Wartung [J P659 - P687-En]

JGS 320 GS-N.
L
Maintenance
Generator set
NAVIGAT FRAME 320 Q3 2012

J P659 - P687
Engine number: _______
Module number: _______
2013-07
© 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 03.07.2013 Delivery ➔ Footer
Riedl
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, 2013-07

Identification Table
Password Module type Module number Module number engine number
NAVIGAT FRAME 320 Q3 JGS 320 GS-N.L J P659 1076385 1076386
2012
2012
2012
2012
2012
2012
2012
2012
2012
2012
2012
2012
2012
2012
2012
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
REACH-Notification and Downstream User Communication for Substances in Articles ............................................... 2.2
Declaration of Conformity ..................................................................................................................................................................................
Boundary conditions for GE Jenbacher gas engines ............................................................................................... TA 1100-0110
General conditions - Operation and Maintenance ................................................................................................... TA 1100-0111
Safety regulations ..................................................................................................................................................................... TA 2300-0005
Guidelines for using the LOTO kit ..................................................................................................................................... TA 2300-0010
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 0
Daily inspection ....................................................................................................................................................................................... I 9002 0
Lubricating oil change/oil filter change .............................................................................................................................. IW 0101 M0
Ignition voltage check / Spark plugs .................................................................................................................................... IW 0309 M0
Intake air filter - engine ............................................................................................................................................................... IW 8041 A0
Leak testing of all pipes and components carrying fuel gas and mixtures .......................................................... IW 8049 0
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 M0
Cooling water pump ...................................................................................................................................................................... W 0202 M3
Ignition ................................................................................................................................................................................................. W 0303 M0
Valve clearance ............................................................................................................................................................................... W 0400 M0
Crankcase ventilation system ................................................................................................................................................... W 0508 M0
Vibration damper ............................................................................................................................................................................ W 0601 M0
Gas mixer ............................................................................................................................................................................................ W 0704 M0
Mixture bypass valve ..................................................................................................................................................................... W 0802 M0
Maintenance after initial commissioning ............................................................................................................................... W 1000 0
Overhaul .............................................................................................................................................................................................. W 2100 M0
Exhaust gas turbocharger .......................................................................................................................................................... W 8023 M0
Generator ............................................................................................................................................................................................ W 8030 A0
GE Jenbacher - switch cabinets ............................................................................................................................................... W 8031 A0
Starter ................................................................................................................................................................................................... W 8032 M0
Elastomer components ................................................................................................................................................................... W 8033 0
Gas pressure control system ...................................................................................................................................................... W 8045 A0
Oil pump .............................................................................................................................................................................................. W 8046 M0
Piston/Piston cooling ..................................................................................................................................................................... W 8047 M0
Connecting rods and connecting rod bearings ................................................................................................................ W 8048 M0
Identification: NAVIGAT FRAME 320 Q3 2012 Module number: J P659 - P687 Module number: _______
Module type: JGS 320 GS-N.L Engine version: C 105
Author: Responsible: Release date: 03.07.2013
Index: 1 Page No.: 1 / 2
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/scraper ring .......................................................................................................................................................... W 8049 M0

Main crankshaft bearing ............................................................................................................................................................. W 8050 M0
Exhaust gas manifold/exhaust gas lagging ....................................................................................................................... W 8051 M0
Camshaft/timing gear .................................................................................................................................................................. W 8052 M0
Cylinder head replacement ........................................................................................................................................................ W 8053 M0
Pre-lubricating pump .................................................................................................................................................................... W 8054 M3
Combustion chamber ................................................................................................................................................................... W 8056 M0
Engine – cooling water circuit / Mixture recirculating water ...................................................................................... W 8080 A0
Maintenance record sheets ....................................................................................................................................................... 5

Maintenance protocol ................................................................................................................................................................................... 5.1
Registering operational data .................................................................................................................................................... 6

Operational data booklet ............................................................................................................................................................................. 6.1
Operational data – Engine lubricating oil ..................................................................................................................................... E 0101
Operational data - Heat exchanger mixture/water ............................................................................................................ E 0103 a
Operational data - crankcase ventilation system ................................................................................................................. E 0103 f
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
Initial commissioning data sheet ............................................................................................................................................. 7

Initial commissioning data sheet ............................................................................................................................................................. 7.1
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: 17.05.2013
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.
GE Jenbacher GmbH & Co OG

Achenseestraße 1-3
Engine type
Motor Typ
Moteur modèle
Engine no.
Motor Nr.
Moteur numèro
kW
HP
kW
HP
Speed min
-1
Drehzahl
Nombre de tours rpm
kg
lbs
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

A-6200 Jenbach | Austria
Type
Serial No.
Year of manufacture
Rated power COP kW
Rated power factor
Maximum site altitude of installation m
Max. ambient temperature ( intake air ) °C
Hz
Rated voltage V
Rated current A
kg
G2
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
1 6
J 3 20 GS C 05
2
3
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
1 6
2 7
3 8
J M S 3 20 GS - N /B . LC
4
9
5
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: 21.06.2013
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
+43 5244 600 566

robert.pichler@ge.com
Author: Doku./Velik Responsible: Documentation Release date: 21.07.2011
1.6
Service and Sales partners

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
Distributor/Service Provider
Intelligent Energy Generating Equipment LLC
(Orient Energy Systems Group Company)
Suite 808, Apricot Building, Dubai Silicon Oasis
P O Box 54652 Dubai, UAE
Tel.: +97 14 392 6207, Cellphone: +97 156 174 1186, Telefax: +97 14 392 6208
e-mail: faheem.shafiq@orient-power.com
Jembas Assistencia Tecnica Lda
Lardo do Soweto Nr. 88, C.P. 10013 Luanda
Angola
Tel: 00244 222 637 000
e-mail: mandy.newman@jembas.com
www: www.jembas.com
1.6
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
Enerflex Service Pty. Ltd.

Eagle Farm, Schneider Road 115
4009 Brisbane, Queensland
Tel.: +61 (0)7 33189 000, Telefax: +61 (0)7 33189 099
e-mail: smccullough@enerflex.com
www: www.enerflex.com
Orient Energy Systems Ltd.

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
1.6
e-mail: jd@ecogen.be
Filter EOOD
7, Iskarsko Shouse Blvd.,
Trade Center Europe
Building 6 Floor 1
PO 1528
Sofia, Bulgaria
Tel: +359 2 974 50 85
Fax: +359 2 974 50 87
e-mail: filter@filter.bg
www: www.filter.bg
Orient Energy Systems FZCO
Dubai Airport Free Zone, LIU, Warehouse No. G 06
DAFZA UAE
Tel: +971 4 2995300
Fax: +971 4 2995123
e-mail: rehan@orient-power.com
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
Filter SZAO
Logoisky Tract and MCAD Crossing, Minsky district,
Administrative Bldg., Office 501
223053 Minsk, Republic of Belarus
Tel.: +375 (172) 95 04 03, Telefax: +375 172 95 96 18
1.6
e-mail: Evgeny.Shakovets@filter.by
European Power Systems Ltd. (greenhouse segment)
2425 Matheson Blvd. East, 8th Floor
Mississauga, ON, L4W 5K4
CANADA
Tel: +141 680 422 03
Fax: +141 690 739 76
e-mail: buijk@epsenergy.ca
www: www.epsenergy.ca
Gas Drive Global LP
4700 47 Street SE
Calgary, AB, T2B 3R1
CANADA
Tel: +1 403 387 6300
e-mail: info@gasdriveglobal.com
www: www.gasdriveglobal.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
International Office & Packaging Operation

GE Energy (Hangzhou) Co. Ltd.
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
1.6
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.
Region: Beijing, Hebei, Shanxi, Henan, Tianjing, Chongwing
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.
Region: Liaoning, Jilin, Heilongjiang
Jiahuan Building No. 39, RM 1306, Heping nan street
Shenyang, Liaoning 110003
China
Tel.: +86 24 232 54 011, Fax: +86 24 832 51 066
e-mail: reader_song@126.com
1.6
Distributor/Service provider
YUMON INTERNATIONAL TRADE (SHANGHAI) CO., LTD.
Region: Shandong, Jiangsu, Zhejiang, Anhui, Shanghai
Rm. 1001 ZhongRong International Building
No. 1088 Pudong S. Road,
Shanghai 200120, China
Telefone: +86-21-58781256
Fax: +86-21-58784945
e-mail: goldenchao@solomon.com.tw, charleswan@solomon.com.tw
www: www.solomon.com.tw
Distributor/Service provider
Guangzhou Shenfa M&E Industry Development Co. LTD
Region: Guangdong; Guangxi; Hunan; Jiangxi; Hainan
1708#, R&F Morgan Plaza, Huaqiang Rd.
Pearl River New Town
Guangzhou, P.R. China
Tel: +86 20 835 59 493
Fax: +86 20 835 63 252
Mobile: +86 13 924 219 065
e-mail: brent.xiao@sf-power.com.cn
www: www.sf-power.com.cn
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
1.6
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
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
1.6
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,
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
1.6
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

GENELCO Power Systems Ltd.
2, Irinis Street
New Smymi Athens 17121
Tel: +30 210 934 69 94
Mobile: +30 6944 358 247
e-mail: mailto:greg.polychronidis@genelco.gr
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
1.6
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
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
1.6
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
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
Jenbacher s.r.l
Via Crocioni, 46 / H
I-37012 Bussolengo (VR)
Tel.: +39 045 6760211, Telefax: +39 045 6766322
e-mail: jes.verona@gejenbacher.com
1.6
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
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
1.6
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
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)
1.6
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
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
1.6
Tel.: +603 5569 1000, Telefax: +603 556 92660

e-mail: chanhh@jdgroup.com.my
Smith Power Mexico, S de R.L de C.V
Circuito de la Productividad Norte #138-5
El Salto, Jalisco Mexico, CP 45690
Tel.: +52 33 3164 1237
e-mail: dgall@smithppi.com
www: www.smithpowerproducts.com
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
ENTEC Services Limited

57G McLaughlins Road, Manukau City 2104
PO Box 76160, Manukau City 2241
Auckland, New Zealand
Tel:: +64 9 277 2211, Fax.: +64 9 277 2210
email: bob.weston@entec.co.nz
www: www.entec.co.nz
1.6
Orient Energy Systems FZCO
Dubai Airport Free Zone, LIU, Warehouse No. G 06
DAFZA UAE
Tel: +971 4 2995300
Fax: +971 4 2995123
e-mail: rehan@orient-power.com
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 # 09, Sector 24,
Korangi Industrial Area,
Karachi 74900, Pakistan
UAN: +92 213 111 507 507
Tel.: +92 21 35072091 4 and +92 21 35069896
Telefax: +92 21 35072095 and +92 21 35077105
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.
1.6
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 Energy Business SA

55, Floreasca St., 6th Floor, 1st District
014453 Bucharest
Tel.: +40 21 569 84 45
Telefax: +40 21 456 84 45
e-mail: office@teb.com.ro
www: www.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
1.6
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 and Volga Region

Intma CJSC
Rabochaya Str.,93, Bld.2, Office 338
109544 Moscow
T: +7 495 974 12 95
Email: d_glushich@intma.ru
Web: www.intma.ru
Focused on the South and Central 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
1.6
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
Singapore 088540
Tel.: +65 6326 3659, Telefax: +65 6326 3623
e-mail: jenbacher.singapore@ge.com
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
Topkapi Endüstri Mallari Ticaret A.S.

Pazartekke, Millet Cad. No.180-184
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
1.6
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
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
1.6
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
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
1.6
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.
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.
2.2
REACH-Notification and Downstream User Communica-
tion for Substances in Articles
Dear customer,
GE Jenbacher is committed to being a market leader in supplying products throughout the world. We have put
in place strong programs to comply with regulations in all countries in which we do business. Our approach to
REACH (Regulation 1907/2006 on the Registration, Evaluation, Authorization and Restriction of Chemicals adopt-
ed by the European Union in December 2006) is being addressed in the same rigorous manner.
GE Jenbacher has been closely following the legislative development of REACH. We are working with our suppli-
ers to identify any potential implications of REACH on the availability of materials. The vast majority of GE Jen-
bacher products including accessories and packaging are considered “articles” under REACH. The candidate
list pursuant to Article 59 of REACH has been published by ECHA at http://echa.europa.eu/chem_data_en.asp
GE Jenbacher Based on a review GE Jenbacher has been informed that the following Candidate List Substance
is contained in the article supplied, above a concentration of 0.1% by weight of product inform you acc. Article
33 accordinglyt:
Part No. Description SvHC Name CAS No. EC No. concentr. Save use
612163 Flexible hose Alkanes, 85535-84-8 287-476-5 3.16% not applicable
C10-13, chloro
C10-13, chloro
C10-13, chloro
C10-13, chloro
C10-13, chloro
C10-13, chloro
165120 O-Ring Di (2-thylhexyl) 117-81-7 204-211-0 >0,1 Gew.-% Protective
phthalat gloves made of
nitrile or butyl
rubber recom-
mended
If you have a question regarding a specific product please do not hesitate to contact:
Roland Eitzinger
GE Energy
Technical Compliance Leader
Jenbacher Gas Engines
roland.eitzinger@ge.com
www.gejenbacher.com
Achenseestr. 1-3
A-6200 Jenbach, Österreich
Author: Bilek Responsible: Eitzinger Roland Release date: 04.09.2012
Declaration of Conformity
Declaration of Conformity - ORIGINAL

according with annex II, 1.A. of the machinery directive 2006/42/EG.
We,
Achenseestraße 1 – 3
A-6200 Jenbach
herewith declare, on our responsibility, that the follow-
ing equipment
Generator set : JGS 320 GS-N.L
Generator No.: _______
together with accessory electrical plant, lifting gear and all electrical and mechanical equipment supplied
and directly associated with it
which this declaration refers to, is in accordance with the basic protective requirements of EC Directive 2006/42/
EC (Machinery Directive), 2004/108/EC (Electromagnetic compatibility) 2006/95/EC (Low-voltage guidelines -
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 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk re-
duction
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.
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.
Dr. Volker Schulte Documentation Officer: Country: IDN

General Manager Robert Pichler, Documentation Manager Date: 2013-07
Technology GE Jenbacher GmbH & Co OG Language:
Achenseestraße 1-3, 6200 Jenbach,Austria
is authorised to compile technical documents
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines
1 Precautions ..................................................................................................................................................... 2
2 Potentially explosive atmospheres ............................................................................................................. 2
3 EMERGENCY STOP .......................................................................................................................................... 2
4 Minimum clearance to be left around the module for maintenance work ......................................... 2
5 Gas and smoke alarm installation .............................................................................................................. 6
6 Fuel gas ............................................................................................................................................................ 6
6.1 Function lines in the fuel-gas system ..................................................................................................................... 7
6.2 Condensate removal in the fuel-gas system ...................................................................................................... 8
6.3 Underrunning the minimum methane value ....................................................................................................... 9
7 Intake air ........................................................................................................................................................ 10
7.1 Engine room ..................................................................................................................................................................... 10
7.1.1 type 2 & 3 engines 12
7.1.2 type 4 & 6 engines 13
7.1.3 Type 9 engine 13
7.2 Generator cooling air ................................................................................................................................................... 14
7.3 Cooling air for switchgear cabinets on the module/generating set ..................................................... 14
8 Cooling water ................................................................................................................................................ 15
8.1 General ............................................................................................................................................................................... 15
8.2 Cooling water quality ................................................................................................................................................... 16
8.3 Engine cooling water ................................................................................................................................................... 16
8.4 Cooling water for the mixture and oil .................................................................................................................. 16
8.4.1 Minimum water volumetric flow and water pressure in the high-temperature circuit (HT) of
type 6 engines 16
8.4.2 Minimum water volumetric flow, minimum pressure and return temperature in the low-temper-
ature circuit (LT) of type 6 and 9 engines 17
8.4.3 Minimum fill pressure in hot water circuits in plants with exhaust-gas heat recovery 18
8.4.4 Circulation pump demand – pump after-run 18
9 Operation with a steam boiler ................................................................................................................... 18
10 Lubricating oil ............................................................................................................................................... 18
11 Exhaust gas ................................................................................................................................................... 19
12 Electrical conditions .................................................................................................................................... 19
13 Operation and maintenance ...................................................................................................................... 20
14 Piping .............................................................................................................................................................. 21
15 Connections (GE Jenbacher's limits of supply) ....................................................................................... 21
16 Refer to the TIs listed below ....................................................................................................................... 22
NOTICE
Observance of the conditions of this Technical Instruction and performance of the ac‐
tivities described therein is the basis of safe and efficient plant operation.
Non-observance of the conditions of this Technical Instruction and/or non-perfor‐
mance of the prescribed activities or any departure from the prescribed activities shall
results in the loss of guarantee rights. This shall not be the case if the operator shows
that althouth the Technical Instruction was observed, defects already existed at the
time of handover or commissioning,
The activities and conditions defined in this Technical Instruction shall be performed
and/or observed by the plant operator. This shall not apply if this Technical Instruction
is expressly allocated to the area of responsibility of GE Jenbacher or a contractual
agreement between the operator and GE Jenbacherprovides for a different arrange‐
ment.
Author: Doku./Bilek/Boxleitner Responsible: TSR/TEM/TCE/TSA Release date: 06.09.2012
1 Precautions
Installation-specific technical conditions: see relevant technical specification.
The limiting values 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 Gas engines and products (e.g. PC compressors) may not be operated in zones 2, 1 or 0 (under
IEC 60079-10-1:2008). The plant operator is responsible for ensuring that these conditions are observed through-
out the entire period of operation (including engine starts and shut-downs).
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.
4 Minimum clearance to be left around the module for maintenance work

The carrying power 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 make sure there are freely accessible areas. If necessary, contact GE Jenbacher for
advice.
There must be room to use the crane to put cylinder heads of type 6 and 9 engines and/or turbochargers and
mixture coolers/intercoolers (of all engine types) in a temporary storage location or on pallets after removal.
Minimum clearance for modules without a turbocharger module
Minimum clearance for modules with a turbocharger module
① Turbocharger module X*) Crane - max load.

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

J 208 1,000 mm 1,000 mm 1,500 mm 1,000 mm 1,000 mm 100 kg -
Type 3, 4 en- 1,000 mm 1,000 mm 1,500 mm 1,000 mm 1,000 mm 500 kg 1,600 mm
gine
Type 6 engine 1,500 mm 1,000 mm 1,500 mm 1,000 mm 1,000 mm 1,000 kg 1,600 mm
J 624 TSTC 1,500 mm 1,000 mm 1,500 mm 1,000 mm 1,000 mm 1,000 kg 2500 mm
Type 9 engine 2500 mm 2500 mm 2500 mm 1,000 mm 1,000 mm 5,000 kg 8500 mm
Y*) type 3, 4, 6, and 9 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 be provided on one side to store any
removed parts during an overhaul.
type 2 to 6 engines: 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 in the engine room in accordance with the
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 %.
– if the gas contains an odorant and the CO content of the fuel gas is >0.5 %.
– in areas where people circulate, particularly hazardous areas (in the vicinity of gas-carrying components).
– in dead zones in terms of air flow (insufficient ventilation).
▪ The sensors must be installed at breathing height.
6 Fuel gas
In accordance with the following Technical Instruction:
▪ 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 of special gas
▪ TI 1100-0112: Installation of GE Jenbacher modules
The gas train is normally designed for a project-specific pressure. Precautions must therefore be taken in the
customer's plant design before the interface to the GE Jenbach scope of supply to prevent the gas pressure
from ever exceeding the admissible maximum pressure at any time.
GE Jenbacher Equipment may only be supplied with fuel gases that - if situated in conditions outside the en-
gine (mixture connection interface) - are not ignitable. Where required, appropriate additional technical mea-
sures must be taken (e.g. monitoring / controlling the oxygen concentration in the gas => emergency shut-
down), taking into account any specific national regulations.
A manual stop valve must be provided outside the engine room, preferably at the point where the gas pipes
enter the engine room, so that the plant can be shut down for repair and maintenance operations and in emer-
gencies.
The manual stop valve must be designed to ensure that no unauthorised person can actuate it, i.e. open it
when in locked position.
In case of CO in fuel gas: If the CO content in the fuel gas is >5 %, a nitrogen flushing installation 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 Function lines in the fuel-gas system

Gas can flow out around the outlet area of the pipes!
Function lines are defined in DVGW G 491 as controller purge lines, vent lines from the leak tester and blow-off
lines from safety valves that have to be run to atmosphere from the engine room. Purge, vent and blow-off
lines must not be run into a common manifold. Function lines of the same kind may be grouped together if this
does not adversely affect the operation of the individual items of equipment (follow the manufacturers' informa-
tion). The function line diameters must be dimensioned in compliance with local conditions and as a function of
the pressure loss (piping, bends, etc.).
Function lines are not included in the GE Jenbacher scope of supply. The design of a permanently technically
leakproof, well-made function line (e.g. to TRBS2152 Part 2) is the responsibility of the plant planner/builder.
The gases discharged at the outlets must be conducted away safely. The function line outlets must be situated
at a safe distance from ignition sources and protected against the ingress of foreign matter (e.g. rain) that
could clog or adversely affect the operation of the equipment.
The area around the function line outlets must be evaluated and designed in accordance with current local
explosion protection and industrial safety 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 extracted can be found in the specific Technical Diagram for
the plant.
Symbols used in the technical diagram
Run the function lines out of 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
Function lines (shown as dotted red lines in the above illustration) are not included in the GE Jenbacher scope
of supply!
6.2 Condensate removal in the fuel-gas system

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 from the gas system in a gas-tight way and
disposed of in accordance with 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 scope of supply. The plant planner/
builder is responsible for designing and constructing a gas-tight, well-made condensate drain in accordance
with current local regulations relating to explosion protection and safety at work.
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 (e.g. due to dirt and vibration). 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 manu-
facturer/supplier and observed accordingly.
▪ Gases dissolved in the condensate may be liberated around the condensate drain (pressure release), 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.
The interior of the condensate drain line and the area around the venting point must be evaluated and
designed as a function of the maximum gas quantity released in accordance with current local industrial
safety regulations (definition and designation of potentially explosive atmospheres e.g. on the basis of DIN
EN 1127).
The illustration below shows the layout 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 Vent point ⑤ Water trap
③ Immediate environment ⑥ Condensate disposal
6.3 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

Forced-draught fans must be installed for the engine-room ventilation. If this rule is not to be applied, a special
technical approval must be obtained from GE Jenbacher.
NOTICE
Air pressure fluctuations e.g. due to switching processes by the ventilation system
can affect the engine mixture formation. This can result in false starts and deflagrations.
a) When the module is demanded, it is essential that the engine room ventilation is
switched on by the "Auxiliaries On" outgoing contact. This activates defined back-
ground conditions during start-up and accelerating to speed.
b) During the starting and accelerating procedure, including synchronisation, no switch-
ing of the engine-room ventilation system should occur until conditions have stabilised.
Air supply to the engine room:

Dust-free air of purity class G3 (type 2 - 6 engines) and F6 (type 9 engine) according to EN 779 and/or a filter
degree of 85 % according to ASHRAE is required. If required, install a coarse-dust filter of the relevant filter class.
Combustion air aspiration from the engine room:

The combustion air is aspirated from the engine room through a combustion air supply system upstream of the
engine. Dust-free air of purity class F6 as per EN 779 must be provided. In addition, the engine room cladding
surfaces must be sealed and free of loose dust and fibres. The mesh size of air filters must not be less than that
required. If refrigeration compressors are installed in the engine room, the intake air should be drawn in from
the outside atmosphere.
Max. engine-room temperature:

The cooling and combustion intake air for the engine and generator must be as close as possible to the outside
temperature. Any temperature difference should not exceed 10 °C. Intake temperatures into the engine room
should be under 40 °C. In the event of a deviation from this, the module must be specially designed after ap-
proval is given by GE Jenbacher.
The resulting engine room temperature should not exceed 47 °C (45 °C for Type 4 engines).
A temperature difference of 10 K must be assumed during the design process when specifying the air quantity.
Max. air intake temperature (at the engine air filter):

Suitable measures must be taken to keep the combustion air temperature low ( +10 °C to +25 °C); this must
remain constant and may only vary by ±X °C. Controlled-speed fans must be used if necessary to achieve this.
NOTICE
The limit values as per ISO 3046 apply to air pressure, air intake temperature and air
humidity: 1000 mbar, +25 °C, 30 % humidity. In the case of differing conditions at the
installation site, the specific engine performance will be reduced. This corresponds to
the standard constraints as assumed by all engine manufacturers.
Other conditions may have been agreed upon prior to completion of the order, howev‐
er, e.g. full load at an intake temperature of 40 °C. In this case, the pressure-charging
system would have to be modified and the technical specifications amended. Such
agreements should be set out in writing in the specification.
Min. air intake temperature and/or engine room temperature:

The starting behaviour of the engine, the starter motor power and the starting batteries (only for engine type
with electric starters) are designed for a minimum ambient temperature of +10 °C. Every engine is equipped
with electrical preheating for the oil and cooling water. Close off the intake and exhaust sound dampers, doors,
gates etc. and switch off the fans when the electrical preheating systems are in operation.
Engine-room air:
Maximum sulphur concentration in the engine-room air < 1.5 mg/m3
Dust content: ≤ 1 mg/m3
Engine room ventilation:

The engine-room ventilation must be designed so as to:
▪ ensure that the entire engine room is properly ventilated (to prevent unwanted gas accumulations and
heat pockets),
▪ guarantee a directed airflow across the engine to ensure the surface temperatures of electrical compo-
nents mounted on the engine such as the ignition system, ignition coils, ignition cable conduits, gas injec-
tion valves, knock controller and charge pressure sensors, actuators, etc.) do not exceed +70 °C! If this is
not ensured and the surface temperatures exceed this temperature, the service life of these components
will be considerably reduced and the failure frequency will increase sharply. Damage and downtime
caused by such a situation are excluded from the warranty. The speed of the frequency-controlled fan is
controlled by a temperature sensor. The sensor should be fitted near the XXXXX.
▪ that outside air is forced into the engine room by the frequency-controlled fans and the engine room is
slightly pressurised.
Engine-room gauge pressure: 0.1 mbar < p < 0.5 mbar.
The effect of this is that when the engine is at rest, particularly in multiple-engine installations, there is always a
defined air flow direction through the engine towards the exhaust chimney and no acidic exhaust gas can be
aspirated by the engine. Not only does this avoid corrosion, but in the event of a false start (which can never be
fully prevented) it also prevents unburned mixture from flowing back to the engine.
If the engine room is under a vacuum, however, e.g. as in greenhouse applications, precautions must be taken
to ensure that no exhaust gas is drawn into the ventilation system (exhaust gas scavenging fan).
The direct air flow to the engine must be designed not only to meet the filtration requirements but also to en-
sure that if the external air is very cold (<10 °C), the air reaching the engine is mixed with warmer engine room
air to ensure it is at 10 °C at least (air circulation control).
7.1.1 type 2 & 3 engines

The following symbols are used in the graphics below:
1 Fan 3 Silencer
2 Filter, stating the purity class
Engine room ventilation for type 2 and 3 engines
1 Generator 4 R = 3 - 4 m 90° if possible

2 Engine 5 Fan
3 Intake filter
7.1.2 type 4 & 6 engines
Engine room ventilation for type 4 and 6 engines
1 Generator 5 Fan
2 Engine 6 Baffle plates
3 Intake filter 7 Air outlet
4 R = 3 - 4 m 90° if possible
Incoming air:
The engine room air intake must be fitted at the generator end. The incoming air must be distributed over the
generator engine and turbocharger end in the ratio 45%:25%:30% by two baffle plates.
Outgoing air:
The air outlet from the engine room must be situated at the other end of the engine, so that the air flow passes
over the entire engine and helps to cool the engine surface.
7.1.3 Type 9 engine

Incoming air:
The engine room air intake must be fitted at both the generator end and the turbocharger end.
Outgoing air:
The air outlet from the engine room must be situated above the middle of the engine, so that the air flow pass-
es over the engine from both the generator and the turbocharger ends and helps to cool the engine surface.
J920 engine room ventilation
① Generator ③ Turbocharger module

② Engine ④ Intake air
The engine aspirates the filtered engine intake air from the room. Consequently, the more highly-filtered air sup-
plied by the engine air intake system must be ducted to a point close to the turbocharger air intake. Attention
should be paid to ensuring that the temperature differential between the left and right air intakes is less than 5 °C.
Design information:
▪ generator-end air: generator cooling air + ½ radiant heat
▪ turbocharger-end air: combustion air + ½ radiant heat
7.2 Generator cooling air

Air inlet temperature: maximum 40 °C
Relative humidity: maximum 80 %
Dust content: ≤ 1 mg/m3
SO2 content ≤ 1.5 mg/m3
At air inlet temperatures greater than 40 °C, check the generator design.
The Pt100 temperature-control sensor must be positioned in the middle of the engine room in front of the ex-
haust air splitter.
7.3 Cooling air for switchgear cabinets on the module/generating set

Make sure that the ambient temperature of switchgear cabinets mounted on the module/generator set does
not exceed 47°C. The switchgear cabinets are equipped with natural or forced draught ventilation, depending
on their internal power losses. This ensures that the maximum temperature of 55°C is not exceeded inside the
cabinet.
If the ventilation system cannot ensure this maximum ambient temperature (47°C) at the switchgear cabinet,
GE Jenbacher must be informed. The optional installation of air-conditioning units means that ambient temper-
atures of up to 53°C are possible.
Switchgear cabinets mounted on the module/generating set:

type 2, 3 and 4 engines: Module interface cabinet
type 4, 6 and 4 engines: Module interface cabinet, prelubrication
pump cabinet
Type 9 engines: TCA interface cabinet, TCA sensor cabi-
net, ENGINE interface cabinets, GENERA-
TOR control cabinet
For medium-voltage generators (type 3, 4, 6 and 9 engines): GENERATOR surge suppressor (JUNC-
TION BOX)
Other switchgear cabinets such as the module control cabinet (DIANE), power cubicle, station control cubicle, ....
are not intended for installation in the engine room. The maximum ambient temperature for these cubicles is
40°C, and they are intended for installation in an electrical switchgear room.
8 Cooling water
8.1 General
WARNING
High-pressure liquid discharges!
The outlets from safety valves must be routed so that persons cannot be injured by
the media discharge when the safety valve responds.
The cooling water heat exchangers are designed on the cooling circuit side for a maximum water pressure of
10 bar. The maximum admissible rate of change of the hot water return temperature is 10°C per minute.
Permissible deviation in the hot water return temperature from the customer:
70°C +0 / -10°C
55°C +0 / -5°C
(Intermediate values can be calculated by interpolation)>
The specified warm-water return temperature should not be exceeded (install emergency cooling, otherwise
the module will shut down). Temperatures above 50°C are not allowed!
Integration into the heating installation and the operating conditions in accordance with GE Jenbacher draw-
ing No. E 92684 and/or after consultation with GE Jenbacher.
We advise installation of a thermostatic control to achieve a constant return temperature at the intake of the
module.
Dirt trap: Mesh size ≤ 0.25 mm
In the event of discrepancies between the Technical Diagram and this TI, the values in the Technical Diagram
shall prevail.
8.2 Cooling water quality

The following Technical Instruction applies:
▪ TI 1000-0200: Quality of cooling water in closed circuits
▪ TI 1000-0201: Antifreeze
▪ 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 cooling circuits
8.3 Engine cooling water

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, J624H101-112 (hot-country version) in generating set version 5.5 bar
Type 9 engine 3.5 bar
If there is more than one engine in a plant, the engine cooling water circuits must be designed as separate.
8.4 Cooling water for the mixture and oil

▪ Maximum intake temperature: refer to the technical diagram and/or the relevant technical specification
▪ Maximum permissible overpressure: refer to the technical diagram.
8.4.1 Minimum water volumetric flow and water pressure in the high-temperature circuit (HT) of type 6
engines
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 tempera-
ture is required (greenhouse application), as a general rule water recirculation is to be preferred to pump speed
control.
The static system pressure at the expansion vessel must be selected so that the limit values for the inlet pres-
sure to the crankcase and the minimum pressure at the intercooler are maintained.
Diagram 1: Water volume flow and minimum pressure to avoid steam bubble formation in the type 6 engine intercooler HT
stage for cooling-water temperatures less than 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] (For the J624TSTC: referred to single coolers connected in
parallel)
② Water volumetric flow through the
intercooler HT stage [m3/h]
8.4.2 Minimum water volumetric flow, minimum pressure and return temperature in the low-temperature
circuit (LT) of type 6 and 9 engines
The cooling water temperature deviation must not exceed ±2 °C.
The following minimum flow values must be maintained in the LT circuit, since otherwise the the cooling effect
of the LT stage will be reduced.
Volumetric flow and minimum pressures in the low-temperature circuit
Engine type Volumetric flow [m³/h] Minimum pressure (bar gauge)
J612 25 0.5
J616 30 0.5
J620 40 0.5
J624 50 0.5
J920 70 0.5
8.4.3 Minimum fill pressure in hot water circuits in plants with exhaust-gas heat recovery
When using an exhaust-gas heat exchanger, the minimum pressure requirements for the heating circuit must
comply with TI No. 1000-0206.
Whichever value is higher from diagram 1 or TI No. 1000-0206 must be selected.
8.4.4 Circulation pump demand – 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 in bypass operation.
9 Operation 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.
10 Lubricating oil
In accordance with the following Technical Instruction:
▪ TI 1000-1108: Lubricating oils for type 9 engines
▪ TI 1000-1109: Lubricating oil for type 2, 3 and 4 GE Jenbacher engines
Oil change in accordance with the following Technical Instructions:
▪ TI 1000-0099A: Approval procedure for various engine oils
▪ TI 1000-0099B: Limit values for used oil in GE Jenbacher gas engines
▪ TI 1000-0099C Procedure for testing the oil service life specific to the plant
▪ TI 1000-0099D Determining the initial pH value (ipH) for used lube oil as defined in TI 1000-0099B
Oil analysis results
NOTICE
Incorrect diagnoses possible due to the presence of copper!
Copper has a major oxidising effect on lubricating oil, especially at high temperatures,
and accelerates its ageing. An increased copper content in oil leads to incorrect diag‐
noses.
a) Pure copper must not be used as a material for oil piping to the engine or valves or
other fittings.
b) Use copper-nickel alloys with a nickel content of ≥ 10 %. These alloys can also be
used instead of the steel piping normally used.
See also
• Link to TI 1000-1109 Lubricating oil type 2, 3, 4 and 6 engines [⇨ TA 1100-0110, Page 0 ]
11 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 transient pressure surges of up to 6 bar. The underpressure following a pres-
sure 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 chim-
neys are used (DIN 4133).
See the technical specification and/or technical diagram for maximum admissible exhaust gas backpressure.
In the case of multi-engine installations, the exhaust-gas systems must not be combined.
Exceptions:
▪ double shut-off valves with intermediate ventilation for each module
▪ if at the point where the systems are combined a continuous underpressure exists (e.g. a continuous flow
in the chimney).
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.
12 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.
13 Operation and maintenance

Minimum operation time:
12 hours per engine start, except when commissioning, carrying out maintenance work and during emergency
power operation.
Increased corrective maintenance costs must be calculated if there are any deviations from this.
Idling
Idling duration limited through the module control unit (except for maintenance and initial setting activities:
keep idling period as short as possible).
Partial load operation

You must always aim for full load operation.
Type 2, 3 and 4 engines Unrestricted partial-load operation as from 40 % of rated load

Type 6 engine Unrestricted partial-load operation as from 50 % of rated load (type 6F, G en-
gines: 22 bar' type 6H engines; 24 bar)
Type 9 engine Unrestricted partial-load operation as from 40 % of rated load, where pme = 22
bar.
Emission values referred to in the technical specifications only apply where a load exceeds 50 %.
Island operation
In island operation, the module may be operated at > 20 % and < 40 % of the rated load 6 times per year for 4
hours out of 24.
Daily inspection
▪ Maintain an engine log.
▪ Maintenance as per GE Jenbacher maintenance plan.
▪ All conditions as described in the TI Nos. should be complied with.
Work on the container roof

Maintenance work on the container roof always entails the risk of falling.
To ensure risk-free maintenance work, the container roof must be fitted with a safety railing or scaffolding and
safety steps for climbing up.
GE Jenbacher Container products are not fitted with such fall-protection equipment as standard. However, ap-
propriate fall-protection equipment can be ordered from GE Jenbacher.
Container fall-protection equipment

If the safety railing, scaffolding and safety steps are not ordered from GE Jenbacher, the customer is responsi-
ble for ensuring that corresponding safety equipment is obtained locally.
See the following TIs for oil changes and oil analyses and assessment:
14 Piping
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.
The instructions in
▪ TI 1400-0131: Pipings
must be observed.
The revision applicable when the contract was signed is valid.
15 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.
16 Refer to the TIs listed below

The revision applicable when the contract was signed is valid.
General conditions
▪ TI 1100-0111: General Conditions Operating & Maintenance [⇨ TA 1100-0111, Page 1]
▪ TI 1100-0112: Installation of GE Jenbacher modules
Signage
▪ TI 1000-0330: Signs 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 of special gas
▪ TI 1400-0091: Fuel gases, freedom from condensate
lubricating oil
▪ TI 1000-1108: Lubricating oils for type 9 engines
▪ TI 1000-1109: Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines
Cooling water
▪ TI 1000-0200: Quality of cooling water in closed circuits
▪ TI 1000-0201: Antifreeze
▪ 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 cooling circuits
Wiring
▪ TI 1000-0505: EMC routing of wiring and earth connections to/between engine modules and control cabinets
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 ............................................................................................................................................ 2
1.4 Maintenance staff ............................................................................................................................................................ 2
1.5 Safety instructions ........................................................................................................................................................... 2
1.6 Cleanliness when working on GE Jenbacher plants ........................................................................................ 2
1.7 Risk assessment ................................................................................................................................................................ 2
1.8 Start-up conditions .......................................................................................................................................................... 3
1.9 Failures .................................................................................................................................................................................. 3
1.10 Recording operational data, maintenance record sheet ............................................................................. 4
1.11 Spare parts .......................................................................................................................................................................... 5
1.12 Lubricating oil ..................................................................................................................................................................... 5
1.13 Spark plugs .......................................................................................................................................................................... 5
1.14 Elastomer components ................................................................................................................................................. 5
1.15 Decommissioning the plant ......................................................................................................................................... 5
1.16 Welding work on the module ...................................................................................................................................... 6
1.17 Components coming into contact with exhaust gas ...................................................................................... 6
1.18 Fuels ........................................................................................................................................................................................ 6
1.19 Fuel gas quality ................................................................................................................................................................. 6
1.20 J624 TSTC turbocharger unit ...................................................................................................................................... 6
1.21 maintenance intervals ................................................................................................................................................... 7
1.22 Documents from original equipment manufacturers .................................................................................... 7
NOTICE
Observance of the conditions of this Technical Instruction and performance of the ac‐
tivities described therein is the basis of safe and efficient plant operation.
Non-observance of the conditions of this Technical Instruction and/or non-perfor‐
mance of the prescribed activities or any departure from the prescribed activities shall
results in the loss of guarantee rights. This shall not be the case if the operator shows
that althouth the Technical Instruction was observed, defects already existed at the
time of handover or commissioning,
The activities and conditions defined in this Technical Instruction shall be performed
and/or observed by the plant operator. This shall not apply if this Technical Instruction
is expressly allocated to the area of responsibility of GE Jenbacher or a contractual
agreement between the operator and GE Jenbacherprovides for a different arrange‐
ment.
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.
Author: Doku./Bilek Responsible: Mayer Markus Release date: 19.03.2013
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.
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 1100-0105 and measures must
be taken to ensure that it cannot be started accidentally.
The operator is responsible for ensuring that the workplaces for service and maintenance work are adequately
lit; additional mobile lighting must be provided if necessary.
1.6 Cleanliness when working on GE Jenbacher plants

▪ When working on GE Jenbacher engines, installations and components, always adhere to the strictest stan-
dards of cleanliness.
▪ Thoroughly clean all engine components or parts within working environment and remove all dirt and de-
posits on the outside of the engine before opening the engine.
▪ Whenever maintenance or revision work is carried out, no dirt from the outside or inside (e.g. from deposits)
may enter the engine or other installation parts. Thoroughly remove any remains of gaskets or deposits on
engine components using suitable means of removal.
▪ Make sure to select the right covers and means of protection for properly carrying out the work.
▪ When re-assembling components make sure to remove all covers on the outside and inside of components
and lines.
▪ Ensure that before recommissioning all systems are free of foreign bodies, dirt and loose bolts or tools.
Failure to comply with this instruction can result in serious damage to components or systems or to per-
sonal injury!
1.7 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.
1.8 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.
1.9 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
Failures: Diane No.: National Risk category

restrictions
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
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.
1.10 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.
1.11 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.
1.12 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.
1.13 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).
1.14 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.
1.15 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.
1.16 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.
Before any welding work is carried out on the generating set, the ignition rail must be removed to prevent any
possible damage to it and it must be stored in a dry place. The ignition rail may not be refitted and correctly
connected until the welding work on the generating set has been completed.
1.17 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.
1.18 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.
1.19 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.
1.20 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.
1.21 maintenance intervals

The intervals stated in the maintenance plan are average empirical values. Where there is a lack of proper op-
eration and maintenance (such as defective oil care, large accumulations of dust or other problematic circum-
stances), 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 down-
times 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.
1.22 Documents from original equipment manufacturers

The customer documentation from GE Jenbacher contains documents from the original equipment manufac-
turers for certain bought-in parts in addition to GE Jenbacher documents.
The following must be observed in relation to this:
▪ The appropriate information and documents from the original equipment manufacturer are taken into ac-
count when drawing up GE Jenbacher documentation.
▪ In the event of discrepancies between GE Jenbacher documents and enclosed documentation from the orig-
inal equipment manufacturer, the GE Jenbacher documentation shall take priority (including any appropri-
ate Technical Instructions, maintenance plans and maintenance etc.)
▪ Any documents from the original equipment manufacturer that are provided are supplementary to the GE
Jenbacher documentation and should be observed in addition to this.
Safety regulations
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 ....................................................................................................................................... 5
6 Transporting - lifting - installing ................................................................................................................. 7
7 Shutdown procedure and making safe ...................................................................................................... 7
8 Engine room .................................................................................................................................................. 11
9 Components .................................................................................................................................................. 16
9.1 Exhaust gas system ..................................................................................................................................................... 16
9.2 turbocharger ................................................................................................................................................................... 17
9.3 Fuel gas system .............................................................................................................................................................. 18
9.4 Cooling system ............................................................................................................................................................... 19
9.5 heat exchanger .............................................................................................................................................................. 20
9.6 Slam Valve ........................................................................................................................................................................ 22
9.7 Lubrication system ....................................................................................................................................................... 22
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 ................................................................................................................................................. 25
9.13 Generator .......................................................................................................................................................................... 26
9.14 Electrical cabinets ......................................................................................................................................................... 27
9.15 Acoustic insulation (container; sound absorber hood) ................................................................................ 29
9.16 Battery ................................................................................................................................................................................ 30
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 machinery. These
documents must be read and understood by the user before starting the
machinery. The most recent edition of the operating instructions must al-
ways 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: 04.10.2012
Safety regulations
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 of its
specified 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 (nach 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 regulations
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 contractors personnel at the site.
This includes provisions for review by the contractor of and safety instruction by the customer on the customer
1 \lquote;s safety practices, proper safe handling and disposal of hazardous substances and the protection of
the contractors personnel from exposure to such substances, activation and deactivation of all power systems
(electrical, mechanical and hydraulic) using a safe and effective lock-out tag procedure, and conducting period-
ic 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 1 \rquote 2 \lquote;s staff require medical attention, the cus-
tomer 2 \lquote;s local facilities will be made available to the contractors staff for as long as necessary.
If, in the contractors 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 1 \lquote 2 \lquote;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 2
\lquote;s fees) incurred by or imposed upon the contractor, its employees and agents, based upon injury to per-
sons (including death) or damage to property resulting from the operation of equipment at the site by the con-
tractors staff.
If the customer provides the contractors 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 contractors work at the site are removed.
Safety regulations
All decontamination necessary for the contractors 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 "on" for für 0,5 s ± 10%
c Phase c signal is "on" 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, be-
fore 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 regulations
▪ 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.
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 having relevant electrical and mechanical training.
Access to the machine room is restricted to persons (specialist staff) who

have read, understood and who 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.
Safety regulations
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.
Activities 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 coolant 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:
Safety regulations
▪ 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.
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 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.
Safety regulations
Before commencing maintenance work, repairs, etc., shut down machinery as described below and secure
to prevent unauthorised start-up!
Shut down and secure.

Engine switch-off:
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 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!
Safety regulations
High-voltage ignition system – 40kV!

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!
Hot surfaces!
Risk of burns
Allow the 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 coolant and lubricating oil are hot and under pres-
sure. Escaping liquids may cause serious injury.
Wear personal protective equipment.

Wear eye protection, thermal insulation gloves and protective clothing!
Allow the engine and coolant to cool down before removing pipes, seals and covers or opening components
that contain liquids. The pressure must first be reduced to zero. Only then, drain the coolant if necessary. Liq-
uids must be drained completely.
Safety regulations
Risk of explosion!
During charging, batteries produce hydrogen and oxygen which under cer-
tain conditions may form an explosive mixture.
The battery is charged with 24 V DC even when the control system is
switched off. Sparks generated at the battery poles can ignite an explo-
sive atmosphere.
Check that the battery poles are firmly secured. No smoking, no naked lights, no sparks!
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)!
Safety regulations
8 Engine room
No admittance for unauthorised persons!
Room contains electrical machinery!
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!
Noise!
The noise produced when the machinery is operating or being started

may damage your hearing.
Wear hearing protection!
Safety regulations
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 at places where they may 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.
Risk of slipping!
Wipe up any spilt oil and coolant immediately and keep the machinery clean!
Safety regulations
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.
Avoid danger zones around safety valve and explosion protection valve
openings.
There are also danger zones around air filters.
Safety regulations
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.
In the event 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 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 personnel 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 regulations
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 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 odours 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 regulations
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.
Shut-down procedure and securing: Refer to section on "Shut-down pro-

cedure and securing" in these safety instructions.
9.1 Exhaust gas system

Exhaust gases may be 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 seals

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

It is the operators responsibility to ensure that there are no leaks in the exhaust system.
Safety regulations
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 regulations
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 Customer Service before you convert the system to another type of fuel gas and each time the fuel gas
quality is changed!
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 so designed that gas concentrations are prevented and a slight overpres-
sure exists in the engine room. (See TA 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 regulations
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.
Wear gas sensors as personal protective equipment (appropriate to the

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

When the engine is at operating temperature, the coolant is hot and pressurised.
Damaged or weathered pipes, seals, hoses and hose clips and other components must be replaced immediate-
ly. If these components break or fracture, hot coolant could injure people and cause a fire.
Keep clear of pressure relief valves when operating the plant.
Safety regulations
Risk of escaping liquids (hot and under pressure)

Depressurise these components accordingly before carrying out mainte-
nance work on them!
Fractured components allow hot coolant to escape, posing a risk of injury.
Regular maintenance/inspection of components. Wear personal protec-
tive equipment (safety glasses, protective clothing and thermal insulation
gloves). Keep away from pressure relief valves.
Hot surfaces!
Risk of burns

To replace pipes and components:
Shut-down procedure and securing → Refer to the "Shut-down proce-

dure and securing" section in these 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!.
Observe any disposal requirements.
9.5 heat exchanger

Heat exchangers are pressure vessels which are designed for specific pressure and temperature limits.
Safety regulations
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, seals, locks and covers.
Any liquids escaping as the result of a leak may cause serious injury.
Keep clear of pressure relief valves when operating the plant.
The fracturing of components causes hot liquids to escape, thereby pos-

ing a risk of injury.
Regular maintenance/inspection, regular pressure-testing. Wear personal

protective equipment (safety glasses, protective clothing and thermal insu-
lation gloves). Keep away from pressure relief valves! Reduce pressure!
Hot surfaces!
Risk of burns
Let the heat exchanger and pipes cool down, wear personal protective
equipment! 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:
Safety regulations

9.6 Slam 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.
Risk of escaping liquids (hot and under pressure)
The actuation of safety valves causes hot liquids to escape, thereby pos-
Wear personal protective equipment (safety glasses, protective clothing

and thermal insulation gloves). Keep away from pressure relief valves.
9.7 Lubrication system

Risk of escaping liquids (during normal operation, lubricants are hot and
under pressure)
The actuation of safety valves causes hot liquids to escape, thereby pos-
Wear personal protective equipment (safety glasses, protective clothing

and thermal insulation gloves). Keep away from pressure relief valves.
Safety regulations
Hot surfaces!
Components of the lubrication system (oil lines and filters, valves, etc.) and
the oil itself are hot and can cause severe burns when working on the
lube oil system (e.g. changing the oil or the oil filters).
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!
Lubricating oils and oily rags must be disposed of as special waste.
Safety regulations
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 – 40kV!
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!
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.
Safety regulations
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.
9.12 Electrical connections

All electrical connections involve a risk of making a direct or indirect elec-

trical contact. Contact could result in a serious, and possibly fatal, electric
shock.
Connected components must be installed only by authorised experts (offi-

cially licensed electricians) in accordance with local regulations.
Safety 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 of the accident has been remedied.
During the commissioning of the generator, the supplier of the power supply cubicle must implement the pro-
tective measures required under local regulations.
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.
Following steps should be taken when working in close proximity with a generator:
1. As with all naturally aspirated generators a catastrophic event could lead to sparks exiting the generator.
Therefore, in order to re-enforce our commitment to safe working conditions we remind you of the follow-
Safety regulations
ing practical steps that should be taken while working in close proximity of a running alternator: Insbeson-
dere empfehlen wir, dass:
a) A risk assessment is performed by the user/operating company to determine all personnel related risks
and the relevant personnel should be aware of these. Access to the power plant/generator set during oper-
ation should be restricted to personnel who have been trained.
b) personnel in the proximity of an operational generator should, at all times, wear suitable protective cloth-
ing in accordance with the risks identified in para. 1.a. above, and with consideration to the following: The
following aspects in particular must be borne in mind:
Ear protection
Head and face protection
Safety footwear
Overalls that protect the lower arms and legs
2. Any work that is likely to require access to electrical conductors must be performed in compliance with all
local and national electrical safety procedures that are applicable to the site and to the voltage levels in-
volved as well as any site specific rules. Zudem müssen alle standortspezifischen Vorschriften eingehalten
werden.
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 the commissioning of the generator, the supplier of the power supply cubicle must implement the pro-
tective measures required under local regulations.
Safety regulations
Ensure proper earthing!
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 regulations
9.15 Acoustic insulation (container; sound absorber hood)

Fire risk!
There is a risk of fire if loose insulation 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!
Safety regulations
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, safety glasses and safety
footwear when handling battery acid!
Risk of explosion!
During charging, batteries produce hydrogen and oxygen which under cer-
tain conditions may form an explosive mixture.
The battery is charged with 24 V DC even when the control system is
switched off. Sparks generated at the battery poles can ignite an explo-
sive atmosphere.
Check that the battery poles are firmly secured. No smoking, no naked
lights, no sparks!
The battery acid level must always be between the minimum and maxi-
mum markings.
Proper maintenance according to the maintenance schedule is a condition!
There is an acute explosion hazard under the following conditions:
▷ The battery's acid level is lower than the acid-level "min" mark.
▷ The battery is short-circuited or heavily overloaded (e.g. attempted en-
gine start when the engine is blocked).
▷ Excessive charge voltage (> 30 V).
Battery acid may leak if batteries are damaged (e.g. during repair work),
its corrosive action causing damage to the environment and property.
Acid can also cause a chemical reaction with the lime in the concrete and
damage the floor.
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!
Safety regulations
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)!
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 enclo-
sure, 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!
Safety regulations
Keep door closed!
All doors must be closed while the plant is operating! Proper operating con-
ditions can only be achieved with doors closed.
10 Maintenance and servicing

Note: The engine is liable to start without warning.
The customer must make sure that the relevant safety precautions have been taken before performing
any maintenance work on the engine.
See point 3 of these safety instructions, “Health and safety during operation and maintenance”.
Before commencing maintenance work, shut down the engine as described below and make sure that it
cannot be started inadvertently.

Safety regulations
Work on the installation may only be carried out by specialist staff having relevant electrical and mechanical
training. There may also be a service contract (maintenance or servicing contract), under which all servicing is
carried out by GE Jenbacher personnel.
Suitable safe lifting gear must be used when fitting or removing heavy components. Handling heavy compo-
nents 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 protection and safety
helmet.
Working at height (above 1.2 m):

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 a
harness and associated equipment (safety rope, carabiner hook, energy absorber, rope shortener or fall arrester).
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. condensate tanks).
Ensure proper ventilation or extraction to remove gas concentrations.

Check the maximum admissible work place values (gas concentration).
Wear gas sensors (appropriate to the poisonous gas components)

as personal protective equipment.
If the maximum admissible workplace values cannot be guaranteed, suitable breathing apparatus must be
worn.
Before carrying out any work on the plant, the customer has a duty to ensure that safety will not be compromised.
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 bolts, which have a specified tightening torque, contrary to the instructions
▪ 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 may to be used.
Safety regulations
DANGER
If the safety equipment for maintenance/servicing work has been dismantled or ren‐
dered ineffective:
All the safety equipment must be restored to its original condition and its effective‐
ness checked.
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 regulations
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.
Guidelines for using the LOTO kit
1 Purpose ............................................................................................................................................................ 1
2 LOTO Kit ........................................................................................................................................................... 2
3 Incorrect applications ................................................................................................................................... 3
4 Shut-off valves ................................................................................................................................................ 6
4.1 Main gas valve ................................................................................................................................................................... 6
4.2 Self-clamping ball valves .............................................................................................................................................. 7
5 Electrical components ................................................................................................................................... 8
5.1 Auxiliaries main breaker ................................................................................................................................................ 9
5.2 Miniature circuit breakers ......................................................................................................................................... 10
5.3 Motor protective circuit breaker ............................................................................................................................. 13
5.4 Key-operated switches ............................................................................................................................................... 13
5.5 Generator breaker - low-voltage ........................................................................................................................... 14
5.5.1 Non-withdrawable generator breaker 14
5.5.2 Withdrawable generator breaker 15
6 Affixing the marking .................................................................................................................................... 18
6.1 DANGER tag ..................................................................................................................................................................... 18
6.2 CAUTION tag (transition tag) .................................................................................................................................... 19
The target recipients of this document are:

Distribution Partners, Service Partners, Commissioning Partners, Subsidiaries/Branches, Jenbach location
or in part.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
1 Purpose
This Technical Instruction describes the possible uses of the LockOut/TagOut locking system (LOTO Kit) on GE
Jenbacher systems.
It is not intended to list every individual application but simply to show by means of application examples how
to proceed when locking out. Since the conditions on any particular site may be completely different, the lock-
out devices may need to be used in a different way to that shown in the photos in order to be effective.
Basic principles of LOTO applications

1. The LOTO lockout device is must always be secured by a personal red padlock.
2. The key to the personal LOTO padlock must never be made available to another person during the work.
3. The lockout must always be applied to whichever system securely prevents the plant part which is being
worked on from operating.
4. If more than one person is operating on the plant (including from outside firms), the LOTO device is fitted
with a hasp and each participant inserts his personal LOTO padlock in the hasp The system cannot be re-
leased until all the padlocks have been removed.
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 26.06.2012
2 LOTO Kit
LOTO Kit
1 Miniature circuit breaker lockout - Tie-Bar (TB) 7 Universal cable lockout
2 Miniature circuit breaker lockout - Pin-In Stan- 8 Universal lockout
dard (PIS)
3 Miniature circuit breaker lockout - Pin-Out 9 Cable lockout (addition to universal lockout)
Standard (POS)
4 Miniature circuit breaker lockout - Pin-Out 10 Additional arm for universal lockout
Wide (POW)
5 LOTO padlock 11 Large hasp
6 480 V breaker lockout 12 Small hasp
Read the safety and hazard advice in the safety instructions (TI 2300-0005) and wear the appropriate personal
protective equipment. GE personnel must also observe the information in the Safety Risk Assessment (SRA).
The LOTO kit must only be used by authorised persons. To obtain the "LOTO Authorised" qualification, a person
must complete the "Lockout / Tagout - Authorised Employee (Initial) [CEP-34] at http://mylearning.ge.com, pass
the associated test, and carry out a practical demonstration of a LOTO application in the presence of another
LOTO-authorised person. The on-line training must be refreshed every 2 years, and the practical demonstration
must be repeated annually.
If one of the LOTO components becomes defective or is lost, please contact your EHS officer so that he can
replace the defective component or complete the LOTO kit.
3 Incorrect applications
DANGER
Faulty locking
The following examples show the results of incorrectly-executed lockout procedures.
Such applications are equivalent to no lock at all!
Key not withdrawn!
Lockout device locked with a normal combination pad-

lock (e.g. a toolbox padlock) instead of a lockout padlock.
Lockout device only secured by a cable tie.
Unmarked padlock and no sign. One of the two possi-

ble ways of marking (directly on the padlock / sepa-
rate tag) must be used.
4 Shut-off valves
4.1 Main gas valve

Main gas valve
Main gas valve locked out with universal lockout and

additional arm
Main gas valve locked out with universal ball valve ca-
ble lockout
4.2 Self-clamping ball valves

Ball valve locked with universal lockout: valve interlock
cannot be released
Ball valve locked with universal lockout: valve interlock

cannot be released
Ball valve locked with universal cable lockout: ball can-

not be turned
Ball valve locked out with universal lockout and addi-

tional arm: ball cannot be turned
5 Electrical components
WARNING
Live electronic components
Dangerous voltages can be present at the outputs of electronic components (e.g. fre‐
quency converters and soft starters) even when the input sides of these components
are separated from the mains or no start command is issued. That dangerous voltage
is also present at any connected individual consumers (e.g. pumps, fans, etc.).
a) That is why - before beginning any maintenance activities - you must always make
absolutely sure that all supply voltages to these electrical components and connected
consumers are safely disconnected.
b) Having disconnected the supply voltage, wait for at least 5 minutes before opening
the equipment to make sure that all capacitators have been discharged.
5.1 Auxiliaries main breaker

Auxiliaries main breaker - old version
Main / repair breakers can be locked out directly with

the lockout padlock.
Auxiliaries main breaker - current version
Turn wheel (1) until the openings (2) for the lockout pad-
lock are accessible. The main breaker has space for 3
lockout padlocks.
5.2 Miniature circuit breakers

Items 1 to 4 in Fig. 1 are intended mainly for miniature circuit breakers.
Fit miniature circuit breaker lockouts (TB) between two

breakers, hook them in and screw them securely in
place.
Multiple circuit breakers locked out with TB lockout

and lockout padlock
Multiple circuit breakers locked out with POS lockout

and lockout padlock.
Select the lockout type (TB, PIS, POS, POW) depending
on the space between the breakers.
Lockouts that grip from the inside (POS or PO) or the top/
bottom (TB) are suitable for circuit breakers which are
not mounted separately.
Circuit breaker locked out with a TB lockout, hasp and

more than one lockout padlocks when more than one
person is working on the plant.
5.3 Motor protective circuit breaker

Motor protective circuit breaker locked out with a uni-
versal cable lockout.
5.4 Key-operated switches

480 V breaker lockout can also be used for key-operat-
ed switches. The lockout covers the keyhole. Only
works if the locked-out switch cannot be turned with-
out the key!
5.5 Generator breaker - low-voltage
5.5.1 Non-withdrawable generator breaker

Check that the generator breaker (2) is displayed as be-
ing OPEN in the control system (screen 11.1).
Check that the main breaker is OFF in the mode selec-

tion display (2).
Pull out the LOTO latch (1) and lock it with the LOTO pad-
lock.
5.5.2 Withdrawable generator breaker

1. Check that the generator breaker (2) is displayed as
being OPEN in the control system (screen 11.1).
2. Check that the main breaker is OFF in the mode se-

lection display (1).
1 Mode selection display 4 Crank handle socket

2 Recessed folding crank handle 5 Crank interlock release
3 Breaker position display 6 LOTO latch
3. Take out the crank handle (2) and insert it in the sock-
et (4).
4. Press the interlock release (5) and wind out the gen-
erator breaker.
5. In the test position, the crank interlock release will re-

engage. Press the crank interlock release (5) again un-
til the breaker position display (3) is at the bottom posi-
tion "Released".
6. Pull out the LOTO latch (6) and lock it with the LOTO
padlock.
Generator breaker locked out
6 Affixing the marking

The marking can be affixed either directly to the padlock or to tags.
Minimum information:
▪ name of the person locking out (to be written on the padlock with a permanent marker)
▪ lockout date (with a non-permanent marker)
▪ Reason for lockout
Optional information:
▪ provisional release date
If not included in the LOTO kit, the "CAUTION" and "DANGER" tags can be ordered from any GE Jenbacher office
or directly from GE Jenbacher.
NOTICE
LOTO marking:
The LOTO markings must always be affixed directly to the padlock with a cable tie!
6.1 DANGER tag

The name of the person working on the engine must
be written on the front (1) of the tag.
The current date must be written on the back (2). You

can also add any further information.
6.2 CAUTION tag (transition tag)

The following must be written on the back (2) of the tag:
- the name of the person who affixed the transition tag
- the date it was affixed
- any other information
3 Maintenance plan
3.1
Maintenance plan - specific intervals
Inspection work Number/Section Interval Remarks

Daily inspection round I 9002 0 Daily Carry out daily visual inspection of the
module.
Operational data booklet --- Daily Gather the operational data daily.
Intake air filter - engine IW 8041 A0 Daily If the manometer at the pocket filter indi-
cates an underpressure of > 10 mbar
(1000 Pa), you must replace the filter
cloth, or else replace it after 2000 operat-
ing 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 M0 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
Battery TI 1000-0050 once a month Check the acid level. Check if the pole
binders are properly secured.
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 30000 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: Technology/Service/PLM Release date: 23.05.2013
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
starter W 8032 M0 10,000 Oh or replace at 10,000 operating hours or at a
max. 4,000 en- max. of 4,000 engine starts
gine starts
Main crankshaft bearings W 8050 M0 30,000 Oh or 30,000 operating hours or a maximum of
max. 4000 en- 4,000 engine starts
gine starts
Battery in DIANE module --- once every 2 replace
years
Storage battery at battery --- once every 2.5 replacing
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 maintanance 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. The operator is responsible for implementing and enforcing these additional measures.
The maintenance intervals are based on empirical values during average types of operation while fully comply-
ing with the manufacturer’s operating and maintenance instructions. In individual cases, the operating condi-
tions and other factors relating to wear may affect the actual amount of maintenance required. The manufac-
turer therefore reserves the right to specify different maintenance intervals where appropriate.
After the overhaul following 60,000 operating hours, the maintenance work to be carried out is repeated at the
same intervals.
3.2
Maintenance plan - operating hours intervals
IZ Inspection work/Maintenance work Number Op hrs
- W 1000 0 ■
Maintenance after initial commissioning
2 Inspection I 0103 0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Ignition W 0303 M0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Valve clearance W 0400 M0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Engine intake air IW 8041 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
A0
2/8/20 GE Jenbacher switchgear cabinets W 8031 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2/30 Control rod assembly/throttle valve/ac- W 0200 M0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
tuator
2/30/60 Gas pressure control system W 8045 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2/40 crankcase ventilation W 0508 M0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
8 leak test IW 8049 0 ■ ■ ■ ■ ■ ■ ■
10 starter W 8032 M0 ■ ■ ■ ■ ■ ■
10 Engine cooling water pump W 0202 M3 ■ ■ ■ ■ ■ ■
10/20 Exhaust-gas turbocharger W 8023 M0 ■ ■ ■ ■ ■ ■
10/20/30 Gas mixer W 0704 M0 ■ ■ ■ ■ ■ ■
20 Vibration damper W 0601 M0 ■ ■ ■
20 Mixture bypass valve W 0802 M0 ■ ■ ■
30 Piston/Piston cooling W 8047 M0 ■ ■
30 Connecting rods and connecting rod W 8048 M0 ■ ■
bearings
30 Cylinder liner/scraper ring W 8049 M0 ■ ■
30 Main crankshaft bearings W 8050 M0 ■ ■
ZK/30 Camshaft/control system W 8052 M0 ■ ■
60 Engine oil pump W 8046 M0 ■
60 Pre-lubrication pump W 8054 M3 ■
60 Overhaul W 2100 M0 ■
ZK Exhaust gas manifold/Insulation W 8051 M0
- Generator W 8030 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
- Elastomer components W 8033 0 ■ ■ ■ ■ ■ ■
- Cylinder head replacement W 8053 M0 if required
Please note that properly carried out maintenance work is to be acknowledged by filling in the mainte-
nance record sheet.
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 0
Daily inspection I 9002 0
Lubricating oil change/oil filter change IW 0101 M0
Ignition voltage check / Spark plugs IW 0309 M0
Intake air filter - engine IW 8041 A0
Leak testing of all pipes and components carrying fuel gas and mixtures IW 8049 0
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 M0
Cooling water pump W 0202 M3
Ignition W 0303 M0
Valve clearance W 0400 M0
Crankcase ventilation system W 0508 M0
Vibration damper W 0601 M0
Gas mixer W 0704 M0
Mixture bypass valve W 0802 M0
Maintenance after initial commissioning W 1000 0
Overhaul W 2100 M0
Exhaust gas turbocharger W 8023 M0
Generator W 8030 A0
GE Jenbacher - switch cabinets W 8031 A0
Starter W 8032 M0
Elastomer components W 8033 0
Gas pressure control system W 8045 A0
Oil pump W 8046 M0
Piston/Piston cooling W 8047 M0
Connecting rods and connecting rod bearings W 8048 M0
Cylinder liner/scraper ring W 8049 M0
Main crankshaft bearing W 8050 M0
Exhaust gas manifold/exhaust gas lagging W 8051 M0
Camshaft/timing gear W 8052 M0
Cylinder head replacement W 8053 M0
Pre-lubrication pump W 8054 M3
combustion chamber W 8056 M0
Engine – cooling water circuit / Mixture recirculating water W 8080 A0
Author: Doku./Provin Responsible: Doku./Bilek Release date: 18.06.2013
Inspection work: I 0103 0
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 Crankcase ventilation system ..................................................................................................................... 4
Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure thatt unautho-
rised persons cannot start the engine.
Interval: every
Inspection work 2000 Oh 4000 Oh 10000 Oh
10 Heat exchanger mixture / water ■
2 Crankcase ventilation system ■
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 Operational data – Heat exchanger mixture / water
(E 0103 a) table.
If the differential pressure exceeds the value measured at initial commissioning by ≥ 20 mbar [0.29 psi] (200
mm [78.74 in] water column), the heat exchanger should be cleaned on the mixture side.
1.2 Mixture-side cleaning

Remove the cooler from the engine.
Install the connection and blind flanges.
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.
Assembling the mixture cooler
▪ Clean the sealing faces and remove any dirt and dust before assembly.
Author: Doku./Bilek Responsible: TEM/Gebhardt Release date: 04.04.2013
Inspection
▪ Replace the mixture-sided gaskets (mixture cooler connection flange or blind flange) and inspect these for
possible damage before assembly.
Two bolt types with differing tightening torques are used!
Since these screws are screwed into the "steel side part", M10 x 45 cylinder screws of property
class 10.9 must be used and tightened to 65 Nm.
As in this case M 10 x 30 cylinder bolts are screwed into the nickel-plated brass part, these must
be tightened to 45 Nm (property class of at least 8.8). As these are connecting holes (leading to
the mixture system), the threads must be sealed off using Loctite 243.
▪ Replace the mixture-sided gaskets and inspect these for possible damage before assembly. Apply a thin
layer of "Curil T" sealing agent to the relevant sealing faces or gaskets and let it cure for approx. 5-10 min-
utes (a slightly longer period of time is not a problem). Ensure the sealing agent is applied evenly and with-
out skipping any part of the surface around the screw holes.
Overall view of an type 3 engine mixture cooler block
Inspection
① Mixture inlet header ④ Mounting plate

② Mixture cooler connection cover (water-side) ⑤ M8 (property class 0.9) with Nord-Lock washer.
③ Exhaust gas turbocharger
▪ Tighten the screws (connection between mixture cooler and header – mixture inlet and outlet) in two stages:
Two different bolt types are used for type 3 engines, both with a different tightening torque!
Caution: There are two variants; variant 2 having also been installed on the mixture intake side “M8 (prop-
erty class 8.8)“. Always check the property class as indicated on the screw heads and subsequently apply
the correct tightening torque – see table below!
Variant 1 : M8 (property class 0.9) with Nord-Lock washer. 31 Nm

Mixture inlet side
Nord-Lock washers
Pay attention to the screw length! (bonded together in
pairs).
The screw length required (45, 50 or 55 mm) is deter-
mined by the header’s flange thickness. The thick-
ness varies according to the turbocharger assem-
bled. Some installations may also have a support in-
stalled, which makes longer screws (+5 mm) neces-
sary at these positions.
Nerd-Lock washer fit-
ted
Support mounted on
the header.
Variants 1 and 2 M8 (property class 8.8) 23 Nm
Mixture outlet side
Variant 2 :
Mixture inlet side
1. After installing the header on the mixture cooler, tighten the screws (using the tightening torque in the
above table) from the centre towards the corners.
Inspection
① When tightening, work from the centre towards the corners.

2. 15 minutes after tightening the screws, retighten the screws as described in point 1, using the same se-
quence and the same tightening torque.
Repeat this procedure after a 45 minute waiting period.
3. Run the engine for a period of at least two hours to thermally load the gaskets. Following the cooling down
phase (max. 50°C / 122°F), retighten all screws according to the procedure described in point 1.
It is absolutely necessary to use a torque wrench when tightening or retightening the screws. The only ex-
ception is when - due to lack of space - a torque wrench cannot be used. In that case, a ring spanner and
sufficient force must be used to tighten the screw.
In the case of bolt fractures or leakages on the mixture intake side when using M8 (property class 8.8)
bolts, all bolts must be upgraded to M8 (property class 10.9)!
2 Crankcase ventilation system

Connect the pressure gauge to the blow-by separator’s measuring points.
Carry out the differential pressure measurement while the system is at full load.
Enter the measured values in the table Operational data – crankcase ventilation system
(E 0103 f).
If the differential pressure measured exceeds 20 mbar (200 mm 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.
Daily inspection
1 Leak testing ..................................................................................................................................................... 1

1.1 Exhaust manifold .............................................................................................................................................................. 1
1.2 Vibration damper ............................................................................................................................................................. 1
1.3 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, highly inflammable 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 manifold

Leaks can be determined through a change in colour or damage of the insulation (noise) or a slight emission of
soot.
1.2 Vibration damper

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.
1.3 Engine cooling water pump

If water is exiting the inspection bore hole, the mechanical seal is defective.
A few drops per minute may be considered as normal.
If oil is exiting, the rotary shaft seal leaks.
The inspection bore hole may not be blocked! (Check for blocks using a wire.)
Author: Doku./Bilek Responsible: Dokumentation Release date: 24.11.2010
Daily inspection
① Mechanical seal ③ Inspection bore hole

② rotary shaft seal
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 GE Jenbacher Customer Service.
Inspection and maintenance work: IW 0101 M0
Lubricating oil change/oil filter change
1 Information ..................................................................................................................................................... 1
2 Procedure when changing oil ...................................................................................................................... 1
2.1 Draining lubricating oil ................................................................................................................................................... 1
2.2 Work to be performed following the first oil drain (for modules with an additional lubricating oil
tank) ........................................................................................................................................................................................ 2
2.2.1 Remove plug at oil pressure control valve 2
2.2.2 Connect the flexible line attached to the module 2
2.2.3 Remove plug at the crankcase cover 3
2.2.4 Connect the flexible line attached to the module 3
2.3 Oil filter replacement – engine lubricating oil filter of the turbocharger aftercooling (only for
ABB exhaust gas turbochargers) .............................................................................................................................. 3
2.4 Fill with lubricating oil ..................................................................................................................................................... 4
2.4.1 without oil gauge or additional lubricating oil tank 4
2.4.2 with oil gauge, without additional lubricating oil tank 4
2.4.3 with or without oil gauge, with additional lubricating oil tank 4
2.4.4 Engines without ABB and/or TPS turbocharger 4
2.4.5 Engines with ABB and/or TPS turbocharger 4
Operational data: E 0101
1 Information
Only use engine lubricating oil recommended by GE Jenbacher.
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.
In TI 1000-0099A
TI 1000-0099B
The sampling and testing procedure for the oil analyses is described in TI 1000-0099C.
Enter the dates of oil analyses and/or oil changes in the table Operational data – Engine lubricat-
ing oil (E 0101).
If the engine lubricating oil has been contaminated with water, the engine oil 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 should once again be changed.
2 Procedure when changing oil
2.1 Draining lubricating oil

The used oil must be drained with the engine at operating temperature. The used oil must also be drained from
the lubricating-oil heat-exchanger and the auxiliary oil tank (if present).
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).
Author: Doku./Bilek Responsible: TKE/Esterhammer Release date: 24.11.2010
2.2 Work to be performed following the first oil drain (for modules with an additional lubricating oil tank)
In the case of container modules with an additional lubricating oil tank mounted against the container
wall, only the activities as described in section 2.2.1 and 2.2.2 must be carried out, as the oil lines have
already been pre-installed (visual inspection).
If the additional lubricating oil tank has been installed on the engine frame, the activities as described in
section 2.2.1 to 2.2.4 must be carried out.
2.2.1 Remove plug at oil pressure control valve
2.2.2 Connect the flexible line attached to the module
2.2.3 Remove plug at the crankcase cover
2.2.4 Connect the flexible line attached to the module
2.3 Oil filter replacement – engine lubricating oil filter of the turbocharger aftercooling (only for ABB ex-
haust gas turbochargers)
You must replace the filter cartridges after every oil change or, at the latest, after 2,000 operating hours.
When installing, ensure that the joint rings are seated correctly on the filter element. Oil them lightly before
installing.
Screw in the filter by hand until the seal touches.
Tighten 3/4 turn by hand.
Fill with oil according to 2.4, start engine.
Check for leaks and tighten further if necessary.
2.4 Fill with lubricating oil
2.4.1 without oil gauge or additional lubricating oil tank

Close all drain cocks.
Turn oil filling valve 1 into the "OPEN" position using a screwdriver and activate the fresh oil pump; the lubricat-
ing oil will now flow from the lubricating oil tank into the engine.
Top up the lubricating oil to the third marking on the inspection glass housing. Subsequently, deactivate the
fresh oil pump and close the oil filling valve.
Once the engine is running, the oil level will drop to the centre of the inspection glass.
If the oil level is significantly lower than the middle of the inspection glass, the above filling procedure must be
repeated until the level has reached the middle of the inspection glass.
2.4.2 with oil gauge, without additional lubricating oil tank

Please note: the oil gauge is only suitable for small flow rates. Never fill through the oil gauge!
Bypass passage through oil gauge by means of three-way cock 4.
Turn oil filling valve 1 into the "OPEN" position using a screwdriver and activate the fresh oil pump; the lubricat-
ing oil will now flow from the lubricating oil tank into the engine.
Top up the lubricating oil to the third marking on the inspection glass housing. Subsequently, close the oil filling
valve, deactivate the fresh oil pump and turn three-way valve 4 into the "oil gauge" position.
2.4.3 with or without oil gauge, with additional lubricating oil tank
Please note:Fill the engine only above the auxiliary tank!
Activate the fresh oil pump.
Fill up the oil to the third marking on the inspection glass housing.
Switch off the fresh oil pump.
2.4.4 Engines without ABB and/or TPS turbocharger

Following the oil change, the exhaust gas turbocharger post-shutdown lubricating pump should be run for 15
minutes.
Operation mode selector switch to: Stop
Press the turbocharger post-shutdown lubricating pump button.
2.4.5 Engines with ABB and/or TPS turbocharger

Run the electrical pre-start lubricating system for a couple of minutes following the oil change to ensure that
the lubricating oil cooler is filled.
① Oil filling valve ④ Three-way cock

② Oil gauge ⑤ Drain cock
③ inspection glass
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 .................................................................................................................................................................. 7
4.3 Optimal electrode distance ......................................................................................................................................... 7
5 Removing the spark plugs ............................................................................................................................ 7
5.1 Ignition systems with ignition coils .......................................................................................................................... 8
5.2 Ignition systems with external coils ......................................................................................................................... 8
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 9
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 17
8 Fitting the spark plugs ................................................................................................................................ 17
8.1 Ignition systems with ignition coils ....................................................................................................................... 18
8.2 Ignition systems with external coils ...................................................................................................................... 18
8.2.1 Spark plug connectors which are mounted directly on the spark plug 18
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
Author: Doku./Boxleitner Responsible: TEAM/TEBM/TEE/VSR/VST Release date: 15.10.2012
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 up to 110 °C. Always take great care when touching hot spark plugs and
use appropriate safety equipment (gloves).
NOTICE
Surfaces sensitive to dirt
Always use clean gloves to touch the surfaces. Dirt and grease on spark plugs ad‐
versely affect 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 plant, 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) Spark plugs that have been subjected to an impact or fall when unpacked may no
longer be used in the engine, as their ceramic body may be cracked.
e) Check the ceramic body of a spark plug for cracks before fitting it in the engine. If any
cracks are found, the spark plug may no longer be used in the engine.
f) If unusual noises are heard from the engine, it must be shut down at once and the
cause of the noise remedied.
g) 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.
▪ Using the Fluke 123 digital storage oscilloscope, see TI No. 1400-0151.
▪ Using the high-voltage pliers, see TI No. 1400-0149.
▪ Use with the MORIS ignition system, see TIs nos. 1502-0068 and 1502-0071.
▪ Using the adjustment tool for spark plugs with hook electrodes: TI no. 1400-0162.
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 Standard series 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 Natural gas 35 0.3
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).
NOTICE
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

Wear appearance:
The precious-metal plates at the central and earth electrodes are seriously eroded. There is, however, enough
material left for further operation. Make sure as well that the earth electrode carriers still have enough material
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:
To adjust DENSO 518 spark plugs, use adjustment tool no. 9010744 as described in TI 1400-0162, Operating
Instructions for the adjustment tool for spark plugs with hook electrodes.
7.2.5 JenP603 spark plug

To adjust JenP604518 spark plugs, use adjustment tool no. 9010744 as described in TI 1400-0162, Operating
Instructions for the adjustment tool for spark plugs with hook electrodes.
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 8041 A0
Intake air filter - engine
1 Intake air filter

If the underpressure exceeds 1000 Pa, you should replace the filter cloths in the prefilter and the pocket filter
(but after 2000 operating hours at the latest).
Inspection and maintenance work: IW 8049 0
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
Inspection and maintenance work: IW 8049 0
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
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.
Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure that unautho-
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 M0
Control rod assembly/throttle valve/actuator
1 control rod assembly ..................................................................................................................................... 1

1.1 Inspection ............................................................................................................................................................................. 1
1.2 Regreasing ........................................................................................................................................................................... 1
1.2.1 Grease type 2
2 Throttle valve .................................................................................................................................................. 2
2.1 Inspection ............................................................................................................................................................................. 2
3 Replace the throttle-valve bearing and O-ring ........................................................................................ 2
4 Adjusting control rod assembly .................................................................................................................. 3
4.1 Woodward actuator/Type ProAct ISC Model 2 ................................................................................................... 3
4.2 Heinzmann actuator/Type STG10 ............................................................................................................................ 4
5 Sectional drawing of the throttle valve / Assembly bores for actuator .............................................. 4
Shut down the engine in accordance with Technical Instruction no. 1100-0105 and secure it against unau-
thorised restarting in accordance with Technical Instruction 2300-0010.
Point Interval Carrying out the

Maintenance work work
2000 Oh 30000 Oh Customer GEJ *)
Control rod assembly – Checking/Regreasing 1. ■ x
Throttle valve - Checking 2. ■ x
Replacing the blow-by filter can - ■ x
*) by GE Jenbacher, or specialist companies authorised to carry out the work.
1 control rod assembly

Unscrew the plug connector for the power supply from the actuator.
1.1 Inspection
Check if the control rod assembly 8 can be moved without play or friction. If necessary, replace the pivot points
2 (guide value: approx. 10,000 operating hours).
After replacing the pivot points, reset the control rod assembly according to section 4.
1.2 Regreasing
Grease pivot points using a grease gun at the grease 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.
Author: Doku./Bilek Responsible: TCC/Greuter Rainer Release date: 05.11.2012
1.2.1 Grease type

Renolit Duraplex EP2
2 Throttle valve
2.1 Inspection
Remove pivot point 2.
Press shaft 4 into the axial end position and, while pressed, move radially from 0 to the fully open position
(there must be no perceptible resistance shown in the end axial position or in the complete radial movement path).
If any noticeable resistance can be felt, the throttle valve bearing must be replaced according to section 3
(guide value: between 6,000 – 10,000 operating hours depending on the gas type).
3 Replace the throttle-valve bearing and O-ring

Remove screws 3, 12 and 13 and remove the throttle valve assembly.
Undo cap screws 7 (note the position of the throttle valve for re-assembly!)
Remove throttle valve 6 and withdraw shaft 12.
Heat up throttle-valve housing 5 near sleeve 9 (until the metal adhesive burns away) and then press sleeve 9
out of throttle-valve housing 5.
Clean throttle-valve housing 5, shaft 4 and throttle valve 6.
Press bearing sleeve 10 into sleeve 9. Apply metal adhesive to the outside and press into throttle-valve housing
5.
Replace O-Ring 8 in the throttle-valve housing and apply a small amount of grease.
Inspect shaft in the bearing region for run-in tracks. Replace if necessary. Then fit the shaft into the throttle-
valve housing (pay attention to the assembly position!). Secure the screws with metal adhesive.
Mount the complete throttle valve with gaskets or sealing compound on to the engine.
Fix the control rod assembly onto the arm.
Please note: If on disassembly arm 1 was removed from the shaft (e.g. when replacing shafts), then the control
rod assembly must be reset according to section 4.
4 Adjusting control rod assembly
4.1 Woodward actuator/Type ProAct ISC Model 2

Adjust actuator length as shown in drawing below. The ball joints must be lubricated before assembly.
Adjust the lever to zero position (0% position) on the actuator as shown in the drawing below. Caution: ensure
that the actuator shaft is at the zero end position (stop at 0% clockwise).
If the lever position is not in the setpoint position (44°), adjust the lever on the actuator to the next flattest possi-
ble position (e.g. 42° - depending on the actuator shaft gearing).
Fit the control rod assembly with the throttle valve closed and tighten the locking screw on the lever beside the
throttle-valve shaft (always fit the right-hand threaded rods on the actuator side).
Press the throttle valve closed and turn the turnbuckle sleeve until the lever on the actuator is at the stop at the
end position, then turn the turnbuckle sleeve slightly in the opposite direction (max. ¼ turn) until the lever is just
lightly touching the stop at the actuator end position but NOT pre-tensioned against the zero point on the end
position.
Tighten the locknuts securely against the turnbuckle nut and ensure that the length of the control rod assem-
bly can no longer be adjusted.
After assembly, please check that all screw connections are still secure and that the control rod assembly oper-
ates smoothly!
When the actuator is fully open, the control rod assembly should not be overextended, i.e. the actuator must
return the throttle valve securely to zero position.
① Right-hand thread
② Max 1/4 turn
③ The throttle valve must be closed.
The drawing shows how to adjust the control rod assembly for the zero point end position with the throttle
valve closed.
4.2 Heinzmann actuator/Type STG10

Connect the control rod assembly to the actuator.
Please note: For correct adjustment of the control rod assembly, the throttle valve must be at the limit stop
when in the zero position and the actuator must have approx. 3° pretension.
When the actuator is fully open, the control rod assembly should not be overextended, i.e. the actuator must
return the throttle valve securely to zero position.
0 = zero position
5 Sectional drawing of the throttle valve / Assembly bores for actuator
① Lever ⑧ O-Ring
② Pivot point ⑨ Bush
③ Hexagonal head bolt ⑩ bearing bush
④ Shaft ⑪ Control rod assembly
⑤ throttle-valve housing ⑫ Hexagonal head bolt
⑥ Throttle valve ⑬ Hexagonal head bolt
⑦ Cylinder screw
Mounting holes for actuators
① Mounting hole for Woodward type ProAct ISC ② Mounting holes for Heinzmann type STG10 ac-
Model 2 actuator tuator
Cooling water pump
The target recipients of this document are:

customer, distribution partners, service partners, commissioning partners, subsidiaries/branches, Jenbach fa-
cility
or in part.
Interval: every
Maintenance work Point - 10,000 Oh
- Water-side gasket 1. only in the case of leak-
age
10 Overhaul 2. ■
1 Replacing the water-side gasket

Drain the cooling water.
Unbolt blind flange 36.
Heat up the water-pump impeller in the thread area (until the metal adhesive burns away), then unscrew water-
pump impeller 8 from the shaft.
Remove mechanical seal 11.
Caution: Before assembling the new mechanical seal 11, inspect the seal visually for possible damage due
to improper storage, transport, etc.
Remove any dirt particles before assembly.
Thoroughly moisten the sealing face of mechanical seal 11 and shaft 5 using low-surface-tension water (water
with washing-up liquid; do not use oil or grease under any circumstances) and push the seal with O-ring 9 onto
the shaft up to the stop.
Apply thread-locking fluid (Loctite® 270TM) to the shaft, screw on the water pump impeller and tighten manually.
Fix blind flange 36 with O-ring 38 and tighten hexagonal nut 48.
Fill the cooling water circuit according to W 8080 A0 and bleed the circuit.
2 Overhaul
Drain the cooling water and remove the cooling water pump from the engine.
Unbolt blind flange 36.
Place the jig (part no. 156910) in the vice and insert the cooling water pump.
Author: Doku./Bilek Responsible: Reperatur Release date: 10.06.2010
Cooling water pump
Part No. 156910

Unscrew hexagonal nut 33.
Remove water-pump gear wheel 15 using a puller – figure 1.
Remove curved washer 29.
Remove shaft 5 from the spiral casing by using a press or by tapping with a rubber hammer.
Fig. 1
Insert the shaft in the vice (Attention: use protective jaws to avoid damaging the shaft). Heat up water-pump
impeller 8 in the thread region (until the metal adhesive burns away) – Figure 2. .
Cooling water pump
Fig. 2
Unscrew the water-pump impeller from the shaft – figure 3.
Remove mechanical seal 11.
Remove parts 27, 18, 22, 24, 20, 13 from spiral casing 1.
Clean spiral casing 1, water-pump impeller 8 and shaft 5.
Check the shaft (especially for run-in tracks on the rotary shaft seal) and replace, if necessary.
Fig. 3
Composite assembly:
The following components must be replaced:
Pos. 27, 18, 22, 20, 13, 11, 50, 38 (Pos. 5 as required).
Caution: Before assembling mechanical seal 11 and rotary shaft seal 13, inspect the seal visually for possi-
ble damage due to improper storage, transport, etc.
Cooling water pump
Thoroughly moisten the sealing face of mechanical seal 11 and shaft 5 using low-surface-tension water (water
with washing-up liquid; do not use oil or grease under any circumstances) and push the seal with O-ring 9
onto the shaft up to the stop.
Insert the shaft in the vice (use protective jaws).
Apply thread-locking fluid (Loctite® 270?) to shaft 5 (impeller end), screw on water-pump impeller 8 and tighten
manually.
Mount spiral casing 1.
Moisten rotary shaft seal 13 and shaft 5 with oil and press the shaft completely until the stop (flat side towards
mechanical seal 11).
Assemble bearing 20, distance sleeves 22 and 24, bearing 18 and snap ring 27.
Fit curved washer 29.
Heat up water-pump gear wheel 15 and mount onto the shaft.
Secure nut 33 using Loctite ® 242TM and then tighten it (tightening torque 300 Nm).
Fix blind flange 36 and O-ring 38 and tighten with hexagonal nut 48.
Mount the cooling water pump onto the engine using new gaskets.
Fill the cooling water circuit according to W 8080 A0 and bleed the circuit.
Cooling water pump
*) Caution: The bore may not be blocked. Check regularly.
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
2.2.3 Replacing the spark plug connector (Type 9 engines) 14
2.3 Cleaning the pick-up .................................................................................................................................................... 15
2.4 Checking the ignition point ....................................................................................................................................... 16
2.5 Measuring the ignition voltage ............................................................................................................................... 17
2.5.1 High-voltage measurement with high-voltage measuring pliers 18
2.5.2 Checking the high-voltage output of an ignition coil 18
2.6 Ignition system self-test ............................................................................................................................................. 19
Please observe the safety and hazard signs 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
Author: Doku./Boxleitner Responsible: Fügenschuh Tobias Release date: 26.02.2013
Ignition
Ignition / Ignition components / miscellaneous Technical Instruction No.

DISN700 1502-0045
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 8,000 h
accordance with Technical Instructions and maintenance instruc-
tions.
Modular ignition system Test after the maintenance interval, a fault or part replacement in 8,000 h
(MORIS) accordance with Technical Instructions and maintenance instruc-
tions.
Ignition coil Test after the maintenance interval, a fault or part replacement in 8,000 h
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 spark-
general nector, condition of the electrical contacts to the ignition coil and plug mainte-
spark plug (dirt, oxidation, contacts seized) at every spark plug main- nance
tenance 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 Replacement 30,000 h
type 9 engine
Spark plug connector seal Replace the spark plug seal after a maximum of 6,000 Oh (see the 6,000 h
replacement instructions in Section 2.2.1 of the Appendix)
Pick-up Clean any swarf off the magnetic component in the pick-up at a 2,000 h
maximum of 200 Oh after initial commissioning, and thereafter ev-
ery 2,000 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 8,000 h
tions.
Wiring Test after the maintenance interval, a fault or part replacement in 8,000 h
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).
2.2.3 Replacing the spark plug connector (Type 9 engines)

Replace the spark plug connectors on Type 9 engines every 30,000 Oh.
Ignition
▪ Remove the spark plug connector cable from the

ignition rail (1).
▪ Remove the spark plug connector flange from the
rocker arm housing (2 bolts, SW 13)
▪ Take out the old spark plug connector, insert the

new one and reconnect it.
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 Tips .................................................................................................................................................................... 1
2 Measuring the valve-stem projection ........................................................................................................ 2
3 Adjusting the valve play ............................................................................................................................... 3
4 Figures .............................................................................................................................................................. 3
4.1 Notes on figures ................................................................................................................................................................ 3
4.2 Key to Figure 1 ................................................................................................................................................................... 4
4.3 Key to Figure 2: .................................................................................................................................................................. 5
1 Tips
The valve play can be checked and/or set in cold or hot condition.
Set values:
Valve play Inlet: 0.40 mm

——————————
Exhaust: 0,60 mm
The total wear of valve and seat ring may amount to max. 0.098 in (2+0.5 mm).
Upon reaching 0.059 in (1.5 mm) total wear and/or by the first discovery of valve wear of more than 0.008 in
(0.2 mm) within an inspection interval, the valve clearance inspection intervals are to be halved. With max.
0.098 in (2.5 mm) wear, the cylinder heads must be changed (top end overhaul).
Projection:
Cylinder head - NEW Inlet: 28,6 mm

——————————
Exhaust: 29 mm
Enter the measured values in the Operational data – Valve-stem pro-
jection (E 0400) table.
When viewed towards the flywheel side, turn the engine counterclockwise to adjust the valve play and mea-
sure the valve-stem projection.
Turn the engine so that the piston of the cylinder head to be checked and/or measured is at the top dead cen-
tre (ignition TDC) (enter ignition TDC at the flywheel).
Instructions for rotating:
Number of teeth / 360° x ignition point = the number of teeth to be turned
e.g.: 164 / 360° x 70° = 31.88 = 32 teeth
J 208 GS
Cylinder identification
Flywheel
No. of teeth = 162
Valve clearance
Firing sequence
Ignition point
J 212/312 GS
Flywheel
No. of teeth = 164

Firing sequence
Ignition point
J 216/316 GS
Flywheel
No. of teeth = 164

Firing sequence
Ignition point
J 320 GS
Flywheel
No. of teeth = 164

Firing sequence
Ignition point
At ignition TDC, both valves are closed and the rocker arms are not loaded. The valve-stem projection is mea-
sured in this position. The valve play can now be checked and/or adjusted.
Measure the valve play between rocker arms and valve stem. The valve play is correctly set if you feel a slight
resistance when pulling the feeler gauge through (0.4 or 0.6 mm respectively).
2 Measuring the valve-stem projection

Clean sealing faces on contact surfaces of the valve cover at the cylinder head.
Valve clearance
Assemble the measuring support on the cylinder head – see figure 2.

Slightly move the rocker arm sideways.
Measure the distance from the measuring support to the valve stem ends using a depth gauge.
Disassemble the measuring support and put the rocker arm back into start position.
Example:
Actual shaft projection = 1.89 in (48 mm) (measuring support height) – measured value.
Measuring support height - measured value = Actual valve stem projection (enter in the table Opera-
tional data)
48 - 17,6 = 30,4
Actual valve stem projection – new value = Actual value (wear)
30,4 – 28,6 = 1,8
3 Adjusting the valve play

Loosen lock nut using a suitable ring spanner (figure 2, pos. 1 and 3).
The valve play is adjusted using the adjusting screw.
Tighten the lock nut using a suitable ring spanner while at the same time holding the adjusting screw.
Check the valve play again, using a feeler gauge. Re-adjust the play if incorrect.
The valve play may have been changed while you were tightening the lock nut. You must replace lock nuts if
you feel resistance while tightening them or if the lock nuts have too much play, e.g. because the screw thread
is damaged.
4 Figures
4.1 Notes on figures

Figure 1: Sectional drawing
Figure 2: Overall view of cylinder head with mounted measuring support for measuring the valve-stem projection
Valve clearance
4.2 Key to Figure 1
Sectional drawing
1 Seat ring I Wear on valve

2 Valve II Wear on seat ring
3 Cylinder head II Valve play
4 rocker arm IV Valve-stem projection
Valve clearance
4.3 Key to Figure 2:
Overall view of cylinder head with mounted measuring support for measuring the valve-stem projection
1 Lock nut A Exhaust valve

2 Adjusting screw for inlet valve E Intake valve
3 Lock nut
4 Adjusting screw for exhaust valve
5 Measuring support for measuring the valve-
stem projection
Crankcase ventilation system
Maintenance work Interval

2,000 Oh ≥ 20 mbar 40,000 Oh
Differential
pressure
2 Differential pressure inspection ■
- Replacing the blow-by filter can ■
40 Crankcase ventilation – replace polypropylene cloth ■
A clogged filter assembly will prevent pressure compensation, possibly resulting in oil leakage (e.g. rotary shaft
seal - crankshaft).
① Blow-by separator ② Measuring nozzles

Once the filter is fully soaked (approx. 48 operating hours), a stable filter differential pressure will be achieved.
Because the filter will get clogged over time, the differential pressure will slowly rise, however. If the differential
pressure exceeds 20 mbar, the filter will soon become clogged, with the risk that oil is entrained in the air flow.
1 Measuring the filter differential pressure

The filter can has two 1/8” threaded connections (see photograph 1). 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 0
Change the whole blow-by filter can if the differential pressure exceeds 20 mbar.
2 Replacing the blow-by filter can of the crankcase ventilation system

▪ Loosen the hose clips at all three hoses.
▪ Loosen all four filter mounting bolts.
▪ Remove the filter can and fit the insulation on the new filter can.
▪ Reassemble the filter using the fixing screws and reconnect the hoses.
① Hose connections ② Blow-by filter

(to be loosened for filter replacement) (to be replaced in its entirety)
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 mixer
Interval: every
Maintenance work 10000 Oh 20000 Oh 30000 Oh
10 Replace the circuit board with rubber sleeve ■
20 Replace the servomotor ■
20/30 Overhaul ■ *) ■
*) only for B15, B16, B17, B21, B27, special gases and engine cooling water temperature > 95 °C
Author: Doku./Bilek Responsible: Entwicklungsgruppe B Release date: 24.11.2010
Gas mixer
Disassembly
Remove hexagon head bolt 1, cap 2 and joint ring 3

(the callout numbers refer to the gas mixer sectional
drawing at the end of the maintenance work section).
Switch off the power supply to the servomotor and the
circuit board (i. e. disconnect DM455 clamp and with-
draw fuse from module interface).
Remove the circuit board from the servomotor and re-

place.
Gas mixer
Remove hexagonal nuts 4, washers 5 and threaded

rod 6.
Remove steel plate.
Turn the circuit-board shaft of the gas mixer in the di-

rection "AUF" (open) (20 mA).
Activate the power supply to the servomotor and the
circuit board (connect clamp of DM455 and fuse to the
module interface).
Caution: Danger of short-circuit!
The servomotor will unscrew itself from the gas mixer
shaft (if the motor does not run, check whether the Auto/
Man button in dia.ne (screen 41) is set to 'Auto', turn
the potentiometer in the direction of "ZU" (shut) (4 mA),
and subsequently in the direction of "AUF" (open)
(20 mA).
Switch off the power supply to the servomotor and cir-
cuit board again.
Remove the wiring from the servomotor and the cir-
cuit board.
Gas mixer
Layout of cables
Description Stepper motor R/I converter circuit board Simulation device

Motor Phase 1 (+) Ph1+ (green) 1 (green) 11 (green)
Motor Phase 1 (-) Ph1- (red) 2 (red) 12 (red)
Motor Phase 2 (+) Ph2+ (black) 3 (black) 21 (black)
Motor Phase 2 (-) Ph2- (grey) 4 (blue) 22 (blue)
+ 24 V IN 1 (yellow) 30 V (yellow)
+ mA OUT 2 (black) Ion
Shielding 3 (shield) no connection
Please note: The colours of the cores might change depending on the manufacturer!
Inspection
Check if the gas mixer shaft can be easily moved in the gas mixer housing.
(Check: slide the motor forward and back while it screws itself out of the gas mixer shaft.)
Check shaft and adjusting thread for wear. Replace if necessary.
Regrease the adjusting screw thread and apply a small amount of grease to the shaft.
Gas mixer
Composite assembly
Mount the spring on the new servomotor.

Connect the cabling of the servomotor and the circuit
board. Turn the circuit-board shaft of the gas mixer in
the direction "ZU" (shut) (4 mA).
Switch on the power supply to the servomotor and cir-
cuit board again. Fit the servomotor into the screw
thread by hand.
The motor will screw itself into the gas mixer shaft and
open the gas mixer valve until it reaches the mechani-
cal stop. Switch off the power supply of the motor and
circuit board again. For assembly, follow the disassem-
bly procedure in reverse order.
Do not mount the circuit board yet.
Adjusting the 0% position:

Turn the circuit-board shaft in the direction "AUF" (open) (20 mA) until it reaches the mechanical stop.
Switch on the power supply of the motor and circuit board. The gas mixer closes until it reaches the mechani-
cal stop. Switch off the power supply of the motor and circuit board again. Turn the circuit-board shaft in the
direction "ZU" (shut) (4 mA) until it reaches the mechanical stop (now the mixer is "ZU" (shut) (0%) and the poten-
tiometer is "ZU" (shut) (4 mA)).
Mount the circuit board with the potentiometer shaft on the servomotor (there are two types: circuit boards
with a ribbed potentiometer shaft and circuit boards with a smooth potentiometer shaft).
Mounting circuit boards with a ribbed potentiometer shaft:
The ribbed potentiometer shaft prevents the shaft from sliding in the rubber sleeve.
Insert the new rubber sleeve into the gear unit leaving only approx. 1 mm of the rubber sleeve sticking out from
the blind hole. Insert the circuit board with potentiometer shaft into the rubber sleeve. Secure the circuit board
with 4 M4 nuts. Lock the M4 nuts using locking paint.
Mounting circuit boards with a smooth potentiometer shaft:
Glue the new rubber sleeve onto the potentiometer shaft using Loctite 454 glue to prevent the potentiometer
shaft from sliding in the rubber sleeve. Before gluing the rubber sleeve to the potentiometer shaft, ensure that
all the white powdery deposit in the rubber sleeve which was left behind during its manufacture is removed.
Slide the rubber sleeve onto the potentiometer shaft. Lift the rubber sleeve at the front from the shaft using a
flat screwdriver. Insert a drop of super glue into the opening created and move the screwdriver one full turn
around the potentiometer shaft (to ensure that the glue is evenly spread along the front part of the rubber
sleeve and to prevent glue from entering the potentiometer). The curing time of the glue is 2 minutes. Slightly
press on the potentiometer to insert the circuit board with potentiometer shaft into the blind hole. Secure the
circuit board with 4 M4 nuts. Lock the M4 nuts using locking paint.
Switch on the potentiometer supply voltage.
For assembly, follow the disassembly procedure in reverse order.
Gas mixer
Gas mixer sectional drawing
Mixture bypass valve
1 Replace mixture bypass valve
① Mixture bypass valve
Maintenance work: W 1000 0
Maintenance after initial commissioning
Operational data: E 0309; E 0400
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 play / cylinder head: W 0400 M0

Adjust the valve play of the inlet and exhaust valves.
Enter the measured values in the Operational data – Valve-stem projection (E 0400) table.
2.2 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.
2.3 Gas filters: W 8045 A0

Check the gas filter.
2.4 Control rod assembly/throttle valve: W 0200 M0

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 Axial and radial play inspection .................................................................................................................. 2
3.1 Axial play inspection ....................................................................................................................................................... 2
3.2 Radial play inspection .................................................................................................................................................... 2
4 Overhaul .......................................................................................................................................................... 2
Interval: every
Maintenance work Responsible 10,000 Oh 20,000 Oh
10 Inspection – compressor side Maintenance staff **) ■
10 Inspection – compressor and tur- **) ■
bine side *)
10 Axial and radial play inspection Maintenance staff ■
20 Overhaul **) ■
*) only for biogas and special gases
**) The exhaust gas turbocharger should only be repaired/overhauled or cleaned 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 → Disassemble manifold and pipe at the turbocharger.
Check the turbocharger housing for deposits.
If deposits are found, the exhaust gas turbocharger should be cleaned.
On-site cleaning possible.
1.2 Check the compressor and turbine side for deposits

Exhaust gas outlet and mixture inlet → Disassemble manifold and pipe at the turbocharger.
Check the turbine and compressor housing for deposits.
If deposits are found, the exhaust gas turbocharger should be cleaned.
On-site turbine-side cleaning is not possible.
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: 03.01.2011
Exhaust gas turbocharger
3 Axial and radial play inspection
3.1 Axial play inspection

Type Axial play A [mm]
RR 131 Max. 0.13
RR 151 Max. 0.17
TPS 48 0,08 - 0,16
TPS 52 0,10 - 0,18
TPS 57 0,12 - 0,21
3.2 Radial play inspection

Type Radial play B [mm]
RR 131 Max. 0.70
RR 151 Max. 0.75
TPS 48 0,54 - 1,22
TPS 52 0,62 - 1,35
TPS 57 0,72 - 1,52
4 Overhaul
The exhaust gas turbocharger should only be overhauled by the manufacturer or by specialised compa-
nies authorised to carry out this work.
Author: Doku./Bilek Responsible: TET/Haidn Markus Release date: 03.01.2011
Maintenance work: W 8030 A0
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 .......................................................................................................................... 3
8 manufacturer's documents .......................................................................................................................... 3
Interval: every
Maintenance work Point Daily 4000 Oh 10000 Oh 20000 Oh 60,000
Oh
t Bearing temperature control 1. ■
04 Relubricating the bearings *) 2. ■ **)
10 Cleaning/Inspection 3. ■
20 Inspection/Expertise/Replacing the bear- 4. ■
ings
60 Overhaul 5. ■
*) Does not apply to generators without grease nipples!
**) If the equipment is used for less than 4000 operating hours a year, the generator should be regreased 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.
Best practice is 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)

(Type 5: optionally regreasable)
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 regreasing to ensure that no particles of dirt get into the bearings.
Author: Doku./Bilek Responsible: Newag Release date: 03.01.2012
Generator
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.
2.2 Lubricating grease

The prescribed type of lubricating grease can be found on the sticker on the generator.
Make sure to use Klüberquiet BQ 72-72 lubricating grease in case of automatic regreasing!
Grease manufacturer: Types of grease: Klüber Lubrication München KG

Gelsenhausenerstraße 7, 81379 München, Germany
Fax: 089 7876 565
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.
Generator
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 to do so!
7 Recommissioning the plant

When the installation is being recommissioned after 6 months, the bearings must be thoroughly lubricated with
the specified quantity of grease to replace the old grease.
Where the installation 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 installation, you must ensure that the installation is in its normal opera-
tional condition again - see manufacturer's instructions.
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 signs 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
Replacing the starter:
▪ 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: Provin, Daniel Responsible: Anderson, Barry Release date: 15.05.2013
Starter
③ Type 3 engine negative battery terminal
④ Type 4 engine negative battery terminal
Starter
⑤ Type 6 engine negative battery terminal

▪ Disconnect the starter cables at the starter motor.
In case of 2 or more starter motors installed, the aluminium-acrylic protective cover ⑥ on and the copper
bar ⑦ in the starter connection bar have to be removed.
▪ 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.
Example for type 6 engines: Rubber caps, aluminium-acrylic protective cover ⑥ and copper bar ⑦
Maintenance work: W 8033 0
Elastomer components
Elastomer components age and become brittle, even when engines are not operational. That is why the
service life of these components depends on more factors than the on-stream service time of the module,
the cooling water temperature and pressure etc. If this number of operating hours is not reached, the elas-
tomer components should still be replaced anyway as a precautionary measure after a maximum of 5 years.
every
Replacing the elastomer components 10000 Oh 20000 Oh 30000 Oh 60,000 Oh
All O-rings: turbocharger installation ■
All O-rings: cooling water line, oil lines, oil cooler ■
All hoses: oil lines, pre-lubrication and re-lubrication, ■
venting system, compensation reservoir, exhaust gas
back pressure control, crankcase ventilation, cooling
water hoses (if present)
Coupling: coupling discs ■
All rubber buffers: air-filter collection cabinets, intake ■
line, gas mixer, ignition cable harness, ignition,
switchgear cabinets at the module, etc.
All O-rings: Cylinder liner, crankcase, cylinder head, pis- ■ *) ■
ton cooling nozzles
Engine / generator bearing: rubber rails ■ **) ■
Anchor bolts: O-rings ■
Plate heat exchanger: rubber gaskets ■ ***) ■
*) only for biogas, landfill gas, special gases or increased engine cooling water temperature >95℃
**) inspect and replace, if necessary
***) only for engine cooling water temperature >95 °C
Gas pressure control system
Interval: every
Maintenance work Point 2000 Oh 30000 Oh 60,000 Oh
02 Gas filters 1. ■
30 Pre-pressure controller 2. ■
60 Gas train 3. ■
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
Have the pre-pressure controller overhauled by a specialist company authorised to carry out this work.
3 Gas train
Have the gas train overhauled by a specialist company authorised to carry out this work.
Oil pump
1 Oil pump
Disassemble and clean the oil pump. Replace the bearing bushes.
Inspect the oil-pump gear wheels. Replace if necessary.
The engine is to be lifted about 40-50 cm [15.748 – 19.685 in] (the engine can be lifted by means of hydraulic
lifting devices with claws).
Caution: After lifting up the engine, secure it immediately using wooden blocks, for example.
Piston/Piston cooling
1 Piston
Replace piston, piston rings and piston pins.
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: TEK/VSA Release date: 24.11.2010
Connecting rods and connecting rod bearings
1 Connecting rods, connecting rod bearings and connecting rod bolts

Replace the connecting rods, connecting-rod bearings and connecting-rod screws.
Cylinder liner/scraper ring
1 Cylinder liner and scraper ring:

Replace the cylinder liner, scraper ring and O-rings.
Only use a hand pump to disassemble the cylinder liner.
Hydraulik- oder. Do not use hydraulic or electric pumps!
Main crankshaft bearing
Interval: every
30,000 Oh 40,000 Oh
Maintenance work (4,000 engine starts) (3000 engine starts)
30 Replace the main crankshaft bearing ■
40 Replace the main crankshaft bearing ■ *)
*) only for biogas, landfill gas and special gas engines
1 Main crankshaft bearings

The main crankshaft bearings must be completely replaced at 40,000 operating hours or when the maximum
number of engine starts has been reached as indicated in the above table.
Author: TED/Jandewerth Responsible: Entwicklung Release date: 24.11.2010
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
Camshaft/timing gear
Carry out the inspection below following each cylinder-head disassembly!
Even if you have replaced a single cylinder head, you should inspect the relevant tappets and cams.
1 Camshaft
Visual inspection of camshaft cams:
Turn the cam gradually 4x90°. Visually inspect the running surface for inadmissible damage/chipping at every
tappet bore along the entire cam circumference.
2 Control parts
Inspect the tappets (replace at max. 30,000 operating hours).
Inspect the push rod, ball screw, rocker arm and rocker arm support.
Author: Doku./Bilek Responsible: Service Team I Release date: 24.11.2010
Cylinder head replacement
1 Cylinder head replacement .......................................................................................................................... 1

1.1 Cylinder head disassembly .......................................................................................................................................... 1
1.2 Cylinder head assembly using a hydraulic drive module – if no hydraulic drive module is avail-
able, assemble the cylinder head according to section 1.3 ......................................................................... 1
1.3 Cylinder head assembly without hydraulic drive module ............................................................................. 4
2 Fill the cooling water according to W 8080 A0! ........................................................................................ 5
Interval: every
Maintenance work Point 30000 Oh ….. Oh
30 Cylinder head replacement 1. ■ *)
- Cylinder head replacement 1. ■ **)
*) To be done on disassembly, when replacing piston and cylinder liner.
Clean the cylinder head at the sealing surfaces and measure the valve-stem projection.
In the event of ≥1.2 mm wear, 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 Cylinder head disassembly

Drain the coolant until the cylinder heads are emptied.
Caution: never re-use drained cooling water when re-filling the cooling system!
Disassemble ignition coils and spark plug.
Disassemble and inspect the exhaust, mixture and cooling water lines.
Disassemble the exhaust gas lagging (if available).
Remove the rocker cover.
Disassemble and check the valve control components (rocker support, rocker arms, tappet push rods and tappets).
Inspect the camshaft.
Remove the cylinder head bolts and the cylinder heads.
Please note:Avoid damaging the sealing surface of the cylinder heads.
1.2 Cylinder head assembly using a hydraulic drive module – if no hydraulic drive module is available,
assemble the cylinder head according to section 1.3
Clean sealing surfaces on crankcase, intermediate ring (for type 3 engines only) and cylinder heads and fit new
gaskets.
Mount the cylinder heads.
Oil double-end studs and nut contact areas of cylinder heads.
Hand-tighten the cylinder head nuts, "starting at the top".
Fit the support plate.
Author: Doku./Bilek Responsible: TEAM/Egger Christoph Release date: 24.11.2010
Support plate
Because of the very limited contact surfaces at the

cylinder head, a support plate must be used.
Fit the hydraulic torque spanner to the cylinder head

nuts A, B, C and D.
Connect the hoses to the four hydraulic cylinders and

to the hydraulic drive module.
Switch on the hydraulic drive module.
Using the remote control unit, tighten the cylinder
head nuts to the tightening pressure as specified in TI
1902-0212.
Hydraulic drive module, remote control unit.
Clamping cylinder pres-
sure.
① Hydraulic drive module.
Maintain a safety distance of 3 - 5 m from the screw clamping cylinder while pressure is being built-up.
It is absolutely forbidden for anyone to remain on the pulling side while pressure is being built up.
The operating staff must check the hydraulic pressure increase using the pressure gauge. If despite contin-
uous pressure generation the pressure no longer increases, the pressure build-up must be stopped imme-
diately.
This may be caused by a plastic deformation. For that reason, check the screw connection for form and
dimensional accuracy.
(e.g. permanent double-end stud elongation).
Having applied pressure, turn all four nuts manually at

the turning device (square) until they rest against the
cylinder head.
① Direction of rotation
Using the remote control unit, reduce the screw clamping cylinder pressure.
Switch off the hydraulic drive module.
Remove the hoses from the hydraulic cylinders and then remove all four hydraulic cylinders.
Assemble and fit the valve control system.
Adjust the valve play according to W 0400 M0.
Clean the sealing surface at the underside of the rocker cover and remove any paint residues.
Fit the cocker cover using a new gasket.
Mount the exhaust, mixture and cooling water lines.
Fit the spark plugs and ignition coils.
Fit the lagging.
1.3 Cylinder head assembly without hydraulic drive module

Clean sealing surfaces on crankcase, intermediate ring (for type 3 engines only) and cylinder heads and fit new
gaskets.
Mount the cylinder heads.
Oil double-end studs and nut contact areas of cylinder heads.
Screw in bolts hand-tight and tighten crosswise with a

torque of 147.4 lb ft (200 Nm) (starting on the intake
side "top"). Fit angle-of-rotation tool (see figure) and
tighten by a further
▪ Br. (type 2)
▪ Br. (type 3) crosswise.
Assemble the valve control system.

Adjust the valve play according to W 0400 M0.
Clean the sealing surface at the underside of the cylinder-head cover and remove any paint residues.
Assemble the cylinder-head cover using a new gasket.
Assemble the exhaust, mixture and cooling water lines.
Assemble spark plug and ignition coils.
Assemble lagging.
Check the valve play again, using a feeler gauge!
2 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: 03.05.2012
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 ............................................................................................................................... 2
2.1 General instructions: ....................................................................................................................................................... 2
2.2 Filling instructions for the cooling water system ............................................................................................... 2
2.3 venting ................................................................................................................................................................................... 4
2.3.1 Electric cooling water pump without permanent bleeding 4
2.3.2 Preheating pump 4
2.3.3 Further vents on the J624 5
2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules ............ 5
2.4.1 Information on measuring the differential temperature 10
2.4.2 Information on adjusting the section control valve 10
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 check at the pressure gauge on the filling valve.
① Pressure gauge
Overview of the recommended settings for the engine cooling water pressure:
Modules Prepressure*) in the ex- Filling pressure*) Operating pressure*)

pansion tank when cold when warm (result**)
J 208 GS – J 320 GS 0.6 bar (gauge pressure) 0.9 bar (gauge pres- 1.5 bar (gauge pressure)
sure)
J 412 GS – J 424 GS 0.6 bar (gauge pressure) 0.9 bar (gauge pres- 1.5 bar (gauge pressure)
sure)
type 6 E module 0.8 bar (gauge pressure) 1.1 bar (gauge pres- 1.5 bar (gauge pressure)
sure)
type 6 F/G/H module 1.7 bar (gauge pressure) 2.1 bar (gauge pres- 2,5 bar(ü)
sure)
type 6 F/G/H generating set 1.7 bar (gauge pressure) 2.1 bar (gauge pres- 2,5 bar(ü)
sure)
Author: Doku./Bilek Responsible: Madl Wolfgang, Lang Jürgen, Thumer Math- Release date: 17.10.2012
ias
ter
Modules Prepressure*) in the ex-

Filling pressure*) Operating pressure*)
pansion tank
when cold when warm (result**)
type 6 F/G generating set 2.0 bar (gauge pressure)
2.5 bar (gauge pres- 3.0 bar (gauge pressure)
„Hot Country“ sure)
*)Binding plant-specific figures can be taken from the technical diagram These settings should be observed
particularly in the case of containerised modules or generating set modules with top-mounted flat-bed coolers.
**)to be obtained by draining off water if necessary, if the operating pressure resulting from the prepressure/
filling pressure is too high
Note 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 no. 1000-0200
Antifreeze: TI no. 1000-0201
Cooling water anti-corrosion additive: TI no. 1000-0204
Quality of circuit water in hot water and warm water heating systems: TI no. 1000-0206
Quality of cooling water in open circuits: TI no. 1000-0208
2.2 Filling instructions for the cooling water system

Reduce the prepressure (if required) using the pressure valve at the diaphragm expansion tank. Make sure that
no cooling water has been filled first.
① Pressure valve
Set the cooling water system pressure at the filling valve.
ias
ter
① Vent cock (to be opened only when filling water)
Permanent vent (only for containerised installations)
① Shut-off cock (to be shut after starting and thereafter kept shut)
Make sure that the filling hose contains no air when it is connected to the filling valve (to prevent the unwanted
ingress of air into the cooling water system).
Filling the cooling water system via the filling valve.
Keep the vent cock open until the water escaping from the vent is completely free of air.
ias
ter
Shut the shut-off cock by turning it clockwise (to the right) and remove the filling hose from the filling valve.
Repeat the filling procedure every time the cooling system is filled or refilled until the cooling-water system is
completely free of air.
2.3 venting
2.3.1 Electric cooling water pump without permanent bleeding

Electric cooling water pump vent screw
Open the bleeding screw until the water escaping no longer contains any air.
2.3.2 Preheating pump
① Preheating pump vent screw
ias
ter
Undo the vent screw until the water escaping no longer contains any air.
Caution: if the engine has been shut down for a long period of time prior to starting, check the preheating
pump shaft for ease of movement → turn the shaft using a screwdriver in the notch of the pump shaft.
Shut off the flow to the filling valve after filling or refilling the cooling system every time.
This will show whether the pressure is maintained in the cooling water system.
Caution when working on installations with single-circuit cooling systems:

Always check the cooling water circuit after working on the cooling system or changing the cooling water.
2.3.3 Further vents on the J624
Further vents on the J624 TSTC
2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules
▪ Types 2, 3 and 4 engines:
ias
ter
Adjust the flow quantity using the section control valve.
① Section control valve

The setting value can easily be recorded and reproduced using the scale. The top number (with the black back-
ground) represents the coarse setting (1 to 4), the bottom number (red background) represents the decimal set-
ting (1 to 9).
The differential temperature is measured between the engine inlet
ias
ter
and engine cooling water outlet.
The differential temperature at full load should be <6°C.
▪ Type 6 engine - generating set

On generating set installations (single-circuit cooling), the engine cooling water flow is adjusted using the sec-
tion control valve. The reduced pressure loss in the small (inner) circuit allows a large flow quantity compared
to that flowing through the full circuit. The temperature level at the engine inlet is slightly higher as a result.
Note that a 15 kW cooling water pump was introduced on the J620as part of the "Cooling" project. However,
this requires different settings at the section control valve compared to the previous 7.5 kW cooling water pump.
The basic figure for the setting is [5/6]. The top number (with the black background) represents the coarse
setting (1 to 8), the bottom number (red background) represents the decimal setting (1 to 9) on the DN65 branch
control valves on Type 6 engines.
ias
ter
Note that any subsequent fine adjustment at the section control valve must be based on the engine cooling
water temperature spread.
The fine adjustment of the section control valve is based on the basic figure (see above). Keep adjusting the
valve until the required temperature spread at the customer interface [generally 60°C (return flow) -> 95°C
(outward flow)] as specified in the hydraulic diagram has been reached.
The differential temperature between the engine inlet and the cooling water outlet from the engine must be
measured as a further check. This must be less than 5°C (expected value 4 - 5°C) if the above settings have
been correctly adjusted.
The throttle valve upstream of the oil cooler is set at 3 on the acceptance test bed at Jenbach.
① Branch control valve on the J620 generating set.
▪ Type 6 engine modules:

Type 6 engine modules: as part of the "Cooling" project, an 11 kW engine cooling water pump was introduced
on J620engines in generating set modules with engine cooling water heat exchangers. A section control
valve was also introduced for generating set modules.
ias
ter
The section control valve for module sets must not be adjusted at the customer's plant, but is set once and for
all on the acceptance test bet at Jenbach (corresponding to the requirements of the different heat exchanger
types).
The target value for the setting is [3/7] on the acceptance test bed at Jenbach. The top number (with the
black background) represents the coarse setting (1 to 8), the bottom number (red background) represents the
decimal setting (1 to 9) on the DN65 branch control valves on Type 6 engines.
As a check, the differential temperature between the engine inlet and the cooling water outlet from the engine
must be measured. This must be less than 5°C (expected value 4 - 5°C) if the above settings have been correct-
ly adjusted. The setting wheel should be removed after the adjustment on the acceptance test bed at Jenbach.
If a setting wheel is fitted to the customer's installation, it should as a rule never be moved.
① Section control valve on J620 module
The differential temperature is measured between the engine cooling water intake (A or B side)
ias
ter
and cooling water outlet from the engine after the two return lines have merged.
The differential temperature at full load should be < 5°C.
2.4.1 Information on measuring the differential temperature

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 Information on adjusting the section control valve

The setting value can easily be recorded and reproduced using the scale. The top number (with the black back-
ground) represents the coarse setting (1 to 8), the bottom number (red background) represents the decimal set-
ting (1 to 9).
ias
ter
▪ Types 2, 3 and 4 engines:

Remove the section control valve lock and safety cap.
The basic setting of the section control valve is approx. [1.5].
Run the engine at half load and adjust the section control valve so that the differential temperature settles at
approx. 4°C (shutting the valve will increase the differential temperature). Then run the engine at full load, wait
until the temperature remains constant (at least 30 minutes) and then set the differential temperature to < 6°C.
Differential temperatures below 5°C (valve opened too far) can result in "Cooling water temperature maximum".
Differential temperatures between 5°C and 6°C are still admissible.
Refit and lock the safety cap.
▪ Type 6 engines:
Remove the section control valve lock and safety cap.
See Section 2.4 for the basic section control valve setting for Type 6 engines.
Run the engine at half load and adjust the control valve so that the differential temperature settles at approx.
5°C (shutting the valve will increase the differential temperature). Then run the engine at full load, wait until the
temperature becomes constant (at least 30 minutes) and set the differential temperature in accordance with
the instructions in Section 2.4 for Type 6 engines.
If the valve is opened too far, "Cooling water temperature maximum" can result.
Refit and lock the safety cap if provided.
ias
5 Maintenance record sheets
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
2000 Oh
Number of starts
4000 Oh
Number of starts
6000 Oh
Number of starts
8000 Oh
Number of starts
10000 Oh
Number of starts
12000 Oh
Number of starts
14000 Oh
Number of starts
16000 Oh
Number of starts
18000 Oh
Number of starts
20000 Oh
Number of starts
22000 Oh
Number of starts
24000 Oh
Number of starts
26000 Oh
Number of starts
28000 Oh
Number of starts
30000 Oh
Number of starts
32000 Oh
Number of starts
5.1
Maintenance protocol
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
34000 Oh
Number of starts
36000 Oh
Number of starts
38000 Oh
Number of starts
40000 Oh
Number of starts
42000 Oh
Number of starts
44000 Oh
Number of starts
46000 Oh
Number of starts
48000 Oh
Number of starts
50000 Oh
Number of starts
52000 Oh
Number of starts
54000 Oh
Number of starts
56000 Oh
Number of starts
58000 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 Registering operational data
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
Operational data booklet
Operational value to be read Unit Mo. Tue. Wed. Thu. Fr. Sa. Su.
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 – Engine lubricating oil
Product applied (brand name):

Operating hours Oil analysis Change oil Date performed by Signature Remarks
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 f
Operational data - crankcase ventilation system
Blow-by separator pres- Differential Pressure Date Recorded by

Inspection intervals sure - intake
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
p2=______mbar
Operational data: E 0103 f
Operational data - crankcase ventilation system
Blow-by separator pres- Differential Pressure Date Recorded by

Inspection intervals sure - intake
Crankcase pressure
Blow-by separator - out-
let
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 – 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
Operational data – spark plugs
Calendar week: ___ Calendar week: ___ Calendar week: ___ Calendar week: ___
Operating hours: ___ Operating hours: ___ Operating hours: ___ Operating hours: ___
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
OV=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
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
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
7 Initial commissioning data sheet
7.1
Initial commissioning data sheet

Wartung [J P659 - P687-En]

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JGS 320 GS-N.

NAVIGAT FRAME 320 Q3 2012

© GE Jenbacher GmbH & Co OG

Original operating instructions

GE proprietary information: CONFIDENTIAL

© GE Jenbacher GmbH & Co OG, 2013-07

User Instructions ......................................................................................................................................................................... 1

General conditions ...................................................................................................................................................................... 2

Maintenance plan ........................................................................................................................................................................ 3

Inspection and maintenance work ........................................................................................................................................... 4

Cylinder liner/scraper ring .......................................................................................................................................................... W 8049 M0

Maintenance record sheets ....................................................................................................................................................... 5

Registering operational data .................................................................................................................................................... 6

Initial commissioning data sheet ............................................................................................................................................. 7

▪ Operation of the system

▪ What inspection work and maintenance work needs to be car-

Spare parts list

▪ Selecting the required spare part

1.1 Engine type plate

GE Jenbacher GmbH & Co OG

Engine type plate

1.2 System type plate

GE Jenbacher GmbH & Co OG

System type plate

Type Type Max. ambient Max. ambient temperature:

2.1 Engine type designation

Term Abbreviation Key to abbreviation e.g.

① Manufacturer ④ Mode of operation

2.2 Module type designation

Term Abbreviation Key to abbreviation e.g.

① Installation type ⑥ Mode of operation

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Hitachi Engineering & Services Co., Ldt.

Hitachi Engineering & Services Co., Ldt.

Osaka Gas Engineering Co., Ldt.

A) B) C D) E) X) Y´)