Jenbacher W 8080 A0

Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating

1. Water pressure inspection (daily): ______________________________________1

2. Filling the cooling water:______________________________________________2
2.1 General tips: 2
2.2 Filling instructions for the cooling-water system: 3
2.3 Bleeding: 4
2.3.1 Electric cooling water pump without permanent bleeding: 4
2.3.2 Preheating pump: 4
2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules: 5
2.4.1 Measuring the differential temperature: 7
2.4.2 Adjusting the bundle control valve 7

Interval: every
day 20,000 30,000
operating operating
Maintenance work Section hours hours
t Water-pressure inspection 1. „
20/30 Cooling water exchange 2. „ *) „
*) only for special gasses and an engine cooling water temperature >95 °C (see module maintenance
plan)

1. Water pressure inspection (daily):

Water pressure inspection using the pressure

gauge on the filling valve.
Pressure gauge

Cooling water system pressure (for cold installation): 1.1 bar

Note down the exact cooling water operating pressure in the operational data booklet.

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 Jenbacher W 8080 A0
Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating

Datenerfassung: E 0101

Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure that
unauthorised persons cannot start the engine.

2. Filling the cooling water:

2.1 General tips:

Quality of cooling water in closed circuits: TI No. 1000-0200
Anti-freeze agents: 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

Air-bleed cock (to be opened

only when filling water)

Shut-off valve (must be closed

following commissioning and
remain closed)

Continuous breather (only for container-based install.)

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 Jenbacher W 8080 A0
Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating

2.2 Filling instructions for the cooling-water system:

Reduce the pre-pressure (if required) using the pressure valve at the membrane pressure compensation
reservoir. Before doing so, make sure cooling water has not yet been filled.

Modules pressure compensation reservoir

pre-pressure

J 208 GS – J 320 GS 0.6 bar

J 412 GS – J 420 GS 0.6 bar
Container-based 0.6 bar
installations
J 612 GS – J 620 GS 0.8 bar

Press. valve

Set the cooling water system pressure at the filling valve.

Make sure when connecting the filling hose to the filling valve that no air can get into the system (to
prevent unwanted air from entering the cooling-water system).
Fill the cooling-water system via the filling valve.
The air-bleed cock must remain open until only water, i.e. no air, flows out of the opening.

Close the shut-off cock by turning it clockwise (to the right) and remove the filling hose from the filling
valve.

Following every filling or re-filling of the cooling system, repeat the filling procedure until the cooling-water
system is fully bled.

Issued: Doku./Bilek Checked: TKA/TEAM/VSR/TPAQ/VSI Date: 2005-07

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 Jenbacher W 8080 A0
Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating

2.3 Bleeding:

2.3.1 Electric cooling water pump without permanent bleeding:

Electric cooling water pump bleeding screw

Open the bleeding screw until the water escaping no longer contains any air.

2.3.2 Preheating pump:

Preheating pump bleeding screw

Open the bleeding screw until the water escaping no longer contains any air.

Caution: make sure to check the preheating pump shaft for smooth operation if the engine has
been decommissioned for a long period of time prior to starting Æ to do so, turn the shaft using a
screw driver in the notch of the pump shaft.

Always shut off the flow to the filling valve after completing the filling and/or refilling procedure.
This is to see whether the pressure in the cooling-water system has been maintained.

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 Jenbacher W 8080 A0
Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating

Attention in the case of single-circuit cooling system modules:

Inspect the cooling water circuit everytime after working on the cooling system and/or every time
the cooling water is changed!

2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules:

Adjust the flow amount using the bundle control valve.

Bundle control valve

The setting value can easily be recorded and reproduced using the scale. The top number (against the
black background) represents the rough setting (1 to 4), the bottom number (red background) represents
the decimal setting (1 to 9).

Issued: Doku./Bilek Checked: TKA/TEAM/VSR/TPAQ/VSI Date: 2005-07

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 Jenbacher W 8080 A0
Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating

Measuring the differential temperature between the engine cooling water intake

and engine cooling water outlet.

The differential temperature at full load should be approx. 6°C.

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 Jenbacher W 8080 A0
Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating

2.4.1 Measuring the differential temperature:

Make sure when establishing the differential temperature that the same equipment is used at both
measuring locations.
The most efficient method is using infrared measuring equipment. Make sure 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 mat (not glossy or
reflecting).
If no infrared measuring equipment is available, the temperature can also be established using contact
measuring equipment. This equipment is not as precise, however, as air flows can affect the surface
temperatures. Therefore, the measuring sensor must be covered and left at both locations for the same
period of time.

2.4.2 Adjusting the bundle control valve

Remove the bundle control valve locking device and the safety cover.
The basic setting of the bundle control valve is approx. 1.5.
Run the engine at half load and adjust the bundle control valve such that a differential temperature of
approx. 4°C is achieved (closing the valve will increase the differential temperature). Consequently, run
the engine at full load and wait until the temperature remains constant (at least 30 minutes) and then set
the differential temperature of approx. 6°C.

Differential temperatures below 5°C (valve opened too wide) can result in “Cooling water temperature
maximum”.
Differential temperatures between 5°C and 7°C are still admissible.

Re-asssemble the safety cover and lock it.

Issued: Doku./Bilek Checked: TKA/TEAM/VSR/TPAQ/VSI Date: 2005-07

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