PDF PDF

JMS 620 GS-N.
L
Maintenance
Cogeneration plant
INNOVATIVE ENERGY 1X620F

J R059
Engine number: 1088292
Module number: 1088291
2013-12
© 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 18.12.2013 Delivery ➔ Footer
Unterrainer
Original operating instructions
GE proprietary information: CONFIDENTIAL

The information contained in this document is General Electric Company proprietary information and is disclosed 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, development or derivation of
any repairs, modifications, spare parts, designs or configuration changes, or for obtaining government or regulatory
approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each
page of this document shall appear in any such reproduction in whole or in part.
© GE Jenbacher GmbH & Co OG, 2013-10

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 6
Daily inspection round.......................................................................................................................................................................... I 9003 0
Lubricating oil................................................................................................................................................................................... IW 0101 M6
Ignition voltage check / Spark plugs...................................................................................................................................... IW 0309 M0
Crankcase ventilation system................................................................................................................................................... IW 0511 M6
In-line air filter - Type 6 F/ engines.......................................................................................................................................... IW 8040 A6
Pre-combustion chamber gas compressor........................................................................................................................... IW 8046 0
Leak testing of all pipes and components carrying fuel gas and mixtures............................................................ IW 8049 0
Flexibly-mounted coupling housing........................................................................................................................................ IW 8079 A6
Scavenging air fans........................................................................................................................................................................ IW 8083 A6
Condensate removal in the fuel-gas system...................................................................................................................... IW 8090 A0
Leanox setting.................................................................................................................................................................................. IW 8090 M6
Exhaust gas system condensate drain line......................................................................................................................... IW 8095 A0
Control rod assembly/throttle valve/actuator............................................................................................................... W 0200 M6ef
Engine cooling water pump......................................................................................................................................................... W 0203 A6
Ignition.................................................................................................................................................................................................. W 0303 M0
Valve clearance................................................................................................................................................................................ W 0400 M6
Prechamber/prechamber gas valve....................................................................................................................................... W 0501 M6
Vibration damper............................................................................................................................................................................. W 0601 M0
Gas quantity controller.................................................................................................................................................................. W 0705 M0
Mixture bypass valve...................................................................................................................................................................... W 0802 M0
Maintenance after initial commissioning................................................................................................................................. W 1000 6
Overhaul............................................................................................................................................................................................... W 2100 M0
Exhaust gas turbocharger........................................................................................................................................................... W 8026 M6
Generator (DIG110, DIG120,DIG130, DIG140, DIG142).................................................................................................... W 8034 A0
GE Jenbacher - switch cabinets................................................................................................................................................. W 8031 A0
Starter.................................................................................................................................................................................................... W 8032 M0
Elastomer components..................................................................................................................................................................... W 8034 6
Oil filter cartridge.............................................................................................................................................................................. W 8038 M6
Plate-type heat exchanger........................................................................................................................................................... W 8043 A0
Gas pressure control system....................................................................................................................................................... W 8045 A0
Engine oil pump................................................................................................................................................................................ W 8046 M6
Identification: INNOVATIVE ENERGY 1X620F Device number: J R059 Module number: 1088291
Module type: JMS 620 GS-N.L Engine version: F 101
Author: Responsible: Release date: 19/12/2013
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
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/thrust bearing.............................................................................................................................. W 8050 M6
Exhaust gas manifold/exhaust gas lagging........................................................................................................................ W 8051 M0
Camshaft/timing gear................................................................................................................................................................... W 8052 M0
Replacing the cylinder head....................................................................................................................................................... W 8053 M6
Pre-lubricating pump..................................................................................................................................................................... W 8054 M0
Combustion chamber.................................................................................................................................................................... W 8056 M0
Mixture cooler O-ring replacement......................................................................................................................................... W 8075 M6
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 Pre-combustion chamber gas differential pressure........................................................................ E 0103 d
Operational data - Flame trap Mixture cooler......................................................................................................................... E 0103 g
Operational data – spark plugs........................................................................................................................................................... E 0309
Operational data - Valve-stem projection..................................................................................................................................... E 0400
Operational data - crankcase ventilation system...................................................................................................................... E 0511
Operational data on leak test for pipes and components carrying fuel gas and mixtures.................................... E 8049
Data collection for flexibly-mounted coupling housing...................................................................................................... E 8079 6
Initial commissioning data sheet............................................................................................................................................... 7

Initial commissioning data sheet............................................................................................................................................................... 7.1
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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
carried 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: 18/07/2013
1.2
Key to Symbols
The following symbols are used to highlight certain text passages in your GE Jenbacherproduct
documentation.
Caution
Follow these instructions to avoid risk of personal injury or risk of damaging engine or
system 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
information or important note.
Info
Important information or important note.
SprungMarke!!!27021597778485003
Author: Doku./Schatz Responsible: Dokumentation Release date: 22/08/2013
1.3
Type Plate and Type Designation of GE Jenbacher Products
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).

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
1.3
Type Type Max. ambient Max. ambient temperature:

temperature
(intake air)
Serial No. Serial No. Rated frequency Rated frequency
Year of Year of manufacture Rated voltage Rated voltage
manufacture
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 class
installation
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
Mode of operation (e.g.) GS Gas engine, turbocharged J 320 GS C05
GSH Gas engine, turbocharged
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
Index: 4 Page No.: 2 / 4
1.3
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
Mode of operation (e.g.) GS Gas engine, turbocharged JMS 320 GS-N.LC
GSH Gas engine, turbocharged
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
1.3

N/B Natural gas /biogas (2-
gas operation)
Exhaust gas purification L LEANOX engine JMS 320 GS-N.LC
LC LEANOX engine with
oxidation-type catalytic
converter
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
SprungMarke!!!27021597778551563
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
download 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
Jenbachercustomer, we are offering you the possibility of increased access rights for which you only need to
register 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
personal 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: 22/08/2013
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
innovations.
"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.
SprungMarke!!!18014398524851339
1.5
Your Opinion Counts!
Dear readers,
The purpose of this product documentation is twofold. Firstly, it should ensure risk-free operation and
maintenance of your GE Jenbachersystem.
Secondly, this product documentation should serve as a reference manual covering technical data,
requirements and descriptions of engine and system components, and can also be used for troubleshooting
and training 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

vocabulary?
Is the documentation comprehensive?

(Have all of the necessary topics been
covered 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

SprungMarke!!!27021597779449995
robert.pichler@ge.com
Author: Doku./Velik Responsible: Documentation Release date: 22/08/2013
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
Industrias Juan F Secco SA

Juan Pablo II 5665
1.6
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
Sales Representative
Ecogen Energy Systems bvba
Vaart Rechteroever 225
B-9800 Deinze
Tel.: +32 938 64860, Telefax: + +32 938 61134
e-mail: jd@ecogen.be
Filter EOOD
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
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
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
e-mail: Evgeny.Shakovets@filter.by
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
1.6
Tel.: + 41 52 320 00 00, Telefax: + 41 52 320 00 01

e-mail: joachim.maier@iwk.ch
www: www.iwk.ch
Distributor / Service Provider

Generadora Trasandina S.A. (GTSA)
Av. Apoquindo 5583, of 101, Las Condes
Santiago
Tel.: +56 2 952 4301, Mobile: +56 9 6570 0343
e-mail: goliver@jfs.com.ar
www: www.generadoratrasandina.com
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
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
Jebsen & Co Ltd.
1.6
Region: Hongkong and Macau

28/F., Lee Gardens Two,
28 Yun Ping Road,
Causeway Bay
Hong Kong
Tel: +852 2923 8883, Fax: +86 852 2882 1588
e-mail: rachelcheung@jebsen.com
www: www.jebsen.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
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
1.6
Dongguan Camda Gererator Work Co. Ltd
Region: INNER MONGOLIA, HEBEI, SHAANXI, SHANXI, HENAN, HAINAN, CHONGQING
FOR COAL MINE GAS APPLICATIONS: Region China
Liaobu Town, Dongguan City, Guangdong Province 523407, P.R. China
Tel: +86-769-88996235; Fax: +86-769-88996282
e-mail: shen@camda.cc
www: www.camda.cc, www.camdapower.com
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
Energas BHKW GmbH
Banneggstraße 90
D-88214 Ravensburg
Tel.: +49 751 88833330, Fax: +49 751 88833339
e-mail: joachim.maier@energas-gmbh.de
GE Jenbacher Denmark
Samsøvej 10
DK-8382 Hinnerup
Tel.: +45 86966788, Telefax: +45 86967072
e-mail: jenbacher.scandinavia@ge.com
Dominikanische Republik
1.6
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
Amimer Energie SARL
za Adha Seddouk, 06500 W. Bejaia, Algeria
Tel.: 00 213 34323154, Telefax.: 00 213 34323135
e-mail: amarboukheddami@amimer.com
Clarke Energy France SAS

Z.A. de la Malle
RD 6
13320 Bouc Bel Air
Tel: +33 442 907575, Fax: +33 442 907576
e-mail: michels@clarke-energy.com
AS Filter
Läike tee 9, Peetri küla, Rae vald
75312 Harjumaa
Tel.: +372 606 6666, Telefax: +372 606 6650
e-mail: filter@filter.ee
www: www.filter-group.com
GE International Inc.
54 Lebanon Street,
El Mohandessin, Floor 13
Cairo
Tel.: + 20 2 3301 8000
1.6
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
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
1.6
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
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
1.6
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
Clarke Energy Ireland Ltd.
1 Stokes Place, St. Stephens Green, Dublin 2, Ireland
Tel.: +353 879 804002
e-mail: johnc@clarke-energy.com
Madei Taas Industrial Controls Ltd.

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

"Shivkiran", Lane no. 4, Dahanukar Colony, Kothrud
Pune 411 038
Tel.: +91 20 30241777
Telefax: +91 20 30241800
e-mail: deodatta.bhishikar@clarke-energy-india.com
www: www.clarke-energy-india.com
GE India Industrial Pvt. Ltd.
A-1, 2nd Floor, Golden Enclave
Corporate Towers, Airport Road
560 017 Bangalore
Tel.: +91 80 4150 1406, Telefax: +91 80 2520 3860
e-mail: jenbacher.india@ge.com
Trinidad & Tobago
1.6
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
Triveni Engineering & Industries Ltd.
Regions: KERALA, TAMIL NADU, KARNATAKA; ANDHRA PRADESH; ORISSA, MADHYA PRADESH, GOA,
LAKSHWADEEP, PONDICHERRY, ANDAMAN AND NICOBAR ISLANDS
12-A Peenya Industrial Area, Peenya, Bengaluru 560058, Karnataka
Tel.: +91 22 2282 4397, Fax: +86 21 5878 4945
e-mail: milind.warke@triveniturbines.com
www: www.triveniturbines.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
NME s.r.L
Via Ferruccio Dell'Orto, 8
24126 Bergamo
Tel: +39 035 320030, Fax: +39 035 312022
e-mail: msturla@nmesrl.it
www: www.nmesrl.it
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)
Tel.: +961 9 444888, Telefax: +961 3 811108
www: www.sakr.com
1.6
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
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
1.6
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
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
1.6
KWE - Technika Energetyczna Sp.z o.o.

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

ATT: Raul Assunção
Carregado Park, Arm. D,
Lugar da Torre,
2580-512 Carregado
LISBOA – PORTUGAL
e-mail: ecocogen@ecopower.pt
www: www.ecopower.pt
Sales Representative (Greenhouse segment only)

Protermia
Praceta Joao Villaret, n°169, 4460-337 Sra. Da Hora
Tel: 351 229 579 130; Fax: 351 229 537 355
e-mail: antasbotelho@protermia.pt
www: www.prtermia.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
1.6
107023 Moscow, Russia

Tel.: +7 495 937 11 11; +7 495 9 81 13 13, Telefax: +7 495 937 11 12
e-mail: jenbacher.russia@ge.com
ZAO Sigma Services (Service)

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

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

Vapor CJSC
B. Moskovskaya 8/2 Letter A,
191002 Saint – Petersburg
T: + 7 812 448 00 70
Email: spb.office@vapor.ru
Web: www.vapor.ru
Focused on the South Ural 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
1.6
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
GreenTech Energy LLC (Tumen and Kurgan Region)

Bld. IX, Begovaya str. 32
125284 Moscow
Phone: +7 495 970 1700
e-mail: zuev@gte.su
URL: www.gte.su
Ali A. Tamimi Trading Company

2nd Industrial City
Al Baqaiq Street
Khobar, 31952
Tel.: +966 3 868 1037 ext. 100
Fax.: +966 3 868 2733
e-mail: DTCO@tco.com.sa
www: www.al-tamimi.com
GE Jenbacher Denmark
Industrivej 19, DK-8881 Thorsø
Tel.: + 45 8 6966788, Telefax: + 45 8 6967072
e-mail: jenbacher.scandinavia@ge.com
IGF Gasprodukter
Årsta Park
Byängsgränd 14
S-120 40 Årsta
Tel. +46 -8 742 22 80, Fax: +46 87 44 44 50
e-mail: kristian@igfgasprodukter.se
www: www.igfgasprodukter.se
GE Pacific Pte Ltd.
240 Tanjong Pagar Road,
# 11-00 GE Tower
1.6
Singapore 088540
Tel.: +65 6326 3659, Telefax: +65 6326 3623
e-mail: jenbacher.singapore@ge.com
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
e-mail: Ali.Hjaiej@clarke-energy.com
Clarke Energy Ltd.
Power House, Senator Point, South Boundary Road, Knowsley Industrial Park, Liverpool L33 7RR
T: +44 151 546 4446, Fax: +44 151 545 5714
Sinapse
1.6
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
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
1.6
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
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
SprungMarke!!!189151184363996555
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
SprungMarke!!!27021597778924939
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
electrical 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
exhaust gases.
Any use not described in the operating or maintenance instructions is not considered a designated use. GE
Jenbacher 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
operating 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.
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.
2.1
Designated Use
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
compromised 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
conditions – 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
engines”, 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
additives, 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
regulations and the danger and disposal information on the product concerned.
SprungMarke!!!18014398524191627
2.2
REACH-Notification and Downstream User Communication for Sub-
stances 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
adopted 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
suppliers to identify any potential implications of REACH on the availability of materials. The vast majority of GE
Jenbacher 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
recommended
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
SprungMarke!!!9007201671064971
Author: Bilek Responsible: Eitzinger Roland Release date: 22/08/2013
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
following equipment
Cogeneration plant : JMS 620 GS-N.L
Generator No.: 1088291
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
reduction
EN 12601:2010 Reciprocating Internal Combustion Engine Driven Generating Sets - Safety.
EN 60204-1:2006 The safety of basic machine terms, - electric equipment of machines.
+A1:2009
EN 60439-1:1999 Combinations of low-voltage switchgear.
+A1:2004
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
standard interference emission for industrial environment.
Dr. Volker Schulte Documentation Officer: Country: PAK

General Manager Robert Pichler, Documentation Manager Date: 2013-10
Technology GE Jenbacher GmbH & Co OG Language:
Achenseestraße 1-3, 6200 Jenbach,Austria
SprungMarke!!!36028797233054347
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 11
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............................................................................................................................................. 15
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-
temperature 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................................................................................................................. 19
14 Piping......................................................................................................................................................... 21
15 Connections (GE Jenbacher's limits of supply)................................................................................... 21
16 Refer to the TIs listed below.................................................................................................................. 21
NOTICE
Observance of the conditions of this Technical Instruction and performance of the
activities described therein is the basis of safe and efficient plant operation.
Non-observance of the conditions of this Technical Instruction and/or non-performance 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 variable or a contractual agreement between the
operator and variableprovides for a different arrangement.
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
throughout 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
Jenbacher 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.
C W
2
E
3
B
Minimum clearance for modules without a turbocharger module
Y*)
X*)
2
E
3
A
B
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 1,000 mm 1,000 mm 1,500 mm 1,000 mm 1,000 mm 500 kg 1,600 mm
engine
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
engine 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
engine (mixture connection interface) - are not ignitable. Where required, appropriate additional technical
measures must be taken (e.g. monitoring / controlling the oxygen concentration in the gas => emergency
shutdown), 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
emergencies.
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'
information). 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
resulting 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
manufacturer/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.
U
4
3
6
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
control 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 background conditions
during start-up and accelerating to speed.
b) During the starting and accelerating procedure, including synchronisation, no switching 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
approval 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, however, 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
components mounted on the engine such as the ignition system, ignition coils, ignition cable conduits, gas
injection 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
ensure 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:
F6
1 2 3
1 Fan 3 Silencer
2 Filter, stating the purity class
3
G
4
F6 3 F6
2
1
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
7
3
G
6 5
4
F6 3 F6
2
1
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
passes over the engine from both the generator and the turbocharger ends and helps to cool the engine
surface.
4
F6
4
F6
3 2 1
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
supplied 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
exhaust 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
temperatures 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
cabinet, ENGINE interface cabinets,
GENERATOR control cabinet
For medium-voltage generators (type 3, 4, 6 and 9 engines): GENERATOR surge suppressor (JUNCTION
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
drawing 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.
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
temperature 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
pressure to the crankcase and the minimum pressure at the intercooler are maintained.
5,5
4,5
4 J6xx Hot-
3 Country
3,5
J612 3
3
1 3 J616
3
2,5 3 J612
2 J624
1,5
0,5
0
25 30 35 40 45 50 55 60 65 70 75
2
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 ③ Minimum water volumetric flow at the intercooler HT stage
outlet 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.
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
separate 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
pressures.
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 diagnoses.
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
• [⇨ Page 18]
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
pressure surge can be in the order of approx. 200 mbar. This must be taken into account in the engineering of
the exhaust gas system. The internal pipe must be resistant to buckling, especially when long double-wall
chimneys 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
control voltage or wire breakage.
To prevent external overvoltages from reaching the installation, overvoltage deflectors should be installed
onsite 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
engines: 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,
appropriate 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
responsible 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 1000-0206: 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
SprungMarke!!!90071992585955467
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................................................................................................................................ 5
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
activities described therein is the basis of safe and efficient plant operation.
Non-observance of the conditions of this Technical Instruction and/or non-performance 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 variable or a contractual agreement between the
operator and variableprovides for a different arrangement.
1 General conditions - Operation and maintenance
1.1 Basic conditions

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

When integrated into the hot water system, appropriate measures must be taken to prevent dirt or sediment
building up in these components on the water side.
Refer to technical diagram and technical instructions for settings.
Author: Doku./Bilek Responsible: Mayer Markus Release date: 19/03/2013
1.3 Interfaces/limits of supply

The conditions specified must be fulfilled and the equipment to be supplied for each specific system in
accordance 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
mechanical 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
prevention 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
standards of cleanliness.
▪ Thoroughly clean all engine components or parts within working environment and remove all dirt and
deposits 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
personal 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
measures to ensure that employees are only provided with equipment which is suitable for the conditions
pertaining 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
engines 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
replacement of various components.
Remote resetting: Based on the risk category selected by the customer (0-4), failures resulting in the installation
being switched off can be reset using remote access to the visualisation system (max. 5 times every 6 hours'
running under load).
Failures: Diane No.: National Risk category
restrictions
Misfiring 1047, 3005 - 3024 0
Cooling water temperature maximum 1021 * 0
Engine room temperature maximum 1135 * 0
Failure of auxiliary equipment 1129 0
Synchronising failure 1039 0
Supply water temperature maximum 1063 0
Missing engine running conditions 1025 1
Starting failure 1023 * 1
gas pressure MINIMUM Controlled gas system 1 1028 * 1
gas pressure MINIMUM Controlled gas system 2 1030 * 1
Mixture temperature maximum 1040
oil temperature maximum 1043 1
ADMISSIBLE CONTROL DEVIATION OF LEANOX controller 1080 1
EXCEEDED
engine cooling water pump FAILURE 1090 1
Generator frequency too low 1110 1
Actual value measuring signal failure 1113 1
Engine speed measurement signal failure 1120 1
TecJet GAS QUANTITY JUMP 3099 1
ENGINE Oil level MINIMUM 1018 2
GENERATOR reverse power 1038 2
Cylinder exhaust gas temperature Deviation from 1044 2
maximum average value
Cylinder exhaust gas temperature Maximum excess over 1049 2
absolute value
Cooling water pressure maximum 1050 2
Failures: Diane No.: National Risk category

restrictions
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 1044 2
maximum average value
Cylinder exhaust gas temperature Maximum excess over 1049, 2001 – 2020 2
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 2021 – 2040 2
positive deviation
Cylinder x deviation from average value, Maximum 2041 – 2060 2
negative 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,
operational 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
necessary 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
lubricating oil analysis, subject to the limit levels laid down in Technical Instruction No. 1000-0099B, must be
presented 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
necessary 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
service, 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
operational 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
welding 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
contract, 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 increased 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
protected 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
given 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
maintenance instructions.
Since these are open pressure equipment items, static overpressures are not possible. However, to avoid
exceeding 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
operation and maintenance (such as defective oil care, large accumulations of dust or other problematic
circumstances), maintenance operations have to be carried out before the specified intervals.
The above can only be judged by the operator. If irregularities are found during the daily inspection, especially
during the warranty period (abnormal sounds or noises, etc.), the operator must take action to minimise any
damage (e.g. by immediately switching off the engine, investigating the cause of the irregularity and rectifying
it, and/or notifying the GE Jenbacher customer service department).
Upcoming maintenance work must be carried out before the maintenance interval is reached to ensure
downtimes 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
manufacturers 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
account when drawing up GE Jenbacher documentation.
▪ In the event of discrepancies between GE Jenbacher documents and enclosed documentation from the
original equipment manufacturer, the GE Jenbacher documentation shall take priority (including any
appropriate Technical Instructions, maintenance plans and maintenance etc.)
▪ Any documents from the original equipment manufacturer that are provided are supplementary to the GE
SprungMarke!!!45035996313497995
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.............................................................................................................................................. 10
9 Components............................................................................................................................................. 15
9.1 Exhaust gas system................................................................................................................................................ 15
9.2 turbocharger.............................................................................................................................................................. 16
9.3 Fuel gas system........................................................................................................................................................ 17
9.4 Cooling system.......................................................................................................................................................... 18
9.5 heat exchanger......................................................................................................................................................... 19
9.6 Slam Valve................................................................................................................................................................... 21
9.7 Lubrication system.................................................................................................................................................. 21
9.8 Control system.......................................................................................................................................................... 23
9.9 Ignition system.......................................................................................................................................................... 23
9.10 Cables and insulated wiring............................................................................................................................... 24
9.11 Throttle valve............................................................................................................................................................. 24
9.12 Electrical connections............................................................................................................................................ 24
9.13 Generator.................................................................................................................................................................... 25
9.14 Electrical cabinets.................................................................................................................................................... 26
9.15 Acoustic insulation (container; sound absorber hood)........................................................................... 27
9.16 Battery........................................................................................................................................................................... 28
9.17 Container/enclosure............................................................................................................................................... 28
10 Maintenance and servicing.................................................................................................................... 30
11 Cleaning..................................................................................................................................................... 32
12 Disposal requirements for waste electrical and electronic equipment........................................ 33
1 General
The operating and maintenance instructions contain basic safety signs,
requirements and directions which must be observed during the delivery,
setting-up, commissioning, operation and maintenance of machinery.GE
Jenbacher These documents must be read and understood by the user
before starting the machinery. The most recent edition of the operating
instructions must always be available at the machine.
The information contained in the safety instructions below is intended to provide you with an overview of
danger 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
damages or the exercise of a warranty claim against GE Jenbacher.
2 Safety signs hazard classification system

The pictograms with hazard classification used in this document are also used on GE Jenbacher products.
They refer to each of the hazards as described in this document.
DANGER (ISO DIS 3864-2)
denotes a high-risk hazard. If this hazard sign is
ignored, death or severe injury will follow as a direct
consequence.
WARNING (ISO DIS 3864-2)

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

denotes a low-risk hazard. If this hazard sign is
ignored, 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
machinery. 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
periodic safety meetings.
The contractor will comply with reasonable health and safety requirements imposed from time to time by the
customer at the facility.
The contractor may conduct occasional safety audits to ensure that safe conditions exist and make
recommendations 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 customer 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
conditions, 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
persons (including death) or damage to property resulting from the operation of equipment at the site by the
contractors 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
disposal, 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.
All decontamination necessary for the contractors work (including any repair work) will be performed by the
customer.
Safety regulations
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
assistance of the fire brigade, the fault or damage professionally rectified, all enclosed spaces
thoroughly ventilated and the area has been declared safe to re-enter.
Bear in mind that ambient and operating conditions differ from plant to plant and the general rule is that,
before work starts in plants using poisonous gases, the operator of the plant should draw up an
EMERGENCY PLAN which takes these specific conditions into account. The relevant statutory regulations must
also be taken into account. This emergency plan must be brought to the attention of all persons employed at
the plant, evidence 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
▪ Location of breathing apparatus independent of ambient air
▪ Other necessary safety information as laid down in statutory regulations, etc.
Safety regulations
4.2 CO pre-alarm
Close the gas safety shut-off valve outside the engine room and make sure that it cannot be opened
unintentionally. Leave the engine to run until it stops of its own accord due to lack of gas. The ventilation is set
to maximum 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
carried 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 safety
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

approaching and working on plant components, even outside the engine
room, consists of eye protection, protective clothing, hand protection and
safety footwear.
Depending on the operational condition of the plant, the ambient

conditions, the type or location of the operation, use hearing protection,
safety helmet, fall prevention equipment, gas sensors, breathing mask or
other personal 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
injury, 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
provision of technical safeguards (e.g. handrails, work platforms, etc.) is either impossible or impractical, you
should use:
▪ personal fall arrest equipment consisting of harness and associated equipment (safety rope, karabiner
hook, damper, lanyard or height safety device)!
Using fuel gas containing CO (read the results of the gas analyses):
Safety regulations
▪ 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
circumstances.
6 Transporting - lifting - installing

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

Automatic machinery: liable to start without warning!
If the operating mode selector switch is in "Aut" position, the module may
start without warning at any time.
Before commencing maintenance work, repairs, etc., shut down machinery as described below and secure
to prevent unauthorised start-up!
Safety regulations
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
‘except 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!
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
components, such as the cable, coil, connector, etc!
Safety regulations
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
pressure. 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.
Liquids must be drained completely.
Risk of explosion!
During charging, batteries produce hydrogen and oxygen which under

certain 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 explosive
atmosphere.
Check that the battery poles are firmly secured. No smoking, no naked lights, no sparks!
Safety regulations
Poisonous gases!
The air in the engine room may be severely polluted with evaporating oil,
cooling water, fuel gases or exhaust gases.
Ventilate the engine room thoroughly before starting work!

Ensure there is a fresh air supply when working in the engine room!
Wear personal protective equipment (gas sensors)!
8 Engine room
No admittance for unauthorised persons!
Room contains electrical 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!
Safety regulations
Noise!
The noise produced when the machinery is operating or being started

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

similar devices, people with such devices are prohibited from entering the
engine 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
establish the types, size and number of extinguishers required with your
supplier and insurance agent.
Safety regulations
Risk of slipping!
Wipe up any spilt oil and coolant immediately and keep the machinery
clean!
Highly flammable materials!
Keep oily rags in fire-proof containers. Never leave them lying on the
engine.
Do not store flammable liquids near engines.

Keep the machinery clean!
Mark escape routes!
Mark escape routes from the engine room and keep them clear of
obstructions.
Safety regulations
Risk of escaping liquids (hot and under pressure)!
Avoid danger zones around safety valve and explosion protection valve
openings.
There are also danger zones around air filters.
Hot surfaces!
Risk of burns

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

fresh air.
Rooms in which gas-consuming devices are operated must be ventilated.
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
equipment 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

procedure 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
adequate ventilation.
Hot surfaces!
Components which are not insulated and through which exhaust gas
passes 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
temperature 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 GE JenbacherCustomer 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
overpressure 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 valveA 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.
The manual stop valve must be designed to ensure that no unauthorised person can actuate it, i.e. open it
when in locked position.
Safety regulations
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
instructions!
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
immediately. 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
maintenance work on them!
Fractured components allow hot coolant to escape, posing a risk of injury.
Regular maintenance/inspection of components. Wear personal
protective 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

procedure 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

products, 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 posing

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

protective equipment (safety glasses, protective clothing and thermal
insulation 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.
The actuation of safety valves causes hot liquids to escape, thereby

posing a risk of injury.
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

posing a risk of injury.
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

instructed!
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
assembly 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,
connector, 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
1100-0111Technical 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

inspections 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
technicians (officially licensed electricians).
GE Jenbacher accepts no liability GE Jenbacherfor injury, loss or damage
due to improper 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

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

(officially 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
accordance 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
emergency 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
protective 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
following practical steps that should be taken while working in close proximity of a running alternator:
Particulary we recommend, that
Safety regulations
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
clothing 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
involved as well as any site specific rules. In addition, all site-specific regulations must be observed.
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
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
emergency 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
protective measures required under local regulations.
Safety regulations
Ensure proper earthing!
The electrical cabinet must be properly earthed to prevent contact

voltages 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 cabinet,
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.
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
instructed!
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
certain 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 explosive
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
maximum 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
engine 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

containers 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
unauthorised persons access to the danger zones.
Doors left open (e.g. during maintenance work) on the container, the
enclosure, 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
measures!
Safety regulations
Keep door closed!
All doors must be closed while the plant is operating! Proper operating
conditions 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
components gives rise to a risk of severe crushing and impact injuries due to the heavy weight of the
components. Wear personal protective equipment such as safety footwear, protective clothing, hand
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
platforms, 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
rendered ineffective:
All the safety equipment must be restored to its original condition and its effectiveness 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
contribute to the reuse, recycling and all other forms of use for waste
SprungMarke!!!36028797056704651
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............................................................................................................................................ 5
4.1 Main gas valve............................................................................................................................................................. 5
4.2 Self-clamping ball valves........................................................................................................................................ 6
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...................................................................................................................... 13
5.5.1 Non-withdrawable generator breaker 14
5.5.2 Withdrawable generator breaker 14
6 Affixing the marking................................................................................................................................ 17
6.1 DANGER tag................................................................................................................................................................ 18
6.2 CAUTION tag (transition tag)............................................................................................................................... 18
The target recipients of this document are:

Distribution Partners, Service Partners, Commissioning Partners, Subsidiaries/Branches, Jenbach location
GE proprietary information: CONFIDENTIAL
The information contained in this document is General Electric Company proprietary information and is
disclosed 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,
development or derivation of any repairs, modifications, spare parts, designs or configuration changes, or for
obtaining government or regulatory approval to do so. If consent is given for reproduction in whole or in part,
this notice and the notice set forth on each page of this document shall appear in any such reproduction in
whole or in part.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
1 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
lockout 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
released until all the padlocks have been removed.
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 26/06/2012
2 LOTO Kit
1 Miniature circuit breaker lockout - Tie-Bar (TB) 7 Universal cable lockout

2 Miniature circuit breaker lockout - Pin-In 8 Universal lockout
Standard (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

padlock (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

possible ways of marking (directly on the padlock /
separate 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

cable 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

cannot be turned
Ball valve locked out with universal lockout and

additional 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. frequency
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
padlock 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
universal cable lockout.
5.4 Key-operated switches

480 V breaker lockout can also be used for key-
operated switches. The lockout covers the keyhole.
Only works if the locked-out switch cannot be turned
without the key!
5.5 Generator breaker - low-voltage
5.5.1 Non-withdrawable generator breaker

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

selection display (2).
Pull out the LOTO latch (1) and lock it with the LOTO
padlock.
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

selection 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

socket (4).
4. Press the interlock release (5) and wind out the

generator breaker.
5. In the test position, the crank interlock release will

re-engage. Press the crank interlock release (5) again
until the breaker position display (3) is at the bottom
position "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
SprungMarke!!!18014399413206027
3 Maintenance plan
3.1
Maintenance plan - specific intervals
Inspection work Number/Section Interval Remarks

Daily inspection round I 9003 0 Daily Carry out daily visual inspection of the
module.
Crankcase ventilation IW 0511 M6 Daily Inspection
Operational data booklet --- Daily Gather the operational data daily.
In-line air filter - engine IW 8040 A6 Daily If the underpressure exceeds 2.5 kPa, you
should replace the filter cartridges (but
after 2,000 operating hours at the latest).
Ignition voltage check/ IW 0309 M0 weekly < 250 oh The result of the ignition voltage check to
Spark plugs be carried out weekly serves as the
indicator for the actual service life of the
spark plug.
Lubricating oil IW 0101 M6 first time after The results from the engine lubricating oil
TI 1000-0099A 150 Bh analyses are decisive for the actual oil
change periods.
TI 1000-0099B
TI 1000-0099C
Pre-combustion chamber IW 8046 0 Weekly Inspect oil level and oil pressure.
gas compressor Check the operation of the float
condensate drain.
Oil filter cartridge - engine W 8038 M6 at every oil after 4,000 operating hours at the latest.
change
Battery TI 1000-0050 once a month Check the acid level. Check if the pole
binders are properly secured.
control cabinet cooling --- once every year Check for clogging and clean using
device compressed air, if necessary.
Mixture cooler W 8075 M6 5,000 Oh, 500 Replace the O-rings
W 8034 6 engine starts or
every 2 years,
whichever occurs
first
Cooling Water TI 1000-0200 once every year Concentration inspection
TI 1000-0201
TI 1000-0204
W 8080 A0 20000 operating Cooling water exchange
hours after
having completed
the overhaul
activities
Condensate removal in the IW 8090 A0 2,000oh at least 4 check for gas leaks
fuel-gas system (if part of times a year
GE Jenbacher scope of
supply)
Automatic condensate
drain
Manual condensate drains when required condensate drain
Exhaust gas system IW 8095 A0 monthly checking the condensate drain line in the
condensate drain line when required exhaust gas system
Scavenging air fans IW 8083 A6 when required condensate drain
Author: Doku./Bilek Responsible: Technology/Service/PLM Release date: 16/12/2013
3.1
Maintenance plan - specific intervals
Inspection work Number/Section Interval Remarks

6 months or Check motor cooling ribs for dirt deposits
4,000 Oh
12 months or Check the impeller blades for dirt deposits
8,000 Oh
All pipes and components IW 8049 0 8.000 Bh at least Leak testing
carrying fuel gas and once a year only
mixtures natural gas
starter W 8032 M0 10,000 Oh or replace at 10,000 operating hours or at a
max. 4,000 max. of 4,000 engine starts
engine starts
Exhaust gas silencer --- six-monthly Check the exhaust silencer and
connection pieces for scaling and
cracking. Leaks can be recognised by a
change in colour or damage to the
insulation (noise) or a slight emission of
soot.
Repairs may only be carried out with
the manufacturer's consent!
Prelubrication pump W 8054 M0 10,000 Oh after 10,000 Oh or max. 3,000 engine
electric motor (3,000 engine starts - brush inspection
starts)
Main crankshaft bearing/ W 8050 M6 30,000 oh (4,000 30,000 operating hours or a maximum of
thrust bearing: engine starts) 4,000 engine starts
Leanox setting IW 8090 M6 after revison Check Leanox settings, see IW 8090 M6
if required
Battery in DIANE module --- once every 2 replace
years
Storage battery at battery --- once every 2.5 replacing
charger years
Emissions measurement --- Measure the If the emission levels listed in the
Cleaning the combustion W 8056 M0 emissions as laid specification are exceeded, inspect and, if
chamber down by the required, clean the combustion
authorities or at chambers.
least every six
months
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
complying with the manufacturer’s operating and maintenance instructions. In individual cases, the operating
conditions and other factors relating to wear may affect the actual amount of maintenance required. The
manufacturer therefore reserves the right to specify different maintenance intervals where appropriate.
After the overhaul following 60,000 operating hours, the maintenance work to be carried out is repeated at the
same intervals.
SprungMarke!!!171136785907369483
3.2
Maintenance plan - operating hours intervals
IZ Inspection work/Maintenance work Number Op hrs
- Maintenance after initial W 1000 6 ■

commissioning
1/10 crankcase ventilation IW 0511 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Valve clearance W 0400 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Ignition W 0303 M0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 Inspection I 0103 6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2 In-line air filter - engine IW 8040 A6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2/6/10/30 Pre-combustion chamber gas IW 8046 0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
compressor
2/8/20 GE Jenbacher switchgear cabinets W 8031 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
2/20/30 Control rod assembly/throttle valve/ W 0200 M6ef ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
actuator
2/30/60 Gas pressure control system W 8045 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
4 Oil filter cartridge W 8038 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
4/20 Flexibly-mounted coupling housing IW 8079 A6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
5 intercooler W 8075 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
6 Pre-combustion chamber/Pre- W 0501 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
combustion chamber gas valve/Spark
plug sleeve
8 leak test IW 8049 0 ■ ■ ■ ■ ■ ■ ■
10 starter W 8032 M0 ■ ■ ■ ■ ■ ■
10/20/30 Exhaust-gas turbocharger W 8026 M6 ■ ■ ■ ■ ■ ■
10/30 Engine cooling water pump W 0203 A6 ■ ■ ■ ■ ■ ■
10/60 Pre-lubrication pump W 8054 M0 ■ ■ ■ ■ ■ ■
20 Vibration damper W 0601 M0 ■ ■ ■
20 Mixture bypass valve W 0802 M0 ■ ■ ■
30 Engine oil pump W 8046 M6 ■ ■
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 bearing/thrust W 8050 M6 ■ ■
bearing
ZK/30 Camshaft/control system W 8052 M0 ■ ■
30/60 Gas quantity controller W 0705 M0 ■ ■
60 Platen-type heat exchanger W 8043 A0 ■
60 Overhaul W 2100 M0 ■
ZK Exhaust gas manifold/Insulation W 8051 M0
- Generator W 8034 A0 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
- Leanox settings IW 8090 M6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
- Elastomer components W 8034 6 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
3.2
Maintenance plan - operating hours intervals
IZ Inspection work/Maintenance work Number Op hrs
- Cylinder head replacement W 8053 M6 if required

Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance record sheet.
IN = Interval reference number = operating hours/1000

ZK = for cylinder head disassembly
SprungMarke!!!198158383689847819
4 Inspection and maintenance work
4.1
Inspection/maintenance work
Inspection I 0103 6
Daily inspection I 9003 0
Lubricating oil/oil filter cartridge IW 0101 M6
Ignition voltage check / Spark plugs IW 0309 M0
crankcase ventilation IW 0511 M6
In-line air filter - engine IW 8040 A6
Pre-combustion chamber gas compressor IW 8046 0
Leak testing of all pipes and components carrying fuel gas and mixtures IW 8049 0
Elastically screwed coupling housing IW 8079 A6
Scavenging air fans IW 8083 A6
Condensate removal in the fuel-gas system IW 8090 A0
Leanox settings IW 8090 M6
Exhaust gas system condensate drain line IW 8095 A0
Control rod assembly/throttle valve/actuator W 0200 M6ef
Engine cooling water pump W 0203 A6
Ignition W 0303 M0
Valve clearance W 0400 M6
Pre-combustion chamber / pre-combustion chamber gas valve W 0501 M6
Vibration damper W 0601 M0
Gas quantity controller W 0705 M0
Mixture bypass valve W 0802 M0
Maintenance after initial commissioning W 1000 6
Overhaul W 2100 M0
Exhaust gas turbocharger W 8026 M6
GE Jenbacher - switch cabinets W 8031 A0
Starter W 8032 M0
Elastomer components W 8034 6
Generator W 8034 A0
Oil filter cartridge W 8038 M6
Plate-type heat exchanger W 8043 A0
Gas pressure control system W 8045 A0
Engine oil pump W 8046 M6
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/thrust bearing W 8050 M6
Exhaust gas manifold/exhaust gas lagging W 8051 M0
Camshaft/timing gear W 8052 M0
Replacing the cylinder head W 8053 M6
Pre-lubricating pump W 8054 M0
combustion chamber W 8056 M0
Mixture cooler O-ring replacement W 8075 M6
SprungMarke!!!198158383692886795
Engine – cooling water circuit / Mixture recirculating water W 8080 A0
Author: Doku./Provin Responsible: Doku./Bilek Release date: 18/12/2013
Inspection work: I 0103 6
Inspection
1 Heat exchanger mixture / water............................................................................................................. 1

1.1 To measure differential pressure on the mixture side.............................................................................. 1
1.2 Mixture-side cleaning............................................................................................................................................... 1
2 Pre-combustion chamber differential pressure................................................................................... 2
3 Data collection for the flexibly-mounted coupling housing.............................................................. 2
4 Flame traps in the mixture cooler.......................................................................................................... 2
4.1 To measure differential pressure on the mixture side.............................................................................. 2
4.2 Replacement................................................................................................................................................................. 3
4.3 Clean................................................................................................................................................................................. 3
5 Flame traps in the bypass line................................................................................................................. 4
5.1 Rating............................................................................................................................................................................... 4
5.2 Replacement................................................................................................................................................................. 4
5.3 Clean................................................................................................................................................................................. 4
Shut down the engine in accordance with Technical Instruction no. 1100-0105 and secure it against
unauthorised restarting in accordance with Technical Instruction 2300-0010.
Interval every
Inspection work 2000 Oh 4000 Oh 10000 Oh
10 Heat exchanger mixture / water ■
10 Mixture cooler flame traps ■
10 Flame traps in the bypass line ■
4 Flexibly-mounted coupling housing ■
2 Pre-combustion chamber differential ■
pressure
1 Heat exchanger mixture / water
1.1 To measure differential pressure on the mixture side

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

Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure thatt
unauthorised persons cannot start the engine.
Remove the cooler from the engine.
Wash out the dry cooler in a solvent (e.g. "P3 - Kaltreiniger") and rinse thoroughly with a powerful jet of water.
Solvents must be used which are not aggressive to nickel-plated brass or tin.
Author: Doku./Licht Responsible: Technology Thermodynamics Release date: 07/03/2013
Inspection
Replace the water-side gaskets (mixture cooler connection flange or blind flange).
2 Pre-combustion chamber differential pressure

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

Measure the gap width at 4 places on the circumference (set value 12mm ± 1 mm).
Enter the measured values in the Data collection for the flexibly-mounted coupling housing
(E 8079 6) table.
The radial alignment of the generator may need to be corrected as described in IW 8079 A6.
4 Flame traps in the mixture cooler
4.1 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.
Measured values in the Flame trap data table for the mixture cooler
(E 0103 g)
If the differential pressure exceeds the value measured on initial commissioning by = 15 mbar (150 mm water
column), the flame traps must be cleaned or replaced.
If two mixture coolers are installed, you must also measure both differential pressures.
Inspection
① Measuring point 1 ② Measuring point 2
4.2 Replacement
Remove flame traps and mounting plates from the engine and mixture cooler.
Carry out a visual inspection of the flame traps. If any damage is evident (fusion, corrosion, etc.), replace the
flame trap. Also replace the gaskets when replacing the flame trap.
Flame traps fused together by corrosion
4.3 Clean
If no damage is apparent, but only dirt, proceed as follows:
Remove flame traps and mounting plates from the engine and mixture cooler.
Immerse dry flame traps in a solution, e.g. "P3 - cold cleansing agent" (minimum 10 hours) and then rinse
thoroughly with a powerful water jet. Finally, use compressed air to blow off the flame traps and dry them.
The flame trap mounting plates are made from zinc coated structural steel. That is why only solvents must
be used which are not aggressive to the zinc coating.
Inspection
5 Flame traps in the bypass line
5.1 Rating
If in the course of the differential pressure measurement on the flame traps in the mixture cooler it is found
that they have to be replaced, the flame traps in the bypass line must also be assessed and if necessary
replaced or cleaned.
5.2 Replacement
Remove flame traps from bypass line.
Carry out a visual inspection of the flame traps. If any damage is evident (fusion, corrosion, etc.), replace the
flame trap.
5.3 Clean
If no damage is apparent, but only dirt, proceed as follows:
Remove flame traps.
Immerse dry flame traps in a solution, e.g. "P3 - cold cleansing agent" (minimum 10 hours) and then rinse
thoroughly with a powerful water jet. Finally, use compressed air to blow off the flame traps and dry them.
SprungMarke!!!45035996331448715
Daily inspection round
1 Leak testing................................................................................................................................................. 1
1.1 Exhaust piping............................................................................................................................................................. 1
1.2 Water/water water/oil platen-type heat exchanger (if part of Jenbacher's scope of supply)...
1
1.3 Oil/water temperature controller........................................................................................................................ 1
1.4 Vibration dampers..................................................................................................................................................... 1
1.5 Electrical engine cooling water pump.............................................................................................................. 1
2 Heat exchanger exhaust gas/water (if included in the GE Jenbacher scope of supply)............... 2
2.1 Condensate line........................................................................................................................................................... 2
2.2 Condensate/neutralisation granulate reservoir:......................................................................................... 2
3 Checking the exhaust gas back pressure monitoring (if installed)................................................... 2
4 Occurrence of unusual noises during operation................................................................................. 2
Before performing any work on the installation, the maintenance staff must ensure that the relevant
safety precautions have been observed regarding the activities to be carried out.
For safety precautions, please refer to the operation or maintenance description (TI No.: 2300-0005).
1 Leak testing
Check the entire plant for leaks, especially hoses, lines, fittings, compensators, etc. (visual inspection).
In the event of mixture exciting in larger quantities, the smell of gas is perceptible. The location of the leak can
be detected using leak spray or a paper strip (is blown away).
In case of carbon monoxide (CO) in the fuel gas:
Carbon monoxide is a poisonous odourless, colourless, fhighly flammable gas, which is about as heavy as air.
If the fuel gas contains CO, CO sensors must be worn as personal protective equipment.
1.1 Exhaust piping

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

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

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

Check the engine cooling water pump for leaks. Replace the gasket set in the case of leaks.
Check the engine cooling water pump for unusual noises. If need be, replace the pump‘s engine bearing.
Author: Doku./Bilek Responsible: Günther Wall Release date: 03/06/2011
Daily inspection round
2 Heat exchanger exhaust gas/water (if included in the GE Jenbacher scope of supply)
2.1 Condensate line

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

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

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

Listen out for unusual noises during operation, find out what is causing them and rectify the fault. If you are
unable to establish the cause or rectify the fault, please contact the Customer Service.
SprungMarke!!!18014398567776011
Author: Doku./Bilek Responsible: Günther Wall Release date: 03/06/2011
Inspection and maintenance work: IW 0101 M6
Lubricating oil
1 Information
Only use engine lubricating oil mentioned in GE Jenbacher Technical Instructions.
The oil service life is substantially affected by the operating conditions. It is therefore impossible to make any
general statements as to the oil-change intervals. To use the oil as efficiently as possible, we recommend
determining its service life by means of oil analyses.
TA 1000-0099A
TA 1000-0099B
TA 1000-0099C describe the sampling and testing procedure for the oil analyses.
Enter the dates of oil analyses and/or oil changes in the table Operational data – Engine
lubricating oil (E 0101).
If the engine lubricating oil has been contaminated with water, the engine oil and oil-filter element should be
changed.
Following this procedure, the engine must be allowed to idle for approx. 10 minutes. After switching the engine
off, the engine oil and filter element should once again be changed.
2 Procedure when changing oil
2.1 Draining lubricating oil

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

Shut-off valve ha remains open.
Close the shut-off valve at the lowest point of the lubricating oil piping (lubricating oil heat exchanger).
Turn 3-way cock h3into the "Fill" position.
Open 2-way valve v2 manually.
The difference in level between the oil pan and the fresh-oil tank will cause engine lubricating oil to run into the
oil pan.
Fill the oil pan to the "MAX" indicator on the dip stick.
Close 2-way valve v2manually.
Author: Doku./Bilek Responsible: TEBM/Rangger Release date: 25/04/2013
Lubricating oil
Run the electrical pre-startup lubrication system for a few minutes to fill the lubricating oil heat exchanger.
Check the oil-pan level once again and, if necessary, top up as described above.
3 Key to Figure
ha Stop valve of Connection for fresh oil tank

h3 3-way valve v2 2-way valve
SprungMarke!!!18014398563514379
oa Connection for used oil tank
Author: Doku./Bilek Responsible: TEBM/Rangger Release date: 25/04/2013
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........................................................................................................................ 4
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........................................................................................................................................ 6
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 8
5.2.2 Life Saver spark plugs with bayonet fitting 9
5.2.3 Life saver spark plugs without bayonet fitting 10
6 Cleaning hints.......................................................................................................................................... 10
7 Wearing characteristics and adjusting the spark plugs.................................................................. 11
7.1 Analysing used spark plugs................................................................................................................................ 11
7.1.1 Premature sparking / overheating 11
7.1.2 Faulty noble metal electrode 11
7.1.3 Silicon and combustion deposits 12
7.1.4 Electrode short-circuit 12
7.2 Adjusting the spark plugs..................................................................................................................................... 13
7.2.1 P3.V3 and P3.V5 spark plugs 13
7.2.2 Spark plugs 7.1V5 and P7.1V6 14
7.2.3 Denso 3-1 spark plug 14
7.2.4 Denso 518 spark plug 15
7.2.5 JenP603 spark plug 16
8 Fitting the spark plugs............................................................................................................................ 16
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 18
8.2.3 Life saver spark plugs without bayonet fitting 19
8.3 High-voltage cable.................................................................................................................................................. 19
9 Checking following recommissioning.................................................................................................. 20
Operational data: E 0309
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
adjust 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 adversely 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
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
absolute 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
subject 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:
requirement electrode
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 Guide value:
voltage electrode
requirement distance
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 250 - 500 Special gas 35 0.3
on request versions:
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
ignition voltages and be ended at ignition voltages which are as high as possible, without endangering
uninterrupted 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 adversely affect
their function.
a) Before disassembling the spark plugs, check the spark plug sleeve for soiling. If necessary,
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
disconnected 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
disconnected 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.
magnet.
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.
magnet.
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
insulator 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 Power reduction followed by engine Visually inspect cylinder.
tightened. damage. Inspect (replace) ignition box.
Early sparking due to defective Possible spark plug insulator Install new spark plug.
ignition box. cracking due to overheated central
electrode. Clean piston and cylinder head near
Combustion knocking causing combustion room.
electrode 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. Decreasing ignition voltages until Installing a new spark plug.
1000-0300). the cylinder fails. Carefully clean the spark plug
Increased oil consumption. Deposits can flake off, resulting in electrodes.
Poor blow-by oil separation. 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 Continuously decreasing ignition Adjust electrodes correctly (see
electrodes. voltages until the cylinder in following instruction).
Incorrect spark-plug type. question fails completely (no more Adjust electrode distance using
combustion): feeler 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.
WARNING
1.
0 1
2. »click«
ISO 3864, ANSI Z535 JWN 080 080 / 403253
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).
SprungMarke!!!27021597814638731
Crankcase ventilation system
1 Scope............................................................................................................................................................ 2
2 Purpose........................................................................................................................................................ 2
3 Maintenance intervals.............................................................................................................................. 3
4 Safety instructions..................................................................................................................................... 4
5 Description of maintenance work.......................................................................................................... 4
5.1 Inspecting the crankcase ventilation system................................................................................................ 4
5.2 Measurement of operational data..................................................................................................................... 6
5.2.1 Measurement methods and measuring instruments 7
5.2.2 Pressure in the crankcase system before and after the blow-by filter 8
5.2.3 Crankcase pressure 9
5.3 Maintain crankcase ventilation system......................................................................................................... 10
5.4 Replacing the blow-by filter................................................................................................................................ 12
5.5 Replacing the prefractionator element......................................................................................................... 15
5.6 Replacing the blow-by hose............................................................................................................................... 20
6 Set parameters for monitoring crankcase pressure......................................................................... 21
7 Relevant documents............................................................................................................................... 22
Author: Kecht S. Responsible: Madl W. Release date: 10/12/2013
1 Scope
This Inspection and Maintenance Instruction applies to the following engine versions with the following
crankcase ventilation system designs.
Engine versions:
▪ J612F, J616F, J620F
▪ J624G, J624H
Crankcase ventilation system designed with:

▪ Prefractionator housing with fabric element
▪ Optional: Crankcase pressure sensor
2 Purpose
This Inspection and Maintenance Instruction describes the maintenance operations to be carried out on the
crankcase ventilation system.
3 Maintenance intervals
Interval
Daily 1,000 Oh 10,000 Oh Differential Crankcase pressure Differential
pressure at pressure in
blow-by filter prefractionator
> 20 mbar > 10 mbar1 > 0 mbar2 > 10 mbar
Inspect crankcase ■
ventilation system
Record operational ■
data
Maintain crankcase ■3
ventilation system
Replacing the blow-by ■4
filter
Replacing the ■
prefractionator
element
Replacing the blow-by See Maintenance Instruction W 8034 6 Elastomer parts!
hose
1
J612F, J616F, J620F
2
J624G, J624H
3
and after prolonged downtimes
4
the filter should be replaced as soon as the limit value for either differential pressure value is reached
Blow-by filter or crankcase pressure. The filter should be replaced after 10,000 Oh at the latest.
4 Safety instructions
You must follow the safety instructions below when carrying out maintenance work on the crankcase
ventilation system:
Please observe the safety and hazard signs in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.
▪ The subjects below are especially important:
– Wearing personal protective equipment
– Information on plant components, i.e. exhaust system, fuel gas system, lubrication system
– Hazard due to hot surfaces
– Working at height, fall arrest equipment
▪ Maintenance work should only be carried out with the engine switched off
– Check the crankcase pressure before working on the crankcase ventilation system. Once you have
switched off the engine, the pressure in the crankcase should be the same as the ambient pressure.
You can check this by taking a reading from the crankcase pressure sensor.
If necessary, you can also take a manual measurement of the crankcase pressure (see Section 5.2).
▪ Work to check the condition of the system and measure operational data should be done while the engine
is running. When measuring operating pressures, make sure that the crankcase pressure and filter
operating pressures within the specified operating limits can also show slight overpressure in relation to
ambient conditions. You can check this by taking a reading from the crankcase pressure sensor.
▪ Crankcase ventilation gas may contain fuel gas and lubrication oil constituents. You must therefore ensure
that the engine room is well ventilated and carry gas sensors when carrying out maintenance work. The
following substances are present in the crankcase ventilation gas:
– Unburnt flammable fuel gas constituents such as methane
– Fuel gas constituents and trace components. Depending on the type of gas used and especially types
of special gas, the crankcase ventilation gas may contain flammable or toxic fuel gas constituents
such as CO, H2S, NH3.
– Lubricating oil droplets and mist
The same personal protective equipment should therefore be used as for maintenance work on the
lubricating oil system.
▪ On completion of the maintenance work, you should always check the condition of the system (see Section
5.1). In particular, you should check for leaks and damage to system components.
▪ Move the engine to full load (see TI 1100-0111 and TI 1400-0100).
5 Description of maintenance work
5.1 Inspecting the crankcase ventilation system

Carry out a visual inspection of the crankcase ventilation system components as part of your daily inspection
of the engine. Pay special attention to the following points:
▪ Check for leaks of gas or lubricating oil
▪ Check for damage to components
▪ Check that components (filter, hoses) have been fitted correctly
If you find leaks, damage or incorrectly fitted components, switch off the engine and replace the affected
component in accordance with maintenance instructions or refit it properly.
① Prefractionator with cover ④ Blow-by hoses

② Blow-by filter with insulation ⑤ Connections for blow-by hoses
③ Oil return hose ⑥ Filter support
Check the following system parts and components:

▪ All flexible hose connections to pipes:
– Blow-by hoses from the preliminary filter housing to the blow-by filter
– Blow-by houses from the blow-by filter to the preliminary filter housing
– Oil drainage hoses from the blow-by filter to the crankcase
If necessary, check the hose connection and/or replace the hose and clamp as described in Section 5.6.
NOTICE
Tighten heavy duty clamps to a maximum torque of 18 Nm!
▪ Blow-by hoses
If you find that a hose is damaged, replace the defective hose as described in Section 5.6.
▪ Cover on prefractionator housing
If leaks occur, replace the cover seal as described in Section 5.5.
▪ Oil return hoses
In the event of any leaks, check or tighten the screw couplings as necessary or replace the oil return hose.
Check the oil drain connection on the blow-by filter for oil leaks as well. Replace the blow-by filter if leaks or
damage are noticed.
▪ Oil drainage bolts on the preliminary filter

housing
In the event of leaks, replace the sealing rings and
check and tighten the bolt connections
accordingly.
▪ Blow-by filter fixing

Check filter fixings such as bolt or clamp connections to the filter support and tighten if necessary.
▪ Blow-by insulation
Check that the insulation is correctly seated and adjust if necessary.
▪ Crankcase pressure sensor
If a crankcase pressure sensor is fitted, read off the crankcase pressure measurement on the DIA.NE. Pay
particular attention to any deviations from normal operating conditions (see Section 5.2).
5.2 Measurement of operational data

Record the following data in order to maintain the crankcase ventilation system:
▪ Gauge pressure in the crankcase system upstream and downstream of the blow-by filter
▪ Crankcase pressure
Enter the measured values in the table Operational data – crankcase ventilation system (E
0510).
In particular, you should look out for deviations from normal operating conditions (observation period 500 Oh):
▪ Occurrence of fluctuations in crankcase pressure
▪ Noticeable increase in crankcase pressure
In the event of deviations from normal operation, collect the following operational data and determine the
cause of the deviation:
▪ Measurement of blow-by volume flow (see TI 1530-0185)
▪ Measurement of operating pressures in the crankcase ventilation system (see Section 5.2)
▪ Function test of the crankcase pressure sensor (see Section 5.3)
5.2.1 Measurement methods and measuring instruments

The listed system gauge pressures must be measured manually using a water column, with the engine at full
load.
If a crankcase pressure sensor is fitted, the crankcase pressure can be read off directly on the DIA.NE as a
measured value (main/auxiliaries1).
Engine operation: engine at full load
Measuring instruments: Water column, crankcase pressure sensor
Analysis: 10 mm water column = 1 mbar
Connecting pieces ② (part number 460134 or 555899)
Transparent plastic hose ① (approx. 2-3 m), to be
connected to the connecting pieces.
¼ inch measurement connection (part number

463258) for connection to oil dipstick tube.
Note:
A digital hand-held measuring instrument may NOT be used for these pressure measurements due to its
limited accuracy with pressure fluctuations.
5.2.2 Pressure in the crankcase system before and after the blow-by filter
Gauge pressure upstream of the blow-by filter:
PBBF-in ②
Gauge pressure downstream of the blow-by filter:

PBBF-out ①
The blow-by filter has two 1/8” threaded connections.

You can use a water column to measure the pressure
before and after the blow-by filter or measure directly
the differential pressure across the filter.
Pressure upstream of the blow-by filter BBF-in

Gauge pressure upstream of the blow-by filter
Example: +37 mm = + 3.7 mbar

Water level ③
Hose against atmosphere ④
Hose connected to filter inlet ⑤
Pressure downstream of the blow-by filter BBF-out

Gauge pressure downstream of the blow-by filter

Water level ③
Hose against atmosphere ④
Hose connected to filter inlet ⑤
5.2.3 Crankcase pressure

Manual measurement of the crankcase gauge pressure at the oil dipstick: PCRC
You can measure the crankcase pressure manually at the connection for the oil dipstick.
WARNING
Risk of engine oil leaking out through the oil dipstick tube!
You must therefore always measure the pressure before the blow-by filter before removing the oil dipstick.
If the pressure upstream of the blow-by filterBBF-in is 0 mbar or greater, a ¼" hydraulic measurement connection
(part no. 463258) must be fitted to the oil dipstick pipe before the measurement is taken.
To do so, switch off and secure the engine (see safety instructions).
Again, you have to carry out the measurement with the engine at full load.
Crankcase gauge pressure at the oil dipstick.

Water level ①
Hose against atmosphere ②
Hose connected to oil dipstick ③
5.3 Maintain crankcase ventilation system

The following maintenance work must be carried out on the crankcase ventilation system after prolonged
engine downtimes:
1. Inspect crankcase ventilation system (see Section 5.1)
2. Check fabric element and seal and clean or replace as necessary (see Section 5.5)
3. Check function of crankcase pressure sensor
Adjust the crankcase pressure measured value to 0 mbar:

– Switch off and secure the engine (see safety instructions)

– Check the crankcase pressure on DIA.NE with the engine switched off.
– If the measured pressure deviates by more than 2 mbar from the setpoint pressure of 0 mbar (ambient
pressure), recalibrate or replace the sensor and then repeat the comparative measurement.
After starting the engine, check the crankcase pressure and carry out the comparative measurement man-
ually:
– Move the engine to full load (see safety instructions)
– Measure the crankcase pressure at full load using the water column method (see Section 5.2) and
compare it with the value displayed on the DIA.NE.
– If the displayed pressure deviates by more than 2 mbar from the reference pressure measured using
the water column, recalibrate or replace the sensor and then repeat the comparative measurement.
4. Inspecting the outlet chamber of the prefractionator
ATTENTION
The prefractionator may contain a residual quantity of trapped engine oil which
could spill out during disassembly!
Open the screw plug ③ and empty out any

accumulated lubricating oil.
Remove the blow-by hose ② on one side and
visually inspect the outlet chamber in the
prefractionator housing ①.
Close the screw plug ③ and attach the blow-by
hose ② and the hose connection.
NOTICE
5. Checking the oil return hose
ATTENTION
The blow-by filter and oil return hose may contain a residual quantity of trapped
engine oil which could spill out during disassembly!
Remove the hose.

Visually inspect the hose for deposits, residues or
emulsion
(If necessary, clean or replace).
Fit the oil drainage hose.
Note: Lock the hose when removing or tightening it,
as the filter element may be damaged otherwise.
6. Checking the condition of the system once the engine has started - see Section 5.1.
5.4 Replacing the blow-by filter

During engine operation, engine oil and particulate deposits can result in ageing of the blow-by filter, which
increases the filter differential pressure and consequently the crankcase pressure as well.
If the filter differential pressure exceeds the stated limit value (see Section 3, Maintenance intervals), the blow-
by filter has reached its maximum service life and must be replaced, irrespective of the crankcase pressure.
If the filter is retained in operation after the replacement criteria have been met, adequate oil separation
efficiency can no longer be assured. This means that increased amounts of oil can enter the intake system,
resulting in a higher maintenance outlay for intake system components (turbocharger, intercooler, ....).
The blow-by filter must also be replaced when the stated limit value for the crankcase pressure value is
reached, either on the DIA.NE or by manual measurement (see Section 3, Maintenance intervals).
Note: However, there may be a variety of other reasons for the rise in crankcase pressure. In the event of
deviations from a normal rise in pressure, you will have to determine the reason for the deviation.
▪ Ageing of the filter
▪ Ageing of the preliminary separator element - see Section 5.5.
▪ Increased amount of crankcase ventilation gas
▪ In-line air filter has been replaced
You must take the following actions:
1. Shut down and secure the engine (see the Safety instructions)
2. Check the crankcase pressure with the engine switched off:
With the engine switched off, there should be no pressure above atmospheric in the crankcase system. Check:
The DIA.NE measured value for crankcase pressure (or manual measurement) does not indicate pressure
above atmospheric.
3. Removing the blow-by filter
ATTENTION
The blow-by filter and the flexible hoses may contain a residual quantity of trapped
engine oil which could spill out during disassembly!
To remove the insulation:

Open the spring clips or Velcro fasteners and
remove the insulation ① from the filter.
Open the connectors ② connecting the blow-by
hoses to the connecting sockets of the blow-by
filters.
Remove the oil return hose.

Note: Lock the hose when removing it, as the filter
element may be damaged otherwise.
Open the screw connections ③ to the filter support

or the filter clamps ④ on the filter support and
remove the used blow-by filter.
Use the transport packing unit in which the new
filter element was supplied to keep the used filter
element.
Note: Oil may leak during storage!
Check the bearing pads (replace if necessary/J 624)
4. Fitting the blow-by filter

Before fitting, check the new filter for shipping damage, damaged packaging, any moisture ingress and
damage to the connection stub. If any damage is found the filter must not be fitted.
Close the clamps or the screw fittings to secure the
filter in the support.
In the case of two-part clamps, position a screw
fitting centrally in the bearing shell of the support.
Use the opposing second screw fitting at the front
of the filter to tighten the clamp.
Check the position of the hose supports before
tightening the clamps! (Check or compare position
prior to disassembly)
NOTICE
Attach the oil return hose

Check the free cross-section in the return hose.
Note: Lock the hose when tightening it, as the
filter element may be damaged otherwise.
Tighten the connections② of the blow-by hoses

Attach the insulation ①
NOTICE
6. Dispose of the blow-by filter and/or the filter cartridges properly, in accordance with local regulations.
5.5 Replacing the prefractionator element

The deposition of trapped oil and particles in the fabric separator element may cause the differential pressure
to rise across the separator element in the preliminary filter - and with it the crankcase pressure.
You can detect dirt on the separator element by measuring the differential pressure across the preliminary
filter. The following pressures must be measured during full-load operation (see Section 5.2).
▪ Crankcase pressure PCRC
▪ Pressure at the inlet to the blow-by filter PBBF-in
This gives the differential pressure ∆P = PCRC – PBBF-in

Enter the measured values in the table Operational data – crankcase ventilation system (E
0511).
If the measured differential pressure exceeds the stated limit value (see Section 3, Maintenance intervals), the
preliminary filter element must be cleaned or replaced. Measure the differential pressure again after replacing
the filter element.
Proceed as follows:
▪ Switch off and secure the engine (see safety instructions).
▪ Check the crankcase pressure with the engine switched off:
With the engine switched off, there should be no pressure above atmospheric in the crankcase system.
Check: The DIA.NE measured value for crankcase pressure (or manual measurement) does not indicate
pressure above atmospheric.
ATTENTION
The prefractionator may contain a residual quantity of trapped engine oil which
could spill out during disassembly!
Open the screw plug ③ on the prefractionator

housing ①.
Unscrew the bolts on the cover ② of the
prefractionator housing.
Remove the mounting brackets ④ for the fabric

element.
Remove the fabric element and clean it (by

steam jet) or replace it.
Attention: Do not use any chemical cleaning
agents
If necessary, replace the surrounding seal.

Make sure the seal is properly seated and that a
continuous seal is made around the entire
circumference of the sealing surface.
Insert the fabric element into the prefractionator

housing. The left and right sides of the
prefractionator filter are symmetrical, i.e. you
can choose any one.
Attaching the brackets

The bolts ⑤ should protrude at the bottom 3-5
mm from the "handle" plate on the
prefractionator filter.
Screw in the bolt ⑥ at the top of the preliminary

filter housing but do not tighten it
Attention:. Lock the bolts ⑥ with a thread
locking compound, such as Loctite 243.
Align the bottom of the bracket with the bottom
nuts parallel to the preliminary filter and fasten
the preliminary filter securely.
Note: The gap between the "handle" on the
preliminary filter and the bracket must not
exceed 20 mm!
Tighten the bolt ⑥ at the top of the preliminary

filter housing and the lock nut ⑦.
Note: The bolted joint on the bracket must
constitute an electrical connection between
the filter and the housing.
Replace the seal for the cover ② and close the

cover.
Close the screw plug ③.
Checking the condition of the system once the
engine has started - see Section 5.1.
Dispose of the fabric element properly, in
5.6 Replacing the blow-by hose

The hoses used to connect the blow-by filter to the crankcase are elastomer components. They undergo an
ageing process and therefore have to be changed at regular intervals.
See also Maintenance Instruction W 8034 6 Elastomer components!
To replace the hoses, proceed as follows:
1. Shut down and secure the engine (see the Safety instructions)
2. Check the crankcase pressure with the engine switched off:
With the engine switched off, there should be no pressure above atmospheric in the crankcase system.
Check: The DIA.NE measured value for crankcase pressure (or manual measurement) does not indicate any
pressure above atmospheric.
3. Remove the hose.
Open the hose clamp/heavy-duty clamp ① for
the hose – pipe connection and the pipe clips for
the hose support and remove the hose ②.
4. Fitting the new hose
The following fitting guidelines need to be

considered here:
▪ A minimum gap of 5 mm must be maintained
between the hose clamp ① and pipe flange
③.
▪ A minimum gap of 5 mm must be maintained
between the pipe flange ③ and the
reinforcement ④ in the flexible hose ②.
▪ To avoid damaging the hose when fitting it,
ensure that:
– hoses are not kinked
– hoses do not touch other engine
components
NOTICE
5. Attach the hose support and the hose clamps for the hose - pipe connections.
7. Dispose of the detached hoses properly, in accordance with local regulations.
6 Set parameters for monitoring crankcase pressure

Use the following set values to monitor crankcase pressure:
Parameters J612F, J616F, J620F J624G, J624H Unit
Maximum 20 20 mbar
Maximum hysteresis 2 2 mbar
Warning limit value 10 0 mbar
Hysteresis warning limit value 2 2 mbar
Measurement active -1 -1 -
Power limit monitoring active 50 50 % P nom
Measuring range at 4 mA -100 -100 mbar
Measuring range at 20 mA +100 +100 mbar
Minimum frequency 0 0 Hz
Parameters J612F, J616F, J620F J624G, J624H Unit

Maximum frequency 0 0 Hz
Use DIA.NE to set the parameters:
▪ The crankcase pressure is displayed in the menu: Hydraulic system
▪ The parameter set is in the menu: Para/Menu 1/Hydraulic System/Crankcase Pressure
▪ Read authorisation required for parameter set: Level 15 (Advanced Customer)
▪ Write authorisation required for parameter set: Level 30 (Service Technician)
DIA.NE parameter setting for crankcase pressure sensor
7 Relevant documents
▪ TI 1100-0105 – Shutting Down the Engine
▪ TI 1100-0111 – General Conditions - Operation and Maintenance
▪ TI 1400-0100 – Regulations for Running in GE Jenbacher Generating Sets
▪ TI 1530-0185 – Measuring the Blow-By Flow Rate with an Orifice Meter
▪ TI 2300-0005 – Safety Instructions
▪ TI 2300-0010 – Guidelines for Using the LOTO Kit
▪ IW 0509 M6 – Crankcase Ventilation System
▪ IW 0510 M6 – Crankcase Ventilation System
▪ W 8034 6 – Elastomer Components
▪ E 0511 – Operational data – crankcase ventilation system
Inspection and maintenance work: IW 8040 A6
In-line air filter - Type 6 F/ engines
1 General........................................................................................................................................................ 1
1.1 Type 6 F, G and H engines...................................................................................................................................... 1
2 Filter replacement..................................................................................................................................... 1
2.1 Opening the in-line air filter................................................................................................................................... 2
2.2 Removing the old filter cartridge......................................................................................................................... 3
2.3 Inserting a new filter package.............................................................................................................................. 3
2.4 Closing the in-line air filter...................................................................................................................................... 4
2.5 Tensioning the filter package............................................................................................................................... 5
3 Remarks....................................................................................................................................................... 6
3.1 Greasing all parts to be tightened...................................................................................................................... 6
3.2 Definitions...................................................................................................................................................................... 6
1 General
1.1 Type 6 F, G and H engines

If the underpressure indicator value exceeds 2.5 kPa, you should replace the filter cartridges (after 2,000 Oh at
the latest – i.e. the replacement interval to be expected) [see photograph of type 6 engine differential
pressure manometer].
Type 6 engine differential pressure manometer
2 Filter replacement
Author: TET/Lang Responsible: TET Release date: 27/07/2010
When replacing the in-line air filter, each side must be replaced (one after the other). [see illustrations below]
Symbolic picture → In-line air filter with two air-intake pipes on J620E
Symbolic picture → In-line air filter with two air-intake pipes on J624 (type 6 G engine)
2.1 Opening the in-line air filter

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

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

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

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

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

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

The stainless steel threaded rod and its sealing face at the end plate of the first filter element must be properly
greased at all times to prevent excessive chafing and/or clamping. To that end, a suitable grease for stainless
steel must be used. [see illustration below]
Greasing the threaded parts
3.2 Definitions
front ... always in the direction of the air flow at the front (at the intake grate)
back ... always in the direction of the air flow at the back (at the gas mixer)
SprungMarke!!!9007199456902539
Inspection and maintenance work: IW 8046 0
Pre-combustion chamber gas compressor
1 Maintenance after initial commissioning.............................................................................................. 1

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

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

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

Check the V belt tension – see manufacturer's instructions.
2 Regular maintenance
Intervals every
Maintenance work Point Weekly 2000 Oh 6000 Oh 10,000 Oh 30,000 Oh
w Oil level / oil pressure 2.1 ■
w condensate drain 2.2 ■
2 Gas filters 2.3 ■
6 Change oil 2.4 ■
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2010
Intervals every
Maintenance work Point Weekly 2000 Oh 6000 Oh 10,000 Oh 30,000 Oh
10 Dirt pan / V belt 2.5 ■
30 Overhaul 2.6 ■
2.1 Oil level / oil pressure
2.1.1 Oil level

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

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

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

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

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

Change the compressor oil according to the lubricant chart in the manufacturer's instructions.
Oil quantity filled:
TEL 50 ..... 0.75 litres [1.387 G]
TEL 60 ..... 2.75 litres [1.387 G]
TEL 80 ..... 5.25 litres [1.387 G]
2.5 Dirt pan / V belt
2.5.1 dirt pan

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

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

Replace the piston rings.
2.6.2 Gas gland packing rings

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

Replace the sleeves in the oil glands.
2.6.4 Valves
Check the valves and, if required, replace them.
3 manufacturer's documents
See description - Operation!
Leak testing of all pipes and components carrying fuel gas and mix-
tures
Operational data: E 8049
1 Leak testing of all pipes and components carrying fuel gas and mixtures
1.1 Instruction
The test covers all pipes and components carrying fuel gas and mixtures under overpressure in the GE
Jenbacherproduct 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
markings 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 degrees (1/6 rad).
A mirror and magnifying lens can be used to improve the observation.
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!
Author: Provin D. Responsible: Madl W. Release date: 19/12/2013
Leak testing of all pipes and components carrying fuel gas and mix-
tures
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).
SprungMarke!!!18014398710656395
Flexibly-mounted coupling housing
Interval Carrying out the
Maintenance work work
4000 Oh 20000 Oh Customer GEJ *)
Measure axial offset ■ x
Replace rubber elements on the coupling housing ■ x
*) By GE Jenbacher or by GE Jenbacher a specialist company authorized to carry out the work!
1 Measure the axial misalignment of the coupling housing on elastic bearings
Gap width: Setpoint value 10mm +/- 2mm Measure the gap width at 4 poinrs around the
circumference: A = 9 o'clock; B = 12 o'clock; C = 3
o'clock, D = 6 o'clock.
Operational data on the flexibly-mounted coupling housing (E 8079 6)

Enter the measured values in the table Data collection for flexibly-mounted coupling housing
(E 8079 6).
The radial alignment of the generator may need to be corrected as described below.
2 Correcting the generator position

Use shim plates to correct the generator height and subsequently recheck the axial offset of the coupling
housing on elastic bearings.
Author: Bilek F. Responsible: Wolf S. Release date: 15/11/2013
Flexibly-mounted coupling housing
SprungMarke!!!27021598273689867
① Shim plate
Author: Bilek F. Responsible: Wolf S. Release date: 15/11/2013
Scavenging air fans
Interval every
Maintenance work Point As required 6 months or 4,000 12 months or 8,000
Oh Oh
- Condensate drain 1. ■
- Motor cooling ribs 2. ■*)
- Impeller blades 3. ■*)
*) whichever occurs first
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.
1 Condensate drain
The motors are each fitted with one condensate drain opening in each side cover and at the terminal box. If
condensate formation is to be expected due to large fluctuations in the operating temperature, remove the
plugs in the condensate drain openings at regular intervals so that accumulated condensate can run off. How
often the plugs need to be removed depends on the environmental conditions.
2 Motor cooling ribs

Check the motor cooling ribs for dirt and clean as necessary.
3 Impeller blades
Check the impeller blades and fan housing for dirt and clean as necessary.
4 Goods inwards inspection/storage

▪ Check the delivery as soon as it has been received to see whether it corresponds to the order and has
suffered any damage during shipping.
▪ If the fan is delivered in a crate (or similar), this is purely for protection against shipping damage. No
equipment may be placed on the crate, and it must not be stacked on other items. The crate structure
must not be used for lifting unless explicitly marked as such.
▪ If the fan is to be put into storage, use bars, barriers or secured rooms to prevent access to the
components by unauthorised persons so that the free-rotating rotors do not present a hazard.
▪ Store the fan in a safe, clean and dry place free of vibrations or jarring. If no such storage location is
available, please contact the Jenbacher Customer Service.
▪ Spin the rotor by hand once a month. This prevents the grease from solidifying and standstill marks
forming on the bearings (brinelling). The rotor should not return to the same angular position after spinning.
Author: Bilek Responsible: Tremmel Michael Release date: 22/02/2012
Scavenging air fans
▪ When dismantling the shipping crate and unpacking the fan, pay attention to the danger of injury due to
sharp edges, nails, staples, splinters, etc.
▪ If the fan is to be stored for 12 months or longer, please contact the Jenbacher Customer Service.
5 Installation
5.1 Mechanical installation

Before installing the fan check that it has not been damaged during shipping, that the housing is not distorted,
that the rotor turns freely and that the fan and motor data on the type plate correspond to the intended use.
▪ Lift the fans slowly to avoid damage and twisting.
▪ Take appropriate precautionary measures and use authorised lifting equipment to ensure that the fan is
properly supported and stable before it is lifted into place. Flange holes or holes for the mounting feet can
be used for lifting, provided that more than one hole is used in order to spread the load. If specific lifting
points are provided, use them.
▪ Mount the fan so that it is correctly aligned for the required air flow direction. An arrow on the type plate
shows the flow direction of the fan.
▪ Use suitable fastenings to secure the fan in the correct position and tighten them to the correct torque as
shown in Figure 1.
▪ The motors are each fitted with one condensate drain opening in each side cover and at the terminal box.
The motor drain opening should be at the lowest point of the motor during installation.
5.2 Electrical installation

▪ In the case of fans with a terminal box mounted on the motor, the power supply is also run through an
opening in the side of the box. Use a cable gland for the cable and tighten it sufficiently to hold the cable
securely and seal off the gland. After starting check that the fan aspirates air. This also ensures that the
direction of rotation is correct.
▪ The mounting of the terminal box bolts is shown in Fig. 2.
▪ Adjust the phase current limiter as follows:
▪ Lower the actual limiting value of each phase by 0.1 amps each (e.g. actual value = 0.7, reduce it to 0.6).
▪ If the fan has been in storage, measure the motor windings resistance to earth (at 500 V DC). If the result of
the measurement is less than 10 megaohms, dry the motor and repeat the measurement before switching
it on.
5.3 Tightening torques for the fastenings

Fan housing cover for the Hexagonal head bolt Tightening torque
electrical connection of the motor
M8 15 Nm
Scavenging air fans
Motor terminal box Hexagonal head bolt (plastic) Tightening torque

M20 22 Nm
Grill mounting plate on the Hexagonal head Tightening torque

diffusor
M8 15 Nm
Connection between fan wheel Hexagonal head Tightening torque

and motor shaft
M8 15 Nm
Connection between bracket and Hexagonal head Tightening torque

housing
M8 15 Nm
Connection between motor and Hexagonal head Tightening torque

bracket
M12 25 Nm
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 1.2 ■
removal
*) 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
precautions 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
resulting 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 protection)!
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
manufacturer'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
(Interface 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
additional 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,
▪ 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!
SprungMarke!!!45035996354927499
Author: Doku./Boxleitner Responsible: Laucher Roland Release date: 19/10/2011
Leanox setting
Interval
Maintenance work 1 x to every every 1 x to To Execution
1,000 Oh 2,000 Oh 20,000 or 21,000 or Revison
30,000 Oh 31,000 Oh
Check Leanox setting, ■2 ■ ■3 ■4 ■5 GEJ 1
if necessary adjusting
as described in TI
1503-0047.
1
By GE-Jenbacher or by GE-Jenbacher a specialist company authorized to carry out the work!
2
Once at 1,000 Oh after commissioning and then every 2,000 Oh.
3
After 30,000 Oh during Major Services (after 20,000 Oh in the case of landfill and special gases), where all the
power units are replaced.
4
Once at 1,000 Oh after Major Service, where all the power units are replaced.
5
In systems where at least 50% of the power units have been replaced and after 1,000 Oh, check again and
then every 2,000 Oh.
Author: Bilek F. Responsible: Boewing R. Release date: 11/12/2013
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
Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure that
1 Removal of condensate
Cooling of the flue gases in the exhaust gas system can result in the formation of condensate. The condensate
must be drained from the exhaust gas system and disposed of in accordance with its composition and local
regulations (e.g. surface-water protection regulations).
1.1 Condensate line

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

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

Check the built-in filters and the neutralisation granulate for deposits
▪ and replace if necessary.
▪ Filters fully functional
1.4 Checking the exhaust gas back pressure monitoring (if installed)
Remove the screw plug
▪ check for amount of condensate produced
Check the line for deposits
▪ if necessary, clean it
▪ Screw on the plug
▪ condensate amount is OK
▪ Line fully functional
Author: Doku./Bilek Responsible: TSC/Burkhardt Wolfgang Release date: 03/05/2011
Maintenance work: W 0200 M6ef
Control rod assembly/throttle valve/actuator
J 612-620
Interval Carrying out the
Maintenance work work
2000 Oh 20000 Oh 30000 Oh Custome GEJ *)
r
Control rod assembly – Checking/ ■ x
Regreasing
Replace the throttle-valve bearing and O- ■ x
ring
Replace the actuator ■ 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 that the throttle valve is operating smoothly.
If the joints show excessive play, replace them (guide value: approx. 10,000 operating hours).
1.2 Regreasing
Grease uncovered joints and bearing locations using a suitable grease gun.
When relubricating, apply the grease to the left and right-hand side of the bearing gap so that the grease film
protects against dust.
Author: Doku./Bilek Responsible: TCC Greuter Release date: 14/11/2012
1.2.1 Grease type

Renolit Duraplex EP2
2 Throttle valve
Replace the throttle-valve bearing and O-ring.
2.1 Setting for throttle valve for type 6 engines, max. 20 cylinders with HEINZMANN actuator, type STG30
or STG40
① The lever on the throttle valve is up against the ③ Default setting

stop screw, while the throttle valve is open 2
mm
② Max. angular displacement ④ Inner stop on actuator

On the Heinzmann actuator, the rod is set so that when in the zero position the throttle is up against the stop
and the controller arm is preloaded by about 3 .
Zero position:valve is opened 2.0 mm and the lever is at the stop screw.
① Insert a 2 mm wire or drill and adjust the stop screw on the lever
Adjust the control rod assembly as shown in the above drawing. The ball joints must be lubricated before
assembly.
The STG30 and STG40 actuators are identical in terms of housing dimensions and assembly.
To adjust the zero position of the throttle valve: fit the lever on to the throttle-valve shaft as shown in the above
drawing. The throttle valve must be opened 2.0 mm at zero position by mechanical means (e.g. by inserting a
wire or drill). To adjust the zero position stop screw, the throttle valve lever must be just touching the stop
screw.
Adjust the zero position of the actuator lever as shown in the above drawing.
Caution: The control rod assembly must be adjusted so that, when at zero position, the throttle valve is at the
stop and the lever on the actuator is preloaded by approx. 3° (actuator scale). This prevents the actuator from
running against its own internal stop when in zero position.
Tighten the locknuts securely against the control rod assembly and ensure that the length of the control rod
assembly can no longer be adjusted.
When the actuator is fully open (100%), the control rod assembly should be overextended, i.e. the actuator
must return the throttle valve securely to zero position.
The ball joints must be lubricated before assembly. After assembly, please check that all screw connections are
still secure and that the control rod assembly operates smoothly!
SprungMarke!!!9007199311097483
Maintenance work: W 0203 A6
Engine cooling water pump
Interval every
Maintenance work 4,000 Oh 10,000 Oh 30,000 Oh
4 Engine cooling water pump – bearing lubrication (only ■*)
for pumps with grease nipples)
10 Mechanical seal - replacement ■
10 Engine cooling water pump - bearing replacement ■*)
30 Have the engine cooling water pump overhauled by a ■
specialist company authorised to carry out this work.
*) only on Type J612-620 version F1xx engines, and a pump power of 11 kW or 15 kW.
SprungMarke!!!27021597814154891
Author: Doku./Bilek Responsible: Thumer Mathias Release date: 06/02/2012
Maintenance work: W 0303 M0
Ignition
1 Maintenance Instructions........................................................................................................................ 1
1.1 List of Technical Instructions used..................................................................................................................... 1
1.2 Overview of maintenance work 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 .................................................................................... 3
1.5 Check list for the ignition system function test ........................................................................................... 4
2 Appendix...................................................................................................................................................... 4
2.1 Checking the mechanical assembly and electrical wiring...................................................................... 4
2.2 Checking the spark plug connector................................................................................................................ 10
2.2.1 Inspection and replacement of the spark plug connector seal 10
2.2.2 Measuring the spark plug connector resistance 12
2.2.3 Replacing the spark plug connector (Type 9 engines) 13
2.3 Cleaning the pick-up.............................................................................................................................................. 13
2.4 Checking the ignition point................................................................................................................................. 14
2.5 Measuring the ignition voltage.......................................................................................................................... 15
2.5.1 High-voltage measurement with high-voltage measuring pliers 16
2.5.2 Checking the high-voltage output of an ignition coil 16
2.6 Ignition system self-test....................................................................................................................................... 16
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
carried 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

Ignition / Ignition components / miscellaneous Technical Instruction No.
IC500 1502-0037
IC900, 910 and 912 1502-0038
IQ724 1502-0043
IQ750 1502-0044
DISN700 1502-0045
DISN801 1502-0046
Author: Provin D. Responsible: Fahringer A. Release date: 06/12/2013
Ignition
Ignition / Ignition components / miscellaneous Technical Instruction No.

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 Overview of maintenance work for ignition system components

Component Test according to the information given or reference to sub-points in the
maintenance instructions
Central ignition system Test after the maintenance interval, a fault or part replacement in accordance
with Technical Instructions and maintenance instructions.
Modular ignition system Test after the maintenance interval, a fault or part replacement in accordance
(MORIS) with Technical Instructions and maintenance instructions.
Ignition coil Test after the maintenance interval, a fault or part replacement in accordance
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 connector,
general condition of the electrical contacts to the ignition coil and spark plug (dirt,
oxidation, contacts seized) at every spark plug maintenance interval.
spark plug connector type 9 Replacement
engine
Spark plug connector seal Replace the spark plug seal (see the 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 maximum of
200 Oh after initial commissioning, and thereafter every 2000 Oh cleaned
according to the maintenance interval (see the cleaning instructions in Section
2.3 of the Appendix).
Ignition
Component Test according to the information given or reference to sub-points in the

maintenance instructions
Cabling rails Test after the maintenance interval, a fault or part replacement in accordance
Wiring Test after the maintenance interval, a fault or part replacement in accordance
1.3 Check list for the ignition system mechanical assembly

OK
Present
Test points for mechanical inspection Y/N Y/N
Ignition system properly mounted? Check in accordance with the corresponding Technical
Instructions (See the table in Section 1.1).
Vibration damping elements in the ignition system or cabling rails present and OK? Check for
mechanical damage, material ageing due to environmental influences and correct installation in
accordance with the corresponding Technical Instructions.
System seals present and OK?
Check for mechanical damage, material ageing due to environmental influences and correct
installation 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?
1.4 Check list for the ignition system electrical 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?
Ignition
1.5 Check list 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
parameters 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
carried 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.
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
location on the system to ensure that the equipment is properly earthed. When checking the condition of the
vibration dampers, the earthing should be checked as well.
The following illustrations show an MIC950 installed on a mounting bracket with the necessary earth
connections.
Ignition
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
Detailed view of a MORIS ignition system mounted on an engine with metal cushion-type dampers
Ignition
Check the installation of the ignition output cables in the cabling rail for any damage to the screw plug
connectors, strain relievers and cable sheath. Check the electrical contacts for corrosion / oxidation.
Cabling from the ignition system to the cabling rail
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.
Ignition
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.
Spark plug connector mounting on a Type 4 engine
Ignition
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 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
presence 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 according to the maintenance interval as part of the ignition system maintenance and in conjunction
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
connector. 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.
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
mechanically from the outset.
Ignition
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
ohmmeter. 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.
Measuring the resistance on a spark plug connector for a Type 3 engine (left) and Type 4 engine (right)
Ignition
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
measurement 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.
▪ 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.
Ignition
The pick-up should therefore be inspected and cleaned as a precaution in accordance with the maintenance
instructions.
Important: The gap between the pick-up and the trigger source should be set correctly as specified in the
applicable Technical Instructions for the ignition system in question.
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
Instructions 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
settings on each cylinder, and can vary during operation under load. This must be taken into account when
checking 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 operating 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-
voltage measurement. Reference is made to the appropriate Technical Instruction (see the table of Technical
Instructions 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
adjusting the oscilloscope measurement settings, read off the measured value for the ignition voltage on the
oscilloscope. 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.
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.
Ignition
Depending on how it is incorporated in the control system (via the CAN bus or similar), the self-test can be
started 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
Instructions for the ignition system in question and the manual for the visual display.
SprungMarke!!!45035996324102539
Valve clearance
1 Checking valve clearance and wear (valve-stem projection)............................................................ 1

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

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

Set values: Valve play
Intake valve 0.8 mm
Exhaust valve 1.0 mm
Intake valves:
The inlet-valve clearance is measured between the valve-stem end and the slide face.
Loosen the check nut of the adjusting screw (at the push rod), and insert feeler gauges at both valves.
Is the valve clearance equal at both inlet valves?
YES NO
OK! Loosen the check nut of the adjusting screw on the right inlet valve.
Adjust the adjusting screw until the valve clearance of the left-hand inlet valve
equals the clearance of the right-hand inlet valve.
Secure the adjusting screw using the locknut.
Please note:if the valve clearance measured is too large (e. g. in excess of 1.5 mm), carbon-deposit crusts may
have built up on the valve disc. Use a small rubber hammer and lightly tap the valve disc (Rotocap) to remove
the carbon deposits between the valve seat.
Set the valve play by adjusting the main adjusting screw.
You should now feel resistance if you try to move the feeler gauges.
Secure the main adjusting screw using the check nut and check the valve clearance once again.
Exhaust valves:
Loosen the check nut of the adjusting screw (at the push rod). Push the ball cup up and slide the feeler gauges
through the openings.
Set the valve play by adjusting the main adjusting screw.
You should now feel resistance if you try to move the feeler gauges.
Valve clearance
Secure the main adjusting screw using the check nut and check the valve clearance once again.
To avoid incorrect adjustments, always use two (2) feeler gauges at the same time when adjusting the
exhaust or inlet valves!
1.2 Measure the valve-stem projection

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

② Valve wear ④ NEW value exhaust valves
③ Valve seat wear ⑥ NEW value intake valves
Enter the measured values in the Operational data – Valve-stem projection (E 0400) table.
Valve clearance
Exhaust valves:
Clean the plane faces.
Measure the valve-stem projection from the exhaust-
valve Rotocap to the plane face of the cylinder head
using a depth gauge.
Intake valves:
Clean the plane faces.
If you can slide the depth gauge from the plane face of
the cylinder head over the Rotocap of the inlet valve,
the wear lies within the tolerance level.
If the Rotocap protrudes beyond the plane face of the
cylinder head, you should – as in the case of the outlet
valve - measure the valve-stem projection using a
depth gauge (from the Rotocap to the plane face of
the cylinder head).
SprungMarke!!!9007199311075467
Prechamber/prechamber gas valve
1 Replacing the pre-combustion chamber gas valve............................................................................. 2

1.1 Prechamber gas valve types / installation position................................................................................... 2
1.1.1 Type 6 engines (except for CMG >4% O2) - installed at the side. 2
1.1.2 J624 G/H – installed at the top (under the spark plug assembly). 2
1.1.3 For Type 6 special gas engines CMG >4% O2 - installed at the side 3
1.1.4 Installation position 3
2 Removal....................................................................................................................................................... 3
2.1 Drain off the engine cooling water completely............................................................................................ 3
2.2 Removing the prechamber gas valve when installed at the side........................................................ 3
2.2.1 Remove the valve cover and spark plug connector. 3
2.2.2 Remove the exhaust valve rocker arm 4
2.2.3 Remove the spark plug sleeve extension 5
2.2.4 Remove the exhaust valve rocker arm 6
2.2.5 Remove the prechamber gas valve 6
2.3 Removing the prechamber for prechamber gas valve part no.: 9007613...................................... 7
2.3.1 Remove the spark plug connector 7
2.3.2 Remove the prechamber gas valve 7
2.4 Remove the spark plug............................................................................................................................................ 8
2.5 Remove the prechamber retaining bracket.................................................................................................. 8
2.6 Remove the spark plug and prechamber assembly.................................................................................. 9
3 Inspection / cleaning............................................................................................................................... 11
3.1 Clean the O-ring seating surfaces in the cylinder head........................................................................ 11
3.2 Clean the prechamber mating surface in the cylinder head.............................................................. 11
3.3 Clean the prechamber bore and the combustion chamber............................................................... 13
3.4 Clean the prechamber........................................................................................................................................... 13
3.5 Clean the spark plug sleeve................................................................................................................................ 13
3.6 Inspect the prechamber and spark plug sleeve........................................................................................ 14
3.6.1 Pre-combustion chamber abrasion test 14
3.6.2 Spark plug sleeve abrasion test 16
3.6.3 Inspecting the spark plug sleeve 17
4 Installation................................................................................................................................................ 17
4.1 Preliminary assembly of the prechamber.................................................................................................... 17
4.2 Preliminary assembly of the spark plug sleeve......................................................................................... 18
4.3 Preliminary assembly of the prechamber and spark plug sleeve..................................................... 19
4.4 Fit the prechamber and spark plug sleeve assembly............................................................................. 19
4.5 Fit the prechamber retaining bracket............................................................................................................ 21
4.6 Fit the exhaust valve rocker arm...................................................................................................................... 24
4.7 Valve play monitoring unit................................................................................................................................... 25
4.8 Fit the spark plug sleeve extension................................................................................................................. 25
4.9 Replace the spark plug joint ring...................................................................................................................... 26
4.10 Fit the valve cover................................................................................................................................................... 27
4.11 Fill up with engine cooling water to the specified pressure................................................................ 27
4.12 Visual inspection for leaks................................................................................................................................... 27
Interval every
Maintenance work Point 6,000 Oh
6 Replace the pre-combustion chamber gas valve 1. ■
Author: Prankl, Stefan Responsible: Boewing, Robert Release date: 09/07/2013
Interval every
Maintenance work Point 6,000 Oh
6 Inspect the pre-combustion chamber and spark 3. ■
plug sleeve
1 Replacing the pre-combustion chamber gas valve
1.1 Prechamber gas valve types / installation position
1.1.1 Type 6 engines (except for CMG >4% O2) - installed at the side.
All type BR6 engines (except for CMG >4% O2) have been fitted with two equivalent valves, Part No. 433894 or
Part No. 389588. Within the one and the same engine, only valves with the same Part No. may be assembled.
2kJ Prt. No. 433894 with two turns at screw
connection.
Tightening torque: 30Nm
① Manufacturing date and 3-5 figure serial number

on the hexagon.
ER system Prt. No. 389588
No turns at screw connection.
① Inscription on the valve body.
1.1.2 J624 G/H – installed at the top (under the spark plug assembly).
Part no. 9007613
Tightening torque: 35 Nm
① 7-digit serial number on the octagon.
② Date of manufacture on the octagon.
1.1.3 For Type 6 special gas engines CMG >4% O2 - installed at the side
4J Prt. No. 321631
Special valve for CMG>4% O2
Slim, solid shaft, no turn at screw connection.
① 3-5 figure serial number on the hexagon.
1.1.4 Installation position

at the side at the top - under the spark plug
① Prechamber gas valve ② Prechamber gas valve assembly

③ Spark plug
2 Removal
2.1 Drain off the engine cooling water completely.
2.2 Removing the prechamber gas valve when installed at the side
2.2.1 Remove the valve cover and spark plug connector.
Clean the mating surface ① on the cylinder

head.
2.2.2 Remove the exhaust valve rocker arm

Item( Description Information
s)
1 Open-ended or SW 24
ring wrench
Undo the M16 hexagonal nuts ①.
Lift the rocker arm and pull out the valve rods using
both hands.
Press the rocker arm downwards with one hand and

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

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

s)
1 Prechamber Item ② Part no.: 222670
extractor tool
1 Adapter nut Item ① Part no.: 567458
(M42 x 2)
1 Adapter nut Item ① Part no.: 303388
(M35 x 1.5)
Screw the adapter nut ① on to the prechamber
extractor tool ②.
Screw the prechamber extractor tool, with the adapter
nut at position ③, on to the spark plug sleeve
extension as far as it will go.
Move the weight ④ sharply upwards in the direction of

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

adapter nut ⑦ of the prechamber extractor tool.
2.2.4 Remove the exhaust valve rocker arm

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

s)
ring wrench
Unscrew the prechamber gas line ① from the
prechamber gas valve.

s)
1 Ratchet
1 Extension piece
1 Socket wrench SW 22
1 link
Unscrew the prechamber gas valve from the cylinder
head using the ratchet wrench and then detach it from
the cylinder head.
2.3 Removing the prechamber for prechamber gas valve part no.: 9007613
2.3.1 Remove the spark plug connector

Quan Description Information
tity
ring wrench
Remove the two hexagonal nuts on the rocker cover
flange.
Undo the nuts on the R or M coil respectively and pull

the electrical plug connector out of the spark plug.
Pull the spark plug connector out of the valve cover at

the flange.
2.3.2 Remove the prechamber gas valve

tity
1 Tool Part no.: 9012812
Position the tool on the prechamber gas valve

tity
1 Ratchet
1 Hexagonal SW 13
socket wrench
Unscrew and remove the prechamber gas valve.
2.4 Remove the spark plug

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

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

s)
ring wrench
Undo the M10 hexagonal nuts ①.
Lift off the spacer sleeves ①.
Remove the prechamber retaining bracket ②.
2.6 Remove the spark plug and prechamber assembly

Before carrying out this step, make absolutely sure that the prechamber gas valve has been removed.
The piston of the cylinder head in question must also have been brought to its top position.
s)
1 Prechamber Part no.: 222670
extractor tool
Screw the prechamber extractor tool with the spark

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

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

head with the prechamber extractor tool.

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

head

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

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

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

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

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

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

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

s)
1 Handheld
vacuum cleaner
Remove the accumulated dirt from the cylinder head
with a handheld vacuum cleaner.
3.4 Clean the prechamber
Clean the prechamber with a wire brush

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

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

In the event of heavy dirt contamination, clean with
abrasive paper, see Figure ②.
Clean the hole in the spark plug sleeve for the

prechamber gas valve ①.
3.6 Inspect the prechamber and spark plug sleeve
3.6.1 Pre-combustion chamber abrasion test

Clean and inspect the precombustion chamber
(optically and using inspection tool TI No. 481483
If the prechamber shows signs of hot corrosion as shown in the
photo, it must be replaced.
If the prechamber is damaged as shown in the photo, it must be

replaced.
In addition, it is advisable to replace the relevant piston.
If the prechamber is damaged as shown in the photo, it must be

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

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

Part No. Nr. 481483.
The wire ring must slide on easily.
8-hole pre-combustion chamber (up to product range 2005).
① Inspection tool
9-hole pre-combustion chamber (up to product range 2000)
Natural gas pre-combustion chamber from product range 2005
Special gas pre-combustion chamber:

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

Clean and inspect the spark plug sleeve (visually)
① Spark plug sleeve ② Gas bore and spark plug thread OK

If the spark plug sleeve shows signs of wear as shown in the gas bore, it must be replaced.
① Wear in the gas bore

If the spark plug sleeve shows signs of wear at the spark plug thread as shown, the spark plug sleeve must be
replaced.
① Wear on the spark-plug thread
3.6.3 Inspecting the spark plug sleeve

Visually inspect the spark plug sleeve for damages (cracks, fractures) near the O-ring ①.
① Spark plug sleeve fracture
Replace the spark plug sleeve if cracks or signs of damage are found.
4 Installation
4.1 Preliminary assembly of the prechamber

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

s)
1 sealing ring Item ① Part no.: 438602
1 O-Ring Part no.: 456735
Replace the O-ring on the prechamber.
Replace the joint ring ①.
4.2 Preliminary assembly of the spark plug sleeve

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

s)
1 O-Ring Part no.: 376475
Replace the O-ring inside the spark plug sleeve.
Lightly oil O-rings before fitting.
4.3 Preliminary assembly of the prechamber and spark plug sleeve

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

s)
1 sealing ring Part no.: 438602
Figure 1: Apply a small amount of grease at two places

③ on the prechamber.
Figure 2: Push the joint ring on ④ and press it into
place.
This prevents the joint ring from falling out when
installing the assembly, see Figure 3.
Insert the spark plug sleeve so that the hole ② in the

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

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

into the cylinder head.
4.5 Fit the prechamber retaining bracket
Figure 1: Caution: the bracket is asymmetric in shape.

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

press it downwards as shown by the arrow by hand.
Figure 3: The dowel pin of the flange must fit into the
hole ④ in the prechamber.
Lever the bracket downwards.
Bracket alignment, the bolts must be centred.
Slide the spacer sleeves ① down over the studs.

s)
1 Torque wrench
1 Extension piece
Fully tighten the M10 hexagonal nuts ① alternately

using a torque wrench in accordance with TIs
1902-0228 C/EF/GH.
Clean the thread on prechamber gas valve ① and wet

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

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

s)
1 Torque wrench
1 Extension piece
1 link
Fully tighten the prechamber gas valve using a torque

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

s)
1 Open-ended SW 19
spanner
Fully tighten the prechamber gas line using an open-

ended wrench in accordance with TIs 1902-0228
C/EF/GH.
4.6 Fit the exhaust valve rocker arm

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

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

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

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

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

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

Maintenance Work W 0400 M6.
4.8 Fit the spark plug sleeve extension
Hold the spark plug sleeve extension as shown in

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

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

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

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

1902-0228 C/EF/GH.
4.10 Fit the valve cover

Clean the valve cover mating surface.

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

SprungMarke!!!72057594092415883
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
intended 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.
SprungMarke!!!9007199307118987
Gas quantity controller
Interval
Maintenance work Point 20,000 Oh 30,000 Oh 40,000 Oh 60,000 Oh
20/3 Gas quantity controller to be cleaned 2. ■*) ■ ■*)
040 on-site by service engineer.
20/3 Replace seal rings 1. ■*) ■ ■*) ■
0/40
/60
60 Replace gas quantity controller - ■
*) only for biogas, landfill gas and special gas
1 Replacing seal rings

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

Clean with a clean cloth without the soap solution.
Oil contamination:
Author: Doku./Bilek Responsible: TCD/Greuter Release date: 25/10/2010
Gas quantity controller
① clean
Author: Doku./Bilek Responsible: TCD/Greuter Release date: 25/10/2010
Mixture bypass valve
1 Replace mixture bypass valve
SprungMarke!!!9007199307154059
① Mixture bypass valve
Maintenance work: W 1000 6
Maintenance after initial commissioning
Operational data: Initial commissioning data sheet; E 0309; E 0400; E 8070

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

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

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

Check the ignition voltage and, if required, readjust the spark plug electrodes.
Enter the measured values in the Operational spark plug data (E 0309) table.
2.4 Data collection for the flexibly-mounted coupling housing: IW 8079 A6

Measure the gap in 3 places on the circumference.
Enter the measured values in the Data collection for the flexibly-mounted coupling housing
(E 8079 6) table.
2.5 Pre-combustion chamber gas compressor: IW 8046 0

Lubricating oil change / retightening bolts / V belt tensioning
Maintenance after initial commissioning
2.6 Control rod assembly/throttle valve: W 0200 M6

Grease pivot points using a grease gun at the lubricating nipples. Remove the excess grease and apply a
grease film to the left and right-hand side of the bearing gap to protect against dust.
SprungMarke!!!18014398568324491
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!
SprungMarke!!!9007199306994571
Exhaust gas turbocharger
1 Scope............................................................................................................................................................ 1
2 Purpose........................................................................................................................................................ 1
3 Inspection.................................................................................................................................................... 1
4 Overhaul...................................................................................................................................................... 1
5 Overhaul and replacement of turbocharger........................................................................................ 1
Table of abbreviations
GEJ+ GE Jenbacher or a company selected by GE Jenbacher
Maintenance intervals
Interval
Maintenance work 10000 Oh 20000 Oh 30000 Oh Work carried out by
Inspection ■ GEJ+
Overhaul *)**)
■ GEJ+
Overhaul ■ GEJ+
Overhaul and replacement of ■ GEJ+
turbocharger
*)
on non-natural gas applications such as biogases and special gases and use of maintenance plans B, C and
D
**)
only with oil cooling
1 Scope
This Maintenance Instruction applies to ABB type A-135 and A-140 turbochargers.
2 Purpose
This Maintenance Instruction describes the inspection and overhaul of the turbocharger.
3 Inspection
▪ Compressor-sided inspection of the casing and diffusor ring for deposits. If deposits are found, the
turbocharger should be cleaned. Cleaning can be done on site by GEJ+.
4 Overhaul
For overhaul, remove the turbocharger and prepare it for shipping.
Turbochargers may only be removed or overhauled by GEJ+.
5 Overhaul and replacement of turbocharger

For overhaul, remove the turbocharger and prepare it for shipping.
During this overhaul the turbocharger gets replaced.
Turbochargers may only be removed or overhauled by GEJ+.
SprungMarke!!!18014399056233739
Author: Provin, D. Responsible: Boewing, R. Release date: 10/12/2013
Generator (DIG110, DIG120,DIG130, DIG140, DIG142)
1 Scope............................................................................................................................................................ 2
2 Purpose........................................................................................................................................................ 2
3 Transport protection................................................................................................................................. 2
4 General overview of the generator........................................................................................................ 2
5 Daily check.................................................................................................................................................. 3
5.1 Visual Inspection......................................................................................................................................................... 3
5.2 Checking for smoke and smells........................................................................................................................... 3
5.3 Checking for unusual noises during operation............................................................................................. 3
6 Grid fault check (if installed).................................................................................................................... 3
7 Record bearing temperature................................................................................................................... 5
8 Re-greasing the bearing........................................................................................................................... 6
9 Decommissioning the plant..................................................................................................................... 7
10 Recommissioning the plant..................................................................................................................... 7
Author: Doku./Bilek Responsible: Günter Krainz Release date: 24/10/2013
Interval
Maintenance work daily 1,000 10,000 20,000 60,000 Carrying out the
Oh Oh Oh Oh work
Daily check ■ Customer
Grid fault check (if installed) ■ Customer
Record bearing temperature ■ Customer
Re-greasing the bearing ■ 2)
Customer
Cleaning the generator ■ GEJ 1)
Check generator for damage ■ GEJ 1)
Check cable for wear (chafing) ■ GEJ 1)
Check the rubber buffer (if fitted) ■ GEJ 1)
Checking the anti-condensation heating (if ■ GEJ 1)
installed)
Measuring the insulation / measuring the ■3) GEJ 1)
polarisation
Vibration measurement ■ GEJ 1)
Check the varistor and rectifier diodes ■ GEJ 1)
Replace earth brush (if fitted) ■ GEJ 1)
Replace bearings ■ GEJ 1)
Generator overhaul ■ GEJ 1)
1)
by GE Jenbacher or a company selected by GE Jenbacher authorised to carry out this work.
2)
If the equipment is used for less than 1,000 operating hours a year, the generator should be regreased
annually!
3)
After 10,000 operating hours or more than 3 months' standstill
1 Scope
This Instruction applies to Type DIG110, DIG120, DIG130, DIG140 and DIG142 generators manufactured by
Cummins.
2 Purpose
This Instruction applies to the maintenance of the generator.
3 Transport protection
The generator is fitted with transport safety pegs to prevent the bearings from being damaged during
transport. Remove all the transport safety pegs before commissioning and keep them for possible future
transport - see TI 1000-0044.
4 General overview of the generator

The generator shown here is a DIG 142, but the appearance can vary depending on the generator type.
① Non-driven end ⑤ Lubricating nipple

② Driven end ⑥ Terminal box
③ Ventilation inlet grille ⑦ Transport protection- see TA 1000-0044
④ Grease outlet ⑧ Ventilation outlet grille
5 Daily check
5.1 Visual Inspection

▪ Check that the bolts are seated properly and inspect for damage.
▪ Check the generator (terminal box, generator surface, grease nipples, ventilation grilles, etc.) for dirt and
damage.
5.2 Checking for smoke and smells

Shut down the engine immediately if smoke or unusual smells are noticed.
5.3 Checking for unusual noises during operation

Shut down the engine immediately if unusual noises are noticed. Contact the GE Jenbacher Customer Service
or a company selected by GE Jenbacher authorised to carry out work on the generator.
6 Grid fault check (if installed)
General:
If a mains failure occurs that causes a defined changed in the voltage, current or frequency at the generator, a
warning or trip message is displayed on the DIA.NE screen (or optionally on a remote computer).
The DIA.NE screen shown below is only a symbolic representation, as different versions of the engine
management exist.
DIA.NE system
① GE Jenbacher DIA.NE (engine management ② Remote computer (optionally)
system)
Course of action with DIA.NE systems:

Press the "Alarm" button in the DIA.NE system and search for the grid faults listed below:
① Grid faults
If any of the above operational messages are displayed, carry out the measures specified in Inspection
Instruction I 8030 0
These error messages are generally due to a mains failure. Consult the Error message list to find out the exact
mains events.
7 Record bearing temperature

Enter the measurements in the operational data booklet.
General:
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. Temperature fluctuations without any
apparent reason (such as changes in ambient temperature) indicate a malfunction somewhere, in which case
the bearing in question should be checked.
Check the temperature of the bearings when re-greasing them. The bearing temperature may increase during
the lubrication process, but should return to normal operating values after a few minutes of operation.
Test method:
Read off and log the bearing temperature value on the DIA.NE or remote computer.
The illustration may vary due to the different DIA.NE system applications.
Assessment criterion:
The temperature rise should remain within the limits. If the temperature increases continuously despite the
load being constant, caution should be exercised.
Bearing temperature limits:

Warning: > 85°C
Trip: > 90°C
Procedure in the event of deviations:

If limit values set in the system are reached, a warning/shutdown is activated automatically. If a limit is found
to be exceeded during the inspection, shut down the engine at once. Contact the GE Jenbacher customer
service.
8 Re-greasing the bearing
Notes:
▪ Failure to observe the following lubrication instructions can result in the escape of grease and/or bearing
damage. Keep the bearings and grease free of dirt to prevent damaging the generator.
▪ Re-grease the bearings when the generating set is running.
▪ Take particular care to avoid contact with rotating parts when re-greasing. Personal injury and/or damage
to the generating can occur otherwise.
▪ The work must be planned so that the generator does not need to be stopped for at least 6 hours after re-
greasing. Furthermore, we do not advise running a generating set under partial load for this length of time
either. Always aim for full load operation.
▪ Check the temperature of the bearings when re-greasing them. The bearing temperature may increase
during the lubrication process, but should return to normal operating values after a few minutes of
operation.
▪ Log the re-greasing:
Enter the regreasing time in the Generator Operational Data Log - Regreasing (E 8030).
Required tools:
Grease pump, grease meter or balance, cleaning cloth (lint-free).
Regreasing:
Step 1:
The prescribed type and quantity of grease can be found on the sticker on the generator. Observe the precise
weight or quantity of grease as per the type plate.
Type plate
① Prescribed grease
② Quantity of grease - drive end / non drive end

③ Note: regreasing intervals as per GE Jenbacher instruction. The intervals specified on the generator
type plate do not apply here!
Step 2:
Fill a clean grease pump with the stated quantity of the specified grease quality. If the grease pump has been
previously filled with a different quality grease, clean it with the utmost thoroughness.
Step 3:
Clean the grease nipples with a flint-free cloth before regreasing to ensure that no particles of dirt get into the
bearings.
Step 4:
Regrease the bearings when the generator is running and at operating temperature so that the grease is
evenly distributed and overgreasing can be avoided.
Step 5:
Pump in the grease with the grease gun at the grease nipple. Regreasing should take between 5 and 30
minutes.
Note: The bearing temperature may rise by a maximum of 25°C during regreasing, but must drop back to the
value at the start of regreasing. This can take up to 96 hours.
Step 6:
Remove any escaped lubricating grease on the underside of the casing cover.
9 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
geographical location (climate, proximity of the sea, etc.). As conditions can vary enormously, we recommend
that you consult a suitable specialist firm concerning the measures to be taken or contract it to carry out the
work.
When the generator is out of service for a prolonged period, the rotor must be rotated every two months
to ensure that the rolling elements change position (a small change of position will suffice).
Do not rotate the rotor at the fan but use the engine flywheel!
10 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 plant is to be recommissioned after a long period of downtime (e.g. 2 years), the bearings must be
replaced as the grease starts to resinify over time, which makes the bearings unusable.
Of course, before recommissioning the plant, you must make sure that it is back in its normal operational
condition.
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GE Jenbacher - switch cabinets
1 Check switchgear cabinets for clogging and clean, if necessary
2 Filter fan
WARNING
Danger of electric shocks!
ü 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
temperature monitor. The expected service life is at least 40,000 Oh (L10, 40°C), making the air filter largely
maintenance-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,
depending on dust conditions.
Author: Provin D. Responsible: Krainz G. Release date: 06/12/2013
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
housing 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.
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good contacts worn contacts
Starter
Iskra
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.
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Example for type 6 engines: Rubber caps, aluminium-acrylic protective cover ⑥ and copper bar ⑦
Elastomer components
Elastomer components age and become brittle, even when engines are not operational. That is why the
service life of these components does not depend solely on the length of time for which the module has
been in service, the cooling water temperature and pressure, etc. If this number of operating hours is not
reached, the elastomer components should still be replaced as a precautionary measure after a maximum
of 5 years.
every
Replacing the elastomer Interval 6000 Oh 10000 Oh 20000 Oh 30000 Oh 60000 Oh
components see
photogra
ph 1)
Mixture cooler: O-rings ■ ***)
pre-combustion chamber gas ■
valve: Grommet
Only for J624TSTC: Mixture cooler - ■
O-rings (between housing and
cooler, high and low pressure)
All O-rings: pre-combustion ■
chamber, cylinder-head cover,
spark-plug extension
All O-rings: cooling water line, oil ■
lines, oil filter installation, oil pump,
turbocharger mounting
Optional for turbocharger module:
Turbocharger with mixture and oil-
cooler mounting
Coupling: coupling discs ■
All hoses: oil lines, pre-lubrication ■
and re-lubrication, venting system,
compensation reservoir, exhaust
gas back pressure control,
crankcase ventilation
All rubber buffers: air-filter ■
collection cabinets, intake line, gas
mixer, ignition cable harness,
ignition, switchgear cabinets at the
module, knock control, etc.
All O-rings: Cylinder liner, ■ *) ■
crankcase, cylinder head, piston
cooling nozzles
Air-intake system up to ■
compressor intake: sleeves and
folding bellows
Engine / generator bearing: rubber ■ **) ■
rails
Flexible coupling housing (if ■
installed): rubber elements
Author: Doku./Bilek Responsible: TEBM/Rangger Alfred Release date: 17/05/2013
Elastomer components
every
Replacing the elastomer Interval 6000 Oh 10000 Oh 20000 Oh 30000 Oh 60000 Oh
components see
photogra
ph 1)
Platen-type heat exchanger: ■
rubber gaskets
1) 5000 Oh, 500 engine start or every 2 years (whichever occurs first)
*) only for biogas, landfill gas, special gases or increased engine cooling water temperature >95 ℃
**) inspect and replace, if necessary
***) only for hot-country version E/F/H 101, 102,111,112
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Author: Doku./Bilek Responsible: TEBM/Rangger Alfred Release date: 17/05/2013
Oil filter cartridge
Interval
Maintenance work at every oil change J612 - J616 after 4000 J 620 / J 624 after 6000
Oh at the latest, Oh at the latest, however
however
- Change the oil filter cartridge ■
4 ■
6 ■
Interval
Maintenance work with differential pressure warning on Diane
- Change the oil filter cartridge ■
1 Change the oil filter cartridge

To drain the engine oil from the oil filter, open the shut-off valve of the oil-filter inlet line.
Unbolt the cover and remove the oil filter cartridge.
Clean the oil filter housing.
Check the new oil filter cartridge inside and outside for packing material, loose accessories supplied with
it, and damage.
Lubricate O-rings (new oil filter cartridge) and slide into the oil filter housing.Replace the O-ring on the cover
and lubricate it.Refit the cover.Close the shut-off valve in the oil-filter inlet line and run the electrical pre-startup
lubrication system for a few minutes.
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Author: Doku./Bilek Responsible: Feyersinger Release date: 26/04/2013
Plate-type heat exchanger
1 Overhaul
The platen-type heat exchanger should only be repaired or overhauled by the manufacturer or by
specialised companies authorised to carry out this work.
Gas pressure control system
Interval: every
Maintenance work Point 2000 Oh 30000 Oh 60,000 Oh
02 Gas filters 1. ■
30 Pre-pressure controller 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.
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Engine oil pump
1 Engine oil pump

Replace the engine oil pump.
1.1 Pressure adjustment

On Type 6 engines, it must be ensured that the pressure at the last lubrication point of the oil pump is set to
between 3.8 bar and a maximum of 4.0 bar.
1.1.1 Checking the pressure at the last lubrication point

▪ Run the engine at full load and normal operating temperature of the oil.
▪ Check the pressure at the last lubrication point in the engine control system.
– If the pressure at the last lubrication point is in the range between 3.8 bar and a maximum of 4.0 bar,
no further action need be taken.
– If the pressure at the last lubrication point is outside the range between 3.8 bar and 4.0 bar, the
pressure must be adjusted as described in the following section.
1.1.2 Adjusting the pressure at the last lubrication point

The pressure adjustment must be carried out when the engine is running at full load and the oil is at operating
temperature, as the pressure at the last lubrication point depends on the oil temperature and the engine power
output.
▪ Setting the pressure on the pilot cartridge on the lubricating oil pump:
1. Remove dome nut ② (32 FA).
2. Loosen sealing hexagonal nut ③ (17 FA).
3. Set the pressure by adjusting spindle ① (6 FA).
– Pressure increase = turn it to the right
– Pressure decrease = turn it to the left
4. Set the pressure at the last lubrication point to a value between 3.8 bar and a maximum of 4.0 bar.
5. Tighten sealing hexagonal nut ③ with 35 Nm.
6. Tighten dome nut ② with 120 Nm.
Author: Doku./Bilek Responsible: Feyrsinger Peter Release date: 09/08/2012
Engine oil pump
Pilot cartridge on the oil pump
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Author: Doku./Bilek Responsible: Feyrsinger Peter Release date: 09/08/2012
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.
SprungMarke!!!9007199307060363
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
NOTICE
This maintenance step entails an increased risk of the ingress of dirt into the clean
oil circuit, which can cause extremely serious damage.
Proceed extremely carefully when following the GE Jenbacher instructions and make sure before
finishing the work that there is no dirt contamination in the engine, in particular in the clean oil
circuit.
Replace the connecting rods, connecting-rod bearings and connecting-rod screws.

SprungMarke!!!18014398561807243
Author: Doku./Bilek Responsible: Anderson, Barry Release date: 16/10/2013
Cylinder liner/scraper ring
1 Cylinder liner and scraper ring
NOTICE
Proceed extremely carefully when following the variable instructions and make sure before
circuit.
Replace the cylinder liner, scraper ring and O-rings.

Only use a hand pump to disassemble the cylinder liner.
Do not use hydraulic or electric pumps!
SprungMarke!!!27021597816552075
Author: Doku./Bilek Responsible: Anderson, Barry Release date: 29/10/2013
Main crankshaft bearing/thrust bearing
Interval: every
Maintenance work 30,000 Oh 40,000 Oh
(4,000 engine starts) (3000 engine starts)
30 Main crankshaft bearings and thrust bearings - replace ■
40 Main crankshaft bearings and thrust bearings - replace ■*)
*) only for biogas, landfill gas and special gas engines
1 Main crankshaft bearing/thrust bearing:
NOTICE
Proceed extremely carefully when following the variable instructions and make sure before
circuit.
At 30,000 operating hours (40,000 operating hours) or when the maximum number of engine starts is reached
as indicated in the above table, the main crankshaft bearings and thrust bearings must be completely
replaced.
SprungMarke!!!18014398565285771
Author: Doku./Bilek Responsible: TEBM/Prada Release date: 30/10/2013
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).
SprungMarke!!!18014398561818763
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.
SprungMarke!!!9007199307081611
Author: Doku./Bilek Responsible: Service Team I Release date: 24/11/2010
Replacing the cylinder head
Interval
Maintenance work Point for J612-J624 only for for J612-J624 ….. Oh
and J624TSTC J624TSTC 30,000 Oh
10,000 Oh 10,000 Oh
1 Rocker cover gasket – replace 2. ■
0
1 Cylinder head visual inspection 3. ■
0
3 Cylinder head replacement 1. ■ *)
0
- ■ **)
*) To be done on disassembly, when replacing piston and cylinder liner.
Clean the cylinder head at the plane faces and measure the valve-stem projection.
If the wear equals or exceeds 1.2 mm, we recommend replacing the cylinder head for reasons of economy.
**) When a check of the valve-stem projection shows that the maximum wear tolerance limit has been
reached.
1 Cylinder head replacement
1.1 Disassembling the cylinder head

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

Clean the mating faces at the crankcase and the cylinder head.
Insert a new cylinder head gasket in the groove.
To lift the cylinder head, screw eye bolt (M16) into the bore of the rocker arm support.
Replace all O-rings near the cylinder head. Oil the O-rings slightly with engine oil before assembly.
Loosen the cylinder-head nuts.
Author: Doku./Bilek Responsible: Konstruktion/Service Team I Release date: 05/10/2011
Pretension the cylinder head screws using the hydraulic tensioning device (610 - 620 bar), and handtighten the
cylinder-head nuts.
Release and remove the hydraulic tensioning device.
Mount the rocker arm support and rocker arm.
Adjust the valve play according to W 0400 M6.
Fit the lines.
See the cylinder head cover gasket section for the assembly of the cylinder head cover gasket.
Fit the cylinder-head cover using a new gasket.
Push the protective caps on to the cylinder head bolts.
See also
• Rocker cover gasket [⇨ Page 2]
2 Rocker cover gasket
2.1 Tips
Never install more than 1 (one) gasket type on the same engine, to prevent both the old O-ring and the
newly formed gasket to be used on the same engine. If necessary, all gaskets must be replaced.
The new gasket is made-to-measure and must therefore not be stretched before assembly!
Never use a screwdriver or a sharp tool to clean the sealing surface or to push the newly formed gasket in
position!
Storage must be suitable for the product, i.e. protected from light and dust. The packing must remain
sealed until the formed gaskets are actually used.
2.2 Fitting the rocker cover gasket

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

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

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

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Pre-lubricating pump
Interval
Maintenance work for series 4 for series 6 Carrying out
2.000 Oh 10,000 Oh 60,000 Oh the work
or max. 1,500 engine or max. 3,000 engine
starts starts
Electric motor – brush ■ ■ GEJ 1)
inspection
Pre-lubricating - overhaul ■ GEJ 1)
1)
by GE Jenbacher or a company selected by GE Jenbacher authorised to carry out this work.
1 Checking the brushes

▪ Remove the cover.
① Cover
▪ Remove the retaining strap, bend the metal plate upwards slightly and carefully remove. Most of the
abrasion dust is at the bottom by the metal plate.
① Retaining strap ② Plate

Author: Doku./Bilek Responsible: Feyrsinger Release date: 02/12/2013
Pre-lubricating pump
▪ Carefully remove the abrasion dust from the motor (using a vacuum cleaner and/or brush / compressed air
as necessary).
▪ Clean the exterior of the motor and the cover plate.
▪ Check if the brushes are properly seated in their holders (they must move freely).
▪ Remove a now-exposed brush and check it for wear.

Note: never wait until brushes are completely worn before replacing them. If one brush is damaged, the entire
set must always be replaced. Only use original brushes.
When carrying out maintenance or replacing brushes, always blow dry compressed air through the free brush
inlets to clear graphite dust out of the motor.
▪ Check the brush lengths. If a brush is shorter than 15 mm, all the brushes must be replaced.
① Brush length
▪ Refit the brush(es) and check that all brushes move freely in their holders.
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▪ Reassemble in reverse order.
Author: Doku./Bilek Responsible: Feyrsinger Release date: 02/12/2013
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).
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▪ Spark plug inspection according to IW 0309 M0.
Mixture cooler O-ring replacement
1 Scope............................................................................................................................................................ 1
2 Purpose of this Maintenance Instruction.............................................................................................. 1
3 Required parts and tools.......................................................................................................................... 1
3.1 Retrofitting package................................................................................................................................................. 1
3.2 Special tool, and lubricant...................................................................................................................................... 2
4 Work duration ........................................................................................................................................... 2
5 Requirements for safe replacement....................................................................................................... 2
5.1 Safety information..................................................................................................................................................... 2
6 Work steps.................................................................................................................................................. 3
6.1 Shut down the engine.............................................................................................................................................. 3
6.2 Drain off the cooling water on the high-temperature side..................................................................... 3
6.3 Drain off the cooling water on the low-temperature side...................................................................... 3
6.4 Disassemble the connections............................................................................................................................... 4
6.5 Remove the air duct from the mixture cooler............................................................................................... 4
6.6 Remove the reversing chamber.......................................................................................................................... 5
6.7 Fit the O-rings............................................................................................................................................................... 5
6.8 Mount the reversing chamber.............................................................................................................................. 7
6.9 Fasten the reversing chamber............................................................................................................................. 9
6.10 Water pressure test................................................................................................................................................... 9
6.11 Fit the water pump.................................................................................................................................................. 10
6.12 Mount the mixture cooler, air duct and water piping............................................................................. 10
6.13 Fill the system with water.................................................................................................................................... 10
6.14 Final inspection......................................................................................................................................................... 11
6.15 Other documents required.................................................................................................................................. 11
1 Scope
This maintenance work only applies to mixture coolers (hot countries) for Type 6 engines.
2 Purpose of this Maintenance Instruction

This specification sets out the instructions for O-ring replacement on the mixture cooler.
3 Required parts and tools
3.1 Retrofitting package

Component no. Quanti Part Number Description
ty
75 2 1212334 Encapsulated PTFE O-ring (small) for floating tube plates, 3.53 mm
76 2 1212335 Encapsulated PTFE O-ring (large) for floating tube plates, 5.33 mm
70 2 1212341 Viton O-ring F7091 for sealing the HT-stage water cover
71 2 1212344 Viton O-ring F7091 for sealing the LT-stage water cover
77 4 280486 Gasket for mixture cooler - HT water side
78 4 306985 Gasket for mixture cooler - LT water side
Author: TPSD/Madl Responsible: Doku./Provin Release date: 01/02/2012
Component no. Quanti Part Number Description

ty
79 6 362337 Gasket for mixture - cooler mixture side
3.2 Special tool, and lubricant

A tool is needed for the concluding pressure test after replacing the O-rings
Qty. Designation Information Part Number
1 Pressure tester 1214338
High-temperature lubricant for use in the intercooler must meet the following requirements:
Thickener Lithium soap
Worked penetration 1/10 mm 287-317 DIN ISO 2137
Dropping point [°C] ≥ 180 IP 396
Base oil Polyglycol
Kin. viscosity at [40°C mm²/s] approx. 120 DIN 51 562
Kin. viscosity at 100°C mm²/s approx. 20 DIN 51 562
colour Yellow / beige
NLGl class 1-2
Operating temperature -40°C to +120°C
Reliable corrosion protection
Excellent resistance to ageing and oxidation
The following product is recommended for use:

▪ Messrs Würth: Brake cylinder paste no. 0893980
4 Work duration
Removal of mixture cooler and associated parts 4 hours
O-ring replacement and mixture cooler reassembly 4 hours
5 Requirements for safe replacement
5.1 Safety information

Observe the safety directions in the operating instructions. Specific national safety and accident prevention
legislation must be obeyed.
Make sure before starting the work that the safety regulations are correctly applied and observed for the work.
Where work can only be carried out when the engine is at rest, the engine must be shut down in accordance
with Technical Instruction 1000-0105 and be secured against unauthorised starting in accordance with
Technical Instruction 2300-0010.
6 Work steps
6.1 Shut down the engine

Make sure that the engine cooling water is brought to its operating temperature.
6.2 Drain off the cooling water on the high-temperature side

Open valve No. 1 to drain off the cooling water
6.3 Drain off the cooling water on the low-temperature side

Once the engine is shut down, drain off the cooling water on the low-temperature side completely.
6.4 Disassemble the connections

Remove pipe no. 2 on the high-temperature side
Remove pipe no. 3 on the low-temperature side
6.5 Remove the air duct from the mixture cooler.

No. 4: Undo the bolts between the mixture cooler and
air duct
No. 5: Undo the bolts between the air duct and
turbocharger flange
No. 6: Undo the bolts between the mixture cooler and

base plate
6.6 Remove the reversing chamber

Replace the two cap screws marked X with studs.
Remove the cap screws (they can be re-used)
Detach and remove the reversing chamber

Remove all the O-rings (qty. 4)
Remove the two studs
6.7 Fit the O-rings

Clean the O-ring grooves and sealing surfaces (remove
any deposits)
Smear the O-ring groove corners and a few areas
between them with high-temperature grease
Smear the O-rings with high-temperature grease as
well for ease of fitting.
The O-ring adhesive joints must be in the straight parts of the grooves, not at the corners! When fitting all
the O-rings check to ensure that they are not damaged.
Place O-ring, part number 75, in the groove in the
floating tube plate
Push O-ring, part number 76, over the floating tube

plate as far as the contact surface
Place O-rings, part numbers 70 and 71, in the O-ring

grooves in the tube plate
6.8 Mount the reversing chamber

Smear the O-ring groove in the chamber with high-
temperature grease
Screw in 4 studs at the locations marked X and Y

Mount the reversing chamber on the studs and
carefully slide it towards the tube plate.
Avoid contact between the reversing chamber and the tube plate/O-rings!
Use the special tool for centring the chambers
Grease all screws before screwing them in!

Use special tools for inserting and screwing the first 6
screws (1.1 to 1.6 in the figure).
Just start the screws on the first few threads at first!
Take care when working, otherwise the O-rings will be damaged!
6.9 Fasten the reversing chamber

Tighten the first 4 screws (1.1 to 1.4) by hand using an
Allen key.
There is still no contact between the chamber and the
tube plate (O-ring 76 prevents this)
Tighten the 4 screws (1.1 to 1-4) with a ratchet until

there is contact between the chamber and tube plate
Remove the 4 studs
Tighten all the screws by hand in the order 1 to 8
Tighten all the screws by a further turn with a torque
of 75 Nm in the order 1 to 8
Fully tighten all the screws with a torque of 75 Nm in
the order 1 to 8
Screw in the M 18 x 1.5 screw plugs and copper joint
rings in the chamber (qty. 5).
6.10 Water pressure test

The two stages of the cooler (LT and HT) must be tested independently of each other.
Seal off all the water connections of both stages with
blanking plates and gaskets
If the screw plugs have been fitted, remove them and
replace them with GE ball cocks (open), if available.
(Air must be able to escape during filling)
Connect the ball cock and pressure gauge (40 bar) to
the two pressure plates of one stage
(use Teflon tape as a gasket if necessary).
6.11 Fit the water pump

Fill the cooler with the vent openings open
When water comes out of the vent openings, close
them with the screw plugs or close the ball cocks.
Bring the pressure to 24 bar and close the water circuit
with the valve
The pressure test will take at least 30 minutes. Check
the pressure gauge during this period
If air is still present in the cooler, the pressure will drop
by 2 to 3 bar. If this happens, open the valve briefly to
bring the pressure back up to 24 bar
If the pressure continues to drop, there is a leak somewhere. If there is a leak, the GEA
"Maschinenkühltechnik" (engine cooling) department must be informed.
When the test pressure has been reached, wipe the outer surfaces of the cooler dry.
Leaks can be located by the discharge of water drops.
After 30 minutes, drain the cooler through the valve.
The cooler is pressurised!
Remove the pressure plates and gaskets.
If no leaks have occurred, the cooler can be returned to operation.
6.12 Mount the mixture cooler, air duct and water piping
▪ Mount the mixture cooler on the base plate
▪ Mount the air duct on the mixture cooler and turbocharger
▪ Mount the high-temperature piping (outward and return flows) on the mixture cooler
▪ Mount the low-temperature piping (outward and return flows) on the mixture cooler
6.13 Fill the system with water

Fill the system with water using the standard procedure
The water quality must comply with Technical Instructions 1000-0200, TI 1000-0201 and TI 1000-0204.
6.14 Final inspection

Step 1: Visual inspection of the connections and installation
Step 2: Close all the drain valves before starting the engine
Step 3: Start the engine
Step 4: Visual inspection of the water-side connections for leaks
6.15 Other documents required

▪ TI 1100-0105: Engine shutdown
▪ TI 2300-0005: Safety regulations [⇨ TA 2300-0005, Page 1]
▪ Link to TI 2300-0010 Guidelines for using the LOTO kit [⇨ TA 2300-0010, Page 1]
Engine – cooling water circuit / Mixture recirculating water
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 Filling pressure*) Operating pressure*)
expansion tank when cold when warm (result**)
J 208 GS – J 320 GS 0.6 bar (gauge pressure) 0.9 bar (gauge 1.5 bar (gauge pressure)
pressure)
J 412 GS – J 424 GS 0.6 bar (gauge pressure) 0.9 bar (gauge 1.5 bar (gauge pressure)
pressure)
type 6 E module 0.8 bar (gauge pressure) 1.1 bar (gauge 1.5 bar (gauge pressure)
pressure)
type 6 F/G/H module 1.7 bar (gauge pressure) 2.1 bar (gauge 2,5 bar(ü)
pressure)
type 6 F/G/H generating set 1.7 bar (gauge pressure) 2.1 bar (gauge 2,5 bar(ü)
pressure)
Author: Doku./Bilek Responsible: Madl Wolfgang, Lang Jürgen, Thumer Mathias Release date: 06/12/2013
Modules Prepressure*) in the Filling pressure*) Operating pressure*)

expansion tank when cold when warm (result**)
type 6 F/G generating set 2.0 bar (gauge pressure) 2.5 bar (gauge 3.0 bar (gauge pressure)
„Hot Country“ pressure)
*)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.
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.
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
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:
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
background) represents the coarse setting (1 to 4), the bottom number (red background) represents the
decimal setting (1 to 9).
The differential temperature is measured between the engine inlet
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
section 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 11/15 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.
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.
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
correctly 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)
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
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 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
background) represents the coarse setting (1 to 8), the bottom number (red background) represents the
decimal setting (1 to 9).
▪ 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.
SprungMarke!!!36028797066269323
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.
Maintena Operating hours Date Signature

nce at Oh Number of starts Mechanic Operator
< 100 Oh
Number of starts
1000 Oh
Number of starts
2000 Oh
Number of starts
3000 Oh
Number of starts
4000 Oh
Number of starts
5000 Oh
Number of starts
6000 Oh
Number of starts
7000 Oh
Number of starts
8000 Oh
Number of starts
9000 Oh
Number of starts
10000 Oh
Number of starts
11000 Oh
Number of starts
12000 Oh
Number of starts
13000 Oh
Number of starts
14000 Oh
Number of starts
15000 Oh
Number of starts
16000 Oh
Number of starts
17000 Oh
5.1
of warranty claims.

Number of starts
18000 Oh
Number of starts
19000 Oh
Number of starts
20000 Oh
Number of starts
21000 Oh
Number of starts
22000 Oh
Number of starts
23000 Oh
Number of starts
24000 Oh
Number of starts
25000 Oh
Number of starts
26000 Oh
Number of starts
27000 Oh
Number of starts
28000 Oh
Number of starts
29000 Oh
Number of starts
30000 Oh
Number of starts
31000 Oh
Number of starts
32000 Oh
Number of starts
33000 Oh
Number of starts
34000 Oh
Number of starts
35000 Oh
5.1
of warranty claims.

Number of starts
36000 Oh
Number of starts
37000 Oh
Number of starts
38000 Oh
Number of starts
39000 Oh
Number of starts
40000 Oh
Number of starts
41000 Oh
Number of starts
42000 Oh
Number of starts
43000 Oh
Number of starts
44000 Oh
Number of starts
45000 Oh
Number of starts
46000 Oh
Number of starts
47000 Oh
Number of starts
48000 Oh
Number of starts
49000 Oh
Number of starts
50000 Oh
Number of starts
51000 Oh
Number of starts
52000 Oh
Number of starts
53000 Oh
5.1
of warranty claims.

Number of starts
54000 Oh
Number of starts
55000 Oh
Number of starts
56000 Oh
Number of starts
57000 Oh
Number of starts
58000 Oh
Number of starts
59000 Oh
Number of starts
60000 Oh
Number of starts
After the overhaul following 60,000 operating hours, the maintenance work to be carried out is repeated
at the same interval periods.
6 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 A
value
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 - Mixture temperature °C
data: Boost pressure bar
Gas mixer position %
Gas quantity controller %
setting (optional)
Throttle valve position %
Author: Doku./Bilek Responsible: Dokumentation Release date: -
6.1
Operational data booklet
Operational value to be read Unit Mo. Tue. Wed. Thu. Fr. Sa. Su.
Turbocharger bypass %
position
Operating hours h
Start counter
Exhaust gas temperature (after heat °C
exchanger)
Gas pressure constant ±3 mbar/30 s yes/no
deviation?
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
confirmed:
*) if included within GE Jenbacher‘s scope of supply!

**) for type 6 engines only!
Operational dataE 0101
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: -
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: -
Operational dataE 0103 a
Operational data - Heat exchanger mixture/water
Mixture pressure at Differential pressure Date Recorded by

Inspection intervals intake
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 dataE 0103 d
Operational data Pre-combustion chamber gas differential pressure
Gas pressure in the pre- Pre-combustion Date Checked by...

Inspection intervals combustion chamber gas chamber gas
line differential pressure
Boost pressure
(displayed by DIA.NE)

2000 p1=______mbar ∆p =_____mbar

p2=______mbar
4000 p1=______mbar ∆p =_____mbar
p2=______mbar
6000 p1=______mbar ∆p =_____mbar
p2=______mbar
8000 p1=______mbar ∆p =_____mbar
p2=______mbar
10000 p1=______mbar ∆p =_____mbar
p2=______mbar
12000 p1=______mbar ∆p =_____mbar
p2=______mbar
14000 p1=______mbar ∆p =_____mbar
p2=______mbar
16000 p1=______mbar ∆p =_____mbar
p2=______mbar
18000 p1=______mbar ∆p =_____mbar
p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
22000 p1=______mbar ∆p =_____mbar
p2=______mbar
24000 p1=______mbar ∆p =_____mbar
p2=______mbar
26000 p1=______mbar ∆p =_____mbar
p2=______mbar
28000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
32000 p1=______mbar ∆p =_____mbar
p2=______mbar
34000 p1=______mbar ∆p =_____mbar
Operational dataE 0103 d
Operational data Pre-combustion chamber gas differential pressure
Gas pressure in the pre- Pre-combustion Date Checked by...

Inspection intervals combustion chamber gas chamber gas
line differential pressure
Boost pressure
(displayed by DIA.NE)
p2=______mbar
36000 p1=______mbar ∆p =_____mbar
p2=______mbar
38000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
42000 p1=______mbar ∆p =_____mbar
p2=______mbar
44000 p1=______mbar ∆p =_____mbar
p2=______mbar
46000 p1=______mbar ∆p =_____mbar
p2=______mbar
48000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
52000 p1=______mbar ∆p =_____mbar
p2=______mbar
54000 p1=______mbar ∆p =_____mbar
p2=______mbar
56000 p1=______mbar ∆p =_____mbar
p2=______mbar
58000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar
Operational dataE 0103 g
Operational data - Flame trap Mixture cooler
Mixture pressure at Differential pressure Date Recorded by

Inspection intervals intake
Mixture pressure at
outlet

10000 p1=______mbar ∆p =_____mbar

p2=______mbar
20000 p1=______mbar ∆p =_____mbar
p2=______mbar
30000 p1=______mbar ∆p =_____mbar
p2=______mbar
40000 p1=______mbar ∆p =_____mbar
p2=______mbar
50000 p1=______mbar ∆p =_____mbar
p2=______mbar
60000 p1=______mbar ∆p =_____mbar
p2=______mbar
Author: Doku./Bilek Responsible: Technology Thermodynamics Release date: 01/06/2010
Operational data – spark plugs
Spark plug type ________________ Optimal electrode distance __________mm

Ignition voltage requirement, preset range from: _________kV to: _________kV
(see IW 0309 M0)
Calendar week: ___ Calendar week: ___ Calendar week: ___ Calendar week: ___
Operating hours: ___ Operating hours: ___ Operating hours: ___ Operating hours: ___
Cyl. Ignition voltage Ignition voltage Ignition voltage Ignition voltage
requirement requirement requirement requirement
ACTUAL after ACTUAL after ACTUAL after ACTUAL after
Value adjustment Value adjustment Value adjustment Value adjustment
or or or 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 Ignition voltage Ignition voltage Ignition voltage
requirement requirement requirement requirement
ACTUAL Value after ACTUAL after ACTUAL after ACTUAL after
adjustment Value adjustment Value adjustmen Value adjustment
or or t or 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
SprungMarke!!!9007199525280651
24
Operational data - Valve-stem projection
AV=Outlet valve IV = Inlet valve
Cyl. Operating hours: ______ Operating hours: ______ Operating hours: ______
Valve-stem projection (mm) Valve-stem projection (mm) Valve-stem projection (mm)
OV IV OV IV OV IV
left right left right left right left right left right left right
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Operational data - Valve-stem projection
AV=Outlet valve IV = Inlet valve
Cyl. Operating hours: ______ Operating hours: ______ Operating hours: ______
Valve-stem projection (mm) Valve-stem projection (mm) Valve-stem projection (mm)
OV IV OV IV OV IV
left right left right left right left right left right left right
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Operational data - crankcase ventilation system
Value to be measured Measured value Measured value Measured value

Operating hours ____________ h ____________ h ____________ h
Engine starts ____________ ____________ ____________
Crankcase pressure on DIA.NE [PCRC-DIANE] ____________ mbar ____________ mbar ____________ mbar
Crankcase pressure manually [PCRC-manual] ____________ mbar ____________ mbar ____________ mbar
Blow-by filter inlet pressure [PBBF in] ____________ mbar ____________ mbar ____________ mbar
Blow-by filter outlet pressure [PBBF out] ____________ mbar ____________ mbar ____________ mbar
Differential pressure across the filter ____________ mbar ____________ mbar ____________ mbar
(PBBF in – PBBF out) [∆filter]
Difference pressure across the preliminary ____________ mbar ____________ mbar ____________ mbar
filter
(PCRC – PBBF in) [∆prelim. filt.]
Filter replacement (Yes/No) YES ❑ NO ❑ YES ❑ NO ❑ YES ❑ NO ❑
Blow-by volumetric flow [VBB] ____________ l/min ____________ l/min ____________ l/min
Operating hours since last filter replacement ____________ h ____________ h ____________ h
Date
Signature
Remarks

Operating hours ____________ h ____________ h ____________ h
Engine starts ____________ ____________ ____________
Crankcase pressure on DIA.NE [PCRC-DIANE] ____________ mbar ____________ mbar ____________ mbar
Crankcase pressure manually [PCRC-manual] ____________ mbar ____________ mbar ____________ mbar
Blow-by filter inlet pressure [PBBF in] ____________ mbar ____________ mbar ____________ mbar
Blow-by filter outlet pressure [PBBF out] ____________ mbar ____________ mbar ____________ mbar
Differential pressure across the filter ____________ mbar ____________ mbar ____________ mbar
(PBBF in – PBBF out) [∆filter]
Difference pressure across the preliminary ____________ mbar ____________ mbar ____________ mbar
filter
(PCRC – PBBF in) [∆prelim. filt.]
Filter replacement (Yes/No) YES ❑ NO ❑ YES ❑ NO ❑ YES ❑ NO ❑
Blow-by volumetric flow [VBB] ____________ l/min ____________ l/min ____________ l/min
Operating hours since last filter replacement ____________ h ____________ h ____________ h
Date
Signature
Operational data - crankcase ventilation system

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

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

Author: Doku./Bilek Responsible: TET/ Fuerhapter Markus Release date: 25/10/2010
Operational dataE 8079 6
Data collection for flexibly-mounted coupling housing
Gap width: Set point value: 10mm +/- 2mm Measure the gap width at 4 poinrs around the
circumference: A = 9 o'clock; B = 12 o'clock; C = 3
o'clock, D = 6 o'clock.
Inspection intervals Gap width Date Checked by...
before initial A = _______mm C = _______mm

commissioning B = _______mm D = _______mm
4000 A = _______mm C = _______mm

B = _______mm D = _______mm
8000 A = _______mm C = _______mm
B = _______mm D = _______mm
12000 A = _______mm C = _______mm
B = _______mm D = _______mm
16000 A = _______mm C = _______mm
B = _______mm D = _______mm
20000 A = _______mm C = _______mm
B = _______mm D = _______mm
24000 A = _______mm C = _______mm
B = _______mm D = _______mm
28000 A = _______mm C = _______mm
B = _______mm D = _______mm
32000 A = _______mm C = _______mm
B = _______mm D = _______mm
36000 A = _______mm C = _______mm
B = _______mm D = _______mm
40000 A = _______mm C = _______mm
B = _______mm D = _______mm
Author: Doku./Bilek Responsible: Field Engineers HQ/Hummel Martin Release date: 15/11/2013
Operational dataE 8079 6
Data collection for flexibly-mounted coupling housing
Inspection intervals Gap width Date Checked by...

44000 A = _______mm C = _______mm
B = _______mm D = _______mm
48000 A = _______mm C = _______mm
B = _______mm D = _______mm
52000 A = _______mm C = _______mm
B = _______mm D = _______mm
56000 A = _______mm C = _______mm
B = _______mm D = _______mm
60000 A = _______mm C = _______mm
B = _______mm D = _______mm
*) A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
A = _______mm C = _______mm
B = _______mm D = _______mm
*) For repairs outside regular maintenance.
SprungMarke!!!27021598290419979
Author: Doku./Bilek Responsible: Field Engineers HQ/Hummel Martin Release date: 15/11/2013
7 Initial commissioning data sheet
7.1
Initial commissioning data sheet
SprungMarke!!!45035997886265611

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JMS 620 GS-N.

INNOVATIVE ENERGY 1X620F

© GE Jenbacher GmbH & Co OG

Original operating instructions

GE proprietary information: CONFIDENTIAL

© GE Jenbacher GmbH & Co OG, 2013-10

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

Piston/Piston cooling...................................................................................................................................................................... W 8047 M0

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

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

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

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