Overhaul and reconditioning of industrial engines

Our workshop performs daily reconditioning on different parts of industrial engines, and additionally Overhaul on them.

Our workshop performs daily overhauls on different parts of industrial engines, and additionally Overhaul on them.

Today we show you the main steps to carry out an Overhaul on any of the industrial engines that RS Motor usually has in its facilities.

These engines operate mainly with natural gas, biogas or other types of gases. There are other industrial engines that RS Motor regularly overhauls, although in this case they are diesel engines.

What is the Overhaul of engines?

We define Overhaul as the complete disassembly of an industrial engine, either at RS Motor or at the customer’s premises, in order to then proceed with the examination of the disassembled parts, repair and/or recondition them, replace the spare parts susceptible to wear and finally reassemble the whole unit.

The reason for the overhaul is to make the engine ready to run another complete working cycle, which will depend on the engine manufacturer’s specifications.

When is an overhaul necessary?

Normally, the engine overhaul is defined according to the manufacturer’s maintenance plan, which recommends the hours of operation at which it should be carried out.

The interval is different if the engine is a DEUTZ, MWM (CAT), Jenbacher or Guascor for example.

If we are talking about DEUTZ/MWM (CAT) engines, the overhaul is usually carried out every 48,000 operating hours or 64,000 operating hours depending on the quality of the gas consumed by the engine. The higher the gas quality (natural gas), the longer the interval between overhauls. However, there are exceptions in the case of very recent engines, where the overhaul is marked at 80,000 operating hours if the gas quality is very good.

As far as Jenbacher engines are concerned, current engines are usually marked for overhaul at 60,000 hours of operation (whatever the type of gas they consume). Like DEUTZ/MWM (CAT), newly installed Jenbacher engines can have their overhaul extended to 80,000 operating hours.

Finally, in Guascor engines, the overhaul if the engine consumes biogas, is usually at 50,400 hours of operation while if it is running on natural gas, the intervention could take place at 60,000 hours.

Types of Overhaul

As a rule, an Overhaul is a complete maintenance of the engine, in which the wearing components of both the upper and lower parts of the engine are replaced. However, RS Motor is able to offer its customers various types of alternatives in order to minimise the impact of engine downtime on the power plant.

Sometimes, if the lead time is not important, the overhaul may be carried out at RS Motor’s facilities.

If lead time is a limiting factor, but not a major one, RS Motor will bring its team to the customer’s site to carry out the overhaul.

If the delivery time is critical, RS Motor will, if possible, provide the customer with an exchange shortblock or exchange longblock.

Finally, if the delivery time is most important, we would offer the possibility of supplying an exchange engine with the overhaul already done. This engine would be fully assembled and would be «plug & play», so plant downtime would be minimal.

Request a quote for an Overhaul from RS Motor

Customers all over the world already rely on RS Motor when they need to overhaul their industrial engines, whether gas or diesel.

Join them and ask us for availability and price if you want to try us. Currently we can say that we are the best alternative to the Official Service offered by the brand, since years of experience in workmanship and the supply and installation of genuine and/or OEM spare parts make this possible.


Engine Refurbishment

The process of reconditioning comprises the disassembly of the mechanical part, analysis and verification of the condition, ultrasonic cleaning of mechanical elements, dimensional checks and/or hydraulic tests, replacement of wear elements and resetting of the reconditioned element to zero hours.

The elements that are usually reconditioned in the «RS Motor» workshop are:

  • Actuators or speed controllers.
  • Plate heat exchangers.
  • Water pumps.
  • Oil pumps.
  • Starters.
  • Crankpipes (check).
  • Plug rods (check).
  • Connecting rods (parallelism check and bushing replacement)
  • Zero valves.
  • Carburets.
  • Jackets.
  • Throttle valves.
  • Butterfly valves.
  • Alternators.
  • Mixing valves or mixers.
  • Fuel pumps.
  • Tubers..


Marks of engines we work with

At RS Motor, we specialise in carrying out work and overhaul on the industrial engines listed below:

TBG616V8 TBD616V8 Jenbacher J208 FG 180 6L
TBG616V12 TBD616V12 Jenbacher J212 FGLD 180 6L
TBG616V16 TBD616V16 Jenbacher J312 SFGLD 180 LL
TBG620V12 TBD620V12 Jenbacher J316 FG 240 8L
TBG620V16 TBD620V16 Jenbacher J320 FGLD 240 8L
TBG620V20 TBD645L6 Jenbacher J412 SFGLD 240 8L
TBG632V12 TBD645L8 Jenbacher J416 HGM 240 8L
TBG632V16 TBD645L9 Jenbacher J420 FGLD 360 12V
TCG2016V8 TCD2016V8 Jenbacher J612 SFGLD 360 12V
TCG2016V12 TCD2016V12 Jenbacher J616 FGLD 480 16V
TCG2016V16 TCD2016V16 Jenbacher J620 SFGLD 480 16V
TCG2020V12 TBD640 Jenbacher J624 SFGLD 560 16V
TCG2020V16 SVB628 SFGM 560 16V
TCG2020V20 ….. and many more HGM 560 16V
CAT CG132-8
CAT CG132-12
CAT CG132-16
CAT CG170-12
CAT CG170-16
CAT CG170-20
CAT CG260-12
CAT CG260-16