Professional Documents
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GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
DATE
JULY 2007
DEP.
1. MAINTENANCE INTERVALS
The satisfactory performance of engines depends on many factors, the most significant being:
-
Mode of operation
Care taken to ensure that engines are adjusted to factory settings in inspections and maintenance
operations
Because of these as well as other similar factors not mentioned, it is difficult to set a precise number of hours
of operation for each engine, before normal servicing becomes necessary.
The maintenance intervals listed in this section do not in any way imply an obligation on behalf of GUASCOR,
and are given only as a guide to users for maintenance scheduling. The number of hours specified for
individual tasks will serve as reasonable limits, which should not be exceeded in order to avoid the risk of
warranty cancellation. The user will determine, according to operating conditions or other circumstances,
specific maintenance schedule for their equipment. It is recommendable to read completely this document
before the first start-up of the engine.
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
DATE
JULY 2007
DEP.
2. DAILY MAINTENANCE
2.1. Control of coolant level
The coolant level must be checked daily. It is necessary to ensure that there arent air or steam bubbles in the
system. In that case the system must be purged by hand or automatic drain valves must be installed in the top
of the circuit.
NEVER USE DIRTY, HARD OR SALT WATER. COOLANT NOT ONLY PRESERVES ENGINE AGAINST
FREEZING, BUT ALSO PRESERVES ENGINE AGAINST CORROSION AND OXIDATION.
2.2. Control of oil level
Check the engine oil level every day under identical conditions. This is to be done with the engine idling, after
running for several minutes.
The oil level should never be below the lower indicator mark, nor above the high limit on the dipstick.
Note: If the engine has crankcase gases recirculation system, the oil level on the dipstick could be erroneous
because the pressure in the crankcase is not at atmospheric pressure. Therefore, the oil level must be checked
when crankcase pressure is at atmospheric pressure or the reading must be done in the devices not influenced
by these pressure differences: lube oil level indicator or oil level regulator (with the filling valve closed).
2.3. Daily recording of the engine data
It is necessary to record pressures, temperatures, levels, energy outputs... in order to be able to detect
possible engine operation failures by analyzing the evolution of the aforementioned parameter values.
Note: Daily records may help you to solve performance problems before they arise, because of that, it is
recommendable to record a high number of parameters of engine performance.
2.4. Cleaning of the engine
Several reasons make it desirable to keep the exterior of the engine clean. Dirt from the outside can be drawn
into the intake filters. Further, exterior dirt can get into the engine during normal maintenance in cylinder heads,
crankcase,
A number of products for cleaning the engine exterior can be used, such as pressurized steam or degreasing
agents. It is necessary to be extremely careful with the electrical components of the engine.
2.5. Clean and keep watch over electrical connectors
Clean the electrical connectors if necessary, but before be sure that there is no tension on them.
NEVER BRING A FLAME OR MAKE SPARKS NEAR THE BATTERIES. FLAMMABLE STEAM CAN BE
PRODUCED.
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
DATE
JULY 2007
DEP.
NEVER USE A FLAME TO DETECT GAS LEAKS BECAUSE THIS CAN PRODUCE AN EXPLOSION AND
PERSONS CAN BE HURT.
2.9. Speed control linkage
It is necessary to check the ball joints of the speed control linkage for clearances (greased and readjusted
where appropriate).
2.10. Check for sensors
Temperature and pressure measures must be checked in order to detect deviations or broken sensors on
engine. It is also necessary to inspect pressure and temperature sensors of the control system.
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
DATE
JULY 2007
DEP.
3. MAINTENANCE PROGRAM
GUASCOR has developed this maintenance program to ensure optimum performance of your engine. Given
that strict adherence to this program will benefit you, it is essential that you follow the instructions detailed in
this manual. Failure to do so may not only jeopardize GUASCORs warranty, but also restrict you from
obtaining the best performance for equipment.
3.1. Basic maintenance operations:
NEW ENGINE OR MAJOR SERVICE WORK START-UP MAINTENANCE
Jobs to be done during the initial start-up of a new engine or during the break-in phases following major overhauls
(change of cylinder liners, pistons, piston rings, cylinder heads,...). They must be carried out by GUASCOR authorized
Repair Shop.
Job
Interval
NA
0h
Job Description
(Operation before starting up the engine)
- General inspection and set-up of the engine
(Operations after starting up or break-in phase)
- Change oil (oil sump and cooler)
- Change oil filters
- Inspection of the gas ramp filter
N1
100 h
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
DATE
JULY 2007
DEP.
The maintenance jobs described below (identified with as an E type task) must be regarded as additive to each other.
Accordingly, the performance of every Ei job implies that all previous Ei-1 jobs must be carried out at the same time.
This will require the availability of such materials and labour as may be necessary at each stage.
Interval
Job Description
(Operations to be performed with the engine stopped)
- Drain coolant circuits. Check automatic drain valves
- Drain condensates out of the exhaust Y-pipe
- Check oil pressure and temperature during the pre-lubrication phase
- With the dipstick, check for a possible increase of the oil level in the oil pan due to
coolant leaks
- Verify oil heating with the pre-heater, if necessary
- Check the oil level of the pneumatic starter lubricator, if necessary
- Clean the engine and its surrounding
(Operations to be carried out with the engine idling)
EO
Daily
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
Job
Interval
DATE
JULY 2007
DEP.
Job Description
- Analyse waste oil
- Change oil GUASCOR MOTOROIL 3040 PLUS (oil sump and cooler)
- Change oil filters
- Clean the metallic sponge of the oil purifier
- Measure crankcase pressure
- Change the filter of crankcase gases recirculation system and clean this circuit (*A*)
- Inspection of cylinders with endoscope (*B*)
- Measure cylinder compression
- Change GUASCOR spark plugs ref.76.64.301
E1
1,250 h
E2
5,000 h
or
once a year
- Disassemble, clean and adjust all the speed and ignition pick-ups
- Measure the exhaust back-pressure
- Change coolant
- Check the tightening torque of knocking sensors on stud head (20 Nm), if necessary
500 h
1,000 h
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
B
DATE
JULY 2007
DEP.
Interval
Job Description
- Recondition cylinder heads. Check springs
- Check and change, if necessary, valves driving system: valve lifters, rocker arms,
push-rods, ball joints, roller rocker arms and cams
- Measure cylinder liners wear
- Change high voltage wires
- Inspection of turbochargers and, if necessary, clean and replace of faulty
components
A
- Clean the intake circuit, from the air filters outlet to the intercooler (* *)
- Clean oil sump
- Check and clean the cooling system. Clean pipe bundles and change gaskets on
heat exchanger and coolers
- Check general condition of water pumps and change defective parts, if any. Change
the seal
R1
10,000 h
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
Job
Interval
DATE
JULY 2007
DEP.
Job Description
- Check main bearings and axial thrust disks. Change if necessary
- Change pistons
- Change piston rings
- Change cylinder liners
- Change cylinder head springs
R2
30,000 h
R3
60,000 h
This maintenance program is specified for dry natural gas. The natural gas specifications are detailed in the last
version of Product Information Sheet IC-G-D-30-002e: Fuel specifications natural gas. Minimum methane
number is specified in the Power Rating of the engine for this application. If methane number is less than the
specified, consult with GUASCOR.
(*)
For installations where the gas composition is variable, its recommended to reduce the periods between
carburation adjustments
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GAS
GROUP
IO
NATURAL
PRODUCT INFORMATION
INDEX
IO-G-M-00-009e
(*A*)
(* *)
DATE
JULY 2007
DEP.
Make this maintenance job only if the engine has crankcase gases recirculation system
Inspect combustion chamber: cylinder liner, cylinder head, valves, pistons and piston rings for polishing,
lines, unusual colors or deposits.
Only for SFGLD 180, 240, 360 and 480 engines: check for valve bumping into the liner. If any bump found,
recondition the cylinder head completely.
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