Maint Inst GEJ320 PDF

Jenbacher 1.
1
Documentation Sections of the GE Jenbacher
Product Documentation
Description - Operation
• Operation of the system
• Fault rectification
• Description of the engine and the system
• Choice of fuels
• Technical instructions
Maintenance
• What inspection work and maintenance work needs to be carried

out?
• When should the work be carried out?
• How should the work be carried out?
• Gathering operational data
Spare Parts List
• Selecting the required spare part
• Ordering the spare part
• Allocating the spare part
Keyword: Baja - Madu Lingga Unit no.: J D651 Module no.: 490458 1
Module type : JGS 320 GS-N.L Version: C105 Engine no.: 490457 1
Issued: Doku./Schartner Checked: Dokumentation Date: 2006-02

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Jenbacher 1.2
Documentation Key to Symbols
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 as described.
Inspect
Inspect the components or operating materials as described
Tightening Torque
Tighten the nut or bolt to the specified tightening torque.
Clean
Clean the component as described.
Lubricate
Lubricate or grease the component as described.
Reference
Reference to a document or a section of the product documentation.
Information
Important information or important note.
Issued: Doku./Velik Checked: Dokumentation Date: 2007-03

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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 crank case.
Engine type
Motor Typ
Moteur modèle
Engine no.
Motor Nr.
Moteur numèro
kW
HP
kW
HP
Speed min
-1
Drehzahl
Nombre de tours rpm
kg
lbs
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
Module type: JGS 320 GS-N.L Version: C105 Engine no.: 490457 1

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Jenbacher 1.3
2. Type designation:
2.1 Engine type designation:
Term Abbreviation Key to abbreviation Example

Manufacturer J GE Jenbacher J 320 GS C05
Type 1
2
3 J 320 GS C05
4
6
No. of cylinders *) 6 6 cylinder in-line engine
8 8 cylinder in-line engine
12 12 cylinder V-engine J 320 GS C05
16 16 cylinder V- engine
20 20 cylinder V- engine
Mode of operation GS Gas engine, turbocharged
(e.g.) J 320 GS C05
GSH Gas engine, turbocharged and hot
cooled
Design A First design
J 320 GS C05
B, C, D, E ... Modified designs
Version (e.g.) 02 Natural gas; ½ TA-Luft
05 Natural gas; TA-Luft J 320 GS C05
27 Biogas; TA-Luft
*) Exception: J 156 GS Æ 6 cylinder in-line engine
Mode of
operation
Design
Manufacturer Version
J 3 20 GS C 05
Series
No. of cylinders

Jenbacher 1.3
2.2 Module type designation:
Term Abbreviation Key to abbreviation Example

Manufacturer J GE Jenbacher JMS 320 GS-N.LC
Unit type (e.g.) M Co-generation plant
G Generator set JMS 320 GS-N.LC
C Compressor set
Installation type S stationary
JMS 320 GS-N.LC
C in a container
Type 1
2 JMS 320 GS-N.LC
3
4
6
No. of cylinders *) 06 6 cylinder in-line engine
08 8 cylinder in-line engine
12 12 cylinder V-engine JMS 320 GS-N.LC
16 16 cylinder V-engine
20 20 cylinder V-engine
Mode of operation (e.g.) GS Gas engine, turbocharged
GSH Gas engine, turbocharged and hot JMS 320 GS-N.LC
cooled
Type of fuel gas N Natural gas
B Biogas
L Landfill gas
P Propane gas JMS 320 GS-N.LC
S Special gas
N/B Natural gas /biogas (2-gas
operation)
Exhaust gas purification L LEANOX engine
LC LEANOX engine with oxidation-
JMS 320 GS-N.LC
type catalytic converter
C 3-way catalytic converter
*) Exception: J 156 GS Æ 6 cylinder in-line engine
Mode of
Installation type
operation
Unit type Type of fuel gas
Alternative
Manufacturer
type of fuel gas
J M S 3 20 GS - N /B . LC
Type
Exhaust gas
purification
No. of cylinders

Jenbacher 1.4
Documentation GE Jenbacher Web Portal
The web portal contains the latest online information on our products, drawings, Service Bulletins,
SPATSL (the digital spare parts catalogue), background knowledge concerning gas engine technology
etc. You can also download interesting documents to your PC via the web portal. The web portal’s url is:
http://information.jenbacher.com
When you first visit the web portal, you will find general information on GE Jenbacher. Since you are a
GE Jenbacher customer, we are offering you the possibility of increased access rights for which you only
need to register online.
Registration:
Click on "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" to enter
your personal profile, which you may edit yourself.
Issued: Doku./Velik Checked: VSB/Steinberger Date: 2007-01

Jenbacher 1.4
As soon as your increased access rights have been confirmed, you can enter the increased access web
portal below:
Menu bullets – Tips:
• “Products + Services” -> “Products 50/60 Hz” menu

Viewing and downloading drawings and diagrams for various engine types and applications.
• “Products + Services” -> “Service” -> “Service 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.

Jenbacher 1.4
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”.
After you have registered, you will receive a regular Newsletter. If you do not wish to receive it, click on
“No“.
If you have any questions, please contact your regular GE Jenbacher contact person.

Jenbacher 1.5
Documentation Your Views Are Important!
Dear Reader,
The purpose of this product documentation is twofold. Firstly, it should ensure risk-free operation 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?
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comprehensive?
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covered in enough depth?)
Any additional comments:
Rating: 1 = excellent 2 = good 3 = satisfactory 4 = adequate 5 = inadequate

EN 1_5___BW_BRall_EN.doc Index: b Page - No.: 1 / 1
Jenbacher 1.6
Documentation Service - and Sales partners
GE Jenbacher GmbH & Co OHG

Achenseestraße 1 - 3, A-6200 Jenbach
Tel.: +43 5244 600-0, Telefax: +43 5244 600 548
e-mail: info@gejenbacher.com
AT
GE Jenbacher
Servicecenter Wien
Am Concorde-Park 1/D2, A-2320 Schwechat
Tel.: +43 1 707 95 10, Telefax: +43 1 707 93 28
e-mail: jes.wien@gejenbacher.com
GE Jenbacher
Servicecenter Villach
Magdalener Straße 81, 9506 Villach
Tel.: +43 4242 431 124, Telefax: +43 4242 431 124 5
e-mail: markus.appenzeller@gejenbacher.com
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: info@powersolutions.ru
AE
United Arab Emirates
International 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.middleeast@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: gregc@clarke-energy.com
www: http://www.clarke-energy.com
BD
ORIENT Energy Systems Ltd.
5th 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: farrukh@orient-power.com
Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

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Jenbacher 1.6
BE
Sales Representative
Ecogen Energy Systems bvba
Vaart Rechteroever 225
B-9800 Deinze
Tel.: +32 938 64860, Telefax: + +32 938 61134
e-mail: jd@ecogen.be
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.bulgaria@ge.com
CA
Integrated Power Systems dba Diesel Allison Canada East
(Ontario, 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
e-mail: sales@ddace.com
Integrated Power Systems dba Waterous DDA (British Columbia, Alberta, Sask. Manitoba)
10025-51 Avenue Edmonton
Alberta T6E 0A8
Tel.: +1 780 437 8271, Telefax: +1 780 504 0255
e-mail: gbailey@wdda.com
CH
IWK Integrierte Wärme und Kraft AG (Sales)
Allmendstrasse 7, Ch-6061 Sarnen, Schweiz
Tel.: +41 522 260 730, Telefax: +41 522 230 733
e-mail: joachim.maier@iwk.ch
www: 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: heinz.lauffenburger@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: info@kogeneracija.co.yu
www: kogeneracija.co.yu

Jenbacher 1.6
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
e-mail: jenbacher asiapacific@ge.com
Distributor/Service 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: cpng@sh.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: Jenbacher.asiapacific@ge.com
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: polak.klor@sendme.cz
www: http://www.jenbacher.cz
JMP (Service)
Plynarenska 1, 65702 Brno
Tel.: +420 545 548 263, Telefax: +420 545 548 263
e-mail: jaroslav.hruska@rwe-jmp.cz
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@gejenbacher.com
DK
GE Jenbacher Denmark
Industrivej 19
DK-8881 Thorsø
Tel.: +45 8 6966788, Telefax: +45 8 6967072
e-mail: energy.jesthorso@ge.com

Jenbacher 1.6
EE
AS Filter
Peterburi road 56
11415 Tallinn
Tel.: +372 606 6666, Telefax: +372 606 6650
e-mail: filter@filter.ee
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: egypt@sakr.com
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
e-mail: alanf@clarke-energy.com
ES
GE Jenbacher Spain and Portugal
Avda. del Camino de lo Cortao, 34 - Nave 8
E-28700 San Sebastián de los Reyes (Madrid)
Tel.: +34 91 658 6800, Telefax: +34 91 652 2616
e-mail: jes.madrid@gejenbacher.com
GE Jenbacher Spain and Portugal

Ctra. de Hospitalet, 147-149 | Cityparc - Ed. Roma
E-08940 Cornellà de Llobregat (Barcelona)
Tel.: +34 93 475 1300, Telefax: +34 93 475 1301
e-mail: jes.barcelona@gejenbacher.com
FI
Höyrytys Oy
Palokorvenkatu 2
FIN-04261 Kerava
Tel.: +358 468 508 070, Telefax: +358 941 746 100
e-mail: jorgen.barlund@hoyrytys.fi

Jenbacher 1.6
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: info.michels@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.hungary@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: ozbolt@tzv-gredelj.hr
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@navigat.net
IE
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: alanf@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: stewart-fox@edina.ie (Service)
www: http://www.edinapower.com

Jenbacher 1.6
IL
MADEI TAAS Industrial Controls Ltd.
21 Hamelacha St. Park-Afek, Rosh Haayn, 48091
Tel.: +972 3 9027174, Telefax: +972 3 9027176
e-mail: mail@madeitaas.co.il
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: bhishikar.dc@clarke-energy-india.com
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@gejenbacher.com
IQ
Sakr Power Systems SAL
Kartaba Road, Industrial Area
Halata (Jbeil), Lebanon
Tel.: +961 9 444888, Telefax: +961 3 811108
e-mail: info@sakr.com
www: http://www.sakr.com
JP
GE Energy
Jenbacher Sales and Service Japan
Akasaka Park Bldg., 5-2-20 Akasaka,
Minato-ku, Tokyo 107-6111
Tel.: + 81 3 3588 5208, Telefax: + 81 3 3589 3372
e-mail: jenbacher.japan@ge.com
Hitachi Engineering & Services Co., Ldt.

2-2 Kandatacho Chiyoda-ku
Tokyo 101-0046
Tel.: +81 3 5297 0514, Telefax: +81 3 5297 0517
e-mail: osamu.fukunaga.ux@hitachi.hes.com

Jenbacher 1.6
Hitachi Engineering & Services Co., Ldt.

15-1, Higashionuma-cho, 1-chome
Hitachi-shi
Ibaraki-ken, 316-0023
Tel.: +81 294 36 7996, Telefax: +81 294 36 9637
e-mail: shigehisa.sugita.yp@hitachi-hes.com
Osaka Gas Engineering Co., Ldt.

1-4-100, Hokuko, Konohana-Ku
Osaka 554-0033
Tel.: +81 6 4804 2600, Telefax: +81 6 4804 2601
e-mail: t-joh@oge.co.jp
JO
Halata (Jbeil), Lebanon
Tel.: +961 9 444888, Telefax: +961 3 811108
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: rnp@rnp-ent.co.kr
LB
Halata (Jbeil)
Tel.: +961 9 444888, Telefax: +961 3 811108
LT
UAB Filter
Draugystes Str. 19, 3031 Kaunas
Tel.: +37 07 400 380, Telefax: +370 0872 1399
e-mail: filter@filter.lt
www: http://www.filter.lt

Jenbacher 1.6
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: enerlux@pt.lu
LV
Filter SIA
Aizkrauklesiela 21, 1006 Riga
Tel.: +371 755 6765, Telefax: +371 755 0224
e-mail: filter@filter.lv
www: http://www.filter-group.com
MY
JD Power Systems Sdn. Bhd.
No. 23, Jln Juruukur U1/19
Section U1
HICOM-Glenmarie Industrial-Park
40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel.: +603 5569 1000, Telefax: +603 556 92660
e-mail: chanhh@jdgroup.com.my
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: haydnr@clarke-energy.com
NL
GE Jenbacher Netherlands
Kelvinring 58
NL-2959 BF ALBLASSERDAM
Tel.: +31 (0) 88 0019700, Telefax: +31 (0) 88 0019701
e-mail: jes.sliedrecht@gejenbacher.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: m.saeed@orient-power.com

Jenbacher 1.6
PL
KWE - Technika 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: kwe.biuro@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: mail@gellweiler.pt
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
e-mail: office@teb.com.ro
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.russia@ge.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: info@sigmat.ru
ZAO Sigma Services (Service)

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

Krasnaja Presnja 28
123022 Moskau - Russische Föderation
Tel.: +7 095 363 95 05, Telefax: +7 095 363 9509
e-mail: info@vado.ru
www: http://www.vado.biz

Jenbacher 1.6
SE
GE Jenbacher Denmark
Industrivej 19, DK-8881 Thorsø
Tel.: + 45 8 6966788, Telefax: + 45 8 6967072
e-mail: jenbacher.scandinavia@ge.com
SI
IMP Inzeniring d.d.
Dunajska cesta 7, SLO-1113 Ljubljana
Tel.: +386 1300 9024, Telefax: +386 1300 9060
e-mail: borut.jurca@imp.si
www: http://www.imp.si
TES d.o.o.
Gregorciceva 3, Maribor 2000
Tel.: +386 2 229 4726, Telefax: +386 2 229 4727
e-mail: tes@siol.net
SK
EMES s.r.o
Trieda SNP 75
974 01 Banska Bystrica
Slovakia
Tel.: +421 48 4145183, Telefax: +421 48 4145183
e-mail: emes@bb.psg.sk
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
Topkapi
34104, Istanbul
Tel.: +90 212 534 04 10, Telefax: +90 212 524 58 46
e-mail: info@topkapigroup.com.tr
www: http://www.topkapigroup.com.tr
UA
Sinapse
7, Vanda Vasilevskaya Str.
03055 Kiev
Tel.: +38 044 238 0967 or +38 044 2380966, Telefax: +38 044 2380967 or +38 044 2380970
e-mail: lvm@sinapse.ua, oksana@sinapse.ua, www.sinapse.ua; www.cogeneration.com.ua

Jenbacher 1.6
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.us@ge.com
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: aclark@neesys.com or ffarrand@neesys.com
www: http://www.neesys.com
Western Energy Systems, a division of Penn Detroit Diesel Allison
(AK, CA, HI, OR)
499 Nibus Street, Brea, California 92821
Telephone: +1 714 529 9700
e-mail: aclark@weesys.com or ffarrand@neesys.com
Inland Diesel, Inc. (MN, MI, WI, IA, IL, IN)

13015 W. Custer Avenue,
Butler, WI 53007
Tel.: +1 262 781 7100, Telefax: +1 262 783 8974
e-mail: tpalmer@inland-dda.com
Smith Power 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: mhayes@smithdda.com
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: mwinkler@unitedengines.com
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: lleblance@nixonpower.com

Jenbacher 1.6
ZA
South Afrika/Botswana/Lesotho/Mozambique/Swaziland
Sales Representative/Service Provider
Agaricus Trading cc
Linkhills
Durban 3652
Tel.: + 27 31 7633222, Telefax: + 27 31 7633041
e-mail: paul@agaricus.co.za

Jenbacher 1.7
Documentation Imprint
This GE Jenbacher Product Documentation consisting of:
Description – Operation
Maintenance
Spare Parts List
was created by the Technical Documentation Department of GE Jenbacher.
If you have any questions, problems or suggestions regarding this Product Documentation please contact
us.
Address: GE Jenbacher GmbH & Co OHG

A-6200 Jenbach | Austria
Tel.: +43 | 5244 | 600-2221
Fax: +43 | 5244 | 600-42221
E-Mail: harald.hochrainer@GEjenbacher.com

Jenbacher 2.1
Documentation Designated Use
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 specifications. 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

3.1
Jenbacher Maintenance schedule
Documentation
Intervals independent of the number of operating hours

Inspection task Number/ Interval Note
section
Daily inspection round I 9002 0 daily Carry out daily visual inspection of the unit.
Operating data log --- daily Log the operating data daily.
If the underpressure increases to more
Intake air filter-Engine IW 8041 A0 daily than 1000 Pa, the filter elements in the pre-
filter and pocket filter should be replaced.
The result of the ignition voltage check to
Check ignition voltage/ weekly be carried out weekly, serves as the
IW 0309 M0
spark plug < 250 oh indicator for the actual service life of the
spark plug.
IW 0101 M0
The results from the engine lubricating oil
TA 1000-0099A first time after
Lubricating oil analyses are decisive for the actual oil
TA 1000-0099B 150 oh
change periods.
TA 1000-0099C
Check the acid level.
Battery TA 1000-0050 once in a month Check if the pole binders are properly
secured.
Check air filter for pollution.
Air filter in switch cabinet --- once in a month
If necessary, clean or replace.
TA 1000-0200
Cooling water TA 1000-0201 once in a year Concentration inspection
TA 1000-0204
30000 oh
after having
W 8080 A0 completed the Cooling water exchange
overhaul
activities
Battery in DIANE module --- every two years Replace
Storage battery at battery
--- every five years Replace
charger
Proper maintenance according to the maintenance schedule is a condition for honouring any claims
under warranty.
After the „Overhaul“ 60000 operating hours, the maintenance work to be carried out is repeated at the
same interval periods.
Issued: Doku./Velik Checked: VMP_Klammer Gerhard/TEAM_Egger Christoph/CSA_Sonnerer Herbert Date: 2007-03

EN 3_1_EN.doc Index: d -- No.: 1 / 4
3.1
Documentation
Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly

Maintenance task/ Number Operating hours
Interval ref. nr
Inspection task
< 100
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
- Maintenance after first start-up W 1000 0
2 Valve clearance W 0400 M0
2 Ignition system W 0303 M0
2/20 Crankcase suction filter W 0506 M0
Regulating rods/Throttle valve/
2/30
Actuator W 0200 M0
2/30/
60 Gas train W 8045 A0
10 Inspection I 0103 0
10 Turbocharger W 8023 M0
10 Engine cooling water pump W 0202 M3
10 Starter W 8032 M0
10/20/
30 Gas mixer W 0704 M0
20 Mixture bypass valve W 0802 M0
20 Torsion vibration damper W 0601 M0
20 GE Jenbacher-switch cabinets W 8031 A0
30 Piston/Piston cooling W 8047 M0
30 Con rod/Con rod bearing W 8048 M0
30 Cylinder liner/Scraper ring W 8049 M0
30 Crankshaft main bearing W 8050 M0
ZK
Camshaft/Steering parts W 8052 M0
30
60 Engine oil pump W 8046 M0
60 Turbocharger after-lubrication
pump W 8054 M0
60 Overhaul W 2100 M0
ZK Exhaust gas manifold/Isolation W 8051 M0
- Cylinder head replacement W 8053 M0 if required
- Generator W 8030 A0
- Elastomer parts W 8033 0
Please note that properly carried out maintenance work is to be acknowledged by

filling in the maintenance protocol.

3.1
Documentation

Interval ref. nr
Inspection task
21000
22000
23000
24000
25000
26000
27000
28000
29000
30000
31000
32000
33000
34000
35000
36000
37000
38000
39000
40000
2/20 Crankcase vent W 0506 M0
2/30
Actuator W 0200 M0
2/30/
10/20/
ZK
30
60 Turbocharger after-lubrication pump W 8054 M0


3.1
Documentation

Interval ref. nr
Inspection task
41000
42000
43000
44000
45000
46000
47000
48000
49000
50000
51000
52000
53000
54000
55000
56000
57000
58000
59000
60000
2/20 Crankcase vent W 0506 M0
2/30
Actuator W 0200 M0
2/30/
10/20/
ZK
30
60 Turbocharger after-lubrication pump W 8054 M0


4.1
Jenbacher Inspections/Maintenance works
Documentation
Index
Inspection I 0103 0
Daily inspection round I 9002 0
Lubrication oil/Oil-filter change IW 0101 M0
Spark plug IW 0309 M0
Intake air filter-Engine IW 8041 A0
Regulating rods/Throttle valve/Actuator W 0200 M0
Engine cooling water pump W 0202 M3
Ignition system W 0303 M0
Valve clearance W 0400 M0
Crankcase vent W 0506 M0
Torsion vibration damper W 0601 M0
Gas mixer W 0704 M0
Mixture bypass valve W 0802 M0
Maintenance after first start-up W 1000 0
Overhaul W 2100 M0
Turbocharger W 8023 M0
Generator W 8030 A0
GE Jenbacher-switch cabinets W 8031 A0
Starter W 8032 M0
Elastomer parts W 8033 0
Gas train W 8045 A0
Engine oil pump W 8046 M0
Piston/Piston cooling W 8047 M0
Connecting rods/Connecting rod bearing shells W 8048 M0
Cylinder liner/Scraper W 8049 M0
Crankshaft main W 8050 M0
Exhaust gas manifold/Isolation W 8051 M0
Camshaft/Control parts W 8052 M0
Cylinder head W 8053 M0
Pre-lubricating pump W 8054 M0
Filling the cooling water W 8080 A0

EN 4_1__W_312-320_EN.doc Index: - Page - No.: 1 / 1
5.1
Jenbacher Maintenance protocol
Documentation
Module no.: . . Engine no.: . .
Maintenance Operating hours Date Signature

at Oh Starts Mechanic 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.
Issued: Doku./Bilek Checked: Dokumentation Date: 2006-02

EN 5_1_2000_EN.doc Index: b Page - No.: 1 / 2
5.1
Jenbacher Maintenance protocol
Documentation
Maintenance Operating hours Date Signature

at Oh Starts Mechanic Operator
Oh
32000
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.
After the "Overhaul" 60000 operating hours, the maintenance work to be carried out is repeated at
the same interval periods.

EN 5_1_2000_EN.doc Index: b Page - No.: 2 / 2
Jenbacher IW 0101 M0
Inspections/Maintenance works:
Documentation Lubrication oil/Oil-filter change
KLS98
1. Note: ______________________________________________________________1
2. Procedure when changing oil: _________________________________________2
2.1 Draining lubricating oil: 2
2.2 Work to be performed following the first oil drain (for modules with an additional lubricating oil
tank): 2
2.2.1 Remove plug at oil pressure control valve. 2
2.2.2 Connect the flexible line attached to the module. 2
2.2.3 Remove plug at crankcase cover. 3
2.2.4 Connect the flexible line attached to the module. 3
2.3 Oil filter replacement - engine lubrication oil filter and oil filter for the supercharger after-cooler
(only for ABB exhaust-gas turbochargers): 3
2.4 Fill with lubricating oil: 3
2.4.1 without oil flow meter, without auxiliary tank: 3
2.4.2 with oil flow meter, without auxiliary tank: 4
2.4.3 with or without oil flow meter, with auxiliary tank: 4
2.4.4 The following applies to engines without ABB-TPS turbocharger: 4
2.4.5 The following applies to engines with ABB-TPS turbocharger: 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 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 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
TI 1000-0099C.
Enter the dates of the oil analyses and/or oil changes in the table Data
Registration Engine Lubrication Oil (E 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 Checked: TKE/Esterhammer Date: 2006-10

EN 0101M0_EN.doc Index: g Page - No.: 1 / 5
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 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. (Pump-
off 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.

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 is started the oil level drops again to the middle of 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.

2.4.2 with oil flow meter, without auxiliary tank:

Attention: The oil flow meter is suitable only for small flow rates. Never fill through the oil flow meter!

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, close the oil
filling valve, deactivate the fresh oil pump and turn three-way valve 4 into the “oil-quantity counter”
position.
2.4.3 with or without oil flow meter, with auxiliary tank:

Attention: Fill the engine only over the auxiliary tank!

Switch on fresh-oil pump.
Fill up the oil to the third marking on the inspection glass housing.
Switch off the fresh-oil pump.
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
Key: Press the turbocharger after-lubrication pump key.
2.4.5 The following applies to engines with ABB-TPS turbocharger:

Activate the electrical prelubrication system for a couple of minutes following the oil change to ensure that
the lubricating oil heat exchanger is filled.
Text to illustrations
Pos. No. Designation
1 oil filling valve
2 oil flow meter
3 sight glass
4 three-way cock
5 drain cock

1
OPEN
CLOSE

Jenbacher W 0200 M0
Maintenance works:
Documentation Regulator linkage/Throttle valve/Actuator
KLS98
1. Regulator linkage: ___________________________________________________1

1.1 Checking: 1
1.2 Re-lubrication: 1
2. Throttle valve: ______________________________________________________1
2.1 Checking: 1
3. Renewing throttle valve bearing and O-ring: _____________________________2
4. Adjusting the Governor Rod Assembly: _________________________________2
5. Actuator: ___________________________________________________________4
Interval every
Maintenance works Point 2000 Oh 30000 Oh
02 Regulator linkage –checking/Re-lubrication 1.
02 Throttle valve - checking 2.
30 Actuator - Overhaul 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 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).

EN 0200M0_EN.doc Index: d Page - No.: 1 / 4
Jenbacher W 0200 M0
Maintenance works:
3. Renewing throttle valve bearing and O-ring:
Remove screws 7, 11 and 13 and completely 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 for grooving. Renew if necessary. Then fit the 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 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.

Jenbacher W 0200 M0
Maintenance works:
0 = zero position

Jenbacher W 0200 M0
Maintenance works:
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 Shaft
13 Hexagonal screw

Jenbacher W 0202 M3
Maintenance works:
Documentation Cooling water pump
KLS98
Interval every
Maintenance works Point - 10000 Oh
- Renew water-side seal 1. only by leakage
10 Overhaul 2.
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 substance (Loctite 270) to shaft thread, screw on water pump running wheel and
tighten by hand.
Replace dummy cover 36 with a new O-ring 38 and hexagon nut 48.
Attention: The bore may not be or become blocked. Check regularly.
Issued: Doku./Bilek Checked: Reparatur Date: 2006-10

EN 0202M3_EN.doc Index: - Page - No.: 1 / 4
Jenbacher W 0202 M3
Maintenance works:
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

Jenbacher Maintenance works:W 0202 M3
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), and push on as far as possible.
Clamp shaft in vice (using protective cheeks).
Apply screw securing substance (Loctite 270) to shaft thread (running wheel side), screw on water pump
running wheel 8 and tighten by hand.
Assemble 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 may not be or become blocked. Check regularly.

Jenbacher W 0202 M3
Maintenance works:
33 29 15 27 18 24 20 13 11 5 1 8 38 36
*)
22 50 52, 56 36, 48
*) ATTENTION: DRILLING MUST NOT BE LOCKED,

CHECK REGULARLY!

Jenbacher Maintenance works: W 0303 M0
Documentation Ignition system
Data registration: E
KLS98
0303
1. Checking the ignition point: ___________________________________________1

2. Checking the ignition unit: ____________________________________________2
3. Checking the ignition harness: ________________________________________2
4. Checking the passive ignition pick-ups in the case of IQ ignition systems:____2
5. Checking the ignition coils: ___________________________________________2
5.1 Checking the ignition coils (Integrated): 2
5.2 Checking the external ignition coils 2
6. Ignition plug socket: _________________________________________________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 (DSO)

• BNC connection cable
• XLR-XLR adaptor
• Ignition coil test 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). If these values are not the same, the ignition point should
be adjusted.
The following test must be carried out at engine standstill!

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 systems:
Check connecting cable as for tottering contact.

After the first 2000 hours of operation and in the event of ignition problems of the machine, 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 the ignition voltage according to TI No. 1502-0048.
For IC 900/IC 910 and IC 912-type ignition systems: Measure the ignition voltage according to
TI No. 1502-0038.
For IQ 750-type ignition systems: Measure the ignition voltage according to TI No. 1502-0044.
For IQ 724-type ignition systems (for J 620): Measure the ignition voltage according to
TI No. 1502-0043.
For IQ 250-type ignition systems (for J 208): Measure the ignition voltage according to
TI No. 1502-0049.
For IQ 250-type ignition systems (for J 208/Single Pickup): Measure the ignition voltage according to
TI No. 1502-0057.
For IQ 250-type ignition 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).
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.

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 must not come into contact with metal parts.
Check the I-coils for firm seat at the maschine.

Inspection Work/Maintenance Work:
Documentation Ignition voltage check/Spark plugs
Data registration: E 0309
1. Important: __________________________________________________________2
1.1 Required regulations/materials/tools: 2
1.1.1 Safety precautions: 2
1.1.2 Operation: 2
1.1.3 Tightening torques: 2
1.1.4 Tool/lubricant: 2
1.2 Spark plug type: 3
1.3 Electrode distance: 3
1.4 Spare spark plugs: 3
1.5 Ignition voltage range: 3
1.6 Ignition voltage measurement: 3
2. Set values for spark plugs: ____________________________________________4
3. Checking the spark plugs: ____________________________________________5
3.1 Example of ignition voltage increase during operation: 5
4. Operational data: ____________________________________________________6
4.1 Ignition voltage requirement: 6
4.2 Spark plug type: 6
4.3 Optimal electrode distance: 6
5. Spark plug disassembly: _____________________________________________6
5.1 Ignition systems with ignition coils: 7
5.2 Ignition systems with external coils: 7
5.2.1 Type 6 engine engine Lifer-Saver spark plug connector: 7
5.2.2 Rail System: 7
6. Cleaning hints: ______________________________________________________8
7. Wearing characteristics and adjusting of the spark plugs:__________________8
7.1 Analysing used spark plugs: 8
7.1.1 Early sparking / overheating: 8
7.1.2 Defective noble metal electrode: 9
7.1.3 Silicon and combustion deposits: 10
7.1.4 Electrode short-circuit: 10
7.2 Adjusting the spark plugs: 11
7.2.1 P3.V3 and P3.V5 spark plugs: 11
7.2.2 P7.1V5 and P7.1V6 spark plugs: 12
7.2.3 Denso 3-1, 357 and 502N spark plugs: 12
8. Assembling the spark plugs: _________________________________________13
8.1 Ignition systems with ignition coils: 14
8.2 Ignition systems with external coils: 14
8.2.1 Type 6 engine Lifer-Saver spark plug connector: 14
8.2.2 Connection to the R coil: 15
8.3 High-voltage cable: 15
9. Checking following recommissioning: _________________________________15
Issued: Doku./Bilek Checked: TEAM/TEBM/TEE/VSR/VST Date: 2005-08

EN 0309M0_EN.doc Index: p Page - No.: 1 / 15
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/tools:

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 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. 1100-0105.
• Operational spark plug data sheet E 0309.
• monic – dia-ne (monic is used to measure automatically the ignition voltages of all cylinders),
see TI No. 1400-0104.
• Checking the spark plugs using a digital storage oscilloscope, see TI No. 1400-0111.
• 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) e.g.: Fluke 123 (not for monic)
• BNC connection cable (not for monic)
• Pointed pliers
• Feeler gauge
• Socket wrench with extension piece
• Strap wrench (to disassemble the integral coils)
• Universal lubricant:
Type 2, 3 and 4 engines: „ULTRA-THERM“
Tl No. 323765 (fluid in bottles) or
TI No. 128407 (spray)
Type 6 engine: „NEVER-SEEZ“
TI No. 305045

1.2 Spark plug type:

GE Jenbacher specifies the spark plug type for every individual installation,
always taking into account the installation-specific 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 prolonged cycle time. This in turn is a prerequisite
for ensuring a longer spark plug service life and lower maintenance costs.
Adjustments to the electrode distance must always be made by the same 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 technique and to adjust the
distance between the electrodes expertly and on time.
1.4 Spare spark plugs:

Another means of keeping maintenance costs as low as possible is to adjust a 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.
1.5 Ignition voltage range:

The ignition voltage range and the installation-specific electrode distance which guarantee a smooth
misfire-free operation depend on many influencing factors, such as engine output, condition of the ignition
coils and the ignition system, gas composition, methane number and emissions. Consequently, these
values may be subject to local restraints and variations.
1.6 Ignition voltage measurement:

In order to identify the right point in time to adjust the spark plugs, you will have to perform an ignition
voltage measurement and inspect the corresponding documentation (data sheet entry). Measurement
recordings are especially important when carrying out analyses of malfunctions.
We particularly advise you to carry out the ignition voltage measurement prior to periods in which a
special degree of reliability is required (e.g. weekends).

2. Set values for spark plugs:
The ignition voltage requirement referred to below (at full load) may not be exceeded or underrun.
Spark plug setting

Guide value:
Ignition voltage electrode
Einsatzgebiet requirement distance
Spark plugs Engine NOx Gas type > kV < kV mm (inch)
Type types [mg/Nm³]
P3.V3 2, 3, 4 250 - 400 landfill gas 12 32 0,35 (0,014)
sludge gas
natural gas
mine gas
propane gas
P3.V5 2, 3, 4 250 - 400 biogasses 12 32 0,35 (0,014)
wood gas
pyrolysis gas
process gas
P7.1V5 3, 4 500 landfill gas 12 32 0,35 (0,014)
sludge gas
natural gas
mine gas
propane gas
P7.1V6 3, 4 500 biogasses 12 32 0,35 (0,014)
wood gas
pyrolysis gas
process gas
Denso 3-1 6 250 - 500 landfill gas 12 30 0,3 (0,012)
Denso 357 natural gas
Denso 502N sludge gas

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 cycle time for the spark plugs, operation should be started at low
ignition voltages and be ended at ignition voltages which are as high as possible, without
endangering uninterrupted engine operation.
Simply stated, the ignition voltage increases as the service life of the spark plug increases. If the initial
voltage is low and the end voltage is high, the operating time (cycle time) elapsed will be longer.
Ignition voltages in [kV]
Spark plug operating 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.

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.
4.3 Optimal electrode distance:
Operational spark plug data (E 0309):
Enter the optimal electrode distance determined for the installation in the
operational spark plug data (E 0309) table.
5. 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.

5.1 Ignition systems with ignition coils:

Loosen the primary side ignition coil connector.
Remove the screws on the integral coil.
Pull the integral coil with spark plug connector out of the spark plug shaft.
Attach a socket wrench with extension piece to the spark plug and unscrew it.
Pull out the spark plug using the socket wrench and ensure that the sealing ring does not remain in the
spark plug sleeve, if necessary, the sealing ring can be removed from the spark plug sleeve using a bar
magnet.
5.2 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.
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.
magnet.
5.2.2 Rail System:

In the case of the Rail System, the connection on the R coil must first be opened.

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 Type: P3.V3 or P3.V5 Type: P7.1V5 or P7.1V6

Possible causes Results / effects Corrective measure

The spark plug is insufficiently Power reduction followed by Visually inspect cylinder.
tightened. engine damage. Inspect (replace) ignition box.
Possible spark plug insulator Install new spark plug.
Early sparking due to defective cracking due to overheated Clean piston and cylinder head
ignition box. central electrode. local to combustion room.
Re-adjust LEANOX and re-
Combustion knocking causing establish control for entire load
electrode to overheat. range.
Defective valves.
Auto-ignition due to deposits.
Incorrectly set LEANOX.
7.1.2 Defective noble metal electrode:

At one or more mass electrodes – loss of the noble metal.
Type: all spark plugs missing noble metal

Too much sulphur or ammonia Ignition voltage increases Select the right spark plug type.
in the fuel gas (see TI No.: sharply when several electrodes
1000-0300). fail.
Noble metal residues can get

stuck between valve and valve
seat, causing damage (valve
burn-through).
This can cause auto-ignition.

7.1.3 Silicon and combustion deposits:

Massive silicon and combustion deposits near the electrodes and the whirl chamber.
Type: all spark plugs

Silicon values (see TI No.: 1000- Decreasing ignition voltages Install new spark plug.
0300). until the cylinder fails. Carefully clean spark plug
Deposits can loosen resulting in electrodes.
Increased oil consumption. auto-ignition.
Poor blow-by oil separation.
Defective piston rings.
7.1.4 Electrode short-circuit:

Thread (molten conductive noble metal) between central and earth electrode.
Type: all spark plugs


Insufficient distance between Continuously decreasing ignition Adjust electrodes correctly (see
electrodes. voltages until the cylinder in following instruction).
Incorrect spark-plug type. question fails completely (no Adjust electrode distance using
more combustion): feeler gauge.
Incorrect ignition point point Exhaust gas temperature drops
(spark-plug overheating). far below average value.
Combustion knocking (spark-

plug overheating).
7.2 Adjusting the spark plugs:
7.2.1 P3.V3 and P3.V5 spark plugs:

Wearing characteristics:
Approximately equal degree of material erosion at the central and earth electrodes.
Feeler gauge
Earth electrode
Central
electrode
Adjustment:
Adjust the spark plugs from the inside to the outside so that these are in parallel to the optimal electrode
distance (guide value 0.35 mm (0,014 inch) ) using pointed pliers.

7.2.2 P7.1V5 and P7.1V6 spark plugs:

Approximately equal degree of material erosion at the central and earth electrodes.
Feeler gauge
Mass electrode
Central
electrode
Adjustment:
Adjust the spark plugs so that these are in parallel to the optimal electrode distance (guide value 0.35 mm
(0,014 inch) ) using pointed pliers.
7.2.3 Denso 3-1, 357 and 502N spark plugs:

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 so that these are in parallel to the optimal electrode distance (guide 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.

Right 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.
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“
Tl No. 323765 (fluid in bottles) or Tl No. 128407 (Spray)
Type 6 engine: „NEVER-SEEZ“
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).

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 accompanied by a noticeable click.
8.2.1 Type 6 engine Lifer-Saver spark plug connector:

1. Firstly, the bayonet catch must be locked by turning the arrow into the specific red dot or 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 catch, it is important that the spark plug connector is connected
to the spark plug electrically. This is achieved by pressing the insulator in the direction of the spark
plug until it locks with a noticeable click.
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!

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 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 high-
voltage cables and engine paint layer from becoming damaged – see pictures below.
Right Wrong
9. Checking following recommissioning:
Following recommissioning, the ignition voltage requirement must be checked and, if necessary, the
values must be noted down in the spark plug data (E 0309) table.
Start the engine and run at full-load operation.

After at least 30 minutes of full-load operation, check the voltages once more.
All voltage values must amount to at least ~15 kV and not exceed ~18 kV. Should the voltage on 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 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, this could be caused by the ignition-voltage
requirement being too low due to the electrode distance being too small, an incorrect engine setting or an
incorrect fuel-gas (CH4:CO2) ratio (particularly in the case of landfill gas of varying gas quality).

Documentation Valve clearance
KLS98
1. Reference: _____________________________________________________1
2. Measurement of valve stem projection: _____________________________3
3. Adjustment of tappet clearance: ___________________________________4
4. Legend: _______________________________________________________4
4.1 Notes on figures: _____________________________________________________________4
4.2 Text of figure 1: ______________________________________________________________4
4.3 Text of figure 2: ______________________________________________________________5
1. Reference:
Tappet clearance can be checked or set in cold or warm condition.
Set - points:
Inlet valve: 0,0157 in (0,40 mm)
Valve clearance
Outlet valve: 0,0236 in (0,60 mm)
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 wear and/or by the first discovery of valve wear of more than 0,008 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:
Inlet valve: 1,13 in (28,6 mm)
Cylinderheads - NEW
Outlet valve: 1,14 in (29 mm)
Enter the values in the table Data Registration Valve-Stem Projection (E 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 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

EN 0400M0_EN.doc Index: j1 Page - No.: 1 / 5
J 208 GS
Cylinder identification
Flaywheel
Tooth number = 162
Firing order:
Firing intervals:
J 212/312 GS
Flaywheel
Tooth number = 164
Firing order:
Firing intervals:
J 216/316 GS
Flaywheel
Tooth number = 164
Firing order:
Firing intervals:

J 320 GS
Flaywheel
Tooth number = 164
Firing order:
Firing intervals:
At ignition TDC both valves are closed and the valve rockers are unloaded; in this position the valve 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 = 1,89 in (48 mm) (measuring stand height) - measured value.
1,89 - 0,69 = 1,2 in

48 - 17,6 = 30,4
Actual valve stem projection (enter into the 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)

New value
Actual valve stem projection

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 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 of cylinder head
Figure 2: Total view of cylinder head with mounted test stand for measuring the valve stem projection.
4.2 Text of figure 1:

It. No. Designation 4
I Wear on valve
III
II Wear on seat ring
III Valve clearance
IV Valve set-back
IV
1 Seat ring
2 Valve
3 Cylinder head
4 Valve rocker bracket
3 I, II 2 1

4.3 Text of figure 2:

It. No. Designation
A Outlet valve
E Inlet valve
1 Fixing nut
2 Adjusting screw for inlet valve
3 Fixing nut
4 Adjusting screw for discharge valve
5 Test stand for measurement of valve stem projection
E 1
3
A

Jenbacher W 0506 M0
Maintenance works:
Documentation Crankcase vent
KLS98
1. Oil mist lubricator: ______________________________________________1

1.1 Replace the filter cartridge of the oil mist lubricator. 1
2. Filter cloth:_____________________________________________________2
2.1 Disassembly: 2
2.2 Disassembly of the crankcase ventilation: 2
2.3 Cleaning: 2
2.4 Replace: 2
Interval every
Wartungsarbeit Punkt 2000 Oh 20000 Oh
2 Oil mist lubricator - filter carteige replace 1.
20 filter cloth - change 2.
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

Jenbacher W 0506 M0
Maintenance works:
Documentation 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

Jenbacher W 0601 M0
Maintenance works:
Documentation Torsinal vibration damper
KLS98
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 before mounting.
Fit the new torsinal vibration damper.
Fit the torsinal vibration damper protector.

EN 0601M0_EN.doc Index: b1 Page - No.: 1 / 1
Documentation Gas-mixer
KLS98
Interval every
Maintenance works 10000 Oh 20000 Oh 30000 Oh
10 Replace the circuit board and the rubber

sleeve
20 Replace the servomotor
20/30 Overhaul *)
*) 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.
Issued: Doku./Bilek Checked: Entwicklungsgruppe B Date: 2002-04

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 in dia.ne (screen 41) is set to '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 W0704 35
board again.
Remove wiring from control motor and circuit board.

Layout of cables:
W0704-36
Name Stepping motor R/I converter plate Simulation device

Motor phase 1 (+) Ph1+ (green) 1 (green) 11 (green)
Motor phase 1 (-) Ph1- (red) 2 (red) 12 (red)
Motor phase 2 (+) Ph2+ (black) 3 (black) 21 (black)
Motor phase 2 (-) Ph2- (grey) 4 (blue) 22 (blue)
+ 24 V IN 1 (yellow) 30 V (yellow)
+ mA OUT 2 (black) Iein
Schirm 3 (Schirm) no connection
Attention: The colours of the cores might change according to the manufacturer!
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 to the 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 gas-
mixer shaft and open until it reaches the W0704 37
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.

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 board with the potentiometer shaft on the servomotor (there are two types: circuit
boards with a ribbed potentiometer shaft and circuit boards with a smooth 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). 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 supply voltage.
The rest of the assembly is carried out in reversed order of the disassembly.
4, 5, 6
2, 3

Jenbacher W 0802 M0
Maintenance works:
Documentation Mixture bypass valve
KLS98
1. Replace the mixture bypass valve:
mixture bypass valve

EN 0802M0_EN.doc Index: a Page - No.: 1 / 1
Jenbacher Inspections: I 0103 0
Documentation Inspection
Data registration: E 0103 a/b/c
1. Mixture/water heat exchanger:
1.1 Mixture-sided 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).
If the differential pressure exceeds 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:
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 side the sealings of the mixture cooler (mixture cooler – connecting cover or blind cover
respectively) should be renewed.

EN 01030a_EN.doc Index: d Page - No.: 1 / 1
Jenbacher Technical Instruction No.: 1100-0110
Documentation Boundary conditions for GE Jenbacher gas engines
1. Tips: ______________________________________________________________2
2. Explosion hazard: ___________________________________________________2
3. Gas and smoke alarm:________________________________________________2
4. Fuel gas: ___________________________________________________________3
4.1 DIANE: 3
5. Intake air: __________________________________________________________3
5.1 Engine room: 3
5.2 Cooling air generator: 5
6. Cooling water for engine cooling: ______________________________________6
7. Cooling water for mixture and oil cooling: _______________________________6
8. Raw water, warm water, hot water: _____________________________________6
9. When operating with steam boiler: _____________________________________6
10. Lubricating oil: _____________________________________________________6
11. Exhaust gas:_______________________________________________________7
12. Electrical conditions:________________________________________________7
13. Operation and maintenance: _________________________________________7
14. Pipelines (pickling and cleaning): _____________________________________8
15. Connections (GE Jenbacher‘s limits of supply): _________________________8
16. The following TIs should be complied with: _____________________________9

EN 1100-0110_EN.doc Index: ai Page - No.: 1 / 9
1. Tips:
Installation-specific conditions: see relevant technical specification.

The limiting values for harmful emissions guaranteed in the technical specification can be met only at a
load of between 50 and 100%.
The characteristics of the product as stated can be guaranteed 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 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.
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:
- 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 the fuel gas is >0%.
• the gas contains odours and the CO content of the fuel gas is >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.

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). 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 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 the fuel gas is >5%, a nitrogen flushing installation must be
installed.
It is the operator’s responsibility to ensure that the fuel gas system is equipped with the necessary
devices, does not leak and meets official 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 (followed by a
decrease in the degree of efficiency);
c) reduce the engine output to 50%;
d) If these anti-knock measures 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 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
equipment ON“. This way, a controlled set of preconditions is created when starting and accelerating.
That is why you must not switch off the engine-room ventilation 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.

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:
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] (to be reached at an outside temperature of max. 35°C [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]). The temperature should be as constant as possible and vary only within the 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:
As for the air pressure, air intake temperature and atmospheric humidity, the limiting values according to
ISO 3046 apply: i.e. 1,000 mbar [14,5 psi], +25°C [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]. 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:

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].
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 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]!

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], < 0.5 mbar [<0,00725 psi].
If the motor is at standstill, especially if multiple-engine installations are concerned, this overpressure
causes a defined ventilation flow through the engine in the direction of the exhaust stack.
In case of a false start (which can never be fully prevented), these provisions will prevent the unburned
mixture from flowing back to the engine.
Never guide the fresh intake air flow all the way up to the air-filter intake to ensure that the very cold
outside air flow (<10°C [50°F]) is thoroughly mixed with the hotter engine-room air (circulation-air control).
target Fan
R=3-4m
90°
Filter
Engine
This is to guarantee that even in the case of low outside temperatures of e.g. –10°C [14°F], the air
temperature at the air-filter intake will not fall below +10°C [50°F]. Extreme temperature fluctuations will
cause control problems, e.g. “pumping" of the turbocharger.
Also make sure that the fresh intake air flow is not directed straight at the air-filter intake, as the dynamic
effect of the air flow will affect the mixture composition and can cause false starts and deflagrations!
5.2 Cooling air generator:

Air intake temperature max. 40°C [104°F]
Relative atmospheric humidity max. 80%
Dust content = 1 mg/m³
SO2 content = 1.5 mg/m³
The Pt100 temperature-control sensor must be positioned in the engine room at the following location:
engine room side, before the centre of the exhaust sound damper.

6. Cooling water for engine cooling:
Must comply with TI No. 1000-0200.

Anti-freeze agent in accordance with TI No. 1000-0201.
Anti-corrosion agent see TI No. 1000-0204.
Maximum admissible cooling water exhaust temperature at the engine: see technical specification and/or
technical diagram.
Max. operating overpressure in the engine: 2.5 bar [36,25 psi]
In the case of multi-engine installations:
make sure that the various engine cooling water circuits are separated.
7. Cooling water for mixture and oil cooling:
Dirt collector (mesh size = 0.1): see technical diagram.

Water quality: see points 6/8.
Maximum intake temperature: see technical diagram and/or the relevant technical specification
(admissible temperature change in accordance with point 8).
Maximum admissible overpressure at intake: 6 bar [87 psi] (10 bar [145 psi] for special versions).
8. Raw water, warm water, hot water:
Dirt collector (mesh size = 0.1): see technical diagram.

Water quality: must comply with TI No. 1000-0206.
The specified warm-water return temperature should not be exceeded (install emergency cooling,
otherwise the module will be shut down).
Admissible return-temperature change: 70°C +3/-20°C [158°F +37,4/-4°F]
50°C +3/-10°C [122°F +37,4/14°F]
Intermediate values should be determined by interpolation.
Admissible return-temperature change speeds: max. 10°C [50°F] per minute.

We advise you to install a thermostatic control to achieve a constant return temperature at the intake of
the module.
In that case, the control must be included into the heating installation and the operating conditions in
accordance with GE Jenbacher drawing No. E 9684 and/or in proper consultation with GE Jenbacher.
9. When operating with steam boiler:
Water quality in accordance with boiler manufacturers‘ specifications.

See technical specifications and technical diagram for maximum admissible temperature and pressures.
10. Lubricating oil:
The lubricating oil should comply with TI No. 1000-1105, TI No. 1000-1106 and/or TI No. 1000-1107 and
TI No. 1000-0125.

Oil changes should be carried out in accordance with TI No. 1000-0099 A/B/C/D or in accordance with
the results of the oil analyses.
Attention:
The oil lines to the engine, fixtures, containers, etc. should not be made from pure copper. Copper has a
strong oxidising effect on the lubricating oil, especially at increased temperatures (increases ageing),
which will result in an increased Cu content in the oil giving rise to incorrect diagnoses. Similar Cu-Ni
alloys (Ni content = 10%) do not have these characteristics and can therefore, if so desired, be used
instead of normal steel tubes.
11. Exhaust gas:
The entire exhaust-gas system (including boiler and heat exchanger), must be designed to cope with
momentary pressure peaks of 6 bar [87 psi].
See the technical specification and/or technical diagram for maximum admissible exhaust gas
backpressure.
In the case of multi-engine installations, the exhaust-gas systems must not be combined.
Exceptions:
• double shut-off valves with intermediate ventilation for every module
• if at the point where the systems are combined a continuous underpressure exists (e.g. a
continuous flow in the smoke stack).
The condensate from the heat-recovery boilers, silencers and the exhaust-gas line, etc. should be
collected and disposed of in an environmentally sound way.
Condensate lines should not be interconnected.
12. Electrical conditions:
Nominal mains voltage change: related to nominal voltage +/-5%.

Max. admissible transient mains voltage changes: +/- 10% of nominal voltage
Nominal mains frequency deviation: max. +/- 1%
Minimum duration of a short interruption: min. 200 ms
Make time of the synchronizing switch: 70 ms
Break time of the circuit-breaking switch: 60 ms
To prevent external overvoltages from reaching the CHP unit, overvoltage deflectors should be installed
at the mains supply voltage location, if required, in combination with capacitators.
13. Operation and maintenance:
Minimum operation time: 12 hours per engine start, except when commissioning, carrying out
maintenance activities and during emergency power operation.
This minimum operating time is not a prerequisite condition, but a reference value in relation to the
maintenance intervals mentioned in the maintenance documentation. This reference value should help
the operator to decide when, contrary to what has been stated in the maintenance manual, various
wearing parts will have to be replaced (if, for example, a starting motor is used three times more
frequently than expected, it will also have to be overhauled sooner).

The maintenance intervals as stated in the maintenance manual are averages for normal operation
based on experience!
Precautionary component inspections can help the operator to determine the exact point in time when the
wearing parts need to be replaced (see also TI No. 1100-0111).
Non-compliance with the minimum operating time will in principle not affect the guarantee. It will,
however, have a substantial influence on the service life of the various components.
Idling:
Idling duration limited through the module control unit (except for maintenance and initial setting activities:
keep idling period as short as possible).
Partial load operation:

Partial load operation without limitations up to > 40% of the nominal load for type 2, type 3 and type 4
engines and/or > 40% related to pme = 18 bar [261 psi] for type 6 engines. Emissions are only
guaranteed in the > 50% load range.
Continuous operation:
In principle, full load should be attempted. Partial load operation without limitations up to > 40% of the
nominal load for type 2, type 3 and type 4 engines and/or > 40% related to pme = 18 bar [261 psi] for
type 6 engines. Emissions are only guaranteed in the > 50% load range.
Isolated operation:
During isolated operation, the module may be operated 6 times per year for 4 out of 24 hours at over 20%
of the rated module load (type 6 engines: related to 18 bar [261 psi]) < 40%.
Daily inspection:
Maintain an engine log.
Carry out all maintenance activities in accordance with GE Jenbacher maintenance schedule.
All conditions as described in the TI Nos. should be complied with.
For oil changes, oil analyses and oil quality assessments see TI No. 1000-0099 A/B/C/D.
14. Pipelines (pickling and cleaning):
All pipelines, especially welded ones, should be cleaned before their installation; e.g. gas lines, oil lines,
cooling-water lines, control lines, etc.
Note: pickling should only be carried out by companies that have sufficient experience carrying out
galvanizing work!
15. Connections (GE Jenbacher‘s limits of supply):
Connections (at GE Jenbacher‘s limits of supply) should be equipped with compensators and/or flexible
hoses.
The installation piping should be arranged in such a way that the compensators at GE Jenbacher‘s limits
of supply are not subjected to mechanical force.

16. The following TIs should be complied with:
The revision applicable when the contract was signed is valid:
General conditions
TI No. 1100-0111 General conditions - Operation and maintenance
TI No. 1100-0112 Installation of GE Jenbacher modules
Warning signs
TI No. 1000-0330 Signs on the engine room door
Fuel gas
TI No. 1000-0300 Fuel gas quality
TI No. 1400-0091 Fuel gases, freedom from condensate
Lubricating oil
TI No. 1000-0099A General instructions for lubricating oils
TI No. 1000-0099B Limiting values for waste lube oil for GE Jenbacher engines
TI No. 1000-0099C Procedure for testing the module specific durability of the oil
TI No. 1000-0099D Determining the initial Ph value (iPh) for waste lube oil according to TI No.
1000-0099B
TI No. 1000-1105 Lubricating oils for type 2 and 3 engines in biogas operation
TI No. 1000-1106 Lubricating oils for type 2 and 3 Leanox engines in sweet-gas operation
TI No. 1000-1107 Lubricating oils for type 4 and type 6 engines in sweet-gas, biogas, landfill-gas
or special-gas operation; for type 2 and 3 engines in natural-gas operation and
for Lambda-1-engines
TI No. 1000-0125 Lubricating oils for type 2 and 3 engines in landfill-gas operation
Cooling water
TI No. 1000-0200 Quality of cooling water in closed circuits
TI No. 1000-0201 Antifreeze additive
TI No. 1000-0204 Cooling water anti-corrosion additive
TI No. 1000-0206 Quality of circuit water in hot water and warm water heating systems
TI No. 1000-0208 Quality of cooling water in open circuits
Cabling
TI No. 1000-0505 Electromagnetically compatible (EMC) cabling and mass connections
on/between engine modules and control cabinets

Documentation General Conditions - Operating and Maintenance
1. General Conditions - Operating and Maintenance: ________________________1

1.1 Marginal conditions: 1
1.2 Cooler/heat exchanger(GE Jenbacher supply quantity): 1
1.3 Supply limits Interfaces: 1
1.4 Maintenance Maintenance personnel: 1
1.5 Safety regulations: 2
1.6 Start conditions: 2
1.7 Malfunctions: 2
1.8 Registering operational data, Maintenance protocol: 2
1.9 Spare parts: 3
1.10 Lubricating oil: 3
1.11 Ignition plug: 3
1.12 Elastomer components: 3
1.13 Decommissioning the installation: 3
1.14 Components coming into contact with exhaust gas: 3
1.15 Operating supplies: 4
1.16 Quality of propellant: 4
1. General Conditions - Operating and Maintenance:
1.1 Marginal conditions:

The specified properties of the product can only be guaranteed, if the reconditions for GE Jenbacher gas
engines as described in Technical Description No. 1100-0110 are met, all compulsory activities are
carried out in accordance with the operational-data sheet and this sheet is filled in correctly, all
compulsory maintenance activities are carried out on time, and a knock-free operation is guaranteed.
1.2 Cooler/heat exchanger(GE Jenbacher supply quantity):

When incorporated into the heating water system these components must be protected at the upstream
side against deposits/soiling by taking adequate measures.
1.3 Supply limits Interfaces:

The conditions and devices pre-determined in the technical scheme, the wiring diagram, the interface list
and the technical specification of the control at the supply limits/interfaces must be fulfilled or available
respectively. Deviations from these can affect guaranteed characteristics of the product and safe
operation and finally lead to a restriction or extinction of warranty claims.
1.4 Maintenance Maintenance personnel:

Work at the plant must only be carried out by specially trained, electric and mechanic specialists. It is
possible to conclude service contracts with GE Jenbacher, GE Jenbacher subsidiaries or authorized and
specialized companies.The intervals in the servicing schedule represent maximum periods that occur
when the system is properly run and serviced. If there are deviations (such as improper oil care, a large
amount of dust or other problematic circumstances), the service jobs must be carried out before the given
time.The above can only be judged by the operator. In case of irregularities during the daily inspection,
especially during the warrantee period (abnormal sounds or noises etc.), the operator shall act so as to
minimise any damage (e.g. immediately switching off the engine, tracking the cause of the irregularity and

EN 1100-0111_EN.doc Index: j Page - No.: 1 / 4
remedying it, and/or notifying the customer-service department).Upcoming service work is to be carried
out before the service deadline for the sake of smooth operation or to avoid interruptions in operation,
such as in the heating season. The service intervals may not be extended to avoid downtime during the
heating season.All parts that contact exhaust are correspondingly not bound to fixed, predetermined
useful lives.
1.5 Safety regulations:

The safety regulations contained in the user's manual must be observed The safety regulations and
regulations for the prevention of accidents set out by the law must be observed. Prior to the
commencement of any work the party ordering must make sure that the applying safety regulations are
observed for the work to be carried out. In the event of work that may only be carried out with the engine
standing still, the engine must be turned off and secured against unauthorized re-starting according to the
technical instruction no. 1100-0105.
1.6 Start conditions:

All GE Jenbacher engines are equipped with a preheating system for the engine cooling water. Only
preheated engines with a engine cooling water temperature of >55°C may be started, loaded and run to
full-load, otherwise the engine may be damaged.
1.7 Malfunctions:
When a failure results in the installation automatically being switched off by the engine control, the cause
of the failure should be remedied first before the installation is started again! It is forbidden simply to reset
a failure and then re-start the engine, as critical or wear-induced damage could possibly result in
premature wear-induced replacement of various components.
Remote resetting: The following failures, if they result in the installation being switched off, can be max. 3
times in 24 hours (remote) reset without too much risk, even if the cause of the failure has not been
remedied.
MALFUNCTIONS: Diane no:

MISFIRING FAILURE 1047, 3005-3024
JACKET WATER TEMPERATURE HIGH 1021
ROOM TEMPERATURE HIGH 1135
FAILURE AUXILIARIES 1129
SYNCHRONIZING FAILURE 1039
HEATING WATER SUPPLY TEMPERATURE HIGH 1063
Resetting (single or multiple resetting) all other failures that have resulted in the installation being
switched off without remedying the cause first will result in a considerable potential risk, endangering
human life and possibly damaging the installation. The client (or the party responsible for the remote
resetting) will be entirely responsible for such damage.
1.8 Registering operational data, Maintenance protocol:

It is compulsory that all operational data are registered and that all special events are described.
Attention:
Just registering the facts in writing is insufficient. The data should be compared with the commissioning
data and be checked for plausibility. In case of deviations, abnormal noises etc. the cause should be
tracked and remedied. If you cannot find the cause, the GE Jenbacher customer-service department
should be notified immediately.
Maintaining and filling in operational data (maintenance protocol, operational data journal, data
registration in the “Maintenance directory”) is in the best interest of the operator. Correctly filled-in

operations journals and data registration sheets are important documents, enabling analysis and support
in case of failures. Moreover, these documents are also important when deciding on warranty claims.
1.9 Spare parts:

Only use original GE Jenbacher spare parts (attention: e.g. oil filter!). Defects and damage caused by the
use of non-original parts are not covered by the warranty.
Important: In order to avoid unexpected standstills due to maintenance work, you are strongly advised to
keep the respective spare parts in store.
1.10 Lubricating oil:

No specific maintenance interval is determined for lubricating oil. It lies within the responsibility of the
operator to take measures necessary for the protection and the safe operation of the plant and which
guarantee the plant's availability.
The oil's service life (depending on gas quality, middle pressure, engine type, oil consumption, oil
temperature and oil type) can be prolonged by an additional oil container. The results of the lubricating oil
analysis with the observation of the limits according to the technical instruction no. 1000-0099B must be
presented in a complete manner also after the warranty period has expired, if premature wear is claimed.
1.11 Ignition plug:

No specific maintenance interval is determined for ignition plugs. It lies within the responsibility of the
operator to take measures necessary for the protection and the safe operation of the plant and which
guarantee the plant's availability. The ignition plugs' service life depends on the marginal conditions of the
plant (e. g. type of ignition plugs, gas type, middle pressure, gas mixing temperature, ignition system,
emission limits).
1.12 Elastomer components:

Elastomer components age and become brittle, even when the engines are not operational.That is why
the service life of these components does not depend on the on-stream service time of the module, the
cooling-water temperature and pressure etc. At normal annual on-stream service times of 5000-6000
operating hours and a cooling-water temperature of 90°C, all elastomer components are exchanged at
the normal intervals as described in the maintenance schedule. If this number of operating hours is not
reached, the elastomer components (e.g. O-rings at cylinder liners, elastic couplings etc.) should still be
replaced as a precautionary measure after a maximum of 5 years.
1.13 Decommissioning the installation:

For long planned or unplanned downtimes such as after the heating season for power plants, the engine
systems need to be prepared for downtime (preservation measures, change old lubricating oil, separate
the chimney connection, etc.) depending on the geographic location (climate, proximity to ocean, type of
gas, etc.).
Since situations can differ greatly, it is recommendable that an appropriate professional company be
consulted or be entrusted with implementing the necessary measures.
Of course, it must be ensured that the system is made ready for use when it is started up again.
1.14 Components coming into contact with exhaust gas:

GE Jenbacher uses only high-grade materials that correspond to the latest state of the art. Due to the
different operating situations and different contents (including traces of pollutants) in the fuel gas, no
binding guarantee can be made on the life of the components such as the exhaust manifold, etc.

1.15 Operating supplies:

Service life and safe operation of the plant strongly depend on the operating supplies that are used. Only
use operating supplies such as propellants, engine cooling water, warm water, frost protection agent,
anticorrosive agent, lubricating oil etc. corresponding to the respective technical instructions of
GE Jenbacher.
1.16 Quality of propellant:

The operator is obliged to regularly check the quality of the propellant as for its thermal value, methane
number and contents of harmful substances. If these values differ from the values stipulated in the
contract, immediate measures must be taken in agreement with the GE Jenbacher customers service. If
the contents of harmful substances increase (e. g. sewage gas, waste dump gas) the lubricating oil can
be heavily acidified within a fraction of the normal oil change interval and acute or irreparable damage
and increased wear occur all of a sudden e. g. on cylinder liners and bearings and/or the oil consumption
increases. In the event of variations of the methane number downwards (within the range stipulated in the
contract) the engine is protected against harmful knock operation by the control (automatic ignition
control, efficiency decrease).
Note:
During the start-up the engine is optimally set according to the methane number given at that time.
If the methane number increases after the start-up (for a longer or decisive period of the operation time of
the plant) the engine setting should be changed in the sense of an operation type optimizing the
efficiency. This task is to be carried out by specialized personnel.

Documentation Overhaul
KLS98
1. Information:
The overhaul is to be carried out at the GE Jenbacher or at one of the companies authorized by the
GE Jenbacher.
Please arrange an appointment in plenty of time to ensure that the work can be carried out on the date
required.
Further, we would like to mention the possibility of using a service-exchange engine instead of carrying
out a large-scale overhaul.
2. Work to be carried out:
2.1 Camshaft and wheel drive are removed, checked and replaced, if necessary.
2.2 Remove, check and - if necessary - regrind crankshaft.
2.3 Check crankcase - if necessary - rework.
Following the overhaul, the engine must be commissioned according to Technical Instruction
1400-0100 „Engine Run-In Specifications for GE Jenbacher generating sets“! The engine must not
immediately be subjected to loads!

EN 2100M0_EN.doc Index: c Page - No.: 1 / 1
Jenbacher Technical Instruction No.:2300-0005
Documentation Safety instructions
1. General: ___________________________________________________________2
2. Safety signs – hazard classification system: _____________________________3
3. Health and safety during operation and maintenance: _____________________4
4. What to do in the event of an alarm: ____________________________________5
4.1 Evacuation alarm (gas alarm, fire alarm, CO alarm, gas pre-alarm): 5
4.2 CO pre-alarm: 5
5. Personal protection: _________________________________________________6
6. Shutdown procedure and securing: ____________________________________8
7. Engine room: ______________________________________________________10
8. Components _______________________________________________________13
8.1 Exhaust-gas system: 14
8.2 Turbocharger: 14
8.3 Fuel gas system: 15
8.4 Cooling system: 16
8.5 Heat exchangers: 17
8.6 Safety valve: 18
8.7 Lubrication system: 18
8.8 Control system: 19
8.9 Ignition system: 20
8.10 Cables and insulated wiring: 20
8.11 Electrical connections: 21
8.12 Generator: 21
8.13 Electrical cabinets: 22
8.14 Acoustic insulation (container; sound absorber hood): 23
8.15 Battery: 23
8.16 Container/enclosure: 24
9. Maintenance and servicing: __________________________________________25
10. Cleaning:_________________________________________________________26
Issued: Doku./Hochrainer Checked: Dokumentation Date: 2007-02

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Jenbacher 2300-0005
Technical Instruction No.:
1. General:
The operating and maintenance instructions contain basic safety signs,

requirements and directions which must be observed during the delivery,
setting-up, commissioning, operation and maintenance of GE Jenbacher
machinery. These documents must be read and understood by the user before
starting the machinery. The most recent edition of the operating instructions
must always be available at the machine.
IS O 3864, ANS I Z535
The information contained in the safety instructions below is intended to provide you with an overview of
danger zones and possible causes of accidents.
While the instructions below are intended for your safety, they cannot cover in detail the scope of all
accident risks posed by industrial machinery.
When operating this machinery it is your duty to comply with all current official and quasi-official safety
rules and codes applicable to your sector. You should also use your own powers of judgement to avoid
hazards and dangerous situations.
Most accidents are caused when people disregard simple, basic safety rules.
Any manipulation of the machine or its control cabinets which causes the machinery to operate outside of
its specified operating range (control range), is prohibited and could result in serious indirect damage.
Any modifications of the item supplied, including changes to the program and software, which are carried
out by the customer or third parties without GE Jenbacher’s prior consent will result in the lapse of any
right to damages or the exercise of a warranty claim against GE Jenbacher.

Jenbacher 2300-0005
2. Safety signs – hazard classification system:
The pictograms with hazard classification used in this document are also used on GE Jenbacher
products. They refer to each of the hazards as described in this document.
DANGER (ISO DIS 3864-2)

denotes a high-risk hazard. If this hazard sign is ignored, death or severe injury will follow as a direct
consequence.
WARNING (ISO DIS 3864-2)

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

denotes a low-risk hazard. If this hazard sign is ignored, minor or moderate injury may result.
NOTICE (similar to ANSI Z535.2)

denotes information directly or indirectly relating to the safety of employees or measures to protect the
machinery. If this hazard sign is ignored, breakdowns or material damage may result.

Jenbacher 2300-0005
3. Health and safety during operation and maintenance:
The customer will take all necessary precautions for the safety of the contractor‘s personnel at the site.
This includes provisions for review by the contractor of and safety instruction by the customer on the
customer‘s safety practices, proper safe handling and disposal of hazardous substances and the
protection of the contractor‘s personnel from exposure to such substances, activation and deactivation of
all power systems (electrical, mechanical and hydraulic) using a safe and effective lock-out tag
procedure, and conducting periodic safety meetings.
The contractor will comply with reasonable health and safety requirements imposed from time to time by
the customer at the facility.
The contractor may conduct occasional safety audits to ensure that safe conditions exist and make
recommendations to the customer concerning such conditions. Neither the performance or non-
performance of safety audits nor the making of any recommendation by the contractor will relieve the
customer of the responsibility to provide a safe place to work. If the contractor‘s personnel require
medical attention, the customer’s local facilities will be made available to the contractor‘s personnel for as
long as necessary.
If, in the contractor‘s opinion, the safe performance of work at the site is or may be endangered by local
conditions, the contractor may remove some or all of its personnel from the site and/or supervise
performance of all or any part of its work and/or evacuate its personnel. The customer will assist with any
such evacuation.
The operation of equipment at the site will be the responsibility of the customer. If the customer requires
or permits the contractor‘s personnel to operate equipment at the site, the customer will indemnify the
contractor, its employees and agents for all costs and liability (including any reasonable attorney‘s fees)
incurred by or imposed upon the contractor, its employees and agents, based upon injury to persons
(including death) or damage to property resulting from the operation of equipment at the site by the
contractor‘s personnel.
If the customer provides the contractor‘s personnel with any tools and equipment to perform work at the
site, these tools and equipment must be in a safe working condition (i.e. subject to inspections and
preventive maintenance).
If the contractor encounters any hazardous material at the site which requires special handling and/or
disposal, the customer will immediately take whatever precautions are required to legally eliminate such
hazardous conditions so that the work under contract may proceed safely. The customer must ensure
that all hazardous materials produced or generated in the course of the contractor’s work at the site are
removed.
All decontamination necessary for the contractor‘s performance (including any repair work) will be
performed by the customer.

Jenbacher 2300-0005
4. What to do in the event of an alarm:
4.1 Evacuation alarm (gas alarm, fire alarm, CO alarm, gas pre-alarm):
Evacuation alarm as specified in ISO 8201/minimum duration 180 seconds.
Key: Phase a signal is "on" for 0.5 s ± 10%

Phase b signal is "off" for 0.5 s ± 10%
Phase c signal is "off" for 1.5 s ± 10% (c = a + 2b)
Length of cycle: 4 s ± 10%
• Leave the affected area immediately. Go out into the fresh air, outdoors, right away.
• Close the gas safety shut-off valve outside the engine room and outside the danger zone and
make sure that it cannot be opened unintentionally.
• Call the fire brigade.
• Do not re-enter the affected area.
• Wait for the fire brigade to arrive.
• Warn other people about the danger.
• Do not re-enter the affected area until the danger has been eliminated with the professional
assistance of the fire brigade, the fault or damage professionally rectified, all enclosed spaces
thoroughly ventilated and the area has been declared safe to re-enter.
Bear in mind that ambient and operating conditions differ from plant to plant and the general rule is that,
before work starts in plants using poisonous gases, the operator of the plant should draw up an
EMERGENCY PLAN which takes these specific conditions into account. The relevant statutory
regulations must also be taken into account. This emergency plan must be brought to the attention of all
persons employed at the plant, evidence of which must be available.
An emergency plan will generally consist of at least the following information:

• Emergency regulations (what to do, evacuation, escape routes, assembly point, etc.)
• Local emergency telephone numbers (rescue, emergency doctor, fire brigade)
• People to be notified in the event of an emergency
• Location of breathing apparatus independent of ambient air
• Other necessary safety information as laid down in statutory regulations, etc.
4.2 CO pre-alarm:
Close the gas safety shut-off valve outside the engine room and make sure that it cannot be opened
unintentionally. Leave the engine to run until it stops of its own accord due to lack of gas. The ventilation
is set to maximum by the engine control system. Call in professionals to look for the gas leak and initiate
damage repair.

Jenbacher 2300-0005
5. Personal protection:
TI 2300-0001 – Employee protection
The operation of the machinery or work on the machinery may only be carried
out by specialist staff having relevant electrical and mechanical training.
Access to the machine room is restricted to persons (specialist staff) who have
read, understood and who observe the safety instructions.
IS O 3864, ANS I Z535
Prohibition, hazard, mandatory and warning signs must be obeyed at all times.
Any failure to do so may result in injury and death or damage the machinery.
Wear personal protective equipment (PPE)!

Wear the personal protective equipment approved by the health and safety
IS O 3864, ANS I Z535 IS O 3864, ANS I Z535
organisations for body, head, eyes, ears and breathing. Never be in the vicinity
of an engine when wearing loose clothing, jewellery or long hair.
The standard equipment required for entering the engine room consists of eye
protection, protective clothing, hand protection and safety footwear.
Depending on the operational condition of the plant, the ambient conditions, the
type or location of the operation, use hearing protection, safety helmet, fall
prevention equipment, gas sensors or other personal protective equipment, as
appropriate.
You should also use your own powers of judgement to avoid hazards and
dangerous situations and wear the appropriate personal protective
equipment.
It is your duty to comply with all current official and quasi-official safety rules and codes
applicable to your sector.
Depending on the operating condition of the machinery or the operation, hazards may arise which cause
injury, so wear the appropriate personal protective equipment. The examples below are not exhaustive.
Activities when machinery is running:

• Hearing protection, eye protection, protective clothing, safety footwear, hand protection
Assembly operations during maintenance and repair:

Caution: many plant and engine components are heavy. This gives rise to a risk of severe crushing and
impact injuries due to the heavy weight of the components.
• Safety footwear, protective clothing, hand protection!
Installation, construction site, difficult access:

Danger of falling, tipping or flying objects, swinging loads and bumping into obstacles, which can cause
severe head injuries.
• Safety helmet, safety footwear!

Jenbacher 2300-0005
Hot surfaces and liquids (oil, cooling water):

The engine, pipework, etc. can reach a surface temperature of up to 150°C.
• Thermal insulation gloves, protective clothing!
Pressurised pipes and containers:

Liquids such as engine cooling water and lubricating oil are hot and under pressure.
• Eye protection, protective clothing, thermal insulation gloves!
Handling acids, starter battery, cleaning products, oil, anti-freeze and anti-corrosion products,
chemicals:
• Acid- or chemical-resistant gloves and clothing, eye protection, safety footwear. Follow the
manufacturer's instructions!
Working at height (above 1.2 m):

Even falls from low heights can result in serious injury. When working at height (above 1.2 m), where the
provision of technical safeguards (e.g. handrails, work platforms, etc.) is either impossible or impractical,
you should use:
• personal fall arrest equipment consisting of harness and associated equipment (safety rope, karabiner
hook, shock absorber, lanyard or height safety device)!
Using fuel gas containing CO (read the results of the gas analyses):
• CO sensors as personal protective equipment! Ensure personal protective equipment is regularly
maintained/calibrated.
People who are under the influence of alcohol and/or drugs represent a danger
to themselves and other people.
They must not be allowed to enter the engine room under any circumstances.
IS O 3864, ANS I Z535

Jenbacher 2300-0005
6. Shutdown procedure and securing:
Automatic machinery: liable to start without warning!
If the operating mode selector switch is in "Aut" position, the module may start
without warning at any time.
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Before commencing maintenance work, repairs, etc., shut down machinery as described below
and secure to prevent unauthorised start-up!
Shut down and secure!
To shut down the engine:

Switch off the engine in accordance with Technical Instruction No. 1100-0105
and ensure that unauthorised persons cannot start the engine.
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Isolate from power supply before starting work!
Before starting work, isolate the machinery from the relevant circuits to prevent
it from being restarted and check to ensure that the system is dead.
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Dangerous voltage!
Despite having isolated the machinery, you should regard all components as
live.
(off) (on) Check that all components are disconnected!
ISO 3864, ANSI Z535
High-voltage ignition system – 40kV!

Improper use may be fatal!
The ignition system may cause electric shock.

Ignition systems may also produce extremely dangerous voltages when the
equipment is not operating. This applies to all ignition system components,
such as the cable, coil, connector, etc!
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Jenbacher 2300-0005
Hot surfaces!
Risk of burns
Let engine cool down, wear personal protective equipment!

Wear thermal insulation gloves and protective clothing!
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Risk of escaping liquids (hot and under pressure)!
Liquids such as engine cooling water and lubricating oil are hot and under
pressure. Escaping liquids may cause serious injury.
Wear personal protective equipment!

Wear eye protection, thermal insulation gloves and protective clothing!
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Allow the engine and cooling water to cool down before removing pipes, gaskets and covers or opening
components that contain liquids. The pressure must first be reduced to zero. Only then, drain the cooling
water if necessary. Liquids must be drained completely.
Risk of explosion!
When charging, batteries produce hydrogen and oxygen which under certain
conditions may form an explosive mixture.
The battery is charged with 24 V DC even when the control system is switched
off. Sparks generated at the battery poles can ignite an explosive atmosphere.
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Check that the battery poles are firmly secured. No smoking, no naked flames,
no sparks!
Poisonous gases!
The air in the engine room may be severely polluted with evaporating oil,
cooling water, fuel gases or exhaust gases.
Ventilate the engine room thoroughly before starting work!

Ensure there is a fresh air supply when working in the engine room!
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Wear personal protective equipment (gas sensors)!

Jenbacher 2300-0005
7. Engine room:
No admittance for unauthorised persons!

Room contains electrical machinery!
Admittance for authorised and trained personnel only
(specialist staff)!
In principle, the engine room is an enclosed, protected room

for the unmanned operation of machinery.
Read the personal protection guidelines in these safety instructions and wear the personal
protective equipment appropriate to the dangers concerned!
Noise!
The noise produced when the machinery is operating or being started may
damage your hearing.
Wear hearing protection!

IS O 3864, ANS I Z535
No pacemakers!
Because of the possibility of electromagnetic effects on pacemakers or similar

devices, people with such devices are prohibited from entering the engine room.
IS O 3864, ANS I Z535
No fire, naked flames or smoking!
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Install fire extinguishers!
Fire extinguishers must be installed at places where they may be easily reached
in the event of a fire. Comply with official regulations and establish the types,
size and number of extinguishers required with your supplier and insurance
agent.
IS O 3864, ANS I Z535

Jenbacher 2300-0005
Risk of slipping!
Wipe up any spilt oil and coolant immediately and keep the machinery clean!
IS O 3864, ANS I Z535
Highly flammable materials!
Keep oily rags in fire-proof containers. Never leave them lying on the engine.
Do not store flammable liquids near engines.

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

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Jenbacher 2300-0005
Poisonous gases!
Enclosed spaces must be well ventilated to ensure a constant supply of fresh

air.
Rooms in which gas-consuming devices are operated must be ventilated.
IS O 3864, ANS I Z535
In the event of unusual machine noise and unusual smells in the engine room, carry out a check. If
you detect a gas concentration in a building, you should always observe the following instructions:
If you fear that a hazard exists, actuate the emergency stop outside the engine room, close the gas
safety shut-off valve outside the engine room and make sure that it cannot be opened unintentionally.
Prevent any possibility of ignition and, if possible, break all the electrical circuits from outside the danger
zone.
Evacuate all personnel from the danger zone.
Allow air into the affected parts of the building by opening windows and doors.
Call in professionals to look for the gas leak and its cause and initiate damage repair.
Poisonous gases (e.g.: CO, H2S, etc.)!

Read the results of the fuel gas analyses!
Fuel gases may be poisonous and may result in death or damage to health if
inhaled.
Wear gas sensors as personal protective equipment (appropriate to the

IS O 3864, ANS I Z535
poisonous gas components) and ensure proper ventilation!
If the fuel gas contains carbon monoxide CO:

Carbon monoxide is a poisonous, odourless, colourless, highly flammable
gas, which is about as heavy as air.
Read the results of the fuel gas analyses!
IS O 3864, ANS I Z535
Wear CO sensors as personal protective equipment when:

• the gas is odourless and the CO content of the fuel gas is >0%.
• the gas contains odours and the CO content of the fuel gas is >0.5%.
Observe these guide values if no other safety guidelines are available or they
are less stringent than the guide values. Country-specific thresholds/guidelines
ALWAYS have priority. Also ensure that personal protective equipment is
IS O 3864, ANS I Z535
regularly maintained/calibrated.

Jenbacher 2300-0005
CO concentration in the air and its effect if inhaled:

• 0.003 Vol% = 30 ppm no/minimal risk to health
• 0.010 Vol% = 100 ppm slight headache after several hours
• 0.050 Vol% = 500 ppm severe headache after several hours,
accompanied by dizziness, fainting
• 0.1 Vol%-0.2 Vol% = 1000-2000 ppm death after 30 minutes
• 0.3 Vol%-0.5 Vol% = 3000-5000 ppm death after a few minutes
Other symptoms: vomiting and nausea, buzzing in the ears, light-headedness, convulsions,
hyperventilation, etc.
Risk of explosion
The air-gas mixture used as engine fuel is easily ignited and may explode.
Close and make secure the manual stop valve, ensure there are no sparks or
naked flames, impose a strict ban on smoking and provide adequate ventilation!
IS O 3864, ANS I Z535
8. Components
Protective devices should not be removed while the machinery is in operation. Repair or replace
damaged protective devices immediately.
Before removing any protective device, secure the machinery to prevent unauthorised start-up.
Shutdown procedure and securing Æ See point 5 of these safety

instructions!
IS O 3864, ANS I Z 535

Jenbacher Technical Instruction No.:2300-0005
8.1 Exhaust-gas system:

Exhaust gases may be poisonous and may result in death or damage to health if inhaled.
Exhaust gases must always be discharged into the atmosphere.
The exhaust-gas system must be inspected regularly to ensure that it is gas-tight:
Visually - Cracks, corrosion, faulty gaskets

Odour - Exhaust smell
Locations at risk: Flange connections, gaskets, compensators, welded joints.

It is the operator’s responsibility to ensure that there are no leaks in the exhaust system.
Poisonous gases!
Inhalation will result in damage to health or death.
Discharge exhaust gases into the atmosphere, check for leaks, provide
adequate ventilation.
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Hot surfaces!
Components which are not insulated and through which exhaust gas passes
are very hot and can cause severe burns.

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8.2 Turbocharger:
As the turbocharger operates at high temperatures, flammable material must be kept at a distance.
Work on the turbocharger must only be carried out once the engine has been shut down and room
temperature has been reached, otherwise there is a risk of injury and fire.
Hot surfaces!
Risk of burns

IS O 3864, ANS I Z535

Jenbacher 2300-0005
Fire risk!
Fire
Avoid contact with flammable material and keep the machinery clean!
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8.3 Fuel gas system:

The engine is equipped for the fuel gas quality specified by the customer when the engine was ordered,
and is adjusted for this gas when it is first put into operation.
GE Jenbacher Customer Service must be notified before you convert the system to another type of fuel
gas and each time the fuel gas quality is changed!
Warning: The air-gas mixture used as engine fuel is easily ignited and may explode.
As soon as fuel gas is present in the pipes no welding work must be carried out in the engine room
concerned.
No naked flames may be used and a strict ban on smoking must be observed.
The guidelines below must be read in conjunction with other mandatory requirements
(arrangement plan, Technical Instructions, statutory regulations, official directives, etc.) when
constructing and operating the machinery:
The engine room ventilation must be so designed that gas concentrations are prevented and a slight
overpressure exists in the engine room. See TI No. 1100-0110.
Ensure that the pipes and components through which the fuel gas passes are fully leakproof.
Install a flame trap (depending on the legal requirements of the country where the equipment is located)
in the gas supply line.
Plant-side safety valves must always be directed downwards.
A manual stop 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.
It is the operator’s responsibility to ensure that the fuel gas system is equipped with the necessary
devices, does not leak and satisfies official requirements.

Jenbacher 2300-0005
Risk of explosion
The air-gas mixture used as engine fuel is easily ignited and may explode.
No welding, no naked flames, strict ban on smoking, efficient

maintenance/inspection, leak tests, adequate ventilation gas alarm system,
manual stop valve closed and made safe!
IS O 3864, ANS I Z535
Poisonous gases (e.g.: CO, H2S, etc.)!

Take the results of the gas analyses into account!
Fuel gases may be poisonous and may result in death or damage to health if
inhaled.
Wear gas sensors as personal protective equipment (appropriate to the

IS O 3864, ANS I Z535
poisonous gas components) and ensure proper ventilation!
You must also read the engine room guidelines in these safety
instructions!
Extreme care is required when carrying out maintenance or repair work on the gas pressure
control system and the gas pipes. These components contain quantities of residual gas which will
escape when, for example, the gas filter is being changed!
8.4 Cooling system:

The engine coolant is hot and under pressure at operating temperature.
Damaged or weathered pipes, gaskets, hoses and hose clips and other components must be replaced
immediately. If these components fracture, hot coolant could injure people and cause a fire.
Keep away from pressure relief valves when operating the machinery.
The fracturing of components causes hot coolant to escape, thereby posing a

risk of injury.
Regular maintenance/inspection of components. Wear personal protective

equipment (protective spectacles, protective clothing and thermal insulation
IS O 3864, ANS I Z535
gloves). Keep away from pressure relief valves!
Hot surfaces!
Risk of burns

IS O 3864, ANS I Z535

Jenbacher 2300-0005
To replace pipes and components:

instructions!
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Coolants are treated with anti-corrosive and anti-freeze products.

Anti-freeze and anti-corrosion products are usually classified as harmful to
health. Follow the manufacturer's instructions!
Wear personal protective equipment when handling anti-corrosion products,

anti-freeze products and coolant! Follow the manufacturer's safety instructions!
Note disposal requirements!
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8.5 Heat exchangers:

Heat exchangers are pressure vessels which are designed for specific pressure and temperature limits.
Operators must be made familiar with the specific design pressure and temperature.
Heat exchangers must be pressure-tested on a regular basis.

A visual inspection of the following points of risk must be carried out: Flange connections, gaskets, locks
and covers.
Any liquids escaping as the result of a leak may cause serious injury.
Keep away from pressure relief valves when operating the machinery.
The fracturing of components causes hot liquids to escape, thereby posing a

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

protective equipment (protective spectacles, protective clothing and thermal
IS O 3864, ANS I Z535
insulation gloves). Keep away from pressure relief valves! Reduce pressure!

Jenbacher 2300-0005
Hot surfaces!
Risk of burns
Let the heat exchanger and pipes cool down, wear personal protective
equipment! Wear thermal insulation gloves and protective clothing!
IS O 3864, ANS I Z535
Do not remove pipes, seals and covers from the cooling system until the components have cooled down,
the pressure has been reduced and all liquids have been fully drained off.
To replace pipes and components:

instructions!
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8.6 Safety valve:

Avoid the danger zones around the valves as they could open at any time during operation. There is a
risk of injury due to hot operating materials under pressure.
The actuation of safety valves causes hot liquids to escape, thereby posing a
risk of injury.
Wear personal protective equipment (protective spectacles, protective clothing

and thermal insulation gloves). Keep away from pressure relief valves!
IS O 3864, ANS I Z535
8.7 Lubrication system:

The lubricant is hot and under pressure at operating temperature.
Hot oil or hot components may cause injury when you are carrying out an oil change or replacing the
filter.
Oil leaks must be scrupulously avoided as oil spray or splashes may ignite on contact with hot engine
components.

Jenbacher 2300-0005
The actuation of safety valves causes hot liquids to escape, thereby posing a
risk of injury.
Wear personal protective equipment (protective spectacles, protective clothing

and thermal insulation gloves). Keep away from pressure relief valves!
IS O 3864, ANS I Z535
Hot surfaces!
Components of the lubrication system (oil lines and filters, valves, etc.) are hot
and can cause severe burns.
Let components cool down, wear personal protective equipment! Wear thermal
insulation gloves and protective clothing!
IS O 3864, ANS I Z535
Fire risk!
Oil leaks must be scrupulously avoided as oil spray or splashes may ignite on
contact with hot engine components.
Keep the machinery clean and carry out maintenance/inspection as instructed!

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Lubricating oils and oily rags must be disposed of as special waste.
!
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8.8 Control system:
The control rod assembly must not be obstructed while the machinery is
operating. Any unauthorised adjustment or bending of the control rod assembly
could cause the engine to race.
!
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Jenbacher 2300-0005
8.9 Ignition system:
High-voltage ignition system – 40kV!

Improper use may be fatal!
The ignition system may cause electric shock.

Ignition systems may also produce extremely dangerous voltages when the
equipment is not operating.
Do not touch ignition system components such as the cable, coil, connector, etc.
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while the engine is running. Do not pull ignition cables off of coils! Ignition cables
must not come into contact with other parts!
The spark plug ignites an air-gas mixture in the combustion chamber. As a

result, any air-gas mixture which has accumulated in the induction port, exhaust
system or turbocharger may ignite. Failures must not simply be reset. Before
restarting the module, you must first remedy the cause of the failure! Please
read the rules on this subject in Technical Instruction 1100-0111.
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Risk of explosion
Failures or incorrect operation (e.g. frequent unsuccessful attempts to start,
resetting the fault contrary to instructions, cause of the failure not remedied,
etc.) may cause an air-gas mixture to accumulate outside the combustion
chamber and explode thereby causing serious injury, death and severe
damage.
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Remedy failures, operate machinery and carry out maintenance and inspections
in accordance with instructions!
8.10 Cables and insulated wiring:
Dangerous electrical voltage
To protect you from the hazards posed by electrical energy, we would point out
that the use of cables and insulated wiring must comply with the technical
specifications issued by VDE, IEC, etc., in accordance with local regulations and
such work may only be performed by authorised technicians (officially licensed
electricians).
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GE Jenbacher accepts no liability for injury, loss or damage due to improper

installation.

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8.11 Electrical connections:
All electrical connections involve a risk of making a direct or indirect electrical

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

licensed electricians) in accordance with local regulations.
8.12 Generator:
The voltage produced by the generator is deadly.
Contact could result in a serious, and possibly fatal, electric shock.

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Make sure that the generator is earthed before it is operated for the first time.
Extreme caution is required if the generator or the area around it is damp or wet.
In the event of an accident caused by electric shock, shut the module down immediately by pressing the
emergency stop button.
If the victim is injured or unconscious, summon a first-aider or medical assistance immediately.
If the generator is shut down by a safety device, do not restart it until the cause of the accident has been
remedied.
During commissioning, the manufacturer of the power supply cubicle must implement the protective
measures required under local regulations.
Ensure machine is properly earthed!
The machine must be properly earthed to prevent contact voltages and

electrostatic charging contrary to regulations.
Make sure that the engine is resting on non-conductive rubber bearings.
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8.13 Electrical cabinets:
The voltage inside electrical cabinets is deadly.
Contact could result in a serious, and possibly fatal, electric shock.

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Make sure that the control cabinet is earthed before the plant is operated for the first time.
Extreme caution is required if the electrical cabinet or the area around it is damp or wet.
In the event of an accident caused by electric shock, shut the module down immediately by pressing the
emergency stop button.
If the victim is injured or unconscious, summon a first-aider or medical assistance immediately.
During commissioning, the manufacturer of the power supply cubicle must implement the protective
measures required under local regulations.
Ensure machine is properly earthed!
The electrical cabinet must be properly earthed to prevent contact voltages

and electrostatic charging contrary to regulations.
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Keep door closed!
Proper operating conditions for electrical devices can only be achieved with the
cabinet door closed (e.g. weather exposure, heat, cold, dust, air-conditioning in
the cabinet, etc.)
This relates to all types of electrical cabinets, e.g. interface, control cabinet,
CLOSE power cubicle, thermal reactor cabinet, etc.
ISO 3864, ANSI Z535 JWN 080 080 / 461646

Jenbacher 2300-0005
8.14 Acoustic insulation (container; sound absorber hood):
Fire risk!
There is a risk of fire if loose lagging material comes into contact with hot engine
parts.
Check acoustic insulation for damage,

keep the machinery clean and carry out maintenance/inspection as instructed!
IS O 3864, ANS I Z535
8.15 Battery:
Corrosive substances!
The batteries used by GE Jenbacher are filled with dilute sulphuric acid, which
may cause serious corrosion.
Avoid contact with eyes and skin!

IS O 3864, ANS I Z535
Wear personal protective equipment!

Wear acid-resistant gloves, protective clothing, protective spectacles and safety footwear when handling
battery acid!
Battery acid may leak if batteries are damaged (e.g. during repair work), its corrosive action causing
damage to health as well as damage to the environment and property. Acid can also cause a chemical
reaction with the lime in the concrete and damage the floor.
Risk of explosion!
When charging, batteries produce hydrogen and oxygen which under certain
conditions may form an explosive mixture.
The battery is charged with 24 V DC even when the control system is switched
off. Sparks generated at the battery poles can ignite an explosive atmosphere.
IS O 3864, ANS I Z535
Check that the battery poles are firmly secured. No smoking, no naked flames,
no sparks!
Batteries, battery acid and rags contaminated with acid must be disposed of as
special waste.
!
IS O 3864, ANS I Z535

Jenbacher 2300-0005
8.16 Container/enclosure:
Extreme caution is required when carrying out maintenance and installation work on the roof. Ensure
workers are always safely harnessed to prevent a fall!
Wear safety harness / Risk of falling!
Climbing on to the roof without a safety harness is extremely dangerous.
Secure the safety harness to suitable points provided on the roof!
IS O 3864, ANS I Z535
Use personal fall arrest equipment consisting of harness and associated

equipment (safety rope, karabiner hook, shock absorber, lanyard or height safety device)!
The container or enclosure housing the plant must be designed so that

the plant does not pose any risks in the accessible area.
No ladders should be permanently attached to freely accessible containers or

enclosures, so as to prevent unauthorised persons from climbing on to the roof.
Where pipework, ducts, system components, etc. have to be laid or installed in

IS O 3864, ANS I Z535
the accessible area, they must be positioned at such a height that they cannot
be used for climbing or the system components installed within the danger zone will also have to be
enclosed.
If this is not possible, or if other dangers exist, the operator must secure the plant so as not to
allow unauthorised persons access to the danger zones.
Doors left open (e.g. during maintenance work) on the container, the
enclosure, the air intake, etc. can be slammed shut by a gust of wind. This may
result in hand or head injuries caused by crushing and impact.
Secure open doors with storm hooks (if available) or by other suitable
measures!
IS O 3864, ANS I Z535
Keep door closed!
All doors must be closed while the plant is operating! Proper operating
conditions can only be achieved with doors closed.
CLOSE
IS O 3864, ANS I Z535

Jenbacher 2300-0005
9. Maintenance and servicing:
Warning: Automatic machinery: liable to start without warning!
IS O 3864, ANS I Z535
The customer must make sure that before performing any maintenance work on the machinery,
the relevant safety precautions are taken.
See point 3 of these safety instructions, “Health and safety during operation and maintenance”.
Before commencing maintenance work, shut down the engine as described below and make sure
that it cannot be started unintentionally!

instructions!
IS O 3864, ANS I Z 535
Work on the machinery may only be carried out by specialist staff having relevant electrical and
mechanical training. There may also be a service or maintenance contract, under which all servicing is
carried out by GE Jenbacher personnel.
Suitable safe lifting gear must be used when fitting or removing heavy components. Handling heavy
components gives rise to a risk of severe crushing and impact injuries due to the heavy weight of the
components. Wear personal protective equipment such as safety footwear, protective clothing, hand
protection and safety helmet.
Working at height (above 1.2 m):

When working at height (above 1.2 m), where the provision of technical safeguards (e.g. handrails, work
platforms, etc.) is either impossible or impractical, you should use personal fall arrest equipment
consisting of harness and associated equipment (safety rope, karabiner hook, shock absorber, lanyard or
height safety device)!

Jenbacher 2300-0005
Before carrying out any work on the machinery, the customer has a duty to ensure that safety will not be
compromised.
Maintenance and repair work must be carried out with care. Temporary measures are not permitted:
• never repair fuses
• never deliberately ignore or re-use defective parts
• never place drip catchers under leaks
• never tighten screws, which have a specified tightening torque, contrary to the specification
• never make temporary repairs
• never implement unsystematic and unsuitable fault-finding procedures
Temporary repairs and makeshift arrangements may result in serious injury or damage the machinery.
Only repair methods specified in the engine documentation are allowed and are to be used.
10. Cleaning:
Fire risk!
Cleaning agents are usually highly flammable.
When carrying out cleaning operations, only use approved cleaning agents in
well ventilated areas. Under no circumstances use petrol, paint thinners and
other easily vaporising agents!
IS O 3864, ANS I Z535
Keep cleaning agents and solvents away from flames and flying sparks!
Poisonous gases!
Avoid inhaling any gases as they may be fatal.
When carrying out cleaning operations, only use approved cleaning agents in
well ventilated areas!
IS O 3864, ANS I Z535
Read the labels on all cleaning agent containers and follow the instructions.
Never use unlabelled products.
!
IS O 3864, ANS I Z535
Note disposal requirements.

Jenbacher W 8023 M0
Maintenance works:
Documentation Exhaust gas turbocharger
KLS98
1. Inspection: _____________________________________________________1
1.1 Check the compressor side for deposits:___________________________________________1
1.2 Check the compressor and the turbine side for deposits: ______________________________1
1.3 Inspecting the axial and radial play:_______________________________________________2
1.3.1 Inspecting the axial play: _______________________________________________________2
1.3.2 Inspecting the radial play: ______________________________________________________2
2. Overhaul: ______________________________________________________2
Interval every
Maintenance works Point 10000 Oh 20000 Oh
10 Check the compressor side for deposits 1.1
10 Check the compressor and the turbine side 1.2

for deposits *)
10 Inspecting the axial and radial play 1.3
20 Overhaul 2.
*) only for biogas and special gasses
1. Inspection:
1.1 Check the compressor side for deposits:

Mixture intake Æ disassemble manifold and pipe at turbocharger.
Check the compressor housing for deposits.
If deposits are found, the exhaust-gas turbo-compressor should be cleaned.
On-site cleaning possible.
1.2 Check the compressor and the turbine side for deposits:
Exhaust gas outlet and mixture intake Æ disassemble manifold and pipe at turbocharger.
Check the turbine and compressor housing for deposits.
If deposits are found, the exhaust-gas turbo-compressor should be cleaned.
On-site turbine-sided cleaning not possible.
Issued: Doku./Bilek Checked: Service Team I Date: 2002-04

Jenbacher W 8023 M0
Maintenance works:
Documentation Exhaust gas turbocharger
1.3 Inspecting the axial and radial play:
1.3.1 Inspecting the axial play:
Model series Axial play A

(Type) [mm] [in]
RR 131 max. 0,13 max. 0,005
RR 151 max. 0,17 max. 0,0067
RR 181 max. 0,19 max. 0,0075
RR 221 max. 0,21 max. 0,0083
TPS 48 0,08 - 0,16 0,0032-0,006
TPS 52 0,10 - 0,18 0,0034-0,007
TPS 57 0,12 - 0,21 0,0047-0,008
1.3.2 Inspecting the radial play:
Model series Radial play A

(Type) [mm] [in]
RR 131 max. 0,70 max. 0,028
RR 151 max. 0,75 max. 0,0295
RR 181 max. 0,83 max. 0,033
RR 221 max. 0,92 max. 0,036
TPS 48 0,54 - 1,22 0,021-0,048
TPS 52 0,62 - 1,35 0,024-0,053
TPS 57 0,72 - 1,52 0,028-0,0598
2. Overhaul:
The exhaust-gas turbo-compressor shall only be repaired and/or cleaned by the compressor
manufacturer or by specialist companies duly authorized by the compressor manufacturer to
carry out these activities.

Jenbacher Maintenance Instruction: W 8030 A0
Documentation Generator
Stamford 5, 6, 7
1. Bearing temperature monitoring (optional): ______________________________1

2. Relubricating the bearings (with engine running):_________________________2
2.1 Tips: 2
2.2 Lubricating grease recommendation: 2
2.3 Grease quantity: 2
3. Cleaning/Inspection: _________________________________________________2
4. Inspection/Expertise/Replacing the bearings: ____________________________2
5. Overhaul: __________________________________________________________3
6. Shutting down the installation: ________________________________________3
7. Recommissioning the installation: _____________________________________3
8. Manufacturer's instructions: __________________________________________3
Interval every
Maintenance work Point day 4000 Oh 10000 Oh 20000 Oh60000 Oh
d Monitoring bearing temperature 1.
04 Relubricating the bearings *) 2. **)
10 Cleaning/Inspection 3.
20 Inspection/Expertise/Replacing the 4.

bearings
60 Overhaul 5.
*) Does not apply to generators without lubricting nipples!
**) If the equipment is used for less than 4000 operating hours a year, the generator should be
relubricated annually!!
1. Bearing temperature monitoring (optional):
Data collection when monitoring the temperature of drive bearings and non-drive bearings:
Enter the data in the operational data booklet.
Best practice is to take the first measurement (see Initial Commissioning data sheet) as a baseline in
order to establish a trend in the deterioration of the condition of the bearings. It will then be possible to
change the bearings when the engine or generator is being serviced.
Check the temperature of the bearings when relubricating them. The bearing temperature may increase
during the lubrication process, but should return to normal operating values after a few minutes of
operation.
Issued: Doku./Bilek Checked: Newage Date: 2005-02

EN 8030A0_Stamford 5, 6, 7_EN.doc Index: h Page - No.: 1 / 3
Stamford 5, 6, 7
2. Relubricating the bearings (with engine running):
(Type 5: optionally regreasable)
2.1 Tips:
Bearings must always be lubricated when the engine is running!
When the engine is at a standstill you run the risk of “overgreasing“ the bearings because the lubricant
has not been evenly distributed.
Relubricate the generator bearing at the drive side and non-drive side lubricating nipples using a grease
gun.
Lubricating nipples should be cleaned before you relubricate to ensure that no particles of dirt get into the
bearings.
Let the engine run for 10 minutes after relubricating it so that any excess grease is expelled. Remove any
escaped lubricating grease on the underside of the casing cover.
2.2 Lubricating grease recommendation:

Klüber Asonic GHY 72 and Klüberquiet BQ 72-72
Make sure to use Klüberquiet BQ 72-72 lubricating grease in case of automatic regreasing!
Different types of grease should not be mixed. Using a different grease type could result in damage to the
bearing!
Preferred grease manufacturer: Klüber Lubrication München KG

Gelsenhausenerstrasse 7, D-81379 Munich, Germany
Fax: +49 (0) 89 7876 565
2.3 Grease quantity:

The prescribed grease quantity can be found on the sticker on the generator.
3. Cleaning/Inspection:
Switch off the engine in accordance with Technical Instruction No. 1100-0105 and make sure that
no unauthorised person can start the engine.
Remove any dirt and dust from the generator (cleaning using a vacuum cleaner).
Clean all parts with dry compressed air.
Check for soiling/contamination and damage, both externally and internally.
Cooling-air inlets and outlets must be free of dirt!
Check the auxiliary wiring for chafe marks.
Check the varistor and rectifier diodes in accordance with the manufacturer’s instructions.
4. Inspection/Expertise/Replacing the bearings:
The generator should only be repaired by the manufacturer or by specialised companies authorised to
carry out this work.

Stamford 5, 6, 7
5. Overhaul:
The generator should only be repaired by the manufacturer or by specialised companies authorised to
carry out this work.
6. Shutting down the installation:
When prolonged scheduled or unscheduled downtimes occur, e.g. after the heating season when
operating as a cogeneration plant, the installation must be prepared (preserved) for its downtime
according to its geographical location (climate, proximity of the sea, etc.). As conditions can vary
enormously, we recommend that you consult a suitable specialist firm concerning the measures to be
taken or contract it to carry out the work.
When the generator is out of service for a prolonged period the rotor must be rotated every two
months to ensure that the rolling elements change position (a small change of position will
suffice).
Do not rotate the rotor at the fan but use the engine flywheel to do so!
7. Recommissioning the installation:
When the installation is being recommissioned after 6 months, the bearings must be thoroughly lubricated
with the specified quantity of grease to replace the old grease.
Where the installation is to be recommissioned after a long period of downtime (e.g. 2 years) the bearings
have to be replaced as the grease starts to resinify over time, which makes the bearings unusable.
Of course, before recommissioning the installation, you must make sure that the installation is in its
normal operational condition again – see manufacturer’s instructions.
8. Manufacturer's instructions:
See description - Operation!

Jenbacher W 8031 A0
Maintenance works:
Documentation GE Jenbacher switch cabinets
1. Check switch cabinet for soiling, if necessary, blow through with dry air.
2. Power cabinet (if within supply quantity):
Check power switch (MERLIN GERIN):
In order to avoid any danger during maintenance work, the switch:

• is to be put in separating position (plug-in switch)
• is to be switched to idle-position (fixed switches)
W8031-01 W8031-02
W8031-03 W8031-04
Check condition of arc-quenching chambers:

• quenching chamber not damaged,
• partition walls of quenching chambers not corroded - if necessary, replace them.
Check wear of contacts:

Close switch to check contact condition.
W8031-05 W8031-06
Contacts fine Contacts worn out

EN 8031A0_EN.doc Index: a Page - No.: 1 / 1
Documentation Starter
KLS98
Starter should be overhauled by an authorized and specialized company!

Jenbacher IW 8041 A0
Documentation Intake air filter - Engine
1. Pocket filter:
If the underpressure increases to more than 1000 Pa, the filter elements in the pre-filter and pocket filter
should be replaced.

EN 8041A0_EN.doc Index: c Page - No.: 1 / 1
Jenbacher Maintenance works: W 8045 A0
Documentation Gas train
Interval every
Maintenance works Point 2000 Oh 30000 Oh 60000 Oh
02 Gas filter 1.
30 Pre-pressure controller 2.
60 Gas train 3.
1. Gas filter:
Remove cover of gas filter.

Disassemble the filter element.
Clean filter case.
Check the filter element for contamination. If required, replace the filter element.
Insert cleaned or new filter element (replace min. 1x of the years)!
Assemble both the filter element and the cover (using a new O ring).
Check filter for tightness (leakage spray).
2. Pre-pressure controller:
Have the pre-pressure controller overhauled by a specialist company authorised to carry out this work.
3. Gas train:
Gas train should be overhauled by an authorized and specialized company!

EN 8045A0_EN.doc Index: b Page - No.: 1 / 1
Documentation Oil pump
KLS98
1. Oil pump:
Disassemble and clean the oil pump. Replace the bearing bushes.
Inspect the oil-pump gearwheels. Replace if necessary.
The engine is to be lifted about 40 - 50 cm [15,748 - 19,685 in] (the engine could be lifted by means of
four hydraulic lifting devices with claw and four wooden clumps for securing).
Attention: After hoisting up the engine, secure it immediately using wooden blocks, for example.

Jenbacher W 8047 M0
Maintenance works:
Documentation Piston/Piston cooling
KLS98
1. Piston:
Replace piston, piston rings and piston pins.
2. Piston cooling:
Replace O ring.
Check all piston cooling nozzles with special device for exact mounting position.
Issued: Doku./Bilek Checked: TEK/VSA Date: 2002-04

Jenbacher W 8048 M0
Maintenance works:
Documentation Connecting rods/connecting rod bearing shells
KLS98
1. Connecting rods and connecting rods bearing shells:
Retrofit the connecting rods.

Replace the connecting-rod bearings and connecting-rod screws.
To keep the costs as low as possible, we recommend replacing the connecting rods by connecting rods
from our service-exchange programme.
For more information, please contact GE Jenbacher CUSTOMER SERVICE.

Jenbacher W 8049 M0
Maintenance works:
Documentation Cylinder liner/Scraping ring
KLS98
1. Cylinder liner and scraping ring:
Replace the cylinder liner, scraper ring and O-rings.

Jenbacher W 8050 M0
Maintenance works:
Documentation Crankshaft main bearing
KLS98
1. Crankshaft main bearing:
The following bearing has to be assessed depending on the specified engine type.
Engine type Bearing number
J 212 4
J 216 5
J 312 4
J 316 5
J 320 6
Check the wear-and-tear.

If the wear-and-tear remains within the tolerance level (= visually inspected by trained specialist staff [GE
Jenbacher Reliability]), only the disassembled bearing will need to be replaced.
If the wear-and-tear exceeds the tolerance levels authorised by us, the crankshaft should be
provided with new bearings.
Examples:
When inspecting the bearing shell, no discoloration of

the bearing running surface may be found. The main
bearing can be re-used.
If the disassembled bearing shell shows signs of a

copper-colored discoloration, the bearings must be
replaced.
Issued: TED/Jandewerth Checked: Entwicklung Date: 2006-10

Jenbacher W 8051 M0
Maintenance works:
Documentation Exhaust-gas collection line and insulation
KLS98
Carry out the inspection below following each cylinder-head disassembly!
1. Exhaust-gas collection line and insulation:
Check the exhaust-gas collection line and connection pieces for scaling and cracking.
Check the inner protection pipes of the compensators for cracks and/or tears.
Check the exhaust-gas insulation.

Jenbacher W 8052 M0
Maintenance works:
Documentation Camshaft/Control parts
KLS98
Carry out the inspection below following each cylinder-head disassembly!

Even when you have replaced a single cylinder head, you should inspect the relevant tappets and
cams.
1. Camshaft:
Cams of camshaft visual inspection:

Turn the cam gradually 4x90° further. Visually inspect the running surface for inadmissible
damage/chipping over every tappet bore along the entire cam circumference.
2. Control parts:
Inspect the tappets (replace at max. 30,000 operating hours).

Check stop rod, ball screw, rocker and rocker block.

EN 8052M0_EN.doc Index: b Page - No.: 1 / 1
Jenbacher W 8053 M0
Maintenance works:
Documentation Cylinder head replacement
KLS98
1. Cylinder head replacement: ___________________________________________1

1.1 Removing cylinder head: 1
1.2 Cylinder head assembly using a hydraulic drive module – if no hydraulic drive module is
available, assemble the cylinder head according to section 1.3: 1
1.3 Tightening the cylinder-head nuts (after 100 operating hours): 4
2. Fill the cooling water according to W 8080 A0! ___________________________5
Interval every
Maintenance works Point 30000 Oh ….. Oh
30 Cylinder head replacement 1. *)
- Cylinder head replacement 1. **)
*) With regard to disassembly, when replacing piston and cylinder liner.

Clean the cylinder head at the sealing planes and measure the valve stem projection.
If wear is in excess of 1.2 mm, we recommend replacing the cylinder head for reasons of economy.
**) When a check of the valve-stem projection shows that the maximum wear tolerance limit has been
reached.
1. Cylinder head replacement:
1.1 Removing cylinder head:

Drain coolant (until cylinder heads are empty).
Attention: never re-use drained cooling water when re-filling the cooling system!
Remove ignition coils and spark plugs.
Disassemble and inspect the exhaust, mixture and cooling-water lines.
Disassemble exhaust insulation (if available).
Disassembly of the cylinder-head cover.
Disassemble the valve control components (rocker support, rocker arms, tappet push rods and tappets).
Inspect the camshaft.
Remove cylinder head bolts cylinder heads.
Caution: Do not damage cylinder head sealing surface.
1.2 Cylinder head assembly using a hydraulic drive module – if no hydraulic drive module is
available, assemble the cylinder head according to section 1.3:
Clean sealing surfaces on crankcase, intermediate ring (only 3-series) and cylinder heads and fit new
gaskets.
Fit cylinder heads.
Oil threaded pins and nut contact area of cylinder heads.
Handtighten the cylinder-head nuts, „start at the top“.
Fit the support plate.
Issued: Doku./Bilek Checked: TEAM/Egger Christoph Date: 2006-03

Jenbacher W 8053 M0
Maintenance works:
A Support plate B
A
B
D
C
D C
Because of the very limited contact

surfaces at the cylinder head, a
support plate must be used.
Fit the hydraulic torque spanner to the cylinder

head nuts A, B, C and D.

Jenbacher W 8053 M0
Maintenance works:
Connect the hoses to the four hydraulic cylinders and to

the hydraulic drive module.
Switch on the hydraulic drive module.
Using the remote control unit, tighten the cylinder head

nuts to the tightening pressure as specified in TI 1902-
0212.
Hydraulic drive module, remote control unit.
Clamping cylinder pressure.
Hydraulic
drive module
Make sure to maintain a safety distance of 3 - 5 m to the screw clamping cylinder while pressure
is being built-up.
It is absolutely forbidden for anyone to remain on the pulling side while pressure is being built-up.
The operating staff must check the hydraulic pressure increase using the pressure gauge. If
despite continuous pressure generation the pressure no longer increases, the pressure build up
must be stopped immediately.
This may be caused by a plastic deformation. For that reason, make sure to check the screw
connection for form and dimensional accuracy.
(e.g. permanent double-end stud elongation).

Jenbacher W 8053 M0
Maintenance works:
Having applied pressure, turn all four nuts manually at the turning
device (square) until they rest against the cylinder head.
Turning device
Using the remote control unit, reduce the screw clamping cylinder pressure.
Switch off the hydraulic drive module.
Remove the hoses from the hydraulic cylinders and then remove all four hydraulic cylinders.
Install valve timing items.
Adjust the valve play according to W 0400 M0.
Clean the sealing plane on the underside of the cylinder-head cover and remove any paint residues.
Assemble the cylinder-head cover using a new gasket.
Install exhaust, mixture and cooling water lines.
Install insulation.
Isolierung montieren.
1.3 Tightening the cylinder-head nuts:

Clean sealing surfaces on crankcase, intermediate ring (only 3-series) and cylinder heads and fit new
gaskets.
Fit cylinder heads.
Oil threaded pins and nut contact area of cylinder heads.
Screw in bolts hand-tight and tighten

crosswise with a torque of 147,4 lb ft (200
Nm) (starting on the intake side “top”). Fit
angle-of-rotation tool (see figure) and tighten
by a further
- Series 2 ... 60 °
- Series 3 ... 70 °
(crosswise).

Jenbacher W 8053 M0
Maintenance works:
Install valve timing items.

Adjust the valve play according to W 0400 M0.
Clean the sealing plane on the underside of the cylinder-head cover and remove any paint residues.
Assemble the cylinder-head cover using a new gasket.
Install exhaust, mixture and cooling water lines.
Install ignition coils and spark plugs.
Fill up cooling water.
Check tappet clearance again with feeler gauge!
2. Fill the cooling water according to W 8080 A0!

Jenbacher W 8054 M0
Maintenance works:
Documentation Pre-lubricating pump
KLS98
Have the Pre-lubricating pump overhauled by a specialist company authorised to carry out this
work.

EN 8054M0_EN.doc Index: b Page - No.: 1 / 1
Jenbacher W 8080 A0
Maintenance works:
Documentation Engine cooling-water circuit / Mixture recirculating
1. Water pressure inspection (daily): ______________________________________1

2. Filling the cooling water:______________________________________________2
2.1 General tips: 2
2.2 Filling instructions for the cooling-water system: 3
2.3 Bleeding: 4
2.3.1 Electric cooling water pump without permanent bleeding: 4
2.3.2 Preheating pump: 4
2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules: 5
2.4.1 Measuring the differential temperature: 7
2.4.2 Adjusting the bundle control valve 7
Interval: every
day 20,000 30,000
operating operating
Maintenance work Section hours hours
t Water-pressure inspection 1.
20/30 Cooling water exchange 2. *)
*) only for special gasses and an engine cooling water temperature >95 °C (see module maintenance
plan)
1. Water pressure inspection (daily):
Water pressure inspection using the pressure

gauge on the filling valve.
Pressure gauge
Cooling water system pressure (for cold installation): 1.1 bar

Note down the exact cooling water operating pressure in the operational data booklet.
Issued: Doku./Bilek Checked: TKA/TEAM/VSR/TPAQ/VSI Date: 2005-07

Jenbacher W 8080 A0
Maintenance works:
Datenerfassung: E 0101
Switch off the engine in accordance with Technical Instruction No. 1100-0105 and ensure that
unauthorised persons cannot start the engine.
2. Filling the cooling water:
2.1 General tips:

Quality of cooling water in closed circuits: TI No. 1000-0200
Anti-freeze agents: TI No. 1000-0201
Cooling water anti-corrosion additive: TI No. 1000-0204
Quality of circuit water in hot water and
warm water heating systems: TI No. 1000-0206
Quality of cooling water in open circuits: TI No. 1000-0208
Air-bleed cock (to be opened

only when filling water)
Shut-off valve (must be closed

following commissioning and
remain closed)
Continuous breather (only for container-based install.)

Jenbacher W 8080 A0
Maintenance works:
2.2 Filling instructions for the cooling-water system:
Reduce the pre-pressure (if required) using the pressure valve at the membrane pressure compensation
reservoir. Before doing so, make sure cooling water has not yet been filled.
Modules pressure compensation reservoir

pre-pressure
J 208 GS – J 320 GS 0.6 bar

J 412 GS – J 420 GS 0.6 bar
Container-based 0.6 bar
installations
J 612 GS – J 620 GS 0.8 bar
Press. valve
Set the cooling water system pressure at the filling valve.

Make sure when connecting the filling hose to the filling valve that no air can get into the system (to
prevent unwanted air from entering the cooling-water system).
Fill the cooling-water system via the filling valve.
The air-bleed cock must remain open until only water, i.e. no air, flows out of the opening.
Close the shut-off cock by turning it clockwise (to the right) and remove the filling hose from the filling
valve.
Following every filling or re-filling of the cooling system, repeat the filling procedure until the cooling-water
system is fully bled.

Jenbacher W 8080 A0
Maintenance works:
2.3 Bleeding:
2.3.1 Electric cooling water pump without permanent bleeding:
Electric cooling water pump bleeding screw
Open the bleeding screw until the water escaping no longer contains any air.
2.3.2 Preheating pump:
Preheating pump bleeding screw
Open the bleeding screw until the water escaping no longer contains any air.
Caution: make sure to check the preheating pump shaft for smooth operation if the engine has
been decommissioned for a long period of time prior to starting Æ to do so, turn the shaft using a
screw driver in the notch of the pump shaft.
Always shut off the flow to the filling valve after completing the filling and/or refilling procedure.
This is to see whether the pressure in the cooling-water system has been maintained.

Jenbacher W 8080 A0
Maintenance works:
Attention in the case of single-circuit cooling system modules:

Inspect the cooling water circuit everytime after working on the cooling system and/or every time
the cooling water is changed!
2.4 Adjusting the cooling water circuit in the case of single-circuit cooling system modules:
Adjust the flow amount using the bundle control valve.
Bundle control valve
The setting value can easily be recorded and reproduced using the scale. The top number (against the
black background) represents the rough setting (1 to 4), the bottom number (red background) represents
the decimal setting (1 to 9).

Jenbacher W 8080 A0
Maintenance works:
Measuring the differential temperature between the engine cooling water intake
and engine cooling water outlet.
The differential temperature at full load should be approx. 6°C.

Jenbacher W 8080 A0
Maintenance works:
2.4.1 Measuring the differential temperature:

Make sure when establishing the differential temperature that the same equipment is used at both
measuring locations.
The most efficient method is using infrared measuring equipment. Make sure that the pipe surface is
equal at both measurement locations (same paint and same surface roughness).
When in doubt, cover both surfaces using wide adhesive tape. The tape must be mat (not glossy or
reflecting).
If no infrared measuring equipment is available, the temperature can also be established using contact
measuring equipment. This equipment is not as precise, however, as air flows can affect the surface
temperatures. Therefore, the measuring sensor must be covered and left at both locations for the same
period of time.
2.4.2 Adjusting the bundle control valve

Remove the bundle control valve locking device and the safety cover.
The basic setting of the bundle control valve is approx. 1.5.
Run the engine at half load and adjust the bundle control valve such that a differential temperature of
approx. 4°C is achieved (closing the valve will increase the differential temperature). Consequently, run
the engine at full load and wait until the temperature remains constant (at least 30 minutes) and then set
the differential temperature of approx. 6°C.
Differential temperatures below 5°C (valve opened too wide) can result in “Cooling water temperature
maximum”.
Differential temperatures between 5°C and 7°C are still admissible.
Re-asssemble the safety cover and lock it.

Jenbacher W 1000 0
Maintenance works:
Documentation Maintenance after first start-up
1. Note:
The following maintenance activities should be carried out once following first commissioning, but before
100 operational hours are reached.
2. Maintenance works:
2.1 Valve play/Cylinder head: W 0400 M0

Adjust the valve play of the inlet and exhaust valves.
2.2 Check ignition voltage/spark plug: IW 0309 M0

Check ignition voltage and, if required, readjust spark-plug electrodes.
Enter the measured values in table Data Registration Spark Plugs (E 0309).
2.3 Gas filter: W 8045 A0

Check gas filter for contamination.

EN 10000_EN.doc Index: d Page - No.: 1 / 1
W 8033 0
Maintenance works:
Jenbacher Elastomer parts
Documentation
Elastomer components age and become brittle, even when the engines are not operational.That is
why the service life of these components does not depend on the on-stream service time of the
module, the cooling-water temperature and pressure etc. If this number of operating hours is not
reached, the elastomer components should still be replaced as a precautionary measure after a
maximum of 5 years.
Every
Replacing the elastomer components 10000 Oh 20000 Oh 30000 Oh 60000 Oh
All O-rings: turbocompressor connection
All O-rings: coolingwater line, oil lines, oil cooler
All hoses: oil lines, prelubrication and relubrication,
venting system, compensation reservoir, exhaust-
gas back pressure control, crankcase ventilation
Coupling: coupling discs
All rubber buffers: air-filter collection cabinets, intake
line, gas mixer, ignition cable harness, ignition,
switch cabinets on the module, etc.
All O-rings: cylinder liners, crankcase, cylinder head,
*)
piston cooling nozzles
Engine/generator bearing: rubber rails **)
Anchoring bolts: O-rings
Platen-type heat exchanger: packings ***)
*) only for biogasses, landfill gas, special gasses or an engine cooling water temperature >95°C
**) inspect and replace, if necessary
***) only for engine cooling water temperature >95 °C

EN 80330_EN.doc Index: h Page - No.: 1 / 1
I 9002 0
Inspections:
Jenbacher Daily inspection
Documentation
1. Leak test: ______________________________________________________1

1.1 Exhaust pipes and supercharger connections: 1
1.2 Vibration damper: 1
1.3 Cooling water pump: 1
2. Heat Exchanger Exhaust gas/water (if mounted): _____________________2
2.1 Condensate line: 2
2.2 Condensate/neutralisation granulate reservoir: 2
3. Checking the exhaust gas counterpressure ducts (if mounted):_________2
4. Unusual operational noises: ______________________________________2
Before performing any work on the installation, the maintenance staff must ensure that the
relevant safety precautions have been observed regarding the activities to be carried out.
For safety precautions, please refer to the operation or maintenance description (TI No.: 2300-
0005).
1. Leak test:
Check the whole plant for leaks, in particular hoses, ducts, fittings, compensators etc. (visual check).
Leakages can be determined through oil traces at the charge-air pipings. In the event of a more intensive
exit of mixture it is also possible to smell gas. The location of the exit can be determined with the help of a
leakage spray or a piece of paper (will be blown away).
In case of carbon monoxide (CO) in the fuel gas:

Carbon monoxide is a poisonous, odourless, colourless, highly flammable gas, which is about as heavy
as air.
If the fuel gas contains CO, CO sensors must be worn as personal protective equipment.
1.1 Exhaust pipes and supercharger connections:

Leakages can be determined through a change in colour or a damage of the insulation (noise) or slight
emission of soot.
1.2 Vibration damper:

The damper protection must be checked for damage and traces of oil splashes (leakages). Even the
smallest damage on the vibration damper can have a great influence on the function or even lead to total
functional disorders. In the event of damage or leakages, the damper has to be replaced immediately,
otherwise the crankshaft may break.
1.3 Cooling water pump:

If water leaks from the check bore hole, the floating ring seal is defective.
Single drops per minute may be considered normal.
If an oil-leakage occurs, the rotary shaft lip seal is defective.
The check bore hole must not be closed! Check with a wire for free motion.

I 9002 0
Inspections:
Jenbacher Daily inspection
Documentation
Check bore hole
floating ring seal
rotary shaft lip seal
2. Heat Exchanger Exhaust gas/water (if mounted):
2.1 Condensate line:

Check the condensate pipes and the connection of the exhaust gas heat exchanger as for possible dirt
and clean them, if necessary, so the condensate can drain off.
2.2 Condensate/neutralisation granulate reservoir:

Check the built-in filters and the neutralisation granulate for soiling; clean if necessary.
3. Checking the exhaust gas counterpressure ducts (if mounted):
Remove the screw plug and check if there is any condensate. Check if the ducts are dirty, if necessary,
clean them and then put the screw plug back on.
4. Unusual operational noises:
Be alert for unusual operational noises. If any such noises are heard, their cause should be established
and they should be resolved. If the cause cannot be established, please contact the GE Jenbacher
customer service department.

Jenbacher
Documentation
Operating data log
Operational data to be read Unit Mo. Tu. We. Th. Fr. Sa. Su.
Electrical power - output P kW
Reactive Power Q kVAr
Apparent Power S kVA
cos phi φ
Current: Im Current Average Value A
Um Voltage Average Value V
In Neutral Conductor Current A
Ue Excitation Voltage V
Active Energy MWh
Reactive Energy MVARH
Exhaust gas 1 11 °C
temperature -
cylinder no.: 2 12 °C
3 13 °C
4 14 °C
5 15 °C
6 16 °C
7 17 °C
8 18 °C
9 19 °C
10 20 °C
Exhaust gas heat exchanger - tube plate
°C
temperature
Drive side (DS) generator bearing
°C
temperature
Non-drive side (NDS) generator bearing
°C
temperature
Engine jacket water temperature after engine °C
Engine jacket water pressure bar
Lube oil temperature °C
Lube oil pressure bar
Crankcase pressure *) **) mbar
Voorkamergasverschildruk *) **) mbar
Leanox -Daten: Fuel/air-mixture temperature °C
Charging pressure bar
Gasmixer Position %
Throttle valve position %
Turbocharger Bypass Pos. %
Operating hours h
Number of starts
Exhaust gas temperature (exhaust gas heat
°C
exchanger outlet) *)
Gas pressure constant ±3 mbar/30 s
yes/no
Deviations ?
Heating water temperature (exhaust gas heat
°C
exchanger inlet) *)
Heating water temperature (exhaust gas heat
°C
exchanger outlet) *)
Air temperatur: Ambient °C
Engine room °C
Correct capture of operating data confirmed:

*) if GE Jenbacher scope of supply! **) Alleen bij modelreeks 6!

EN BDB_BR2+3+6_EN.doc Index: e Page - No.: 1 / 1
Jenbacher CE
Documentation Declaration of conformity
CE Declaration of conformity
In accordance with CE Guidelines 98/37 (Machine Safety), 89/336 (Electromagnetic Compatibility),
2006/95 (73/23) (Low-voltage guidelines - electrical units, to be used within specific voltage limits).
We
GE Jenbacher GmbH & Co OHG
Achenseestraße 1 - 3
A-6200 Jenbach
declare of our own responsibility, that the product

Generator set: JGS 320 GS-N.L
Module no.: 490458 1
together with accessory electrical plant, lifting gear and all electrical and mechanical equipment
supplied and directly associated with it
to which this declaration refers, conforms to the relevant fundamental safety objectives of the
CE Guidelines 98/37 (Machine Safety), 89/336 (Electromagnetic Compatibility) and 2006/95 (73/23) (Low-
voltage guidelines - electrical units, to be used within specific voltage limits).
The following standards and technical specifications, among others, have been applied in order to
properly satisfy the requirements specified in the CE Directives:
ISO 12100 T1/T2 Safety of Machinery: Basic Concepts, General Principles for Design.
EN 12601 Reciprocating Internal Combustion Engine Driven Generating Sets – Safety.
EN 60204 T1 The safety of basic machine terms, - electric equipment of machines.
EN 60439 T1 Combinations of low-voltage switchgear
ISO 8528 / DIN 6280 Electricity generation sets with reciprocating internal combustion engines.
ISO 3864 Graphical symbols -- Safety Colours and Safety Signs.
DVGW Gas appliances are CE-DVGW-certified (EC Type-Examination Certificate in
accordance with the EC Gas Appliance Directive 90/396/EEC) and the fuel gas
lines and controlled gas pressure system on the module have been leak-tested in
accordance with DVGW- TRGI 1986 – Work Sheet G600 (Technical Guidelines
for Gas Installations issued by the German Technical and Scientific Association
for Gas and Water).
CISPR 12 Limits and methods of measurement of radio interference characteristics of
vehicles, motor boats, and spark-ignited engine-driven devices.
EN 55011 (Class B) Limits and measuring methods for radio interference of industrial, scientific and
medical high-frequency devices (ISM-devices).
Ing. Volker Schwemberger Dr. Volker Schulte CE Date: 2006-09 Country: IDN
Department Head Department Head
Planning & Logistics Development Issued on: 2007-03 Language: EN
E 0101
Jenbacher Data capture engine lubricant
Documentation
Product used (brand name): ……………………....................... .
Oil analysis
Oil change
Operating hours Date performed by Signature Note
150 Oh 9

EN E0101_EN.doc Index: c Page - No.: 1 / 2
E 0101
Jenbacher Data capture engine lubricant
Documentation
Product used (brand name): ……………………....................... .
Oil analysis
Oil change
Operating hours Date performed by Signature Note

E 0103 a
Jenbacher Data capture heat exchanger mixture/water
Documentation
Inlet mixture
pressure:
Inspection interval: Difference pressure Date captured by
Outlet mixture
pressure:
Initial taking into p1=______mbar ∆p =_____mbar

(desired value)
operation p2=______mbar
p1=______mbar
10000 ∆p =_____mbar
p2=______mbar
p1=______mbar
20000 ∆p =_____mbar
p2=______mbar
p1=______mbar
30000 ∆p =_____mbar
p2=______mbar
p1=______mbar
40000 ∆p =_____mbar
p2=______mbar
p1=______mbar
50000 ∆p =_____mbar
p2=______mbar
p1=______mbar
60000 ∆p =_____mbar
p2=______mbar

EN E0103a_EN.doc Index: a Page - No.: 1 / 1
E 0303
Jenbacher Data capture ignition coils
Documentation
Ignition voltage provided by a correctly functioning ignition coil > 35kv
2000 Oh 4000 Oh 6000 Oh 8000 Oh 10000 Oh

Cylinder Ignition Cylinder Ignition Cylinder Ignition Cylinder Ignition Cylinder Ignition
voltage voltage voltage voltage voltage
supply supply supply supply supply
1 1 1 1 1
2 2 2 2 2
3 3 3 3 3
4 4 4 4 4
5 5 5 5 5
6 6 6 6 6
7 7 7 7 7
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
11 11 11 11 11
12 12 12 12 12
13 13 13 13 13
14 14 14 14 14
15 15 15 15 15
16 16 16 16 16
17 17 17 17 17
18 18 18 18 18
19 19 19 19 19
20 20 20 20 20
12000 Oh 14000 Oh 16000 Oh 18000 Oh 20000 Oh

1 1 1 1 1
2 2 2 2 2
3 3 3 3 3
4 4 4 4 4
5 5 5 5 5
6 6 6 6 6
7 7 7 7 7
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
11 11 11 11 11
12 12 12 12 12
13 13 13 13 13
14 14 14 14 14
15 15 15 15 15
16 16 16 16 16
17 17 17 17 17
18 18 18 18 18
19 19 19 19 19
20 20 20 20 20

EN E0303_EN.doc Index: b Page - No.: 1 / 3
E 0303
Documentation
22000 Oh 24000 Oh 26000 Oh 28000 Oh 30000 Oh

1 1 1 1 1
2 2 2 2 2
3 3 3 3 3
4 4 4 4 4
5 5 5 5 5
6 6 6 6 6
7 7 7 7 7
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
11 11 11 11 11
12 12 12 12 12
13 13 13 13 13
14 14 14 14 14
15 15 15 15 15
16 16 16 16 16
17 17 17 17 17
18 18 18 18 18
19 19 19 19 19
20 20 20 20 20
32000 Oh 34000 Oh 36000 Oh 38000 Oh 40000 Oh

1 1 1 1 1
2 2 2 2 2
3 3 3 3 3
4 4 4 4 4
5 5 5 5 5
6 6 6 6 6
7 7 7 7 7
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
11 11 11 11 11
12 12 12 12 12
13 13 13 13 13
14 14 14 14 14
15 15 15 15 15
16 16 16 16 16
17 17 17 17 17
18 18 18 18 18
19 19 19 19 19
20 20 20 20 20

E 0303
Documentation
42000 Oh 44000 Oh 46000 Oh 48000 Oh 50000 Oh

1 1 1 1 1
2 2 2 2 2
3 3 3 3 3
4 4 4 4 4
5 5 5 5 5
6 6 6 6 6
7 7 7 7 7
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
11 11 11 11 11
12 12 12 12 12
13 13 13 13 13
14 14 14 14 14
15 15 15 15 15
16 16 16 16 16
17 17 17 17 17
18 18 18 18 18
19 19 19 19 19
20 20 20 20 20
52000 Oh 54000 Oh 56000 Oh 58000 Oh 60000 Oh

1 1 1 1 1
2 2 2 2 2
3 3 3 3 3
4 4 4 4 4
5 5 5 5 5
6 6 6 6 6
7 7 7 7 7
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
11 11 11 11 11
12 12 12 12 12
13 13 13 13 13
14 14 14 14 14
15 15 15 15 15
16 16 16 16 16
17 17 17 17 17
18 18 18 18 18
19 19 19 19 19
20 20 20 20 20

E 0309
Jenbacher Data capture spark plugs
Documentation

Spark plug type . . Optimal electrode distance . . mm
Ignition voltage requirement, preset range (see IW 0309 M0) from: . . kV to: . . kV
Calendar week: . . Calendar week: . . Calendar week: . . Calendar week: . .

Service hours: . . Service hours: . . Service hours: . . Service hours: . .
Cylinder Ignition voltage Cylinder Ignition voltage Cylinder Ignition voltage Cylinder Ignition voltage
requirement requirement requirement requirement
after after after after
adjust- adjust- adjust- adjust-
actual- ment or actual- ment or actual- ment or actual- ment or
value exchange value exchange value exchange value exchange
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
10 10 10 10
11 11 11 11
12 12 12 12
13 13 13 13
14 14 14 14
15 15 15 15
16 16 16 16
17 17 17 17
18 18 18 18
19 19 19 19
20 20 20 20
Calendar week: . . Calendar week: . . Calendar week: . . Calendar week: . .
Service hours: . . Service hours: . . Service hours: . . Service hours: . .
Cylinder Ignition voltage Cylinder Ignition voltage Cylinder Ignition voltage Cylinder Ignition voltage
requirement requirement requirement requirement
after after after after
adjust- adjust- adjust- adjust-
actual- ment or actual- ment or actual- ment or actual- ment or
value exchange value exchange value exchange value exchange
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
10 10 10 10
11 11 11 11
12 12 12 12
13 13 13 13
14 14 14 14
15 15 15 15
16 16 16 16
17 17 17 17
18 18 18 18
19 19 19 19
20 20 20 20

E 0400
Jenbacher Data capture Valve-stem protrusion
Documentation
AV = Outlet valve EV = Inlet valve

Intitial taking into operation 2000 Operating hours . . Operating hours
valve-stem protrusion (mm) valve-stem protrusion (mm) valve-stem protrusion (mm)
Cylinder
Cylinder
Cylinder
AV EV AV EV AV EV
1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
11 11 11
12 12 12
13 13 13
14 14 14
15 15 15
16 16 16
17 17 17
18 18 18
19 19 19
20 20 20
. . Operating hours . . Operating hours . . Operating hours

Cylinder
Cylinder
Cylinder
AV EV AV EV AV EV
1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
11 11 11
12 12 12
13 13 13
14 14 14
15 15 15
16 16 16
17 17 17
18 18 18
19 19 19
20 20 20

EN E0400_BR2+3_EN.doc Index: c Page - No.: 1 / 2
E 0400
Documentation

Cylinder
Cylinder
Cylinder
AV EV AV EV AV EV
1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
11 11 11
12 12 12
13 13 13
14 14 14
15 15 15
16 16 16
17 17 17
18 18 18
19 19 19
20 20 20

Cylinder
Cylinder
Cylinder
AV EV AV EV AV EV
1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
11 11 11
12 12 12
13 13 13
14 14 14
15 15 15
16 16 16
17 17 17
18 18 18
19 19 19
20 20 20

Jenbacher
Documentation Commissioning protocol:
Keyword: Baja - Madu Lingga Design No.: J D651

Generator type: JGS 320 GS-N.L Year of construction: 2007
Type/version: C105 Country of installation: IDN
Software version B&R/SAM

RPS: (computer-controlled control)
VISU: (Dia.ne visualisation)
MMU: (Multi-function transducer)
ZÜND: (Ignition)
MONIC: (Ignition visualisation)
KLS98: (Knock control)
TEC: (Tecjet)
SAM:
EMS3000:
Software version Siemens/B&R
Sps: (PLC control)
Syn: (Synchronisation)
Stat: (Station control)
Engine No.
490457 1
Engine No. 490457 1
Operating hours Bh
Number of starts
Power, electric kW
Voltage - average value V
Current - average value A
Zero conductor current A
Cos phi Ind/Kap
Exciter voltage V
Mixture temperature °C
Charge pressure mbar
Gas-mixer position / TEC mm / %
Throttle valve position %
Flow-Tech position %
After cooler differential pressure, mixture side
mbar
Mixture cooling water temperature, intake, stage 1
°C
Mixture cooling water temperature, intake, stage 2
°C
Engine cooling-water temperature °C
Engine cooling-water pressure bar
Oil temperature °C
Oil pressure bar
Gas pressure before pre-pressure controller
mbar
Gas pressure after pre-pressure controller
mbar
Pre-combustion chamber differential pressure
mbar
Gas pressure before differential-pressure controller
bar
Methane content (CH4) %
Gas temperature before activated carbon filter
°C
Engine Type
Camshaft offset ° v OTH
GET
Knock limit
Pulse slope retard
Pulse slope forward
Erstellt: Service Datum: 26.03.2007

Index: n Seite: 1 von 4
Jenbacher
Engine No.
490457 1
Cylinder temp. 1/2 °C
Ignition-voltage requirement min/max kV
Ignition point °KWvOT
Hot water forward temperature °C
Hot water return temperature °C
Exhaust-gas heat exchanger - tube-plate temperature
°C
Drive side (DS) generator bearing temperature
°C
Non-drive side (NDS) generator bearing temperature
°C
Generator winding temperature 1 °C
Exhaust-gas temperature before heat exchanger
°C
Exhaust-gas temperature after heat exchanger
°C
Cooling water inlet temperature at exhaust-gas heat
exchanger °C
Cooling water outlet temperature at exhaust-gas heat
exchanger °C
Differential pressure - exhaust-gas heat exchanger
mbar
Differential pressure - catalytic converter mbar
Exhaust-gas backpressure after exhaust-gas
turbocharger
mbar
O2 value Vol./%
CO value (related to 5% O2) mg/Nm3
NOx value (related to 5% O2) mg/Nm3
Engine cooling water - concentration test

Vol./%
Product applied / additive
Mixture cooling circuit (2nd stage) concentration test

Vol./%
Product applied / additive
Intake temperature at engine air-filter intake

°C
Generator cooling-air intake temperature
°C
Crankcase pressure (at dipstick)
mm/WS
Engine-room pressure mbar
Valve noise (KLS 98) mV
Zero pressure controller setting mm/U

Jenbacher
Engine No.
Valve stem projection: 490457 1
Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2 Cyl. 1 Cyl. 2
Left-hand intake valve mm

Right-hand intake valve mm
Left-hand exhaust valve mm
Right-hand exhaust valve mm










Jenbacher
Additional data for biogas installations with exhaust-gas heat exchanger

Measure these data at different load points. Make sure, however, to carry out measurements only after each of
the load points has been stable for a certain period of time (approx. 15 min.)!!
CH4 content to determine the calorific value (if online

measurement available) %
H2S concentration in fuel gas ppm
Output in % of Pn % 50 75 100
O2 value upstream/downstream of catalytic converter
(if available) Vol./% / / /
O2 value (related to 5% O2) upstream/downstream of
catalytic converter (if available) mg/Nm3 / / /
NOx value (related to 5% O2) upstream/downstream of
catalytic converter (if available)
mg/Nm3 / / /
Exhaust-gas temperature before heat exchanger
°C
Exhaust-gas temperature after heat exchanger
°C
Cooling water outlet temperature at exhaust-gas heat
exchanger °C
Cooling water inlet temperature at exhaust-gas heat
exchanger °C
Exhaust-gas back pressure upstream of exhaust-gas
heat exchanger mbar
Exhaust-gas back pressure downstream of exhaust-gas
heat exchanger mbar
Produced electrical power MWh
Oxidation catalyst installed? Ja Nein
GEJ part number of the oxidation catalyst according
spare parts book
Manufacturer and type of exhaust-gas heat exchanger

according to type plate
Remote data transfer

To select an outside line (if not main telephone
connection)
Modem type
Internal modem
External modem
Jenbacher scope of supply
Power cubicle yes no
Synchronisation yes no
Lubricating oil type:
While commissioning the equipment, you must note down all data to be able to use this as a "reference list" and
compare the data with more recent data. Comparing the reference data with recent data enables you to detect
possible problems at an early stage or to analyse the problem afterwards.
Name:
Drafted on:
(signature)

Jenbacher
Documentation Index
Considerations for use 1.

Sections of the GE Jenbacher Product Documentation 1.1
Key to Symbols 1.2
Type plate and type designation of GE Jenbacher Products 1.3
GE Jenbacher Web Portal 1.4
Your views are important ! 1.5
Service – and sales partners 1.6
Imprint 1.7
General Conditions 2.
Designated use 2.1
CE - Declaration of conformity
General conditions - Operating and Maintenance (TI 1100-0111)
Parameter for GE Jenbacher gas engines (TI 1100-0110)
Safety precautions (TI 2300-0005)
Maintenance plan 3.
Maintenance plan 3.1
Inspections / Maintenance works 4.

Inspections / Maintenance works 4.1
Maintenance protocol 5.
Maintenance protocol 5.1
Registration of operational data 6.

Operating data log
Data capture engine lubricant E 0101
Data capture heat exchanger mixture/water E 0103 a
Data capture ignition coils E 0303
Data capture spark plugs E 0309
Data capture valve-stem protrusion E 0400
Commissioning protocol 7.
Commissioning protocol
This product documentation section, drawn up by the Technical Documentation Department of

GE Jenbacher, is not assigned it is own section number.

EN Index_W_EN.doc Index: - Page - No.: 1 / 1
Jenbacher
Documentation Navigation on this CD
N A V I G A T I O N in the digital documentation
Navigating
Klick on the Bookmarks on the left side of

Acrobat Reader to navigate through the
documents.

EN Navigation_EN.doc Index: a Page - No.: 1 / 1
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GE
Energy
Jenbacher
Maintenance
Generator set JGS 320 GS-N.L

Baja - Madu Lingga
J D651
Module Number: 490458 1
Engine Number: 490457 1
EN 2007-03
© GE Jenbacher GmbH & Co OHG

Achenseestr. 1-3
A-6200 Jenbach (Austria)
E 0400
Documentation

Cylinder
Cylinder
Cylinder
AV EV AV EV AV EV
1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
11 11 11
12 12 12
13 13 13
14 14 14
15 15 15
16 16 16
17 17 17
18 18 18
19 19 19
20 20 20

Cylinder
Cylinder
Cylinder
AV EV AV EV AV EV
1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
11 11 11
12 12 12
13 13 13
14 14 14
15 15 15
16 16 16
17 17 17
18 18 18
19 19 19
20 20 20


Maint Inst GEJ320 PDF

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Jenbacher 1.

• Operation of the system

• Description of the engine and the system

• What inspection work and maintenance work needs to be carried

• When should the work be carried out?

• How should the work be carried out?

• Gathering operational data

Spare Parts List

• Selecting the required spare part

• Ordering the spare part

• Allocating the spare part

Issued: Doku./Schartner Checked: Dokumentation Date: 2006-02

Disassemble the component as described.

Assemble the component as described.

Inspect the components or operating materials as described

Tighten the nut or bolt to the specified tightening torque.

Clean the component as described.

Lubricate or grease the component as described.

Reference to a document or a section of the product documentation.

Important information or important note.

Issued: Doku./Velik Checked: Dokumentation Date: 2007-03

1.1 Engine type plate:

1.2 System type plate:

Issued: Doku./Schartner Checked: Dokumentation Date: 2005-01

2.1 Engine type designation:

Term Abbreviation Key to abbreviation Example

Issued: Doku./Schartner Checked: Dokumentation Date: 2005-01

2.2 Module type designation:

Term Abbreviation Key to abbreviation Example

Issued: Doku./Schartner Checked: Dokumentation Date: 2005-01

Issued: Doku./Velik Checked: VSB/Steinberger Date: 2007-01

Menu bullets – Tips:

• “Products + Services” -> “Products 50/60 Hz” menu

• “Products + Services” -> “Service” -> “Service Database” menu

• “Experts Know-How” menu

Issued: Doku./Velik Checked: VSB/Steinberger Date: 2007-01

Issued: Doku./Velik Checked: VSB/Steinberger Date: 2007-01

Subject: Rating Comments

How easy is it to locate information?

What do you think about our

Any additional comments:

Rating: 1 = excellent 2 = good 3 = satisfactory 4 = adequate 5 = inadequate

Issued: Doku./Schartner Checked: Dokumentation Date: 2002-02

GE Jenbacher GmbH & Co OHG

Power Solutions Vertriebs und Handels GmbH

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

IWK Integrierte Wärme und Kraft AG (Service)

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

GE Energy Jenbacher Sales China

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

GE Jenbacher Spain and Portugal

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

Edina Power Plant (Service)

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

Hitachi Engineering & Services Co., Ldt.

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

Hitachi Engineering & Services Co., Ldt.

Osaka Gas Engineering Co., Ldt.

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

Issued: Doku./Lechner Checked: Dokumentation Date: 2007-03

ZAO Sigma Technologies (Sales)

ZAO Sigma Services (Service)

ZAO VADO International GUS (Sales)