ST-245

Service Technician Instruction

Cylinder head - type 6 engines

Conversion of an engine from version "H" cylinder heads to version "F" cylinder heads

© INNIO Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach, Austria
www.innio.com
 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

1 Scope ..................................................................................................................................... 1
2 Purpose.................................................................................................................................. 1
3 Additional information.......................................................................................................... 1
4 General notes ........................................................................................................................ 2
4.1 Requirements for the replacement of cylinder heads from version "H" to "F"......................... 2
4.2 Required tasks for converting cylinder heads from version "H" to "F" .................................... 2
5 Converting the cylinder head from "H" to version "F"...................................................... 3
5.1 Removing "H" cylinder heads.................................................................................................. 3
5.2 Replacing the central prechamber gas orifice......................................................................... 3
5.3 Removing the plug from the oil return flow hole...................................................................... 4
5.4 Mounting "F" cylinder heads ................................................................................................... 5
5.5 Replacing the peripheral prechamber gas orifice ................................................................... 6
5.6 Installing the prechamber gas pipe ......................................................................................... 7
5.7 Adjusting the prechamber gas supply pressure ...................................................................... 7
5.8 Mounting the cooling water pipe ............................................................................................. 7
5.9 Installation of prechamber, spark plug socket and prechamber gas valve ............................. 7
5.10 Mounting the inlet valve rocker arm ........................................................................................ 8
5.11 Mounting the exhaust valve rocker arm .................................................................................. 8
5.12 Mounting the cylinder head cover and spark plug connector.................................................. 8
5.13 Setting parameters in DIA.NE ................................................................................................. 8
6 Revision code........................................................................................................................ 9
The target recipients of this document are:
Service partners, commissioning partners, subsidiaries/branches, Jenbach location
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1 Scope
This Service Technician Instruction (ST) applies to the following Jenbacher Gas Engines:
• Type 6 engines, versions F, G, H and J

2 Purpose
This Service Technician Instruction (ST) describes the work steps for converting an engine with cylinder
heads of the "H" version to cylinder heads of the "F" version. This conversion may only be carried out
after the approval by your INNIO service manager.

The INNIO service manager will provide the required parts list for the conversion and have the
documentation (e.g. spare parts catalogue) updated.

3 Additional information
When working on Jenbacher Engines, all locally applicable regulations must be observed.

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

Index: 1 Page No.: 1/9
INNIO proprietary information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

Relevant documents:
• FSM.600.00.310 - "F" cylinder head replacement
• FSM.600.00.320 - "H" cylinder head replacement
• FSM.600.14.301 - Prechamber “F” cylinder head
• FSM.600.14.302 - Prechamber "H" cylinder head
• ST-099 – Prechamber gas valves, spark plug sockets and prechambers - General view
• TA 1100-0111 - General Conditions - Operation and Maintenance
• TA 1400-0179 - Jib crane for removing cylinder heads on type 6 engines
• TA 1503-0047 - Engine adjustment instruction - Type 6 engines (DIA.NE XT)
• TA 1902-0228E/F/J - Tightening torques J 6..GS-E/F/J
• TA 1902-228G/H/K - Tightening torques J 624 G/H/K
• TA 2110-0023 - Prechamber differential pressure monitoring and prechamber gas pressure
monitoring - Type 6 engines
• TA 2300-0001 - Employee Protection
• TA 2300-0005 - Safety Regulations
• W 0501 M6 - Prechamber/prechamber gas valve

Abbreviations used:
CMS Content Management System
FSM Field Service Manual
ST Service Technician Instruction
SPATSL Spare Parts List
TA Technical Instruction
W Maintenance Instruction

4 General notes

4.1 Requirements for the replacement of cylinder heads from version "H" to "F"
• ALL cylinders of the engine must be equipped with "F" cylinder heads, i.e. any mixed installation of
"F" and "H" cylinder heads is NOT acceptable.

4.2 Required tasks for converting cylinder heads from version "H" to "F"
The following work steps are required to convert type 6 engines with cylinder heads of version "H" to "F":
1. Remove "H" cylinder heads from the engine.
2. Replace the central prechamber gas orifice.
3. Remove the plug from the oil return flow hole.
4. Mount "F" cylinder heads.
5. Replace the peripheral prechamber gas orifice.
6. Install the prechamber gas pipe.
7. Adjust the prechamber gas supply pressure.
8. Mounting the cooling water pipe
9. Mount the prechamber and spark plug socket.
10. Mount the inlet valve rocker arm.

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

Index: 1 Page No.: 2/9
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 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

11. Mount the exhaust valve rocker arm.

12. Mount the cylinder head cover and spark plug connector.
13. Set parameters in DIA.NE & LEANOX.
14. Update engine documentation and spare parts catalogue.

5 Converting the cylinder head from "H" to version "F"

5.1 Removing "H" cylinder heads

Remove "H" cylinder heads according to FSM.600.00.320.

Use the lifting gear according to TA 1400-0179.

5.2 Replacing the central prechamber gas orifice

The conversion to "F" cylinder heads requires the replacement of the central prechamber gas orifice.
Depending on the camshaft installed in the corresponding engine, the central prechamber gas orifice may
have a different part number. The only difference is the orifice diameter.
Screw the central prechamber gas orifice ① provided with a sealing ring into the sensor block as shown
in Figure 1.

For more information on the central prechamber gas orifice, see TA 2110-0023.

The correct hole diameter of the central prechamber gas orifice is important for the prechamber gas valve
and for the service life of the spark plugs.

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

Index: 1 Page No.: 3/9
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 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

Figure 1: Adapter plate with pressure sensors and central prechamber gas orifice
① Central prechamber gas orifice with sealing ring

5.3 Removing the plug from the oil return flow hole
On crankcases with "H" cylinder heads, a plug ① is inserted in the top right oil return flow hole. When
converting cylinder heads to the "F" version, this plug must be removed so that the oil can flow back into
the oil pan.
To remove the plug from the crankcase hole, use the slide hammer PN 9004382 together with the
adapter PN 9036460. The plug has an M12 female thread. Mount the tool on the thread as shown in
Figure 3 and carefully remove the plug.

Clean the top of the crankcase before removing the plug to prevent dust and dirt particles from entering
the oil system!

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

Index: 1 Page No.: 4/9
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 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

Figure 2: Mounted connection plug - view with mounted "H" cylinder head

Figure 3: Removing the plug

① Plug ② Oil return flow hole
③ Cooling water hole

5.4 Mounting "F" cylinder heads

Before installing the cylinder heads make sure that all sealing surfaces are clean and free of deposits.
Place the cylinder head gasket ① on the crankcase according to Figure 4.

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

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 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

Figure 4: Installing the cylinder head gasket

① Cylinder head gasket

Install the "F" cylinder heads according to FSM.600.00.310.

If lifting the cylinder heads is not possible due to local conditions, use a jib crane that can be mounted
directly on the engine.

The use of this crane is described in TA 1400-0179.

5.5 Replacing the peripheral prechamber gas orifice

Remove the existing gas orifice ① and replace it with the orifice suitable for "F" cylinder heads. The
required diameter of the orifice is 0.9 mm.

Figure 5: Position of the peripheral prechamber gas orifice

① Position of the peripheral prechamber gas orifice ② Rail
③ Prechamber gas pipe

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

Index: 1 Page No.: 6/9
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 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

5.6 Installing the prechamber gas pipe

Connect the peripheral prechamber gas orifice and the prechamber gas valve to the pipe ③ according to
Figure 5.

5.7 Adjusting the prechamber gas supply pressure

As part of the retrofit operation, the prechamber gas pressure regulator must be set to 50 mbar differential
pressure. Details can be found in TA 1503-0047.
To adjust the differential pressure, it may be necessary to modify the prechamber gas pressure regulator
(replacement of the regulator spring) or, in rare cases, to replace the prechamber gas pressure regulator.
For more information on the pressure regulators used and part numbers, see ST-099.

For further details and parameter settings, see TA 2110-0023.

5.8 Mounting the cooling water pipe

Remove the existing cooling water pipe and mount the cooling water pipe (1) suitable for "F" cylinder
heads, see Figure 6.

Figure 6: Mounting the cooling water pipe

① Cooling water pipe ② Flat gasket

5.9 Installation of prechamber, spark plug socket and prechamber gas valve
When converting the cylinder heads from version "H" to "F", the spark plug socket, prechamber and
prechamber gas valve must be replaced according to ST-099.
For the installation of the prechamber and the spark plug socket see FSM.600.14.301.

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

Index: 1 Page No.: 7/9
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 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

After completion, mount the prechamber gas valve according to W 0501 M6.

5.10 Mounting the inlet valve rocker arm

To mount the inlet valve rocker arm, follow the steps in FSM.600.00.310.
The corresponding tightening torques are specified in TA 1902-0228.

5.11 Mounting the exhaust valve rocker arm

The installation process of the exhaust valve rocker arm is described in FSM.600.00.310.
The corresponding tightening torques are specified in TA 1902-0228.

5.12 Mounting the cylinder head cover and spark plug connector
When converting to "F" cylinder heads, the cylinder head covers must be replaced. The spark plug
connector can be reused if the connector was installed with PN 657541.

See FSM.600.00.310 for installation details.

5.13 Setting parameters in DIA.NE

The following table lists the parameter settings required for conversion to "F" cylinder heads.

Table 1: DIA.NE settings

Parameter tree structure Parameter Type 6xx-F/J & J624 G Type 624-H/K
→ Gas Maximum point 1 See Technical Instruction TA 2110-0023 for parameter
→ Prechamber differential specifications
pressure
→ Limit differential pressure
→ Gas Maximum point 2
→ Prechamber differential
pressure
→ Limit differential pressure
→ Gas Maximum point 1
→ Prechamber differential
pressure
→ Limit differential pressure
→ Gas Maximum point 2
→ Prechamber differential
pressure
→ Limit differential pressure
→ Gas Reduction from 1500 mbar to 1300 mbar
→ Prechamber differential
pressure
→ Switching point, prechamber
gas maximum

Check parameters according to TA 1503-0047 and TA 2110-023 and set them according to the
configuration.

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

Index: 1 Page No.: 8/9
INNIO proprietary information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
 ST-245
Cylinder head - type 6 engines
Conversion of an engine from version "H" cylinder heads to version "F" cylinder
heads

Set LEANOX.

6 Revision code
Revision history
Index Date Description / Revision summary

SprungMarke!!!74680044299
1 21/08/2020 First version of this document

Author(s): Bauer C. Responsible: Fürhapter M. Release date: 21/08/2020

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