16000 Hours Standard Maintenance Procedure

AJAX 2803 NON LE

1. Turn off the machine at least a day in advance of the maintenance work
so as to allow sufficient time for cooling the engine.
2. Ensure that the machine has been depressurized and vented, post this
check for readings in all pressure gauges and panel for zero value.
3. Before beginning the work ensure that the relevant piping valves have
been locked with correct tags.
4. Ensure that the PTW, JSA and the Isolation certificate have been duly
complied with followed by the permit holder conducting a Tool box talk
with all relevant personnel.
5. Drain all the jacket water and store it in an empty barrel
6. Drain the crankcase lubrication oil and store it in a clean empty barrel.
7. Drain the distance piece chamber oil and measure its quantity. Post this
dispose it in burnt oil collection bin.
Note: - Under no circumstance the distance chamber oil and crankcase
oil be mixed.
8. COMPRESSOR CYLINDER
A. Both the first stage and second stage piston rings should be replaced.
This can be done by loosening the set screws and lock nut and then
unscrewing the piston rod from the crosshead, followed by opening
the head end enclosure of the cylinder and slowly pulling the piston-
rod assembly out of the cylinder with the help of a mobile crane.
B. The piston should be cleaned to remove all accumulated dirt and
carbon deposits
C. Replace the piston rings and check for side clearance between piston
and groves as well as end gaps in the ring.
D. Clean the cylinder casing and inspect for any wear.
E. Before reinstalling the piston assembly in the cylinder apply a coat of
fresh lube oil in the ring and groove area
 F. Piston rod lock nut should be torqued at 3200 lb-ft,set screws and
jam nuts at 55 lb-ft and 50 lb-ft respectively.
G. Post installation take striking clearance reading in both Head End and
Crank End and ensure that it is within recommended limits.

I. POPPET VALVES
a. Remove the suction and discharge valves of the 1st stage and 2nd
stage
b. Remove the poppet and springs and clean the valve body. Post this
inspect the poppet seat and look for any wear.
c. In case of any deformities in the valve body replace the entire valve,
else simply install new poppets and springs.
d. Replace both the inner and outer valve gaskets in the compressor
cylinder.
II. COMPRESSOR CYLINDER STUFFING BOX
Replace all the packing rings in the gland housing with new ones.
9. CROSSHEAD
a. Remove the crosshead chamber cover plates, in case of any stubborn
remnants of old gaskets, carefully use wood chisel to remove it.
b. Thoroughly clean the crosshead chamber and remove the
accumulated oil deposits with a clean cotton cloth
c. Check for clearance between crosshead to crosshead guide: -
compressor crosshead - 0.012” to 0.015”
Power crosshead – 0.009” to 0.013”
d. measure the total indicator Rod runout in both vertical and
horizontal position in the distance piece.

10. AIR MIXING VALVES

 a. Remove the air mixing valves along with their gaskets from the
scavenging chamber. Precaution should be taken during this process
as any foreign material, tools & fasteners might fall inside the
scavenging duct.
b. Use wood chisel to remove any stubborn gasket remnants from the
valve.
c. Clean and remove any carbon deposits from the valve
d. Replace the reeds,springs and gaskets with new ones.
11. AIR INTAKE FILTER
Replace both the air intake filters

12. CRANKCASE
a. Remove the crankcase cover and gasket, put it in a clean place
b. Clean the crankshaft with clean cotton clothes.
c. Measure the web deflection, The total indicator run out should not
be more than 0.0013” (with flywheel installed)
d. Measure the end play
Note:- before doing the procedures in c & d, apply a coat of fresh
lubrication oil over the bearings.
e.
f. Refill the crankcase with new lubrication oil, ensure that the oil level
is kept at 27.5” from the top of the crankcase. The crankshaft should
be rotated atleast once in the oil before making this measurement.
g. Clean the breather and saturate it with oil before installing on
crankcase top covers
13. FLYWHEEL
Remove the flywheel guard and check for bolt tightness. The torque
should be at 185 Ft-Lbs.

14. SPARK PLUGS

a. Carefully remove all the spark plugs
b. Before installing new ones, ensure the electrode gap is at 0.030 “
c. The spark plug should be torqued at 60 Ft-Lbs
15. CHECK VALVES
a. Remove all the fuel injection check valves and replace their
b. Before fitting in the cartridges,conduct a leak test on the cartridges

16. POWER CYLINDR

a. Remove the power cylinder heads and inspect the cylinder and
piston for any wear.
b. Remove carbon deposits from cylinder ports.
c. Replace the head gaskets
d. Check for the piston striking clearance using a long soldering wire.
e. The head bolts should be torqued at 600 Ft-Lbs
17. IGBT
a. Loosen the IGBT bolts and remove it, check the seat for any wear
b. Replace the O-rings
18. LUBE OIL PUMP
a. Clean the strainer
b. Drain the lube oil and inspect the camshaft and the gear for any wear
c. Remove the plunger and clean it.Check the springs and lock rings,
replace it if required.

19. COOLER
a. Clean the cooler fins with pressurized air followed by water wash
b. Inspect for fan bolt tightness
c. Check the fan blade pitch
d. Grease the cooler fan bearings, Plummer block, two bearing housing and
the jacket water pump in recommended quantities.

20. BELT TENSION & PULLEY ALIGNMENT

a. Proper belt tension is achieved when a 10 pounds of force applied to the
center of the belt’s span causing a belt deflection of 0.45".
Note: - Do not Overtighten the belts as it may lead to bearing failure.
b. Check the alignment between the sheave and the fan pulley and between
the fan pulley and pump pulley.
c. Use inner nut and the outer nut to adjust the belt tension