W 8053 M6

Maintenance Instruction

Cylinder head

© INNIO Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach, Austria
www.innio.com
 W 8053 M6
Cylinder head

1 Scope ..................................................................................................................................... 1
2 Purpose.................................................................................................................................. 1
3 Maintenance interval............................................................................................................. 1
4 Safety information................................................................................................................. 3
5 Additional information.......................................................................................................... 3
6 Required tools, equipment and materials........................................................................... 4
7 Work steps............................................................................................................................. 5
7.1 Tightening the nuts on the prechamber retaining bracket....................................................... 5
7.2 Replacing the rocker cover moulded gasket ........................................................................... 5
7.3 Replace the cylinder head with a new or overhauled cylinder head ..................................... 10
7.4 Replacing the O-rings on the cylinder head .......................................................................... 10
8 Revision code...................................................................................................................... 10

The target recipients of this document are:

Customers, distribution partners, service partners, commissioning partners, subsidiaries/branches,
Jenbach location
INNIO proprietary information: CONFIDENTIAL
The information contained in this document is the proprietary information of INNIO Jenbacher GmbH &
Co OG and its subsidiaries and is disclosed in confidence. It is the property of INNIO and shall not be
used, disclosed to others or reproduced without express written consent. This includes but is not limited
to use for the creation, manufacture, development or derivation of any repairs, modifications, spare parts,
designs or configuration changes, or for obtaining 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.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY

1 Scope
This Maintenance Instruction (W) applies to the following Jenbacher Gas Engines:
• Type 6 engines

2 Purpose
This Maintenance Instruction (W) lays down the maintenance interval and describes the following activity:
• Replacing the rocker cover moulded gasket

3 Maintenance interval
Maintenance work Maintenance interval Carried out by *)
⇨ Tightening the nuts on the prechamber
2,000 Oh K
retaining bracket
⇨ Replacing the rocker cover moulded gasket 10,000 Oh / 5 years K
⇨ Replace the cylinder head with a new or 30,000 Oh / 6,000 starts
1) INNIO
overhauled cylinder head
⇨ Replace the cylinder head with a new or
30,000 Oh 2) INNIO
overhauled cylinder head
⇨ Replacing the O-rings on the cylinder head 30,000 Oh / 5 years INNIO
1)
Only applies to "H" cylinder head. When the total wear limit as shown by measuring the valve-stem pro-
jection has been reached (see W 0400 M6)

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

Index: 11 Page No.: 1/10
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 W 8053 M6
Cylinder head

2)
Only applies to "F" cylinder head. When the total wear limit as shown by measuring the valve-stem pro-
jection has been reached (see W 0400 M6)

Valid for:
• Type 6: Maintenance schedule A

Maintenance work Maintenance interval Carried out by *)

⇨ Tightening the nuts on the prechamber
2,000 Oh K
retaining bracket
⇨ Replacing the rocker cover moulded gasket 10,000 Oh / 5 years K
⇨ Replace the cylinder head with a new or
30,000 Oh 1) INNIO
overhauled cylinder head
⇨ Replacing the O-rings on the cylinder head 30,000 Oh / 5 years INNIO
1)
Or when the total wear limit as shown by measuring the valve-stem projection has been reached (see
W 0400 M6)

Valid for:
• Type 6: Maintenance schedule B Maintenance schedule D

Maintenance work Maintenance interval Carried out by *)

⇨ Tightening the nuts on the prechamber
2,000 Oh K
retaining bracket
⇨ Replacing the rocker cover moulded gasket 10,000 Oh / 5 years K
⇨ Replace the cylinder head with a new or
28,000 Oh 1) INNIO
overhauled cylinder head
⇨ Replacing the O-rings on the cylinder head 28,000 Oh 2) INNIO
1)
Or when the total wear limit as shown by measuring the valve-stem projection has been reached (see
W 0400 M6)

Valid for:
• Version X

*) Carried out by This column defines who carries out the maintenance work.
K This activity is to be carried out by the customer, INNIO or a company selected and
authorised by INNIO to carry out this work.
INNIO This activity is to be carried out by INNIO or a company selected by INNIO author-
ised to carry out this work.

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

Index: 11 Page No.: 2/10
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 W 8053 M6
Cylinder head

4 Safety information

WARNING
Danger from unauthorised restarting
Serious injuries such as cutting, crushing, severing or shearing of body parts due to
unintentional contact with rotating or moving machine parts.
Ø Shut down the engine as described in TA 1100-0105.
Ø Secure the engine against unauthorised restarting in accordance with TA 2300-0010.

WARNING
Personal injury
Failure to use personal protective equipment and comply with safety instructions or
employee protection information may lead to personal injury.
Ø Wear the relevant personal protective equipment (PPE).
Ø Observe the safety instructions as per TA 2300-0005.
Ø Observe the employee protection information as per TA 2300-0001.

5 Additional information

Distinguishing between the two cylinder head version

"F" cylinder head "H" cylinder head

Relevant documents:
TA 1100-0105 – Engine shut-down
TA 1310-0011 – Standard tool catalogue

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

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 W 8053 M6
Cylinder head

TA 1902-0228E/F/J – Tightening torques for type J 6... engines, versions GS-E/F/J

TA 1902-0228G/H/K – Tightening torques for J 624 G/H/K engines
TA 1902-0228DS – J 6..DS tightening torques
TA 2300-0001 – Employee protection
TA 2300-0005 – Safety instruction
TA 2300-0010 – Guidelines for using the LOTO kit
W 0400 M6 – Valve lash

6 Required tools, equipment and materials

You will need the following tools, equipment or materials to carry out this work:
All the standard tools are included in TA 1310-0011 – Standard tool catalogue.
Please inform us if you use tools and equipment different to those on the list.
Tools and aids required for the following work are listed below.
Part number Designation Note Illustration
• Only use conventional tested workshop tools.
1234353 Tool Mechanical hand tools
for EMER service
technicians

Illustration for information

only
1246988 Ring spanner attachment For loosening/tightening
for screwing the the prechamber retainer
prechamber retainer screw connection without
toggle lever disassembly

1210145 Cleaning materials Various cleaning

materials, preferably
order on-site.
For details see
TA 1310-0011
Illustration for information
only
---- Cleaner Acetone-free residue-free
degreasing agent, e.g.
PORTA® brake cleaner
79-02).

Illustration for information

only

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

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 W 8053 M6
Cylinder head

7 Work steps

7.1 Tightening the nuts on the prechamber retaining bracket

• Remove the rocker cover as described in Chapter ⇨ Replacing the rocker cover moulded gasket.
• Using a curved wrench, tighten the nuts on the
prechamber retaining bracket to the tightening
torque specified in TA 1902-0228E/F/J or TA
1902-0228G/H/K respectively.

TA 1902-0228E/F/J – Tightening torques for type J

6... engines, versions GS-E/F/J
TA 19020228G/H/K – Tightening torques for J 624
G/H/K engines

Illustration for information only

7.2 Replacing the rocker cover moulded gasket

• Disconnect the ignition cable at the ignition coil.

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

Index: 11 Page No.: 5/10
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 W 8053 M6
Cylinder head

• Push the spark plug connector ➀ downwards

and rotate it clockwise ②.

• Remove the spark plug connector.

• Undo and remove the bolts ① (3 off).

• Shake the rocker cover gently and lift it off.

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

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 W 8053 M6
Cylinder head

• Clean the rocker cover thoroughly inside and

outside and remove any grease or oil residues.
• Remove the moulded gasket.

Illustration for information only

• Place the new moulded gasket in the groove.

Illustration for information only

NOTE
Leaks
If seals (O-rings, flat gaskets, etc.) are not properly seated or if there are burrs or cuts on
the contact surfaces, grooves, etc., leaks may occur during operation.
Ø Check contact surfaces, grooves, etc. for damage such as burrs or cuts.
Ø Check seals for damage.
Ø Check that seals are properly seated.

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

Index: 11 Page No.: 7/10
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 W 8053 M6
Cylinder head

• The projections on the moulded gasket must be

pressed cleanly into the groove to prevent the
gasket from being crushed when fitting the
rocker cover.

Illustration for information only

• Place the rocker cover on the cylinder head.
• Insert the bolts ① and tighten as described in
TA 1902- 0228xx (3 off).

TA 1902-0228E/F/J – Tightening torques for type J

6... engines, versions GS-E/F/J
TA 1902-0228G/H/K – Tightening torques for J 624
G/H/K engines
TA 1902-0228DS – J 6..DS tightening torques

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

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 W 8053 M6
Cylinder head

• Insert the spark plug connector.

• Push the spark plug connector ➀ downwards

and lock it in place by rotating it anticlockwise
②.

• Connect the ignition cable to the ignition coil.

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

Index: 11 Page No.: 9/10
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 W 8053 M6
Cylinder head

7.3 Replace the cylinder head with a new or overhauled cylinder head
This activity is to be carried out by INNIO or a company selected by INNIO authorised to carry out this
work.

7.4 Replacing the O-rings on the cylinder head

This activity is to be carried out by INNIO or a company selected by INNIO authorised to carry out this
work.

8 Revision code
Revision history
Index Date Description / Revision summary Expert
Auditor
11 31.07.2019 Arbeitsschritt „Muttern der Vorkammerbrille nachziehen“ Engensteiner S.
ergänzt / Work step „Tighten the nut of the prechamber Waldron P.
retaining bracket“ added
10 30.04.2019 GE durch INNIO ersetzt / GE replaced by INNIO Fallzberger F.
Pichler R.
9 30.11.2018 Arbeitsschritt „Formdichtung an Zylinderkopfhaube tauschen“ Dris M.
ergänzt / Work step “replace moulded gasket on cylinder head Waldron P.
cover” added
Arbeitsschritt O-Ringe am Zylinderkopf tauschen ergänzt /
Work step „replace O-rings on cylinder head“ added
8 30.07.2018 Strukturelle Anpassungen / Structural adaptions Dris M.
Standard Peaking Wartungsintervall für „H“-Zylinderkopf Waldron P.
ergänzt / Standard peaking maintenance interval for „H“
cylinder head added
Formulierungen angepasst / Wordings adapted
7 31.05.2017 Wartungsschritt Zylinderkopf Sichtkontrolle gelöscht / Becker F.
Maintenance task cylinder head visual inspection deleted Waldron P.
6 21.12.2016 Strukturelle Anpassungen / Structural adaptions De sanctis A.
SprungMarke!!!90071992603217547
Waldron P.

Author(s): Kecht S. Responsible: Waldron P. Release date: 31/07/2019

Index: 11 Page No.: 10/10
INNIO 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.