Jenbacher
1.1 Sections of the GE Jenbacher Product Documentation
Documentation
Description - Operation Operation Operation of of the system system
•
Fault rectification
•
Description Description of of the engine engine and and the system
•
Choice Cho ice of fuels
•
Technical instructions 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 Gathering operational data data
•
Spare Parts List Selecting the required spare part
•
Ordering the spare part
•
Allocating llocating the spare part part
•
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Schartner
Checked:
Dokumentation Dokumentation
EN
1_1___BW_BRall_EN.doc
Index:
b1 b1
Date: 2006-02 2006-02 Page - No.: 1 / 1 1
Jenbacher
1.2 Key to Symbols
Documentation
The following symbols are used to highlight certain text passages in your GE Jenbacher product 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.
Assemble Assemble the component component as described. described.
Inspect Inspect the components or operating materials as described
Tightening Torque Tighten the nut or bolt to the specified tightening torque. 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.
Information Important information or important note.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Velik Doku./Velik
Checked:
Dokumentation Dokumentation
EN
1_2___BW_BRall_EN.doc
Index:
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Date: 2007-03 2007-03 Page - No.: 1 / 1 1
Jenbacher
1.3
Documentation
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 t he crank case.
Engine type Motor Typ Moteur modèle Engine no. Motor Nr. Moteur numèro kW HP kW HP Speed Drehzahl Nombre de tours
-1
min
rpm kg lbs
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).
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
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type:
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Schartner
Checked:
Dokumentation Dokumentation
Date: 2005-01 2005-01
1_3___BW_BRall_EN.doc
Index:
e
age - No.: 1 / 3 3
EN
Jenbacher
1.3
Documentation
Type Plate and Type Designation of GE Jenbacher Products
2. Type designation: 2.1
Engine type designation: Term Manufacturer Type
No. of cylinders *)
Mode of operation (e.g.)
Abbreviation J 1 2 3 4 6 6 8 12 16 20 GS
Key to abbreviation GE Jenbacher
Example J 320 GS C05
J 320 GS C05
6 cylinder in-line engine 8 cylinder in-line engine 12 cylinder V-engine 16 cylinder V- engine 20 cylinder V- engine Gas engine, turbocharged
GS C05 J 320 320 GS
GSH
Gas engine, turbocharged and hot cooled Design First design A B, C, D, E ... Modified designs Version (e.g.) 02 Natural gas; ½ TA-Luft Natural gas; TA-Luft 05 27 Biogas; TA-Luft *) Exception: J 156 GS 6 cylinder in-line engine
J 320 GS C05 GS C05 J 320 GS C05
J 320 GS C05 C05
Mode of operation operation Design Manufacturer
Version
J 3 20 GS C 05 Series Series No. of cylinders
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type:
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Schartner
Checked:
Dokumentation Dokumentation
Date: 2005-01 2005-01
1_3___BW_BRall_EN.doc
Index:
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age - No.: 2 / 3 3
EN
2.2
Jenbacher
1.3
Documentation
Type Plate and Type Designation of GE Jenbacher Products
Module type designation: Term Manufacturer Unit type (e.g.)
Abbreviation J M
G C Installation type S C Type 1 2 3 4 6 No. of cylinders *) 06 08 12 16 20 Mode of operation (e.g.) GS GSH Type of fuel gas
Key to abbreviation GE Jenbacher Co-generation plant
Example JMS 320 GS-N.LC
Generator set Compressor set stationary in a container
JMS 320 GS-N.LC JMS 320 GS-N.LC JMS
JMS 320 GS-N.LC
N B L
6 cylinder in-line engine 8 cylinder in-line engine 12 cylinder V-engine 16 cylinder V-engine 20 cylinder V-engine Gas engine, turbocharged Gas engine, turbocharged and hot cooled Natural gas Biogas Landfill gas
P
Propane gas
S
Special gas
Natural gas /biogas (2-gas operation) Exhaust gas purification L LEANOX engine LC LEANOX engine with oxidationtype catalytic converter 3-way catalytic converter C *) Exception: J 156 GS 6 cylinder in-line engine
JMS 320 320 GS-N.LC GS-N.LC
JMS 320 GS-N.LC GS-N.LC
JMS 320 GS-N.LC
N/B
JMS 320 GS-N. GS-N.LC LC
Mode of operation operation
Installation type type
Type of fuel gas
Unit type type
Alternative type of fuel gas gas
Manufacturer
J M S 3 20 GS - N /B . LC Type Type Exhaust gas purification
No. of cylinders Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type:
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Schartner
Checked:
Dokumentation Dokumentation
Date: 2005-01 2005-01
1_3___BW_BRall_EN.doc
Index:
e
age - No.: 3 / 3 3
EN
Jenbacher
1.4 GE Jenbacher Web Portal
Documentation
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 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 Jenbacher customer, we are offering you the possibility of increased access rights for which you only need to register online.
Registration:
Click on "registrieren "registrieren"" (registering) and fill in the requested personal data. It is very important to also fill in your regular GE Jenbacher contact person, as he or she is responsible for granting you the increased access rights. Once you have registered, you will immediately be sent an email containing the web portal link. You will then be able to enter the required password. At this stage, you do not have increased access right 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" login" to enter your personal profile, which you may edit yourself.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type:
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Doku./Velik Doku./Velik
Checked:
VSB/Steinberger
1_4___BW_BRall_EN.doc
Index:
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Issued:
EN
Date: 2007-01 2007-01 Page - No.: 1 / 3 3
Jenbacher
1.4 GE Jenbacher Web Portal
Documentation
As soon as your your increased access rights ha have ve been confirm confirmed, ed, you can enter enter the increased increased access web portal below:
Menu bullets – Tips: “Products + Services” Services” -> “Products “Products 50/60 Hz ” menu Viewing and downloading drawings and diagrams for various engine types and applications.
•
“Products + Services” -> “Service” -> “Service Database” Database ” menu Online access to all published Service Bulletins and therefore access to all service-related changes and innovations.
•
“Experts Know-How ” menu Comprehensive information on co-generation, fuel gas conditioning, exhaust-gas treatment, etc.
•
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type:
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Doku./Velik Doku./Velik
Checked:
VSB/Steinberger
1_4___BW_BRall_EN.doc
Index:
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Issued:
EN
Date: 2007-01 2007-01 Page - No.: 2 / 3 3
Jenbacher
1.4 GE Jenbacher Web Portal
Documentation
For security reasons, you must change your password every 6 months. You will be sent an email reminder containing a link to your personal profile. To extend your increased excess rights for another 6 months, just overwrite your existing password in your “know-how profile”, repeat the password and click on “send “send ”. ”.
After you have registered, you will receive a regular Newsletter. If you do not wish to receive it, click on “No No“. “. If you have any questions, please contact your regular GE Jenbacher contact person.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type:
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Velik Doku./Velik
Checked:
VSB/Steinberger
1_4___BW_BRall_EN.doc
Index:
-
EN
Date: 2007-01 2007-01 Page - No.: 3 / 3 3
Jenbacher
1.5 Your Views Are Important!
Documentation
Dear Reader, The purpose of this product documentation documentation is twofold. Firstly, it should ensure risk-free operatio operation n and maintenance of your GE Jenbacher system. Secondly, this product documentation should serve as a reference manual covering technical data, boundary conditions 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 working 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 in enough depth?)
Any additional comments:
Rating:
1 = excellent
2 = good
3 = satisfactory
4 = adequate
5 = inadequate
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Schartner
Checked:
Dokumentation Dokumentation
1_5___BW_BRall_EN.doc
Index:
b
EN
Date: 2002-02 2002-02 Page - No.: 1 / 1 1
Jenbacher
1.6 Service - and Sales partners
Documentation
GE Jenbacher GmbH & Co OHG Achenseestraße Achenseestr aße 1 - 3, A-6200 A-6200 Jenbach Jenbach Tel.: +43 5244 600-0, Telefax: +43 5244 600 548 e-mail:
[email protected] [email protected]
AT
GE Jenbacher Servicecenter Wien Am Concorde-Park Concorde-Park 1/D2, A-2320 A-2320 Schwechat Schwechat Tel.: +43 1 707 95 10, Telefax: +43 1 707 93 28 e-mail: jes.wien@g e-mail: jes.wien@gejenbache ejenbacher.com r.com GE Jenbacher Servicecenterr Villach Servicecente Magdalener Straße 81, 9506 Villach Tel.: +43 4242 431 124, Telefax: +43 4242 431 124 5 e-mail:
[email protected] Power Solutions Vertriebs und Handels GmbH Eduard-Keil-Gasse 22 8041 Graz Tel.: +43 676 535 14 44 or + 7 495 935 78 35 e-mail:
[email protected] AE
United Arab Emirates International Internation al Offices GEII Jenbacher Sales UAE Office G01, Bldg. 18, Dubai Internet City, Dubai Tel.: +971 4 4296570, Telefax: +971 4 429 6105 e-mail: jenbacher e-mail: jenbacher.middleeast
[email protected] @ge.com AU
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:
[email protected] [email protected] www: http://www.clarke-energy.com BD
ORIENT Energy Systems Ltd. th 5 floor, Hosna Center 106, Gulshan Avenue Dhaka – 1212, Bangladesch Tel.: +880 173 047776, +880 288 61638, +880 288 57355, Telefax: +880 288 626530 e-mail:
[email protected] [email protected]
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 1 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
BE
Sales Representative Ecogen Energy Systems bvba Vaart Rechteroever 225 B-9800 Deinze Tel.: +32 938 64860, Telefax: + +32 938 61134
[email protected] .be e-mail: jd@ecogen e-mail: BG
Jenbacher Sales Bulgaria Office 419B, WTC Interpred 36, Dragan Tsankov Blvd. 1040 Sofia Tel.: +359 2 971 4390, Telefax: + 359 2 971 4384 e-mail: jenbacher.b e-mail: jenbacher.bulgaria@ge
[email protected] .com CA
Integrated Power Systems dba Diesel Allison Canada East (Ontario, Quebec, Quebec, New Brunswick, Nova Scotia) 1 Moyal Court Concord, Ontario L4K 4R8 Tel.(Sales):: +1 416 804 2203, Tel.(Service): +1 514 636 0680 Telefax: +1 416 352 5868 Tel.(Sales)
[email protected] e-mail:
[email protected] Integrated Power Systems dba Waterous DDA (British Columbia, Alberta, Sask. Manitoba) 10025-51 Avenue Edmonton Alberta T6E T6E 0A8 Tel.: +1 780 437 8271, Telefax: +1 780 504 0255 e-mail:
[email protected] [email protected] CH
IWK Integrierte Wärme und Kraft AG (Sales) Allmendstrasse Allmendstra sse 7, Ch-6061 Ch-6061 Sarnen, Sch Schweiz weiz Tel.: +41 522 260 730, Telefax: +41 522 230 733
[email protected] [email protected] e-mail: joachim.maie e-mail: www: http://www.iwk.ch http://www.iwk.ch IWK Integrierte Wärme und Kraft AG (Service) Schlosstalstrasse 210, Ch-8408 Winterthur, Schweiz Tel.: +41 522 260 730, Telefax: +41 522 260 733 e-mail:
[email protected] http://www.iwk.ch www: http://www.iwk.ch CS
MPD Trade Carli Caplina 7, 11000 Beograd, Serbia, SCG Telephone: +381 11 32 93 795 Telefax: +381 11 32 93 600 e-mail:
[email protected] e-mail: www: kogeneracija.co.yu kogeneracija.co.yu Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 2 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
CN
GE Energy Jenbacher Sales and Service China 8/F., The Lee Gardens 33 Hysan Avenue Causeway Bay Hong Kong, CN Tel.: +852 2100 6976, Telefax: +852 2100 6630 jenbacher a asiapacific
[email protected] @ge.com e-mail: jenbacher e-mail: Distributor/Service Distributor/S ervice Provider Jebsen & Co. (China) Ltd. 29/F., Lee Garden Two, 28 Yun Ping Road, Causeway Bay, Hong Kong, China Tel.: + 8610 6518 1188, Telefax: + 8610 6518 2066 e-mail:
[email protected] [email protected] http://www.jebsen.com www: http://www.jebsen.com 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:
[email protected] CZ
Klor GmbH Manesova 92, 12000 Praha 2 Tel.: +420 2 22 72 00 46, or -534, Telefax: +420 2 22 71 23 85 e-mail:
[email protected] www: http://www.jenbacher.cz JMP (Service) Plynarenska 1, 65702 Brno Tel.: +420 545 548 263, Telefax: +420 545 548 263 jaroslav.hruska@rwe
[email protected] -jmp.cz e-mail: jaroslav.hr e-mail: www: http://www.jmpas.cz DE
GE Jenbacher Germany Amselstraße 28 D-68307 Mannheim Tel.: +49 621 77094-0, Telefax: +49 621 77094-70 e-mail: jes.mannheim e-mail: jes.mannheim@gejenbac @gejenbacher.com her.com DK
GE Jenbacher Denmark Industrivej 19 DK-8881 Thorsø Tel.: +45 8 6966788, Telefax: +45 8 6967072 e-mail:
[email protected] [email protected]
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
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Date: 2007-03 2007-03 Page - No.: 3 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
EE
AS Filter Peterburi road 56 11415 Tallinn Tel.: +372 606 6666, Telefax: +372 606 6650 e-mail:
[email protected] [email protected] www: http://www.filter-group.com EG
Distributor / Service Provider Sakr Power Systems 17 Farid Symeka Street Heliopolis Cairo Tel.: + 202 6355561, Telefax: +202 6355569 e-mail:
[email protected] [email protected] EN
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
[email protected] e-mail:
[email protected] www: http://www.clarke-energy.com ES
GE Jenbacher Spain and Portugal Avda. del Camino Camino de lo Cortao, Cortao, 34 - Na Nave ve 8 E-28700 San Sebastián de los Reyes (Madrid) Tel.: +34 91 658 6800, Telefax: +34 91 652 2616 e-mail: jes.madrid@g e-mail: jes.madrid@gejenbach ejenbacher.com er.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.barcelon e-mail: jes.barcelona@gejenb
[email protected] acher.com FI
Höyrytys Oy Palokorvenkatu 2 FIN-04261 Kerava Tel.: +358 468 508 070, Telefax: +358 941 746 100 jorgen.barlund@hoyry
[email protected] tys.fi e-mail: jorgen.barlu e-mail:
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 4 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
FR
Clarke Energy France SAS Parc Eiffel Batiment A, 415 rue Claude Nicolas Ledoux BP 445 13592 Aix en Provence cedex 3 Frankreich Tel.: +33 442 907 575, Telefax: +33 442 907 576 e-mail:
[email protected] www: http://www.clarke-energy.com HU
GE Energy Jenbacher Hungary (Service) Kisret ut1 H-2112 Veresegyhaz Tel.: + 36 2858 7376 , Telefax: + 0036 2858 7491 e-mail: jenbacher.h e-mail: jenbacher.hungary@
[email protected] ge.com HR
TZV Gredelj d.o.o. (Service) Trnjanska Cesta 1, HR-10000 Zagreb Tel.: +385 1 6111 311, Telefax: +385 1 6110 121 e-mail:
[email protected] [email protected] ID
PT. Navigat Innovative Indonesia Gedung BRI II, JI.Jend.SudirmanKav44-46 Fl. 8,808, Jakarta Tel.: +62 21 572 4944, Telefax: +62 21 572 7614 e-mail: jakarta@n e-mail:
[email protected] avigat.nett IE
Distributor/Service Provider Distributor/Service Clarke Energy Ltd. Power House, Senator Point, South Boundary Road, Knowsley Industrial Park, Liverpool L33 7RR Telephone: + 44 151 546 4446, Fax: + 44 151 545 5714 e-mail:
[email protected] [email protected] www: http://www.clarke-energy.com Edina Power Plant (Service) 142A Slaney Close, Dublin Industrial Estate, Glasnevin, Dublin 11 Tel.: +353 1 830 7788, Telefax: +353 1 830 7422 e-mail:
[email protected] (Service) (Service) www: http://www.edinapower.com
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
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Date: 2007-03 2007-03 Page - No.: 5 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
IL
MADEI TAAS Industrial Controls Ltd. 21 Hamelacha St. Park-Afek, Rosh Haayn, 48091 Tel.: +972 3 9027174, Telefax: +972 3 9027176 e-mail:
[email protected] IN
Clarke Energy India Private Limited 'Shivkiran', Lane no.4, Dahanukar Colony, Kothrud Pune 411 038 Tel.: +91 20 30241704, Telefax: +91 20 30241800 e-mail:
[email protected] www: http://www.clarke-energy-india.com IT
GE Jenbacher Italy Via Crocioni, 46 / H, Casella Postale n. 41 Aperta I-37012 Bussolengo (VR) Tel.: +39 045 6760211, Telefax: +39 045 6766322 e-mail: jes.verona@ e-mail: jes.verona@gejenbach gejenbacher.com er.com IQ
Distributor / Service Provider Sakr Power Systems SAL Kartaba Road, Industrial Area Halata (Jbeil), Lebanon Tel.: +961 9 444888, Telefax: +961 3 811108
[email protected] e-mail:
[email protected] www: http://www.sakr.com http://www.sakr.com JP
GE Energy Jenbacher Sales and Service Japan Akasaka Park Park Bldg., 5-2-20 5-2-20 Akasaka, Minato-ku, Tokyo 107-6111 Tel.: + 81 3 3588 5208, Telefax: + 81 3 3589 3372 e-mail: jenbacher.ja e-mail:
[email protected] [email protected] om Hitachi Engineering Engineering & Services Co., Ldt. 2-2 Kandatacho Chiyoda-ku Tokyo 101-0046 Tel.: +81 3 5297 0514, Telefax: +81 3 5297 0517 e-mail:
[email protected]
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
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Date: 2007-03 2007-03 Page - No.: 6 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
Hitachi Engineering 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:
[email protected] 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:
[email protected] [email protected] JO
Distributor / Service Provider Sakr Power Systems SAL Kartaba Road, Industrial Area Halata (Jbeil), Lebanon Tel.: +961 9 444888, Telefax: +961 3 811108 e-mail:
[email protected] [email protected] http://www.sakr.com www: http://www.sakr.com KP
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:
[email protected] LB
Distributor / Service Provider Sakr Power Systems SAL Kartaba Road, Industrial Area Halata (Jbeil) Tel.: +961 9 444888, Telefax: +961 3 811108
[email protected] e-mail:
[email protected] http://www.sakr.com www: http://www.sakr.com LT
UAB Filter Draugystes Str. 19, 3031 Kaunas Tel.: +37 07 400 380, Telefax: +370 0872 1399 e-mail:
[email protected] [email protected] http://www.filter.lt www: http://www.filter.lt
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
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Date: 2007-03 2007-03 Page - No.: 7 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
LU
ENERGOLUX S.A. 12, rue de Bitbourg, L-1273 Luxembourg-Hamm Tel.: +352 43 42 43-1, Telefax: +352 43 68 33 e-mail:
[email protected] [email protected] LV
Filter SIA Aizkrauklesiela Aizkrauklesiel a 21, 1006 Riga Tel.: +371 755 6765, Telefax: +371 755 0224 e-mail:
[email protected] [email protected] www: http://www.filter-group.com MY
JD Power Systems Sdn. Bhd. No. 23, Jln Juruukur U1/19 Section U1 HICOM-Glenmarie HICOM-Glen marie Industrial-Pa Industrial-Park rk 40150 Shah Alam, Selangor Darul Ehsan, Malaysia Tel.: +603 5569 1000, Telefax: +603 556 92660 e-mail:
[email protected] [email protected] NG
Clarke Energy Ltd. Power House, Senator Point, South Boundary Road Knowsley Industrial Park Liverpool L33 7RR, United Kingdom Tel.: +44 151 546 4446, Telefax: +44 151 545 5714 e-mail:
[email protected] [email protected] NL
GE Jenbacher Netherlands Kelvinring 58 NL-2959 BF ALBLASSERDAM Tel.: +31 (0) 88 0019700, Telefax: +31 (0) 88 0019701 e-mail: jes.sliedrech e-mail: jes.sliedrecht@gejenb
[email protected] acher.com PK
ORIENT Energy System Ltd. Plot # 16, Sector 24, Korangi Industrial Area, Karachi 75950, Pakistan Tel.: +92 21 507 2091-4(four lines), Telefax: +92 21 507 2095 e-mail:
[email protected]
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 8 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
PL
KWE - Technika Energetyczna Energetyczna Sp.z o.o. Ul. Bosmanska 29 43-305 Bielsko-Biała, Polen Tel.: +48 338 215 093, Telefax: +48 338 216 562 e-mail:
[email protected] [email protected] http://www.kwe.com.pl www: http://www.kwe.com.pl PT
GELLWEILER Trav. do Alecrim 3-2°, P-1200 Lisboa, Portugal Tel.: +351 21 3420021, Telefax: +351 21 342 00 26 e-mail:
[email protected] [email protected] RO
SC Total Eurobusiness SRL (TEB) Str. Calea Rahovei nr. 266-268 Corp D Etaj 3; Sector 5 050912 Bucharest Tel.: +40 21 408 08 80 221, Telefax: +40 21 423 23 15
[email protected] e-mail:
[email protected] RU
Jenbacher Sales and Service Russia Taganskaya street, 17-23 Business Center Mosenka 4, 109147 Moskow Tel.: + 7 495 775 58 85, Telefax: + 7 495 775 58 84 e-mail: jenbacher.r e-mail: jenbacher.russia@ge
[email protected] .com ZAO Sigma Technologies (Sales) h. 15. bld. 33, M. Kaluzhskaya str. 117071 Moscow Tel.: +7 095 935 7835, Telefax: +7 095 935 7888 e-mail:
[email protected] [email protected] 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:
[email protected] [email protected] 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:
[email protected] [email protected] www: http://www.vado.biz
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 9 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
SE
GE Jenbacher Denmark Industrivej 19, DK-8881 Thorsø Tel.: + 45 8 6966788, Telefax: + 45 8 6967072 jenbacher.scandinav
[email protected] [email protected] e-mail: jenbacher.s e-mail: SI
IMP Inzeniring d.d. Dunajska cesta 7, SLO-1113 Ljubljana Tel.: +386 1300 9024, Telefax: +386 1300 9060 e-mail:
[email protected] [email protected] www: http://www.imp.si http://www.imp.si TES d.o.o. Gregorciceva 3, Maribor 2000 Tel.: +386 2 229 4726, Telefax: +386 2 229 4727 e-mail:
[email protected] [email protected] SK
EMES s.r.o Trieda SNP 75 974 01 Banska Bystrica Slovakia Tel.: +421 48 4145183, Telefax: +421 48 4145183 e-mail:
[email protected] [email protected] TH
ITALTHAI INDUSTRIAL CO. LTD. 2013 NEW PETCHBURI ROAD Bangkapi, Huay kwang T 10310 BANGKOK / THAILAND Tel.: +66(0) 2319 1031-40, Telefax: +66(0) 2318 2654 TK
Topkapi Endüstri Mallari Ticaret A.S. Pazartekke, Millet Cad. No.180-184 No.180-184 Topkapi 34104, Istanbul Tel.: +90 212 534 04 10, Telefax: +90 212 524 58 46 e-mail:
[email protected] [email protected] http://www.topkapigroup.com.tr www: http://www.topkapigroup.com.tr UA
Sinapse 7, Vanda Vasilevskaya Str. 03055 Kiev Tel.: +38 044 238 0967 0967 or +38 044 2380966, Telefax: +38 044 2380967 or +38 044 2380970 e-mail:
[email protected],
[email protected] ,
[email protected], www.sinapse.ua; www.cogeneration.com.ua
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 10 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
US
GE Energy Jenbacher Sales and Service USA 5244 N. Sam Houston Parkway East, Houston, TX 77032 Tel.: +1 832 295 5600 e-mail: jenbacher.u e-mail:
[email protected] [email protected] Distributor/Service Provider Distributor/Service Northeast Energy Systems, a division of Penn Detroit Diesel Allison (ME, VT, NH, MA, PA, NY, CT, DE, NJ, RI, OH) 8330 State Road, Philadelphia PA 19136 Telephone: +1 215 335 5010, Fax: +1 215 335 2163 e-mail:
[email protected] or
[email protected] [email protected] http://www.neesys.com www: http://www.neesys.com Distributor/Service Provider Distributor/Service 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:
[email protected] or
[email protected] [email protected] Inland Diesel, Inc. (MN, MI, WI, IA, IL, IN) IN ) 13015 W. Custer Avenue, Butler, WI 53007 Tel.: +1 262 781 7100, Telefax: +1 262 783 8974 e-mail:
[email protected] Smith Power Products Products (WA, MT, ID, WY, NV, UT, AZ) 3065 West California Ave. Salt Lake City, UT 84104 Tel.: +1 801 415 5000, Telefax: +1 801 415 5700 e-mail:
[email protected] [email protected] United Engines (CO, KS, MO, NM, TX, OK) 5555 W.Reno Oklahoma City, OK 73127 Tel.: +1 405 947 3321, Telefax: +1 405 947 0460 e-mail:
[email protected] GENEVA LLC, DBA Nixon Power Services Company (AR, LA, MS, TN, AL, GA, KY, FL, SC, NC, VA, WV, MD) 14300 South Lakes Drive Charlotte, NC 28273 Tel.: +1 704 588 1043 ext. 2535 e-mail:
[email protected]
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 11 / 12 12
Jenbacher
1.6 Service - and Sales partners
Documentation
ZA
South Afrika/Botswana/Lesotho/Mozambique/Swaziland Sales Representa Representative/Service tive/Service Provider Agaricus Trading Trading cc Linkhills Durban 3652 Tel.: + 27 31 7633222, Telefax: + 27 31 7633041 e-mail:
[email protected]
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Lechner
Checked:
Dokumentation Dokumentation
EN
1_6___BW_BRall_EN.doc
Index:
am
Date: 2007-03 2007-03 Page - No.: 12 / 12 12
Jenbacher
1.7 Imprint
Documentation
This GE Jenbacher 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: Tel.: Fax: E-Mail:
GE Jenbacher GmbH & Co OHG OHG A-6200 Jenbach | Austria Austria +43 | 5244 | 600-2221 600-2221 +43 | 5244 | 600-42221 600-42221
[email protected]
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Velik Doku./Velik
Checked:
Dokumentation Dokumentation
EN
1_7___BW_BRall_EN.doc
Index:
b
Date: 2002-02 2002-02 Page - No.: 1 / 1 1
Jenbacher
2.1 Designated Use
Documentation
1. Designated use GE Jenbacher co-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 exploit thermal energy from engine cooling water, engine oil, mixtures and exhaust gases. GE Jenbacher systems are designed individually to the customer’s specification specifications. s. These specific requirements also clearly define the designated use of the system and its proper operating conditions. Therefore any subsequent changes to the system must be approved by GE Jenbacher.
Gas engine
Generator
Heat exchanger
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Velik Doku./Velik
Checked:
Dokumentation Dokumentation
EN
2_1___BW_BRall_EN.doc
Index:
b
Date: 2002-02 2002-02 Page - No.: 1 / 1 1
3.1 Maintenance schedule
Jenbacher
Documentation
Intervals independent of the number of operating hours Inspection task task Number/ Interval section Daily inspection round daily I 9002 0 --daily Operating data log Intake air filter-Engin filter-Engine e
IW 8041 A0
daily
Check ignition voltage/ spark plug
IW 0309 M0
weekly < 250 oh
Lubricating oil
IW 0101 M0 TA 1000-0099A TA 1000-0099B TA 1000-0099C
first time after 150 oh
Battery
TA 1000-0050
Air filter in switch cabinet
---
Cooling water
TA 1000-0200 TA 1000-0201 TA 1000-0204
Carry out daily visual inspection of the unit. Log the operating data daily. If the underpressure increases to more than 1000 Pa, the filter elements in the prefilter and pocket filter f ilter should be replaced. The result of the ignition voltage check to be carried out weekly, serves as the indicator for the actual service life of the spark plug. The results from the engine lubricating oil analyses are decisive for the actual oil change periods.
Check the acid level. once in a month Check if the pole binders are properly secured. Check air filter for pollution. once in a month If necessary, clean or replace. once in a year
Concentration Concentrat ion inspection inspecti on
---
30000 oh after having completed the Cooling water exchange overhaul activities every eve ry two ye year ars s Repla Replace ce
---
every ever y five years years Replace Replace
W 8080 A0
Battery in DIANE module Storage battery at battery charger
Note
Proper maintenance according to the maintenance schedule is a condition for honouring any claims under warranty. After the „Overhaul“ „Overhaul“ 60000 60000 opera operating ting hours, th the e maintena maintenance nce work to be carried out out is repeated repeated at the same interval periods.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Velik Doku./Velik
Checked:
VMP _ K Klammer lammer Gerhard/TEAM_Egger Christoph/CSA_Sonnerer Herbert Herbert
Index:
d
EN
3_1_EN.doc
Date: 2007-03 2007-03 -- No.: 1 / 4 4
3.1 Maintenance schedule
Jenbacher
Documentation
Interval reference number = Operating hours/1000 r n . f e r l a v r e t n I
Maintenance task/ Inspection task
Number
ZK = on the occasion of cylinderhead disassembly
Operating hours 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 < 1 1 1 1 1 1 1 1 1 1 2
W 0200 M0
Gas train
W 8045 A0
Inspection Turbocharger Engine cooling water pump Starter
I 0103 0 W 8023 M0 W 0202 M3 W 8032 M0
Gas mixer
W 0704 M0
Mixture bypass valve Torsion vibration damper GE Jenbache Jenbacher-switch r-switch cabinets Piston/Piston cooling Con rod/Con rod bearing Cylinder liner/Scraper ring Crankshaft main bearing
2 2
Maintenance after first start-up Maintenance Valve clearance Ignition system 2/20 Crankcase suction filter Regulating rods/Throttle valve/ 2/30 Actuator Actua tor
W 1000 0 W 0400 M0 W 0303 M0 W 0506 M0
2/30/ 60
W 0802 M0 W 0601 M0 W 8031 A0 W 8047 M0 W 8048 M0 W 8049 M0 W 8050 M0
Camshaft/Steering Camshaft/Steer ing parts
W 8052 M0
Engine oil pump Turbocharger after-lubrication pump 60 Overhaul manifold/Isolation ZK Exhaust gas manifold/Isolation
W 8046 M0
W 8054 M0
W 2100 M0 W 8051 M0
10 10 10 10 10/20/ 30
20 20 20 30 30 30 30 ZK 30 60 60
-
Cylinder head replacement Generator Elastomer parts
W 8053 M0 W 8030 A0 W 8033 0
if required
Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Checked:
VMP _ K Klammer lammer Gerhard/TEAM_Egger Christoph/CSA_Sonnerer Herbert Herbert
Index:
d
Issued:
EN
Doku./Velik Doku./Velik 3_1_EN.doc
Date: 2007-03 2007-03 -- No.: 2 / 4 4
3.1 Maintenance schedule
Jenbacher
Documentation
Interval reference number = Operating hours/1000 r n . f e r l a v r e t n I
Maintenance task/ Inspection task task
ZK = on the occasion of cylinderhead disassembly
Number
Operating hours 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4
W 0400 M0 W 0303 M0 W 0506 M0
W 0200 M0
Gas train
W 8045 A0
Inspection Turbocharger Engine cooling water pump Starter
I 0103 0 W 8023 M0 W 0202 M3 W 8032 M0
Gas mixer
W 0704 M0
20
Mixture bypass valve
W 0802 M0
20 20 30 30 30 30 ZK 30 60 60 60 ZK -
Torsion vibration damper GE Jenbache Jenbacher-switch r-switch cabinets Piston/Piston cooling Con rod/Con rod bearing Cylinder liner/Scraper ring Crankshaft main bearing
W 0601 M0 W 8031 A0 W 8047 M0 W 8048 M0 W 8049 M0 W 8050 M0
Camshaft/Steering Camshaft/Steer ing parts
W 8052 M0
Engine oil pump Turbocharger after-lubrication pump Overhaul Exhaust gas manifold/Isolation manifold/Isolation Cylinder head replacement Generator
W 8046 M0 W 8054 M0 W 2100 M0 W 8051 M0 W 8053 M0 W 8030 A0
Elastomer parts
W 8033 0
Valve clearance Ignition system 2/20 Crankcase vent Regulating rods/Throttle valve/ 2/30 Actuator Actua tor 2 2
2/30/ 60
10 10 10 10 10/20/ 30
-
if required
Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Checked:
VMP _ K Klammer lammer Gerhard/TEAM_Egger Christoph/CSA_Sonnerer Herbert Herbert
Index:
d
Issued:
EN
Doku./Velik Doku./Velik 3_1_EN.doc
Date: 2007-03 2007-03 -- No.: 3 / 4 4
3.1 Maintenance schedule
Jenbacher
Documentation
Interval reference number = Operating hours/1000 r n . f e r l a v r e t n I
Maintenance task/ Inspection task task
ZK = on the occasion of cylinderhead disassembly
Number
Operating hours 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 6
W 0400 M0 W 0303 M0 W 0506 M0
W 0200 M0
Gas train
W 8045 A0
Inspection Turbocharger Engine cooling water pump Starter
I 0103 0 W 8023 M0 W 0202 M3 W 8032 M0
Gas mixer
W 0704 M0
20
Mixture bypass valve
W 0802 M0
20 20 30 30 30 30 ZK 30 60 60 60 ZK -
Torsion vibration damper GE Jenbache Jenbacher-switch r-switch cabinets Piston/Piston cooling Con rod/Con rod bearing Cylinder liner/Scraper ring Crankshaft main bearing
W 0601 M0 W 8031 A0 W 8047 M0 W 8048 M0 W 8049 M0 W 8050 M0
Camshaft/Steering Camshaft/Steer ing parts
W 8052 M0
Engine oil pump Turbocharger after-lubrication pump Overhaul Exhaust gas manifold/Isolation manifold/Isolation Cylinder head replacement Generator
W 8046 M0 W 8054 M0 W 2100 M0 W 8051 M0 W 8053 M0 W 8030 A0
Elastomer parts
W 8033 0
Valve clearance Ignition system 2/20 Crankcase vent Regulating rods/Throttle valve/ 2/30 Actuator Actua tor 2 2
2/30/ 60
10 10 10 10 10/20/ 30
-
if required
Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Checked:
VMP _ K Klammer lammer Gerhard/TEAM_Egger Christoph/CSA_Sonnerer Herbert Herbert
Index:
d
Issued:
EN
Doku./Velik Doku./Velik 3_1_EN.doc
Date: 2007-03 2007-03 -- No.: 4 / 4 4
4.1 Inspections/Maintenance works
Jenbacher
Documentation
Index Inspection Daily inspection round Lubrication oil/Oil-filter change Spark plug Intake air filter-Engin filter-Engine e Regulating rods/Throttle valve/Actuator Engine cooling water pump Ignition system Valve clearance Crankcase vent Torsion vibration damper Gas mixer Mixture bypass valve Maintenance Maintenan ce after first start-up Overhaul
I 0103 0 I 9002 0 IW 0101 M0 IW 0309 M0 IW 8041 A0 A0 W 0200 M0 W 0202 M3 W 0303 M0 W 0400 M0 W 0506 M0 W 0601 M0 W 0704 M0 W 0802 M0 W 1000 0 W 2100 M0
Turbocharger Generator GE Jenbacher-switch cabinets Starter Elastomer parts Gas train Engine oil pump Piston/Piston cooling Connecting rods/Connecting rod bearing shells Cylinder liner/Scraper Crankshaft main Exhaust gas manifold/Isola manifold/Isolation tion Camshaft/Control parts Cylinder head
W 8023 M0 W 8030 A0 W 8031 A0 W 8032 M0 W 8033 0 W 8045 A0 W 8046 M0 W 8047 M0 W 8048 M0 W 8049 M0 W 8050 M0 W 8051 M0 W 8052 M0 W 8053 M0
Pre-lubricating pump Filling the cooling water
W W 8054 8080 M0 A0 A0
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Velik Doku./Velik
Checked:
Dokumentation Dokumentation
4_1__W_312-320_EN.doc
Index:
-
EN
Date: 2007-03 2007-03 Page - No.: 1 / 1 1
5.1 Maintenance protocol
Jenbacher
Documentation
Module no.:
.
.
Engine no.:
.
.
Maintenance at Oh Oh
Operating hours
Date Date
Signature Mechanic
Starts
Operator
Oh < 100
Starts Oh
2000
Starts Oh
4000
Starts Oh
6000
Starts Oh
8000
Starts Oh
10000
Starts Oh
12000
Starts Oh
14000
Starts Oh
16000
Starts Oh
18000
Starts Oh
20000
Starts Oh
22000
Starts Oh
24000
Starts Oh
26000
Starts Oh
28000
Starts Oh
30000
Starts
Proper maintenance according to the maintenance schedule is a condition for honouring any claims under warranty. Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol. protocol.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
5_1_2000_EN.doc
Index:
b
EN
Date: 2006-02 2006-02 Page - No.: 1 / 2 2
5.1 Maintenance protocol
Jenbacher
Documentation
Module no.:
.
Maintenance at Oh Oh
.
Engine no.:
Date Date
Operating hours
.
Signature Mechanic
Starts
.
Operator
32000
Oh Starts Oh
34000
Starts Oh
36000
Starts Oh
38000
Starts Oh
40000
Starts Oh
42000
Starts Oh
44000
Starts Oh
46000
Starts Oh
48000
Starts Oh
50000
Starts Oh
52000
Starts Oh
54000
Starts Oh
56000
Starts Oh
58000
Starts Oh
60000
Starts
Proper maintenance according to the maintenance schedule is a condition for honouring any claims under warranty. Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol. protocol. After the "Overhaul" 60000 operating hours, the maintenance work to be carried out is repeated at the same interval periods.
Keyword:
Baja - Madu Lingga Lingga
Unit no.:
J D651 D651
Module no.: 490458 1 1
Module type :
JGS 320 GS-N.L GS-N.L
Version:
C105 C105
Engine no.: 490457 1 1
Issued:
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
5_1_2000_EN.doc
Index:
b
EN
Date: 2006-02 2006-02 Page - No.: 2 / 2 2
Jenbacher
Inspections/Maintenance works: IW
0101 M0 Lubrication oil/Oil-filter change
Documentation
KLS98
1. Note: __________ ______________________ _______________________ ______________________ _______________________ __________________1 ______1 2. Procedure when changing oil: ___________ _______________________ ________________________ __________________2 ______2 2.1 2.2
2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5
Draining lubricating oil: Work to be performed following the first oil drain (for modules with an additional lubricating oil tank): Remove plug at oil pressure control valve. Connect the flexible line attached to the module. Remove plug at crankcase cover. Connect the flexible line attached to the module. Oil filter replacement - engine lubrication lubrication oil filter and oil filter for the superchar supercharger ger after-cooler (only for ABB exhaust-gas turbochargers turbochargers): ): Fill with lubricating oil: without oil flow meter, without auxiliary tank: with oil flow meter, without auxiliary tank: with or without oil flow meter, with auxiliary tank: The following applies to engines without ABB-TPS turbocharger: The following applies to engines with ABB-TPS turbocharger:
2
2 2 2 3 3 3 3 3 4 4 4 4
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
1. Note: Only use engine lubricating oil recommended by GE Jenbacher. The service life of the t he oil is determined mainly by the operational conditions. That is why no general indications can be given for the oil-change intervals. To use the oil as efficiently as possible, we recommend determining determining its service life by means of oil analyses. The sampling and testing procedure for the oil analyses is described in the technical Instructions TI 1000-0099A, TI 1000-0099B and 1000-0099B and TI 1000-0099C.
Enter the dates of the oil analyses and/or oil changes in the table Data Registration Engine Lubrication Oil (E 0101). 0101).
If the engine lubrication 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-off the engine, the engine oil and filter element should once again be changed.
Issued:
Doku./Bilek Doku./Bilek
Checked:
TKE/Esterhammer
EN
0101M0_EN.doc
Index:
g
Date: 2006-10 2006-10 Page - No.: 1 / 5 5
Jenbacher
Inspections/Maintenance works: IW
0101 M0 Lubrication oil/Oil-filter change
Documentation
2. Procedure when changing oil: 2.1
Draining lubricating oil: The used oil must be drained with the engine at operating temperature. The used oil must also be drained from the lubricating-oil heat-exchanger heat-exchanger and the auxiliary oil tank (if present). It is important that the system is emptied thoroughly in order to avoid contaminating the fresh oil with too much residual used oil. (Pumpoff once more after 15 min if necessary).
2.2
Work to be performed following the first oil drain (for modules with an additional lubricating oil tank): In the case of container modules with an additional lubricating oil tank mounted against the container wall, only the activities as described in section 2.2.1 and 2.2.2 must be carried out, as the oil lines have already been pre-installed (visual inspection). If the additional lubricating oil tank has been installed on the engine frame, the activities as described in section 2.2.1 to 2.2.4 must be carried out.
2.2.1 Remove plug at oil pressure control valve.
2.2.2 Connect the flexible line attached to the module.
Issued:
Doku./Bilek Doku./Bilek
Checked:
TKE/Esterhammer
EN
0101M0_EN.doc
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Inspections/Maintenance works: IW
0101 M0 Lubrication oil/Oil-filter change
Documentation
2.2.3 Remove plug at crankcase cover.
2.2.4 Connect the flexible line attached to the module.
2.3
Oil filter replacement - engine lubrication oil filter and oil filter for the supercharger after-cooler (only for ABB exhaust-gas turbochargers): The filter elements must be renewed at every oil change and at the latest after 2000 operating hours. When installing, make sure that the sealing ring is seated correctly on the filter element. Smear it lightly with oil before installing. Screw in the filter by hand until the seal is touching. Tighten by hand 3/4 turn further. Fill with oil according to 2.3, start engine. Check for leaks and tighten further if necessary.
2.4
Fill with lubricating oil:
2.4.1 without oil flow meter, without auxiliary tank: Close all drain cocks. Turn oil filling valve 1 into the „OPEN“ position using a screwdriver and activate the fresh oil pump; the lubricating oil will now flow from the lubricating oil tank into the engine. Top up the lubricating oil to the third marking on the inspection glass housing. Subsequently, deactivate the fresh oil pump and close the oil filling valve. After the engine engine is started the the oil level drops drops again to th the e middle of the the sight glass. If the oil level is significantly lower than the middle of the sight glass, the above filling procedure must be repeated until the level has reached middle of the sight glass.
Issued:
Doku./Bilek Doku./Bilek
Checked:
TKE/Esterhammer
EN
0101M0_EN.doc
Index:
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Date: 2006-10 2006-10 Page - No.: 3 / 5 5
Jenbacher
Inspections/Maintenance works: IW
0101 M0 Lubrication oil/Oil-filter change
Documentation
2.4.2 with oil flow meter, meter, without auxiliary tank: tank: Attention: The Attention: The oil flow meter is suitable only for small flow rates. Never fill through the oil flow meter! Close all drain cocks. Bypass passage through oil flow meter by means of three-way cock 4. Turn oil filling valve 1 into the „OPEN“ position using a screwdriver and activate the fresh oil pump; the lubricating oil will now flow from the lubricating oil tank into the engine. Top up the lubricating oil to the third marking on the inspection glass housing. Subsequently, Subsequently, close the oil filling valve, deactivate the fresh oil pump and turn three-way three-way valve 4 into the “oil-quantity counter” position. After the engine engine is started the the oil level drops drops again to th the e middle of the the sight glass. If the oil level is significantly lower than the middle of the sight glass, the above filling procedure must be repeated until the level has reached middle of the sight glass. 2.4.3 with or without oil flow flow meter, with auxiliary auxiliary tank: Attention: Fill Attention: Fill the engine only over the auxiliary tank! Close all drain cocks. Switch on fresh-oil pump. Fill up the oil to the third marking on the inspection glass housing. Switch off the fresh-oil pump. After the engine engine is started the the oil level drops drops again to th the e middle of the the sight glass. If the oil level is significantly lower than the middle of the sight glass, the above filling procedure must be repeated until the level has reached middle of the sight glass. 2.4.4 The following applies to engines without ABB-TPS turbocharger: Following the oil change the exhaust-gas turbocharger after-lubrication pump should be run for 15 minutes. Operation mode selector switch to: Stop Stop Key: Press the turbocharger after-lubrication pump key. pump key. 2.4.5 The following applies to engines with ABB-TPS turbocharger: Activate the electrical electrical prelubrication prelubrication system for a couple of minutes minutes following following the oil change change to ensure ensure that the lubricating oil heat exchanger is filled. Text to illustrations Pos. No. Designatio Designation n 1 oil filling valve 2 oil flow meter 3 sight glass 4 three-way cock 5 drain cock
Issued:
Doku./Bilek Doku./Bilek
Checked:
TKE/Esterhammer
EN
0101M0_EN.doc
Index:
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Jenbacher
Inspections/Maintenance works: IW
0101 M0 Lubrication oil/Oil-filter change
Documentation
1 OPEN
CLOSE
2
3
4
5
Issued:
Doku./Bilek Doku./Bilek
Checked:
TKE/Esterhammer
EN
0101M0_EN.doc
Index:
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Date: 2006-10 2006-10 Page - No.: 5 / 5 5
Jenbacher
Maintenance works: W
0200 M0 Regulator linkage/Throttle valve/Actuator
Documentation
KLS98
1. Regulator linkage: ____________ ________________________ ________________________ ________________________ _______________1 ___1 1.1 1.2
1 1
Checking: Re-lubrication:
2. Throttle valve: ___________ _______________________ ________________________ ________________________ ___________________1 _______1 2.1
1
Checking:
3. Renewing throttle bearing and O-ring: ____________ _________________________ _________________2 ____2 throttle valve bearing Rod Assembly: ___________ 4. Adjusting the Governor Rod _______________________ ______________________2 __________2 5. Actuator: Actuator:___________ ______________________ _______________________ _______________________ _______________________ ______________4 __4
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
Maintenance works
Point
02 Regulator linkage –checking/Re-lubrication 02 Throttle valve - checking Overhaul 30 Actuator - Overhaul
Interval every 2000 Oh 30000 Oh
1. 2. 5.
1. Regulator linkage: Unscrew the plug connection of the electricity supply on from the setting device. 1.1
Checking: Check if regulator linkage 8 can be moved without play or friction. If necessary the swivel heads 2 are to be renewed (reference value: approx. 10,000 operating hours). After changing the swivel heads, the regulator linkage linkage is to be reset in accordance with 4.
1.2
Re-lubrication: Re-lubricate the swivel heads using a grease gun on the lubricating nipple. Spread grease penetrating, when re-lubricating, left and right over the area of the bearing gap so that a dust protection is established by the grease layer.
2. Throttle valve: 2.1
Checking: Remove swivel head 2. Press shaft 12 into the axial end position and, while pressed, move radially from 0 to the fully open position (there must be no perceptible resistance shown in the end axial position or in the complete radial movement path). If resistance is felt, the throttle valve bearing must be renewed in accordance with section 3 (reference value: 6,000 - 10,000 operating hours, dependent on gas type).
Issued:
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
EN
0200M0_EN.doc
Index:
d
Date: 2002-03 2002-03 Page - No.: 1 / 4 4
Jenbacher
Maintenance works: W
0200 M0 Regulator linkage/Throttle valve/Actuator
Documentation
3. Renewing throttle valve bearing and O-ring: Remove screws 7, 11 and 13 and completely disassemble disassemble the throttle valve. Loosen cylinder screws 4 (note the position of the throttle valve for re-assembly). Remove throttle valve 5 and withdraw shaft 12. Heat throttle housing 3 near the sleeve 9 (until the metal adhesive burns away) and then press the sleeve 9 out of the throttle housing 3. Clean throttle valve housing 3, shaft 12 and throttle valve 5. Press the bearing sleeve 10 into the sleeve 9. Apply metal adhesive to the outside and press into the throttle housing 3. Replace O-Ring 6 in the throttle-valve housing and apply a small amount of grease. Inspect shaft in the bearing region region for grooving. Renew if necessary. Then fit tthe he shaft into the throttle valve housing (pay attention to the fitting position). Secure the screws with metal adhesive. Mount the complete throttle valve with gaskets or gasket compound on to the engine. Refix regulator linkage on to the lever. Caution: If on disassembly the lever 1 was removed from the shaft (e.g. when changing shafts) then the regulator linkage is to be reset in accordance with 4.
4. Adjusting the Governor Rod Assembly: Connect governor rod assembly at the actuator. Caution: For correct adjustment adjustment of the control rod assembly the throttle flap must be at the limit stop when in zero position and the actuator must have approx. 3° pretension. If the actuator is opened the control rod assembly must not overshoot, i.e. the actuator must position the throttle flap safely in the zero position again.
Issued:
EN
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
0200M0_EN.doc
Index:
d
Date: 2002-03 2002-03 Page - No.: 2 / 4 4
Jenbacher
Maintenance works: W
0200 M0 Regulator linkage/Throttle valve/Actuator
Documentation
0 = zero position
Issued:
EN
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
0200M0_EN.doc
Index:
d
Date: 2002-03 2002-03 Page - No.: 3 / 4 4
Jenbacher
Maintenance works: W
0200 M0 Regulator linkage/Throttle valve/Actuator
Documentation
5. Actuator: Actuator should be overhauled by an authorized and specialized company!
Text for diagram: Item no. Designation 1 Lever 2 Swivel head 3 Throttle valve housing 4 Cylindrical screw 5 Throttle valve 6 O-ring 7 Hexagonal screw 8 Regulator linkage 9 Sleeve 10 Bearing bush 11 Hexagonal screw 12 13
Issued:
EN
Shaft Hexagonal screw
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
0200M0 EN.doc
Index:
d
Date: 2002-03 2002-03 Page - No.: 4 / 4 4
EN
Jenbacher
Maintenance works: W
0202 M3 Cooling water pump
Documentation
KLS98
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
10
Maintenance works Renew water-side seal Overhaul
Point 1. 2.
Interval every 10000 Oh only by leakage leakage
1. Renew water-side seal: Drain cooling water. Unscrew dummy cover 36. Heat water pump running wheel in the thread area (until metal adhesive burns away). Then unscrew water pump running wheel from shaft. Remove axial face seal 11 and insert new replacements. Attention: Before installing the axial face seal 11, examine it carefully for possible damage caused by wrong storage, transport etc. Remove any particles of dirt before installing. Wet the seat of the axial face seal 11 and shaft 5 thoroughly with low surface tension water (use detergent and never oil or grease), and push on as far as possible. Apply screw securing securing substance substance (Loctite 27 270) 0) to shaft thread, thread, screw on water water pump running running wheel wheel and tighten by hand. Replace dummy cover 36 with a new O-ring 38 and hexagon nut 48. Attention: The bore bore may not not be or beco become me blocked. Check Check regula regularly. rly.
Issued:
Doku./Bilek Doku./Bilek
Checked:
Reparatur
0202M3 EN.doc
Index:
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Date: 2006-10 2006-10 Page - No.: 1 / 4 4
EN
Jenbacher
Maintenance works: W
0202 M3 Cooling water pump
Documentation
2. Overhaul: Drain cooling water and dismount cooling water pump from the engine. Unscrew dummy cover 36. Clamp tool (Part No. 156910) in vice and mount cooling water pump on it.
Loosen hexagonal nut 33.
Remove water pump gear 15 using puller - Diagram 1. Remove Woodruff key 29. Remove shaft 5 from spiral housing using a press or by tapping with a rubber hammer.
1
Clamp shaft in vice (Attention: use protective cheeks to avoid damaging the shaft). Heat water pump running wheel 8 in the thread region (until the metal adhesive burns away) - Diagram 2. 2
Issued:
Doku./Bilek Doku./Bilek
Checked:
Reparatur
Date: 2006-10 2006-10
EN
0202M3_EN.doc
Index:
Page No.: 2 / 4 4
Jenbacher
Maintenance works: W
0202 M3 Cooling water pump
Documentation
Unscrew water pump running wheel from shaft - Diagram 3. Remove axial face seal 11. Remove parts 27, 20, 22, 24, 18, 13 from the spiral housing 1. 3
Clean spiral housing 1, water pump running wheel 8 and shaft 5. Examine shaft (especially for signs of wear in the vicinity of the radial shaft seal) and replace if necessary.
Assembly: The following parts must be renewed: No. 20, 22, 18, 13, 11, 50, 38 (No. 5 as needed) Attention: Before installing the axial face seal 11 and the radial shaft seal 13, examine it carefully for possible damage caused by wrong storage, transport etc. Remove any particles of dirt before installing. Wet the seat of the axial face seal 11 and shaft 5 thoroughly with low surface tension water (use detergent and never oil or grease), grease), and push on as far as possible. Clamp shaft in vice (using protective cheeks). Apply screw securing securing substance substance (Loctite 27 270) 0) to shaft thread thread (running (running wheel side), side), screw on water water pump running wheel 8 and tighten by hand. Assemble spiral spiral casing 1. Smear radial shaft sealing ring 13 and shaft 5 with oil and press completely onto the shaft (flat side towards axial face seal 11). Mount bearing 20, distance sleeve 20 and 24, bearing 18 and locking ring 27. Insert Woodruff key 29. Heat water pump gear 15 and place on shaft. Secure nut 33 using Loctite 242 and then tighten (tightening torque 300 Nm [221.3 lbf. ft]. Mount dummy cover 36, O-ring 38 and secure by tightening hexagon nut 48. Mount cooling water pump on engine using a new gasket. Attention: The bore bore may not not be or beco become me blocked. Check Check regula regularly. rly.
Issued:
Doku./Bilek Doku./Bilek
Checked:
Reparatur
Date: 2006-10 2006-10
EN
0202M3_EN.doc
Index:
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Page No.: 3 / 4 4
Jenbacher
Maintenance works: W
0202 M3 Cooling water pump
Documentation
33
29
15
27
18
24
20
13
11
5
1
8
38 36
*
22
50
52 56
36 48
*) ATTENTION: ATTENTION: DRILLING MUST NOT BE LOCKED, CHECK REGULARLY! REGULARLY!
Issued:
Doku./Bilek Doku./Bilek
Checked:
Reparatur
Date: 2006-10 2006-10
EN
0202M3_EN.doc
Index:
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Page - No.: 4 / 4 4
Jenbacher
Maintenance works: W
0303 M0 Ignition system
Documentation
Data registration: E KLS98 0303
1. Checking the ignition point: ____________ ________________________ ________________________ ___________________1 _______1 2. Checking the ignition unit: ___________ _______________________ ________________________ _____________________2 _________2 3. Checking harness: ___________ _______________________ ________________________ _________________2 _____2 Checking the ignition harness: systems: ____2 4. Checking the passive ignition pick-ups in the case of IQ ignition systems:____2 5. Checking the ignition coils: coils: ____________ ________________________ ________________________ ___________________2 _______2 5.1 5.2
2 2
Checking the ignition coils (Integrated (Integrated): ): Checking the external ignition coils
socket: ____________ 6. Ignition plug socket: ________________________ ________________________ ________________________ _____________3 _3
Necessary devices: The following devices are necessary to check the ignition system (ignition point, ignition cable, ignition pick-up, ignition coils): Digital storage oscilloscope oscilloscope (DSO) BNC connection connection cable XLR-XLR adaptor Ignition coil test apparatus apparatus DISN-PG01 (only in the case of DISN ignitions) High-voltage clamp-on probe (HV clamp-on probe) – for external ignition coils only
•
• • • •
Note: For the use of the DSO Fluke 123 see technical instruction. 1400-0151. For operation of the HV clamp-on probe see TI no. 1400-0149. The order of the following points must be strictly observed!
1. Checking the ignition point: To prevent engine damage the ignition point must be checked as quickly as possible after the engine speed has been reached (before the engine is put under load, however)! The ignition point depends on the fuel gas used and is set according to the knock sensitivity. Using a strobe light, you can check if the actual ignition point (IST) compares to the desired ignition point (SOLL) (see first-commissioning protocol). protocol). If these values are not the same, the ignition point should be adjusted.
The following test must be carried out at engine standstill! Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
Issued:
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
Date: 2004-07 2004-07
EN
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Maintenance works: W
0303 M0 Ignition system
Documentation
2. Checking the ignition unit: Check plug-type connections and connecting terminals at the ignition box for firm seat. Discoloured (mostly black), scoured or scorched contact pins in the plug-type connections are places of malfunction and need to be replaced.
3. Checking the ignition harness: Check for heat damage and tottering contact.
4. Checking the passive ignition pick-ups in the case of IQ ignition i gnition systems: Check connecting cable as for tottering contact. After the first 2000 2000 hours of operation a and nd in the eve event nt of ignition p problems roblems of the machine, chips chips must be removed from the pick-ups at the flywheel (reset, trigger), if IQ ignition systems are used. When putting back the pick-ups make sure you keep the correct distance (0.8 mm [0,031 in] = ¾ rotation). In order to avoid a mechanical damage of the pick-up, the distance must be set to the highest elevation.
5. Checking the ignition coils: 5.1
Checking the ignition coils (Integrated): For DISN-type ignition systems: Measure systems: Measure the ignition voltage according to TI No. 1502-0048. For IC 900/IC 910 and IC 912-type ignition systems: Measure systems: Measure the ignition voltage according to TI No. 1502-0038. For IQ 750-type ignition systems: Measure systems: Measure the ignition voltage according to TI No. 1502-0044. For IQ 724-type ignition systems (for systems (for J 620): Measure the ignition voltage according to TI No. 1502-0043. For IQ 250-type ignition systems (for systems (for J 208): Measure the ignition voltage according to TI No. 1502-0049. For IQ 250-type ignition systems (for systems (for J 208/Single Pickup): Measure the ignition voltage according to TI No. 1502-0057. For IQ 250-type ignition systems (for systems (for J 208/Dual Pickup): Measure the ignition voltage according to TI No. 1502-0060.
Enter the readings into the table Data capture ignition coils (E 0303). 0303).
5.2
Checking the external ignition coils Checking the external ignition coils using the DSO (digital storage oscilloscope) and HV clamp-on probe at the engine See TI no. 1400-0111 for high-voltage trend guidance values. For the use of the DSO Fluke 123 see technical instruction. 1400-0151. For operation of the HV clamp-on probe see TI no. 1400-0149.
Issued:
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
Date: 2004-07 2004-07
EN
0303M0_EN.doc
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Maintenance works: W
0303 M0 Ignition system
Documentation
6. Ignition plug socket: Check inside and outside for cleanliness and traces of choked fire. Check spring for possible defects. Before re-starting : Check the cable and XRL-plug (conection to the cable chennel) for firm seat. High-voltage cables cables must not come into contact with metal parts. Check the I-coils for firm seat at the maschine.
Issued:
Doku./Bilek Doku./Bilek
Checked:
Dokumentation Dokumentation
Date: 2004-07 2004-07
EN
0303M0_EN.doc
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Page - No.: 3 / 3 3
Jenbacher
Inspection Work/Maintenance Work: IW
0309 M0 Ignition voltage check/Spark plugs
Documentation
Data registration: E 0309
1. Important: ___________ _______________________ _______________________ _______________________ ________________________ ____________2 2 1.1 1.1.1 1.1.2
Required regulatio regulations/materials/too ns/materials/tools: ls: Safety precautions: Operation:
2 2 2
1.1.3 1.1.4 1.2 1.3 1.4 1.5 1.6
Tightening torques: Tool/lubricant: Spark plug type: Electrode distance: Spare spark plugs: Ignition voltage range: Ignition voltage measurement:
2 2 3 3 3 3 3
2. Set values for spark plugs: ____________ ________________________ ________________________ ____________________4 ________4 3. Checking the spark plugs: ___________ _______________________ ________________________ _____________________5 _________5 3.1
Example of ignition voltage increase during operation:
5
4. Operational data: ___________ _______________________ ________________________ ________________________ _________________6 _____6 4.1 4.2
Ignition voltage requirement: Spark plug type:
6 6
4.3
Optimal electrode distance:
6
5.1 5.2 5.2.1 5.2.2
Ignition systems with ignition coils: Ignition systems with external coils: Type 6 engine engine Lifer-Saver spark plug connector: Rail System:
5. Spark plug disassembly: ____________ ________________________ ________________________ _____________________6 _________6 7 7 7 7
6. Cleaning hints: hints:___________ _______________________ ________________________ _______________________ ___________________8 ________8 7. Wearing characteristics and adjusting of the spark plugs:__________________8 plugs:__________________8 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.2 7.2.1 7.2.2 7.2.3
Analysing used spark plugs: Early sparking / overheating: Defective noble metal electrode: Silicon and combustion deposits: Electrode short-circu short-circuit: it: Adjusting the spark spark plugs: P3.V3 and P3.V5 spark plugs: P7.1V5 and P7.1V6 spark plugs: Denso 3-1, 357 and 502N spark plugs:
8 8 9 10 10 11 11 12 12
8. Assembling the spark plugs: _______________________ ________________________ __________________13 ______13 plugs: ___________ 8.1 8.2 8.2.1 8.2.2 8.3
Ignition systems with ignition coils: Ignition systems with external coils: Type 6 engine Lifer-Saver spark plug connector: Connection to the R coil : High-voltage cable:
14 14 14 15 15
9. Checking following recommissioning: recommissioning: ___________ ________________________ ______________________15 _________15
Issued:
Doku./Bilek Doku./Bilek
Checked:
TEAM/TEBM/TEE/VSR/VST
Date: 2005-08 2005-08
EN
0309M0_EN.doc
Index:
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Page - No.: 1 / 15 15
Jenbacher
Inspection Work/Maintenance Work: IW
0309 M0 Ignition voltage check/Spark plugs
Documentation
1. Important: This instruction describes how to measure the ignition voltage supply of the ignition coils and how to expertly adjust the distance between the ignition coil electrodes. Note: Please report cases of damage immediately to GE Jenbacher Reliability Group! (Tel. +43 5244 600 2265) 1.1 Required regulations/materials/too regulations/ materials/tools: ls: 1.1.1 Safety precautions: 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 components with a properly earthed tool such as high-voltage measuring pliers. 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.
•
1.1.2 Operation: Engine switch-off, see TI No. 1100-01 1100-0105. 05. 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. 1400-0111. Operating the Fluke 123 digital storage oscilloscope, see TI No. 1400-0151. Operating the high-voltage pliers, see TI No. 1400-0149. •
• •
•
•
•
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) (DSO) e.g.: Fluke 123 (not for monic) BNC connection connection ca cable ble (n (not ot for monic) Pointed pliers Feeler gauge Socket wrench with e extension xtension piece Strap wrench wrench (to disa disassemble ssemble th the e integral coils) Universal lubricant: Type 2, 3 and 4 engines: „ULTRA-THERM“ „ULTRA-THE RM“ Tl No. 323765 (fluid in bottles) or TI No. 128407 (spray) Type 6 engine: „NEVER-SEEZ“ TI No. 305045 •
•
•
•
•
•
•
Issued:
Doku./Bilek Doku./Bilek
Checked:
TEAM/TEBM/TEE/VSR/VST
Date: 2005-08 2005-08
EN
0309M0_EN.doc
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0309 M0 Ignition voltage check/Spark plugs
Documentation
1.2
Spark plug type: GE Jenbacher specifies the spark plug type for every individual installation, always taking into account the installation-specific operation 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’s prior written approval and clearance.
1.3
Electrode distance: In principle, a smaller electrode distance will result in a prolonge prolonged d cycle time. This in turn is a prerequisite prerequisite for ensuring a longer spark plug service life and lower maintenance costs. Adjustments to the the electrode distance must a always lways be made by the same person. person. 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 measurement technique and to adjust the distance between the electrodes expertly and on time.
1.4
Spare spark plugs: Another means means of keeping keeping maintenance maintenance costs as low a as s possible is to adjust adjust a complete complete set of spark plugs at a time (prepared beforehand) or to renew a complete set and not adjust the individual spark plugs of a machine. This procedure clearly makes more sense for installations which operate without direct supervision. 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).
Issued:
Doku./Bilek Doku./Bilek
Checked:
TEAM/TEBM/TEE/VSR/VST
Date: 2005-08 2005-08
EN
0309M0_EN.doc
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Page - No.: 3 / 15 15
Jenbacher
Inspection Work/Maintenance Work: IW
0309 M0 Ignition voltage check/Spark plugs
Documentation
2. Set values for spark plugs: The ignition voltage requirement referred to below (at full load) may not be exceeded or underrun.
Spark plugs Type P3.V3
Engine types 2, 3, 4
P3.V5
2, 3, 4
P7.1V5
3, 4
P7.1V6
3, 4
Denso 3-1 Denso 357 Denso 502N
6
Issued:
Doku./Bilek Doku./Bilek
Einsatzgebiet NOx Gas type [mg/Nm³] 250 - 400 400 landfill gas sludge gas natural gas mine gas propane gas 250 - 400 400 biogasses wood gas pyrolysis gas process gas landfill gas 500 500 sludge gas natural gas mine gas propane gas 500 500 biogasses wood gas pyrolysis gas process gas 250 - 500 landfill gas natural gas sludge gas
Checked:
Spark plug setting Guide value: Ignition voltage electrode requirement distance > kV < kV mm (inch) 12
32
0,35 (0,014)
12
32
0,35 (0,014)
12
32
0,35 (0,014)
12
32
0,35 (0,014)
12
30
0,3 (0,012)
TEAM/TEBM/TEE/VSR/VST
Date: 2005-08 2005-08
EN
0309M0_EN.doc
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Jenbacher
Inspection Work/Maintenance Work: IW
0309 M0 Ignition voltage check/Spark plugs
Documentation
3. Checking the spark plugs: 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. In the event of misfiring or at 32 kV at the latest, you must adjust the electrode distance. 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 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, 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.
]
V k [ n i s e g a t l o v n o i t i n g I
Spark plug operating hours hours
The course of the curve 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.
Issued:
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Documentation
4. Operational data: In the case of ignition or spark plug problems, these data provide important information on 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 used spark plug type in the operational spark plug data (E 0309) table. 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. 0309) table.
5. Spark plug disassembly: Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure that unauthorised persons cannot start the engine. Before disassembling the spark plugs, check the spark plug sleeve for soiling. If necessary, clean the opening using a vacuum cleaner. 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.
Issued:
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Date: 2005-08 2005-08
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0309 M0 Ignition voltage check/Spark plugs
Documentation
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 s park plug connector out of the spark plug shaft. Attach a socket wrench wrench with exten extension sion piece to th the e spark plu plug g and unscrew unscrew it. 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.. magnet
5.2
Ignition systems with external coils: Remove the spark plug connector insulator from the spark plug by hand. The insulator must not be disconnected from the cable. Attach a socket wrench wrench with exten extension sion piece to the spark plu plug g and unscrew unscrew it. 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.. magnet
5.2.1 Type 6 engine engine Lifer-Saver spark plug connector: First of all, press down the bayonet catch and turn the arrow into the specific red dot or the 0 position. Remove the spark plug connector insulator from the spark plug by hand (see the illustration below). The insulator must not be disconnected from the cable. Use the groove as the point of application. Pull upwards using two fingers.
Unscrew the union nut and pull the spark plug connector of the spark plug shaft. Attach a socket wrench wrench with extension extension piece to the spark plug a and nd unscrew unscrew it. 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.. magnet 5.2.2 Rail System: In the case of the Rail System, System, the connection on the R coil must first be opened.
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Documentation
6. Cleaning hints: Before the assembly of new or newly adjusted spark plugs, the spark plug openings in the cylinder heads must be cleaned with a vacuum cleaner and a suitable hose, in order to remove all dry Ultraterm remnants and other dust and dirt residue. 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. Make sure that there is no foreign metal between the electrodes, to prevent metal swarf from forming bridges. The spark plug ceramic insulators must be free of grease, oil or Ultraterm residues. Clean the parts that have become soiled using a lint-free cleaning cloth and a degreasing agent. Do not wash the engine area near the spark plugs or the cylinder head.
7. Wearing characteristics and adjusting of 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, only use the pliers included within GE Jenbacher‘s scope of supply. Never use a screwdriver or similar tool. 7.1
Analysing used spark plugs:
7.1.1 Early sparking / overheating: Outside spark plug appearance: Molten central and earth electrodes. Melting beads and metallic deposits near electrode.
Type: P3.V3 or P3.V5
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Type: P3.V3 or P3.V5
Checked:
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Type: P7.1V5 or P7.1V6
Date: 2005-08 2005-08
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Documentation
Possible causes The spark plug is insufficiently tightened. Early sparking due to defective
Results / effects Power reduction followed by engine damage. Possible spark plug insulator cracking due to overheated
Corrective measure Visually inspect cylinder. Inspect (replace) ignition box. Install new spark plug. Clean piston and cylinder head
ignition box.
central electrode.
local to combustion Re-adjust LEANOX room. and reestablish control for entire load range. range.
Combustion knocking causing electrode to overheat. Defective valves. Auto-ignition Auto-ignitio n due to deposits. deposits. Incorrectly set LEANOX. LEANOX. 7.1.2 Defective noble metal electrode: Outside spark plug appearance: At one or more more mass electrodes electrodes – loss of the no noble ble metal.
Type: all spark plugs Possible causes Too much sulphur or ammonia in the fuel gas (see TI No.: 1000-0300). 1000-0300).
missing noble metal Results / effects Ignition voltage increases sharply when several electrodes fail.
Corrective measure Select the right spark plug type. type.
Noble metal residues can get stuck between valve and valve seat, causing damage (valve burn-through). This can cause auto-ignition. auto-ignition.
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Documentation
7.1.3 Silicon and combustion deposits: Outside spark plug appearance: Massive silicon and combustion deposits near the electrodes and the whirl chamber.
Type: all spark plugs
Possible causes Silicon values (see TI No.: 10000300). Increased oil consumption. consumption.
Results / effects Decreasing ignition voltages until the cylinder fails. Deposits can loosen resulting in auto-ignition. auto-ignition.
Corrective measure Install new spark plug. Carefully clean spark plug electrodes. electrodes.
Poor blow-by oil separation. Defective piston rings. rings. 7.1.4 Electrode short-circuit: Outside spark plug appearance: Thread (molten conductive noble metal) between central and earth electrode.
Type: all spark plugs
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Documentation
Possible causes Insufficient distance between electrodes. Incorrect spark-plug type.
Results / effects Continuously decreasing ignition voltages until the cylinder in question fails completely (no
Corrective measure Adjust electrodes electrodes correctly correctly (see following instruction). Adjust electrode electrode distance using using
Incorrect ignition point point (spark-plug overheating).
more combustion): Exhaust gas temperature drops far below average value. value.
feeler gauge. gauge.
Combustion knocking (sparkplug overheating). overheating). 7.2
Adjusting the spark plugs:
7.2.1 P3.V3 and P3.V5 spark plugs: Wearing characteristics: Approximately Approximatel y equal degree degree of mate material rial erosio erosion n at the centra centrall and earth earth electrodes. electrodes.
Feeler gauge Earth electrode
Central electrode
Adjustment: Adjust the spark plugs plugs from th the e inside to the outside so that th these ese are in parallel parallel to the the optimal electrode electrode distance (guide value 0.35 mm (0,014 inch) ) using pointed pliers.
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Date: 2005-08
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0309 M0 Ignition voltage check/Spark plugs
7.2.2 P7.1V5 and P7.1V6 spark plugs: Wearing characteristics: Approximately Approximatel y equal degree degree of mate material rial erosio erosion n at the centra centrall and earth earth electrodes. electrodes.
Feeler gauge
Mass electrode
Central electrode
Adjustment: Adjust the spark plugs plugs so tha thatt these are in parallel parallel to the optimal electrode electrode distance distance (guide value value 0.35 mm (0,014 inch) ) using pointed pliers. 7.2.3 Denso 3-1, 357 and 502N spark plugs: Wearing characteristics: The precious-metal plates at the central and earth electrodes are seriously eroded. There is, however, enough material left for further operation.
Mass electrode
Electrode erosion
Central electrode Adjustment: Adjust the spark plugs plugs so tha thatt these are in parallel parallel to the optimal electrode electrode distance distance (guide value value 0.3 mm (0,012 inch)) using pointed pliers. When adjusting the spark plugs, ensure that the electrodes are parallel to and right above each other.
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Right
Inspection Work/Maintenance Work: IW
0309 M0 Ignition voltage check/Spark plugs
Wrong
8. Assembling the spark plugs: Defective spark plug connectors that are damaged mechanically or which have a high-voltage ignition spark must be replaced immediately. Renewing the spark plug sealing ring (very important). In the case of old sealing rings, combustion gasses 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 flexible for the following disassembly. Spark plug assembly: 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. life. Fitting a new sealing 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. Moisten the spark plug screw thread using universal lubricant. Type 2, 3 and 4 engines: „ULTRA-THERM“ „ULTRA-TH ERM“ Tl No. 323765 (fluid in bottles) or Tl No. 128407 (Spray) Type 6 engine: „NEVER-S „NEVER-SEEZ“ EEZ“ TI 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).
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0309 M0 Ignition voltage check/Spark plugs
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: 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 accompani accompanied ed by a noticeable click. click.
8.2.1 Type 6 engine Lifer-Saver spark plug connector: 1. Firstly, the bayo bayonet net catch must b be e locked by tur turning ning the ar arrow row into the specific specific red dot or the the 0 position and pressing down.
Use the groove as the point of application and press down using two fingers: 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. 2. Following the locking of the bayonet bayonet catch, it is imp important ortant that the spark plug connector is connected 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.
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 engine is started! started!
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Documentation
8.2.2 Connection to the R coil : The spark plug connector must be connected to the R coil and the union nut must be screwed hand-tight. Attention: The Attention: The intermediate thread ring for the R coil must be replaced where worn.
Thread ring
8.3
High-voltage cable: Ensure that the high-voltage cable stars (distance pieces) are assembled correctly to prevent the highvoltage cables and engine paint layer from becoming damaged – see pictures below.
Right
Wrong
9. Checking following recommissioning: Following recommissioning, 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 minutes of full-load full-load opera operation, tion, check the voltages voltages once more. All voltage values values must amount amount to at least ~15 ~15 kV and not e exceed xceed ~18 kV. Should Should the voltage voltage on one one or more of the spark plugs be less than ~15kV without misfiring occurring at full-load operation or in the range between full-load and idling speed, no further measures will be required. Alternatively, the electrode distance of spark plugs with low voltage must be increased by approximately approximately 0.05 mm. The voltage must then be retested. Should the voltage exceed ~18 kV, 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 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) (CH4:CO2) ratio (particularly in the case of landfill gas of varying gas quality).
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Maintenance works: W 0400 M0 Valve clearance
Documentation
KLS98
1.
______________________ ________________________ _______________________ ___________________1 ________1 Reference: __________
2.
Measurement of valve projection: ____________ ________________________ _________________3 _____3 valve stem projection:
3.
Adjustment of tappet clearance: ___________ _______________________ ________________________4 ____________4
4. 4.1 4.2 4.3
_______________________ ___________ _______________________ ______________________ _____________________4 __________4 Legend: Notes on figures: _________________ _________ ________________ _________________ _________________ ________________ _________________ ___________4 __4 Text of figure 1: ________ ________________ ________________ ________________ _________________ _________________ ________________ _____________4 _____4 Text of figure 2: ________ ________________ ________________ ________________ _________________ _________________ ________________ _____________5 _____5
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
1. Reference: Tappet clearance can be checked or set in cold or warm condition. Set - points: Inlet valve: 0,0157 in (0,40 mm) Outlet valve: 0,0236 in (0,60 mm)
Valve clearance
The wear of valve and seat ring may totally amount to max. 0,098 in (2
+0,5
mm).
After 0,059 in (1,5 mm) total total wear and/o and/orr by the first disco discovery very of valve wear wear of more than than 0,008 in in (0,2 mm) within an inspection interval, the valve clearance inspection intervals are to be halved. With more than 0,098 in (2,5 mm) wear, the cylinder heads are to be changed (top end overhaul). Dimensions of projections: Cylinderheads - NEW
Inlet valve: 1,13 in (28,6 mm) Outlet valve: 1,14 in (29 mm)
Enter the values in the table Data Registration Valve-Stem Projection (E 0400). 0400).
Turn the engine counter clockwise, when viewed towards the fly-wheel side, to adjust the valve play and measure the valve stem projection. Turn the engine so that the piston of the cylinder head to be checked or measured respectively respectively stands at the upper dead centre (ignition upper dead centre) (enter ignition upper dead centre at the flywheel). Observation as for further turning: tooth number / 360° x ignition distance = the tooth number to be turned e. g.: 164 / 360° x 70° = 31,88 = 32 teeth
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Maintenance works: W 0400 M0 Valve clearance
Documentation
J 208 GS Cylinder identification l e e h w y a l F
Tooth number = 162
Firing order: Firing intervals:
J 212/312 GS Cylinder identification l e e h w y a l F
Tooth number = 164 Firing order: Firing intervals:
J 216/316 GS Cylinder identification l e e h w y a l F
Tooth number = 164 Firing order: Firing intervals:
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Maintenance works: W 0400 M0 Valve clearance
Documentation
J 320 GS Cylinder identification l e e h w y a l F
Tooth number = 164 Firing order: Firing intervals:
At ignition TDC both both valves are closed closed and the valve rockers a are re unloaded; unloaded; in this position position the valve stem stem projection is measured, followed by checking or setting of the valve clearance. The tappet clearance is measured between rocker and valve stem. It is correctly set if the feeler gauge (0,016 in or 0,023 in (0.4 or 0.6 mm) respectively) can be pulled through with little resistance.
2. Measurement of valve stem projection: Clean sealing surface on supporting surfaces of the valve cover at cylinder head. Mount the test stand on the cylinder head - refer to figure 2. Slightly move the valve rocker laterally. Measure the distance between test stand and valve stem ends by means of a depth gauge. Dismount measuring stand and put rocker back into start position.
Example: Actual shaft projection projection = 1,89 in (48 (48 mm) (m (measuring easuring stand height) - measured measured value. 1,89 - 0,69 = 1,2 in 48 - 17,6 = 30,4 Actual valve stem projection projection (e (enter nter into the data-acquisition data-acquisition table) Actual valve stem projection Test stand height 1,197 - 1,126 = 0,071 in 30,4 - 28,6 = 1,8 Actual value (wear) (wear) New value Actual valve stem projection
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Maintenance works: W 0400 M0 Valve clearance
3. Adjustment of tappet clearance: Slacken fastening nut with adequate ring spanner (fig. 2, pos. 1 and 3). The valve play is adjusted using the adjusting screw. Screw down fastening nut with adequate ring spanner while simultaneously holding up the adjusting screw. Check tappet clearance again with feeler gauge, correct gauge, correct if necessary. The tappet clearance might have been changed during fixing of the fastening nut by a locknot. Fastening nuts which are too stiff or have too big a face clearance, i. e. show a damaged thread, must be replaced.
4. Legend: 4.1
Notes on figures: Figure 1: Sectional view view of cylinder cylinder head Figure 2: Total view of cylinder head with mounted mounted test stand for measuring the valve stem projection.
4.2
Text of figure 1: It. No. Designation I Wear on valve II Wear on seat ring III Valve clearance IV Valve set-back 1 Seat ring 2 Valve 3 Cylinder head 4 Valve rocker bracket
4 I I I
V I
3
I, II
2
1
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4.3
Maintenance works: W 0400 M0 Valve clearance
Text of figure 2: It. No. Designation A Outlet valve E Inlet valve 1 2 3 4 5
Fixing nutscrew for inlet valve Adjusting Fixing nut Adjusting screw for discharge valve Test stand for measurem measurement ent of valve stem projection E
1
2
5 3 A 4
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Maintenance works: W
0506 M0 Crankcase vent
Documentation
KLS98
1.
1.1
2.
2.1
2.2 2.3 2.4
Oil mist lubricator: ____________ ________________________ ________________________ ______________________1 __________1 1
Replace the filter cartridge of the oil mist lubricator.
Filter cloth:_____________ cloth:________________________ _______________________ _______________________ _________________2 ______2 Disassembly:
2
Disassembly of the crankcase ventilation: Cleaning: Replace:
2 2 2
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
2 20
Wartungsarbeit Oil mist lubricator - filter carteige replace filter cloth - change
Punkt 1. 2.
Interval every 2000 Oh 20000 Oh
A clogged filter will prevent pressure compensation, possibly resulting in oil leakage (e. g. rotary shaft seal - crankshaft).
1. Oil mist lubricator: 1.1
Replace the filter cartridge of the oil mist lubricator.
Filter housing
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Maintenance works: W
0506 M0 Crankcase vent
2. Filter cloth: 2.1
Disassembly: Disassemble the venting line, remove the fastening screws and then remove the entire crankcase ventilation from the crankcase.
2.2
Disassembly of the crankcase ventilation: Remove the screws. Remove hood, cover and filter with filter cloth without tilting the components. Remove the filter cloth from the filter and dispose of the element in an environmentally responsible way.
2.3
Cleaning: Clean all components using white spirit.
2.4
Replace: Replace the filter cloth. Connection for vent line Flange
Sieve
Filter cloth
Cover
Cap Screws
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Maintenance works: W
0601 M0 Torsinal vibration damper KLS98
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart. The slightest damage to the torsinal vibration damper housing can severely impair its function or make it impossible.
1. Change the torsinal vibration damper: Disassemble the torsinal vibration damper protection. Remove hexagonal socket screws. Dismantle the torsinal vibration damper. (For easier disassembly, and assembly of the new torsinal vibration damper, the rod-device intended for this purpose should be used – TL-Nr. 156911). Apply lube oil to bolt thread and contact surface surface befor before e mounting. Fit the new torsinal vibration damper. Fit the torsinal vibration damper protector.
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Maintenance works: W
0704 M0 Gas-mixer
Documentation
KLS98
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
Interval every 10 20 20/30
Maintenance works works Replace the circuit board and the rubber sleeve Replace the servomotor Overhaul
10000 Oh
20000 Oh
*) only for B15, B16, B17, B21, B27, special gasses, hot cooling 95 – 110 °C
Disassembly: Hexagon head cap screw 1, Remove cover 2 and conical nipple 3. Switch off supply voltage to control motor and circuit board (i. e. disconnect clamp of DM455 and withdraw fuse from module interface).
Disassemble the circuit board and servomotor and replace these.
*) *)
30000 Oh
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Entwicklungsgruppe B B
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Documentation
Remove hexagon nut 4, discs 5 and threaded rod 6.
Remove steel plate.
Turn the circuit-board shaft of the gas mixer in the direction "AUF" (open) (20 mA). Switch on supply voltage to control motor and circuit board (connect clamp of DM455 and insert fuse into module interface). Caution: danger of short-circuit The control motor will unscrew itself out of the gas-mixer shaft (if the motor does not run, check whether the Auto/Man button button in dia.ne (screen (screen 41 41)) is set to 'Auto', 'Auto', turn the potentiometer in the direction of "ZU"(shut)(4 mA), and subsequently in the direction of "AUF" (open) (20 mA)). Switch off supply voltage to control motor and circuit board again. Remove wiring from control motor and circuit board.
Maintenance works: W
0704 M0 Gas-mixer
Issued:
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Entwicklungsgruppe B B
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Maintenance works: W
0704 M0 Gas-mixer
Documentation
Layout of cables:
W0704-36
Name Stepping motor R/I converter plate Motor phase 1 (+) Ph1+ (green) 1 (green) Motor phase 1 (-) Ph1- (red) 2 (red) Motor phase 2 (+) Ph2+ (black) 3 (black) Motor phase 2 (-) Ph2- (grey) 4 (blue) + 24 V IN 1 (yellow) + mA OUT 2 (black) Schirm 3 (Schirm) Attention: The colours colours of the cores cores might ch change ange accor according ding to the manufacture manufacturer! r!
Simulation device 11 (green) 12 (red) 21 (black) 2 (blue) 2 30 V (yellow) Iein no connection
Inspection: Check if the gas mixer shaft can be easily moved in the gas mixer case. (Check: slide the motor forward and back while it screws itself out of the gas-mixer shaft.) Check shaft and setting thread for wear. Replace, if necessary. Relubricate the adjusting screw thread and apply a small amount of grease to the shaft.
Assembly: Assemble the spring spring to the new new servomotor. Connect the cabling of the servomotor and the circuit board. Turn the circuit-board shaft of the gas mixer in the direction "ZU" (shut) (4 mA). Switch on the power supply of the servomotor and circuit board again. Fit the servomotor into the screw thread by hand. The motor will screw itself into the gasmixer shaft and open until it reaches the mechanical stop. Switch off the power supply of the motor and circuit board again. To continue the assembly, follow the disassembly procedure in reverse order. Do not assemble the circuit board yet.
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0704 M0 Gas-mixer
Adjusting the 0% position: Turn the circuit-board shaft in the direction "AUF" (open) (20 mA) until it reaches the mechanical stop. Switch on the power supply of the motor and circuit board. The gas mixer closes until it reaches the mechanical stop. Switch off the power supply of the motor and circuit board again. Turn the circuit-board shaft in the direction "ZU" (shut) (4 mA) until it reaches the mechanical stop (now the mixer is "ZU" (shut) (0%) and the potentiometer is "ZU" (shut) (4mA)). Assemble the circuit circuit board with the poten potentiometer tiometer shaft o on n the servomotor servomotor (there (there are two types: types: circuit boards with a ribbed ribbed potentiometer potentiometer shaft and circuit boards with a smooth smooth potentiometer potentiometer shaft).
Assembling circuit boards with a ribbed potentiometer shaft: The ribbed potentiometer shaft prevents the shaft from sliding in the rubber sleeve. Insert the new rubber sleeve into the transmission unit leaving only approx. 1 mm of the rubber sleeve sticking out from the blind hole. Insert the circuit board with potentiometer shaft into the rubber sleeve. Assemble the circuit board using 4 M4 nuts. Lock the M4 nuts using locking paint. Assembling circuit boards with a smooth potentiometer shaft: Glue the new rubber sleeve onto the potentiometer shaft using Loctite 454 glue to prevent the potentiometer shaft from sliding in the rubber sleeve. Before gluing the rubber sleeve to the potentiometer shaft, make sure to carefully remove all the white powdery deposit in the rubber sleeve which was left behind during its manufacture. Slide the rubber sleeve onto the potentiometer shaft. Lift the rubber sleeve at the front from the shaft using a flat screwdriver. Insert a drop of super glue into the opening created and move the screwdriver one full turn around the potentiometer shaft (to make sure that the glue is evenly spread along the front part of the rubber sleeve and to prevent glue from entering the potentiometer). potentiomete r). The curing time of the glue is 2 minutes. Slightly press on the potentiometer to insert the circuit board with potentiometer shaft into the blind hole. Assemble the circuit board using 4 M4 nuts. Lock the M4 nuts using locking paint. Switch on the potentiometer potentiometer supply voltage. The rest of the assembly is carried out in reversed order of the disassembly.
1 4, 5, 6 2, 3
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0802 M0 Mixture bypass valve KLS98
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
1. Replace the mixture bypass valve:
mixture bypass valve
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Inspections: I
0103 0 Inspection
Data registration: E 0103 a/b/c
Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart.
1. Mixture/water heat exchanger: 1.1
Mixture-sided differential-pressure differential- pressure measurement: Connect pressure gauge to measuring points. Measure the differential pressure at full load.
Enter the readings in table Data Capture Mixture/Water Heat Exchanger (E 0103 a). a).
If the differential pressure exceed exceeds s the value measured at commissioning by ≥ 20 mbar [0,29 psi] (200 mm [78,74 in] water column), the heat exchanger should be cleaned on the mixture side. 1.2
Clean on mixture side: Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart. Remove cooler. Wash out the dry cooler in a solvent, e. g., "P3 - Kaltreiniger," and rinse thoroughly with a powerful stream of water. Only solvents which affect neither brass nor tin may be used. At the upstream upstream side the sealings sealings of the mixtu mixture re cooler ((mixture mixture cooler cooler – connecting connecting cover or blind blind cover respectively) should be renewed.
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Technical Instruction No.: No.: 1100-0110
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Boundary conditions for GE Jenbacher gas engines
1. Tips: ______________________________________________________________2 2. Explosion hazard: ___________ ______________________ _______________________ ________________________ _________________2 _____2 3. Gas and smoke alarm:________________________________________________2 4. Fuel gas: _______________________ ____________ _______________________ _______________________ ______________________ _____________3 __33 4.1 DIANE: 5. Intake air: _______________________ _______________________ _______________________ _______________________ ____________3 3 air: ____________ 5.1 5.2
Engine room: Cooling air generator:
3 5
6. Cooling water for engine cooling: ___________ _______________________ ________________________ _______________6 ___6 7. Cooling water for mixture and oil cooling: cooling: ___________ _______________________ ____________________6 ________6 8. Raw water, warm water, hot water: ___________ _______________________ ________________________ ______________6 __6 9. When operating with steam boiler: ____________ _______________________ _______________________ ______________6 __6 10. Lubricating oil: ____________ ________________________ _______________________ _______________________ __________________6 ______6 11. Exhaust gas:_________ gas:____________________ _______________________ ________________________ _______________________ ___________7 7 12. Electrical conditions:_______ conditions:___________________ ________________________ ________________________ _________________7 _____7 13. Operation and maintenance: ____________ ________________________ ________________________ _________________7 _____7 14. Pipelines (pickling and cleaning): ____________ ________________________ ________________________ _____________8 _8 15. Connections (GE Jenbacher‘s Jenbacher‘s limits of supply): ___________ _______________________ ______________8 __8 16. The following TIs should be complied with: ___________ _______________________ __________________9 ______9
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Boundary conditions for GE Jenbacher gas engines
1. Tips: Installation-specific Installation-sp ecific conditions: see relevant technical specification. The limiting values for harmful emissions guaranteed guaranteed in the technical t echnical specification specification can be met only at a load of between 50 and 100%. The characteristics of the product as stated can be guarante guaranteed ed only if the conditions specified in the Technical Instruction are met and if the maintenance is carried out regularly and expertly.
2. Explosion hazard: In principle, GE Jenbacher products are not not intended intended or suitable for use in surroundings in which there is a risk of explosion.
3. Gas and smoke alarm: 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. regulations. The number of sensors applied must correspond to the requirements of this TI as a minimum. Natural gas: at least 1 sensor / engine Non-natural gas: at least 2 sensors / engine CO in fuel gas: adjust number of CO sensors per installation (at least 2 sensors / engine) The sensors must be suited to the gas components (taking toxicity into account!). Take the results of the gas analyses into account! Take into account the following fundamental principles when determining the installation location for the gas-alarm sensors: sensors: - If the engine is run on natural gas, a sensor must be placed above the gas pressure control system. - 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 pressure control system. - If the fuel gas contains CO, CO sensors must be installed if: the gas is odourless and the CO content of content of the fuel gas is >0% >0%.. the gas contains odours odours and and the CO content of content of the fuel gas is >0.5% >0.5%.. CO sensor(s) in areas where people work, especially dangerous areas (next to components containing gas) and CO sensor(s) in areas without air flow (insufficient room ventilation). The sensors must be installed at breathing height. •
•
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4. Fuel gas: Make sure that the fuel gas quality is in accordance with TI No. 1400-0091 and TI No. 1000-0300. When supplying fuel gas to GE Jenbacher products, gases must be used that will not ignite under the conditions that prevail outside the engine (mixer connection interface) interface).. Where required, take additional technical measures (e.g. monitoring / controlling the oxygen concentration in the gas -> emergency switch-off), thereby taking into account any specific national regulations. A manual stop valve must 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. In case of CO in fuel gas: if the CO content in content in the fuel gas is >5% >5%,, a nitrogen flushing installation installation must be installed. It is the operator’s responsibility responsibility to ensure that the fuel gas system is equipped with the necessary devices, does not leak and meets official requirements. requirements.
4.1
DIANE: If the contractually agreed minimum methane value (see technical specification) is underrun, the engine control will automatically take the following steps to achieve a knock-free operation and/or to prevent knock damage: a) reduce the mixture temperature (if a controller has been installed and the ambient conditions so allow); b) set the ignition point to a later point in time, but still within the admissible range range (followed by a decrease in the degree of efficiency); c) reduce the engine output to 50%; d) If these anti-knock measures prove prove to be insufficient, the knock-control system will switch off the engine.
5. Intake air: 5.1
Engine room: Use forced-draught fans for engine-room ventilation. To prevent false starts and deflagrations deflagrations when starting (the engine-sided air/gas mixer functions just like a carburettor and is very sensitive to temperature fluctuations and pressure differences), the engine-room ventilation must also be activated when requested by the module via the output contact „Auxiliary equipmentt ON“. This way, a controlled set of preconditions is created when starting and accelerating. equipmen That is why you must not switch off the engine-room ventila ventilation tion until approx. 5 minutes after synchronization when the preset engine-room temperature is reached (engine-room thermostat), nor should you switch from the mains to the generator within this period of time. This means that during the starting and accelerating procedure (including synchronization), no switching of the engine-room ventilation system should occur.
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Boundary conditions for GE Jenbacher gas engines
Intake (of combustion air) from the engine room: When taking in combustion air from the engine room, the engine room (cladding) should be free from dust and fibres. The required filter mesh rate should be strictly adhered to. If refrigeration compressors are installed in the engine room, the intake air should be drawn in from the outside atmosphere. Intake air: air: Dust-free air of purity class G3 according to EN 779 and/or a filter degree of 85% according to ASHRAE. If required, install a coarse-dust filter of the relevant filter class! Max. engine-room temperature: 40°C [104°F] [104°F] (to (to be reached at an outside temperature of max. 35°C [95°F] [95°F]). ). If higher engine-room temperatures are expected, have GE JENBACHER supply a special module version! Max. air intake temperature (at the engine air filter): Take appropriate measures to keep the combustion air temperature down (+10°C to +25°C [+50°F to +77°F]). +77°F] ). The temperature should be as constant as possible and vary only within the t he smallest possible bandwidth. The following steps may be taken: e.g. separate air guide systems up to the air-filter intake, circulation-air control facilities at the engine-room air intake, speed-controlled fans to keep the temperature constant, etc. Attention: Attention: As for the air pressure, pressure, air intake intake temper temperature ature and atmospher atmospheric ic humidity, the limiting limiting values according according to ISO 3046 apply: i.e. 1,000 mbar [14,5 psi], psi], +25°C [77°F] [77°F],, 30% humidity. In the case of differing conditions at the installation site, the specific engine performance will be reduced. This corresponds to the standard preconditions as applied 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 [104°F] [104°F].. In that case, the compressor system would have to be modified and the technical specifications corrected. Such arrangements should be contained in writing in the specification. Min. air intake temperature and/or engine room temperature: temperature: The starting behaviour of the engine and the power of the starting motor and the starting batteries are designed for a minimum ambient temperature of +10°C [50°F] [50°F].. To prevent starting problems, an electric cooling water preheating system is installed in every engine. Engine room ventilation: The engine-room ventilation must be designed so as to: - make sure that the entire engine room is properly ventilated (to prevent unwanted collection of gases), - guarantee a directed airflow across the engine to make sure that the surface temperatures of the electrotechnical electrotechni cal components installed on top of the engine (ignition coils, ignition cables, knock-control and charge-pressure sensors, throttle-valve actuator, etc.) do not exceed a temperature of +70°C [158°F]!! [158°F]
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Boundary conditions for GE Jenbacher gas engines
If this is not guaranteed 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. - guarantee that outside air is pushed into the engine room by the frequency-controlled fans and the engine room is slightly overpressurised. Engine-room overpressure: > 0.1 mbar [>0,00145 psi], psi], < 0.5 mbar [
