overhauling a 4stroke engine unit by amukotuwa special app

Engine make : DEUTZMWM Engine type : BV 16M640Power : 6590kw

Overdue the running hours.

Water leak on the engine block in to the

sump.

Seize the liner or piston.

Seize the big end bearing.

This is the document that can prove the

work we are doing in the engine is

permitted.

This document describes the work doing.

Contains the all the isolations made.

signatures of the watch keeper and

maintenance engineer prove the working

conditions are clear.

Working environment.

The engine was allowed to cool down.

Crankcase doors were opened.

Proper ventilation was arranged with air

blowers.

cylinder head.

Piston was take to its compression tdc

position.

Jacket water system was drained.

Close valves and drain all lube oil and

fuel oil pipes.

Cylinder head tappet cover was

removed.

all the piping were disconnected from

the cylinder head. e.i high pressure

fuel, injector nozzle cooling, leak off

fuel, starting pilot air, charge air bello

rings, starting air, exhaust gas, ht water

in and out, rocker arm lubrication pipes

and also the indicator cock and the

exhaust gas thermo couple.

Tappet screws were loosened and the

pushrods and covers were pulled out.

All the cylinder

head studs’ thread

was cleaned.

Four hydraulic

jacks were

mounted safely on

the studs.

Hydraulic cables

were

connected, jacks

were tightened

and the

clearances were

kept.

Jacks were operated with all the safety

steps up to 900 bar.

The jack operator must wear eye

protectors and hand gloves in case of

accidents could occur.

Round nuts were loosened with a Tommy

bar.

Hydraulic pressure was released and the

same steps were followed with the

remaining 4 studs.

Cyl. head lifting tool was secured and

the head was lifted slowly with a chain

block.

The wear edge was the removed with a power

buff. Otherwise the cyl liner will come out

together with the piston.

In some liners the fire rings are fitted, so it has

to be removed first before the piston.

The bolt holes on the piston crown was cleaned

with wd40 and a tap. This is where the piston

lifting tool get secured to.

Piston was taken to its compression tdc

position.

lifting tool was secured to the piston.

Loose the big end keeper holding annular nut by

raising hydraulic pressure to 1020 bar.

Bottom annular nuts were loosened and take

out with the waisted studs.

The slider was placed under the bearing half.

The remaining tow annular nuts were also taken

out with the waisted studs.

The big end bottom half was taken out from the

the crank case with the slider.

A chain block was attached to the lifting

tool and the piston was lifted slowly. The

big end should be observed because it

may hit the cyl liner or the crank pin.

Once the piston was taken out, the rings

were removed and inspected.

Cyl liner pulling tool was secured to the

liner.

Removing cyl liner.

When the liner is pulled the remaining jacket

water may enter the crank case. A suitable

arrangament has to be made to prevent it.

The liner was loosened and pulled out.

Inspections.

Dp test was run on the cyl line after

cleaning it.

An ovelity check was done for the liner and

after liner horning and face grinding was

done.

Engine block was also cleaned and checked

for cracks and damages.

In case present of damages, they have to be

filled with JB Weld or using any other

suitable material.

cyl liner.

When the the piston moves up down in the

cylinder, the cylinder surface get warned due to

the friction between liner and piston rings.

So to obtain a better lubrication between rings

and the cyl liner, the liner has to be horn.

The horning process makes small smooth grove

pattern inside the liner surface.

cyl liner horning.

The liner was placed and mounted to the horning

machine.

Grinding pieces were widened so as to touch the

liner bore and locked.

The grinding tool was moved downward and

checked the clearances.

Guide tool was entered to the liner.

Sensor tool was mounted.

horning machine was loaded by turning handle

then turn for pneumatic operation from manual

operation by operating valve.

Open the two valve together which valve is

grinding piece with guide rotating valve and

grinding piece up and down moving valve. full

open the up and down moving valve and open the

guide rotating valve as get correctly cutting

angle .

Cutting angle must be 120 degree it was

settled visually by opening tool rotating

valve.

We horning until remove damage as well as

apply the diesel on the grinding surface

while horning.

Horng the liner for that firstly using rough

grinding piece and secondly smooth

grinding piece.

Stop the horning machine finally we must

close valve together, rotating movement

and up and down movement.

Loose the above sensor and turn handle for

manual operation of the machine.

Release the load on the grinding machine.

Move the guide tool with grinding piece on

the up ward away from the liner.

Remove the liner on the base of the trolley.

Liner face must be seated on the liner

base with the sealing ring. we applied

sealing ring from 1.5 to 2 mm thickness.

we selected required ring by calibration

liner face height and base height on the

head after the liner horning and head

lapped. if not seated liner and head with

sealing ring can be leak gas on the unit.

because liner face grinding is very

important thing.

Firstly select the liner for face grinding by

using digital venire caliper.

Place the liner on the wood plate.

Place the grinding machine on the liner.

We must concern the placing

machine, because alignment ring must be

enter in to the liner correctly.

Connect the service air line on to the

grinding machine.

Cylinder liner face means the seat which

seats with the cyl head.

This has to be in good condition, if not

exhaust gas could escape through the non

sealing area.

So to prevent happening that, a good sealing

surface should be given to the liner face by

grinding.

This can be done either with a grinding

machine or with a lapping tool.

After the horning and grinding the liner has to

be calibrated.

In the calibration three axial readings and

three transverse readings were taken at

different heights.

Connecting rod crack testing

procedure. Magnet particle test is done on the con rod for

the test.

Bottom half was attached and tightened with

hydraulic jacks with a pressure of 900 bars.

The inner big bearing side was cleaned by

using sand paper and cleaner.

Detection cleaner was applied for remove dust

particles.

Spray the magnaflux liquid on the relevant

surface and keep uv York can identify crack on

the surface. Cracks appear as yellow lines

some times.

Keep york vertically to the surface for identify

a crack. Crack located horizontally or near

horizontally for magnetic field.

• Ovality of the big end was then measured with an

inside micro meter.

Crank pin.

•The crank pin was inspected for damages and

scratches.

•If there are scratches are present, the y have to

be removed by polishing.

•If the damage is bigger then we have to grind

the pin and reduce the diameter.

•This is a long time taking procedure.

•A specially designed pneumatically operated

tool was used for the job.

Enter the “o” ring on the liner.

Enter the liner in to the engine block.

Set the piston with the big end bearing.

Set the fire ring.

Place the Engine head applying gasket

and sealing ring.

Connect the all removing line.

Finally set the tappet.

Thank you.

Prepaired by,

A.G.G.A.Amukotuwa

mm/09/7788