GE Power

Manuel FISCHER
Service Engineering
Distributed Power
GE Jenbacher GmbH & Co OG
Distribution list Achenseestr. 1-3
Jenbach, Subsidiaries, Service Providers A-6200 Jenbach, Austria
T +43 5244 600 3462
manuel.fischer@ge.com

Service Technician Instruction ST-183 29 January 2016

Engine type J612…J620-E/F & J624-G/H

Subject Sensor Package
Retrofitting various sensor modules

Service Technician Instruction ST-183 describes how to retrofit the sensor modules for automated detection and
utilisation of the crankcase pressure, blow-by filter differential pressure, ambient pressure, mixture cooler/flame
trap differential pressure, and the oil filter differential pressure.

PURPOSE OF THIS BULLETIN / NEED FOR ACTION

No proactive action is necessary, i.e. ST-183 can be used as an aid for organising and carrying out the work if the
sensor package or one of the sensor modules is to be retrofitted to an engine.

AFFECTED ENGINES / SCOPE OF THIS BULLETIN

Type J612-E/F, J616-E/F, J620-E/F and J624-G/H engines with the DIA.NE XT, DIA.NE XT3 or XT4 engine control system,
which has not yet been fitted with the above-mentioned sensors and to which the complete sensor package or
individual sensor modules are to be retrofitted.

Note: In the following Service Technician Instruction, Type J612-F, J616-F and J620-F engines are referred to as
J6xx-F for simplicity.

GE PROPRIETARY INFORMATION

The information contained in this document is General Electric Company proprietary information and is disclosed in confidence. It is the property of GE and may not be used, disclosed to
others or reproduced without the express written consent of GE. This includes, but is not limited to, use of the information to create, manufacture, develop or derive any repairs, modifications,
spare parts, designs or configuration changes, or to obtain government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set
out on each page of this document shall appear in any such reproduction in whole or in part.

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 SERVICE TECHNICIAN INSTRUCTION ST-183
Sensor Package
Retrofitting various sensor modules

Table of contents
1 GENERAL / OVERVIEW ......................................................................................................................................................................................................................3
1.1 Overview of the assemblies ..............................................................................................................................................................................................4
1.2 Positions of the installed modules .................................................................................................................................................................................5
2 PROCEDURE FOR RETROFITTING .................................................................................................................................................................................................7
2.1 Retrofitting the crankcase pressure module.............................................................................................................................................................7
2.1.1 Basic principles ...........................................................................................................................................................................................................7
2.1.2 Installation of the new crankcase pressure module (J6xx-F) ................................................................................................................7
2.1.3 Installation of the crankcase pressure module (J624-G/H) ................................................................................................................. 10
2.2 Retrofitting the blow-by filter differential pressure module (J6xx-F and J624-G/H) ............................................................................ 12
2.2.1 Basic principles ........................................................................................................................................................................................................ 12
2.2.2 Blow-by filter differential pressure module installation (for filter housings with replaceable filter elements) ............. 12
2.2.3 Blow-by filter differential pressure module installation (2-filter system with preliminary separator) .............................. 16
2.2.4 Blow-by filter differential pressure module installation (single-filter system without preliminary separator) ............. 17
2.2.5 Pressure sensor cabling ...................................................................................................................................................................................... 18
2.3 Retrofitting the air-filter pressure and ambient pressure modules (J6xx-F and J624-G/H) ............................................................. 19
2.3.1 Basic principles ........................................................................................................................................................................................................ 19
2.3.2 Air filter sensor installation ................................................................................................................................................................................. 19
2.3.3 Ambient pressure sensor installation ............................................................................................................................................................ 21
2.4 Pressure sensor installation downstream of the mixture cooler and flame trap .................................................................................. 22
2.4.1 Basic principles ........................................................................................................................................................................................................ 22
2.4.2 Pressure sensor installation (downstream of the mixture cooler) (J6xx-F) ................................................................................... 22
2.4.3 Pressure sensor installation (downstream of the flame trap) (J6xx-F) ........................................................................................... 24
2.5 Pressure sensor installations upstream and downstream of the mixture cooler and downstream of the flame trap
(J624-H) 26
2.5.1 Basic principles ........................................................................................................................................................................................................ 26
2.6 Installation of the oil filter differential pressure module (J6xx-E) .................................................................................................................. 28
2.6.1 Basic principles ........................................................................................................................................................................................................ 28
2.6.2 Installation of the module ................................................................................................................................................................................... 28
3 SOFTWARE.......................................................................................................................................................................................................................................... 29
4 PARTS LISTS........................................................................................................................................................................................................................................ 30
4.1 Part no. 9019940 - Crankcase pressure sensor (J6xx-F)................................................................................................................................... 30
4.2 Part no. 9020315 - Crankcase pressure sensor (J624-G/H) ............................................................................................................................ 31
4.3 Part no. 9019814 - Blow-by filter differential pressure sensor (J6xx-F) ..................................................................................................... 32
4.4 Part no. 9019814 - Blow-by filter differential pressure sensor (J624-G/H) ............................................................................................... 33
4.5 Part no. 9019817 - Air filter pressure sensor and ambient pressure sensor (J6xx-F) .......................................................................... 34
4.6 Part no. 9019817 - Air filter pressure sensor and ambient pressure sensor (J624-G/H).................................................................... 34
4.7 Part no. 9019818 - Mixture cooler and flame trap pressure sensors (J6xx-F) ........................................................................................ 35
4.8 Part no. 9019819 - Mixture cooler and flame trap pressure sensors (J624-H) ....................................................................................... 35
4.9 Part no. 1231840 - Oil filter differential pressure module (J6xx-E) ............................................................................................................... 36
5 MISCELLANEOUS ............................................................................................................................................................................................................................. 37
5.1 Required time ....................................................................................................................................................................................................................... 37
5.2 Relevant documents ......................................................................................................................................................................................................... 37
5.3 Revision history .................................................................................................................................................................................................................... 37
6 LIST OF FIGURES .............................................................................................................................................................................................................................. 38

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 SERVICE TECHNICIAN INSTRUCTION ST-183
Sensor Package
Retrofitting various sensor modules

1 GENERAL / OVERVIEW

This Service Technician Instruction deals with the retrofitting of various sensors to J6xx-E/F and J624 G/H engines.

The complete package consists of the following sensor modules:

• Crankcase pressure sensor module

• Blow-by filter differential pressure sensor module
• Air filter differential pressure sensor module
• Mixture cooler and flame trap differential pressure sensor module
• Oil filter differential pressure sensor module

Advantages of the sensor package:

• Direct monitoring of pressures

• Individual components can be monitored better
• Improved alarm management
• Better maintenance prognoses

Each sensor module includes the necessary sensor(s), all mechanical and electrical parts for installation and
connection, and any necessary software and parameter matching or activation, depending on the engine control
system in question.

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 SERVICE TECHNICIAN INSTRUCTION ST-183
Sensor Package
Retrofitting various sensor modules

1.1 Overview of the assemblies

The following Table gives an overview of the modules used for each engine version.

Assemblies J6xx-F J624-G/H

Crankcase pressure module

J6xx-F and J624-G/H

Blow-by filter differential

pressure module

J6xx-F and J624-G/H

Air filter differential pressure

module

J6xx-F J624-H

Mixture cooler and flame trap

differential pressure module

J6xx-E

Oil filter differential pressure

module

Table 1: Overview of the assemblies/sensors used in the J6xx-E/F and J624-G/H engines

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 SERVICE TECHNICIAN INSTRUCTION ST-183
Sensor Package
Retrofitting various sensor modules

1.2 Positions of the installed modules

Air filter pressure sensor

Mixer cooler pressure

sensor

Flame trap pressure sensor

Crankcase pressure module

Ambient pressure sensor

Figure 1: General overview of the modules (1) - J620-F

Oil filter differential

pressure module

Blow-by filter differential

pressure module

Figure 2: General overview of the modules (2) - J620-F

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 SERVICE TECHNICIAN INSTRUCTION ST-183
Sensor Package
Retrofitting various sensor modules

Air filter pressure sensor

Blow-by filter differential pressure module

Figure 3: General overview of the modules (1) - J624-H

Pressure sensor at the LP mixture cooler

Crankcase pressure module

Pressure sensor downstream from the HP

mixture cooler
Figure 4: General overview of the modules (2) - J624-H Pressure sensor downstream from the flame trap

Ambient pressure sensor

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 SERVICE TECHNICIAN INSTRUCTION ST-183
Sensor Package
Retrofitting various sensor modules

2 PROCEDURE FOR RETROFITTING

The retrofitting of the various sensors is described in more detail in the following sections.

2.1 Retrofitting the crankcase pressure module

Shut down the engine in accordance with Technical Instruction No. 1100-0105 and secure it against
inadvertent restarting in accordance with Technical Instruction No. 2300-0010.
Observe the safety and hazard advice in the safety instructions (TA 2300-0005) and wear the
appropriate personal protective equipment.

2.1.1 Basic principles

The purpose of the crankcase pressure sensor is to measure the pressure in the crankcase. This allows the crankcase
pressure to be measured continuously, which gives an indication of the condition of the crankcase ventilation system.

CAUTION:
If the engine is fitted with crankcase cover plates, these must be removed before the new crankcase
pressure sensor is retrofitted, as otherwise the bolts cannot be inserted at the crankcase covers. The
installation and removal of the crankcase cover plates is described in detail in ST-138. Crankcase cover
plates are not fitted to J624 engines.

2.1.2 Installation of the new crankcase pressure module (J6xx-F)

Figure 5 shows the crankcase pressure module when installed. The new bracket is mounted on the crankcase (using
the existing stud and hexagonal nut). Two rubber buffers are mounted on this bracket, and in turn are fastened to the
mounting for the crankcase pressure sensor by two hexagon-head bolts. The ribbed hose is connected to the
crankcase cover at one end, and to an elbow union at the other, which is screwed into the fitting on the mounting. The
pressure sensor is screwed on to the other side of the fitting.

Stud + hexagonal nut

Bracket

Rubber buffer

Mounting for crankcase

pressure sensor

Crankcase pressure sensor

Ribbed hose

Figure 5: New crankcase pressure module installation (J6xx-F)

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Sensor Package
Retrofitting various sensor modules

CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

Figure 6: Pressure sensor

Figure 6 shows the pressure sensor to be used.

CAUTION:
Group the pressure sensor cables to give a single cable run. It is advisable to bundle these cables with
other existing cables (using cable ties).

CAUTION:
After completing the installation of all the sensor modules, the measuring points must all be checked
during operation. This leak test is carried out using a leak detection agent.

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Sensor Package
Retrofitting various sensor modules

Figure 7: Drawing - Crankcase pressure module (J6xx-F)

Figure 7 shows the drawing for the crankcase pressure module for J6xx-F engines. This is intended to act as an aid
during installation. The parts list for this module can be found in the Appendix.

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Sensor Package
Retrofitting various sensor modules

2.1.3 Installation of the crankcase pressure module (J624-G/H)

As the crankcase covers are wider on J624-G/H engines, the crankcase pressure sensor and its bracket can be
mounted directly on the crankcase cover (see Figure 8).

Rubber buffer

Mounting

Crankcase pressure sensor

Bracket

Ribbed hose

Crankcase cover

Figure 8: Crankcase pressure module installation (J624-G/H)

The mounting to which the crankcase pressure sensor is fitted is bolted to the bracket with two rubber buffers and
hexagon-head bolts. The bracket is bolted to this with two bolts from the crankcase cover. The ribbed hose is
connected to the two elbow unions.

CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

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Sensor Package
Retrofitting various sensor modules

Figure 9: Drawing - Crankcase pressure module (J624-G/H)

Figure 9 shows the drawing for the crankcase pressure module for J624-G/H engines. This is intended to act as an aid
during installation. The parts list for this module can be found in the Appendix.

CAUTION:
Group the pressure sensor cables to give a single cable run. It is advisable to bundle these cables with
other existing cables (using cable ties).

CAUTION:
After completing the installation of all the sensor modules, the measuring points must all be checked
during operation. This leak test is carried out using a leak detection agent.

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 SERVICE TECHNICIAN INSTRUCTION ST-183
Sensor Package
Retrofitting various sensor modules

2.2 Retrofitting the blow-by filter differential pressure module (J6xx-F and J624-G/H)
2.2.1 Basic principles
The two sensors of the blow-by filter differential pressure module measure the pressures upstream and downstream
of the blow-by filter. The differential pressure across the blow-by filter can be calculated from these two pressures
and gives an indication of the condition of the filter element.

Note:
Only one blow-by filter differential pressure module is installed. This module is mounted on the filter housing
bracket on cylinder bank B (to the right, when viewed from the generator towards the flywheel).
If the engine is a J624, the crankcase ventilation consists of four instead of two blow-by filter housings. In this
case as well, only one blow-by filter differential pressure module is installed. This is also mounted on cylinder
bank B at the generator-end blow-by filter housing.

2.2.2 Blow-by filter differential pressure module installation (for filter housings with replaceable filter
elements)

Elbow union

Filter housing

Ribbed hoses

Pressure sensors

Sensor block

Filter housing console

Figure 10: Blow-by filter differential pressure module installation

CAUTION:
Precondition: The filter housing with replaceable filter elements must already be mounted in order to allow this blow-
by filter differential pressure module to be retrofitted.

Figure 10 shows the installation of the blow-by filter differential pressure module. Two pressure sensors have been
screwed into the sensor block before mounting it on to the filter housing bracket. The pressure sensors are fitted with
sealing rings to ensure they are leak-proof. The sensor block is then placed on the filter housing bracket and fastened
to it with two M12 x 50 cap screws (including M12 hexagonal nuts and washers) (Figure 11, Figure 12).

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Sensor Package
Retrofitting various sensor modules

Elongated slots for mounting the sensor

block

Figure 11: Elongated slots for mounting the sensor block

Sensor block

M12x50 cap screws

Filter housing console

Figure 12: Sensor block installation (underside)

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Sensor Package
Retrofitting various sensor modules

Ribbed hose

Ribbed hose

Blow-by hoses

Figure 13: Connecting the ribbed hoses to the filter housing

Figure 13 shows how the ribbed hoses are connected to the filter housing.

CAUTION:
When connecting the ribbed hoses make sure that the hoses are not kinked and are not in contact with
other components, such as filter housings or blow-by hoses, as this can lead to chafing in operation
resulting in possible failure of the components!

CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

CAUTION:
After completing the installation of all the sensor modules, the measuring points must all be checked
during operation. This leak test is carried out using a leak detection agent.

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Sensor Package
Retrofitting various sensor modules

Figure 14: Drawing – Blow-by filter differential pressure module (J6xx-F and J624-G/H)

Figure 14 is the drawing for the crankcase ventilation. This is intended to act as an aid during installation. The parts list
for this module can be found in the Appendix.

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Sensor Package
Retrofitting various sensor modules

2.2.3 Blow-by filter differential pressure module installation (2-filter system with preliminary
separator)
This section describes the retrofitting of the blow-by filter differential pressure module for blow-by filters with a
preliminary separator and without replaceable filter elements.

Figure 15: Installation of the sensor block (on filter housings without replaceable filter elements)

Figure 15 shows the installation of the differential pressure module for filter housings without replaceable filter
elements. The sensor block is mounted as shown in Figure 15 using two cap screws (with hexagonal nuts and spring
washers). However, an additional hole must be drilled before fitting, as the installation of the sensor block was not
originally anticipated (Figure 16).
=

Note:

Figure 14 shows the blow-by filter differential

pressure assembly in various installation positions
(single-filter housing solution, dual-filter housing
40

solution).
=

Figure 16: Positions of the holes to be drilled

CAUTION:
When mounting the sensor block, it is essential to ensure that it does not contact the blow-by hoses
running adjacent to it, as this can lead to chafing in operation resulting in possible failure of the hoses!

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Sensor Package
Retrofitting various sensor modules

CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

2.2.4 Blow-by filter differential pressure module installation (single-filter system without preliminary
separator)
It is also possible to retrofit the sensors to a blow-by filter system without a preliminary separator and with one filter
housing. Hose clip Distance = 400 mm

Figure 17: Sensor block installation (without preliminary separator and without replaceable filter elements)
Wall plate

The sensor block is mounted here on the console of the filter housing bracket. Two holes (13mm dia.) must be drilled
for this. The sensor block is then fastened with 2 M12 cap screws (with hexagonal nuts and spring washers). The
positions of the holes to be drilled are shown in Figure 18.

Distance = 45mm

Hole spacing = 40mm

Distance to the wall plate = 100mm

Figure 18: Hole positions

A hose clip must also be manufactured for each hole to provide an additional retainer for the ribbed hose (see Figure
17).

CAUTION:
When connecting the ribbed hoses make sure that the hoses are not kinked and are not in contact with
other components, such as filter housings or blow-by hoses, as this can lead to chafing in operation
resulting in possible failure of the components!

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Retrofitting various sensor modules

2.2.5 Pressure sensor cabling

Cable protective sleeve

Cable protective sleeves fastened to the other cable

protective sleeves with cable ties

Figure 19: Pressure sensor cabling

Figure 19 shows the cable (and protective cable sleeve) routing for the pressure sensors. These are fitted with
protective cable sleeves before installation. They are then bundled with the other hoses (with cable ties) to ensure a
single hose run.

The design of the sensor module is shown in Figure 14.

CAUTION:
Make sure here as well that the cable protective sleeves are not kinked and do not contact other
engine components (apart from the points where they are connected), as this can lead to chafing
during operation!

CAUTION:
After completing the installation of all the sensor modules, the measuring points must all be checked
during operation. This leak test is carried out using a leak detection agent.

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Sensor Package
Retrofitting various sensor modules

2.3 Retrofitting the air-filter pressure and ambient pressure modules (J6xx-F and
J624-G/H)
2.3.1 Basic principles
The pressure sensor downstream of the air filter and ambient pressure sensor allows the differential pressure across
the air filter to be measured, which gives an indication of the condition of the air filter.

2.3.2 Air filter sensor installation

Pressure sensor

Connection to in-line air

filter

Figure 20: Air filter pressure sensor installation

Figure 20 shows the installation and position of the air filter pressure sensor. It is screwed into the fitting provided for
the purpose on the connection between the two in-line air filters. Make sure here as well that the cable protective
sleeves are not kinked and do not contact other engine components.

CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

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Thread adapter

Fitting for screwing in the thread adapter

Figure 21: Fitting for screwing in the adapter for the pressure sensor

Figure 22: Drawing - Air filter differential pressure module (J6xx-F/G/H)

Figure 22 is the drawing for the air filter differential pressure module. This is intended to act as an aid during
installation. The parts list for this module can be found in the Appendix.
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2.3.3 Ambient pressure sensor installation

The ambient pressure is measured by a pressure sensor installed in the engine switchgear cabinet.

Figure 23: Ambient pressure sensor installation

Pressure sensor Bracket Rittal clip Mounting rail

The ambient pressure sensor is mounted on the rail in the engine switchgear cabinet by means of a bracket bolted to
a Rittal clip. The cabling must be connected directly to the PLC without Wago terminals.

Rittal clip

Bracket

Lock nut for fitting

Figure 24: Ambient pressure sensor with bracket

Figure 24 shows how the pressure sensor is fastened to the bracket by means of the locknut on the fitting. The
bracket is mounted on the Rittal clip with the screws provided.

CAUTION:
Group the pressure sensor cables to give a single cable run. It is advisable to bundle these cables with
other existing cables (using cable ties).

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2.4 Pressure sensor installation downstream of the mixture cooler and flame trap
2.4.1 Basic principles
Measuring the pressure downstream from the mixture cooler and the flame trap allows the differential pressure
across the mixture cooler and flame trap to be calculated. This gives an indication of the condition of the mixture
cooler and flame trap.

2.4.2 Pressure sensor installation (downstream of the mixture cooler) (J6xx-F)

Mixture cooler

Thread adapter

Pressure sensor

Figure 25: Installation of the pressure sensor on the mixture cooler

The thread adapter is screwed into the thread provided for the purpose on the mixture cooler. The pressure
downstream of the mixture cooler is measured.

Pressure sensor

Sealing ring

Thread adapter

Sealing ring

Figure 26: Mixture cooler pressure sensor module

The pressure sensor module for the mixture cooler is pre-assembled as shown in Figure 26.
CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

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Pressure sensor

Fastened with cable ties

Cable protective sleeve attached to the metal

hose (if present), if not the cable protective sleeve
can be fastened to the console (with cable ties).

Cable protective sleeve

Figure 27: Cable protective sleeve path from the pressure sensor on the mixture cooler

The cable protective sleeve (in Figure 27) is attached by the cable tie to the metal hose (if present), but if not the cable
protective sleeve can also be fastened to the console (with cable ties). The protective cable run here as well should
avoid kinks and contact with other engine components (apart from fastening points).

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2.4.3 Pressure sensor installation (downstream of the flame trap) (J6xx-F)

Mixture cooler console

Thread adapter

Pressure sensor

Figure 28: Pressure sensor installation downstream of the flame trap

The pressure sensor downstream of the flame trap is designed in the same way as the pressure sensor after the
mixture cooler (Figure 26).

Mixture cooler console

Thread for the pressure sensor

adapter

Figure 29: Console for mixture cooler, pressure sensor connection

The pressure sensor downstream of the flame trap is screwed with its adapter into the thread provided for the
purpose on the mixture cooler console.

CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

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Figure 30: Drawing - flame trap differential pressure module (J6xx-F)

Figure 30 shows the drawing for the flame trap differential pressure module for J6xx-F engines. This is intended to act
as an aid during installation. The parts list for this module can be found in the Appendix.

CAUTION:
Group the pressure sensor cables to give a single cable run. It is advisable to bundle these cables with
other existing cables (using cable ties).

CAUTION:
After completing the installation of all the sensor modules, the measuring points must all be checked
during operation. This leak test is carried out using a leak detection agent.

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2.5 Pressure sensor installations upstream and downstream of the mixture cooler
and downstream of the flame trap (J624-H)
2.5.1 Basic principles
Measuring the pressure upstream and downstream from the mixture cooler and downstream from the flame trap
allows the differential pressure across the mixture cooler and flame trap to be calculated. This gives an indication of
the condition of the mixture cooler and flame trap, as deposits can accumulate at this flame trap during operation.

Figure 31: Mixture cooler and flame trap pressure sensors (J624-H)

Figure 32: Detailed views

The pressure sensors are screwed into the threads provided for the purpose (see Figure 32).
CAUTION:
When mounting the sensors, make sure that the thread is wrapped in Teflon tape before screwing it in,
to seal the thread.

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Figure 33: Drawing - flame trap differential pressure module (J624-H)

Figure 33 shows the drawing for the flame trap differential pressure module (J624-H). This is intended to act as an aid
during installation. The parts list for this module can be found in the Appendix.

CAUTION:
Group the pressure sensor cables to give a single cable run. It is advisable to bundle these cables with
other existing cables (using cable ties).

CAUTION:
After completing the installation of all the sensor modules, the measuring points must all be checked
during operation. This leak test is carried out using a leak detection agent.

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2.6 Installation of the oil filter differential pressure module (J6xx-E)

2.6.1 Basic principles
This module is a special installation as part of the Efficiency Package for J6xx-E engines (see ST-184). The additional
installation of a pressure transducer (see Figure 34) allows the differential pressure across the oil filter to be
measured. This gives an indication of the condition of the oil filter.

2.6.2 Installation of the module

Oil filter

Pressure transducer (upstream of the oil

filter)

Oil filter differential

Pressure transducer (downstream of the

oil filter)

Figure 34: Oil filter differential pressure module

Figure 34 shows the oil filter differential pressure module to be fitted. A pressure transducer is screwed into the fitting
welded on to the module frame. The individual components of the oil filter differential pressure module are shown in
Figure 35.
Adapter (6)

Sealing ring (7)

Elbow fitting (2)

Ribbed hose (3)

Pressure transducer (1)

Sealing ring (5)

Reducer fitting (4)

Elbow fitting (2)

Figure 35: Oil filter differential pressure module assembly

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CAUTION:
When installing the individual components, make sure that the threads on the components are
wrapped in Teflon tape before screwing in if no sealing ring is used (to seal the thread).

3 SOFTWARE
To be able to install the sensor package, at least DIA.NE XT, DIA.NE XT3 or DIA.NE XT4 must be installed.

Note:
The customer must contact their responsible Service Sales Manager about buying the software modification and
spares, as only then will the engine documentation be updated as well. The customers will also be given a special
CM&U price if this is ordered through the Service Sales Manager.

DIA.NE XT:
If the sensor package is to be installed on engines equipped with DIA.NE XT, note that additional software must be
installed.

DIA.NE XT3:
If the sensor package is to be installed on engines equipped with DIA.NE XT3, note that additional software must be
installed.

DIA.NE XT4:
Additional software is still currently needed. However, activation of individual parameters for recording measured
data will be all that is required in future.

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4 PARTS LISTS

4.1 Part no. 9019940 - Crankcase pressure sensor (J6xx-F)

Item no. Part No. Qty. Description

1 9010018 1 Crankcase cover
3 240531 1 Gasket
5 9019942 1 Bracket
7 9020222 1 Plate
9 516962 1 Hose
11 1231726 1 Pressure sensor
13 337550 1 Sealing ring
15 102159 1 Straight union
17 100953 1 Elbow fitting
21 100466 6 Hexagon-head bolt
25 113109 2 Rubber buffer
27 100399 2 Hexagon-head bolt
29 101807 2 Hexagonal nut
31 156354 2 Hexagon-head bolt
-additional- 1201697 0.25 Analog input – card part 1
-additional- 1201685 0.25 BUS Module – card part 2
-additional- 1201700 0.25 Plug module / terminal – card part 3
-additional- 200387 1 Terminal
-additional- 620576 7 Bracket/clamp - clip
-additional- 620577 7 Bracket/clamp - cover
-additional- 110534 3.5 m Cable
-additional- 620586 3.5 m Hose
Table 2: Parts no. 9019940 - Crankcase pressure sensor module (J6xx-F)

This parts list consists of 22 components.

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4.2 Part no. 9020315 - Crankcase pressure sensor (J624-G/H)

Item no. Part No. Qty. Description

1 9018585 1 Crankcase cover
3 9017971 1 Gasket
5 9019942 1 Bracket
7 9020316 1 Plate
9 597353 1 Hose
11 1231726 1 Pressure sensor
13 337550 1 Sealing ring
15 100953 1 Straight union
17 100473 1 Elbow fitting
21 100477 6 Hexagon-head bolt
25 113109 2 Rubber buffer
27 100399 2 Hexagon-head bolt
29 101807 2 Hexagonal nut
31 101167 2 Washer
-additional- 1201697 0.25 Analog input – card part 1
-additional- 1201685 0.25 BUS Module – card part 2
-additional- 1201700 0.25 Plug module / terminal – card part 3
-additional- 200387 1 Terminal
-additional- 620576 7 Bracket / clamp - clip
-additional- 620577 7 Bracket / clamp - cover
-additional- 110534 6m Cable
-additional- 620586 6m Hose
Table 3: Parts no. 9020315 - Crankcase pressure sensor module (J624-G/H)

This parts list consists of 22 components.

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4.3 Part no. 9019814 - Blow-by filter differential pressure sensor (J6xx-F)

Item no. Part No. Qty. Description

1 9019815 1 Plate
3 1231726 2 Pressure sensor
5 337550 2 Sealing ring
7 9019816 2 Hose
8 659117 1 Ribbed hose
9 100949 4 Elbow fitting
10 100884 1 Straight union
11 334989 2 Screw plug
13 100066 2 Sealing ring
15 101604 2 Cap screw
17 101823 2 Hexagonal nut
19 101167 2 Washer
25 106121 1 Pipe bracket
27 400328 1 Cap screw
29 110965 1 Washer
31 100427 1 Hexagon-head bolt
33 101812 1 Hexagonal nut
-additional- 1201697 0.5 Analog input – card part 1
-additional- 1201685 0.5 BUS Module – card part 2
-additional- 1201700 0.5 Plug module / terminal – card part 3
-additional- 200387 2 Terminal
-additional- 620576 13 Bracket / clamp - clip
-additional- 620577 13 Bracket / clamp - cover
-additional- 110534 11 m Cable
-additional- 620586 11 m Hose
Table 4: Part no. 9019814 - Blow-by filter differential pressure sensor (J6xx-F)

This parts list consists of 25 components.

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4.4 Part no. 9019814 - Blow-by filter differential pressure sensor (J624-G/H)

Item no. Part No. Qty. Description

1 9019815 1 Plate
3 1231726 2 Pressure sensor
5 337550 2 Sealing ring
7 9019816 2 Hose
8 659117 2 Ribbed hose
9 100949 4 Elbow fitting
10 100884 1 Straight union
11 334989 2 Screw plug
13 100066 2 Sealing ring
15 101604 2 Cap screw
17 101823 2 Hexagonal nut
19 101167 2 Washer
25 106121 1 Pipe bracket
27 400328 1 Cap screw
-additional- 1201697 0.5 Analog input – card part 1
-additional- 1201685 0.5 BUS Module – card part 2
-additional- 1201700 0.5 Plug module / terminal – card part 3
-additional- 200387 2 Terminal
-additional- 620576 13 Bracket / clamp - clip
-additional- 620577 13 Bracket / clamp - cover
-additional- 110534 15 m Cable
-additional- 620586 15 m Hose
Table 5: Part no. 9019814 - Blow-by filter differential pressure sensor (J624-G/H)

This parts list consists of 22 components.

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4.5 Part no. 9019817 - Air filter pressure sensor and ambient pressure sensor (J6xx-F)

Item no. Part No. Qty. Description

1 9019621 1 Adapter
3 100813 1 Sealing ring
4 9020227 1 Bracket
5 337550 1 Sealing ring
7 1231726 1 Pressure sensor
9 389486 1 Pressure transducer
11 113760 1 Locknut
12 9020301 1 Bracket
13 101624 2 Cap screw
-additional- 1201697 0.25 Analog input – card part 1
-additional- 1201685 0.25 BUS Module – card part 2
-additional- 1201700 0.25 Plug module / terminal – card part 3
-additional- 200387 1 Terminal
-additional- 620576 13 Bracket / clamp - clip
-additional- 620577 13 Bracket / clamp - cover
-additional- 110534 6.5 m Cable
-additional- 620586 6.5 m Hose
Table 6: Part no. 9019817 - Air filter pressure sensor and ambient pressure sensor (J6xx-F)

This parts list consists of 17 components.

4.6 Part no. 9019817 - Air filter pressure sensor and ambient pressure sensor (J624-
G/H)

Item no. Part No. Qty. Description

1 9019621 1 Adapter
3 100813 1 Sealing ring
4 9020227 1 Bracket
5 337550 1 Sealing ring
7 1231726 1 Pressure sensor
9 389486 1 Pressure transducer
11 113760 1 Locknut
12 9020301 1 Bracket
13 101624 2 Cap screw
-additional- 1201697 0.25 Analog input – card part 1
-additional- 1201685 0.25 BUS Module – card part 2
-additional- 1201700 0.25 Plug module / terminal – card part 3
-additional- 200387 1 Terminal
-additional- 620576 13 Bracket / clamp - clip
-additional- 620577 13 Bracket / clamp - cover
-additional- 110534 9.5 m Cable
-additional- 620586 9.5 m Hose
Table 7: Parts list 9019817 - Air filter pressure sensor and ambient pressure sensor (J624-G/H)

This parts list consists of 17 components.

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4.7 Part no. 9019818 - Mixture cooler and flame trap pressure sensors (J6xx-F)

Item no. Part No. Qty. Description

1 9019621 2 Adapter
3 100813 2 Sealing ring
5 337550 2 Sealing ring
7 415442 2 Pressure transducer
-additional- 1201697 0.5 Analog input – card part 1
-additional- 1201685 0.5 BUS Module – card part 2
-additional- 1201700 0.5 Plug module / terminal – card part 3
-additional- 200387 2 Terminal
-additional- 620576 10 Bracket / clamp - clip
-additional- 620577 10 Bracket / clamp - cover
-additional- 110534 3.5 m Cable
-additional- 620586 3.5 m Hose
Table 8: Parts list no. 9019818 - Mixture cooler and flame trap pressure sensors (J6xx-F)

This parts list consists of 12 components.

4.8 Part no. 9019819 - Mixture cooler and flame trap pressure sensors (J624-H)

Item no. Part No. Qty. Description

1 9019621 2 Adapter
3 100813 2 Locknut
5 337550 2 Sealing ring
7 415442 2 Pressure transducer
-additional- 1201697 0.5 Analog input – card part 1
-additional- 1201685 0.5 BUS Module – card part 2
-additional- 1201700 0.5 Plug module / terminal – card part 3
-additional- 200387 2 Terminal
-additional- 620576 10 Bracket / clamp - clip
-additional- 620577 10 Bracket / clamp - cover
-additional- 110534 8m Cable
-additional- 620586 8m Hose
Table 9: Parts list no. 9019819 - Mixture cooler and flame trap pressure sensors (J624-H)

This parts list consists of 12 components.

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4.9 Part no. 1231840 - Oil filter differential pressure module (J6xx-E)

Item no. Part No. Qty. Description

1 285283 1 Pressure transducer
2 100957 2 Elbow fitting
3 659117 1 Ribbed hose
4 110402 1 Reducer fitting
5 100834 1 Sealing ring
6 104716 1 Sealing ring
-additional- 1201697 0.25 Analog input – card part 1
-additional- 1201685 0.25 BUS Module – card part 2
-additional- 1201700 0.25 Plug module / terminal – card part 3
-additional- 200387 1 Terminal
-additional- 620576 8 Bracket / clamp - clip
-additional- 620577 5 Bracket / clamp - cover
-additional- 168267 6m Cable
-additional- 620586 5m Hose
Table 10: Part no. 1231840 - Oil filter differential pressure module (J6xx-E)

This parts list consists of 14 components.

Note:
The customer must contact their responsible Service Sales Manager about buying the software modification and
spares, as only then will the engine documentation be updated as well. The customers will also be given a special
CM&U price if this is ordered through the Service Sales Manager.

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5 MISCELLANEOUS

5.1 Required time

The following table shows roughly how much time should be allowed for retrofitting the sensor package for each
J6xx-E/F and J624-G/H engine.

ACTIVITY ENGINE REQUIRED TIME

Retrofitting the crankcase pressure sensor on
J6xx-F or J624-G/H 0.5 day for 1 technician
1 engine
Retrofitting the blow-by filter differential
J6xx-F or J624-G/H 0.5 day for 1 technician
pressure module on 1 engine
Retrofitting the air filter differential pressure
J6xx-F or J624-G/H 0.25 day for 1 technician
module on 1 engine
Retrofitting the mixture cooler and flame trap
differential pressure sensor module on 1 J6xx or J624-H 0.5 day for 1 technician
engine
Retrofitting the oil filter differential pressure
J6xx-E 0.5 day for 1 technician
module on 1 engine
Table 11: Required time

5.2 Relevant documents

When working on GE Jenbacher modules, all applicable local regulations must of course be observed in addition to
our documentation. In relation to this Service Technician Instruction we stress the fact that the following documents
must also be observed:

• Technical Instruction TA 1100-0105: Engine shutdown

• Technical Instruction TA 1100-0111: General conditions - Operation and maintenance
• Technical Instruction TA 2300-0010: Guidelines for using the LOTO kit
• Technical Instruction TA 2300-0005: Safety regulations
• Service Technician Instruction ST-138: Crankcase ventilation
• Drawing: part no. 9019940 - Crankcase pressure sensor (J6xx-F)
• Drawing: part no. 9020315 - Crankcase pressure sensor (J624-G/H)
• Drawing: part no. 9019814 - Blow-by filter differential pressure sensor (J6xx-F/G/H)
• Drawing: part no. 9019817 - Air filter pressure sensor and ambient pressure sensor (J6xx-F/G/H)
• Drawing: part no. 9019818 - Mixture cooler and flame trap pressure sensors (J6xx-F)
• Drawing: part no. 9020319 - Mixture cooler and flame trap pressure sensors (J624-H)

5.3 Revision history

INDEX DATE DESCRIPTION / REVISION SUMMARY

01 29/01/2016 First version of this document

Table 12: Revision history

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6 LIST OF FIGURES
Figure 1: General overview of the modules (1) - J620-F ...............................................................................................................................................................5
Figure 2: General overview of the modules (2) - J620-F ...............................................................................................................................................................5
Figure 3: General overview of the modules (1) - J624-H...............................................................................................................................................................6
Figure 4: General overview of the modules (2) - J624-H...............................................................................................................................................................6
Figure 5: New crankcase pressure module installation (J6xx-F)...............................................................................................................................................7
Figure 6: Pressure sensor............................................................................................................................................................................................................................8
Figure 7: Drawing - Crankcase pressure module (J6xx-F) ...........................................................................................................................................................9
Figure 8: Crankcase pressure module installation (J624-G/H) ............................................................................................................................................... 10
Figure 9: Drawing - Crankcase pressure module (J624-G/H) .................................................................................................................................................. 11
Figure 10: Blow-by filter differential pressure module installation ....................................................................................................................................... 12
Figure 11: Elongated slots for mounting the sensor block ....................................................................................................................................................... 13
Figure 12: Sensor block installation (underside) ............................................................................................................................................................................ 13
Figure 13: Connecting the ribbed hoses to the filter housing ................................................................................................................................................. 14
Figure 14: Drawing – Blow-by filter differential pressure module (J6xx-F and J624-G/H) ......................................................................................... 15
Figure 15: Installation of the sensor block (on filter housings without replaceable filter elements)...................................................................... 16
Figure 16: Positions of the holes to be drilled ................................................................................................................................................................................. 16
Figure 17: Sensor block installation (without preliminary separator and without replaceable filter elements) ............................................... 17
Figure 18: Hole positions.......................................................................................................................................................................................................................... 17
Figure 19: Pressure sensor cabling ..................................................................................................................................................................................................... 18
Figure 20: Air filter pressure sensor installation ............................................................................................................................................................................ 19
Figure 21: Fitting for screwing in the adapter for the pressure sensor .............................................................................................................................. 20
Figure 22: Drawing - Air filter differential pressure module (J6xx-F/G/H) .......................................................................................................................... 20
Figure 23: Ambient pressure sensor installation........................................................................................................................................................................... 21
Figure 24: Ambient pressure sensor with bracket........................................................................................................................................................................ 21
Figure 25: Installation of the pressure sensor on the mixture cooler .................................................................................................................................. 22
Figure 26: Mixture cooler pressure sensor module...................................................................................................................................................................... 22
Figure 27: Cable protective sleeve path from the pressure sensor on the mixture cooler ........................................................................................ 23
Figure 28: Pressure sensor installation downstream of the flame trap ............................................................................................................................. 24
Figure 29: Console for mixture cooler, pressure sensor connection.................................................................................................................................... 24
Figure 30: Drawing - flame trap differential pressure module (J6xx-F) .............................................................................................................................. 25
Figure 31: Mixture cooler and flame trap pressure sensors (J624-H).................................................................................................................................. 26
Figure 32: Detailed views ......................................................................................................................................................................................................................... 26
Figure 33: Drawing - flame trap differential pressure module (J624-H)............................................................................................................................. 27
Figure 34: Oil filter differential pressure module ........................................................................................................................................................................... 28
Figure 35: Oil filter differential pressure module assembly ...................................................................................................................................................... 28

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