GE Power

Klaus GLOISER
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 2269
Klaus.Gloiser@ge.com

Service Technician Instruction ST-117 23 October 2017

Engine type J6xx-E/F/J

Subject Gear train inspection
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The Service Technician Instruction ST-117 deals with a gear train inspection to be carried out on Types J6xx-E,
J6xx-F and J6xx-J engines (depending on the gear train version) at every 10.000-hours scheduled maintenance.

AFFECTED ENGINES / SCOPE OF THIS BULLETIN

All Types J612-E, J616-E, J620-E, J612-F, J616-F, J620-F, J612-J, J616-J and J620-J engines NOT equipped with the
CURRENT VERSION of the GEAR TRAIN (see Service Technician Instruction ST-125).

DESCRIPTION / PURPOSE OF THIS LETTER

The following points must be checked on all the above engines:
• Make sure the camshaft idler gear (Item 29) and the shaft (Item 31) on which it runs are securely fastened
✓ Does the camshaft idler gear have axial play corresponding to normal bearing play?
✓ Could the slotted round nut/central bolt (Item 37) for securing the camshaft idler gear be loose (insufficiently tightened)?
✓ Could the shaft on which the camshaft idler gear runs be loose?
• Make sure the oil pump idler gear (Item 43) and the shaft (Item 46) on which it runs are securely fastened
✓ Does the oil pump idler gear have axial play corresponding to normal bearing play?
✓ Could the slotted round nut/central bolt (Item 49/37) for securing the oil pump idler gear be loose (insufficiently tightened)?
✓ Could the shaft on which the oil pump idler gear runs be loose?
• Do all the gears exhibit normal wear patterns, or are there any unusual features that indicate loose parts?
Item numbers: See the drawings below!

NEED FOR ACTION

The inspection must be carried out in accordance with this Service Technician Instruction.
• If the result of the inspection is IN ORDER:
✓ Bring the plant back into operation
✓ Record the gear train inspection and its result in the engine log book/Oracle
• If the result of the inspection is NOT IN ORDER:
✓ Carry out repairs if possible and then bring the plant back into operation
✓ If immediate repairs are not possible, clarify the further course of action to rectify the damage and resume operation
✓ Record the gear train inspection, its result and the failure/repair in the engine log book/Oracle

SCHEDULE
Carry out the inspection as part of every 10.000-hours scheduled maintenance.

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 shall not be used, disclosed to
others or reproduced without the express written consent of GE. This includes but not limited to use for the creation, manufacture, development or derivation of any repairs, modifications,
spare parts, designs or configuration changes, or for obtaining 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-117
Gear train inspection
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ORIGINAL VERSION (gears on angular ball bearings fixed by slotted round nuts): NEEDS TO BE CHECKED!

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 SERVICE TECHNICIAN INSTRUCTION ST-117
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INTERIM VERSION (gears on angular ball bearings fixed by central bolts): NEEDS TO BE CHECKED!

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 SERVICE TECHNICIAN INSTRUCTION ST-117
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SEQUENCE OF WORK
➢ Shut down the engine as per TA 1100-0105 and secure it against unauthorised restarting in accordance with TA
2300-0010.
➢ Observe the safety instructions in TA 2300-0005 and wear the relevant Personal Protective Equipment (PPE).
➢ Open the gear train at the camshaft idler gear. Depending on the engine version and configuration (air intake
system, crankcase ventilation) different parts need to be removed to carry out this step. Secure parts to prevent
them from falling if required (air intake pipes, ROLF in-line air filter,…).
J6xx-E with air filter housing and housing support J6xx-F with ROLF and blow-by preliminary separator

➢ Close off all openings (intake pipes, air filter housing, crankcase ventilation,…) so they are dust-proof.
➢ Check that the camshaft idler gear is securely seated and check the axial play of the camshaft idler gear
(tolerance limits further down). This measurement should be recorded in the engine log book and the values
obtained compared to previous measured values to determine if a trend in play is visible or if play is stable. If an
increasing trend is visible, then please contact GE for further guidance.

➢ Remove the oil pump.

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➢ Close off all openings (oil pump, oil piping) so they are dust-proof.
➢ Check that the oil pump idler gear is securely seated and check the axial play of the oil pump idler gear (tolerance
limits further down). This measurement should be recorded in the engine log book and the values obtained
compared to previous measured values to determine if a trend in play is visible or if play is stable. If an increasing
trend is visible, then please contact GE for further guidance.

➢ Visually inspect all the gears, i.e. all the teeth on the camshaft gear, camshaft idler gear and oil pump idler gear
must be checked (this will necessitate barring the engine).
➢ If any loose parts (slotted round nuts/central bolts, fastening bolts) or other damage are found, the gear train must
be dismantled and repaired. Consult the responsible Customer Service Manager/Area Service Manager.
➢ If everything is in order, refit everything in reverse order.

TOLERANCE LIMITS FOR THE AXIAL PLAY OF THE CAMSHAFT IDLER GEAR AND THE OIL PUMP IDLER GEAR
≤0.3mm Axial play is fine
>0.3mm to ≤0.6mm Clarify further proceedings
Contact the responsible Customer Service Manager/Service Area Manager
>0.6mm Open gear box, check parts and replace them if necessary
Contact the responsible Customer Service Manager/Service Area Manager
Table 01: Tolerance limits for the axial play of the camshaft idler gear and the oil pump idler gear

REQUIRED GASKETS AND SEALS

The following list contains the necessary parts that would be required as a minimum for this gear train inspection. Any
additional material needed in case of an eventual replacement of gear train parts has not been included.
REQUIRED QUANTITY
PART NUMBER DESCRIPTION ASSEMBLY POSITION
J612 J616 J620
Air filter housing support or blow-by console or blow-by preliminary
294887 1 1 1 O-ring
separator / gear train housing
376510 2 2 2 O-ring O-ring carrier / gear train housing (blow-by return into manifold)
196526 1 1 1 O-ring Oil pump / gear train housing
240789 2 --- ---
Flat gasket Oil pump / oil pipes (suction and delivery line)
240792 --- 2 2
456718 1 1 1 O-ring Oil pipe (delivery line)
Table 02: Required gaskets and seals

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 SERVICE TECHNICIAN INSTRUCTION ST-117
Gear train inspection
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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 shut-down
• Technical Instruction TA 1100-0111: General conditions – Operation and maintenance
• Technical Instruction TA 2102-0020: Check list for engine repairs and overhauls
• Technical Instruction TA 2300-0005: Safety instructions
• Technical Instruction TA 2300-0010: Guidelines for using the LOTO kit

REVISION CODE
INDEX DATE DESCRIPTION / REVISION SUMMARY
03 Oct. 23, 2017 Definition of the affected engines updated:
• Current/new gear train version (oil pump idler and camshaft idler gears on tapered roller bearings fixed by
central bolts) not affected
02 Jan. 27, 2017 Fundamental revision:
• Inspection interval – Change from 20.000-hours to 10.000-hours maintenance
• Definition of the affected engines – Change from J620-E in Bangladesh to all J6xx-E/F
• Scope of work – Additional check of axial play of camshaft idler gear and oil pump idler gear
• Layout, sequence of work, required gaskets and seals, relevant documents - Update
01 Dec. 18, 2011 First version of this document
Table 03: Revision history

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