The Project for Introduction of Hybrid Power Generation System

in Pacific Island Countries

MAINTENANCE OF DIESEL ENGINE GENERATOR

Name: Tobia Nayaqayaqa

Organization: EFL
Department: Thermal
Email Address: TobiaN@efl.com.fj

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 1

Table of Content
No. Topics Page No.

1 Introduction Of DEG 3

2 Maintenance Recommendation Period 4 to 16

3 Maintenance Of Cylinder Heads 18 to 22

4 Maintenance Of Cylinder Liner 23 to 25

5 Maintenance Of Piston 26 to 29

6 Maintenance Of Camshaft 30 to 34

7 Maintenance Of Charge Air Cooler 35 to 38

8 Maintenance Of Con Rods 39 to 42

9 Maintenance Of Pumps 43 to 48

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 2
Table of Content

No. Topics Page No.

10 Maintenance Of Thermostat 49 to 50

11 Maintenance Of Over speed 51 to 53

12 Maintenance Of Engine Block 54 to 56

13 Maintenance Of Explosion door 57 to 59

14 Maintenance Of Suction Strainers 60 to 61

15 Maintenance Of Cooling Water Pipes 62 to 64

16 Maintenance Of Spring drive 65 to 66

17 Overhaul Pictures 67 to 73

18 Failure for Exceeding Recommendation Periods 74

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 3

INTRODUCTION OF DEG (1)

 Manufacturers had suggested maintenance period for inspections which to suit

the engine performance.
 Manufacturer recommended certain components to be tested or replaced once
reaches suggested running hours.
 It is advisable to stock sufficient assemblies of spares so the engine can be
return to service quickly.
 Parts can be removed for reconditioning on overhaul and can returned for spares
for the next overhaul.
 Review of maintenance record give clear idea on the engine performance before
dismantling.
 Dismantled parts should be transferred to a properly equipped workshop for
cleaning, examination and for necessary renovation.
The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 4
INTRODUCTION OF DEG (2)
 The aim for the heavy overhaul is to restore all parts of the engine to the first class
condition. This will ensure that the engine will perform to the satisfactory result.
 Parts cleaning is great important for all parts, particularly in the fuel and
lubricating oil system and must undergo a final examination just before
reassemble, to ensure they are clean.
 Cotton waste should never be used for cleaning because of the danger of leaving
dust, threads or fluff. Use only well washed cotton rags or wipers.
 Use recommended torque wrench figures for tightening of certain components as
quoted in the manual. Note that the torque loading are affected by the damaged
components and therefore need to check threads are undamaged and free
running.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 5

Maintenance Recommended Period

• Daily Checks
 250 Hours Maintenance
 1250 Hours Maintenance
 2500 Hours Maintenance
 5000 Hours Maintenance
 10000 Hours Maintenance
 15000 Hours Maintenance (Light Overhaul)
 20000 Hours Maintenance
 30000 Hours Maintenance
 60000 Hours Maintenance (Heavy Overhaul)

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 6
Daily Maintenance Check sheet (1)
SUBJECT WORKSCOPE
Record Load
ENGINE LOAD
Record Mvars
Check oil level
GOVERNOR Check oil leaks
Lubricate Linkages
Check fuel leaks
FUEL PUMPS Record fuel pressure
Check mounting bolts
Check Exhaust leaks
EXAUST
Check peak pressure leaks
Check oil leaks
TURBO CHARGER Check air maize oil level
Check screen (dirty/clean)
Check level/leaks
COOLING Record outlet temp.
Record PH level

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 7

Daily Maintenance Check sheet (2)

SUBJECT WORKSCOPE
Check pedestrial bearing oil level/leaks
Check lube oil level
LUBRICATION
Record oil pressure
Check system leaks
Record oil differential pressure
Check oil pumps & rubber flange
PUMPS Check water pump & rubber flange
Check fuel transfer pumps and leaks
Drain all air bottles
AIR BOTTLE
Check for air leaks
Check for leaks
RADIATOR Record inlet temp
Record outlet temp.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 8
1250 Hours Maintenance of DEG-(Ruston Engine)
# 1250 hours -Checklist Comments
1 Charge cooler  Check for air /water leaks when engine running
2 Cooling System  Check chemical analysis-adjust if necessary
 Check joint for leaks –when engine running
 Check tappet clearance
3. Cylinder Head and Valve Gear
 Check oil supply to valve gear
 Check relief valve for leaks-when engine running
4 Fuel control linkages  Check for operation
5 Governor  Lubricate eternal linkages
 Check for chemical analysis-renew if necessary
6 Lubrication  Renew filter element if differential pressure exceed 1
bar
7 Over speed Trip  Lubricate reset lever bearing and check operation
8 Turbo Charger  Clean air intake filter

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 9

2500 Hours Maintenance Of DEG-(Ruston Engine)

# 2500 Hours Checklist Comments

9 AV Mounts Check rebound setting and height

10 Crankshaft Check alignment (flywheel end web only

11 Fuel damping vessels Check for leaks when engine running

12 Fuel filter Renew filter elements

13 Fuel Injector Check operations

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 10
5000 Hours Maintenance Of DEG- (Ruston Engine)

# 5000 Hours Checklist Comments

14 Camshaft  Inspect drive gear

15 Crankshaft  Check alignment

16 Cylinder Head  Renew rocker cover joint

17 Fuel Injectors  Renew nozzles

18 Governor/actuator  Drain oil and refill

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 11

10000 Hours Maintenance Of DEG

# 10000 Hours -Checklist Comments

19 Charge cooler  Dismantle, clean, renew joint and clean air duct

20 Explosion relief valve  Clean and examine

21 Fuel linkage  Examine pin and bushes

22 Turbocharger  Remove cartridge and check clearance

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 12
15000 Hours Maintenance- (Ruston Engine) Light Overhaul

# 15000 Hours Checklist Comments

 Examine lub-oil and water pump driving gear

23 Auxiliary Drive
 Check backlash

24 Camshaft  Examine cams and followers and check end float

25 Cooling Water Pumps  Dismantle, clean and examine

26 Cooling Water Thermostatic Valve  Dismantle, clean and test

 Clean and examine
27 Connecting Rods  Check large end nuts and bolts
 Renew large end bearing shells

 Decarbonise combustion face and crack detect

 Dismantle and examine valve gear
28 Cylinder Head And Valve Gear
 Examine valve and seats
 Renew all joints and hoses

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 13

15000 Hours Maintenance- Light Overhaul

# 15000 Hours Checklist Comments

29 Cylinder Liners  Clean, examine and measure

30 Fuel Injection Pumps  Remove and overhaul
31 Fuel Linkages  Examine pin and bushes
32 Fuel Transfer Pumps  Dismantle, clean and examine
33 Lubricating Pressure Relief Valve  Dismantle ,clean and examine
34 Lubricating oil Thermostatic Valve  Dismantle,clean examine and test
35 Lubrication  Renew rubber hose connection
 Inspect bearing shell
36 Main Bearing
 Examine cap to bedplate faces
 Clean and examine
37 Piston
 Renew top piston ring
38 Vibration Damper  Check fluid viscosity

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 14
20000 Hours Maintenance Of DEG

# 20000 Hours Checklist Comments

39 Turbocharger Renew bearing seals

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 15

30000 Hours Maintenance Of DEG

# 30000 Hours Checklist Of DEG Comments

40 Air Chest  Remove cover and clean

41 Connecting Rod  Check small end bushes

 Examine water spacers and remove any

42 Crankcase
debris, Sludge and scale

43 Cylinder Heads and Valve Gear  Renew valve seats if necessary

 Remove, clean inspect and rehone bores

44 Cylinder Liner
 Renew sealing ring

 Renew bellows and joints.

45 Exhaust Manifold System
 Inspect pipes and replace if necessary

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 16
30000 Hours Maintenance Of DEG

# 60000 Hours Checklist Comments

46 Fuel Injection Pumps  Renew high pressure pipes

47 Lubricating Oil Pumps  Renew bearings

48 Lubricating oil Gallery  Renew ‘O’ rings

49 Main Bearings  Renew bearing shell

 Renew piston ring
50 Pistons
 Check gudgeon pin and clearance

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 17

60000 Hours Maintenance Of DEG -Major Overhaul

# 60000 Hours Checklist Comments

51 Auxiliary Drive  Dismantle and check

52 Bedplate  Clean out

 Remove check coupling,replace joints and
bushes.
53 Camshaft and Drive
 Check Clearance,examine gears,shaft and
bushes
 Renew large end bolts and nuts
54 Connecting Rod
 Renew small end bushes
55 Cooling water pipes  Dismantle clean and fit new joints
 Dismantle, clean and renew joints.
56 Crankcase Breather
 Overhaul fan and motor assembly

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 18
60000 Hours Maintenance -Major Overhaul

# 60000 Hours Checklist Comments

57 Crankshaft  Examine and measure journals and pins.
58 Cylinder Liner  Renew
59 Governor/Actuator  Overhaul
60 Lubricating Oil pipework  Remove. Clean and fit new joints/’O’ rings
61 Main Bearing  Inspect bolts, nuts and pin
62 Overspeed Trip  Dismantle clean and examine
63 Piston  Renew
64 Spring Dive  Dismantle and check
65 Suction Strainer  Clean and Renew Joints
66 Vibration Damper  Overhaul

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 19

1.0 Cylinder Heads

 Cylinder heads is made up of cast iron secured to the crankcase by studs.

 Joint ring is fitted between the cylinder head and the liner to form gas tight seals
 It is water cooled which fed from the crankcase to each head through external
connectors into the inter passage
 It has two inlet and two exhaust valves made of heat resisting steel, loaded by
inner/outer spring with spring plate and locked by pair of split collet.
 The valve seat are hard alloy insert pressed into it.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 20
Diagram Of Cylinder Head

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 21

1.1 Maintenance Of Cylinder Heads

 Decarbonised the combustion face and place in the hot water tank for cleaning
purposes
 Check condition of the injector tubes and replace if necessary
 Compare free length of the spring with figure in the DATA and replace if
necessary
 Crack test the combustion face
 Pressure test
 Renew the valves and seats as necessary
 Reface valve seat.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 22
1.2 Maintenance Of Cylinder Head

• Cylinder head placed in caustic hot • Valve seat grinding

water tank

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 23

2.0 Cylinder Liners

Made of cast iron of individual wet type and flange at the top.
Cutting ring is fitted at the top liner to reduce carbon built up on the piston crown
It is secured in the position in the crankcase by each cylinder heads on top of the
liner
Top face of the liner provides space for the cylinder head joint ring.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 24
2.1 Maintenance Of Cylinder Liner
 Examine the liner bore for the sign of scoring
 Check the diameter of the bore at the top limit of the ring travel, take two sets of reading at
90deg from each other (inline and across the crankshaft centre line.
 If the bore at the top limit of the ring travel exceeds the permissible figure given in the DATA,
or the surface of the bore is damaged the liner must be replaced.
 Clean the liner and carry out crack test.
 Replace the “O” sealing ring

‘O’ sealing ring replaced Crack test

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 25

2.2 Honed of Cylinder liner

 Glazing must be removed before new pistons or piston ring is fitted to provide correct bedding
of the rings
 A medium grade carbonrundum stone using a swirling movement using a low speed drilling
machine.
 A lather pocket to be temporarily installed to hold metal particles during the horning processes.

Horning of liner Outcome process

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 26
3.0 Pistons
Consists of two piece of aluminum alloy and steel crown.
It is equipped with chromium plated ‘O’ rings seal fitted in the piston crown and held together with 4 bolts
There is top ring and two taper face ring bellow.
The oil scraper oil ring fitted to the piston body chromium plate on the wiping surface slotted and house a latch
pin and spring

Removal and Dismantling Of Piston

1. Slack all the connecting rod bolts and rotate the crank to about 20 to 30
degrees past the rotation direction.
2. Remove one of the top bolts and insert the special tools to hold the large end cap.
3. Remove the other three bolts and slide down the large end cap.
4. Remove special tools and pull out the large end cap
5. Remove carbon deposit and mount the special piston removing tools
6. Use chain block to hook on the special tools and hook on the crane.
7. Hold the connecting rod in a free position while pulling the chain block. Make sure
the con rod is not stuck on the liner.
The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 27

3.1 Removal and Dismantle Of Piston

8. Turn the piston upside down, and lifting the connecting rod with the crane
9. Rest the piston on a clean board and remove the circlip pin using circlip pliers and pull the
piston pin
10. Remove piston rings

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 28
3.2 Piston Calibration
 Clean and examine the piston for the sign of damage OR deformation
 Measure the inner and outer bore of the piston and compare with manufacturer recommendation
 Measure ring gap and range with DATA
 Measure piston pin inner/outer diameter and compare in the DATA.
 Crack test / colour test.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 29

3.3 Dressing Of Pistons

 Check oil gallery/passage for blockage using compressed air.
 Apply oil to oil passage
 Check matching serration and fit back on the same pair
 Fit all rings and cover in garbage bags to prevent it from dust and
corrosion.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 30
4.0 Camshaft

 It is driven from the flywheel end on the crankshaft through a train of

hardened and ground spur gear
 A journal consists of a number of single cylinder length section.
 Each journal consist of inlet/exhaust valves through tappet and push rods
and fuel injection pumps direct fro the tappet arrangement.
 Secured with white metal lined bearing bushes secured in the crankshaft
bolts- piece of bearing housing.
 The governor drive wheel is in corporate into the gear/hub arrangement
which the other end drives the over speed trip.
 Each camshaft can be removed sideways from the crankcase and refitted by
reversing the procedure as detail later.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 31

4.1 Maintenance Of Camshaft

 Inspect the cam and follower rollers. Check that the rollers are free to rotate
on their pin. New part should be fitted as necessary.
 Check the cam end float.
 Remove and dismantle the camshaft ,replace the journals and bushes.
 Check the running clearances and fit new parts when any exceeds the
maximum permissible figure quoted in the DATA.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 32
4.2 Camshaft Drive
 It is driven by from the split gear
 Intermediate gear transmit the drive through the train of idler gear to
the gear attached to the end journal on each camshaft

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 33

4.2 Inspection Of Camshaft

Cylinder length section form part of journal system
White metal lined bearing buses secured in the crankshaft bolt-on, on apiece
bearing housing
Check the cam end float

Checking the camshaft end

Camshaft element float

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 34
 4.3 Maintenance Of cam drive

Check the running clearance and fit new parts when any exceeds the maximum
permissible figure quoted in the DATA.
Crack test to examine the drive gears for the damage or excessive worn.
Remove and dismantle the camshaft renew idler spindles and gear shafts and
all bushes. Inspect the gear and replace as necessary

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 35

5.0 Charge Air Cooler

Charge air cooler or after cooler, is used to

cool the charge air used for the combustion.
Turbo charger suck the air from the
surrounding which passes through the oil
bath/air maize.
From the air maize, it passes through charge
cooler/after cooler for cooling process before
it used for combustion

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 36
5.1 Maintenance Of Charge Air Cooler

 Dismantle Charge air cooler and clean

 With the mean of long drill, clean the water tubes
 Hot water tank cleaning for overnight
 Change all joint and reassemble

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 37

5.2 Cleaning Of Charge Air Cooler

• Hot water tank cleaning • Cleaning works

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 38
5.2 Cleaning Of Charge Air Cooler

• Before Maintenance • After Maintenance

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 39

6.0 Maintenance Of Con- Rods

 It is the alloy steel connecting rod fitted with

large end bearing cap.
 It a dowel with matching serration bearing
cap secured with high tensile bolts.
 The large end bearing consist of two steel
backed shell with grooved for oil flow.
 The small end bushes are backed and
pressed into the connecting rod eye.
 Oil is supplied through drilling from large end
bearing shell to the small end bush.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 40
6.1 Maintenance Of Con Rod

 Withdraw the pistons and connecting rods. Ensure the

assembly is marked indicating which cylinder it was
removed from.
 Examine and measure the crankpin as detailed in the
CRANKSAHFT instruction.
 Remove the large end bearing shells and refit the large
end caps and bolts, tighten to the correct stretch. Measure
the large end bore using a ball ended micrometre. Any
connecting rod with ovality exceeding the maximum
permissible figure quoted in the DATA must be renewed.
 Check each gudgeon pin and its small end bush, replacing
any which are worn beyond the limit specified in the DATA.
 Renew the large end bearing shells on the assembly.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 41

6.2 Maintenance of connecting rod

① Cleaning
 ・Clean connecting rod
 ・Check for clogging of lubricating hole (piston pin,
crankpin)
 ・Check condition of crankpin metal contact
 ・Check condition of the housing surface at the big
end
② Colour check
 ・Piston pin metal colour check
 ・Colour check connecting rod serration
 ・Crankpin metal colour check

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 42
6.3 Maintenance Of Cod Rods
 Withdraw piston from the con rods
 Examine the crankpin
 Check for ovalty for the con rod large end bore-(refit large end cap and bolt and tighten to the
correct stretch)
 Check for the con rod small end bush

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 43

7.0 Lubricating Oil Pumps

 It is the positive displacement type and is self priming which mounted on the free
end of the engine .
 The pumps end cover allows on one, the lube oil injection pump to be mounted
and driven by a split coupling from the lubricating oil pump main shaft.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 44
7.1 Maintenance Of Pumps
 Remove the oil pump from the engine and examine for wear
 Check the clearance between the bearing bushes and the main shaft also the clearance between
the follower gear bushes and the follower shaft.
 When the clearance exceed the maximum permissible figure in the quoted in DATA, renew the
bushes
 Examine the oil pump gears and check the radial clearance between each gear wheel and the
pump casing.
 When this clearance exceeds the maximum figure quote in the DATA, renew the gears.
 Reface the casing when the end clearance of the gear exceeds the maximum permissible figure
quoted.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 45

7.2 Dismantling & Inspection Of Lube Oil Pump

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 46
7.3 Jacket/Raw Water Pumps

 It is driven from the free end via spring drive and idler gear.
 Jacket water (high temperature) and Raw water low temperature water
pumps.
 Low temperature water pumps supplies water to the charge cooler.
 The high water temperature water pumps circulate the engine cooling water.
 It has seals which prevent leakage of water along the shaft.
 If seal fails, the excessive water/oil will comes out from the bottom drain hole
which simply means that seal need to be replace.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 47

7.3 Maintenance Of Jacket/Raw Water Pumps

 Drain water and disconnect all connection pipes.

 Remove the pumps and transfer to suitable work bench.
 Mark the housing before separating and dismantle the pumps.
 Replace pumps and pipe gasket if worn or ensure that they are of the correct
thickness and off the suitable material for the liquid being pump.
 On completion of overhaul, assemble the pumps to the engine and check the
backlash between the pump drive gear and the idler gears.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 48
7.4 Dismantle and Inspection of jacket/raw water pump
1 Disassembly
 Open the casing and extract the impeller and shaft
 Extract the bearing from the shaft
2 Maintenance
 Clean the disassembled parts
 Check the wear status of each part
 Apply anti-rust coating where necessary
3 Assembly
 Replace and assemble bearings and consumables
4 Centering adjustment
 Set and adjust the dial gauge to the coupling
 Adjust core run out and face deflection to within the reference value
The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 49

8.0 Thermostatic Valve

 It is direct acting present wax element type with automatic temperature regulator.
 It fitted across the cooler to regulate the temperature of fluid (water/oil) entering the engine.
 It is arrange to bypass the cooler when the fluid temperature is bellow the operating temperature
ensuring engine fluild warms up quickly.
 Maintain the correct operating temperature regardless of the variation in speed and power.
Opening temperatures:
Oil - 74°C - 77°C
Jacket water - 78⁰C
Raw water - 44⁰C

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 50
8.1 Maintenance Of Thermostat
 Apart from cleaning and testing no maintenance should be necessary.
 Operating range is present cannot be adjusted. It can be altered by using element of a different
temperature rating.
 Remove the valve element from the housing, clean ,examine and test
 Repalce ‘O’ rings and reassemble.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 51

9.0 Over speed Trip

 It is driven by the camshaft and operates to return the fuel pump to NO fuel
position thus stopping the engine.
 If engine rises to the above pre-set maximum, the micro-switch send signal to
remote panel to indicate operation of over speed trip.
 A spring loaded counter weight is keyed to the camshaft and rotate in the
centrifugal force up to rated maximum.
 It speed raises to the above the rated maximum, the centrifugal force will
overcome the resisting force of the spring so that the weight will project from
the carrier to strike the trip lever. This release the latch lever which free the
spring loaded operating piston. The piston then move rapidly across to push
out the fuel shut off lever and rotates the control shaft to the NO FUEL
position.
 When it trips, it should be reset before the engine is running.
The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 52
9.1 Maintenance Of Overspeed
 Lubricate the trip resetting lever that it works freely.
 Gradually raise the engine speed by means of a spanner applied to the lever at the end of the
governor control shaft until the over speed trip operates, this will be indicated by the shock felt
at the spanner .Check the speed at which this occurs using hand tachometer
 As soon as its trips operates, release the spanner and conform that the engine is brought to
rest.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 53

9.2 Over speed weight carrier

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 54
10.0 Maintenance Of Engine Block
 Remove attached parts on the engine block such as cylinder heads, fuel pumps, camshaft, am
rollers and etc.
 Clean engine block with degreasing agent
 Clean and remove rust deposit in the water cooling passage
 Clean and remove carbon deposited in the air chest.
 Crack test contact area on the cylinder liner bore.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 55

11.0 Bedplate
 It is made up of iron casting with integral diaphragms which support the main bearings.
 Each diaphragm is at the main bearing station and the main bearing cap are located by
registers formed on the bedplate diaphragms to which they are secured by stud bolts and nuts.
 One wide bearing is fitted at the main bearing station nearest the flywheel which also acts as
the thrust bearing. A second wide bearing is fitted towards the centre of the crankcase on vee
form engine. All the remaining bearing includes an outrigger outboard of the thrust bearing are
narrow bearing.
 A lubricating oil dipstick and filler elbow are usually supplied and fitted to the most convenient
side to suit operational requirements. Oil is taken from the gallery through ducts in the
bedplate, to provide a fee to the crankshaft, main bearing etc.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 56
11.1 Maintenance Of Bed Plate
 Remove the crankcase, bearing and crankshaft
 Clean the bedplate thoroughly with white spirit or a propriety degreasing. Inspect the mating
faces of the bedplate and the main bearing caps for bruises or other damage. Flush through
the lubricant oil passage to ensure that they are clear.
 Examine the painted internal surfaces of the bedplate and when necessary, repaint with two
coats of oil resisting enamel, brushing it well into the pores of the metal.
 Crack test on the integral diaphragms

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 57

12.0 Explosion Relief Valve

 Explosion relief valves are fitted to avoid a dangerous pressure rise and resultant damage in the
event of an explosion in the engine crankcase.
 Each valve comprises a spring loaded relief valve and an oil wetted wire gauze flame trap
mounted on the carrier fitted to the crankcase door.
 The flame trap is an assembly of multiple layers of steel wire gauze located inside the
crankcase and wetted by the oil splash and mist.
 The trap will absorb much of the heat of an explosion before passing flame.
 The relief valve is normally closed but opens at a very low
pressure in the event of a crankcase explosion.
 Escaping gasses are deflected downwards through an escape
aperture in the valve cover and the valve closes immediately
after pressure relief to prevent the entry of air into the
crankcase and possibility of a further explosion.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 58
12.1 Maintenance

MAINTENANCE
Remove each complete unit by unscrewing the centre fastening knob to
release the clamp bar and manoeuvring the bar out through the aperture.
Dismantle the assemblies and clean all parts.
Examine the gauze assembly and renew if damaged.
Renew the spindle ‘O’ ring
Check the ‘O’ ring on the valve plate ,fit a new seal if the seal is damaged.
Renew the valve spring if necessary.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 59

12.2 Maintenance Of Explosion Relief Valve

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 60
 13.0 Suction Strainers
 The lubricating oil suction strainers is fitted low in the engine bedplate and the oil is drawn
through it and its suction pipes by the engine driven pump.
 The strainer is made from perforated metals plates and is secured by four bolts and
washers and two strip washers' bracket is located on the bolts and holds a spring to
maintain a seal between the strainer and angle pipe with ‘U’ bolt, support the main pipe.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 61

13.1 Maintenance Of Suction Strainers

 The only maintenance necessary is to

ensure that the suction pipes and the
strainer are thoroughly cleaned and this
is best done at the heavy overhaul
period when the engine is dismantled.
 Clean the lubrication oil suction pipes
and strainer.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 62
14.0 Cooling Water Pipes

 Corrosion or scale formation in the water lines can result in the loss of
engine efficiency therefore cooling water should be treated to minimise
harmful effects of these element.
 These defect will make efficient cooling impossible and the result is a
general inefficiency of the engine, high fuel and lubrication oil
consumption, overheating and high engine wear.
 It is essential that the Ph value is kept between 8.5 to 9 .High degree of
acidity in the cooling system attacks ferrous metal and strong alkaline
water aluminium therefore the aim should be maintained to near neutral.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 63

14.1 Maintenance Of Cooling Water Line

 Degreasing- Oil and grease contamination of a cooling system must be removed before a water
treating agent is added.
 Degresants, and instruction for their use can be obtained from the supplier.
 Descaling- Any scale must be removed from the cooling surfaces and flushed out of the system
before water treating agent is added.
 Recommended degreasing and descaling agent from the supplier should be used to clean the
cooling system.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 64
14.2 Maintenance Of Cooling Water Pipes

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 65

15.0 Spring Drive

 It is secured to the engine crankshaft flange to transmit the drive from the crankshaft to the
spur gear in the auxiliary drive casing.
 These gears drive the jacket water pumps, lubricating pumps and fuel oil transfer pump.
 The spring drive consists of a main drive gear which has eight protruding fingers that mate
with eight slotted segments on the drive body an is secured by a circlip.
 Fitted between each pair of mated fingers and segments is a dual spring arrangements,
consisting of one spring inside another with a retainer at each end. The spring assemblies
are held in position by spring pins, two wrapper plates and two back plate.
 Sandwiched between the drive body and the crankshaft flange is an extension shaft,
distance piece and the vibration damper ,the complete assembly being held firmly together
by spring dowels, special studs, fitted bolts, washers, and self locking nuts.

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 66
15.1 Maintenance Of Spring Drive
 Remove, dismantle and inspect for damage on the spring drive

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 67

Overhaul Maintenance Pictures

Removing Of Cylinder Heads

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 68
 Overhaul Maintenance Pictures
Removing Of Pistons

Removing Of Liners

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 69

Overhaul Maintenance Pictures

Removing Of Turbo Charger and Charger Air Cooler

Removing Of Auxiliary Pumps

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 70
 Overhaul Maintenance Pictures
Remove Of Damper Cover/Spring Drive /Balancer

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 71

Overhaul Maintenance Pictures

Removing Of Engine Block

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 72
 Removal Of Bedplate

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 73

Failures For Exceeding Manufacturer Recommended Period

Leaking cooling water on the cylinder liner

Failure on the bottom shell main bearing

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 74
 Failures Occurs For Exceeding Manufacturer
Recommended Period
Crack on the bedplate diaphragm

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 75

Thank you For Your Attention

The Project for Introduction of Hybrid Power Generation System in Pacific Island Countries 76