips
Anlagenspezifische technische Bedingungen: siehe jeweilige techn. Spezifikation.
The limit levels for harmful emissions guaranteed in the technical specification can be met only at a load of
between 50% and 100%.
The values in the Technical Instruction applicable to the device must be observed and maintenance must be
carried out regularly and expertly.
2 Potentially explosive atmospheres

GE Jenbacher Jenbacher products are generally not intended or suited to be used in surroundings in which
there is a risk of explosion.
3 EMERGENCY STOP
When installing Jenbacher modules, a manually-operated emergency stop facility (EMERGENCY STOP button)
must be fitted on the customer side - on the inside and outside of the engine room - and integrated into the
Jenbacher control system.
When installing Jenbacher container modules, a manually operated emergency stop facility (EMERGENCY STOP
button) must be fitted on the customer side - on the outside of the container - and integrated into the Jenbach-
er control system.
The EMERGENCY STOP buttons must comply with the requirements of ISO 13850 and IEC 60947-5-5.

Author: Doku./Bilek/Pichler Responsible: TSR/TEM/TCE/TSA Release date: 19.10.2011
4 Minimum clearance to be left around the module for maintenance work

The lifting capacity of the crane, minimum travel for the crane and minimum clearance around the module as
detailed below must be taken into account in the planning of the engine room. It must be possible to remove
the generator from the engine room. When installing equipment in the engine room, you must allow space for
the crane to operate and ensure there are freely accessible areas. If necessary, contact GE Jenbacher for advice.
① Engine X*) Crane - max load.

② Generator ③ Min. travel distance for crane*)
A*) B*) C D*) E*) X*) Y´*)

J 208 1000 mm 1000 mm 1500 mm 1000 mm 1000 mm 100 kg -
Engine type 1000 mm 1000 mm 1500 mm 1000 mm 1000 mm 500 kg 1600 mm
3,4

A*) B*) C D*) E*) X*) Y´*)

Engine type 6 1500 mm 1000 mm 1500 mm 1000 mm 1000 mm 1000 kg 1600 mm
J 624 TSTC 1500 mm 1000 mm 1500 mm 1000 mm 1000 mm 1000 kg 25000 mm
Y*) type 3, 4 and 6 engines: Crane on 2 overhead rails running above the cylinder heads. The overhead rails
must be designed such that heavy machine parts can be moved at least up to the footboards and/or to the
rear into the direction of the generator. The dimension specified is the ideal dimension for the rail distance.
X*) The stated weight is the minimum crane load capacity (not including the generator).
J 208: An overhead crane (trolley) with a rails above the cylinder heads would be helpful, but is not necessary.
A, B, D, E*): The dimensions specified are the minimum dimensions. Make sure that not on all sides of the en-
gine only the minimum dimensions are maintained. Enough room must remain on one side to be able to store
any disassembled parts during a revision.
It must be possible to position the engine type 6 cylinder heads and/or turbochargers and mixture coolers (for
all engine types) which are disassembled at their temporary storage location or on pallets!
Not possible to maintain the minimum clearances?

If the minimum clearances around the module cannot be maintained in the engine room, openings must be
provided in the engine room as shown in areas ③ and ④ in the illustration below to permit maintenance work
to be carried out on the engine, and removed parts to be brought out.

① Engine
② Generator
③ Place for an opening for heavy engine parts
④ Place for an opening to the side of the engine
5 Gas and smoke alarm installation

GE Jenbacher requires a gas and smoke alarm with an acoustic alarm (alarm horn) to be installed.
It is the operator's responsibility to install a gas and smoke alarm system in the engine room in accordance
with official regulations.
The number of sensors used must satisfy at least the minimum requirements laid down in this TI.

▪ Natural gas: at least 1 sensor per engine

▪ Non natural gas: at least 2 sensors per engine
▪ CO in fuel gas: The number of CO sensors must be specified specifically for each plant (at least 2 sensors
per engine)
The sensors must be suitable for the gas components (taking toxicity into account!). Note the results of the gas
analyses!
Take into account the following fundamental principles when determining the installation location for the
gas-alarm sensors:
▪ If the engine is run on natural gas, a sensor must be placed above the gas train.
▪ If the engine is run on a gas other than natural gas (non-natural gas), at least 2 sensors must be installed.
1 sensor at ground level and 1 sensor above the gas train.
▪ If the fuel gas contains CO, CO sensors must be installed if:
– the gas is odourless and the CO content of the fuel gas is > 0%.
– the gas contains odorants and the CO content of the fuel gas is > 0.5%.
CO sensor(s) in areas where people work, especially hazardous areas (next to components containing gas)
and CO sensor(s) in areas without air flow (insufficient ventilation).
The sensors must be installed at breathing height.
5.1 Exhaust, breather and air-bleed lines in the fuel-gas system

Gas can flow out around the outlet area of the pipes!
Breathing lines from the controller, air-bleed lines from the leak tester and exhaust lines should not be routed
together and must be terminated outside the engine room to the open air. The diameter of the lines must be
selected in accordance with local conditions (because of pressure loss over length, angulations, etc.).
The gas exhaust line is not supplied by GE Jenbacher. The design of a permanently technically leakproof, well-
made gas exhaust line (e.g. to TRBS2152/Part 2) is the responsibility of the plant planner/builder.
Gas leaks at the outlet of air-bleed lines must be taken into account.
The outlet area of the lines must be evaluated and designed in accordance with current local regulations (e.g.
94/9/EG, IEC 60079, EN 1127-1).
Example of a high-pressure gas train (inlet gas pressure exceeding 499 mbar):
Details of the exact points at which gas should be exhausted can be found in the plant-specific technical diagram.
Symbol used in the technical diagram
Terminate exhaust, breather and air-bleed lines outside the engine room!
Gas can flow out around the outlet area of the pipes!

Symbolic drawing of a high-pressure gas train
① High-pressure controller
② Safety blow-off valve
③ Safety shut-off valve
6 Fuel gas
Make sure that the fuel gas quality is in accordance with TI 1400-0091 and TI 1000-0300.
The gas train is normally designed for a project-specific pressure. Design precautions must therefore be taken
to prevent the gas pressure from exceeding the admissible maximum pressure. In addition, certified safety
valves (SOV2) must be installed to prevent excessive pressure at all times.
GE Jenbacher When supplying fuel gas to products, make sure to only use gases that will not ignite under the
conditions that prevail outside the engine (mixer connection interface). Where required, you must take addition-
al measures in the plant (e.g. monitoring/controlling the oxygen concentration in the gas -> emergency shut-
down), in order to comply with any specific national regulations.
A manual stop valve must be provided outside the engine room so that the plant can be shut down for repair
and maintenance operations and in emergencies, preferably at the point where the gas pipes enter the engine
room.
The manual stop valve must be designed to ensure that no unauthorised person can actuate it, i.e. open it
when in locked position.
If there is CO in the fuel gas: if the CO content of the fuel gas is >5%, a nitrogen flushing system must be installed.
It is the operator’s responsibility to ensure that the fuel gas system is equipped with the necessary devices,
does not leak and satisfies official requirements.
6.1 Condensate removal in the fuel-gas system

Cooling of gases in the fuel-gas system can cause the water in the gases to condense. The condensate must
be drained from the gas system and disposed of taking account of its composition and local regulations (e.g.
surface-water protection regulations, explosion protection).

Condensate discharge, drainage and disposal is not part of the GE Jenbacher cope of supply. The design and
construction of a gas-tight proper condensate drain line is the responsibility of the plant designer/builder and
must comply with all local regulations regarding explosion protection and industrial safety.
Notes on condensate drain lines:
▪ Not all commercially-available condensate drain lines are gas-tight, and some line can leak in the course of
operation. The suitability for use as a gas-tight condensate drain line for fuel gases and the conditions for
securing permanent gas-tightness must be expressly confirmed by the manufacturer/supplier.
▪ Gases dissolved in the condensate can come out of solution in the condensate drain line (pressure drop),
which can lead to the formation of an explosive atmosphere in the condensate drain line.
The condensate drain line should therefore be fitted with a vent to atmosphere.
Depending on the maximum gas quantity released, the interior of the condensate drain line and the area
around the venting point must be evaluated and designed in accordance with current local industerial safe-
ty regulations (e.g. the DIN 1127 standard).
The adjacent illustration shows the layout in principle, with a vent point to atmosphere and a possible gas
outlet location.
▪ The danger of frost in the condensate drain line to atmosphere should always be taken into account.
▪ The design of the condensate drain line must be approved by the site safety officer and taken into account
when drawing up the plant safety plan.

Fuel gas system condensate drain system
① Fuel gas + condensate ④ Gas-tight condensate discharge

② Possible gas escape area ⑤ Water trap
③ Environment ⑦ Condensate disposal
6.2 Underrunning the minimum methane value

If the contractually agreed minimum methane value (see technical specification) is not reached, the engine con-
trol will automatically take the following steps to achieve knock-free operation and/or to prevent knock damage:
1. reduce the mixture temperature (if a controller has been installed and the ambient conditions so allow);
2. set the ignition point to a later time, but still within the permissible range (followed by a decrease in the
degree of efficiency);
3. reduce the engine output to 50%.
4. If these anti-knock measures prove to be insufficient, the knock-control system will shut down the engine.

7 Intake air
7.1 Engine room

Use forced-draught fans for engine-room ventilation.
To prevent false starts and deflagrations when starting (the engine-side air/gas mixer functions just like a car-
burettor and is very sensitive to temperature fluctuations and pressure differences), the engine-room ventila-
tion system must also be activated when requested by the module via the output contact "Auxiliary Equipment
ON". In this way, a controlled set of boundary conditions is created when starting and accelerating. That is why
you must not switch off the engine-room ventilation system until approx. 5 minutes after synchronisation when
the preset engine-room temperature is reached (engine-room thermostat), nor should you switch from the
mains to the generator within this period.
This means that during the starting and accelerating procedure (including synchronisation), no switching of the
engine-room ventilation system should occur until conditions have stabilised.
Intake (of combustion air) from the engine room:

When taking in combustion air from the engine room, the engine room cladding should be free from dust and
fibres.
The required filter mesh rate should be strictly adhered to.
If refrigeration compressors are installed in the engine room, the intake air should be drawn in from the outside
atmosphere.
Intake air:
Dust-free air of purity class G3 to EN 779 and/or a filter degree of 85% to ASHRAE standards.
If required, install a coarse-dust filter of the relevant filter class!
Max. engine-room temperature:

40°C (to be reached at a maximum outside temperature of 35°C).
If higher engine-room temperatures are expected, have GE Jenbacher supply a special module version!
Maximum air intake temperature (at the engine air filter):

Take appropriate measures to keep the combustion air temperature down (+10°C to +25°C). The temperature
should remain as constant as possible and vary only within the smallest possible bandwidth.
Measures this purpose: e.g. separate air guide systems up to the air-filter intake, circulation-air control facilities
at the engine-room air intake, speed-controlled fans to keep the temperature constant, etc.
Warning:
As for the air pressure, air intake temperature and atmospheric humidity, the limit levels specified in ISO 3046
apply: i.e. 1,000 mbar, +25°C, 30% humidity. If local conditions differ, the specific engine performance will be
reduced.
This corresponds to the standard boundary conditions as applied by all engine manufacturers.
However, other conditions may have been agreed upon before the order was placed! For example, full load at
an intake temperature of 40°C. In this case, the booster system would have to be modified and the technical
data corrected. Such arrangements should be stated in writing in the specification.

Min. air intake temperature and/or engine room temperature:

The starting behaviour of the engine and the power of the starter motor and the starter batteries are designed
for a minimum ambient temperature of +10°C.
To prevent starting problems, every engine is fitted with an electric cooling water preheating system. During
operation of the electric cooling-water pre-heating system, the intake and exhaust sound dampers, doors,
gates etc. must be closed and the fans must be switched off.
Engine-room air:
Maximum sulphur concentrations in the engine-room air < 1.5 mg/m³.
Engine room ventilation:

The engine-room ventilation must be designed so as to:
▪ make sure that the entire engine room is properly ventilated (to prevent an undesirable accumulation of
gases),
▪ guarantee a directed airflow across the engine to make sure that the surface temperatures of the electrical
components installed on top of the engine (ignition coils, ignition cables, knock-control and charge-pres-
sure sensors, throttle-valve actuator, etc.) do not exceed a temperature of +70°C!
If this is not guaranteed and the surface temperatures exceed this temperature, the service life of these
components will be considerably reduced and the failure frequency may increase sharply. Any resulting
damage and downtime are not covered by the warranty.
▪ guarantee that outside air is forced into the engine room by the frequency-controlled fans and the engine
room is slightly overpressurised.
Engine-room overpressure: > 0.1 mbar, < 0.5 mbar.
If the engine is at standstill - especially if multiple-engine systems are in use - this overpressure causes a de-
fined ventilation flow through the engine towards the exhaust stack.
In the event of a false start (which can never be fully prevented), this will prevent the unburned mixture from
flowing back to the engine.
To ensure that the very cold outside air flow (<10°C) is thoroughly mixed with the hotter engine-room air (circu-
lation-air control), never guide the fresh intake air flow directly to the air-filter intake.

Positioning the fresh air flow for the air filter intake
① Engine ③ R = 3 - 4 m 90° if possible

② Filter ④ Fan
This is to guarantee that even when outside temperatures are as low as e.g. –10°C, the air temperature at the air-
filter intake will not fall below +10°C. Extreme temperature fluctuations will cause control problems, e.g. 'pump-
ing" of the turbocharger.
Also make sure that the fresh intake air flow is not directed straight at the air-filter intake, as the dynamic ef-
fect of the air flow will affect the mixture composition and can cause false starts and deflagrations!
7.2 Cooling air generator

Air intake temperature max. 40°C
Relative atmospheric humidity max. 80%
Dust content ≤ 1 mg/m³
SO2 content ≤ 1.5 mg/m³
The Pt100 temperature-control sensor must be positioned in the engine room at the following location:
engine room side, before the centre of the exhaust sound damper.
8 Engine cooling water circuit

Must comply with TI 1000-0200.
Anti-freeze agent as specified in TI 1000-0201.
Anti-corrosion agent as described in TI 1000-0204.
Maximum permissible cooling water outlet temperature at the engine: refer to technical specification and/or
technical diagram.

Max. operating pressure at the crankcase inlet

▪ Type 2, 3, 4 and 6E engines (average pressure 20 bar) 2.5 bar
▪ Type 6F engine (average pressure 22 bar), J624G, J624H 3.5 bar
▪ Type 6F101 -112 engine (hot-country version) in generating set version 5.5 bar
In the case of multi-engine systems: make sure that the various engine cooling water circuits are separated.
The standard engine cooling water heat exchangers must be designed on the cooling circuit side for a maxi-
mum water pressure of 10 bar. If higher pressures are required (e.g. 16 bar), suitable heat exchangers for the
required pressures must be provided.
9 Cooling water for the mixture and oil

Dirt collector (mesh size ≤ 0.1): refer to technical diagram.
See Section [⇨ TA 1100-0110, Page 11] and Section [⇨ TA 1100-0110, Page 14] for the water quality.
Maximum intake temperature: refer to the technical diagram and/or the relevant technical specification
(see Section [⇨ TA 1100-0110, Page 14] for the permissible temperature change).
Maximum permissible gauge pressure 16 bar. When integrating the cooler in the cooling circuit, make sure that
the engine cooling water heat exchanger is designed for a permissible pressure of 10 bar as standard. (see
section [⇨ TA 1100-0110, Page 14])
Minimum water volume flow and water pressure in the high-temperature circuit (HT) of type 6 engines:
The HT stage of type 6 engine intercooler is subject to the relation between minimum pressure and water flow
as shown in Diagram 1 (boundary conditions: average pressure 22 bar, cooling water inlet temperature at first
cooler stage 70-80°C*). Keeping to the minimum values will prevent steam bubble formation at the highest ex-
pected tube wall temperature in the cooler.

Diagram 1: Water volume flow and minimum pressure to prevent steam bubbles from developing in the type 6 engine mixture
cooler’s HT stage at an average pressure of 22 bar and a cooling-water temperature of 70-80°C.
① Minimum water pressure at the out- ③ Minimum water volumetric flow at the intercooler HT stage
let from the intercooler HT stage [m3/h]
[bar gauge]
② Water volumetric flow through the
intercooler HT stage [m3/h]
*at higher warm water inlet temperatures, the water pressure must be designed as 1.0 bar / 10K higher
Additional design guidelines for the HT cooling circuit:

The minimum volume flow ③ for the number of cylinders of the engine must be guaranteed in order for the
cooler to reach its cooling performance.
MODUL (intercooler and engine housing separate).
▪ Irrespective of the integration variant of the intercooler (parallel, serial, etc.), the water flow and pressure
values at the HT stage outlet must at least comply with the limit values from diagram 1.
▪ The volumetric flow must not drop below the minimum in any operating mode. For example, if a constant
warm water circuit inlet temperature is required (greenhouse application), as a general rule water recircula-
tion is to be preferred to pump speed control.
GENERATING SET (intercooler and engine block in the same water circuit)
▪ The water flow and pressure at the outlet from the intercooler HT stage must meet the limit values in dia-
gram 1 as a minimum.
▪ The pressure at the crankcase cooling water inlet must not exceed 5.5 bar.
▪ The static system pressure at the expansion tank must be selected so that the both the stated require-
ments are met under operating conditions (warm water circuit).
Water volume flow and minimum pressure in the low-temperature circuit (LT) of type 6 engines:
The following minimum flow values must be maintained in the LT circuit, since otherwise the temperature gradi-
ent across the cooler surface might be worse and reduce the cooling effect of the LT stage.
▪ J624: 50 m³/h
▪ J620: 40 m³/h
▪ J616: 30 m³/h
▪ J612: 25 m³/h
Minimum fill pressure in hot water circuits in plants using exhaust gas heat:
When an exhaust gas heat exchanger is fitted, the minimum-pressure requirements for the heating circuit
must be as stated in TI 1000-0206.
Whichever value is higher from diagram 1 or TI No. 1000-0206 must be selected!
Demand by circulation pump – pump after-run:

In general, the circulation pump's demand for the warm water circuit (high temperature circuit) and other sepa-
rate circuits is controlled by GE Jenbacher.
Customers must ensure at least 5 minutes' after-run, especially for plants with exhaust gas heat recovery
where the pumps are not controlled by GE Jenbacher.
Because of the arrangement of valves in the exhaust gas system, the exhaust gas heat exchanger must also
be flushed with coolant when in bypass operation.
10 Raw water, warm water, hot water

Dirt collector (mesh size ≤ 0.1): refer to technical diagram.
Water quality: must comply with TI 1000-0206.
The specified warm-water return temperature should not be exceeded (install emergency cooling, otherwise
the module will be shut down).
Permissible return-temperature change: 70°C +3/-20°C

50°C +3/-10°C
Intermediate values should be determined by interpolation.
Permissible return-temperature change speeds: maximum 10°C per minute.
We advise you to install a thermostatic control to achieve a constant return temperature at the module intake.
In that case, the control must be integrated into the heating system and the operating conditions in accor-
dance with GE Jenbacher Drawing No. E 9684 and/or in consultation with GE Jenbacher.
11 When operating with a steam boiler

Water quality must be in accordance with boiler manufacturer's specifications.

Refer to the technical specifications and technical diagram for the maximum permissible temperature and pres-
sures.
12 Lubricating oil
Must comply with TI 1000-1109.
Oil changes should be carried out in accordance with TI 1000-0099 A/B/C/D or in accordance with the results
of the oil analyses.
Warning:
The oil lines to the engine, fixtures, vessels, etc. should not be made from pure copper. Copper has a strong
oxidising effect on lubricating oil, especially at increased temperatures (accelerates ageing), which will result in
an increased Cu content in the oil, giving rise to incorrect diagnoses.
Similar Cu-Ni alloys (Ni content ≥ 10%) do not have these characteristics and can therefore, if so desired, be
used instead of normal steel tubes.
13 Exhaust gas
Engine malfunctions can cause backfiring in the exhaust gas system. The exhaust gas system as a whole must
therefore be capable of absorbing short-term pressure surges of up to 6 bar. The underpressure following a
pressure surge can be in the order of approx. 200 mbar. This must be taken into account in the engineering of
the exhaust gas system. The internal pipe must be resistant to buckling, especially when long double-wall fun-
nels are used (DIN 4133).
See the technical specification and/or technical diagram for maximum permissible exhaust gas backpressure.
In the case of multi-engine systems, exhaust gas systems must not be combined.
Exception:
▪ double shut-off valves with intermediate ventilation for each module
▪ if a continuous underpressure exists at the point where the systems are combined (e.g. a continuous flow
in the smoke stack).
The condensate from the heat-recovery boilers, silencers and the exhaust manifold, etc. should be collected
and disposed of in an environmentally sound way.
Condensate lines should not be interconnected.
14 Electrical conditions
Nominal mains voltage change: +/-10%*) of nominal voltage
Max. permissible transient mains voltage changes: +/19% of nominal voltage*)
Nominal mains frequency deviation: max. +/- 2%
Minimum duration of a short interruption: min. 200 ms
Make time of the synchronising switch: 70 ms
Break time of the circuit-breaking switch: 60 ms
*) Note: The ranges relate to default voltages in accordance with IEC 60038/ EN 50160. In the case of countries
with 415/240V, a maximum voltage tolerance of +6% applies because the related default voltage is 400/230V
+/-10%.

Apart from the normal connecting and disconnecting coils, the generator switch must also be fitted with a DC
low-voltage disconnecting coil. This coils disconnects the generator from the mains in the case of loss of con-
trol voltage or wire breakage.
To prevent external overvoltages from reaching the installation, overvoltage deflectors should be installed on-
site at the mains supply voltage location. To protect the generator, overvoltage deflectors must be fitted onsite
on the generator, if required, in combination with capacitors.
To mains supply locations with nominal voltages ≤ 1000V applies: The Up protective peak must be selected in
accordance with the measurement surge voltage for IEC 60364-4-44 overvoltage category II, Table 44.B.
For example, the protective Up peak must not exceed 2.5 kV for 230/400V installations.
To mains supply locations with nominal voltages > 1000V applies: Select and apply overvoltage deflectors in
accordance with EN / IEC 60099-5.
See TI No. 1100 -0112 for the overvoltage deflectors on the generator.
15 Operation and maintenance

Minimum operation time: 12 hours per engine start, except when commissioning, carrying out maintenance
work and during emergency power operation.
This minimum operating time is not an essential condition, but a reference value for the maintenance intervals
specified in the maintenance documentation. This reference value should help the operator to decide when,
contrary to what has been stated in the maintenance manual, various wearing parts will have to be replaced
(if, for example, a starter motor is used three times more frequently than expected, it will also have to be over-
hauled sooner).
The maintenance intervals as stated in the maintenance manual are averages for normal operation based on
experience!
Preventive inspections of components can help the operator to determine the exact point in time when the
wearing parts need to be replaced (see also TI 1100-0111).
Failure to adhere to the minimum operating time can have a serious effect on the service life of various parts.
Idling mode
Idling duration limited through the module control unit (except for maintenance and initial setting work: keep
idling period as short as possible).
Partial load operation

Partial load operation without limitations up to > 40% of the nominal load for type 2, type 3 and type 4 engines
and/or > 40% at pme = 18 bar for type 6 engines. Emission values referred to in the technical specifications
only apply where a load exceeds 50%.
Continuous operation
You must always aim for full load operation. Partial load operation without limitations up to > 40% of the nomi-
nal load for type 2, type 3 and type 4 engines and/or > 40% at pme = 18 bar for type 6 engines. Emission values
referred to in the technical specifications only apply where a load exceeds 50%.
isolated operation
During isolated operation, the module may be operated 6 times per year for 4 out of 24 hours at > 20% and <
40% of the rated module load.

Daily inspection
Maintain an engine log.
Maintenance as per GE Jenbacher maintenance plan.
All conditions as described in the TIs should be complied with.
For oil changes, oil analyses and oil quality assessments, refer to TI 1000-0099 A/B/C/D.
16 Pipelines (pickling and cleaning)

The inside of all piping, especially welded piping, must be cleaned before assembly;
e.g. gas lines, oil lines, cooling water lines, control lines, etc.
Note: pickling should only be carried out by companies that have sufficient experience in carrying out galvaniz-
ing work!
17 Connections (GE Jenbacher's limits of supply)

Connections (at GE Jenbacher limits of supply) should be equipped with compensators and/or flexible hoses.
The plant piping should be arranged in such a way that the compensators at GE Jenbacher limits of supply are
not subjected to mechanical force.
18 Refer to the TIs listed below

The revision applicable when the contract was signed is valid:
General conditions
TI 1100-0111 General conditions - Operation and maintenance

TI no. 1100-0112 TI no. 1100-0112 Installation of GE Jenbacher modules
Warning signs
TI 1000-0330 Signage on the engine room door
Fuel gas
TI 1000-0300 Fuel gas quality - natural, associated petroleum, bio- and landfill gas
TI 1000-0301 Fuel gas quality: mine gas
TI 1000-0302 Fuel-gas quality - special gases
TI 1400-0091 Fuel gases, freedom from condensate
Lubricating oil
TI 1000-0099A General instructions for lubricating oils

TI 1000-0099B Limit levels for used oil on GE Jenbacher engines
TI 1000-0099C Procedure for testing plant-specific oil service life
TI 1000-0099D Determining the initial Ph value (iPh) for waste lube oil as defined in TI
1000-0099B
TI 1000-1109 Lub. oil for GE Jenbacher engine types 2, 3, 4 and 6

Cooling Water
TI 1000-0200 Quality of cooling water in closed circuits

TI 1000-0201 Anti-freeze agent
TI 1000-0204 Cooling water anti-corrosion additive
TI 1000-0206 Quality of circuit water in hot water and warm water heating systems
TI 1000-0208 Quality of cooling water in open circuits
Cabling
TI 1000-0505 Electromagnetically compatible (EMC) cabling and earth connections

on and between engine modules and control cabinets

Safety instructions
1 General ............................................................................................................................................................. 1
2 Safety signs – hazard classification system .............................................................................................. 2
3 Health and safety during operation and maintenance .......................................................................... 3
4 What to do in the event of an alarm .......................................................................................................... 4
4.1 Evacuation alarm (gas alarm, fire alarm, CO alarm, gas pre-alarm) ....................................................... 4
4.2 CO pre-alarm ...................................................................................................................................................................... 5
5 Personal protection ....................................................................................................................................... 6
6 Transporting - lifting - installing ................................................................................................................. 8
7 Shutdown procedure and making safe ...................................................................................................... 8
8 Engine room .................................................................................................................................................. 11
9 Components .................................................................................................................................................. 16
9.1 Exhaust system .............................................................................................................................................................. 16
9.2 Turbocharger ................................................................................................................................................................... 17
9.3 Fuel gas system .............................................................................................................................................................. 18
9.4 Cooling system ............................................................................................................................................................... 19
9.5 heat exchanger .............................................................................................................................................................. 21
9.6 Safety valve ...................................................................................................................................................................... 22
9.7 Lubrication system ....................................................................................................................................................... 23
9.8 Control system ................................................................................................................................................................ 24
9.9 Ignition system ............................................................................................................................................................... 24
9.10 Cables and insulated wiring ..................................................................................................................................... 25
9.11 Throttle valve ................................................................................................................................................................... 25
9.12 Electrical connections ................................................................................................................................................. 26
9.13 Generator .......................................................................................................................................................................... 26
9.14 Electrical cabinets ......................................................................................................................................................... 27
9.15 Acoustic insulation (container; sound absorber hood) ................................................................................ 29
9.16 Battery ................................................................................................................................................................................ 29
9.17 Container/enclosure .................................................................................................................................................... 30
10 Maintenance and servicing ........................................................................................................................ 32
11 Cleaning ......................................................................................................................................................... 34
12 Disposal requirements for waste electrical and electronic equipment ............................................ 35
1 General
The operating and maintenance instructions contain basic safety signs, re-
quirements and directions which must be observed during the delivery, set-
ting-up, commissioning, operation and maintenance of GE Jenbacher ma-
chinery. These documents must be read and understood by the user be-
fore starting the machinery. The most recent edition of the operating in-
structions must always be available at the machine.
The information contained in the safety instructions below is intended to provide you with an overview of dan-
ger zones and possible causes of accidents.

Author: Doku./Hochrainer Responsible: Dokumentation Release date: 08.11.2011
Safety instructions
While the instructions below are intended for your safety, they cannot cover in detail the scope of all accident
risks posed by industrial machinery.
When operating this machinery it is your duty to comply with all current official and quasi-official safety rules
and codes applicable to your sector. You should also use your own powers of judgement to avoid hazards and
dangerous situations.
Most accidents are caused when people disregard simple, basic safety rules.
Any manipulation of the machine or its control cabinets which causes the machinery to operate outside its spec-
ified operating range (control range), is prohibited and could result in serious indirect damage.
Any modifications of the item supplied, including changes to the program and software, which are carried out
by the customer or third parties without GE Jenbacher prior consent will result in the lapse of any right to dam-
ages or the exercise of a warranty claim against GE Jenbacher.
2 Safety signs – hazard classification system

The pictograms with hazard classification used in this document are also used on GE Jenbacher products.
They refer to each of the hazards as described in this document.
DANGER (ISO DIS 3864-2)

denotes a high-risk hazard. If this hazard sign is ig-
nored, death or severe injury will follow as a direct con-
sequence.
WARNING (ISO DIS 3864-2)

denotes a medium-risk hazard. If this hazard sign is ig-
nored, death or severe injury may result.
CAUTION (ISO DIS 3864-2)

denotes a low-risk hazard. If this hazard sign is ig-
nored, minor or moderate injury may result.

Safety instructions
NOTICE (similar to ANSI Z535.2)

denotes information directly or indirectly relating to
the safety of employees or measures to protect the ma-
chinery. If this hazard sign is ignored, breakdowns or
material damage may result.
3 Health and safety during operation and maintenance

The customer will take all necessary precautions to ensure the safety of the contractor‘s personnel at the site.
This includes provisions for review by the contractor of and safety instruction by the customer on the cus-
tomer‘s safety practices, proper safe handling and disposal of hazardous substances and the protection of the
contractor‘s personnel from exposure to such substances, activation and deactivation of all power systems (elec-
trical, mechanical and hydraulic) using a safe and effective lock-out tag procedure, and conducting periodic
safety meetings.
The contractor will comply with reasonable health and safety requirements imposed from time to time by the
customer at the facility.
The contractor may conduct occasional safety audits to ensure that safe conditions exist and make recommen-
dations to the customer concerning such conditions. Neither the performance or non-performance of safety
audits nor the making of any recommendation by the contractor will relieve the customer of the responsibility
to provide a safe place to work. If the contractor‘s staff require medical attention, the customer’s local facilities
will be made available to the contractor‘s staff for as long as necessary.
If, in the contractor‘s opinion, the safe performance of work at the site is or may be endangered by local condi-
tions, the contractor may remove some or all of its staff from the site and/or supervise performance of all or
any part of its work and/or evacuate its staff. The customer will assist with any such evacuation.
The operation of equipment at the site will be the responsibility of the customer. If the customer requires or
permits the contractor‘s staff to operate equipment at the site, the customer will indemnify the contractor, its
employees and agents for all costs and liability (including any reasonable attorney‘s fees) incurred by or im-
posed upon the contractor, its employees and agents, based upon injury to persons (including death) or dam-
age to property resulting from the operation of equipment at the site by the contractor‘s staff.
If the customer provides the contractor‘s staff with any tools and equipment to perform work at the site, these
tools and equipment must be in a safe working condition (i.e. subject to inspections and preventive maintenance).
If the contractor encounters any hazardous material at the site which requires special handling and/or dispos-
al, the customer will immediately take whatever precautions are required to legally eliminate such hazardous
conditions so that the work under contract may proceed safely. The customer must ensure that all hazardous
materials produced or generated in the course of the contractor’s work at the site are removed.

Safety instructions
All decontamination necessary for the contractor‘s work (including any repair work) will be performed by the
customer.
4 What to do in the event of an alarm
4.1 Evacuation alarm (gas alarm, fire alarm, CO alarm, gas pre-alarm)
Evacuation alarm as specified in ISO 8201/minimum duration 180 seconds.
a Phase a signal is "On" for 0.5 s ± 10%

b Phase b signal is "Off" for 0.5 s ± 10%
c Phase c signal is "Off" for 1.5 s ± 10% (c = a + 2b)
Cycle Length of cycle: 4 s ± 10%
▪ Leave the affected area immediately. Go out into the fresh air, outdoors, right away.
▪ Close the gas safety shut-off valve outside the engine room and outside the danger zone and make
sure that it cannot be opened unintentionally.
▪ Call the fire brigade.
▪ Do not re-enter the affected area.
▪ Wait for the fire brigade to arrive.
▪ Warn other people about the danger.
▪ Do not re-enter the affected area until the danger has been eliminated with the professional assis-
tance of the fire brigade, the fault or damage professionally rectified, all enclosed spaces thoroughly
ventilated and the area has been declared safe to re-enter.
Bear in mind that ambient and operating conditions differ from plant to plant and the general rule is that,
before work starts in plants using poisonous gases, the operator of the plant should draw up an EMERGENCY
PLAN which takes these specific conditions into account. The relevant statutory regulations must also be taken
into account. This emergency plan must be brought to the attention of all persons employed at the plant, evi-
dence of which must be available.
An emergency plan will generally consist of at least the following information:

▪ Emergency regulations (what to do, evacuation, escape routes, assembly point, etc.)
▪ Local emergency telephone numbers (rescue, emergency doctor, fire brigade)
▪ People to be notified in the event of an emergency
Safety instructions
▪ Location of breathing apparatus independent of ambient air

▪ Other necessary safety information as laid down in statutory regulations, etc.
4.2 CO pre-alarm
Close the gas safety shut-off valve outside the engine room and make sure that it cannot be opened uninten-
tionally. Leave the engine to run until it stops of its own accord due to lack of gas. The ventilation is set to maxi-
mum by the engine control system. Call in professionals to look for the gas leak and initiate damage repair.

Safety instructions
5 Personal protection
TI 2300-0001 – Employee protection
The operation of the machinery or work on the machinery may only be car-
ried out by specialist staff who have received relevant electrical and me-
chanical training.
Access to the engine room is restricted to persons (specialist staff) who

have read, understood and will observe the safety instructions.
Prohibition, hazard, mandatory and warning signs must be obeyed at all

times. Any failure to do so may result in injury and death or damage to the
machinery.
Wear personal protective equipment (PPE)!
Wear the personal protective equipment approved by the health and safe-
ty organisations for body, head, eyes, ears and breathing. Never be in the
vicinity of an engine when wearing loose clothing, jewellery or long hair.
The standard equipment required for entering the engine room or approach-
ing and working on plant components, even outside the engine room, con-
sists of eye protection, protective clothing, hand protection and safety
footwear.
Depending on the operational condition of the plant, the ambient condi-

tions, the type or location of the operation, use hearing protection, safety
helmet, fall prevention equipment, gas sensors, breathing mask or other per-
sonal protective equipment, as appropriate.
You should also use your own powers of judgement to avoid hazards
and dangerous situations and wear the appropriate personal protective
equipment.
It is your duty to comply with all current official and quasi-official safety rules and codes applicable to your
sector.
Depending on the operating condition of the machinery or the operation, hazards may arise which cause in-
jury, so wear the appropriate personal protective equipment. The examples below are not exhaustive.

Safety instructions
Working when machinery is running:

▪ Hearing protection, eye protection, protective clothing, safety footwear, hand protection
Assembly operations during maintenance and repair:

Caution: many plant and engine components are heavy. This gives rise to a risk of severe crushing and impact
injuries due to the heavy weight of the components.
▪ Safety footwear, protective clothing, hand protection!
Installation, construction site, difficult access:

Danger of falling, tipping or flying objects, swinging loads and bumping into obstacles, which can cause severe
head injuries.
▪ Safety helmet, safety footwear!
Hot surfaces and liquids (oil, cooling water):

The engine, pipework, etc. can reach a surface temperature of up to 150°C.
▪ Thermal insulation gloves, protective clothing!
Pressurised pipes and containers:

Liquids such as engine cooling water and lubricating oil are hot and under pressure.
▪ Eye protection, protective clothing, thermal insulation gloves!
Working in dusty conditions:

Changing the air filter, cleaning operations, changing the active carbon, etc.
▪ Wear a breathing mask, eye protection, protective clothing and safety footwear!
Handling acids, starter battery, cleaning products, oil, anti-freeze and anti-corrosion products, chemicals:
▪ Acid- or chemical-resistant gloves and clothing, eye protection, safety footwear. Follow the manufacturer's
instructions!
Working at height (above 1.2 m):

Even falls from low heights can result in serious injury. When working at height (above 1.2 m), where the provi-
sion of technical safeguards (e.g. handrails, work platforms, etc.) is either impossible or impractical, you should
use:
▪ personal fall arrest equipment consisting of harness and associated equipment (safety rope, karabiner
hook, damper, lanyard or height safety device)!
Using fuel gas containing CO (read the results of the gas analyses):
▪ CO sensors as personal protective equipment! Ensure personal protective equipment is regularly maintained/
calibrated.

Safety instructions
People who are under the influence of alcohol and/or drugs represent a
danger to themselves and other people.
They must not be allowed to enter the engine room under any circum-
stances.
6 Transporting - lifting - installing

Familiarise yourself with the technical instructions concerning the require-
ments for the installation surface, lifting, transport safety pegs, transport-
ing and positioning and installing GE Jenbacher modules, containers and
switch cabinets, and the corresponding constraints.
Never use transport security shackles to lift components or modules. They
are only used to secure components or modules to the transport vehicle.
7 Shutdown procedure and making safe

Automatic machinery: liable to start without warning!
If the operating mode selector switch is in "Aut" position, the module may
start without warning at any time.
Before commencing maintenance work, repairs, etc., shut down machinery as described below and secure
to prevent unauthorised start-up!

Safety instructions
Shut down and secure!

To shut down the engine:
Switch off the engine in accordance with Technical Instruction No.
1100-0105
and ensure that unauthorised persons cannot start the engine.
Isolate from power supply before starting work!

Before starting work, isolate the machinery from the relevant circuits to
prevent it from being restarted and check to ensure that the system is dead.
Dangerous voltage!
If you see this warning near the mains isolating device, this means that
the mains isolating device does not switch off all electrical circuits. The ‘ex-
cept for’ electrical circuits - i.e. the circuits that are not switched off - are
shown in the circuit diagram.
Despite having isolated the machinery, you should regard all components
as live.
Check that all components are disconnected!
High-voltage ignition system – 40 kV!

Improper use may be fatal!
The ignition system may cause electric shock.
Ignition systems may also produce extremely dangerous voltages when
the equipment is not operating. This applies to all ignition system compo-
nents, such as the cable, coil, connector, etc!

Safety instructions
Hot surfaces!
Risk of burns
Let engine cool down, wear personal protective equipment!

Wear thermal insulation gloves and protective clothing!
Risk of escaping liquids (hot and under pressure) !
Liquids such as engine cooling water and lubricating oil are hot and under
pressure. Escaping liquids may cause serious injury.
Wear personal protective equipment!

Wear eye protection, thermal insulation gloves and protective clothing!
Allow the engine and cooling water to cool down before removing pipes, gaskets and covers or opening compo-
nents that contain liquids. The pressure must first be reduced to zero. Only then, drain the cooling water if nec-
essary. Liquids must be drained completely.
Risk of explosion!
When charging, batteries produce hydrogen and oxygen which under cer-
tain conditions may form an explosive mixture.
The battery provides 24 V DC even when the control system is switched
off. Sparks generated at the battery poles can ignite an explosive atmo-
sphere.
Check that the battery poles are firmly secured. No smoking, no naked flames, no sparks!

Safety instructions
Poisonous gases!
The air in the engine room may be severely polluted with evaporating oil,
cooling water, fuel gases or exhaust gases.
Ventilate the engine room thoroughly before starting work!

Ensure there is a fresh air supply when working in the engine room!
Wear personal protective equipment (gas sensors)!
8 Engine room
No admittance for unauthorised persons!
Room contains electrical equipment!
Admittance for authorised and trained personnel only (specialist staff)!
In principle, the engine room is an enclosed, protected room for the unmanned
operation of machinery.
Read the "Personal protection guidelines" in these safety instructions and wear the personal protective
equipment appropriate to the dangers concerned!

Safety instructions
Noise!
The noise produced when the machinery is operating or being started

may damage your hearing.
Wear hearing protection!
No pacemakers!
Because of the possibility of electromagnetic effects on pacemakers or sim-

ilar devices, people with such devices are prohibited from entering the en-
gine room.
No fire, naked flames or smoking!
Install fire extinguishers!
Fire extinguishers must be installed in places where they can be easily

reached in the event of a fire. Comply with official regulations and estab-
lish the types, size and number of extinguishers required with your suppli-
er and insurance agent.

Safety instructions
Risk of slipping!
Wipe up any spilt oil and coolant immediately and keep the machinery clean!
Highly flammable materials!
Keep oily rags in fire-proof containers. Never leave them lying on the engine.
Do not store flammable liquids near engines.

Keep the machinery clean!
Mark escape routes!
Mark escape routes from the engine room and keep them clear of obstruc-
tions.

Safety instructions
Avoid danger zones around safety valve and explosion protection valve
openings.
There are also danger zones around air filters.
Hot surfaces!
Risk of burns

Poisonous gases!
Enclosed spaces must be well ventilated to ensure a constant supply of

fresh air.
Rooms in which gas-consuming devices are operated must be ventilated.
If you become aware of unusual machine noise and unusual smells in the engine room, carry out a check. If
you detect a gas concentration in a building, you should always observe the following instructions:
If you fear that a hazard exists, actuate the Emergency Stop button outside the engine room, close the gas
safety shut-off valve outside the engine room and make sure that it cannot be opened unintentionally.
Prevent any possibility of ignition and, if possible, break all the electrical circuits from outside the danger zone.
Evacuate all staff from the danger zone.
Allow air into the affected parts of the building by opening windows and doors.
Call in professionals to look for the gas leak and its cause and initiate damage repair.

Safety instructions
Toxic gases (e.g.: CO, H2S, etc.)!

Read the results of the fuel gas analyses!
Fuel gases may be poisonous and may result in death or damage to

health if inhaled.
Wear gas sensors as personal protective equipment (appropriate to the

poisonous gas components) and ensure proper ventilation!
If the fuel gas contains carbon monoxide CO:

Carbon monoxide is a poisonous, odourless, colourless, highly in-
flammable gas, which is about as heavy as air.
Read the results of the fuel gas analyses!
Wear CO sensors as personal protective equipment when:

▪ the gas is odourless and the CO content of the fuel gas is > 0%.
▪ the gas contains odorants and the CO content of the fuel gas is >
0.5%.
Observe these guide values if no other safety guidelines are available or

they are less stringent than the guide values. Country-specific thresholds/
guidelines ALWAYS have priority. Also ensure that personal protective equip-
ment is regularly maintained/calibrated.
CO concentration in the air and its effect if inhaled:
▪ 0.003 Vol% = 30 ppm no/minimal risk to health

▪ 0.010 Vol% = 100 ppm slight headache after several hours
▪ 0.050 Vol% = 500 ppm severe headache, dizziness, fainting after several hours
▪ 0.1 Vol%-0.2 Vol% = 1000-2000 ppm death after 30 minutes
▪ 0.3 Vol%-0.5 Vol% = 3000-5000 ppm death after a few minutes
Other symptoms: vomiting and nausea, buzzing in the ears, light-headedness, convulsions, hyperventilation, etc.

Safety instructions
Risk of explosion
The air-gas mixture used as engine fuel is easily ignited and may explode.
Close and make secure the manual stop valve, ensure there are no sparks
or naked flames, impose a strict ban on smoking and provide adequate
ventilation!
9 Components
Protective devices should not be removed while the machinery is in operation.
Repair or replace damaged protective devices immediately.
Before removing any protective device, secure the machinery to prevent unauthorised start-up.
Shutdown procedure and securing: Refer to section on "Shutdown pro-

cedure and securing" in these safety instructions!
9.1 Exhaust system

Engine exhaust gases are poisonous and may result in death or damage to health if inhaled.
Exhaust gases must always be discharged into the atmosphere.
The exhaust gas system must be inspected regularly to ensure that it is gas-tight:
Visually Cracks, corrosion, faulty gaskets

Odour Exhaust smell
Locations at risk: Flange connections, gaskets, compensators, welded joints.

It is the operator’s responsibility to ensure that there are no leaks in the exhaust system.

Safety instructions
Poisonous gases!
Inhalation will result in damage to health or death.
Discharge exhaust gases into the atmosphere, check for leaks, provide ad-
equate ventilation.
Hot surfaces!
Components which are not insulated and through which exhaust gas pass-
es are very hot and can cause severe burns.

9.2 Turbocharger
As the turbocharger operates at high temperatures, flammable material must be kept at a distance.
Work on the turbocharger must only be carried out once the engine has been shut down and room tempera-
ture has been reached, otherwise there is a risk of injury and fire.
Hot surfaces!
Risk of burns


Safety instructions
Fire risk!
Fire
Avoid contact with flammable material and keep the machinery clean!
9.3 Fuel gas system

The engine is equipped for the fuel gas quality specified by the customer when the engine was ordered, and is
adjusted for this gas when it is first put into operation.
Notify GE Jenbacher Customer Service before you convert the system to another type of fuel gas and each
time the fuel gas quality is changed!
Please note: The air-gas mixture used as engine fuel is easily ignited and may explode.
As soon as fuel gas is present in the pipes no welding work must be carried out in the engine room concerned.
No naked flames may be used and a strict ban on smoking must be observed.
The guidelines below must be read in conjunction with other mandatory requirements (arrangement plan,
Technical Instructions, statutory regulations, official directives, etc.) when assembling and operating the
machinery:
The engine room ventilation must be designed so that gas concentrations are prevented and a slight overpres-
sure exists in the engine room. (see TI 1100-0110 [⇨ TA 1100-0110, Page 1])
Ensure that the pipes and components through which the fuel gas passes are fully leakproof.
A leak test as described in IW 8049 0 is required if a leak is detected or after repairs to pipes or components
carrying fuel gas and mixtures.
Install a flame trap (depending on the legal requirements of the country where the equipment is located) in the
gas supply line.
Plant-side safety valves must always be directed downwards.
A manual stop valve must be provided outside the engine room for intentional shutdown of the machinery
(e.g. for repair and maintenance and in emergencies), preferably at the point where the gas pipes enter the
engine room.
Safety instructions
The manual stop valve must be designed to ensure that no unauthorised person can actuate it, i.e. open it
when in locked position.
It is the operator’s responsibility to ensure that the fuel gas system is equipped with the necessary devices,
does not leak and satisfies official requirements.
Risk of explosion
The air-gas mixture used as engine fuel is easily ignited and may explode.
Gas being discharged could create a potentially explosive atmosphere.
No welding, no naked flames, strict ban on smoking, efficient maintenance/
inspection, leak tests, adequate ventilation gas alarm system, manual
stop valve closed and made safe!
Toxic gases (e.g.: CO, H2S, etc.)!

Note the results of the gas analyses!
Fuel gases may be poisonous and may result in death or damage to

health if inhaled.

poisonous gas components) and ensure proper ventilation!
You must also read the engine room guidelines in these safety instruc-
tions!
Extreme care is required when carrying out maintenance or repair work on the gas train and the gas
pipes. These components contain quantities of residual gas which will escape when, for example, the gas
filter is being changed!
9.4 Cooling system

The engine coolant is hot and under pressure at operating temperature.
Damaged or weathered pipes, gaskets, hoses and hose clips and other components must be replaced immedi-
ately. If these components fracture, hot coolant could injure people and cause a fire.
Keep away from pressure relief valves when operating the machinery.

Safety instructions
The fracturing of components causes hot coolant to escape, thereby pos-

ing a risk of injury.
Regular maintenance/inspection of components. Wear personal protec-

tive equipment (protective spectacles, protective clothing and thermal in-
sulation gloves). Keep away from pressure relief valves!
Hot surfaces!
Risk of burns

To replace pipes and components:


Safety instructions
Coolants are treated with anti-corrosive and anti-freeze products.

Anti-freeze and anti-corrosion products are usually classified as harmful
to health. Follow the manufacturer's instructions!
Wear personal protective equipment when handling anti-corrosion prod-

ucts, anti-freeze products and coolant! Follow the manufacturer's safety
instructions!
Note disposal requirements!
9.5 heat exchanger

Heat exchangers are pressure vessels which are designed for specific pressure and temperature limits.
Operators must be made familiar with the specific design pressure and temperature.
Heat exchangers must be pressure-tested on a regular basis.

A visual inspection of the following points of risk must be carried out: Flange connections, gaskets, locks and
covers.
Any liquids escaping as the result of a leak may cause serious injury.
Keep away from pressure relief valves when operating the machinery.
Risk of escaping liquids (hot and under pressure)
The fracturing of components causes hot liquids to escape, thereby pos-

Regular maintenance/inspection, regular pressure-testing. Wear personal

protective equipment (protective spectacles, protective clothing and ther-
mal insulation gloves). Keep away from pressure relief valves! Reduce pres-
sure!

Safety instructions
Hot surfaces!
Risk of burns
Let heat exchangers and pipes cool down, wear personal protective equip-
ment! Wear thermal insulation gloves and protective clothing!
Do not remove pipes, seals and covers from the cooling system until the components have cooled down, the
pressure has been reduced and all liquids have been fully drained off.
To replace pipes and components:

9.6 Safety valve

Avoid the danger zones around the valves as they could open at any time during operation. There is a risk of
injury due to hot operating materials under pressure.
The actuation of safety valves causes hot liquids to escape, thereby pos-
Wear personal protective equipment (protective spectacles, protective

clothing and thermal insulation gloves). Keep away from pressure relief
valves!

Safety instructions
9.7 Lubrication system

The lubricant is hot and under pressure at operating temperature.
Hot oil or hot components may cause injury when you are carrying out an oil change or replacing the filter.
Oil leaks must be scrupulously avoided as oil spray or splashes may ignite on contact with hot engine components.
The actuation of safety valves causes hot liquids to escape, thereby pos-
Wear personal protective equipment (protective spectacles, protective

clothing and thermal insulation gloves). Keep away from pressure relief
valves!
Hot surfaces!
Components of the lubrication system (oil lines and filters, valves, etc.) are
hot and can cause severe burns.
Let components cool down, wear personal protective equipment! Wear

thermal insulation gloves and protective clothing!
Fire risk!
Oil leaks must be scrupulously avoided as oil spray or splashes may ignite
on contact with hot engine components.
Keep the machinery clean and carry out maintenance/inspection as in-

structed!

Safety instructions
Lubricating oils and oily rags must be disposed of as special waste.
9.8 Control system

The control rod assembly must not be obstructed while the machinery is
operating. Any unauthorised adjustment or bending of the control rod as-
sembly could cause the engine to race.
9.9 Ignition system

High-voltage ignition system – 40 kV!
Improper use may be fatal!
The ignition system may cause electric shock.

Ignition systems may also produce extremely dangerous voltages when
the equipment is not operating.
Do not touch ignition system components such as the cable, coil, connec-
tor, etc. while the engine is running. Do not pull ignition cables off of coils!
Ignition cables must not come into contact with other parts!

Safety instructions
The spark plug ignites an air-gas mixture in the combustion chamber. As

a result, any air-gas mixture which has accumulated in the induction port,
exhaust system or turbocharger may ignite. Failures must not simply be
reset. Before restarting the module, you must first remedy the cause of
the failure! Please read the rules on this subject in Technical Instruction
1100-0111.
Risk of explosion
Failures or incorrect operation (e.g. frequent unsuccessful attempts to
start, resetting the fault contrary to instructions, cause of the failure not
remedied, etc.) may cause an air-gas mixture to accumulate outside the
combustion chamber and explode, thereby causing serious injury, death
and severe damage.
Remedy failures, operate machinery and carry out maintenance and in-
spections in accordance with instructions!
9.10 Cables and insulated wiring

Dangerous electrical voltage
To protect you from the hazards posed by electrical energy, we would

point out that the use of cables and insulated wiring must comply with the
technical specifications issued by VDE, IEC, etc., in accordance with local
regulations and such work may only be performed by authorised techni-
cians (officially licensed electricians).
GE Jenbacher accepts no liability for injury, loss or damage due to improp-
er installation.
9.11 Throttle valve

Do not obstruct or block the control rod assembly.
Do not attach objects to or suspend them from the control rod assembly.
Do not misuse the control rod assembly as a fixing point for fall prevention equipment.

Safety instructions
9.12 Electrical connections

All electrical connections involve a risk of making a direct

or indirect electrical contact. Contact could result in a serious, and possi-
bly fatal, electric shock.
Connected components must be installed only by authorised experts (offi-

cially licensed electricians) in accordance with local regulations.
9.13 Generator
The voltage produced by the generator is deadly.
Contact could result in a serious, and possibly fatal, electric shock.
Connected components must be installed only by authorised experts (officially licensed electricians) in accor-
dance with local regulations.
Make sure that the generator is earthed before it is operated for the first time.
Extreme caution is required if the generator or the area around it is damp or wet.
In the event of an accident caused by electric shock, shut the module down immediately by pressing the emer-
gency stop button.
If the victim is injured or unconscious, summon a first-aider or medical assistance immediately.
If the generator is shut down by a safety device, do not restart it until the cause has been remedied.
During commissioning, the manufacturer of the power supply cubicle must implement the protective measures
required under local regulations.

Safety instructions
Ensure proper earthing!
The machine must be properly earthed to prevent contact voltages and

electrostatic charging contrary to regulations.
Make sure that the engine is resting on non-conductive rubber bearings.
9.14 Electrical cabinets

The voltage inside electrical cabinets is deadly.
Contact could result in a serious, and possibly fatal, electric shock.
Connected components must be installed only by authorised experts (officially licensed electricians) in accor-
dance with local regulations.
Make sure that the control cabinet is earthed before the plant is operated for the first time.
Extreme caution is required if the electrical cabinet or the area around it is damp or wet.
In the event of an accident caused by electric shock, shut the module down immediately by pressing the emer-
gency stop button.
If the victim is injured or unconscious, summon a first-aider or medical assistance immediately.
During commissioning, the manufacturer of the power supply cubicle must implement the protective measures
required under local regulations.

Safety instructions
Ensure machine is properly earthed!
The electrical cabinet must be properly earthed to prevent contact volt-

ages and electrostatic charging contrary to regulations.
Keep door closed!
Proper operating conditions for electrical devices can only be achieved

with the cabinet door closed (e.g. weather exposure, heat, cold, dust, air-
conditioning in the cabinet, etc.)
This relates to all types of electrical cabinets, e.g. interface, control cabi-
net, power cubicle, thermal reactor cabinet, etc.
Isolate from power supply before starting work!

Caution: electrical cabinets can be supplied from a number of energy
sources!
Before starting work in electrical cabinets, isolate them from all energy
sources to prevent them from being reactivated and check to ensure that
the system is dead.

Safety instructions
9.15 Acoustic insulation (container; sound absorber hood)

Fire risk!
There is a risk of fire if loose lagging material comes into contact with hot
engine parts.
Check acoustic insulation for damage,

Keep the machinery clean and carry out maintenance/inspection as in-
structed!
9.16 Battery
Corrosive substances!
The batteries used by GE Jenbacher are filled with dilute sulphuric acid,
which may cause serious corrosion.
Avoid contact with eyes and skin!
Wear personal protective equipment!
Wear acid-resistant gloves, protective clothing, protective spectacles and safety footwear when handling bat-
tery acid!
Battery acid may leak if batteries are damaged (e.g. during repair work), its corrosive action causing damage to
health as well as damage to the environment and property. Acid can also cause a chemical reaction with the
lime in the concrete and damage the floor.

Safety instructions
Risk of explosion!
When charging, batteries produce hydrogen and oxygen which under cer-
tain conditions may form an explosive mixture.
The battery provides 24 V DC even when the control system is switched
off. Sparks generated at the battery poles can ignite an explosive atmo-
sphere.
Check that the battery poles are firmly secured. No smoking, no naked
flames, no sparks!
Batteries, battery acid and rags contaminated with acid must be disposed
of as special waste.
9.17 Container/enclosure
Extreme caution is required when carrying out maintenance and installation work on the roof. Ensure workers
are always safely harnessed to prevent a fall!
Wear safety harness / Risk of falling!
Climbing on to the roof without a safety harness is extremely dangerous.
Secure the safety harness to suitable points provided on the roof!
Use personal fall arrest equipment consisting of harness and associated equipment (safety rope, karabiner
hook, damper, lanyard or height safety device)!

Safety instructions
The container or enclosure housing the plant must be designed so that

the plant does not pose any risks in the accessible area.
No ladders should be permanently attached to freely accessible contain-

ers or enclosures, so as to prevent unauthorised persons from climbing on
to the roof.
Where pipework, ducts, system components, etc. have to be laid or installed in the accessible area, they must
be positioned at such a height that they cannot be used for climbing or the system components installed within
the danger zone will also have to be enclosed.
If this is not possible, or if other dangers exist, the operator must secure the plant so as not to allow unau-
thorised persons access to the danger zones.
Doors left open (e.g. during maintenance work) on the container, the en-
closure, the air intake, etc. can be slammed shut by a gust of wind. This
may result in hand or head injuries caused by crushing and impact.
Secure open doors with storm hooks (if available) or by other suitable mea-
sures!
Keep door closed!
All doors must be closed while the plant is operating! Proper operating
conditions can only be achieved with doors closed.

Safety instructions
10 Maintenance and servicing

Caution: Automatic machinery: liable to start without warning!
The customer must make sure that before performing any maintenance work on the machinery, the rele-
vant safety precautions are taken.
Refer to the section on "Health and safety during operation and maintenance" in these safety instructions.
Before commencing maintenance work, shut down the engine as described below and make sure that it
cannot be started unintentionally!

Work on the machinery may only be carried out by specialist staff who have received relevant electrical and
mechanical training. There may also be a service or maintenance contract, under which all servicing is carried
out by GE Jenbacher personnel.
Suitable safe lifting gear must be used when assembling or disassembling heavy components. Handling
heavy components gives rise to a risk of severe crushing and impact injuries due to the heavy weight of the
components. Wear personal protective equipment such as safety footwear, protective clothing, hand protec-
tion and safety helmet.
Working at height (above 1.2 m):

Safety instructions
When working at height (above 1.2 m), where the provision of technical safeguards (e.g. handrails, work plat-
forms, etc.) is either impossible or impractical, you should use personal fall arrest equipment consisting of har-
ness and associated equipment (safety rope, karabiner hook, damper, lanyard or height safety device)!
Poisonous gases in vessels below ground level, or in basins and pits!
Poisonous gases can accumulate in basins and pits, as well as in vessels

below ground level (e.g. in condensate vessels).
Ensure proper ventilation or extraction to remove gas concentrations!

Check the maximum permissible workplace values (gas concentration).

poisonous gas components).
If the maximum admissible workplace values cannot be guaranteed, a suitable breathing apparatus must
be worn.
Before carrying out any work on the machinery, the customer has a duty to ensure that safety will not be com-
promised.
Maintenance and repair work must be carried out with care. Temporary measures are not permitted:
▪ never repair fuses
▪ never deliberately ignore or re-use defective parts
▪ never place drip catchers under leaks
▪ never tighten screws, which have a specified tightening torque, contrary to the specification
▪ never make temporary repairs
▪ never implement unsystematic and unsuitable fault-finding procedures
Temporary repairs and makeshift arrangements may result in serious injury or damage the machinery.
Only repair methods specified in the engine documentation are allowed and are to be used.

Safety instructions
11 Cleaning
Fire risk!
Cleaning agents are usually highly flammable.
When carrying out cleaning operations, only use approved cleaning

agents in well ventilated areas. Under no circumstances use petrol, paint
thinners and other easily vaporising agents!
Keep cleaning agents and solvents away from flames and flying sparks!
Poisonous gases!
Avoid inhaling any gases as they may be fatal.
When carrying out cleaning operations, only use approved cleaning

agents in well ventilated areas!
Read the labels on all cleaning agent containers and follow the instructions.
Never use unlabelled products.
Note disposal requirements.

Safety instructions
12 Disposal requirements for waste electrical and electronic equipment

Electrical and electronic equipment can contain harmful substances
which can affect the environment and human health.
WEEE symbol (Waste of Electrical and Electronic Equipment):
the symbol for the separated disposal of electrical and electronic equipment
is a crossed-out waste bin on wheels (Directive 2002/96/EC Waste Electrical
and Electronic Equipment).
You must not dispose any electrical and electronic equipment marked with
this symbol (battery-operated electrical appliances, measurement equipment,
light-bulbs, etc.) in the domestic waste but dispose of these separately.
Always use the waste return and collection systems locally available and con-
tribute to the reuse, recycling and all other forms of use for waste electrical
and electronic equipment.

3 Maintenance plan
3.1
Maintenance plan - specific intervals
Inspection work Number/Section Interval Remarks

Daily inspection round I 9003 0 Daily Carry out daily visual inspection of the
module.
Operational data booklet --- Daily Gather the operational data daily.
In-line air filter - engine IW 8040 A6 Daily If the underpressure exceeds 2.5 kPa, you
should replace the filter cartridges (but af-
ter 2,000 operating hours at the latest).
Ignition voltage check/ IW 0309 M0 weekly < 250 oh The result of the ignition voltage check to
Spark plugs be carried out weekly serves as the indi-
cator for the actual service life of the
spark plug.
Lubricating oil IW 0101 M6 first time after The results from the engine lubricating oil
TI 1000-0099A 150 Bh analyses are decisive for the actual oil
change periods.
TI 1000-0099B
TI 1000-0099C
Pre-combustion chamber IW 8046 0 Weekly Inspect oil level and oil pressure.
gas compressor Check the operation of the float conden-
sate drain.
Oil filter cartridge - engine W 8038 M6 at every oil after 4,000 operating hours at the latest.
change
Battery TI 1000-0050 once a month Check the acid level. Check if the pole
binders are properly secured.
Air filter in control cabinet --- once a month Check air filter for clogging and clean or
replace, as necessary.
control cabinet cooling de- --- once every year Check for clogging and clean using com-
vice pressed air, if necessary.
Cooling Water TI 1000-0200 once every year Concentration inspection
TI 1000-0201
TI 1000-0204
W 8080 A0 20000 operating Cooling water exchange
hours after hav-
ing completed
the overhaul ac-
tivities
Condensate removal in the IW 8090 A0 2,000oh at least check for gas leaks
fuel-gas system (if part of 4 times a year
GE Jenbacher scope of sup-
ply)
Automatic condensate
drain
Manual condensate drains when required condensate drain

Author: Doku./Bilek Responsible: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Release date: 27.10.2011
3.1
Maintenance plan - specific intervals
Inspection work Number/Section Interval Remarks

Exhaust gas system con- IW 8095 A0 monthly checking the condensate drain line in the
densate drain line when required exhaust gas system
All pipes and components IW 8049 0 8.000 Bh at least Leak testing
carrying fuel gas and mix- once a year only
tures natural gas
Main crankshaft bearing/ W 8050 M6 30,000 oh (4,000 30,000 operating hours or a maximum of
thrust bearing: engine starts) 4,000 engine starts
Battery in DIANE module --- once every 2 replace
years
Storage battery at battery --- once every 5 replace
charger years
Emission measurement --- Emission measurement according to official guidelines. Com-
ment: If the emission levels listed in the specification are ex-
ceeded, inspect and, if required, clean the combustion cham-
bers (W 8056 M0).
Proper maintenance according to the maintenance schedule is a condition for the acceptance of warranty claims.
The risk assessment to be performed by the plant operator and the official and quasi-official safety rules and
laws may give rise to acceptance tests, inspections and maintenance operations which are not included in the
Maintenance Plan. It is the operator’s responsibility to implement and enforce these additional measures.
The maintenance intervals have been determined on the basis of experience of maintaining average operating
levels while fully complying with the manufacturer’s operating and maintenance instructions. In individual cas-
es, the operating conditions and other factors relating to wear may affect the actual amount of maintenance
required. The manufacturer therefore reserves the right to specify different maintenance intervals where appro-
priate.
After the overhaul following 60,000 operating hours, the maintenance work to be carried out is repeated at the
same interval periods.

3.2
Maintenance plan - operating hours intervals
IN Inspection work/Maintenance work Number Operating hours
- Maintenance after initial commissioning W 1000 6 ■

2 Valve clearance W 0400 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Ignition system W 0303 M0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Inspection I 0103 6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Intake air filter (ROLF) - Engine IW 8040 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
A6
2 Crankcase ventilation system W 0509 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2/6/10/30 Pre-combustion chamber gas compres- IW 8046 0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
sor
2/8/20 GE Jenbacher switch cabinets W 8031 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2/20/30 Control rod assembly/throttle valve/ac- W 0200 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
tuator M6ef
2/30/60 Gas pressure control system W 8045 A6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
4 Oil filter cartridge W 8038 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
4/20 Elastically screwed coupling housing IW 8079 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
A6
6 Prechamber/Prechamber gas valve/ W 0501 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Spark plug sleeve
8 Leak testing IW 8049 0 ■ ■ ■ ■ ■ ■ ■
10 Starter W 8032 M0 ■ ■ ■ ■ ■ ■
10/20/30/ Exhaust gas turbocharger W 8026 M6 ■ ■ ■ ■ ■ ■
60
10/30 Engine cooling water pump W 0203 A6 ■ ■ ■ ■ ■ ■
20 Vibration damper W 0601 M0 ■ ■ ■
30 Piston/Piston cooling W 8047 M6 ■ ■
30 Cylinder liner W 8049 M6 ■ ■
30/60 Gas quantity controller W 0705 M0 ■ ■
30 Engine oil pump W 8046 M6 ■ ■
30 Connecting rods and connecting rod W 8048 M0 ■ ■
bearings
30 Main crankshaft bearing/thrust bearing: W 8050 M6 ■ ■
ZK/30 Camshaft/timing gear W 8052 M0 ■ ■
60 Pre-lubricating pump W 8054 M0 ■
60 Plate-type heat exchanger W 8043 A0 ■
60 Overhaul W 2100 M0 ■
- Generator W 8030 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
- Elastomer components W 8034 6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
- Replacing the cylinder head W 8053 M6 if required
Please note that properly carried out maintenance work is to be acknowledged by filling in the mainte-
nance record sheet.

3.2
Maintenance plan - operating hours intervals
IN = Interval reference number = operating hours/1000

ZK = for cylinder head disassembly

4 Inspection and maintenance work
4.1
Inspection/maintenance work
Inspection I 0103 6
Daily inspection I 9003 0
Lubricating oil/oil filter cartridge IW 0101 M6
Ignition voltage check / Spark plugs IW 0309 M0
In-line air filter - engine IW 8040 A6
Pre-combustion chamber gas compressor IW 8046 0
Leak testing of all pipes and components carrying fuel gas and mixtures IW 8049 0
Elastically screwed coupling housing IW 8079 A6
Condensate removal in the fuel-gas system IW 8090 A0
Exhaust gas system condensate drain line IW 8095 A0
Control rod assembly/throttle valve/actuator W 0200 M6ef
Engine cooling water pump W 0203 A6
Ignition system W 0303 M0
Valve clearance W 0400 M6
Pre-combustion chamber / pre-combustion chamber gas valve W 0501 M6
Crankcase ventilation system W 0509 M6
Vibration damper W 0601 M0
Gas quantity controller W 0705 M0
Maintenance after initial commissioning W 1000 6
Overhaul W 2100 M0
Exhaust gas turbocharger W 8026 M6
Generator W 8030 A0
GE Jenbacher - switch cabinets W 8031 A0
Starter W 8032 M0
Elastomer components W 8034 6
Oil filter cartridge W 8038 M6
Plate-type heat exchanger W 8043 A0
Gas pressure control system W 8045 A6
Engine oil pump W 8046 M6
Piston/Piston cooling W 8047 M6
Connecting rods and connecting rod bearings W 8048 M0
Cylinder liner W 8049 M6
Main crankshaft bearing/thrust bearing W 8050 M6
Exhaust gas manifold/exhaust gas lagging W 8051 M0
Camshaft/timing gear W 8052 M0
Replacing the cylinder head W 8053 M6
Pre-lubricating pump W 8054 M0
combustion chamber W 8056 M0
Engine – cooling water circuit / Mixture recirculating water W 8080 A0

Author: Doku./Provin Responsible: Doku./Bilek Release date: 16.12.2011
Inspection work: I 0103 6
Inspection
1 Heat exchanger mixture / water ................................................................................................................. 1

1.1 To measure differential pressure on the mixture side .................................................................................... 1
1.2 Mixture-side cleaning ..................................................................................................................................................... 1
2 Pre-combustion chamber differential pressure ....................................................................................... 2
3 Data collection for the flexibly-mounted coupling housing .................................................................. 2
4 Crankcase ventilation system ..................................................................................................................... 2
5 Flame traps in the mixture cooler ............................................................................................................... 2
5.1 To measure differential pressure on the mixture side .................................................................................... 2
5.2 Replacement ....................................................................................................................................................................... 3
5.3 Clean ....................................................................................................................................................................................... 4
6 Flame traps in the bypass line ..................................................................................................................... 4
6.1 Rating ..................................................................................................................................................................................... 4
6.2 Replacement ....................................................................................................................................................................... 4
6.3 Clean ....................................................................................................................................................................................... 4
Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure that unautho-
rised persons cannot start the engine.
Interval: every
Inspection work 2000 Oh 4000 Oh 10,000 Oh
10 Mixture/water heat exchanger ■
10 Mixture cooler flame traps ■
10 Flame traps in the bypass line ■
4 Flexibly-mounted coupling housing ■
2 Pre-combustion chamber differential pres- ■
sure
1 Heat exchanger mixture / water
1.1 To measure differential pressure on the mixture side

Connect a pressure gauge to the measuring points.
Carry out the differential pressure measurement while the system is at full load.
Enter the measuring values in the table Operational data – Heat exchanger mixture / water
(E 0103 a).
If the differential pressure exceeds the value measured at initial commissioning by ≥ 20 mbar (200 mm water
column), the heat exchanger should be cleaned on the mixture side.
If two mixture coolers are installed, you must also measure both differential pressures.
1.2 Mixture-side cleaning

Remove the cooler from the engine.
Wash out the dry cooler in a solvent (e.g. "P3 - Kaltreiniger") and rinse thoroughly with a powerful jet of water.
Solvents must be used which are not aggressive to nickel-plated brass or tin.
Author: Doku./Licht Responsible: Technology Thermodynamics Release date: 06.09.2011
Inspection
Replace the water-side gaskets (mixture cooler connection flange or blind flange).
2 Pre-combustion chamber differential pressure

The pre-combustion chamber gas differential pressure can be calculated by comparing the gas pressure in the
pre-combustion chamber line (to be read off from the pressure gauge after the pre-combustion chamber gas
pressure controller) and the boost pressure (to be read off from the engine management display).
Enter the measured values in the table Operational data – pre-combustion chamber gas dif-
ferential pressure (E 0103 d).
3 Data collection for the flexibly-mounted coupling housing

Measure the gap in 3 places on the circumference.
Enter the measured values in the Data collection for the flexibly-mounted coupling housing
(E 8079 6) table.
The measured value must be within the ±2 mm tolerance range of the value measured during commissioning,
otherwise the radial alignment of the generator must be adjusted as described in IW 8079 A6.
4 Crankcase ventilation system

Connect the pressure gauge to the blow-by separator’s measuring points.
Enter the measured values in the table Operational data – crankcase ventilation system
(E 0103 f).
If the differential pressure measured exceeds 20 mbar (200mm water column), the blow-by separator must be
replaced. Having replaced the blow-by separator, you must measure the differential pressure again. If the dif-
ferential pressure exceeds 20 mbar with the new filter, you must inspect the cylinders for possible piston fric-
tion using an endoscope.
5 Flame traps in the mixture cooler
5.1 To measure differential pressure on the mixture side

Connect a pressure gauge to the measuring points.

Inspection
Measured values in the Flame trap data table for the mixture cooler
(E 0103 g)
If the differential pressure exceeds the value measured on initial commissioning by = 15 mbar (150 mm water
column), the flame traps must be cleaned or replaced.
If two mixture coolers are installed, you must also measure both differential pressures.
① Measuring point 1 ② Measuring point 2
5.2 Replacement
Remove flame traps and mounting plates from the engine and mixture cooler.
Carry out a visual inspection of the flame traps. If any damage is evident (fusion, corrosion, etc.), replace the
flame trap. Also replace the gaskets when replacing the flame trap.
Flame traps fused together by corrosion

Inspection
5.3 Clean
If no damage is apparent, but only dirt, proceed as follows:
Remove flame traps and mounting plates from the engine and mixture cooler.
Immerse dry flame traps in a solution, e.g. "P3 - cold cleansing agent" (minimum 10 hours) and then rinse thor-
oughly with a powerful water jet. Finally, use compressed air to blow off the flame traps and dry them.
The flame trap mounting plates are made from zinc coated structural steel. That is why only solvents must
be used which are not aggressive to the zinc coating.
6 Flame traps in the bypass line
6.1 Rating
If in the course of the differential pressure measurement on the flame traps in the mixture cooler it is found
that they have to be replaced, the flame traps in the bypass line must also be assessed and if necessary re-
placed or cleaned.
6.2 Replacement
Remove flame traps from bypass line.
Carry out a visual inspection of the flame traps. If any damage is evident (fusion, corrosion, etc.), replace the
flame trap.
6.3 Clean
If no damage is apparent, but only dirt, proceed as follows:
Remove flame traps.
Immerse dry flame traps in a solution, e.g. "P3 - cold cleansing agent" (minimum 10 hours) and then rinse thor-
oughly with a powerful water jet. Finally, use compressed air to blow off the flame traps and dry them.

Daily inspection round
1 Leak testing ..................................................................................................................................................... 1

1.1 Exhaust piping ................................................................................................................................................................... 1
1.2 Water/water water/oil platen-type heat exchanger (if part of Jenbacher's scope of supply)
.................................................................................................................................................................................................... 1
1.3 Oil/water temperature controller .............................................................................................................................. 1
1.4 Vibration dampers ........................................................................................................................................................... 1
1.5 Electrical engine cooling water pump .................................................................................................................... 1
2 Heat exchanger exhaust gas/water (if included in the GE Jenbacher scope of supply) ................... 2
2.1 Condensate line ................................................................................................................................................................ 2
2.2 Condensate/neutralisation granulate reservoir: ............................................................................................... 2
3 Checking the exhaust gas back pressure monitoring (if installed) ....................................................... 2
4 Occurrence of unusual noises during operation ...................................................................................... 2
Before performing any work on the installation, the maintenance staff must ensure that the relevant safe-
ty precautions have been observed regarding the activities to be carried out.
For safety precautions, please refer to the operation or maintenance description (TI No.: 2300-0005).
1 Leak testing
Check the entire plant for leaks, especially hoses, lines, fittings, compensators, etc. (visual inspection).
In the event of mixture exciting in larger quantities, the smell of gas is perceptible. The location of the leak can
be detected using leak spray or a paper strip (is blown away).
In case of carbon monoxide (CO) in the fuel gas:
Carbon monoxide is a poisonous odourless, colourless, fhighly flammable gas, which is about as heavy as air.
If the fuel gas contains CO, CO sensors must be worn as personal protective equipment.
1.1 Exhaust piping

Leaks can be determined through a change in colour or damage of the insulation (noise) or a slight emission of
soot.
1.2 Water/water water/oil platen-type heat exchanger (if part of Jenbacher's scope of supply)
Carry out a visual inspection to check for leaks and, if necessary:
▪ replace the platen-type heat exchanger, if of the soldered type;
▪ replace the leaky plates or the gaskets in the case of the bolted type.
1.3 Oil/water temperature controller

Carry out a visual inspection to check for leaks. If you find any leaks, replace the gaskets.
1.4 Vibration dampers

Check the vibration damper cap for damage and traces of oil splashes (leaks). Even a small amount of damage
of the vibration damper can have a huge impact on the operation or even lead to total malfunction. In the
event of damage or leaks, immediately replace the vibration damper, otherwise the crankshaft may break.
1.5 Electrical engine cooling water pump

Check the engine cooling water pump for leaks. Replace the gasket set in the case of leaks.
Check the engine cooling water pump for unusual noises. If need be, replace the pump‘s engine bearing.
Author: Doku./Bilek Responsible: Günther Wall Release date: 03.06.2011
Daily inspection round
2 Heat exchanger exhaust gas/water (if included in the GE Jenbacher scope of supply)
2.1 Condensate line

Check the condensate drain and connection for deposits. If necessary, clean it so that the condensate can flow
freely through the drain.
2.2 Condensate/neutralisation granulate reservoir:

Check the built-in filters and the neutralisation granulate for deposits and replace if necessary.
3 Checking the exhaust gas back pressure monitoring (if installed)

Remove the screw plug and check for condensates. Check the line for deposits and, if necessary, clean it.
4 Occurrence of unusual noises during operation

Listen out for unusual noises during operation, find out what is causing them and rectify the fault. If you are
unable to establish the cause or rectify the fault, please contact the Customer Service.

Author: Doku./Bilek Responsible: Günther Wall Release date: 03.06.2011
Inspection and maintenance work: IW 0101 M6
Lubricating oil/oil filter cartridge
1 Information
Only use engine lubricating oil mentioned in GE Jenbacher Technical Instructions.
The oil service life is substantially affected by the operating conditions. It is therefore impossible to make any
general statements as to the oil-change intervals. To use the oil as efficiently as possible, we recommend deter-
mining its service life by means of oil analyses.
TI 1000-0099A ,
TI 1000-0099B
and TI 1000-0099C describe the sampling and testing procedure for the oil analyses.
Enter the dates of oil analyses and/or oil changes in the table Operational data – Engine lu-
bricating oil (E 0101).
If the engine lubricating oil has been contaminated with water, the engine oil and oil-filter element should be
changed.
Following this procedure, the engine must be allowed to idle for approx. 10 minutes. After switching the engine
off, the engine oil and filter element should once again be changed.
2 Procedure when changing oil
2.1 Draining lubricating oil

Drain the waste oil while the engine is at operating temperature.
Turn 3-way cock h3 into the "Drain" position.
Open shut-off valve ha.
Open the shut-off valve at the lowest point of the lubricating oil piping to drain the lubricating oil cooler.
It is important that the system is drained thoroughly in order to avoid contaminating the fresh oil with too
much residual used oil (pump off once more after 15 min if necessary).
2.2 Replacing the oil filter cartridge

You must replace the oil filter cartridge following every oil change or after 10,000 operating hours at the latest.

Author: Doku./Bilek Responsible: TEBM/Rangger Release date: 01.02.2012
Oil filter cartridge
Loosen the cover and remove the oil filter cartridge.

Clean the oil filter housing.
Moisten the O-rings (new oil filter cartridge) and slide into the oil filter housing.
Replace the O-ring at the cover and lubricate it.
Refit the cover.
The engine must never be started before the oil circulation system has been filled!
(Danger of severe damage!)
2.3 Fill with lubricating oil

Shut-off valve ha remains open.
Close the shut-off valve at the lowest point of the lubrication-oil piping (lubrication-oil heat exchanger).
Turn 3-way cock h3 into the "Fill" position.
Open 2-way valve v2 manually.
The difference in level between the oil pan and the fresh-oil tank will cause the engine lubricating oil to run into
the oil pan.
Fill the oil pan to the “MAX” indicator on the dip stick.
Close 2-way valve v2 manually.
Activate the electrical prelubrication system for several minutes, in order to fill the lubrication-oil heat exchanger
Check the oil-pan level once again and, if necessary, top up as described above.

3 Key to Figure
ha Shut-off valve of Connection for fresh oil tank

h3 3-way cock v2 2-way valve
oa Connection for used oil tank

Ignition voltage check / Spark plugs
1 Important ........................................................................................................................................................ 2
1.1 Required regulations/materials/tools ..................................................................................................................... 2
1.1.1 Safety instructions 2
1.1.2 Operation 3
1.1.3 Tightening torques 3
1.1.4 Tool/lubricant 3
1.2 Spark plug type .................................................................................................................................................................. 4
1.3 Electrode air gap ............................................................................................................................................................... 4
1.4 Spare spark plugs ............................................................................................................................................................. 4
1.5 Ignition voltage range .................................................................................................................................................... 4
1.6 Ignition voltage measurement: .................................................................................................................................. 4
2 Set values for spark plugs ............................................................................................................................ 5
2.1 Type 2, 3 and 4 engines ................................................................................................................................................. 5
2.2 Type 6 and 9 engines ...................................................................................................................................................... 5
3 Checking the spark plugs (measuring the ignition voltage) .................................................................. 6
3.1 Example of ignition voltage increase during operation ................................................................................. 6
4 Operational data ............................................................................................................................................ 7
4.1 Ignition voltage requirement ...................................................................................................................................... 7
4.2 Spark plug type .................................................................................................................................................................. 8
4.3 Optimal electrode distance ......................................................................................................................................... 8
5 Removing the spark plugs ............................................................................................................................ 8
5.1 Ignition systems with ignition coils .......................................................................................................................... 8
5.2 Ignition systems with external coils ......................................................................................................................... 9
5.2.1 Spark plug connectors which are mounted directly on the spark plug 9
5.2.2 Life Saver spark plugs with bayonet fitting 10
5.2.3 Life saver spark plugs without bayonet fitting 11
6 Cleaning hints ............................................................................................................................................... 11
7 Wearing characteristics and adjusting the spark plugs ...................................................................... 12
7.1 Analysing used spark plugs ...................................................................................................................................... 12
7.1.1 Premature sparking / overheating 12
7.1.2 Faulty noble metal electrode 12
7.1.3 Silicon and combustion deposits 13
7.1.4 Electrode short-circuit 13
7.2 Adjusting the spark plugs .......................................................................................................................................... 14
7.2.1 P3.V3 and P3.V5 spark plugs 14
7.2.2 Spark plugs 7.1V5 and P7.1V6 15
7.2.3 Denso 3-1 spark plug 15
7.2.4 Denso 518 spark plug 16
7.2.5 JenP603 spark plug 18
8 Fitting the spark plugs ................................................................................................................................ 18
8.1 Ignition systems with ignition coils ....................................................................................................................... 19
8.2 Ignition systems with external coils ...................................................................................................................... 19
8.2.1 Spark plug connectors which are mounted directly on the spark plug 19
8.2.2 Life-saver spark plug connector with bayonet fitting 19
8.2.3 Life saver spark plugs without bayonet fitting 20
8.3 High-voltage cable ....................................................................................................................................................... 21
9 Checking following recommissioning ...................................................................................................... 21
Operational data: E 0309

Author: Doku./Boxleitner Responsible: TEAM/TEBM/TEE/VSR/VST Release date: 04.10.2011
1 Important
This instruction describes how to measure the ignition voltage supply of the ignition coils and how to ad-
just the distance between the ignition coil electrodes in a professional manner.
Tip: Please report cases of damage immediately to GE Jenbacher Reliability Group!
(Tel. +43 5244 600 2265)
1.1 Required regulations/materials/tools
1.1.1 Safety instructions
DANGER
Hot spark plug surfaces
After the engine has been shut down, the spark plug surfaces are hot and can have a
temperature of up to 110 °C. Always take great care when touching hot spark plugs
and use the appropriate safety equipment (gloves).
TIP
Surfaces sensitive to dirt
Always use clean gloves to touch the surfaces. Dirt and grease on spark plugs ad‐
versely affects their function.
DANGER
High voltage in the ignition system
For safety reasons, the high-voltage cable and the insulator must not be touched
while the engine is in operation or during an ignition self-test. An exception to the
above is touching both components with a properly earthed tool such as high-voltage
measuring pliers.

ATTENTION
Before performing any work on the installation, the maintenance staff must ensure
that the relevant safety precautions have been observed regarding the activities to be
carried out.
a) For safety precautions, please refer to the operation or maintenance description.
b) Do not apply an excessive amount of paste to the thread. See the safety sheet for safe
handling of the paste.
c) Observe the correct tightening torque in order to ensure proper operation of the spark
plug. If the tightening torque is too high or too low, this can pose a danger to persons
and lead to damage to the spark plug and spark plug connector.
d) If unusual noises are heard from the engine, it must be shut down at once and the
cause of the noise remedied.
e) It is prohibited to approach the vicinity of the spark plugs until the engine has shut down.
1.1.2 Operation
▪ Engine switch-off, see TI No. 1100-0105.
▪ Operational spark plug data sheet E 0309.
▪ monic – dia-ne (monic is used to measure automatically the ignition voltages of all cylinders), see TI no.
1400-0104.
▪ Checking the spark plugs using a digital storage oscilloscope, see TI No. 1400-0111.
▪ Operating the Fluke 123 digital storage oscilloscope, see TI No. 1400-0151.
▪ Operating the high-voltage pliers, see TI No. 1400-0149.
▪ Operation with the MORIS ignition system, see TIs nos. 1502-0068 and 1502-0071.
1.1.3 Tightening torques

▪ Tightening torques type 2 and 3 engines, see TI No. 1902-0212.
▪ Tightening torques type 4 engine, see TI No. 1902-0213.
▪ Tightening torques type 6 engine, see TI No. 1902-0228.
1.1.4 Tool/lubricant
▪ Digital storage oscilloscope (DSO) e.g.: Fluke 123 (not for MONIC or MORIS)
▪ BNC connection cable (not for MONIC or MORIS)
▪ Pointed pliers
▪ Feeler gauge
▪ Socket wrench with extension piece
▪ Strap wrench (to disassemble the integral coils)
▪ Universal lubricant:

Type 2, 3 and 4 engines: "ULTRA-THERM“

Part No. 323765 (fluid in bottles) or
Part. No. 128407 (spray)
Type 6 and 9 engines: "NEVER-SEEZ“
Part no. 305045
1.2 Spark plug type

GE Jenbacher specifies the spark-plug type for every individual installation,
always taking into account the installation-specific operating conditions.
It is forbidden to use a spark plug type other than the one specified by GE Jenbacher. Doing so will immediately
restrict or even nullify any warranty and guarantee claims. The use of any spark plug type other than specified
will require GE Jenbacher prior written approval and clearance.
1.3 Electrode air gap

In principle, a smaller electrode distance will result in a prolonged cycle time. This in turn is a prerequisite for
ensuring a longer spark plug service life and lower maintenance costs.
To increase the reliability of operation and the service life of the spark plugs, correct maintenance is an abso-
lute necessity. It is especially important to use the correct measurement technique and to adjust the electrode
gap expertly and in good time.
For long service intervals, it is extremely important to ensure that the spark plug electrode surfaces are parallel.
Adjusting the spark plug may lead to the electrode surfaces not being parallel, which in turn results in a shorter
spark plug service life.
1.4 Spare spark plugs

Another means of keeping maintenance costs as low as possible is to adjust or replace a complete set of spark
plugs at a time (prepared beforehand) and not to adjust the individual spark plugs of a machine. This procedure
clearly makes more sense for installations which operate without direct supervision.
1.5 Ignition voltage range

The ignition voltage range and the installation-specific electrode distance which guarantee a smooth misfire-
free operation depend on many influencing factors, such as engine output, condition of the ignition coils and
the ignition system, gas composition, methane number and emissions. Consequently, these values may be sub-
ject to local restraints and variations.
1.6 Ignition voltage measurement:

In order to identify the right point in time to adjust the spark plugs, you will have to perform an ignition voltage
measurement and inspect the corresponding documentation (data sheet entry). Measurement recordings are
especially important when carrying out analyses of malfunctions.
We particularly advise you to carry out the ignition voltage measurement prior to periods in which a special
degree of reliability is required (e.g. weekends).

2 Set values for spark plugs

The following ignition voltage requirement (at full load) must not be exceeded for any reason.
2.1 Type 2, 3 and 4 engines

Spark plug setting
Application Ignition voltage Guide value: elec-
requirement trode distance
Spark-plug type Engine type NOx [mg/Nm³] Gas type < kV mm
P3.V3 2, 3, 4, 250 - 500 landfill gas 32 0.35
sludge gas
Natural gas
Mine gas
Propane gas
P3.V3 2, 3, 4, 250 - 500 biogases 32 0.35
wood gas
pyrolysis gas
Process gas
P7.1V5 3, 4, 500 Landfill gas 32 0.35
Sludge gas
Natural gas
Mine gas
Propane gas
P7.1V6 3, 4, 500 biogases 32 0.35
wood gas
pyrolysis gas
Process gas
2.2 Type 6 and 9 engines

Spark plug setting
Application Ignition volt- Guide value:
age require- electrode dis-
ment tance
Spark-plug type Engine type NOx [mg/Nm³] Gas type < kV mm
Denso 3-1 Type 6 to version C 250 - 500 Landfill gas 35 0.3
Natural gas
Sludge gas
Denso 3-1 Type 6 engine - all ver- 250 - 500 Special gas 35 0.3
on request sions:

Denso 518 Type 6 as from version 250 - 500 Landfill gas 35 0.3
E, Type 9 all versions Natural gas
Sludge gas
JenP603 6 and 9 500 Landfill gas 35 0.3
Natural gas
Sludge gas
3 Checking the spark plugs (measuring the ignition voltage)

Checking the spark plugs using the Fluke 123 digital storage oscilloscope and the BNC connecting cable, see TI
No. 1400-0151.
The spark plugs can only be assessed with the engine at full load and the Leanox controller fully adjusted.
The electrode gap must be adjusted or the spark plugs replaced if misfiring occurs, but at 32 kV (Type 2, 3 and
4 engine) and 35 kV (Type 6 engine) respectively at the latest.
Depending on the gas type and emissions, the operational range of a specific installation may be limited.
3.1 Example of ignition voltage increase during operation

To ensure a maximum service life or cycle time for the spark plugs, operation should be started at low igni-
tion voltages and be ended at ignition voltages which are as high as possible, without endangering uninter-
rupted engine operation.
Simply stated, the ignition voltage increases as the service life of the spark plug increases. If the initial voltage is
low and the end voltage is high, the operating time (cycle time) elapsed will be longer.

Operating period v. ignition voltage

Examining the curved shape provides valuable information on the condition of the ignition system as a whole
(spark plug, spark plug connector, ignition coil). This allows defects to be detected in their initial stages, so that
corrective measures can be taken.
4 Operational data
In the case of ignition or spark plug problems, these data provide important information about how to
solve the problem quickly.
4.1 Ignition voltage requirement

Operational spark plug data (E 0309) – not for monic:
Enter the measured ignition voltage requirement in the operational spark plug data (E 0309)
table.

4.2 Spark plug type

Operational spark plug data (E 0309):
Enter the spark plug type used in the Operational spark plug data (E 0309) table.
4.3 Optimal electrode distance

Operational spark plug data (E 0309):
Enter the optimal electrode distance determined for the installation in the operational spark
plug data (E 0309) table.
5 Removing the spark plugs

DANGER
Hot spark plug surfaces
After the engine has been shut down, the spark plug surfaces are hot and can have a
temperature up to 110 °C. Always take great care when touching hot spark plugs and
use appropriate safety equipment (gloves).
TIP
Surfaces sensitive to dirt
Always use clean gloves to touch the surfaces. Dirt and grease on spark plugs ad‐
versely affect their function.
a) Before disassembling the spark plugs, check the spark plug sleeve for soiling. If neces-
sary, clean the opening using a vacuum cleaner.
b) Do not touch the integral coil, the spark plug connector and spark plugs with oily
hands, particularly insulating parts such as plastic and ceramic parts, and prevent
these from coming into contact with other greasy components.
5.1 Ignition systems with ignition coils

Loosen the primary side ignition coil connector.

Remove the screws on the integral coil.

Pull the integral coil with spark plug connector out of the spark plug shaft.
Attach a socket wrench with extension piece to the spark plug and unscrew it.
Pull out the spark plug using the socket wrench and ensure that the joint ring does not remain in the spark plug
sleeve. If necessary, the joint ring can be removed from the spark plug sleeve using a bar magnet.
5.2 Ignition systems with external coils
5.2.1 Spark plug connectors which are mounted directly on the spark plug
Spark plug connectors mounted directly on the spark plug

1. Remove the spark plug connector insulator from the spark plug by hand. The insulator must not be discon-
nected from the cable.
2. Attach a socket wrench with extension piece to the spark plug and unscrew it.
3. Pull out the spark plug using the socket wrench and ensure that the sealing ring does not remain in the
spark plug sleeve. If necessary, the sealing ring can be removed from the spark plug sleeve using a bar magnet.

5.2.2 Life Saver spark plugs with bayonet fitting
Removing the spark plug

1. If the spark plug is connected to an R or M coil, undo the nuts on the R or M coil and pull the electrical plug
connector out of the spark plug.
2. Press the spark plug connector bayonet catch on the valve cover downwards and turn the arrow to the
position with the single red dot or the 0 position.
1. Remove the spark plug connector insulator from the spark plug by hand. The insulator must not be discon-
nected from the cable. Use the groove as the point of application. Pull upwards using two fingers.
2. Pull the spark plug connector out of the spark plug well.
5.2.3 Life saver spark plugs without bayonet fitting
Spark plug connector nuts

1. Undo the two nuts from the spark plug connector.
Remove the spark plug.

2. Undo the nuts on the R or M coil respectively and pull the electrical plug connector out of the spark plug.
3. Pull the spark plug connector out of the valve cover at the flange.
6 Cleaning hints
Before fitting new or newly adjusted spark plugs, clean the spark plug openings in the cylinder heads with a
vacuum cleaner and a suitable hose to remove any dried Ultratherm residue and other dust and dirt residues.
The spark plugs must neither be sand-blasted nor ground. They may become unusable as a result. The metal
coating on the combustion chamber side of the ceramic section may create external arc-over in the event of
damage.
In order to avoid external arc-over, all spark plug extension plastic insulators (Hyperflon) must also be cleaned
accordingly.
Check that there is no foreign metal between the electrodes so as to prevent metal swarf from forming jumpers.
The spark plug ceramic insulators must be free of grease, oil or Ultratherm residues. Clean any dirty parts with
a lint-free cleaning cloth wetted with a degreasing agent.

Do not wash the engine in the area near the spark plugs or the engine cylinder head.
7 Wearing characteristics and adjusting the spark plugs

Do not leave the feeler gauge between the spark plug electrodes when adjusting the electrode distance, as
the pressure could be transferred to the central electrode and may cause the nose of the spark-plug insu-
lator to break.
Only use the feeler gauge for checking the electrode distance.
When adjusting the electrodes, GE Jenbacher only use the pliers included in the scope of supply.
7.1 Analysing used spark plugs
7.1.1 Premature sparking / overheating

Spark plug external appearance:
Molten central and earth electrodes.
Melting beads and metallic deposits near electrode.
Type: P3.V3 or P3.V5 Type: P3.V3 or P3.V5 Type: P7.1V5 or P7.1V6
Possible causes Results / effects Corrective measure

The spark plug is insufficiently tight- Power reduction followed by engine Visually inspect cylinder.
ened. damage. Inspect (replace) ignition box.
Early sparking due to defective igni- Possible spark plug insulator crack- Install new spark plug.
tion box. ing due to overheated central elec-
Clean piston and cylinder head
Combustion knocking causing electrode. near combustion room.
trode to overheat.
Re-adjust LEANOX and re-establish
Defective valves. control for entire load range.
Auto-ignition due to deposits.
Incorrectly set LEANOX.
7.1.2 Faulty noble metal electrode

At one or more earth electrodes – loss of the precious metal.

Type: all spark plugs missing precious metal
Possible causes Results / effects Corrective measure.

Too much sulphur or ammonia in Ignition voltage increases sharply Use the right spark plug type
the fuel gas (see TI No. 1000-0300). when several electrodes fail.
Precious metal residues can get
stuck between valve and valve
seat, causing damage (valve burn-
through).
This can cause auto-ignition.
7.1.3 Silicon and combustion deposits

Massive silicon and combustion deposits near the electrodes and the whirl chamber.
Type: all spark plugs
Possible causes Results / effects Corrective measure.

Silicon values (see TI No. 1000-0300). Decreasing ignition voltages until Installing a new spark plug.
Increased oil consumption. the cylinder fails. Carefully clean the spark plug elec-
Poor blow-by oil separation. Deposits can flake off, resulting in trodes.
auto-ignition.
Defective piston rings.
7.1.4 Electrode short-circuit

Thread (molten conductive precious metal) between central and earth electrode.

Type: all spark plugs
Possible causes Results / effects Corrective measure

Insufficient distance between elec- Continuously decreasing ignition Adjust electrodes correctly (see fol-
trodes. voltages until the cylinder in ques- lowing instruction).
Incorrect spark-plug type. tion fails completely (no more com- Adjust electrode distance using feel-
bustion): er gauge.
Incorrect ignition point (spark-plug
overheating). Exhaust gas temperature drops far
below average value.
Combustion knocking (spark-plug
overheating).
7.2 Adjusting the spark plugs
7.2.1 P3.V3 and P3.V5 spark plugs

Wearing characteristics:
Approximately equal degree of material erosion at the central and earth electrodes.
① Feeler gauge ③ Central electrode

② Earth electrode

Adjustment:
Adjust the spark plugs from the inside to the outside so that these run parallel to the optimal electrode distance
(guide value 0.35 mm) using pointed pliers.
7.2.2 Spark plugs 7.1V5 and P7.1V6

Approximately equal degree of material erosion at the central and earth electrodes.
① Feeler gauge ③ Central electrode

② Earth electrode
Adjustment:
Adjust the spark plugs so that these run parallel to the optimal electrode distance (guide value 0.35 mm) using
pointed pliers.
7.2.3 Denso 3-1 spark plug

The precious-metal plates at the central and earth electrodes are seriously eroded. There is, however, enough
material left for continued operation.

① Earth electrode ③ Central electrode

② Electrode erosion
Adjustment:
Adjust the spark plugs so that these run parallel to the optimal electrode distance (guide value 0.3 mm) using
pointed pliers.
When adjusting the spark plugs, ensure that the electrodes are parallel to and right above each other.
Right Wrong
7.2.4 Denso 518 spark plug

The precious-metal plates at the central and earth electrodes are seriously eroded. There is, however, enough
material left for continued operation. Make sure as well that the earth electrode carriers still have enough mate-
rial stock to prevent auto-ignition. On spark plugs operated at up to 35 kV, the electrode carrier is often so worn
that it tapers to a point or there is so little noble metal stock left that adjustment will result in severe knocking
or very short service intervals.
Denso 518 - can be adjusted

Denso 518 - adjustment not recommended due to the danger of auto-ignition

We therefore recommend operating the DENSO 518 at up to 35 kV after fitting new spark plugs, and thereafter
replacing them with new spark plugs.
Adjustment:
Adjusting the spark plug

Carefully strike the spark plug with a hammer no heavier than 300 g on a round bar with the electrode cross-
section until the optimal electrode gap (guideline value 0.3 mm) is set. Do not leave the feeler gauge between
the electrodes while carrying out the adjustment, and do not allow the earth and centre electrodes to come
into contact, as this will damage the spark plug.
When adjusting the spark plugs, ensure that the electrodes are parallel to and right above each other.

7.2.5 JenP603 spark plug

As this spark plug has a very massive earth electrode carrier with a very small gap between it and the elec-
trode face, we do not recommend adjusting it.
8 Fitting the spark plugs

Defective spark plug connectors that are damaged mechanically or which have a high-voltage flashover
or puncture must be replaced immediately.
Before fitting the spark plugs, the spark plug sleeve thread must be re-cut.
Grease the M18x1.5 thread die before re-cutting in order to trap lose material produced by the tap. While doing
this work, please ensure that the piston of the thread to be tapped is situated at bottom dead centre to prevent
the piston from being damaged by the tap.
Replace the spark plug joint ring (very important).
In the case of old sealing rings, combustion gases may escape which may rapidly overheat the spark
plugs. Even if the old seal is still functioning correctly, spark plug overheating may occur. This is the result
of a lack of heat transmission due to insufficient contact surface between the spark plug and the water-
cooled spark plug opening.
Moisten the spark plug screw thread using universal lubricant:
As a result of the heat transmission, the spark plug threads remain cool and do not become stuck enabling
future disassembly.
Fitting spark plugs: Never drop the spark plug into the opening (as the electrode distance may no longer be
correct as a result). The correct tightening torque is decisive for the spark plug’s service life and safety.
Fit a new joint ring.
Ensure that the flat side of the sealing ring is positioned on the spark plug sealing support.
Ensure that the ribbed side of the sealing ring is positioned on the spark plug electrode side.
Apply universal lubricant to the spark plug screw thread.
Type 2, 3 and 4 engines: "ULTRA-THERM“

Part no. 323765 (fluid in bottles) or Rt. No. 128407 (Spray)
Type 6 and 9 engines: "NEVER-SEEZ“
Part no. 305045
Ensure that that the first part of the electrode side screw thread is correctly greased.
Do not spray the electrodes!
Insert the spark plug carefully using a self-clamping socket wrench. Tighten the spark plug first by hand and
then using a torque wrench (see TI 1902-.... for tightening torque).
When fitting spark plugs to all GE Jenbacher engines, especially however in the case of special gas direct
ignition type 6 engines (without pre-combustion chamber), pay attention to the following:
Ensure that the spark plug is fitted correctly into the spark plug sleeve. If you suspect that, because
▪ a spark plug can only be screwed in difficultly, or
▪ you need fewer turns to achieve the required torque, that the spark plug has not been fitted correctly, you
must remove the spark plug and check if it was fitted correctly. In this case you must check the pressing of
the spark plug sealing ring by comparing the height of the sealing ring present on the spark plug and a
new one.
▪ If the spark plug joint ring is not compressed in despite following the assembly procedure as described in
the TI, the fault must be found and rectified.
Possible errors:
a dirty and/or deformed spark plug or spark plug sleeve thread or foreign matter between spark plug
sleeve and spark plug, e.g. (parts of) a used sealing ring.
▪ If the spark plug is pressed in correctly, you may assume that all components are in good condition.
8.1 Ignition systems with ignition coils

Screw on the integral coil.
Fix the primary side ignition coil connector.
8.2 Ignition systems with external coils
8.2.1 Spark plug connectors which are mounted directly on the spark plug
Insert the spark plug connector insulator into the spark plug shaft and lock the spark plug into place. Locking
the spark plug into place must be accompanied by a noticeable click.
8.2.2 Life-saver spark plug connector with bayonet fitting

1. Insert the spark plug connector into the bayonet socket in the spark plug well and then lock it by turning
the arrow to the position with the single red dot or 0 and pressing it downwards.
In the event of malfunction, specific components or the spark plugs as a whole may be forced or shot out
of the engine. This presents a risk to both people in the vicinity of the engine and to the engine itself. In
order to avoid this risk, the spark plug connector bayonet catch must be secured correctly before the en-
gine is started!
2. In the pressed position, turn the arrow to both green dots or the 1 and release. The bayonet catch will be
locked when it can no longer be turned or lifted.

Use the groove as the point of application and press down using two fingers.
3. Following the locking of the bayonet catch, it is important that the spark plug connector is connected to the
spark plug electrically. This is achieved by pressing the insulator in the direction of the spark plug until it
locks with a noticeable click.
If the spark plug connector is connected to an R or M coil:

Plug the connector into the R or M coil and then hand-tighten the union nut.
8.2.3 Life saver spark plugs without bayonet fitting

▪ Insert the spark plug connector into the spark plug well, ensuring that the two valve cover studs pass
through the two holes in the flange on the spark plug connector.
▪ The spark plug connector must be placed on the spark plug.
▪ Put the nuts on the two valve cover studs and tighten them.
▪ Plug the connector into the R or M coil and then hand-tighten the union nut.
If the spark plug connector is connected to an R or M coil:

Plug the connector into the R or M coil and then hand-tighten the union nut.

8.3 High-voltage cable

Ensure that the high-voltage cable stars (distance pieces) are correctly mounted to prevent the high-voltage
cables and engine paintwork from being damaged – see pictures below.
Right Wrong
9 Checking following recommissioning

After recommissioning, the ignition voltage requirement must be checked and, if necessary, the values must be
noted down in the spark plug data (E 0309) table.
Start the engine and run at full-load operation.
After at least 30 minutes of full-load operation, check the voltages once more.
All the voltages should be in the range of ± 3 kV from average. If the voltage at one or more plugs is slightly
under this limit but the engine does not misfire at full load or in the range between full load and idling speed,
leave them as they are. Alternatively, the electrode distance of spark plugs with low voltage must be increased
by approximately 0.05 mm. The voltage must then be retested.
If the voltage is above this range, the engine must be shut down at the first opportunity. Reduce the electrode
distance slightly with respect to the first setting.
If misfiring is detected after renewed commissioning, this could be caused by the ignition-voltage requirement
being too low due to the electrode distance being too small, an incorrect engine setting or an incorrect fuel gas
(CH4:CO2) ratio (particularly in the case of landfill gas of varying gas quality).

Inspection and maintenance work: IW 8040 A6
In-line air filter - Type 6 F/ engines
1 General ............................................................................................................................................................. 1
1.1 Type 6 F, G and H engines ............................................................................................................................................ 1
2 Filter replacement .......................................................................................................................................... 1
2.1 Opening the in-line air filter ......................................................................................................................................... 2
2.2 Removing the old filter cartridge .............................................................................................................................. 3
2.3 Inserting a new filter package .................................................................................................................................... 3
2.4 Closing the in-line air filter ........................................................................................................................................... 5
2.5 Tensioning the filter package ..................................................................................................................................... 5
3 Remarks ........................................................................................................................................................... 6
3.1 Greasing all parts to be tightened ............................................................................................................................ 6
3.2 Definitions ............................................................................................................................................................................ 6
1 General
1.1 Type 6 F, G and H engines

If the underpressure indicator value exceeds 2.5 kPa, you should replace the filter cartridges (after 2,000 Oh at
the latest – i.e. the replacement interval to be expected) [see photograph of type 6 engine differential pres-
sure manometer].
Type 6 engine differential pressure manometer
2 Filter replacement

Author: TET/Lang Responsible: TET Release date: 27.07.2010
When replacing the in-line air filter, each side must be replaced (one after the other). [see illustrations below]
Symbolic picture → In-line air filter with two air-intake pipes on J620E
Symbolic picture → In-line air filter with two air-intake pipes on J624 (type 6 G engine)
2.1 Opening the in-line air filter

To open the in-line air filter, the nut and check nut must first be loosened from each other and then screwed
against each other again (e.g. at the end of the threaded rod) [see illustration below]
Subsequently, unscrew the threaded rod until just before the stop, fully loosening the filter package.

Nut/check nut to secure and/or tighten/loosen the filter package

Now that the filter package is in loosened condition, loosen the quick-release locks and turn the upper shell
upward. The upper shell must rest in a stable position on the second in-line air filter.
2.2 Removing the old filter cartridge

Remove – starting at the front – the end plate/adapter plate and/or the filter element from the lower shell [see
illustration: Filter package with end and/or adapter plates]
Clean the pipe and/or the transition pieces to the gas mixer if necessary. When changing filters, make absolute-
ly sure that dirt cannot reach the clean-air side. If required, remove any dirt thoroughly.
2.3 Inserting a new filter package

Insert – starting at the back end – the filter element and/or end plate/adapter plate into the lower shell. [see
illustration: Filter package with end and/or adapter plates]

Filter package with end and/or adapter plates
Check that all filters are seated correctly on the sealing faces
When doing so, make sure that you position the adapter plates - even when untensioned – as parallel as possi-
ble to and in full contact with the sealing faces [see illustration: Check that all filters are seated correctly on
the sealing faces]
After positioning the end plate, screw the central threaded rod in again until the filter package is in position but
not pretensioned.
Check every seal for its correct fit before closing the upper shell.

2.4 Closing the in-line air filter

Lower the upper shell to close the filter. When doing so, make sure that the cut-outs in the upper shell fit over
the locking projections (front) and/or the end-plate projections (back).
Next, close the quick-release locks in loosened condition [see illustration below]
Closed in-line air filter with correctly fitted locking projections
2.5 Tensioning the filter package

To correctly tension the filter package, turn the threaded rod manually until it has no play left (i.e. lightly tensioned).
Subsequently, tension the filter package to 29mm for J624/J620 and/or to 22mm for J616/J612. If you en-
counter an unusually high tightening torque despite the fact that the prescribed tensioning distance has not
yet been reached, you must reassemble the filter package and repeat the tensioning procedure. In that case,
one of the filter elements has probably been positioned incorrectly.
When pre-assembling the in-line air filter, check the correct tensioning of the rear element by using the check-
ing distance between the filter cover and diffusor. This distance must not exceed 6-8mm when correctly tensioned.
During service, this check is generally not possible as the rear of the filter package can only be accessed during
pre-assembly of the in-line air filter (that is to say, when the in-line air filter is removed from the engine).
Also check the correct tensioning of the front using a flashlight (visual inspection).
Finally, loosen the nut and check nut at the end of the threaded rod and screw these against each other again
at the star-shaped closing plate (stop) to really lock the filter package in place.

3 Remarks
3.1 Greasing all parts to be tightened

The stainless steel threaded rod and its sealing face at the end plate of the first filter element must be properly
greased at all times to prevent excessive chafing and/or clamping. To that end, a suitable grease for stainless
steel must be used. [see illustration below]
Greasing the threaded parts
3.2 Definitions
front ... always in the direction of the air flow at the front (at the intake grate)
back ... always in the direction of the air flow at the back (at the gas mixer)

Inspection and maintenance work: IW 8046 0
Pre-combustion chamber gas compressor
1 Maintenance after initial commissioning .................................................................................................. 1

1.1 Change oil ............................................................................................................................................................................ 1
1.2 Retightening bolts ............................................................................................................................................................ 1
1.3 V-belt tension ..................................................................................................................................................................... 1
2 Regular maintenance .................................................................................................................................... 1
2.1 Oil level / oil pressure ...................................................................................................................................................... 2
2.1.1 Oil level 2
2.1.2 Oil pressure 2
2.2 condensate drain ............................................................................................................................................................. 2
2.2.1 Condensate drain valves 2
2.2.2 Condensate drain 2
2.3 Gas filters .............................................................................................................................................................................. 2
2.4 Change oil ............................................................................................................................................................................ 2
2.5 Dirt pan / V belt .................................................................................................................................................................. 3
2.5.1 dirt pan 3
2.5.2 V-belt tension 3
2.6 Overhaul ............................................................................................................................................................................... 3
2.6.1 Piston rings 3
2.6.2 Gas gland packing rings 3
2.6.3 Oil glands 3
2.6.4 Valves 3
3 manufacturer's documents .......................................................................................................................... 3
1 Maintenance after initial commissioning
1.1 Change oil

Change the compressor oil according to the lubricant chart in the manufacturer's instructions.
Oil quantity filled:
TEL 50 ..... 0.75 litres [1.387 G]
TEL 60 ..... 2.75 litres [1.387 G]
TEL 80 ..... 5.25 litres [1.387 G]
1.2 Retightening bolts

Retighten the cylinder cover and pressure flange bolts with 26.5 Nm [19.5 lb ft].
1.3 V-belt tension

Check the V belt tension – see manufacturer's instructions.
2 Regular maintenance
Intervals every
Maintenance work Point Weekly 2000 Oh 6000 Oh 10,000 Oh 30,000 Oh
w Oil level / oil pressure 2.1 ■
w condensate drain 2.2 ■
2 Gas filters 2.3 ■
6 Change oil 2.4 ■

Intervals every
Maintenance work Point Weekly 2000 Oh 6000 Oh 10,000 Oh 30,000 Oh
10 Dirt pan / V belt 2.5 ■
30 Overhaul 2.6 ■
2.1 Oil level / oil pressure
2.1.1 Oil level

Check the oil level (the centre of the inspection glass marks the normal level).
2.1.2 Oil pressure

Check the oil pressure (between 0.5 [7.25 psi] and 1 bar [14.5 psi] with engine at operating temperature (when
the engine is not at operating temperature, it may briefly exceed 1 bar [14.5 psi]).
2.2 condensate drain
2.2.1 Condensate drain valves

Briefly open the condensate drain valves on the separators and the pressure vessels while under pressure.
2.2.2 Condensate drain

Check the operation of the float condensate drain.
If condensate is present when opening the manual drain valve which is not being discharged, dismantle and
clean the condensate drain.
2.3 Gas filters

Replace the gas filter of the air compressor.
2.4 Change oil

Change the compressor oil according to the lubricant chart in the manufacturer's instructions.
Oil quantity filled:
TEL 50 ..... 0.75 litres [1.387 G]
TEL 60 ..... 2.75 litres [1.387 G]
TEL 80 ..... 5.25 litres [1.387 G]

2.5 Dirt pan / V belt
2.5.1 dirt pan

Clean the dirt pan before the float condensate drains.
2.5.2 V-belt tension

Check the V belt tension – see manufacturer's instructions.
2.6 Overhaul
2.6.1 Piston rings

Replace the piston rings.
2.6.2 Gas gland packing rings

Replace the gas gland packing rings and the sleeves.
2.6.3 Oil glands

Replace the sleeves in the oil glands.
2.6.4 Valves
Check the valves and, if required, replace them.
3 manufacturer's documents
See description - Operation!

Leak testing of all pipes and components carrying fuel
gas and mixtures
Interval every
Maintenance work 2,000 Oh 8,000 Oh
- leak test ■ *) ■ **)
*) for biogas, landfill gas, associated petroleum gas, mine gas and special gases (e.g. wood gas) only
**) only for natural gas
1 Leak testing of all pipes and components carrying fuel gas and mixtures
1.1 Precautions
The test covers all pipes and components carrying fuel gas and mixtures under overpressure in the GE Jen-
bacherproduct range:
▪ Connection points with the main shut-off device, gas pressure controllers, gas meters, gas appliances, gas
connecting lines, fittings and fuel-gas carrying pipes.
▪ Branch and device connecting lines.
▪ Locks on test openings
▪ Connection points carrying mixture to the engine (e.g. sealing connections before and after mixture cooler.
▪ Etc.
1.2 Procedure
Testing the module containing fuel gas or mixture under operating pressure in accordance with current safety
regulations. The test covers all pipe connections, fittings and flanges.
Constraints
▪ Local inspection using the bubble emission technique as per EN 1593:2004-06
▪ Surface preparation: the area must be free of weld spatters, slag, corrosion, oil, grease, dust, coloured mark-
ings and must be dry.
▪ Test pressure: operating pressure in the section in question
▪ Luminous intensity: 350 lx to 500 lx
▪ Testing agent: foaming agent as per DIN 30657:1983-02
Test procedure:
1. Introduce test gas into the pipe.
2. Holding (stabilisation) time at least 2 minutes.
3. Spray or brush on the testing agent
A test duration of at least 3 minutes must be maintained in order to observe the slow foam formation at
any small leaks. If necessary, apply the testing agent again.
4. The surfaces should be inspected from a distance of less than of 0.6 metre at an angle greater than 30 de-
grees (1/6 rad).
A mirror and magnifying lens can be used to improve the observation.

Author: Doku./Boxleitner Markus Responsible: TET/ Ast Gabor Release date: 06.06.2011
Leak testing of all pipes and components carrying fuel
gas and mixtures
If no foaming occurs, the connections are free of leaks. A foam mushroom growing at a certain location
must be interpreted as representing a leak. If leaks occur, replace the relevant components, e.g. gaskets,
and repeat the leak test.
Note: Undoing and/or tightening bolted joints and connecting pieces is prohibited unless the system has
been completely depressurised!
Enter details of the tests and work carried out in the Data Entry Sheet for leak tests for pipes
and components carrying fuel gas and mixtures (E 8049).

Author: Doku./Boxleitner Markus Responsible: TET/ Ast Gabor Release date: 06.06.2011
Flexibly-mounted coupling housing
Interval
Maintenance work 4000 Oh 20,000 Oh
4 Measure the axial play ■
20 Replace the rubber elements in the coupling housing ■
1 Measure the axial misalignment of the coupling housing on elastic bearings
Measure the gap in 3 places on the circumference. A = 12 o'clock; B = 9 o'clock; C = 3 o'clock - Position
Guide value: ~12 mm
Operational data on the flexibly-mounted coupling housing (E 8079 6)
Enter measured data in the Operational data flexibly-mounted coupling housing (E 8079 6) table.
The measured values must be within ± 2 mm tolerance of the value measured during commissioning (see Oper-
ational data E 8079 6), otherwise the radial alignment of the generator must be corrected as described below.
2 Correcting the generator position

Use shim plates to correct the generator height and subsequently recheck the axial offset of the coupling hous-
ing on elastic bearings.

Author: Doku./Bilek Responsible: TEM/Waldron Paull Release date: 17.12.2010
Flexibly-mounted coupling housing
① Shim plate

Author: Doku./Bilek Responsible: TEM/Waldron Paull Release date: 17.12.2010
Condensate removal in the fuel-gas system
.
Interval: every
Inspection Work/ Maintenance Work Point 2000 Oh when required
2 Automatic condensate drain – leak test 1.1 ■*)
- Manual condensate drains – condensate removal 1.2 ■
*) We suggest at least quarterly (not in the GEJ scope of supply)
Before performing any work on the plant, the maintenance staff must ensure that the relevant safety pre-
cautions have been observed regarding the activities to be carried out.
1 Removal of condensate
Cooling of gases in the fuel-gas system can cause the entrained water in the gas to condense, with the result-
ing formation of condensate. The condensate must be drained gastight from the gas system and disposed of in
accordance with its composition and local regulations (e.g. surface-water protection regulations, explosion pro-
tection)!
1.1 Automatic condensate drain

Automatic condensate drains are not supplied by GE Jenbacher!
Automatic condensate drain equipment must be checked for gas-tightness in accordance with the manufactur-
er's information and local regulations in force.
1.2 Manual condensate drain

All drains to remove condensate manually during maintenance which are part of GEJ’s scope of supply (Inter-
face F, Technical Diagram) are in principle fitted with a drain valve (ball valve) and an additional plug (screw plug).
DANGER! A manual condensate drain must in principle only be activated under the following conditions:
▪ Safety instructions as specified in TI 2300-0005 are observed
▪ personal protective equipment is used (gas detector)
▪ the engine is shut down
▪ the gas supply is closed
▪ the gas system has been inerted according to accepted technical regulations
▪ the venting conditions are satisfactory
▪ the pressure in the gas system is discharged
DANGER! Explosion hazard due to escaping gas!
In cases where the fuel gas may contain toxic elements (H2S, NH3etc.), you must also take into account the addi-
tional effect of the escape of toxic substances.
DANGER! Before putting the plant back into operation, make sure that
▪ the drain valve (ball valve) is fully closed,

Author: Doku./Boxleitner Responsible: Laucher Roland Release date: 19.10.2011
Condensate removal in the fuel-gas system
▪ the screw plug is fitted,

▪ the gastightness of the manual drain line is ensured.
A leak test in accordance with IW 8049 0 is necessary before the plant is put back into operation!

Author: Doku./Boxleitner Responsible: Laucher Roland Release date: 19.10.2011
Exhaust gas system condensate drain line
Interval: every
Inspection Work/ Maintenance Work monthly when required
m Checking the exhaust gas system condensate drain line ■
- Checking the exhaust gas system condensate drain line ■
Before performing any work on the installation, the maintenance staff must ensure that the relevant safe-
ty precautions have been observed regarding the activities to be carried out.
1 Removal of condensate
Cooling of the flue gases in the exhaust gas system can result in the formation of condensate. The condensate
must be drained from the exhaust gas system and disposed of in accordance with its composition and local
regulations (e.g. surface-water protection regulations).
1.1 Condensate line

Check the condensate drain and connection for deposits.
▪ if necessary, clean it
▪ so that the condensate can flow freely through the drain.
1.2 Condensate vessel

Check the water level in the condensate vessel
▪ top up with water as necessary
1.3 Condensate/neutralisation granulate reservoir

Check the built-in filters and the neutralisation granulate for deposits
▪ and replace if necessary.
▪ Filters fully functional
1.4 Checking the exhaust gas back pressure monitoring (if installed)
Remove the screw plug
▪ check for amount of condensate produced
Check the line for deposits
▪ if necessary, clean it
▪ Screw on the plug
▪ condensate amount is OK
▪ Line fully functional

Author: Doku./Bilek Responsible: TSC/Burkhardt Wolfgang Release date: 03.05.2011
Maintenance work: W 0200 M6ef
Control rod assembly/throttle valve/actuator
J 612-620
Interval: every
Maintenance work Point 2000 Oh 20000 Oh 30,000 Oh
02 Regulator linkage - checking/Re-lubrication 1. ■
20 Overhaul throttle valve 2. ■
30 Overhaul actuator 3. ■
1 control rod assembly

Unscrew the plug connector for the power supply from the actuator.
1.1 Inspection
Check that the throttle valve is operating smoothly.
If the joints show excessive play, replace them (guide value: approx. 10,000 operating hours).
1.2 Regreasing
Grease uncovered joints and bearing locations using a suitable grease gun.
When relubricating, apply the grease to the left and right-hand side of the bearing gap so that the grease film
protects against dust.
1.2.1 Grease type

Renolit Duraplex EP2

Author: Doku./Bilek Responsible: TCC Greuter/ TEM Silberberger Release date: 24.03.2011
2 Throttle valve
Replace the throttle-valve bearing and O-ring.
2.1 Setting for throttle valve for type 6 engines, max. 20 cylinders with HEINZMANN actuator, type STG30
or STG40

① The lever on the throttle valve is up against ③ Default setting

the stop screw, while the throttle valve is open
2 mm
② Max. angular displacement ④ Inner stop on actuator
On the Heinzmann actuator, the rod is set so that when in the zero position the throttle is up against the stop
and the controller arm is preloaded by about 3 .
Zero position:valve is opened 2.0 mm and the lever is at the stop screw.
① Insert a 2 mm wire or drill and adjust the stop screw on the lever
Adjust the control rod assembly as shown in the above drawing. The ball joints must be lubricated before assembly.
The STG30 and STG40 actuators are identical in terms of housing dimensions and assembly.
To adjust the zero position of the throttle valve: fit the lever on to the throttle-valve shaft as shown in the above
drawing. The throttle valve must be opened 2.0 mm at zero position by mechanical means (e.g. by inserting a
wire or drill). To adjust the zero position stop screw, the throttle valve lever must be just touching the stop screw.
Adjust the zero position of the actuator lever as shown in the above drawing.
Caution: The control rod assembly must be adjusted so that, when at zero position, the throttle valve is at the
stop and the lever on the actuator is preloaded by approx. 3° (actuator scale). This prevents the actuator from
running against its own internal stop when in zero position.
Tighten the locknuts securely against the control rod assembly and ensure that the length of the control rod
assembly can no longer be adjusted.

When the actuator is fully open (100%), the control rod assembly should be overextended, i.e. the actuator
must return the throttle valve securely to zero position.
The ball joints must be lubricated before assembly. After assembly, please check that all screw connections are
still secure and that the control rod assembly operates smoothly!
3 Actuator
Have the actuator overhauled by a specialist company authorised to carry out this work.

Maintenance work: W 0203 A6
Engine cooling water pump
Interval: every
10 Mechanical seal - replace ■
30 Have the engine cooling water pump overhauled by a specialist ■
company authorised to carry out this work.

Maintenance work: W 0303 M0
Ignition
1 Maintenance Instructions ............................................................................................................................ 1

1.1 List of Technical Instructions used ........................................................................................................................... 1
1.2 Maintenance intervals for ignition system components ............................................................................... 2
1.3 Check list for the ignition system mechanical assembly ............................................................................... 3
1.4 Check list for the ignition system electrical wiring .......................................................................................... 4
1.5 Check list for the ignition system function test ................................................................................................. 4
2 Appendix .......................................................................................................................................................... 5
2.1 Checking the mechanical assembly and electrical wiring ............................................................................ 5
2.2 Checking the spark plug connector ...................................................................................................................... 11
2.2.1 Inspection and replacement of the spark plug connector seal 11
2.2.2 Measuring the spark plug connector resistance 13
2.3 Cleaning the pick-up .................................................................................................................................................... 14
2.4 Checking the ignition point ....................................................................................................................................... 15
2.5 Measuring the ignition voltage ............................................................................................................................... 16
2.5.1 High-voltage measurement with high-voltage measuring pliers 17
2.5.2 Checking the high-voltage output of an ignition coil 17
2.6 Ignition system self-test ............................................................................................................................................. 18
Please observe the safety and hazard information in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.
For safety reasons, the high-voltage cable and the insulator must not be touched while the engine is in
operation or during an ignition self-test. An exception to the above is touching both components with a
properly earthed tool such as high-voltage measuring pliers.
Further safety instructions can be taken from the Technical Instructions listed in the document.
1 Maintenance Instructions
Checks on the mechanical assembly, electrical wiring, ignition system operation and components must be car-
ried out in accordance with the following maintenance instructions and current Technical Instructions for the
ignition system in question.
The ignition point must always be checked with the aid of a suitable measuring instrument (strobe light, LED
timing light, etc.) (see Section 2.4 - Checking the Ignition Point - or the Technical Instructions for the ignition
system in question) at initial commissioning and whenever the ignition system is replaced or the parameters
affecting the ignition point (RESET position, ignition point limits, mA signal for adjusting the ignition point, etc.)
are changed.
When components are replaced, the current regulations regarding the disposal requirements for old electrical
and electronic equipment must be observed (WEEE coding, see also TI 2300-0005 - Safety Instructions).
1.1 List of Technical Instructions used

List of Technical Instructions for ignition systems
Ignition / Ignition components / miscellaneous Technical Instruction No.
IC500 1502-0037
IC900, 910 and 912 1502-0038
IQ724 1502-0043
IQ750 1502-0044
DISN700 1502-0045

Author: Doku./Provin Responsible: Gschirr Arno Release date: 12.12.2011
Ignition
Ignition / Ignition components / miscellaneous Technical Instruction No.

DISN801 1502-0046
IQ250 1502-0049
IQ250 Single Pick-up Version 1502-0057
IQ250S-Dual Pick-up, shielded version 1502-0060
Dual ignition system IC900/IC910/IC912 1502-0062
IC100 1502-0063
IC920, IC921 and IC922 1502-0067
MORIS 1502-0068
MPM (MORIS Power Module) 1502-0069
Rail System 1502-0070
SAFI (Sensor Actor Function Interface) 1502-0071
SPA24 (SAFI pick-up amplifier) 1502-0072
MIC950 1502-0073
Monic Measuring Adapter MA1 1400-0103
monic-DIA.NE and DIA.NE XT 1400-0104
monic-msd 1400-0106
Checking the ignition system with FLUKE 99 DSO 1400-0114
High-voltage pincers (HV pincers) 1400-0149
Checking the ignition system with FLUKE 123 DSO 1400-0151
Spark plug check / spark plugs IW 0309 M0
Diane user manual (XT, XT3)
1.2 Maintenance intervals for ignition system components

List of maintenance intervals for ignition system components
Component Test according to the information given or reference to sub- Maintenance
points in the maintenance instructions interval after
operating
hours
Central ignition system Test after the maintenance interval, a fault or part replacement in 8000 Oh inter-
accordance with Technical Instructions and maintenance instruc- val
tions.
Modular ignition system Test after the maintenance interval, a fault or part replacement in 8000 Oh inter-
(MORIS) accordance with Technical Instructions and maintenance instruc- val
tions.
Ignition coil Test after the maintenance interval, a fault or part replacement in 8000 Oh inter-
tions.
The high-voltage output is only measured in the event of a fault
(see Section 2.5).
Spark plug connector in Visual inspection for dirt, condition of the seal in the spark plug con- with
general nector, condition of the electrical contacts to the ignition coil and Spark plug
spark plug (dirt, oxidation, contacts seized) at every spark plug main- maintenance
tenance interval. interval

Ignition
Component Test according to the information given or reference to sub-

Maintenance
points in the maintenance instructions interval after
operating
hours
Spark plug connector seal Replace the spark plug seal after a maximum of 6000 Oh (see the 6000 Oh inter-
replacement instructions in Section 2.2.1 of the Appendix) val
Pick-up Clean any swarf off the magnetic component in the pick-up at a 2000 Oh inter-
maximum of 200 Oh after initial commissioning, and thereafter ev- val
ery 2000 Oh (see the cleaning instructions in Section 2.3 of the Ap-
pendix).
Cabling rails Test after the maintenance interval, a fault or part replacement in 8000 Oh inter-
tions.
Cabling Test after the maintenance interval, a fault or part replacement in 8000 Oh inter-
tions.
1.3 Check list for the ignition system mechanical assembly

List of test points for the mechanical inspection on the ignition system
OK
Present
Test points for mechanical inspection Y/N Y/N
Ignition system properly mounted? Check in accordance with the corresponding Technical Instruc-
tions (See the table in Section 1.1).
Vibration damping elements in the ignition system or cabling rails present and OK? Check for me-
chanical damage, material ageing due to environmental influences and correct installation in ac-
cordance with the corresponding Technical Instructions.
System seals present and OK?
Check for mechanical damage, material ageing due to environmental influences and correct in-
stallation in accordance with the corresponding Technical Instructions.
No visible mechanical damage found on the ignition system or its sub-components? Check the
ignition system, cabling rail, ignition coil, spark plug connectors, pick-up and cabling.
Check that all bolted joints on the mounting system and components are secure.
Were there any engine shutdowns cause by pick-up faults in recent operating hours? Distance
between pick-ups and trigger source correctly set in accordance with the Technical Instructions?
Pick-up free of metallic deposits?

Ignition
1.4 Check list for the ignition system electrical wiring

List of test points for electrical testing of the ignition system wiring
OK
Present
Test points for inspecting the electrical wiring Y/N Y/N
Is the ignition system earthed in accordance with the requirements of the Technical Instructions
and as specified in the circuit diagram (ignition system earthed; cabling rails earthed at both
ends, etc.)? See also Appendix 2.1.
Check that there is no break in the earthing system (vibration damper elements bridged, etc.)
Check that all earth connection bolted joints are secure.
No damage at all found to plug connectors, sockets or cabling.
Check the contact areas for corrosion or dirt contamination.
Cabling properly connected. Check that screw plug connectors, terminal connections and other
plug connections are secure.
All the power supplies present?
1.5 Check list for the ignition system function test

List of test points for the ignition system function test
OK
Present
Test points for the ignition system function test Y/N Y/N
Checking the ignition point
Before starting for the first time, as part of commissioning or re-commissioning, after replacing
the ignition system or pick-ups, check all the parameters in general and particularly the parame-
ters for the reset position, ignition point limits and ignition point adjustment (mA signal).
The ignition point must be checked during the starting procedure with the gas supply turned off
(see the Technical Instructions or operating instructions) and corrected, depending on how far it
deviates from the set point (see Section 2.4 in the Appendix).
Do not run the engine unless the ignition point has been checked!
Failure to observe this can lead to severe engine damage or hazards to persons. Please observe
the safety information in the relevant Technical Instructions and operating instructions!
High-voltage measurement (ignition voltage check)
Check the condition of the spark plugs with the aid of a high-voltage measurement.
A high-voltage or high-voltage output measurement can be used for fault diagnostic purposes
(see Section 2.5 - Ignition Voltage measurement - in the Appendix).
Self-test
Most ignition systems include a self-test capability to check the basic functions. This can be car-
ried out either from the visual display or a specific tool for the ignition system. Corresponding
instructions and safety instructions can be taken from the relevant Technical Instructions (see
the Table in Section 1.1) or the operating instructions.

Ignition
2 Appendix
2.1 Checking the mechanical assembly and electrical wiring

Central ignition systems are installed on a mounting bracket with vibration dampers for vibration decoupling.
When vibration dampers are used, the ignition system must be earthed with an earth cable at a suitable loca-
tion on the system to ensure that the equipment is properly earthed. When checking the condition of the vibra-
tion dampers, the earthing should be checked as well.
The following illustrations show an MIC950 installed on a mounting bracket with the necessary earth connections.
Central ignition system mounting with vibration dampers and earth connections (bridging the vibration dampers)
The cabling rails, mounting elements and vibration dampers must be checked to ensure that the mechanical
fastenings are in good condition.
Detailed view of a C-coil cabling rail mounting on a Type 3 engine

Ignition
Detailed view of a MORIS ignition system mounted on an engine with metal cushion-type dampers
Check the installation of the ignition output cables in the cabling rail for any damage to the screw plug connec-
tors, strain relievers and cable sheath. Check the electrical contacts for corrosion / oxidation.
Cabling from the ignition system to the cabling rail

Ignition
MORIS ignition system earthing, checking the cabling at the rail
When fitting spark plug connectors on Type 3 engines, make sure the connector latches onto the SAE contact
on the spark plug. Fit the rubber sleeve over the spark plug well. This prevents vibratory motion by the spark
plug connector and any consequential damage to the spark plug contact area.
Spark plug connector mounting on a Type 3 engine (l.), SAE spark plug latch contact (r.)
Spark plug connectors for Type 4 and 6 engines are fastened by means of a flange on the rocker cover. The
maximum tightening torque for the mounting bolts is 20 Nm.

Ignition
Spark plug connector mounting on a Type 4 engine
If a spark plug connector is fitted with a spring contact, the spring resistance must be felt during assembly. If it
is not, the spring contact in the spark plug connector must be checked. A spring contact is also used at the coil.
Check that the screw connection to the coil is securely seated.

Ignition
Ignition cable, knock sensors and thermocouple mountings
The mountings of the ignition coil, SAFI, knock sensors, thermocouples and presence of the required seals must
also be checked. The corresponding tightening torques can be taken from the relevant Technical Instructions.
Spring contact on a spark plug connection for Type 4.6 engines, left: coil contact, right: spark plug contact

Ignition
The following Figures show a typical pick-up mounting and cabling on an engine. One of more pick-ups may be
necessary, depending on the engine type and ignition system. They are mounted on the engine by a thread in
the gear train housing and a lock nut. A thread adapter may be necessary in some cases
Mounting of the camshaft pick-up (left) and starter ring gear (trigger) / reset pick-up (right)
Mounting of the camshaft pick-up (left) and starter ring gear pick-up (trigger) / reset pick-up (right)
The connector plug for the active camshaft pick-up is fitted with two LEDs; the green LED indicates the pres-
ence of the 24 V supply and the yellow LED shows the camshaft signal.
When checking, or in the event of a fault, clean any metallic deposits off the pick-up and make sure the gap to
the trigger source is correctly set (see Section 2.3 - Cleaning the pick-up and relevant Technical Instructions).
Caution! Make sure when installing the pick-up that no mechanical collision occurs with the trigger source,
such as the starter ring hear for the trigger signal, bolt head for the reset and/or camshaft signal (see also the
section on pick-up adjustment in the Technical Instructions for the ignition system).

Ignition
Check the pick-up wiring for damage and to ensure that the plug connectors are screwed together correctly.
2.2 Checking the spark plug connector

Interruptions to the high-voltage line, faulty interference suppression elements or excessively high resistances
at contact areas can lead to power losses in the ignition system and in turn to impaired ignition behaviour by
the engine, which ultimately can result in misfiring or complete failure of a cylinder.
Check the spark-plug connector for trouble-free operation as part of the ignition system maintenance at the
set intervals or in the event of a fault.
The spark plug connector should be clean from any dirt, particularly the isolator. The condition of the spark
plug seal ring (corrugated ring) must also be checked (see Section 2.2.1 - Inspection and Replacement of the
spark plug connector seal)
In the event of a fault, check the resistance with an ohmmeter (see 2.2.2. - Spark plug connector resistance
measurement).
2.2.1 Inspection and replacement of the spark plug connector seal

Due to the prevailing temperatures at the spark plug, the material of the corrugated seal ring hardens over
time. This causes the seal to fail in its essential function, namely keeping the contact to the spark plug and its
insulator free of dirt contamination.
Dirt at the spark plug connector insulator or the spark plug itself can result in arcs tracking across the insulator
and subsequently to misfiring.
➔ The maintenance instructions therefore specify that the condition of the corrugated seal ring must always
be inspected visually as part of the spark plug maintenance, and the seal ring replaced if damaged.
New corrugated seal ring (part no. 354846) Corrugated seal ring after approx. 6000 Oh
The average service life of the corrugated seal ring is between 6,000 and 8,000 operating hours.
➔ To ensure proper operation of the spark plug connector and spark plug, the corrugated seal ring must be
replaced after no more than 6,000 operating hours as part of the ignition system maintenance and in conjunc-
tion with the spark plug maintenance.
➔ Spare part number of the corrugated seal ring: 354846 – "Spark plug seal ring, corrugated, red"
Using a suitable tool, such as screwdriver, lever the seal ring out of the insulator part of the spark plug connec-
tor. The ring may break into several pieces, depending on the condition of the material. After removing the ring,
clean the groove in the spark plug connector where it sits.

Ignition
When the groove is cleaned, fit a new seal ring by pressing the sides of the ring together and inserting it into
the groove provided. Never use a sharp implement for this, as this would damage the new seal ring mechanical-
ly from the outset.
The illustrations below show the procedure for replacing the seal ring in the spark plug connector.

Ignition
Illustration sequence for replacing the corrugated seal ring.
2.2.2 Measuring the spark plug connector resistance

To check the resistance of a spark plug connector, a measurement must be carried out with a suitable ohmme-
ter. The entire resistance from the coil connection to the contact with the spark plug is measured. The total
resistance is 2 kOhm or 5 kOhm, depending on the spark plug connector type.
The measured resistance may not deviate by more than ±15% from the specified value. If the value is outside
the tolerance, the spark plug connector must be replaced.

Ignition
Measuring the resistance on a spark plug connector for a Type 3 engine (left) and Type 4 engine (right)
If there is any dirt or contact erosion, care must be taken to ensure a good contact at the measuring probes or
clips. If no suitable measuring probes are available for gaining access to the contact for the spark plug, contact
can be made using a screwdriver or a highly-conductive metal item (left-hand illustration - resistance measure-
ment on a spark plug connector for a Type 3 engine).
2.3 Cleaning the pick-up

Due to the mechanical wear at the gear train, metallic particles can accumulate on the pick-up magnets after
long periods of operation (left-hand illustration). This changes the magnetic circuit and signal amplitude of the
pick-up, which can in turn result in the ignition system tripping due to a pick-up fault.
The pick-up should therefore be inspected and cleaned as a precaution every 2,000 operating hours in accor-
dance with the maintenance instructions.
Important: The gap between the pick-up and the trigger source should be set correctly as specified in the appli-
cable Technical Instructions for the ignition system in question.

Ignition
Dirty pick-up (l.); cleaned pick-up without deposits (r.)
2.4 Checking the ignition point

The ignition point must always be checked on initial commissioning, and whenever the ignition system or pick-
up is replaced or the parameters affecting the ignition point are changed (RESET position, ignition point limits,
mA signal for varying the ignition point, etc.).
The ACTUAL ignition point is also checked to see whether it agrees with the SET ignition point. If this is not the
case, the ignition point must be corrected with the aid of the reset position.
Check the ignition point with a suitable measuring instrument (strobe light, LED timing light, etc.). The ignition
point is always measured at cylinder 1. Attach the ignition pick-up to the ignition of line cylinder 1 (left-hand
illustration). Adjust the ignition point on the basis of the measured deviation from the markings on the flywheel,
using the parameter for the reset position (right-hand illustration)!
Check the ignition point during the starting procedure with the gas supply turned off (see the Technical Instruc-
tions or operating instructions) and correct it depending on how far it deviates from the set point. Measure the
ignition point again during both no-load and full-load operation, and check it for any deviations.
Caution! The ignition point depends on the operating point of the engine and the individual ignition point set-
tings on each cylinder, and can vary during operation under load. This must be taken into account when check-
ing the ignition point.
Measuring the IP with a timing light (strobe lamp)

Ignition
DANGER
Do not run the engine unless the ignition point has been checked!
Failure to observe this can lead to severe engine damage or hazards to persons.
Please observe the safety information in the relevant Technical Instructions and oper‐
ating instructions!
2.5 Measuring the ignition voltage

The ignition voltage measurement gives information about the condition of the spark plugs and can also be
used for ignition system malfunction diagnostic purposes.
The high-voltage can be measured in two ways, either integrally from within the ignition system (MORIS and
the central ignition system with MONIC), or using high-voltage measuring pliers and an oscilloscope.
The display is shown on DIA.NE (XT, XT3). A more detailed description can be taken from the DIA.NE user manual.
High-voltage measurement with MORIS on a DIA.NE XT3
High-voltage measurement with monic (left: DIA.NE blue, right: DIA.NE XT)

Ignition
More detailed information can be taken from the Technical Instructions for MONIC, MORIS and DIA.NE (see the
Table of Technical Instructions in Section 1.1).
2.5.1 High-voltage measurement with high-voltage measuring pliers

The high-voltage measurement is used primarily to detect the adjustment intervals of the spark plugs. This is
described in detail in the Maintenance Instructions for checking the ignition voltage/spark plugs (MI 0309 M0).
High-voltage measuring pliers, GEJ part no. 340369, and a suitable oscilloscope are required for the high-volt-
age measurement. Reference is made to the appropriate Technical Instruction (see the table of Technical In-
structions in Section 1.1) for adjusting and measuring with a FLUKE 99 and 123 oscilloscope.
First, connect the earth terminal of the high-voltage pliers to a suitable earthing point in the vicinity of the spark
plug connector. Do not place the pliers over the high-voltage cable before they have been earthed. When doing
so, make sure that the high-voltage cable is fully enclosed over the entire length of the pliers.
Connect the BNC connection of the pliers to the corresponding input channel of the oscilloscope. After adjust-
ing the oscilloscope measurement settings, read off the measured value for the ignition voltage on the oscillo-
scope. The measurement must always be made during full-load operation.
General oscilloscope settings: 5 kV/DIV with 100µs/DIV, trigger level at 10 kV
High-voltage measurement with HV pliers and FLUKE 123 oscilloscope
2.5.2 Checking the high-voltage output of an ignition coil

The high-voltage output of an ignition coil should only be checked for diagnostic purposes in the event of a
failure and not at regular intervals!
Carry out the check by unplugging the high-voltage connector when the engine is at rest. When doing so, make
sure that no metallic parts come into contact with the high-voltage cable in order to avoid arcing to earth.
The self-test can be started afterwards and the high-voltage output checked on the display. The ignition coil high-
voltage output must reach at least 35 kV. If this is not the case, replace the coil.

Ignition
2.6 Ignition system self-test

Ignition systems include a self-test capability for diagnostic purposes which activates the ignition outputs to
test the operation of the ignition coils when the engine is at rest. If the ignition system possesses an integrated
high-voltage measurement facility, the ignition voltage and the ignition coil high-voltage output can be tested
simultaneously.
Depending on how it is incorporated in the control system (via the CAN bus or similar), the self-test can be start-
ed either from the control system/display or the ignition system diagnostics tool, as desired. In either case, the
self-test is ended automatically after 10 minutes.
The self-test can only be carried out if the machine is at rest. Make sure first that the gas supply is shut off. On
recent installations, the control system carries out a scavenging start automatically before activating the self-
test. If an engine speed occurs during the self-test, the test is ended automatically.
More detailed information on activating and evaluating the self-test can be taken from the Technical Instruc-
tions for the ignition system in question and the manual for the visual display.

Valve clearance
1 Checking valve clearance and wear (valve-stem projection) ................................................................ 1

1.1 Check and adjust valve play ....................................................................................................................................... 1
1.2 Measure the valve-stem projection ......................................................................................................................... 2
Interval: every
Maintenance work Point 2,000 Oh 4,000 Oh
02 Check and adjust valve play 1.1 ■
02 Inspect the cylinder-head cover O-ring. Replace, - ■
if required.
04 Measure the valve-stem projection 1.2 ■
1 Checking valve clearance and wear (valve-stem projection)

When adjusting the valve clearance, measuring the valve-stem projection and disassembling the cylinder-
head, the valves must be closed and the rocker arms must be unloaded.
Turn the crankshaft manually until the piston of the relevant cylinder-head is positioned in the top dead centre
(TDC, push rods and rocker arms are unloaded).
Check the valve-stem projection and valve clearance in this position.
1.1 Check and adjust valve play

Set values: Valve play
Intake valve 0.8 mm
Exhaust valve 1.0 mm
Intake valves:
The inlet-valve clearance is measured between the valve-stem end and the slide face.
Loosen the check nut of the adjusting screw (at the push rod), and insert feeler gauges at both valves.
Is the valve clearance equal at both inlet valves?

YES NO
OK! Loosen the check nut of the adjusting screw on the right inlet valve.
Adjust the adjusting screw until the valve clearance of the left-hand inlet valve
equals the clearance of the right-hand inlet valve.
Secure the adjusting screw using the locknut.
Please note:if the valve clearance measured is too large (e. g. in excess of 1.5 mm), carbon-deposit crusts may
have built up on the valve disc. Use a small rubber hammer and lightly tap the valve disc (Rotocap) to remove
the carbon deposits between the valve seat.
Set the valve play by adjusting the main adjusting screw.
You should now feel resistance if you try to move the feeler gauges.
Secure the main adjusting screw using the check nut and check the valve clearance once again.
Exhaust valves:
Loosen the check nut of the adjusting screw (at the push rod). Push the ball cup up and slide the feeler gauges
through the openings.
Set the valve play by adjusting the main adjusting screw.
Valve clearance
You should now feel resistance if you try to move the feeler gauges.
Secure the main adjusting screw using the check nut and check the valve clearance once again.
To avoid incorrect adjustments, always use two (2) feeler gauges at the same time when adjusting the ex-
haust or inlet valves!
1.2 Measure the valve-stem projection

You can determine the valve and valve seat wear by measuring the distance between the top side of the Roto-
cap and the plane face of the cylinder head. After completing the measurement, compare the NEW value with
the ACTUAL value.
The NEW value is entered in the initial commissioning data sheet.
In case of older engines, the NEW value is stamped on the cylinder head - see the following Figure.
If the total wear comes to 1.5 mm [0.06 in], the valve-inspection intervals should be halved.
If the total wear comes to 2.5 mm [0.10 in], the cylinder heads must be replaced.
① Exhaust valve ④ Intake valve

② Valve wear ④ NEW value exhaust valves
③ Valve seat wear ⑥ NEW value intake valves

Valve clearance
Enter the measured values in the Operational data – Valve-stem projection (E 0400) table.
Exhaust valves:
Clean the plane faces.
Measure the valve-stem projection from the exhaust-
valve Rotocap to the plane face of the cylinder head
using a depth gauge.
Intake valves:
Clean the plane faces.
If you can slide the depth gauge from the plane face
of the cylinder head over the Rotocap of the inlet
valve, the wear lies within the tolerance level.
If the Rotocap protrudes beyond the plane face of the
cylinder head, you should – as in the case of the outlet
valve - measure the valve-stem projection using a
depth gauge (from the Rotocap to the plane face of
the cylinder head).

Pre-combustion chamber / pre-combustion chamber
gas valve
1 Replacing the pre-combustion chamber gas valve ................................................................................. 2

1.1 Pre-combustion chamber gas valve types .......................................................................................................... 2
1.1.1 Type 6 engines (except for CMG >4% O2) 2
1.1.2 For type 6 engines special gas CMG >4% O2 2
2 Disassembly .................................................................................................................................................... 3
2.1 Drain off the engine cooling water completely. ................................................................................................. 3
2.2 Remove the prechamber gas valve. ........................................................................................................................ 3
2.2.1 Remove the valve cover and spark plug connector. 3
2.2.2 Remove the exhaust valve rocker arm 3
2.2.3 Remove the spark plug sleeve extension 4
2.2.4 Remove the exhaust valve rocker arm 6
2.2.5 Remove the prechamber gas valve 6
2.3 Remove the spark plug .................................................................................................................................................. 7
2.4 Remove the prechamber retaining bracket ........................................................................................................ 7
2.5 Remove the spark plug and prechamber assembly ........................................................................................ 8
3 Inspection / cleaning ..................................................................................................................................... 9
3.1 Clean the O-ring seating surfaces in the cylinder head ................................................................................. 9
3.2 Clean the prechamber mating surface in the cylinder head .................................................................... 10
3.3 Clean the prechamber bore and the combustion chamber ..................................................................... 11
3.4 Clean the prechamber ................................................................................................................................................ 12
3.5 Clean the spark plug sleeve ...................................................................................................................................... 12
3.6 Inspect the prechamber and spark plug sleeve ............................................................................................. 12
3.6.1 Pre-combustion chamber abrasion test 12
3.6.2 Spark plug sleeve abrasion test 14
3.6.3 Inspecting the spark plug sleeve 15
4 Assembly ........................................................................................................................................................ 16
4.1 Preliminary assembly of the prechamber ......................................................................................................... 16
4.2 Preliminary assembly of the spark plug sleeve ............................................................................................... 17
4.3 Preliminary assembly of the prechamber and spark plug sleeve .......................................................... 18
4.4 Fit the prechamber and spark plug sleeve assembly .................................................................................. 18
4.5 Fit the prechamber retaining bracket .................................................................................................................. 20
4.6 Fit the exhaust valve rocker arm ........................................................................................................................... 23
4.7 Check the valve clearance ........................................................................................................................................ 24
4.8 Fit the spark plug sleeve extension ....................................................................................................................... 25
4.9 Replace the spark plug joint ring ........................................................................................................................... 25
4.10 Fit the valve cover ......................................................................................................................................................... 26
4.11 Fill up with engine cooling water to the specified pressure ...................................................................... 26
4.12 Visual inspection for leaks ......................................................................................................................................... 26
Interval: every
Maintenance work Point 6,000 Oh
6 Replace the pre-combustion chamber gas valve 1. ■
6 Inspect the pre-combustion chamber and spark 3. ■
plug sleeve

Author: TEBM/Rangger Responsible: Entwicklung Release date: 13.07.2011
gas valve
1 Replacing the pre-combustion chamber gas valve
1.1 Pre-combustion chamber gas valve types
1.1.1 Type 6 engines (except for CMG >4% O2)

All type BR6 engines (except for CMG >4% O2) have been fitted with two equivalent valves, Part No. 433894 or
Part No. 389588. Within the one and the same engine, only valves with the same Part No. may be assembled.
2kJ Prt. No. 433894 with two turns at screw connec-

tion.
Tightening torque: 30Nm
① Manufacturing date and 3-5 figure serial number

on the hexagon.
ER system Prt. No. 389588
No turns at screw connection.
Tightening torque: 30Nm
① Inscription on the valve body.
1.1.2 For type 6 engines special gas CMG >4% O2

4J Prt. No. 321631
Special valve for CMG>4% O2
Slim, solid shaft, no turn at screw connection.
① 3-5 figure serial number on the hexagon. Tightening torque: 20Nm

gas valve
2 Disassembly
2.1 Drain off the engine cooling water completely.
2.2 Remove the prechamber gas valve.
2.2.1 Remove the valve cover and spark plug connector.
Clean the mating surface ① on the cylinder

head.
2.2.2 Remove the exhaust valve rocker arm

Item Description Information
1 Open-ended or 24 AF
ring wrench
Undo the M16 hexagonal nuts ①.
Lift the rocker arm and pull out the valve rods using
both hands.

gas valve
Press the rocker arm downwards with one hand and

with the other one remove the push rod ② from its re-
tainer.
Lift the rocker arm as shown by the arrow and remove

the tension springs ③.
2.2.3 Remove the spark plug sleeve extension

1 Prechamber ex- Item ② Part no.: 222670
tractor tool
1 Adapter nut Item ① Part no.: 567458
(M42 x 2)
1 Adapter nut Item ① Part no.: 303388
(M35 x 1.5)
Screw the adapter nut ① on to the prechamber extrac-
tor tool ②.

gas valve
Screw the prechamber extractor tool, with the adapter

nut at position ③, on to the spark plug sleeve exten-
sion as far as it will go.
Move the weight ④ sharply upwards in the direction

of the arrow so that it strikes the stop ⑤. Repeat until
the spark plug sleeve extension has been slackened.
Unscrew the spark plug sleeve extension ⑥ from the

adapter nut ⑦ of the prechamber extractor tool.

gas valve
2.2.4 Remove the exhaust valve rocker arm

Lift the exhaust valve rocker arm off the cylinder head
as shown by the arrow.
2.2.5 Remove the prechamber gas valve

ring wrench
Unscrew the prechamber gas line ① from the precham-
ber gas valve.

1 Ratchet
1 Extension piece
1 Socket wrench 22 AF
1 Universal joint
Unscrew the prechamber gas valve from the cylinder
head using the ratchet wrench and then detach it
from the cylinder head.

gas valve
2.3 Remove the spark plug

1 Ratchet
1 Extension piece
1 Spark plug sock- Item ① Part no.: 314941
et
Unscrew the spark plug from the cylinder head using
the ratchet, extension piece and spark plug socket ①.
Remove the ratchet, and withdraw the spark plug

from the cylinder head using the extension piece and
spark plug socket.
2.4 Remove the prechamber retaining bracket

ring wrench
Undo the M10 hexagonal nuts ①.
Lift off the spacer sleeves ①.
Remove the prechamber retaining bracket ②.

gas valve
2.5 Remove the spark plug and prechamber assembly

Before carrying out this step, make absolutely sure that the prechamber gas valve has been removed.
The piston of the cylinder head in question must also have been brought to its top position.

1 Prechamber ex- Part no.: 222670
tractor tool
Screw the prechamber extractor tool with the spark

plug socket to position ① on the cylinder head.
Move the weight ② sharply upwards as shown by the

arrow so that it strikes the stop ③. Repeat until the
spark plug sleeve has been slackened.
Withdraw the spark plug sleeve ① from the cylinder

head with the prechamber extractor tool.

gas valve

1 Pliers
Withdraw the prechamber ① from the cylinder head
with the pliers.
3 Inspection / cleaning
3.1 Clean the O-ring seating surfaces in the cylinder head
Clean the O-ring seating surfaces ① in the cylinder head

gas valve

1 Fleece wheel suitable cleaning tool
Clean the O-ring seating surfaces with a fleece wheel
(fine corundum / 55 diameter and less) or a suitable
hand grinder ② with a maximum grain size of 220.
3.2 Clean the prechamber mating surface in the cylinder head

1 Hand milling tool Item ① Part no.: 361189
Figure 1: Carefully push the hand milling tool with the

milling head into the cylinder head as far as the stop.
Figure 2: Turn the hand milling tool with milling head

clockwise in several cycles until a visually-clean mat-
ing surface can be seen.

1 Hand milling tool Item ① Part no.: 361189
1 Abrasive paper Item ② / Ⓐ 8 mm dia. / Ⓑ 33
mm dia. / grain size 220
1 Allen key 10 AF
The abrasive paper ② can be cut to the desired shape
with scissors or with a suitable punch.

gas valve
Push the hand milling tool together with the abrasive

paper into the opening in the cylinder head and grind
the prechamber bore for about 20 revolutions.
Figure 1: Prechamber bore before grinding with abra-

sive paper.
Figure 2: Prechamber bore after grinding with abrasive
paper.
3.3 Clean the prechamber bore and the combustion chamber

1 Handheld vacu-
um cleaner
Remove the accumulated dirt from the cylinder head
with a handheld vacuum cleaner.

gas valve
3.4 Clean the prechamber
Clean the prechamber with a wire brush

and then blow it out with compressed air.
3.5 Clean the spark plug sleeve

Remove the 3 O-rings ①.
Clean the spark plug sleeve, see Figure ①.

In the event of heavy dirt contamination, clean with
abrasive paper, see Figure ②.
Clean the hole in the spark plug sleeve for the precham-
ber gas valve ①.
3.6 Inspect the prechamber and spark plug sleeve
3.6.1 Pre-combustion chamber abrasion test

Clean and inspect the pre-combustion chamber
gas valve
(optically and using inspection tool Prt. Nr. 481483)
If the pre-combustion chamber shows signs of wear (see illustra-

tion) due to corrosion, the pre-combustion chamber must be re-
placed.

tion), it must be replaced.
In addition, it is advisable to replace the relevant piston.

tion), it must be replaced.
In addition, it is advisable to replace the relevant piston.
Pre-combustion chambers which show no signs of abrasion,

must be subjected to an abrasion test using the test instrument
shown. If the inspection tool can be slid tangentially through two
bores (as shown in the illustration), the abrasion limit has been
reached and the pre-combustion chamber must be replaced.
The inspection tool can be used for all pre-combustion chambers
shown.
Checking the diameter of inspection tool

Part No. 481483.
The wire ring must slide on easily.
8-hole pre-combustion chamber (up to product range 2005).
① Inspection tool

gas valve
9-hole pre-combustion chamber (up to product range 2000)
Natural gas pre-combustion chamber from product range 2005
Special gas pre-combustion chamber:

if the diameter of the pre-combustion chamber bores is reduced
due to deposits, the pre-combustion chamber must be cleaned
before the inspection.
3.6.2 Spark plug sleeve abrasion test

Clean and inspect the spark plug sleeve (visually)

gas valve
① Spark plug sleeve ② Gas bore and spark plug thread OK

If the spark plug sleeve shows signs of wear (see Figure) in the gas bore, the spark plug sleeve must be replaced.
① Wear in the gas bore

If the spark plug sleeve shows signs of wear (see the Figure) at the spark plug thread, the spark plug sleeve
must be replaced.
① Wear on the spark-plug thread
3.6.3 Inspecting the spark plug sleeve

Visually inspect the spark plug sleeve for damages (cracks, fractures) near the O-ring ①.

gas valve
① Spark plug sleeve fracture
Replace the spark plug sleeve if cracks or signs of damage are found.
4 Assembly
4.1 Preliminary assembly of the prechamber

Replace the O-ring and joint ring on the prechamber:

1 Joint ring Item ① Part no.: 438602
1 O-ring Part no.: 456735
Replace the O-ring on the prechamber.
Replace the joint ring ①.

gas valve
4.2 Preliminary assembly of the spark plug sleeve

Replace the O-ring on the spark plug sleeve:

2 O-ring Item ① Part no.: 319744
1 O-ring Item ② Part no.: 319743
Replace the O-ring on the spark plug sleeve.
Lightly oil O-rings before fitting.

1 O-ring Part no.: 376475
Replace the O-ring inside the spark plug sleeve.
Lightly oil O-rings before fitting.

gas valve
4.3 Preliminary assembly of the prechamber and spark plug sleeve

Push the prechamber ① on to the spark plug sleeve
②.
4.4 Fit the prechamber and spark plug sleeve assembly

1 Joint ring Part no.: 438602
Figure 1: Apply a small amount of grease at two

places ③ on the prechamber.
Figure 2: Push the joint ring on ④ and press it into place.
This prevents the joint ring from falling out when in-
stalling the assembly, see Figure 3.

gas valve
Insert the spark plug sleeve so that the hole ② in the

prechamber for the prechamber valve faces the the
prechamber valve hole ① in the cylinder head.
In addition, make sure during installation that the two

holes ① in the prechamber are vertical.
Push the spark plug sleeve and prechamber assembly

into the cylinder head.

gas valve
4.5 Fit the prechamber retaining bracket
Figure 1: Caution: the bracket is asymmetric in shape.

Distance Ⓑ is larger than distance Ⓐ.
Figure 2: Push the bracket on to the cylinder head and

press it downwards as shown by the arrow by hand.
Figure 3: The dowel pin of the flange must fit into the
hole ④ in the prechamber.
Lever the bracket downwards with the ratchet exten-

sion piece.
Slide the spacer sleeves ① down over the studs.

gas valve
Clean the thread on prechamber gas valve ① and wet

with Ultratherm Spray/Paste.
The conical sealing surface ② on the prechamber gas

valve must be free of Ultratherm
Screw the prechamber gas valve into the side of the
cylinder head by hand.

1 Torque wrench
1 Extension piece
Fully tighten the M10 hexagonal nuts ① alternately us-

ing a torque wrench in accordance with TIs
1902-0228 C/EF/GH.

1 Torque wrench
1 Extension piece
1 Universal joint
Fully tighten the prechamber gas valve using a torque

wrench in accordance with TIs 1902-0228 C/EF/GH.

gas valve

1 Open-ended 19 AF
wrench
Fully tighten the prechamber gas line using an open-

ended wrench in accordance with TIs 1902-0228 C/EF/
GH.

gas valve
4.6 Fit the exhaust valve rocker arm

Figure 1: Slide the exhaust valve rocker arm down over
the studs ③.
Figure 2: Screw the hexagonal nuts ④ on to the studs.
Do not fully tighten yet!

Hook the tension spring ① in place between the rock-
er arm and cylinder head.
Push the exhaust valve rocker arm downwards with

one hand as shown by the arrow and place the push
rod in the rocker arm cup ①.
Loosen the hexagonal nuts ① far enough to allow the

exhaust valve rocker arm to be lifted as shown by the
arrow so that the valve rods ② can be placed in their
cups.

gas valve

1 Torque wrench
ring wrench
Fully tighten the 2 hexagonal nuts on the exhaust

valve rocker arm alternately using a torque wrench in
accordance with TIs 1902-0228 C/EF/GH.
4.7 Check the valve clearance
Check the valve clearance in accordance with Mainte-

nance Work W 0400 M6.

gas valve
4.8 Fit the spark plug sleeve extension
Hold the spark plug sleeve extension as shown in Fig-

ure ①, with the snap ring gap facing upwards ③.
Push the spark plug sleeve extension into the opening
in the spark plug sleeve.
Drive in the spark plug sleeve extension as far as it will

go with sharp blows by hand.
4.9 Replace the spark plug joint ring

Replace the joint ring ①.
Check the spark plug in accordance with IW 0309 M0

and TA-1400-0104.
Push the spark plug into the spark plug sleeve.
Tighten the spark plug to the torque specified in TIs

1902-0228 C/EF/GH.

gas valve
4.10 Fit the valve cover

Clean the valve cover mating surface.

1 Allen key 10 AF
Tighten the hexagonal socket screws ①.
4.11 Fill up with engine cooling water to the specified pressure
4.12 Visual inspection for leaks

Crankcase ventilation system
Interval
≥ 20mbar differ-
2000 Oh ential pressure
Maintenance work Point
2 Differential pressure inspection 1. ■
- Replacing the blow-by filter can 2. ■
1 Measuring the filter differential pressure

The filter can has two 1/8“ threaded connections (see photograph 4). One of the connections leads into the
prefractionator (before the filter), the other connection into the volume after the filter. At these connections, you
can directly measure the differential pressure before and after the filter using water column or a handheld pres-
sure gauge.
Differential pressure inspection in acc. with I 0103 6.
Change the blow-by filter can if the differential pressure exceeds 20 mbar.
2 Replacing the blow-by filter can of the crankcase ventilation system

Tips:
Clogged filter cartridges will result in less engine oil being filtered from the blow-by.
As a result, the turbochargers and the mixture cooler will become soiled.
Example picture J620
① Insulated blow-by filter

Author: Doku./Bilek Responsible: TEM/Gebhardt Release date: 28.07.2010
Loosen the hose clips at all three blow-by filter connections (A, B and C) – (see photograph of insulated blow-by
filter). Loosen all four blow-by filter fixing screws and remove the filter can (including the insulation) from the
engine.
Connection B Connection C
① Loosen filter-sided hose clips
Remove the insulation from the old filter can and fit the insulation on the new filter can. Remove all tensioning
springs and assembly belts.
Photograph of insulated blow-by filter

① Belts ④ tensioning spring

② Connection B ⑤ Measuring nozzle
③ Connection C ⑥ Connection A
Having fitted the new insulation, re-assemble the filter can.

Vibration damper
Even a small amount of damage of the damper housing can have a huge impact on the operation or even
lead to total malfunction.
1 Replace vibration damper

Disassemble protective vibration damper cap.
Remove hexagonal socket screws.
Remove vibration damper (for easier removal and installation of the new vibration damper, the rod device in-
tended for this purpose should be used – Part No. 156911).
Lubricate the bolt threads and contact surfaces.
Assemble the new vibration damper.
Assemble protective vibration damper cap.

Gas quantity controller
Interval
Maintenance work Point 20,000 Oh 30,000 Oh 40,000 Oh 60,000 Oh
20/3 Gas quantity controller to be cleaned 2. ■*) ■ ■*)
040 on-site by service engineer.
20/3 Replace seal rings 1. ■*) ■ ■*) ■
0/40
/60
60 Replace gas quantity controller - ■
*) only for biogas, landfill gas and special gas
1 Replacing seal rings

The seal rings on the device connection flanges generally must be replaced when reassembling or replacing
the device after cleaning.
2 Cleaning
When cleaning, ensure that the pressure and gas sensor openings are not dirty to guarantee that the gas quan-
tity controller operates properly. The position of the pressure and temperature sensors is indicated by an arrow
in the photographs below.
Please note: Ensure that the surface of the internal pipe is not damaged by the cleaning process, which should
not leave behind scratch marks as this will increase the build-up of deposit there.
2.1 Deposits
Clean with a soap solution.
Leave the soap solution for a while to take effect and then remove the deposits/dirt with a bottle brush or simi-
lar. Wipe the device dry with a clean cloth.
Deposits around the valves:
① clean

Author: Doku./Bilek Responsible: TCD/Greuter Release date: 25.10.2010
Gas quantity controller
2.2 Oil contamination

Clean with a clean cloth without the soap solution.
Oil contamination:
① clean

Author: Doku./Bilek Responsible: TCD/Greuter Release date: 25.10.2010
Maintenance work: W 1000 6
Maintenance after initial commissioning
Operational data: Initial commissioning data sheet; E 0309; E 0400; E 8070

1 Information
After initial commissioning and before reaching 100 operating hours, the following maintenance work should
be carried out once.
2 Maintenance work
2.1 Valve-stem projection: W 0400 M6

Measuring the valve-stem projection.
Enter the measured values on the initial commissioning data sheet.
2.2 Valve play: W 0400 M6

Adjust the valve play of the inlet and exhaust valves.
Enter the measured values in the Operational data – Valve-stem projection (E 0400) table.
2.3 Ignition voltage check / spark plugs: IW 0309 M0

Check the ignition voltage and, if required, readjust the spark plug electrodes.
Enter the measured values in the Operational spark plug data (E 0309) table.
2.4 Gas filters: W 8045 A6

Check the gas filter.
2.5 Data collection for the flexibly-mounted coupling housing: IW 8079 A6

Measure the gap in 3 places on the circumference.

Maintenance after initial commissioning
Enter the measured values in the Data collection for the flexibly-mounted coupling housing
(E 8079 6) table.
2.6 Pre-combustion chamber gas compressor: IW 8046 0

Lubricating oil change / retightening bolts / V belt tensioning
2.7 Control rod assembly/throttle valve: W 0200 M6

Grease pivot points using a grease gun at the lubricating nipples. Remove the excess grease and apply a
grease film to the left and right-hand side of the bearing gap to protect against dust.

Overhaul
1 Tips
The overhaul must be carried out by GE Jenbacher or a specialist company recognised by GE Jenbacher. We
kindly ask you to contact us in time, so we can ensure the work is carried out at the time requested.
We would also like to mention the possibility of using a service-exchange engine instead of carrying out a large-
scale overhaul.
2 Maintenance work to be carried out
2.1 Camshaft and gear train: inspect and replace, if necessary.
2.2 Crankshaft: disassemble, inspect and rework, if necessary.
2.3 Crankcase: inspect and rework, if necessary.

Following the overhaul, the engine must be commissioned according to Technical Instruction 1400-0100
"Regulations for running in GE Jenbachergenerating sets"! The engine must not immediately be subjected
to loads!

Exhaust gas turbocharger
1 Inspection ........................................................................................................................................................ 1
1.1 Check the compressor side for deposits ............................................................................................................... 1
1.2 Check the compressor and turbine side for deposits ..................................................................................... 1
2 Cleaning interval ............................................................................................................................................ 1
3 Tensioner for A-140 charger ........................................................................................................................ 2
3.1 Fitting the lock nuts ......................................................................................................................................................... 2
3.2 Removing the lock nuts ................................................................................................................................................. 3
3.3 Cleaning and inspecting the tensioner .................................................................................................................. 4
Interval: every
Maintenance work Responsible 10000 Oh 20000 Oh 30000 Oh 60000 Oh
10 Inspection – compressor side Maintenance staff ■
10 Inspection – compressor and tur- Maintenance staff ■
bine side *)
20 Journal bearings - check ■
30 Compressor - exchange ■
60 Turbine - exchange ■
*) only for biogas and special gases.
Any work on the exhaust gas turbocharger should only be undertaken by the manufacturer or by specialised
companies authorised to carry out this work.
1 Inspection
1.1 Check the compressor side for deposits

Mixture inlet → Detach the elbow and pipe from the turbocharger.
Check the compressor housing for deposits.
If deposits are found, the exhaust gas turbocharger should be cleaned.
In-situ cleaning possible.
1.2 Check the compressor and turbine side for deposits

Exhaust gas outlet and mixture inlet → Detach the elbow and pipe from the turbocharger.
Check the turbine and compressor housings for deposits.
If deposits are found, the exhaust gas turbocharger should be cleaned.
The turbine side cannot be cleaned in situ.
2 Cleaning interval
The cleaning interval is very dependent on the gas type and quality.
With natural gas, cleaning every 20,000 Oh is generally sufficient.
With biogas and special gases, the turbocharger may need to cleaned more often, which will become clear by
a noticeable drop in engine power output, for example. The inspection interval should be adapted appropriate-
ly in this case.

Author: Doku./Bilek Responsible: TET/Haidn Markus Release date: 08.02.2011
3 Tensioner for A-140 charger
3.1 Fitting the lock nuts
Tightening the lock nut
① Jackbolt ③ Hardened washer

② Lock nut ④ Bolt thread
▪ Clean main thread 4 and contact surfaces.

▪ Spray bolt thread with Ultratherm.
▪ Fit hardened washer 3.
Jackbolts 1 should not protrude beyond lock nut 2 towards hardened washer 3.
To fit the lock nut correctly, make sure that the jackbolts are not protruding towards the hardened washer.
▪ Tighten the lock nut manually and turn it one quarter turn back.
The gap between the hardened washer and the lock nut will now be approx. 1mm.

Tightening the jackbolts
▪ Tighten the jackbolts crosswise by hand.

▪ Tighten two opposite jackbolts by 50% (18 Nm).
▪ Tighten the other two opposite jackbolts by 100% (36 Nm).
▪ Tighten all the jackbolts by 100% (36 Nm) in a circular pattern.
▪ Repeat until all the jackbolts have been equally tightened (less than 20° residual movement).
3.2 Removing the lock nuts

Loosening the jackbolts requires an exact procedure. The jackbolts must be released step by step!
Under no circumstances should you release individual bolts completely, as the remaining jackbolts would
then have to bear the whole load and would therefore be more difficult to loosen. In extreme cases, the
jackbolts could mushroom, making them impossible to loosen.
Working at normal temperatures (<100°)

Before loosening, apply a little penetrating oil, especially if rust is present.
Step 1
Moving in a circular pattern, loosen each jackbolt by about one quarter turn (breaking loose is sufficient). After
the first round, jackbolt 1 will tighten again but at a reduced load level.
Step 2
In a second round, repeat Step 1, again on all tensioners.
Step 3
Repeat Step 1 in a third round.
Step 4
Release the jackbolts completely. The tensioner can now be removed by hand.
Note: Long screws expand more and may therefore need one or two more rounds.
Before re-using the tensioner, clean it and inspect it as described below.

3.3 Cleaning and inspecting the tensioner

Clean the thread and end of the jackbolt and spray with Ultratherm.
Do not use molybdenum sulphide (MoS2)!
The hardened washer can be re-used despite indentations simply by turning it over. Impressions of a few hun-
dredths of a millimetre are normal.
The hardened washer can be re-used despite indentations simply by turning it over. Impressions of a few
hundredths of a millimetre are normal.
Tensioners do not lose their preload force even after several years in service, provided that they are correctly
tightened. Nevertheless, the preload force should be checked each time they are removed.
To do so, use a torque wrench adjusted to 100% of the permitted torque for the tensioner.
Should some jackbolts unexpectedly have lost some of their preload force, the following procedure is recom-
mended:
▪ Loosen a single jackbolt and remove it, clean and spray with Ultratherm. Then screw in the jackbolt again
and tighten it. Repeat for each jackbolt, so that the nut is always tensioned.

Generator
1 Bearing temperature monitoring (optional) ............................................................................................. 1

2 Relubricating the bearings (with engine running) ................................................................................... 1
2.1 Tips .......................................................................................................................................................................................... 1
2.2 Lubricating grease ........................................................................................................................................................... 2
2.3 Grease quantity ................................................................................................................................................................. 2
3 Cleaning/Inspection ...................................................................................................................................... 2
4 Inspection/Expertise/Replacing the bearings .......................................................................................... 2
5 Overhaul .......................................................................................................................................................... 2
6 Decommissioning the plant ......................................................................................................................... 2
7 Recommissioning the plant .......................................................................................................................... 2
8 manufacturer's documents .......................................................................................................................... 3
Interval: every
Maintenance work Point Daily 1000 Oh 10000 Oh 20000 Oh 60,000
Oh
t Bearing temperature control 1. ■
1 Regreasing the bearings 2. ■*)
10 Cleaning/Inspection 3. ■
20 Inspection/Expertise/Replacing the bear- 4. ■
ings
60 Overhaul 5. ■
*) If the equipment is used for less than 1000 operating hours a year, the generator should be relubricated annually!
1 Bearing temperature monitoring (optional)

Data collection when monitoring the temperature of drive bearings and non-drive bearings:
Enter the data in the operational data booklet.
It is best practice to take the first measurement (see Initial Commissioning data sheet) as a baseline in order to
establish a trend in the deterioration of the condition of the bearings. It will then be possible to change the
bearings when the engine or generator is being serviced.
Check the temperature of the bearings when relubricating them. The bearing temperature may increase during
the lubrication process, but should return to normal operating values after a few minutes of operation.
2 Relubricating the bearings (with engine running)
2.1 Tips
Bearings must always be lubricated when the engine is running!
When the engine is at standstill, you run the risk of “overgreasing“ the bearings because the lubricant has not
been evenly distributed.
Regrease the generator bearings at the driven end and non-driven end grease nipples using a grease gun.
Grease nipples should be cleaned before you regrease in order to ensure that no particles of dirt get into the
bearings.
Let the engine run for 10 minutes after relubricating it so that any excess grease is expelled. Remove any es-
caped lubricating grease at the underside of the casing cover.

Author: Doku./Bilek Responsible: AvK Release date: 23.12.2011
Generator
2.2 Lubricating grease

The prescribed type of lubricating grease can be found on the sticker on the generator.
Different types of grease should not be mixed.
Using a different grease type could result in damage to the bearing!
2.3 Grease quantity

The prescribed grease quantity can be found on the sticker on the generator.
3 Cleaning/Inspection
Remove any dirt and dust from the generator (using a vacuum cleaner).
Clean all parts with dry compressed air.
Check for soiling/contamination and damage, both externally and internally.
Cooling-air inlets and outlets must be free of dirt!
Check the auxiliary wiring for chafe marks.
Check the varistor and rectifier diodes in accordance with the manufacturer’s instructions.
4 Inspection/Expertise/Replacing the bearings

The generator should only be repaired by the manufacturer or by specialised companies authorised to carry
out this work.
5 Overhaul
The generator should only be repaired by the manufacturer or by specialised companies authorised to carry
out this work.
6 Decommissioning the plant

When prolonged scheduled or unscheduled downtimes occur, e.g. after the heating season when operating as
a cogeneration plant, the installation must be prepared (preserved) for its downtime according to its geographi-
cal location (climate, proximity of the sea, etc.) As conditions can vary enormously, we recommend that you
consult a suitable specialist firm concerning the measures to be taken or contract it to carry out the work.
When the generator is out of service for a prolonged period, the rotor must be rotated every two months
to ensure that the rolling elements change position (a small change of position will suffice).
Do not rotate the rotor at the fan but use the engine flywheel!
7 Recommissioning the plant

If the plant is being recommissioned after 6 months, the bearings must be thoroughly lubricated with the speci-
fied quantity of grease to replace the old grease.
Where the plant is to be recommissioned after a long period of downtime (e.g. 2 years), the bearings must be
replaced as the grease starts to resinify over time, which makes the bearings unusable.
Of course, before recommissioning the plant, you must ensure that it is in its normal operational condition
again - see manufacturer's instructions.

Generator
8 manufacturer's documents
See description - Operation!

GE Jenbacher - switch cabinets
Interval: every
Maintenance work Point 2,000 Oh 8,000 Oh, 20,000 Oh
max. 1 year
Clean the air filter 1. ■
Inspect the filter mat and replace as necessary. 2. ■
Check switchgear cabinets for dirt contamination and 3. ■
clean, if necessary
1 Check switchgear cabinets for clogging and clean, if necessary
2 Filter fan
WARNING
Danger of electric shocks!
▷ The unit is live.
a) Switch off the power supply before opening it and secure it against being switched on
again inadvertently.
WARNING!
The fan installed uses plain and/or ball bearings, is protected against moisture and dust and fitted with a tem-
perature monitor. The expected service life is at least 40,000 Oh (L10, 40°C), making the air filter largely mainte-
nance-free.
Maintenance work sequence:
a) Checking the degree of dirt contamination
b) Filter dirty?
Replace filter as necessary
c) Filter louvres dirty?
Clean as necessary
d) Check the fans for noise
e) CLean with compressed air
2.1 Cleaning the filter fan

If visibly dirty, the components can be cleaned from time to time with a vacuum cleaner or compressed air.
Stubborn oily dirt can be removed with a non-flammable cleaning agent (e.g. "Kaltreiniger").

WARNING
Fire hazard due to hot surfaces!
a) Do no use any flammable liquids for cleaning.
2.2 Changing the filter

A standard filter mat is fitted as standard in the filter fan and outlet filter for preliminary filtering of dry coarse
dust and fluff in the ambient air. We recommend the use of fine filter mats (available as an option) to increase
the degree of protection and for dusts with a grain size < 10 µm. Filters must be replaced now and again, de-
pending on dust conditions.
2.2.1 Rittal Type SK 323X / 324X filter
Removing the louvred panel
a) Pull the function logo in the louvred panel upwards slightly with a finger to release the panel. The panel can
now be swivelled through about 70°, allowing the filter mat to be changed.

Fitting a new filter mat

b) Insert the filter mat in the housing as shown in the above illustration and shut the louvred panel in the hous-
ing until it latches audibly in place.
2.2.2 Rittal Type SK 332X filter
Replacing the filter mat in the Rittal SK 332X filter

a) Open the louvred panel with a plain screwdriver as shown in the above illustration.
b) Replace the standard filter mat (A), and the fine filter mat (B) if present.
c) Push the louvred panel back into the fan housing until it latches audibly in place.
3 Power cabinet (if included in the GE Jenbacher scope of supply):

Check the power circuit breaker (MERLIN GERIN):
In order to avoid any danger during maintenance work, the breaker must be:
▪ disconnected (drawout breaker)
▪ de-energized (fixed breaker)
Check condition of arc chutes:

▪ arc chute body not damaged,
▪ separators not corroded - if necessary, replace them.
Check wear of contacts:
Close breaker to check the wear of the contacts.
good contacts worn contacts

Starter
Iskra
Please observe the safety and hazard information in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.
Check the touch guards for the starter installation
Touch guards to IP2X or IPXXB (protection against fingers) are fitted to starter motor battery poles, the
battery cable, battery busbars and starter motor terminals.
1 Starter
Replace the starter motor as follows:
▪ Following the automatic shutdown of all auxiliary equipment, deactivate the engine circuit breaker/cable
circuit breaker (according to the circuit diagram) for the battery charger and control memory in the control
cabinet.
▪ Remove the negative terminal from the module frame and isolate the cable once removed.
① Iskra starter with thermal protection ② J 208 negative battery terminal

Author: Doku./Bilek Responsible: TEM/Rangger Fred / TCE/Kruckenhauser Release date: 04.04.2011
Erich
Starter
③ Type 3 engine negative battery terminal
④ Type 4 engine negative battery terminal

Erich
Starter
⑤ Type 6 engine negative battery terminal

▪ Disconnect the starter cables at the starter motor. In the case of engines with more than one starter motor,
you must also remove the plastic cover from the starter motors (by loosening and removing the plastic cap
nut) to be able to disconnect the parallel starter relay cable at connection 45.
▪ Loosen and remove the starter assembly nuts at the gear-train housing and remove the starter(s).
▪ When assembling the starter(s), ensure that the terminal screw threads (connections 30 and 31) used are
copper and/or brass. Tighten the relevant hexagonal nuts onto the screws using the tightening torque as
specified in TI 1902-0...
▪ Refit the protective devices correctly.

Erich
Starter
Example for type 6 engines: Rubber caps and plexiglass

Erich
Elastomer components
Elastomer components age and become brittle, even when engines are not operational. That is why the
service life of these components does not depend solely on the length of time for which the module has
been in service, the cooling water temperature and pressure, etc. If this number of operating hours is not
reached, the elastomer components should still be replaced as a precautionary measure after a maximum
of 5 years.
every
Replacing the elastomer compo- Interval 6000 Oh 10000 Oh 20000 Oh 30000 Oh 60000 Oh
nents see pho-
tograph
1)
Mixture cooler: O-rings ■ ***)
pre-combustion chamber gas ■
valve: Protective cap
Only for J624TSTC: Mixture cooler - ■
O-rings (between housing and cool-
er, high and low pressure)
All O-rings: pre-combustion cham- ■
ber, cylinder-head cover, spark-
plug extension
All O-rings: cooling water line, oil ■
lines, oil filter installation, oil pump,
turbo-compressor connection
Optional for turbocharger module:
Turbocharger with mixture and oil-
cooler mounting
Coupling: coupling discs ■
All hoses: oil lines, pre-lubrication ■
and re-lubrication, venting system,
compensation reservoir, exhaust
gas back pressure control,
crankcase ventilation
All rubber buffers: air-filter collec- ■
tion cabinets, intake line, gas mix-
er, ignition cable harness, ignition,
switch cabinets on the module,
knock control, etc.
All O-rings: Cylinder liner, ■ *) ■
crankcase, cylinder head, piston
cooling nozzles
Air-intake system up to compres- ■
sor intake: sleeves and bellows

Author: Doku./Bilek Responsible: TEBM/Rangger Alfred Release date: 06.10.2011
Elastomer components
every
Replacing the elastomer compo- Interval 6000 Oh 10000 Oh 20000 Oh 30000 Oh 60000 Oh
nents see pho-
tograph
1)
Engine / generator bearing: rubber ■ **) ■
rails
Elastic coupling housing (if in- ■
stalled): rubber elements
Plate heat exchanger: rubber gas- ■
kets
1) 5000 Oh, 500 engine start or every 2 years (whichever occurs first)
*) only for biogas, landfill gas, special gases or engine cooling water temperature >95 °C
**) inspect and replace, if necessary
***) only for hot-country version F101-F112

Oil filter cartridge
Interval
Maintenance work at every oil for J 620 / J 612/
change J624 J 616
after 4000 after 6,000
operating operating
hours at the hours at the
latest latest
- Change the oil filter cartridge ■
4 ■
6 ■
Experience has shown that the oil filter cartridge must be changed after
J 620 / J 624 every 4000 operating hours
J 612/J 616 every 6000 operating hours.
1 Change the oil filter cartridge

To drain the engine oil from the oil filter, open the shut-off valve of the oil-filter feed line.
Unbolt the cover and remove the oil filter cartridge.
Clean the oil filter housing.
Moisten the O-rings (new oil filter cartridge) and slide it into the oil filter housing.
Replace the O-ring at the cover and lubricate it.
Refit the cover.
Close the shut-off valve in the oil-filter feed line and run the electrical pre-startup lubrication system for a few
minutes.

Plate-type heat exchanger
1 Overhaul
The platen-type heat exchanger should only be repaired or overhauled by the manufacturer or by spe-
cialised companies authorised to carry out this work.

Gas pressure control system
Interval: every
Maintenance work Point 2000 Oh 30000 Oh 60,000 Oh
02 Gas filters 1. ■
30 Pre-pressure controller / Pre-combustion chamber dif- 2. ■
ferential pressure controller
60 Controlled gas system / Pre-combustion chamber con- 3. ■
trolled gas system
1 Gas filters
Remove the gas filter cover.
Remove the filter cartridge and check it for clogging.
Clean the filter housing.
Replace the O-ring.
Insert cleaned or new filter cartridge.
The filter cartridge should be replaced at least once a year!
Bolt the cover back on, with a special gas filter, insert the bolts for the filter cover crosswise and hand-tighten
them, then tighten them fully to a torque of 70 Nm.
Check the filter for leaks (leak detection spray).
2 Pre-pressure controller / Pre-combustion chamber differential pressure controller

Have the pre-pressure controller and pre-combustion chamber differential pressure controller overhauled by a
specialist company authorised to carry out this work.
3 Controlled gas system / Pre-combustion chamber controlled gas system

Have the gas pressure control system overhauled by a specialist company authorised to carry out this work.

Piston/Piston cooling
1 Piston
▪ Disassemble and inspect the piston.
▪ Replace piston rings and piston pins.
The inspection must be carried out by GE Jenbacheror a specialist company authorised by GE Jenbacher.
2 Piston cooling
Provide the piston cooling nozzles with a new O-ring.
Check the assembly position of all piston cooling nozzles using the special inspection equipment.

Author: Doku./Bilek Responsible: TEM/VSB/VMP Release date: 01.06.2010
Cylinder liner
1 Cylinder liner
Replace the cylinder liner and O-rings.
Only use a hand pump to disassemble the cylinder liner.
Do not use hydraulic or electric pumps!

Author: Doku./Bilek Responsible: TEM/VSB/VMP Release date: 06.12.2010
Main crankshaft bearing/thrust bearing
Interval: every
(4,000 engine starts) (3000 engine starts)
30 Main crankshaft bearings and thrust bearings - replace ■
40 Main crankshaft bearings and thrust bearings - replace ■*)
*) only for biogas, landfill gas and special gas engines
1 Main crankshaft bearing/thrust bearing:

At 30,000 operating hours (40,000 operating hours) or when the maximum number of engine starts is reached
as indicated in the above table, the main crankshaft bearings and thrust bearings must be completely replaced.

Author: Doku./Bilek Responsible: TEBM/Prada Release date: 10.06.2010
Exhaust gas manifold/exhaust gas lagging
Carry out the inspection below following each cylinder-head disassembly!
1 Exhaust manifold and lagging:

▪ Check the exhaust manifold and connecting pieces for scale and cracks.
Possible leaks can be recognised by discolouration of the insulation.
▪ Check the compensators for cracks and/or tears on the inner protective pipes.
▪ Check the exhaust gas lagging.
Exhaust manifold locking hook for assembly

Use the locking hook provided (see the illustration above).

Author: Doku./Bilek Responsible: Service Team I Release date: 26.07.2011
Replacing the cylinder head
Interval
Maintenance work Point for J612-J624 only for for J612-J624 ….. Oh
and J624TSTC J624TSTC 30,000 Oh
10,000 Oh 10,000 Oh
1 Rocker cover gasket – replace 2. ■
0
1 Cylinder head visual inspection 3. ■
0
3 Cylinder head replacement 1. ■ *)
0
- ■ **)
*) To be done on disassembly, when replacing piston and cylinder liner.
Clean the cylinder head at the plane faces and measure the valve-stem projection.
If the wear equals or exceeds 1.2 mm, we recommend replacing the cylinder head for reasons of economy.
**) When a check of the valve-stem projection shows that the maximum wear tolerance limit has been reached.
1 Cylinder head replacement
1.1 Disassembling the cylinder head

Drain the coolant until the cylinder heads are emptied.
Caution: never re-use drained cooling water when re-filling the cooling system!
Unscrew the assembly bolts of the exhaust gas and cooling water drain pipes.
Remove the rocker cover.
Disassemble the rocker arm supports, rocker arm and tappet push rods.
Ensure that no oil can enter the pre-combustion chamber!
Clean the cylinder-head thoroughly to remove any oil contamination.
Remove the protective rubber caps from the cylinder head bolts.
Assemble the hydraulic tensioning device.
Increase the oil pressure of the device until the cylinder-head nuts can be loosened manually using a guide
pin.
If the oil pressure (of the tensioning device) increases to 760 bar [11020 psi] and the nuts can still not be loos-
ened, stop the disassembly procedure to avoid damaging the cylinder head bolts.
Check the tensioning device for correct operation.
Check the cylinder head bolts for damage (galling).
1.2 Assemble the cylinder head

Clean the mating faces at the crankcase and the cylinder head.
Insert a new cylinder head gasket in the groove.

Author: Doku./Bilek Responsible: Konstruktion/Service Team I Release date: 05.10.2011
To lift the cylinder head, screw eye bolt (M16) into the bore of the rocker arm support.
Replace all O-rings near the cylinder head. Oil the O-rings slightly with engine oil before assembly.
Loosen the cylinder-head nuts.
Pretension the cylinder head screws using the hydraulic tensioning device (610 - 620 bar), and handtighten the
cylinder-head nuts.
Release and remove the hydraulic tensioning device.
Mount the rocker arm support and rocker arm.
Adjust the valve play according to W 0400 M6.
Fit the lines.
See the cylinder head cover gasket section for the assembly of the cylinder head cover gasket.
Fit the cylinder-head cover using a new gasket.
Push the protective caps on to the cylinder head bolts.
See also
• Rocker cover gasket [⇨ W 8053 M6, Page 2]
2 Rocker cover gasket
2.1 Tips
Never install more than 1 (one) gasket type on the same engine, to prevent both the old O-ring and the
newly formed gasket to be used on the same engine. If necessary, all gaskets must be replaced.
The new gasket is made-to-measure and must therefore not be stretched before assembly!
Never use a screwdriver or a sharp tool to clean the sealing surface or to push the newly formed gasket in
position!
Storage must be suitable for the product, i.e. protected from light and dust. The packing must remain
sealed until the formed gaskets are actually used.
2.2 Fitting the rocker cover gasket

▪ Remove any silicon and paint residues from the cylinder head sealing surface and groove.
▪ Insert the new formed gasket into the groove.
▪ Carefully insert the gasket into the groove using the assembly tool.
The projections of the gasket must be pressed into the respective bores in the groove to prevent the gasket
from being crushed when assembling the cylinder head cover onto the cylinder head.
3 Cylinder head visual inspection (only for J624TSTC)

▪ Disassembling the cylinder head according to section 1.
▪ Check the cylinder near the prechamber for signs of cracks. If any cracks are found, the cylinder head must
be replaced.

Crack near the prechamber

▪ Even if no cracks can be found, the valve wear must still be checked. If the total wear comes to > 2 mm, the
cylinder heads must be replaced.
▪ W 0400 M6: valve play [⇨ W 0400 M6, Page 1]
4 Fill the cooling water according to W 8080 A0!

Pre-lubricating pump
Have the pre-startup lubricating pump overhauled by a specialist company authorised to carry out this work.

Author: Doku./Bilek Responsible: Dokumentaiton Release date: 24.11.2010
Combustion chamber
1 Inspection / cleaning of the combustion chambers

▪ Spark plug removal according to IW 0309 M0.
▪ Inspect all cylinders using an endoscope for any deposits that may have accumulated.
Make sure to pay special attention to the six-o-clock-position!
▪ If necessary, clean the combustion chambers using a vacuum cleaner (ensure that you attach a small hose
to the vacuum cleaner).
▪ Spark plug inspection according to IW 0309 M0.

Engine – cooling water circuit / Mixture recirculating wa-
ter
1 Water pressure inspection (daily) ............................................................................................................... 1

2 Filling the cooling water ............................................................................................................................... 1
2.1 General instructions: ....................................................................................................................................................... 1
2.2 Filling instructions for the cooling water system ............................................................................................... 2
2.3 venting ................................................................................................................................................................................... 3
2.3.1 Electric cooling water pump without permanent bleeding 3
2.3.2 Preheating pump 4
2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules ............ 5
2.4.1 Measuring the temperature differential 6
2.4.2 Adjusting the bundle control valve 6
Interval: every
Maintenance work Section Daily 20000 Oh 30000 Oh
t Water-pressure inspection 1. ■
20/30 Cooling water exchange 2. ■ *) ■
*) only for special gases and an engine cooling water temperature >95 °C (see module maintenance plan)
1 Water pressure inspection (daily)

Water pressure inspection using the pressure gauge
on the filling valve.
① Pressure gauge
Cooling water system pressure (for cold installation): 1.1 bar
Note down the exact cooling water operating pressure in the operational data booklet.
2 Filling the cooling water
2.1 General instructions:

Quality of cooling water in closed circuits: TI 1000-0200
Anti-freeze agents: TI 1000-0201
Cooling water anti-corrosion additive: TI 1000-0204

Author: Doku./Bilek Responsible: TKA/TEAM/VSR/TPAQ/VSI Release date: 24.11.2010
ter
Quality of circuit water in hot water and warm water heating systems: TI 1000-0206
Quality of cooling water in open circuits: TI 1000-0208
Continuous breather (only for container-based installa-

tions)
① Air-bleed cock (to be opened only when fill- ② Shut-off valve (to be closed and remain
ing water) closed following commissioning!)
2.2 Filling instructions for the cooling water system

Reduce the pre-pressure (if required) using the pressure valve at the membrane pressure compensation reser-
voir. Before doing so, ensure that the cooling water system has not yet been filled.

ter
Modules pressure compensation reservoir pre-

pressure
J 208 GS – J 320 GS 0.6 bar
J 412 GS – J 420 GS 0.6 bar
Container-based installations 0.6 bar
J 612 GS – J 624 GS 0.8 bar
① Pressure valve
Set the cooling water system pressure at the filling valve.
Ensure that when connecting the filling hose to the filling valve no air can get into the system (to prevent un-
wanted air from entering the cooling water system).
Fill the cooling water system via the filling valve.
The air-bleed cock must remain open until only water, i.e. no air, flows out of the opening.
Close the shut-off cock by turning it clockwise (to the right) and remove the filling hose from the filling valve.
Following every filling or re-filling of the cooling system, repeat the filling procedure until the cooling water sys-
tem is fully bled.
2.3 venting
2.3.1 Electric cooling water pump without permanent bleeding

Electric cooling water pump vent screw

ter
Open the bleeding screw until the water escaping no longer contains any air.
2.3.2 Preheating pump
① Preheating pump bleeding screw

Open the bleeding screw until the water escaping no longer contains any air.
Caution: check the preheating pump shaft for smooth operation if the engine has been decommissioned
for a long period of time prior to starting; to do so, turn the shaft using a screw driver in the notch of the
pump shaft.
Always shut off the flow to the filling valve after completing the filling and/or refilling procedure.
This is to see whether the pressure in the cooling water system has been maintained.
Please not in the case of single-circuit cooling system modules:
Inspect the cooling water circuit every time after working on the cooling system and/or every time the cool-
ing water is changed!

ter
2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules
Adjust the flow amount using the bundle control valve.
① Bundle control valve

The setting value can easily be recorded and reproduced using the scale. The top number (against the black
background) represents the rough setting (1 to 4), the bottom number (red background) represents the decimal
setting (1 to 9).
Measuring the temperature differential between the engine cooling water intake

ter
and engine cooling water outlet.
The temperature differential at full load should be approx. 6°C.
2.4.1 Measuring the temperature differential

Make sure when establishing the temperature differential that the same equipment is used at both measuring
points.
The most efficient method is using infrared measuring equipment. Ensure that the pipe surface is equal at both
measurement locations (same paint and same surface roughness).
When in doubt, cover both surfaces using wide adhesive tape. The tape must be matt (not glossy or reflecting).
If no infrared measuring equipment is available, the temperature can also be established using contact measur-
ing equipment. This equipment is not as precise, however, as air flows can affect the surface temperatures.
Therefore, the measuring sensor must be covered and left at both locations for the same period of time.
2.4.2 Adjusting the bundle control valve

Remove the bundle control valve locking device and the safety cover.
The basic setting of the bundle control valve is approx. 1.5.
Run the engine at half load and adjust the bundle control valve such that a temperature differential of approx.
4°C is achieved (closing the valve will increase the temperature differential). Consequently, run the engine at full

ter
load and wait until the temperature remains constant (at least 30 minutes) and then set the temperature differ-
ential of approx. 6°C.
Temperature differentials below 5°C (valve opened too wide) can result in "Cooling water temperature maxi-
mum".
Temperature differentials between 5°C and 7°C are still admissible.
Refit the safety cap and secure it in place.

5 Maintenance protocol Module 1
5.1
Maintenance protocol
Generator No.: Engine No.:
Proper maintenance according to the maintenance schedule is a condition for the acceptance
of warranty claims.
Please note that properly carried out maintenance work is to be acknowledged by filling in the
maintenance record sheet.
Mainte- Operating hours Date Signature

nance at Number of starts Mechanic Operator
Oh
< 100 Oh
Number of starts
1000 Oh
Number of starts
2000 Oh
Number of starts
3000 Oh
Number of starts
4000 Oh
Number of starts
5000 Oh
Number of starts
6000 Oh
Number of starts
7000 Oh
Number of starts
8000 Oh
Number of starts
9000 Oh
Number of starts
10000 Oh
Number of starts
11000 Oh
Number of starts
12000 Oh
Number of starts
13000 Oh
Number of starts
14000 Oh
Number of starts
15000 Oh
Number of starts
16000 Oh
Number of starts

5.1
of warranty claims.

Oh
17000 Oh
Number of starts
18000 Oh
Number of starts
19000 Oh
Number of starts
20000 Oh
Number of starts
21000 Oh
Number of starts
22000 Oh
Number of starts
23000 Oh
Number of starts
24000 Oh
Number of starts
25000 Oh
Number of starts
26000 Oh
Number of starts
27000 Oh
Number of starts
28000 Oh
Number of starts
29000 Oh
Number of starts
30000 Oh
Number of starts
31000 Oh
Number of starts
32000 Oh
Number of starts
33000 Oh
Number of starts
34000 Oh
Number of starts

5.1
of warranty claims.

Oh
35000 Oh
Number of starts
36000 Oh
Number of starts
37000 Oh
Number of starts
38000 Oh
Number of starts
39000 Oh
Number of starts
40000 Oh
Number of starts
41000 Oh
Number of starts
42000 Oh
Number of starts
43000 Oh
Number of starts
44000 Oh
Number of starts
45000 Oh
Number of starts
46000 Oh
Number of starts
47000 Oh
Number of starts
48000 Oh
Number of starts
49000 Oh
Number of starts
50000 Oh
Number of starts
51000 Oh
Number of starts
52000 Oh
Number of starts

5.1
of warranty claims.

Oh
53000 Oh
Number of starts
54000 Oh
Number of starts
55000 Oh
Number of starts
56000 Oh
Number of starts
57000 Oh
Number of starts
58000 Oh
Number of starts
59000 Oh
Number of starts
60000 Oh
Number of starts
After the overhaul following 60,000 operating hours, the maintenance work to be carried out is repeated
at the same interval periods.

6 Registration of operational data Module 1
6.1
Operational data booklet
Operational value to be read Unit Mo. Tue. Wed. Thu. Fr. Sa. Su.
Electrical power P kW
Reactive energy Q kVAr
Apparent power S kVA
cos phi φ
Current: Im Current average val- A
ue
Um Voltage average V
value
In Neutral current A
Ue Exciter voltage V
WP Active power demand MWh
WP Reactive power demand MVARH
Exhaust gas 1 13 °C
temp. - cylinder 2 14 °C
no.: 3 15 °C
4 16 °C
5 17 °C
6 18 °C
7 19 °C
8 20 °C
9 21 °C
10 22 °C
11 23 °C
12 24 °C
Exhaust gas heat exchanger - tube-plate °C
temperature
Generator bearing temperature AS °C
Generator bearing temperature NAS °C
Cooling-water temperature °C
Cooling-water pressure bar
Oil temperature °C
Oil pressure bar
Crankcase pressure *) **) mbar
Pre-combustion chamber differential mbar
pressure *) **)
Leanox -da- Mixture temperature °C
ta: Boost pressure bar
Gas mixer position %
Gas quantity controller set- %
ting (optional)
Throttle valve position %

6.1
Turbocharger bypass posi- %
tion
Operating hours h
Start counter
Exhaust gas temperature (after heat ex- °C
changer)
Gas pressure constant ±3 mbar/30 s devi- yes/no
ation?
Hot water temp. before heat exchanger *) °C
Hot water temp. after heat exchanger *) °C
Air temperature: Ambient (in the °C
open air)
Engine room °C
Correct registering of operational data con-
firmed:
*) if included within GE Jenbacher‘s scope of supply!

**) for type 6 engines only!

Operational data – Engine lubricating oil
Product applied (brand name):

Operating hours Oil analysis Change oil Date performed by Signature Remarks
150 Oh ✓

Author: Doku./Bilek Responsible: Dokumenation Release date: 24.11.2010


Operational data: E 0103 a
Operational data - Heat exchanger mixture/water
Mixture pressure at in- Differential pressure Date Recorded by

Inspection intervals take
Mixture pressure at
outlet
Initial commissioning p1=______mbar ∆p =_____mbar

p2=______mbar (setpoint value)
10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

Operational data: E 0103 d
Operational data Pre-combustion chamber gas differen-
tial pressure
Gas pressure in the pre- Pre-combustion Date Checked by...

Inspection intervals combustion chamber chamber gas differ-
gas line ential pressure
Boost pressure (dis-
played by DIA.NE)

2000 p1=______mbar ∆p =_____mbar

p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

Operational data: E 0103 f
Operational data - crankcase ventilation system
Crankcase pressure Differential pressure Date Recorded by

Inspection intervals Blow-By-Abscheider - in-
take
Crankcase pressure
Blow-by separator - out-
let
2000 p1=______mbar ∆p =_____mbar
p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar


take
Crankcase pressure
let
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

Operational data: E 0103 g
Operational data - Flame trap Mixture cooler

Mixture pressure at out-
let

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

Author: Doku./Bilek Responsible: Technology Thermodynamics Release date: 01.06.2010
Operational data – spark plugs
Spark plug type ________________ Optimal electrode distance __________mm

Ignition voltage requirement, setpoint from: _________kV to: _________kV
range (see IW 0309 M0)
Calendar week: ___ Calendar week: ___ Calendar week: ___ Calendar week: ___
Operating hours: ___ Operating hours: ___ Operating hours: ___ Operating hours: ___
Cyl. Ignition voltage require- Ignition voltage require- Ignition voltage require- Ignition voltage require-
ment ment ment ment
ACTUAL after ad- ACTUAL after ad- ACTUAL after ad- ACTUAL after ad-
Value justment or Value justment or Value justment or Value justment or
exchange exchange exchange exchange
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Cyl. Ignition voltage require- Ignition voltage re- Ignition voltage re- Ignition voltage re-
ment quirement quirement quirement
ACTUAL Val- after ad- ACTUAL after ad- ACTUAL after ad- ACTUAL after ad-
ue justment Value justment Value justment Value justment
or ex- or ex- or ex- or ex-
change change change change
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Operational data - Valve-stem projection
AV=Outlet valve IV = Inlet valve
Cyl. Operating hours: ______ Operating hours: ______ Operating hours: ______
Valve-stem projection (mm) Valve-stem projection (mm) Valve-stem projection (mm)
OV IV OV IV OV IV
left right left right left right left right left right left right
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Operational data on leak test for pipes and components
carrying fuel gas and mixtures
Operat- Leak test- Date performed by Signature Comments

ing ing (carried out work)
hours
8000 ✔
16000
24000
32000
40000
48000
56000
*)
*) If any changes, repairs, unscheduled maintenance!

Author: Doku./Bilek Responsible: TET/ Fuerhapter Markus Release date: 25.10.2010
Operational data: E 8079 6
Data collection for flexibly-mounted coupling housing
Guide value: ~12 mm
Inspection inter- Gap width Date Collected by

vals
Tolerance: ± 2 mm
Commissioning A = _______mm C = _______mm
B = _______mm
4000 A = _______mm C = _______mm

B = _______mm
8000 A = _______mm C = _______mm
B = _______mm
12000 A = _______mm C = _______mm
B = _______mm
16000 A = _______mm C = _______mm
B = _______mm
20000 A = _______mm C = _______mm
B = _______mm
24000 A = _______mm C = _______mm
B = _______mm
28000 A = _______mm C = _______mm
B = _______mm
32000 A = _______mm C = _______mm
B = _______mm
36000 A = _______mm C = _______mm
B = _______mm

Author: Doku./Bilek Responsible: Field Engineers HQ/Hummel Martin Release date: 17.12.2010

vals
40000 A = _______mm C = _______mm
B = _______mm
44000 A = _______mm C = _______mm
B = _______mm
48000 A = _______mm C = _______mm
B = _______mm
52000 A = _______mm C = _______mm
B = _______mm
56000 A = _______mm C = _______mm
B = _______mm
60000 A = _______mm C = _______mm
B = _______mm
*) A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
*) For repairs outside regular maintenance!

7.1
of warranty claims.

Oh
< 100 Oh
Number of starts
1000 Oh
Number of starts
2000 Oh
Number of starts
3000 Oh
Number of starts
4000 Oh
Number of starts
5000 Oh
Number of starts
6000 Oh
Number of starts
7000 Oh
Number of starts
8000 Oh
Number of starts
9000 Oh
Number of starts
10000 Oh
Number of starts
11000 Oh
Number of starts
12000 Oh
Number of starts
13000 Oh
Number of starts
14000 Oh
Number of starts
15000 Oh
Number of starts
16000 Oh
Number of starts

7.1
of warranty claims.

Oh
17000 Oh
Number of starts
18000 Oh
Number of starts
19000 Oh
Number of starts
20000 Oh
Number of starts
21000 Oh
Number of starts
22000 Oh
Number of starts
23000 Oh
Number of starts
24000 Oh
Number of starts
25000 Oh
Number of starts
26000 Oh
Number of starts
27000 Oh
Number of starts
28000 Oh
Number of starts
29000 Oh
Number of starts
30000 Oh
Number of starts
31000 Oh
Number of starts
32000 Oh
Number of starts
33000 Oh
Number of starts
34000 Oh
Number of starts

7.1
of warranty claims.

Oh
35000 Oh
Number of starts
36000 Oh
Number of starts
37000 Oh
Number of starts
38000 Oh
Number of starts
39000 Oh
Number of starts
40000 Oh
Number of starts
41000 Oh
Number of starts
42000 Oh
Number of starts
43000 Oh
Number of starts
44000 Oh
Number of starts
45000 Oh
Number of starts
46000 Oh
Number of starts
47000 Oh
Number of starts
48000 Oh
Number of starts
49000 Oh
Number of starts
50000 Oh
Number of starts
51000 Oh
Number of starts
52000 Oh
Number of starts

7.1
of warranty claims.

Oh
53000 Oh
Number of starts
54000 Oh
Number of starts
55000 Oh
Number of starts
56000 Oh
Number of starts
57000 Oh
Number of starts
58000 Oh
Number of starts
59000 Oh
Number of starts
60000 Oh
Number of starts

8.1
cos phi φ
ue
value
no.: 3 15 °C
4 16 °C
5 17 °C
6 18 °C
7 19 °C
8 20 °C
9 21 °C
10 22 °C
11 23 °C
12 24 °C
temperature
Oil temperature °C
Oil pressure bar
pressure *) **)
ting (optional)

8.1
tion
Operating hours h
Start counter
changer)
ation?
open air)
Engine room °C
firmed:



150 Oh ✓




Mixture pressure at
outlet

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)

2000 p1=______mbar ∆p =_____mbar

p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


take
Crankcase pressure
let
2000 p1=______mbar ∆p =_____mbar
p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar


take
Crankcase pressure
let
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


let

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


ment ment ment ment
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24


hours
8000 ✔
16000
24000
32000
40000
48000
56000
*)

Guide value: ~12 mm

vals
Tolerance: ± 2 mm
B = _______mm
4000 A = _______mm C = _______mm

B = _______mm
8000 A = _______mm C = _______mm
B = _______mm
12000 A = _______mm C = _______mm
B = _______mm
16000 A = _______mm C = _______mm
B = _______mm
20000 A = _______mm C = _______mm
B = _______mm
24000 A = _______mm C = _______mm
B = _______mm
28000 A = _______mm C = _______mm
B = _______mm
32000 A = _______mm C = _______mm
B = _______mm
36000 A = _______mm C = _______mm
B = _______mm


vals
40000 A = _______mm C = _______mm
B = _______mm
44000 A = _______mm C = _______mm
B = _______mm
48000 A = _______mm C = _______mm
B = _______mm
52000 A = _______mm C = _______mm
B = _______mm
56000 A = _______mm C = _______mm
B = _______mm
60000 A = _______mm C = _______mm
B = _______mm
*) A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm

9.1
of warranty claims.

Oh
< 100 Oh
Number of starts
1000 Oh
Number of starts
2000 Oh
Number of starts
3000 Oh
Number of starts
4000 Oh
Number of starts
5000 Oh
Number of starts
6000 Oh
Number of starts
7000 Oh
Number of starts
8000 Oh
Number of starts
9000 Oh
Number of starts
10000 Oh
Number of starts
11000 Oh
Number of starts
12000 Oh
Number of starts
13000 Oh
Number of starts
14000 Oh
Number of starts
15000 Oh
Number of starts
16000 Oh
Number of starts

9.1
of warranty claims.

Oh
17000 Oh
Number of starts
18000 Oh
Number of starts
19000 Oh
Number of starts
20000 Oh
Number of starts
21000 Oh
Number of starts
22000 Oh
Number of starts
23000 Oh
Number of starts
24000 Oh
Number of starts
25000 Oh
Number of starts
26000 Oh
Number of starts
27000 Oh
Number of starts
28000 Oh
Number of starts
29000 Oh
Number of starts
30000 Oh
Number of starts
31000 Oh
Number of starts
32000 Oh
Number of starts
33000 Oh
Number of starts
34000 Oh
Number of starts

9.1
of warranty claims.

Oh
35000 Oh
Number of starts
36000 Oh
Number of starts
37000 Oh
Number of starts
38000 Oh
Number of starts
39000 Oh
Number of starts
40000 Oh
Number of starts
41000 Oh
Number of starts
42000 Oh
Number of starts
43000 Oh
Number of starts
44000 Oh
Number of starts
45000 Oh
Number of starts
46000 Oh
Number of starts
47000 Oh
Number of starts
48000 Oh
Number of starts
49000 Oh
Number of starts
50000 Oh
Number of starts
51000 Oh
Number of starts
52000 Oh
Number of starts

9.1
of warranty claims.

Oh
53000 Oh
Number of starts
54000 Oh
Number of starts
55000 Oh
Number of starts
56000 Oh
Number of starts
57000 Oh
Number of starts
58000 Oh
Number of starts
59000 Oh
Number of starts
60000 Oh
Number of starts

10.1
cos phi φ
ue
value
no.: 3 15 °C
4 16 °C
5 17 °C
6 18 °C
7 19 °C
8 20 °C
9 21 °C
10 22 °C
11 23 °C
12 24 °C
temperature
Oil temperature °C
Oil pressure bar
pressure *) **)
ting (optional)

10.1
tion
Operating hours h
Start counter
changer)
ation?
open air)
Engine room °C
firmed:



150 Oh ✓




Mixture pressure at
outlet

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)

2000 p1=______mbar ∆p =_____mbar

p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


take
Crankcase pressure
let
2000 p1=______mbar ∆p =_____mbar
p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar


take
Crankcase pressure
let
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


let

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


ment ment ment ment
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24


hours
8000 ✔
16000
24000
32000
40000
48000
56000
*)

Guide value: ~12 mm

vals
Tolerance: ± 2 mm
B = _______mm
4000 A = _______mm C = _______mm

B = _______mm
8000 A = _______mm C = _______mm
B = _______mm
12000 A = _______mm C = _______mm
B = _______mm
16000 A = _______mm C = _______mm
B = _______mm
20000 A = _______mm C = _______mm
B = _______mm
24000 A = _______mm C = _______mm
B = _______mm
28000 A = _______mm C = _______mm
B = _______mm
32000 A = _______mm C = _______mm
B = _______mm
36000 A = _______mm C = _______mm
B = _______mm


vals
40000 A = _______mm C = _______mm
B = _______mm
44000 A = _______mm C = _______mm
B = _______mm
48000 A = _______mm C = _______mm
B = _______mm
52000 A = _______mm C = _______mm
B = _______mm
56000 A = _______mm C = _______mm
B = _______mm
60000 A = _______mm C = _______mm
B = _______mm
*) A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm

11.1
of warranty claims.

Oh
< 100 Oh
Number of starts
1000 Oh
Number of starts
2000 Oh
Number of starts
3000 Oh
Number of starts
4000 Oh
Number of starts
5000 Oh
Number of starts
6000 Oh
Number of starts
7000 Oh
Number of starts
8000 Oh
Number of starts
9000 Oh
Number of starts
10000 Oh
Number of starts
11000 Oh
Number of starts
12000 Oh
Number of starts
13000 Oh
Number of starts
14000 Oh
Number of starts
15000 Oh
Number of starts
16000 Oh
Number of starts

11.1
of warranty claims.

Oh
17000 Oh
Number of starts
18000 Oh
Number of starts
19000 Oh
Number of starts
20000 Oh
Number of starts
21000 Oh
Number of starts
22000 Oh
Number of starts
23000 Oh
Number of starts
24000 Oh
Number of starts
25000 Oh
Number of starts
26000 Oh
Number of starts
27000 Oh
Number of starts
28000 Oh
Number of starts
29000 Oh
Number of starts
30000 Oh
Number of starts
31000 Oh
Number of starts
32000 Oh
Number of starts
33000 Oh
Number of starts
34000 Oh
Number of starts

11.1
of warranty claims.

Oh
35000 Oh
Number of starts
36000 Oh
Number of starts
37000 Oh
Number of starts
38000 Oh
Number of starts
39000 Oh
Number of starts
40000 Oh
Number of starts
41000 Oh
Number of starts
42000 Oh
Number of starts
43000 Oh
Number of starts
44000 Oh
Number of starts
45000 Oh
Number of starts
46000 Oh
Number of starts
47000 Oh
Number of starts
48000 Oh
Number of starts
49000 Oh
Number of starts
50000 Oh
Number of starts
51000 Oh
Number of starts
52000 Oh
Number of starts

11.1
of warranty claims.

Oh
53000 Oh
Number of starts
54000 Oh
Number of starts
55000 Oh
Number of starts
56000 Oh
Number of starts
57000 Oh
Number of starts
58000 Oh
Number of starts
59000 Oh
Number of starts
60000 Oh
Number of starts

12.1
cos phi φ
ue
value
no.: 3 15 °C
4 16 °C
5 17 °C
6 18 °C
7 19 °C
8 20 °C
9 21 °C
10 22 °C
11 23 °C
12 24 °C
temperature
Oil temperature °C
Oil pressure bar
pressure *) **)
ting (optional)

12.1
tion
Operating hours h
Start counter
changer)
ation?
open air)
Engine room °C
firmed:



150 Oh ✓




Mixture pressure at
outlet

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)

2000 p1=______mbar ∆p =_____mbar

p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


take
Crankcase pressure
let
2000 p1=______mbar ∆p =_____mbar
p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar


take
Crankcase pressure
let
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


let

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


ment ment ment ment
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24


hours
8000 ✔
16000
24000
32000
40000
48000
56000
*)

Guide value: ~12 mm

vals
Tolerance: ± 2 mm
B = _______mm
4000 A = _______mm C = _______mm

B = _______mm
8000 A = _______mm C = _______mm
B = _______mm
12000 A = _______mm C = _______mm
B = _______mm
16000 A = _______mm C = _______mm
B = _______mm
20000 A = _______mm C = _______mm
B = _______mm
24000 A = _______mm C = _______mm
B = _______mm
28000 A = _______mm C = _______mm
B = _______mm
32000 A = _______mm C = _______mm
B = _______mm
36000 A = _______mm C = _______mm
B = _______mm


vals
40000 A = _______mm C = _______mm
B = _______mm
44000 A = _______mm C = _______mm
B = _______mm
48000 A = _______mm C = _______mm
B = _______mm
52000 A = _______mm C = _______mm
B = _______mm
56000 A = _______mm C = _______mm
B = _______mm
60000 A = _______mm C = _______mm
B = _______mm
*) A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm

13.1
of warranty claims.

Oh
< 100 Oh
Number of starts
1000 Oh
Number of starts
2000 Oh
Number of starts
3000 Oh
Number of starts
4000 Oh
Number of starts
5000 Oh
Number of starts
6000 Oh
Number of starts
7000 Oh
Number of starts
8000 Oh
Number of starts
9000 Oh
Number of starts
10000 Oh
Number of starts
11000 Oh
Number of starts
12000 Oh
Number of starts
13000 Oh
Number of starts
14000 Oh
Number of starts
15000 Oh
Number of starts
16000 Oh
Number of starts

13.1
of warranty claims.

Oh
17000 Oh
Number of starts
18000 Oh
Number of starts
19000 Oh
Number of starts
20000 Oh
Number of starts
21000 Oh
Number of starts
22000 Oh
Number of starts
23000 Oh
Number of starts
24000 Oh
Number of starts
25000 Oh
Number of starts
26000 Oh
Number of starts
27000 Oh
Number of starts
28000 Oh
Number of starts
29000 Oh
Number of starts
30000 Oh
Number of starts
31000 Oh
Number of starts
32000 Oh
Number of starts
33000 Oh
Number of starts
34000 Oh
Number of starts

13.1
of warranty claims.

Oh
35000 Oh
Number of starts
36000 Oh
Number of starts
37000 Oh
Number of starts
38000 Oh
Number of starts
39000 Oh
Number of starts
40000 Oh
Number of starts
41000 Oh
Number of starts
42000 Oh
Number of starts
43000 Oh
Number of starts
44000 Oh
Number of starts
45000 Oh
Number of starts
46000 Oh
Number of starts
47000 Oh
Number of starts
48000 Oh
Number of starts
49000 Oh
Number of starts
50000 Oh
Number of starts
51000 Oh
Number of starts
52000 Oh
Number of starts

13.1
of warranty claims.

Oh
53000 Oh
Number of starts
54000 Oh
Number of starts
55000 Oh
Number of starts
56000 Oh
Number of starts
57000 Oh
Number of starts
58000 Oh
Number of starts
59000 Oh
Number of starts
60000 Oh
Number of starts

14.1
cos phi φ
ue
value
no.: 3 15 °C
4 16 °C
5 17 °C
6 18 °C
7 19 °C
8 20 °C
9 21 °C
10 22 °C
11 23 °C
12 24 °C
temperature
Oil temperature °C
Oil pressure bar
pressure *) **)
ting (optional)

14.1
tion
Operating hours h
Start counter
changer)
ation?
open air)
Engine room °C
firmed:



150 Oh ✓




Mixture pressure at
outlet

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)

2000 p1=______mbar ∆p =_____mbar

p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


take
Crankcase pressure
let
2000 p1=______mbar ∆p =_____mbar
p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar


take
Crankcase pressure
let
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


let

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


ment ment ment ment
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24


hours
8000 ✔
16000
24000
32000
40000
48000
56000
*)

Guide value: ~12 mm

vals
Tolerance: ± 2 mm
B = _______mm
4000 A = _______mm C = _______mm

B = _______mm
8000 A = _______mm C = _______mm
B = _______mm
12000 A = _______mm C = _______mm
B = _______mm
16000 A = _______mm C = _______mm
B = _______mm
20000 A = _______mm C = _______mm
B = _______mm
24000 A = _______mm C = _______mm
B = _______mm
28000 A = _______mm C = _______mm
B = _______mm
32000 A = _______mm C = _______mm
B = _______mm
36000 A = _______mm C = _______mm
B = _______mm


vals
40000 A = _______mm C = _______mm
B = _______mm
44000 A = _______mm C = _______mm
B = _______mm
48000 A = _______mm C = _______mm
B = _______mm
52000 A = _______mm C = _______mm
B = _______mm
56000 A = _______mm C = _______mm
B = _______mm
60000 A = _______mm C = _______mm
B = _______mm
*) A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm

15.1
of warranty claims.

Oh
< 100 Oh
Number of starts
1000 Oh
Number of starts
2000 Oh
Number of starts
3000 Oh
Number of starts
4000 Oh
Number of starts
5000 Oh
Number of starts
6000 Oh
Number of starts
7000 Oh
Number of starts
8000 Oh
Number of starts
9000 Oh
Number of starts
10000 Oh
Number of starts
11000 Oh
Number of starts
12000 Oh
Number of starts
13000 Oh
Number of starts
14000 Oh
Number of starts
15000 Oh
Number of starts
16000 Oh
Number of starts

15.1
of warranty claims.

Oh
17000 Oh
Number of starts
18000 Oh
Number of starts
19000 Oh
Number of starts
20000 Oh
Number of starts
21000 Oh
Number of starts
22000 Oh
Number of starts
23000 Oh
Number of starts
24000 Oh
Number of starts
25000 Oh
Number of starts
26000 Oh
Number of starts
27000 Oh
Number of starts
28000 Oh
Number of starts
29000 Oh
Number of starts
30000 Oh
Number of starts
31000 Oh
Number of starts
32000 Oh
Number of starts
33000 Oh
Number of starts
34000 Oh
Number of starts

15.1
of warranty claims.

Oh
35000 Oh
Number of starts
36000 Oh
Number of starts
37000 Oh
Number of starts
38000 Oh
Number of starts
39000 Oh
Number of starts
40000 Oh
Number of starts
41000 Oh
Number of starts
42000 Oh
Number of starts
43000 Oh
Number of starts
44000 Oh
Number of starts
45000 Oh
Number of starts
46000 Oh
Number of starts
47000 Oh
Number of starts
48000 Oh
Number of starts
49000 Oh
Number of starts
50000 Oh
Number of starts
51000 Oh
Number of starts
52000 Oh
Number of starts

15.1
of warranty claims.

Oh
53000 Oh
Number of starts
54000 Oh
Number of starts
55000 Oh
Number of starts
56000 Oh
Number of starts
57000 Oh
Number of starts
58000 Oh
Number of starts
59000 Oh
Number of starts
60000 Oh
Number of starts

16.1
cos phi φ
ue
value
no.: 3 15 °C
4 16 °C
5 17 °C
6 18 °C
7 19 °C
8 20 °C
9 21 °C
10 22 °C
11 23 °C
12 24 °C
temperature
Oil temperature °C
Oil pressure bar
pressure *) **)
ting (optional)

16.1
tion
Operating hours h
Start counter
changer)
ation?
open air)
Engine room °C
firmed:



150 Oh ✓




Mixture pressure at
outlet

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)

2000 p1=______mbar ∆p =_____mbar

p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar

tial pressure

played by DIA.NE)
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


take
Crankcase pressure
let
2000 p1=______mbar ∆p =_____mbar
p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
p2=______mbar
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar


take
Crankcase pressure
let
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


let

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar


ment ment ment ment
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

OV IV OV IV OV IV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24


hours
8000 ✔
16000
24000
32000
40000
48000
56000
*)

Guide value: ~12 mm

vals
Tolerance: ± 2 mm
B = _______mm
4000 A = _______mm C = _______mm

B = _______mm
8000 A = _______mm C = _______mm
B = _______mm
12000 A = _______mm C = _______mm
B = _______mm
16000 A = _______mm C = _______mm
B = _______mm
20000 A = _______mm C = _______mm
B = _______mm
24000 A = _______mm C = _______mm
B = _______mm
28000 A = _______mm C = _______mm
B = _______mm
32000 A = _______mm C = _______mm
B = _______mm
36000 A = _______mm C = _______mm
B = _______mm


vals
40000 A = _______mm C = _______mm
B = _______mm
44000 A = _______mm C = _______mm
B = _______mm
48000 A = _______mm C = _______mm
B = _______mm
52000 A = _______mm C = _______mm
B = _______mm
56000 A = _______mm C = _______mm
B = _______mm
60000 A = _______mm C = _______mm
B = _______mm
*) A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm
A = _______mm C = _______mm
B = _______mm

17 Initial commissioning data sheet
Commissioning protocol:
Keyword: DADU ENERGY 1 - 6 Design No.: J J245

Generator type: JGS 620 GS-N.L Year of construction: 2011
Type/version: F 101 Country of installation: PAK
Software version B&R/SAM

RPS: (computer-controlled control)
VISU: (Dia.ne visualisation)
MMU: (Multi-function transducer)
ZÜND: (Ignition)
MONIC: (Ignition visualisation)
KLS98: (Knock control)
TEC: (Tecjet)
SAM:
EMS3000:
Software version Siemens/B&R
Sps: (PLC control)
Syn: (Synchronisation)
Stat: (Station control)
Engine No.
1022346 1021789 1021828 1021849 1021864
Engine No. 1022346 1021789 1021828 1021849 1021864
Operating hours Bh
Number of starts
Power, electric kW
Voltage - average value V
Current - average value A
Zero conductor current A
Cos phi Ind/Kap
Exciter voltage V
Mixture temperature °C
Charge pressure mbar
Gas-mixer position / TEC mm / %
Flow-Tech position %
After cooler differential pressure, mixture side
mbar
Mixture cooling water temperature, intake, stage 1
°C
°C
Engine cooling-water temperature °C
Engine cooling-water pressure bar
Oil temperature °C
Oil pressure bar
Gas pressure before pre-pressure controller
mbar
Gas pressure after pre-pressure controller
mbar
Pre-combustion chamber differential pressure
mbar
Gas pressure before differential-pressure controller
bar
Methane content (CH4) %
Gas temperature before activated carbon filter
°C
Engine Type
Camshaft offset ° v OTH
GET
Knock limit
Pulse slope retard
Pulse slope forward
Erstellt: Service Datum: 02.02.2012

ndex: s Seite: 1 von 4
Engine No.
1022346 1021789 1021828 1021849 1021864
Cylinder temp. 1/2 °C
Ignition-voltage requirement min/max kV
Ignition point °KWvOT
Hot water forward temperature °C
Hot water return temperature °C
Exhaust-gas heat exchanger - tube-plate temperature
°C
Drive side (DS) generator bearing temperature
°C
Non-drive side (NDS) generator bearing temperature
°C
Generator winding temperature 1 °C
Exhaust-gas temperature before heat exchanger
°C
Exhaust-gas temperature after heat exchanger
°C
Cooling water inlet temperature at exhaust-gas heat
exchanger °C
Cooling water outlet temperature at exhaust-gas heat
exchanger °C
Differential pressure across flame trap, mixture side
mbar
Differential pressure - exhaust-gas heat exchanger
mbar
Differential pressure - catalytic converter mbar
Exhaust-gas backpressure after exhaust-gas
turbocharger
mbar
O2 value Vol./%
CO value (related to 5% O2) mg/Nm3
NOx value (related to 5% O2) mg/Nm3
Engine cooling water - concentration test

Vol./%
Product applied / additive
Mixture cooling circuit (2nd stage) concentration test
Vol./%
Intake temperature at engine air-filter intake
°C
Generator cooling-air intake temperature
°C
Crankcase pressure (at dipstick)
mm/WS
Engine-room pressure mbar
Valve noise (KLS 98) mV
Zero pressure controller setting mm/U

Index: s Seite: 2 von 4
Engine No.
Valve stem projection: 1022346 1021789 1021828 1021849 1021864
Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2
Left-hand intake valve mm

Right-hand intake valve mm
Left-hand exhaust valve mm
Right-hand exhaust valve mm











Additional data for biogas installations with exhaust-gas heat exchanger

Measure these data at different load points. Make sure, however, to carry out measurements only after each of
the load points has been stable for a certain period of time (approx. 15 min.)!!
CH4 content to determine the calorific value (if online

measurement available) %
H2S concentration in fuel gas ppm
Output in % of Pn % 50 75 100
O2 value upstream/downstream of catalytic converter
(if available) Vol./% / / /
O2 value (related to 5% O2) upstream/downstream of
catalytic converter (if available) mg/Nm3 / / /
NOx value (related to 5% O2) upstream/downstream of
catalytic converter (if available)
mg/Nm3 / / /
°C
°C
exchanger °C
exchanger °C
Exhaust-gas back pressure upstream of exhaust-gas
heat exchanger mbar
Exhaust-gas back pressure downstream of exhaust-gas
heat exchanger mbar
Produced electrical power MWh
Oxidation catalyst installed? yes no
GEJ part number of the oxidation catalyst according
spare parts book
Manufacturer and type of exhaust-gas heat exchanger

according to type plate
Remote data transfer

To select an outside line (if not main telephone
connection)
Modem type
Internal modem
External modem
Jenbacher scope of supply
Power cubicle yes no
Synchronisation yes no
Lubricating oil type:
While commissioning the equipment, you must note down all data to be able to use this as a "reference list" and
compare the data with more recent data. Comparing the reference data with recent data enables you to detect
possible problems at an early stage or to analyse the problem afterwards.
Name:
Drafted on:
(signature)

Keyword: DADU ENERGY 1 - 6 Design No.: J J245

Generator type: JGS 620 GS-N.L Year of construction: 2011
Type/version: F 101 Country of installation: PAK
Software version B&R/SAM

RPS: (computer-controlled control)
VISU: (Dia.ne visualisation)
MMU: (Multi-function transducer)
ZÜND: (Ignition)
MONIC: (Ignition visualisation)
KLS98: (Knock control)
TEC: (Tecjet)
SAM:
EMS3000:
Software version Siemens/B&R
Sps: (PLC control)
Syn: (Synchronisation)
Stat: (Station control)
Engine No.
1021883
Engine No. 1021883
Operating hours Bh
Number of starts
Power, electric kW
Voltage - average value V
Current - average value A
Zero conductor current A
Cos phi Ind/Kap
Exciter voltage V
Mixture temperature °C
Charge pressure mbar
Gas-mixer position / TEC mm / %
Flow-Tech position %
After cooler differential pressure, mixture side
mbar
°C
°C
Engine cooling-water temperature °C
Engine cooling-water pressure bar
Oil temperature °C
Oil pressure bar
Gas pressure before pre-pressure controller
mbar
Gas pressure after pre-pressure controller
mbar
Pre-combustion chamber differential pressure
mbar
Gas pressure before differential-pressure controller
bar
Methane content (CH4) %
Gas temperature before activated carbon filter
°C
Engine Type
Camshaft offset ° v OTH
GET
Knock limit
Pulse slope retard
Pulse slope forward

Engine No.
1021883
Ignition-voltage requirement min/max kV
Ignition point °KWvOT
Hot water forward temperature °C
Hot water return temperature °C
Exhaust-gas heat exchanger - tube-plate temperature
°C
Drive side (DS) generator bearing temperature
°C
Non-drive side (NDS) generator bearing temperature
°C
°C
°C
exchanger °C
exchanger °C
Differential pressure across flame trap, mixture side
mbar
Differential pressure - exhaust-gas heat exchanger
mbar
Differential pressure - catalytic converter mbar
Exhaust-gas backpressure after exhaust-gas
turbocharger
mbar
O2 value Vol./%
CO value (related to 5% O2) mg/Nm3
NOx value (related to 5% O2) mg/Nm3
Engine cooling water - concentration test

Vol./%
Mixture cooling circuit (2nd stage) concentration test
Vol./%
Intake temperature at engine air-filter intake
°C
Generator cooling-air intake temperature
°C
Crankcase pressure (at dipstick)
mm/WS
Engine-room pressure mbar
Valve noise (KLS 98) mV
Zero pressure controller setting mm/U

Engine No.
Valve stem projection: 1021883












Additional data for biogas installations with exhaust-gas heat exchanger

Measure these data at different load points. Make sure, however, to carry out measurements only after each of
the load points has been stable for a certain period of time (approx. 15 min.)!!
CH4 content to determine the calorific value (if online

measurement available) %
H2S concentration in fuel gas ppm
Output in % of Pn % 50 75 100
O2 value upstream/downstream of catalytic converter
(if available) Vol./% / / /
O2 value (related to 5% O2) upstream/downstream of
catalytic converter (if available) mg/Nm3 / / /
NOx value (related to 5% O2) upstream/downstream of
catalytic converter (if available)
mg/Nm3 / / /
°C
°C
exchanger °C
exchanger °C
Exhaust-gas back pressure upstream of exhaust-gas
heat exchanger mbar
Exhaust-gas back pressure downstream of exhaust-gas
heat exchanger mbar
Produced electrical power MWh
Oxidation catalyst installed? yes no
GEJ part number of the oxidation catalyst according
spare parts book
Manufacturer and type of exhaust-gas heat exchanger

according to type plate
Remote data transfer

To select an outside line (if not main telephone
connection)
Modem type
Internal modem
External modem
Jenbacher scope of supply
Power cubicle yes no
Synchronisation yes no
Lubricating oil type:
While commissioning the equipment, you must note down all data to be able to use this as a "reference list" and
compare the data with more recent data. Comparing the reference data with recent data enables you to detect
possible problems at an early stage or to analyse the problem afterwards.
Name:
Drafted on:
(signature)


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JGS 620 GS-N.

© GE Jenbacher GmbH & Co OG

Original operating instructions

GE proprietary information: CONFIDENTIAL

© GE Jenbacher GmbH & Co OG, 2012-01

User Instructions ......................................................................................................................................................................... 1

General conditions ...................................................................................................................................................................... 2

Maintenance plan ........................................................................................................................................................................ 3

Inspection and maintenance work ........................................................................................................................................... 4

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Cylinder liner ..................................................................................................................................................................................... W 8049 M6

Maintenance protocol Module 1 ............................................................................................................................................... 5

Registration of operational data Module 1 ............................................................................................................................. 6

Maintenance protocol Module 2 ............................................................................................................................................... 7

Registration of operational data Module 2 ............................................................................................................................. 8

Maintenance protocol Module 3 ............................................................................................................................................... 9

Registration of operational data Module 3 ........................................................................................................................... 10

Maintenance protocol Module 4 ............................................................................................................................................. 11

Registration of operational data Module 4 ........................................................................................................................... 12

Maintenance protocol Module 5 ............................................................................................................................................. 13

Registration of operational data Module 5 ........................................................................................................................... 14

Maintenance protocol Module 6 ............................................................................................................................................. 15

Registration of operational data Module 6 ........................................................................................................................... 16

Initial commissioning data sheet ........................................................................................................................................... 17

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

▪ Operation of the system

▪ What inspection work and maintenance work needs to be car-

Spare parts list

▪ Selecting the required spare part

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

1.1 Engine type plate

Engine type plate

1.2 System type plate

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

System type plate

Type Type Max. ambient Max. ambient temperature:

2.1 Engine type designation

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Term Abbreviation Key to abbreviation e.g.

Engine type designation

① Manufacturer ④ Mode of operation

2.2 Module type designation

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Term Abbreviation Key to abbreviation e.g.

Plant type designation

① Installation type ⑥ Mode of operation

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Menu bullets – Tips:

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

Identification: DADU ENERGY 1 - 6 Module number: J J245 Module number: _______

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