GAS

GROUP

IO

NATURAL

PRODUCT INFORMATION

INDEX

IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

DATE

JULY 2007
DEP.

1. MAINTENANCE INTERVALS
The satisfactory performance of engines depends on many factors, the most significant being:
-

Mode of operation

Humidity, barometric pressure and air temperature

Number of hours operating at full load

Number of hours operating at full speed

Engine parameters: ignition timing, cooling temperatures, water flows,

Fuel and lube oil quality

Proper loading of engine after start sequence

Oil and filters changes intervals

Use of GUASCOR products and original spare parts

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.

These circumstances can modify the intervals of maintenance operations:

-

Excessive exhaust back-pressure

Insufficient air supply to intake. Air quality

High crankcase pressure

Low oil pressure

Over heating of the jacket water system (boiling)

Changes in fuel quality

High air temperature

Sudden stops and alarms

Incorrect realization of maintenance operations

Deficient installation or ventilation

Incorrect air/fuel ratio

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GROUP

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PRODUCT INFORMATION

INDEX

IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

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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GROUP

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NATURAL

PRODUCT INFORMATION

INDEX

IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

DATE

JULY 2007
DEP.

2.6. Lube oil leaks

Inspect plant lubrication piping for oil leaks. Tighten hardware or change seals and gaskets if necessary.
In addition, make sure the dipstick and filling plug on the inspection cover are tight.
2.7. Coolant leaks
Inspect plant water piping for water leaks. Tighten hardware or change seals and gaskets if necessary.
Verify that the drain holes on the water pumps are unobstructed, as their plugging could lead to serious
damage.
2.8. Gas leaks
Inspect gas piping for leaks using a gas detector or water with soap. Tighten hardware or change gaskets if
necessary.

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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PRODUCT INFORMATION

INDEX

IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

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

- Adjustment of rocker arms and valve lifters

- Check damper temperature
- Inspect for leaks in all coolant, oil, gas and exhaust gases system
- Inspection and retightening of flanges and clamps. Inspection of battery terminals,
flexible couplings, air filter supports, exhaust piping, oil pipes, etc.

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PRODUCT INFORMATION

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IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

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.

ROUTINE MAINTENANCE (Type "E")

Minor Jobs
Job

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

- Check oil level

(Operations to be carried out with the engine stabilized)
- Check coolant level / pressure. Drain circuits
- Check oil pressure
- Inspect the air filter plugging level (reset the pilot first)
- Check oil, coolant and exhaust gases temperature
- Check the filter cleaning state pilot of the crankcase gases recirculation system.
A
Control the crankcase pressure (* *)
- Record engine parameters on a regular basis
- Control operational stability and unusual noise
- Detect and repair gas, coolant, oil and exhaust gases leaks

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IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

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

- Check high voltage wires and change if necessary

- Verify the ignition timing
- Adjust air/fuel ratio (*)
- Inspect, clean and, if necessary, replace the main air filters
- Adjustment of rocker arms and valve lifters. Measure valve height and check valve
guides clearances
- Check damper temperature
- Check safety devices and connections: temperature and pressure switches
- Check battery acid level
- Check battery and starter connections
- Change main and safety air filters
- Change gaskets in the rocker arm covers

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

- Change GUASCOR spark plugs ref.76.64.291

1,000 h

- Change GUASCOR spark plugs ref.76.64.293

If oil GUASCOR MOTOROIL 3040 PLUS is not used, consult GUASCOR.

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IO-G-M-00-009e

B
DATE

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

JULY 2007
DEP.

PERIODIC MAINTENANCE WORKS (Type "R")

Major overhauls
Job

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

- Change oil thermostat (only V engine)

- Test thermostats of coolant circuit and change if necessary
- Test control and safety devices: temperature and pressure switches
- Check the butterfly valve bearings and change it if necessary
- Grease and check for clearances in ball joints of the speed control linkage and
change them if necessary
- Retighten connections in knocking detection system unit if necessary
- Inspect flexible coupling condition and change it if necessary
- Inspection of elastic suspensions and alignments
- Check-up of electric or pneumatic starting motor, battery charging alternator, etc.
- Analyse the inside damper silicon
- Change hoses and clamps, if necessary
- Check gas safety valves on intake manifolds

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INDEX

IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

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

- Verify the oil circuit safety and regulation valves

- Check connecting rods
- Change conrod bearings and small end bushings
- Change the connecting rod bolts (maximum of 3 retightenings). Mark number of
retightenings on the bolt
- Change thermostats of coolant circuit
- Recondition water pumps of coolant circuit
- Engine Overhaul, including its major components and systems:
Cylinder block
Crankshaft and, if necessary, grinding of crankshaft
- Inspection of camshafts and bushings
- Inspection of timing gears and change ball-bearings

R3

60,000 h

- Inspection of oil pump: check gears and change bushings

- Change of counterweights fixing screws
- Change damper
- Overall inspection of coolant, oil, gas, intake air, exhaust gas, automation systems,
wiring, etc. Change if necessary
- Change turbochargers

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

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PRODUCT INFORMATION

INDEX

IO-G-M-00-009e

MAINTENANCE OF NATURAL GAS ENGINE SFGLD

1500 RPM

(*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.

4. ENGINE LONG TERM STORAGE

When a customer has specified in advance that the engine is going to be stored, the instructions contained in
Product Information Sheet IM-C-C-00-001e apply.
In that case, the engine is supplied perfectly packed and sealed against external agents.
It is however very important that the temperature in the warehouse used for storing the engine should remain
at all times above the outside temperature to prevent condensation.

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