1000-0046 - EN Transportation of Type 6 PDF

Jenbacher 1000-0046
Technical Instructions No.:

Documentation Lifting, Transporting and Positioning
GE Jenbacher Units in Engine Rooms
1. Purpose: ___________________________________________________________2
2. Lifting:_____________________________________________________________2
2.1 Load suspension device: 2
2.2 Lifting Type 6 E standard engine and Type 4 standard module: 3
2.3 Generator: 5
3. Transport on transport vehicles: _______________________________________5
3.1 General tips: 5
3.2 Rail transport: 6
4. Positioning in the engine room: ________________________________________7
4.1 Transporting Type 6 E standard engines and Type 4 standard module into the engine room: 7
4.2 Bringing the generator into the building: 8
5. In the final stages of setting up the engine and/or module, you cannot use a
crane: _________________________________________________________9
5.1 Lowering onto rollers: 9
5.2 Moving on rollers: 10
5.2.1 Pulling with a forklift or a cable winch: 10
5.2.2 Pushing with a forklift or manpower: 10
5.3 Transferring onto steel rollers/pipes: 11
5.4 Transferring onto rollers: 13
5.5 Inserting Sylomer strips: 14
5.6 Checking the Sylomer strips: 15
5.7 Inserting plate: 15
6. The generator cannot be put into place using a crane: ____________________16
6.1 Lowering onto rollers: 16
6.2 Moving on rollers: 16
6.2.1 Pulling with a forklift or a cable winch: 16
6.2.2 Pushing with a forklift or manpower: 16
6.3 Transferring onto steel rollers: 17
7. Attaching the generator and engine to each other: _______________________17
8. Positioning transmissions:___________________________________________21
8.1 Transporting generator frame with generator and transmissions: 21
8.2 Positioning: 22
Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

EN 1000-0046_EN.doc Index: p Page - No.: 1 / 22
Jenbacher 1000-0046
1000-0041
Applies to GE Jenbacher modules with split module frame and Type 4 standard 1000-0044
i
1. Purpose:
This Technical Instruction describes how to lift, transport on appropriate transport vehicles and bring
GE Jenbacher modules into engine rooms and how to use and maintain the load suspension device
(hoisting gear, chains, cables, etc.).
The module arrangement surface shall comply with Technical Instruction 1000-0041.
2. Lifting:
Always check whether the load suspension device is in a ready-for-use condition (see 'Guidelines for
use') prior to using it.
2.1 Load suspension device:
Normal operating conditions

This load suspension device is meant to lift GE Jenbacher modules in accordance with the relevant
European and national standards, subject to the restrictions listed below.
Guidelines for use

Make sure that this load suspension device is only used by a trained hanger-on. When using the load
suspension device always make sure that
• the device is not damaged to such an extent that its safety and functionality are affected (e. g.:
fractures, notches, cracks, wear, deformation, damage due to heat, etc.),
• there are no knots or distortions,
• the device is not run across sharp edges without taking the necessary precautions,
• the device is not overloaded due to jolting,
• the device is not required to lift loads in excess of its lifting capacity as mentioned on the plate (lifting
capacity plate, rating plate, label),
• the device is not non-symmetrically loaded without your taking the necessary precautions,
• the device is applied and loaded appropriately when using shortening devices.
Disregarding the above instructions and improper use of the device can result in bodily injury and damage
to property.
Maintenance
Make sure that this load suspension device is checked by an expert at least once a year for external
damage, distortions, wear and corrosion, cracks and breaks. Reject the device if the defects found are
intolerable. Do not make any modifications to the load suspension device which will affect the function
and lifting capacity of the device.
Limitations to the use of the load suspension device

In case of high temperatures, the lifting capacity of the load suspension device must be reduced
accordingly. Always check whether the load suspension device can be used in aggressive environments
prior to actually using it.
Never use the load suspension device in circumstances in which the load can accidentally become
unstrapped.

Jenbacher 1000-0046
2.2 Lifting Type 6 E standard engine and Type 4 standard module:

Please read and follow the instructions on the stickers affixed to engine and lifting equipment.
Jenbacher
DANGER gas engines
GE Jenbacher GmbH & Co OHG | A-6200 Jenbach | Austria
301287
Siehe / see
Engine type
type 4 type 6
150 Nm 900 Nm
111 lb ft 663 lb ft
Gewicht siehe Typenschild

Weight see identification plate
JWN 080 576 / 321656
Attach the lifting lugs to the engine.

Tightening torque: Type 6 E --> 900 Nm [663 lb ft]
Type 4 --> 150 Nm [111 lb ft]
Engine type Design To be assembled between cylinder head

J 620 E 4/5 8/9 14/15 18/19
J 616 E 5/6 6/7 13/14 14/15
J 612 E 4/5 5/6 10/11 11/12
J 420 2/3 4/5 12/13 14/15
J 416 1/2 3/4 9/10 11/12
J 412 1/2 3/4 7/8 9/10
Cylinder number 1 is located on the left engine side when facing the flywheel.
Flywheel Cylinder number 1
1 2 3 4 5

Jenbacher 1000-0046
Attach the lifting equipment to the lifting lugs and hoist the module with a
crane or mobile crane.
Make sure when attaching the lifting equipment that the angle of force
coincides with the V-angle.
When hoisting the module, always make sure that its

maximum admissible angle of inclination in longitudinal
direction does not exceed 5°.
If the angle exceeds 5°, you must immediately stop the
hoisting procedure!
Before hoisting the module again, first adjust the hook-in
points at the hoisting rig so that the admissible angle of
inclination is not exceeded.
The hook-in points as shown on the hoisting rig sticker
are merely guide marks!
Make sure that the yellow transport safety pegs are correctly installed when lifting the engine, module or
generator.
The lifting device can be ordered from GE Jenbacher.

Jenbacher 1000-0046
Lifting lugs
Transport safety
2.3 Generator:
Lift the generator using suitable textile hoisting belts, chains or cables.
Make sure that the yellow transport safety pegs are correctly installed when
lifting the engine, module or generator.
3. Transport on transport vehicles:
3.1 General tips:

Transport safety devices must be installed according to TI 1000-0044.
This applies to the lifting, transporting on transport vehicles and positioning in engine rooms.
When transporting on transport vehicles it must be ensured that a suitable backing consisting of timber,
rubber or similar is used between unit frame and platform.
Risk of skidding and tipping must be excluded by the proper attachment of strapping.
The transport security shackles are not suitable for lifting modules. These shackles are only intended for
securing the modules on transport vehicles!

Jenbacher 1000-0046
Do not lift the engine by the yellow security shackles!
Lifting the motor by the transport security shackles with result in the shackles
breaking off and the engine being seriously damaged.
Caution! Extreme danger!
IS O 3864, ANS I Z535
Lift the module using only the lifting lugs intended for that purpose!
lifting shackle
security shackle
20 Nm (15 lbf.ft)
Remove the transport security shackles before commissioning.
Fit the knock sensors using the indicated tightening torques.
60 Nm (44 lbf.ft)
ISO 3864, ANSI Z535
3.2 Rail transport:

If possible, railway trucks must not be used for transport purposes as rail transport often involves frequent
and hard bumping. Bumping can result in damage to the generator’s roller bearings, also called false
brinelling. There is also the risk during shunting of railway trucks being pushed away, possibly damaging
the engine sliding bearings, and especially the main bearings. Cold welding has been known to be
caused by railway trucks being pushed away resulting in very high axial accelerations.
If, due to local conditions rail transport cannot be avoided, silomer strips or other damping elements must
be placed under the module frame (this does not apply to container versions as these are automatically
provided with damping elements). The shipping company must also guarantee that the railway truck
carrying the engine/module will NOT be pushed away during shunting.

Jenbacher 1000-0046
4. Positioning in the engine room:
4.1 Transporting Type 6 E standard engines and Type 4 standard module into the engine room:
Lifting 2.
Transport on transport
vehicles 3.
YES NO
Crane reaches
installation area
Position Sylomer
strips
YES NO
unit with base
Position unit with
crane
YES NO YES NO
Oil drip pan Oil drip pan
Lowering onto Lowering onto Lowering onto

rollers 5.1/a rollers 5.1/b rollers 5.1/c Lowering onto
rollers 5.1/d
Moving on rollers Moving on rollers Moving on rollers
5.2 5.2 5.2 Moving on rollers
5.2
Transfering onto steel Transfering onto Transfering onto steel
pipes/rollers 5.3 rollers 5.4 pipes/rollers 5.3 Inserting Sylomer
strips 5.5
Inserting Sylomer Inserting Sylomer Inserting Sylomer
strips 5.5 strips 5.5 strips 5.5
Checking Sylomer strips

5.6
YES NO
Sylomer OK
Inserting plate 5.7
Removing transport
quards TI 1000-0044

Jenbacher 1000-0046
4.2 Bringing the generator into the building:
Lifting 2.3
Transport on transport
vehicles 3.
YES NO
Crane reaches
installation area
YES NO
unit with base
Lowering onto Lowering onto

rollers 6.1/a rollers 6.1/b
Moving on rollers Moving on rollers

6.2 6.2
Transfering onto
rollers 6.3
Connect the generator

and engine 7.

Jenbacher 1000-0046
5. In the final stages of setting up the engine and/or module, you cannot use a crane:
5.1 Lowering onto rollers:

Position transport rollers at the distance of the frame I-sections and position spacing timber onto the
transport rollers if required.
5.1/a Height of spacing timber h = base height + height of oil collection tray
5.1/b Height of spacing timber h = base height
5.1/c Height of spacing timber h = height of oil collection tray
5.1/d No spacing timber is necessary! (Frame can be directly lowered onto the transport rollers.)
Lift unit with crane into the building as far as possible.
Transport rollers
Position the longitudinal frame support on transport rollers with wooden distance blocks on top.
The engine should now be positioned almost horizontally on the transport rollers.

Jenbacher 1000-0046
5.2 Moving on rollers:

There are various options for moving the unit by means of transport rollers.
5.2.1 Pulling with a forklift or a cable winch:

Attach a chain, bar or cable to the unit frame cross member with a textile loop.
5.2.2 Pushing with a forklift or manpower:

If the engine is to be moved using a forklift truck, a protective piece of wood should be placed at the
engine face between forklift truck and engine. The unit can now be moved by positioning the forklift forks
against this square timber.
Experience has shown that even three to four strong persons will be able to move a unit. However, the
following must be observed in order to prevent damage. The prerequisite for this is a level footing.
Otherwise, the footing must be made level using sheet steel.
Under no circumstances must force be applied to unit components such as module interfaces, ignition
box, etc.

Jenbacher 1000-0046
5.3 Transferring onto steel rollers/pipes:

In this case steel pipes/rollers must be used which are not wider than the oil collection tray and protrude
over the upper edge so that the unit frame need only be lifted very little.
Move the unit directly to the oil collection tray.
Install hydraulic jacks at the lifting points.
Lifting point
As the amount of space available is limited, especially if the engine is equipped with an engine oil pan,
bear in mind the following advice relating to the dimensions of the hydraulic jacks.
[Hub=5.51 in]
[13.4 in]
[8.27 in]
[1.2 in]
[max.=15.55 in]
[10 in]
[5.7 in]
[3.3 in]
[0.59 in]
[10.2 in]

Jenbacher 1000-0046
Roll suitable steel pipes/rollers in the oil collection tray under the frame and remove the front transport
roller pair.
Lower the unit onto the steel pipes/rollers.
Steel tube
Transfer of the second transport roller pair is done in like manner.

Jenbacher 1000-0046
5.4 Transferring onto rollers:

Move the unit directly to the base.
Install hydraulic jacks at the lifting points. Remove spacing timber, lift transport roller onto the base and
lower unit frame onto the base.
Transfer of the second transport roller pair takes place in like manner.

Jenbacher 1000-0046
5.5 Inserting Sylomer strips:

Position a square timber under one end of the frame. At the other end, the module frame is lifted using
hydraulic jacks.
For reasons of safety, place the unit chassis on squared timber to prevent it from sinking.
Remove transport roller and install Sylomer trips up to the square timber.
If four (4) hydraulic jacks are available, the module can be lifted at both ends to assemble and align the
sylomer strips in one go.
Lift unit frame on the other end and remove square timber.
Install Sylomer strips over the entire length and arrange so that the Sylomer strip protrusion under the
frame side members is the same all round.
Trim Sylomer strips to the same length as the longitudinal chassis bearers.

Jenbacher 1000-0046
5.6 Checking the Sylomer strips:

The load resulting from the unit frame must be evenly distributed on the Sylomer strips along the entire
length.
At no point must it be possible to shift the Sylomer strip under the frame side member.
5.7 Inserting plate:

If the Sylomer strips are unevenly loaded, shim plate must be inserted (under Sylomer strips) at those
points where the Sylomer strips can be moved.
The thickness of the inserted plate must correspond to the deviation (between unit installation surface
and Sylomer strips) plus ~ 2 mm [0,079 in].

Jenbacher 1000-0046
6. The generator cannot be put into place using a crane:
6.1 Lowering onto rollers:

Position transport rollers at the distance of the frame I-sections and position spacing timber onto the
transport rollers if required.
6.1/a Height of spacing timber h = base height + height of oil collection tray
6.1/d No spacing timber is necessary! (Frame can be directly lowered onto the transport rollers.)
Position the generator on transport rollers using a crane or forklift truck.

Lift unit with crane into the building as far as possible.
6.2 Moving on rollers:

There are various options for moving the unit by means of transport rollers.
6.2.1 Pulling with a forklift or a cable winch:

Attach a chain, bar or cable to the unit frame cross member with a textile loop.
6.2.2 Pushing with a forklift or manpower:

If the engine is to be moved using a forklift truck, a protective piece of wood should be placed at the
engine face between forklift truck and engine. The unit can now be moved by positioning the forklift forks
against this square timber.
Experience has shown that even three to four strong persons will be able to move a unit. However, the
following must be observed in order to prevent damage. The prerequisite for this is a level footing.
Otherwise, the footing must be made level using sheet steel.

Jenbacher 1000-0046
6.3 Transferring onto steel rollers:

When moving the generator the transport equipment should be attached at its pedestal.
Install hydraulic jacks at the lifting points. Remove the wooden distance blocks, position the transport
rollers onto the pedestal and place the generator frame onto these.
Transfer of the second transport roller pair takes place in like manner.
7. Attaching the generator and engine to each other:
Lift (using a crane) or roll the generator towards the module which was already aligned on the sylomer
strips. Stop the movement when the measuring gauge touches the cross frame support on the flywheel
side.
Measuring gauge Cross-frame support

on the flywheel side
Lift generator using hydraulic lifting equipment. Place sylomer strips underneath the generator (both in
longitudinal direction and crosswise). Place sylomer strips on the engine side underneath the generator
(both in longitudinal direction and crosswise).

Jenbacher 1000-0046
The generator frame must be evenly spread over the entire length of the sylomer strips.
At no point must it be possible to shift the Sylomer strip under the frame side member.
If an engine oil pan is fitted, the difference in frame height between module and generator must be
adequately compensated for (e. g. all-welded form tube frames.)
All-welded tube frames

(„Form tube package“)
Removing the yellow

transport safety pegs
The construction of the generator frame guarantees that the module frame hangs over the generator
frame (approx. 5 mm [0,2 in]). This difference is compensated for using distance plates.

Jenbacher 1000-0046
To install these plates, the generator should be lifted hydraulically or mechanically using four (4) jacking
bolts (inserted into the fine screw-thread inserts at the generator pedestal).
Fine screw-thread inserts at the

generator frame.
Install distance plates
Insert two threaded rods (M16 x 370) opposite to the flywheel casing
and pull the generator at right angles and smoothly towards the engine
by tightening the hexagonal nuts.
Hexagonal nut
Threaded rod (M16 x 370)
You should now be able to slide the coupling element (rubber band) into the coupling flange without
exerting too much force.
The connecting plane of the flywheel casing and coupling housing must be in perfect parallel alignment.
Any deviations should be compensated for by installing distance plates between the generator frame and
the elastic generator bearing.

Jenbacher 1000-0046
Radial: max. 2 mm [0,079 in] Axial: max. 3 mm [0,12 in]
• Use hexagonal bolts M16 x ..*) with hardened-steel washers to connect the engine and generator.
*) The screw length differs from one generator type to another.
Tighten the hexagonal bolts using a tightening torque of 190 Nm [140 lb ft] and then secure these using
Loctite 242.

Jenbacher 1000-0046
8. Positioning transmissions:
8.1 Transporting generator frame with generator and transmissions:
Lugs on the generator and transmission should not under any circumstances be used to hoist the
complete module.
These lugs should only be used to move the generator frame containing the generator and transmission.
Attach the lifting lugs to the

generator
Attach the lifting lugs to the

transmission

Jenbacher 1000-0046
8.2 Positioning:
In case of multiple engines with transmissions, make sure that the generator and engine frames are
correctly positioned – 1 on 1, 2 on 2 ….. etc. (see the illustration below for markings).
Markings on
engine frame
Markings on
generator frame
Coupling transmissions, see IW 8071 A0!


1000-0046 - EN Transportation of Type 6 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1000-0046 - EN Transportation of Type 6 PDF

Uploaded by

Copyright:

Available Formats

Jenbacher 1000-0046

Technical Instructions No.:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

2.1 Load suspension device:

Normal operating conditions

Guidelines for use

Limitations to the use of the load suspension device

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

2.2 Lifting Type 6 E standard engine and Type 4 standard module:

Gewicht siehe Typenschild

JWN 080 576 / 321656

Attach the lifting lugs to the engine.

Engine type Design To be assembled between cylinder head

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

When hoisting the module, always make sure that its

The lifting device can be ordered from GE Jenbacher.

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

3. Transport on transport vehicles:

3.1 General tips:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

Do not lift the engine by the yellow security shackles!

Fit the knock sensors using the indicated tightening torques.

3.2 Rail transport:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

4. Positioning in the engine room:

Lowering onto Lowering onto Lowering onto

Checking Sylomer strips

Inserting plate 5.7

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

4.2 Bringing the generator into the building:

Lowering onto Lowering onto

Moving on rollers Moving on rollers

Connect the generator

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

5.1 Lowering onto rollers:

Lift unit with crane into the building as far as possible.

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

5.2 Moving on rollers:

5.2.1 Pulling with a forklift or a cable winch:

5.2.2 Pushing with a forklift or manpower:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

5.3 Transferring onto steel rollers/pipes:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

Transfer of the second transport roller pair is done in like manner.

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

5.4 Transferring onto rollers:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

5.5 Inserting Sylomer strips:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

5.6 Checking the Sylomer strips:

5.7 Inserting plate:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

6. The generator cannot be put into place using a crane:

6.1 Lowering onto rollers:

Position the generator on transport rollers using a crane or forklift truck.

6.2 Moving on rollers:

6.2.1 Pulling with a forklift or a cable winch:

6.2.2 Pushing with a forklift or manpower:

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06

6.3 Transferring onto steel rollers:

7. Attaching the generator and engine to each other:

Measuring gauge Cross-frame support

Issued: Doku./Beck Checked: Dokumentation Date: 2007-06