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Keyword: Sarfraz Yaqub Unit no.: J C066 Module no.: 425769 1-3

Module type : JGS 320 GS-N.L Version: C105 Engine no.: 424977 1/424978 1/424979 1

Issued: Doku./Schartner Checked: Dokumentation Date: 2004-01

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5.1.1Description

1. General: ___________________________________________________________22. Engine principle: ____________________________________________________23. Crankcase: _________________________________________________________24. Oil pan: ____________________________________________________________25. Cylinder liners:______________________________________________________26. Cylinder heads: _____________________________________________________37. Crankshaft:_________________________________________________________48. Connecting rod: _____________________________________________________49. Vibration damper: ___________________________________________________510. Main and big-end bearing shells:______________________________________511. Pistons:___________________________________________________________612. Gear train:_________________________________________________________713. Timing gear: _______________________________________________________814. Exhaust gas turbocharger: ___________________________________________915. Engine oil pump: __________________________________________________1016. Engine cooling water pump:_________________________________________1117. Starter: __________________________________________________________1218. Air-gas mixer:_____________________________________________________12

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5.1.1Description

1. General:

The GE Jenbacher gas engine works on the 4-stroke principle and is a water-cooled 20 cylinder V-engine(70) with an exhaust gas turbocharger for pressure charging of the intake mixture.

2. Engine principle:

GE Jenbacher gas engines use the LEANOX method, which is a further development of the lean-mix

engine principle.

Here the engine is supplied with a mixture of gas and a surplus of air to minimise emissions already at the

combustion stage in the engine.

3. Crankcase:

The crankcase is a special casting and features side crankcase covers that provide easy access during

assembly/disassembly.

The flywheel-sided gear train is sealed off by the gearbox, and the vibration damper-sided geartrain by

the crankcase cover.

4. Oil pan:

The oil pan is made out of welded steel plate and closes off the bottom of the crankcase.

5. Cylinder liners:

The cylinder liners are wet and can be exchanged individually. They are spun cast and are inserted into

the cylinder block from above.

As they heat up they are free to expand downwards.

The water room and the crankcase are separated by O-rings on the outside of the cylinder liners.

Scraper ring

Cylinder head gasket

Water room

Crankcase

O-ring

Spacer ring

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5.1.1Description

6. Cylinder heads:

The water-cooled cylinder heads which can be replaced separately are all equipped with an inlet and

exhaust valve and with a spark plug.

The intake and exhaust valves feature a valve rotation device (Rotocaps). The pressed valve seat rings

can be renewed.

Spark plug sleeve

Ignition coil

Spark plug

MixtureExhaust gas

Exhaust valve

Rotocap

Valve spring

Valve guide

Valve seat

Ignition coil

Rocker arm (Exhaust valve)

Push rod

Water room

Thermowell for

thermocouplesExhaust gas

Mixture

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5.1.1Description

7. Crankshaft:

The drop-forged crankshaft runs on eleven bearings, is statically and dynamically balanced and has

bolted-on counterweights. All bearing journals have been surface hardened and fine polished.

One of the main bearings is designed as a guide bearing and takes the axial forces exerted by the

crankshaft.

The crankshaft main bearings are lubricated via oil ducts in the crankcase.

A balanced flywheel with starter pinion is mounted on one end of the crankshaft, and at the other end a

vibration damper is fitted.

8. Connecting rod:

The connecting rods are drop-forged and quenched and tempered. They are separated diagonally across

the big-end and have serrated joins. The cross-section is designed as an I-profile to provide maximum

stability of the connecting rods.

The big-end bearing shells are replaceable plain bearings. The small end bushings are pressed in.

The big-end bearings are lubricated via oil ducts in the crankshaft.

The gudgeon pins are supplied with oil from the piston cooling nozzles.

Counterweight Driving gear wheel

Oil ducts Main bearingConnecting rod bearing

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5.1.1Description

9. Vibration damper:

A viscous damper is used to reduce rotational vibrations on the crankshaft.

This viscous damper consists of a completely sealed housing into which a flywheel is mounted. The

cavities between housing and flywheel are filled with silicone oil.

10. Main and big-end bearing shells:

Two-part, replaceable crankshaft main bearings and big-end bearings.

Sputter bearing Grooved bearing

3-material

bearing

Big end bearing: upper bearing shell X

lower bearing shell X

Main bearing: upper bearing shell X

lower bearing shell X

Flywheel

Housing

Cavities

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5.1.1Description

11. Pistons:

The light metal alloy pistons feature a cooling duct and are equipped with a wedge compression ring, a

taper face compression ring and an oil-control ring with expander.

Cooling oil is supplied via fixed spray nozzles mounted in the crankcase.

Wedge compression ring

Taper face compression ring

Oil control ring with expander

Gudgeon pin

Snap ring

Cooling oil duct

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5.1.1Description

12. Gear train:

The gear driving the engine oil pump, the engine cooling water pump and the camshaft can be found on

the flywheel-side.

The crankshaft toothed gear, the intermediate gears and the camshaft timing gear all have timing marks

to ensure that the timing is correctly adjusted.

Gear train (flywheel-sided):

Intermediate gears

Camshaft timing gear

Crankshaft toothed gear

Intermediate gear

Driving gear of engine oil pump

Driving gear wheel for enginecooling water pump

Intermediate gear

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5.1.1Description

13. Timing gear:

The camshaft runs on eleven bearings in replaceable bushings, and is driven by the crankshaft via

intermediate gears. The rocker arms on the intake and exhaust valves are operated by the camshaft by

means of tappets and push rods. An adjustment bolt on each rocker arm is used for accurate adjustment

of the tappet clearance. Pressurised oil is used to lubricate the tappets and the rocker arm mountings,

whereby the oil is supplied to each rocker arm through a bore in the push rod. The other moving parts in

the cylinder head are lubricated by the spray oil emerging at the rocker arm mountings.

Adjustment bolt

(Tappet clearance)

Exhaust valve

Rocker arm

bracket

Rocker arm

(Exhaust valve)

Rocker arm

(Intake valve)

Intake valveValve spring

Adjustment bolt

(Tappet clearance)

Rocker arm bracket

Rocker arm

(Intake valve)

Rocker arm

(Exhaust valve)

Push rod

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5.1.1Description

14. Exhaust gas turbocharger:

The exhaust gases entering the turbine housing drive the turbine wheel, and therefore also the

compressor impeller which sits on the same shaft as the turbine wheel. The compressor impeller sucks

air-gas mixture from the air-gas mixer and passes it on under pressure via the mixture cooler

(mixture/water heat exchanger) and the throttle valve to the intake chamber of the engine.

The exhaust gas turbocharger is lubricated by the engine lubricating system.

Mixture

Mixture

Exhaustgas

Exhaust gas

Plain bearing

Turbine wheelCompresso

r impeller

Engineoil

Engineoil

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5.1.1Description

15. Engine oil pump:

GE Jenbacher engines are equipped with a forced feed lubrication system.

A mechanical gear pump is used as the engine oil pump.

Driving gear

Oil pump gear wheel

Engineoil

Engine oil Engine oil

Engineoil

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5.1.1Description

16. Engine cooling water pump:

The cooling water is pumped around the closed engine cooling system by means of a mechanical pump.

Shaft

Driving gear wheel of the engine

cooling water pump

Roller bearing Wheel

Mechanical seal

Sealing ring

Check bore hole

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5.1.1Description

17. Starter:

An electrical sliding gear starting motor.

18. Air-gas mixer:

In the air-gas mixer, a propellant is added to the intake air via a variable gas aperture in order to create a

burnable air-gas mixture.

The size of the gas aperture is increased/decreased by a servomotor, as a result of which the amount of

gas and hence the air ratio can be varied.

The air-gas mixer is part of the LEANOX control system.

Gas

Mixture

Gas aperture (variable)Servomotor

Air

Air ratio = actual air charge supplied for combustion

stoichiometrically required air charge

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