MAJOR OVERHAULING OF JGS 620

Initial Details:

Engine was running in normal condition at and previously all parameters found normal on Gas Genset.

Dismantling work:
After cool down time start dismantling work.
 Removed Air intake duct
 Removed Air intake housing, filters and its frame.
 Remove ignition rails
 Removed throttle elbow
 Removed by pass valves
 Removed After cooler core and its accessories
 Removed exhaust manifold
 Removed platforms
 Removed all accessories of heads
 Removed all heads
 Removed starting motors
 Removed hub
 Removed breather Filters
 Removed oil pump
 Removed Spacer Plates
 Decouple Alternator and removed coupling and fly wheel.
 Remove Vibration Dampers
 Removed all electrical connections of sensors and power cables
 Preserved all holes

Schedule for Overhauling of JGS620

Sr Man Engineers
Day Date Work Description
# Power Mechanical Electrical
Removal of 20x Cyl Heads and accessories.
Exhaust lines, after cooler core, throttle
elbow, Gas mixer, TBV and water lines, Intake
manifold, 20 x heads thermocouples &
xxx
1st

1 tagging, Mix temp. Sensor and Air intake 4 1

5

sensor. Remove J/Water Pump and

disengage the batteries. Remove the starting
motor. Remove +M panel and power cables
and electrical accessories.
 Remove alternator and its accessories.
Rigged the alternator also perform loading.
2 xxx Also following items, 20x Cyl. Heads, and, 4 1
2

5
J/W pump, sent to work shop

Removed oil pump and accessories,

Removed coupling aluminum removed
xxx

3 4 1
3

flywheel, Hub and gear train housing Also

removed main oil seal

Removed water blocks and removed

camshaft also removed cam shaft bushing
xxx

4 4 1
4

Remove cam follower and perform

inspection Cover block with polythene.

Replace main oil seal with new one. Fitted fly

xxx

5 4 1
5

wheel. Couple the alternator.

Performed Main bearing Jobs Replaced main

xxx

6 4 1
6

bearings and thrust bearings

Install Cylinder Heads with related parts.

xxx

7 Also torque. Install after cooler core and 4 1

7

throttle elbow.

Install oil pump also install jacket water

xxx

8 pump. Install Exhaust manifold also install 4 1

8

return water lines.

 Installed Cam bushing and installed cam

xxx
9 4 1
9
shaft

Installed cam followers push rod and rocker

xxx

10 4 1
10

assembly

Performed Throttle bushing and installed ac

xxx

11 4 1
11

core also installed turbochargers

Xxx installed all accessories parts like rocker

4 1
12
12

assembly push rods water lines

Inspection of dismantled parts:

Inspection carried out of dismantled parts and following below are the observations.

 Heads:
Cylinders heads sent to workshop for overhauling as per scope.

 Big End Bearings:

Big end bearing already installed in short block

 Small End Bearing:

Small end bearing already installed in short block

 Other parts replaced/Inspected:

All other parts such as elastomer components replacement done as per manual

Installation work:

 Installed spacer plates, & liners.

 Installed DE shaft seal.
 Couple the fly wheel and aluminum coupling.
  Couple the alternator and installed its accessories.
 Installed piston rings.
 Assemble the piston and con-rods.
 Installed all pistons and torque
 Installed scraper rings, head gaskets, water and oil O-rings.
 Installed all cylinder heads and torque
 Installed rocker arm assembly.
 Installed A/C core and its accessories.
 Installed throttle bushing
 Installed by pass valve.
 Installed water lines.
 Installed exhaust manifolds.
 Installed ignition rails.
 Installed starting motor.
 Installed Oil Pump with accessories.
 Assemble Jacket water circulation pump.
 Installed Air intake duct.
 Installed Air filter frame, housing and filter.
 Installed all sensors.
 Close the crankcase cover.

Main segment for memorandum:

 Liner replaced
 Con rods inspected whereas con rod bearings are replaced.
 Cylinder heads overhauled.
 Alternator overhauled.
 Jacket water pump overhauled
 After cooler core cleaned by customer
 Oil pump overhauled

Required Tools
Hydric pump with pipes
Hydric Jack M30 X 04 M33 X 2
Liner Remover and Installer Tool
Piston Holder and Teflon bar
Fly wheel remover and installer tool
Gear train special tool
Torque convertor
Torque wrench heavy duty