3.

(b) VIEWING PROCEDURE OF CRANK SHAFT

AIM:
To view the crankshaft and check out its dimensions.
TOOLS REQUIRED:

 Surface table

 V-blocks

 Dial indicator

 Vernier caliper

 Micrometer

Magnifying glass
PROCEDURE:
1. Check for cracks by contact current method.
2. Check for corrosion, pitting etc..
3. Check for ovality and taperness using micrometer.
4. Check external dimensions of crank pin and journals.
5. Carry out rip check before measuring internal dimensions.
6. Check for central journal errors due to ovality.
7. Check the crank web for parallelism.
8. Check crank pin for parallelism. Error allowed is 0.0016” per unit length.
9. Check if propeller shaft has a tapered end in the hub.
10. Check propeller shaft for threads and keyways for burrs and beveling.
11. Check oil seal retainer and sealing for burrs and correct seating.
12. Carry out static and dynamic hardness tests.
RECTIFICATION:
1. Score, taper and ovality can be removed by grinding.
2. Slight score and pitting can be removed by grinding or dressing with
carborundum or polishing with emery paper.
RESULT:
3.
Thus the crankshaft is viewed and its dimensions are checked with the manufacturers’
maintenance manual.
 3.(c) VIEWING PROCEDURE OF CYLINDER ASSEMBLY

AIM:
To perform the task of maintenance and inspection of cylinder assembly.

TOOLS REQUIRED:
  
DIP basket
  
Stud removing tool
  
Spark plug insert tool
  
Hand vice drill bit
 
Drift and bore gauge

PROCEDURE:

CLEANING:
Clean the cylinder head with petroleum solvent. Dip it in petroleum
agent using cleaning basket.

VISUAL INSPECTION:
1. Inspect the cylinder head visually using a magnifying glass.
2. Inspect the cylinder for
3. Loose damaged studs.(replace new ones)
4. Loose spark plug (insert new oversize ones.)
5. Loose cracked valve guide.
6. Damaged mounting ports, rocker box cover
7. Cracked or damaged fins

DIMENSIONAL CHECKS:
1. Check internal dimensions of intake and exhaust valves.
2. Check diameter and roundness of guide bore with gauge.
3. Check wear and tear in rocker arm bush.
4. Dimension checks are done in processes.
CYLINDER BARREL:

TOOLS REQUIRED:

 Cleaning basket

 Feeler gauge

 Dial gauge

Bore gauge
PROCEDURE:

CLEANING:
Clean the barrel using petroleum solvent dipping it on the cleaning basket.

VISUAL INSPECTIONS:
1. In cooling fins, check for nicks and notches.
2. In barrel, check for cracks (result in rejection)
3. In skirt, check for cracks, bends, and breaks.
4. In mounting flange, check for nicks, cracks and warping.
5. Inside the barrel inspect for corrosion and scoring.

DIMENSIONAL CHECKS:
1. Maximum clearance between piston skirt and cylinder is 0.021”
2. Maximum taper of cylinder wall in 0.018”.
3. Maximum ovality is 0.018”.

RESULT:
Thus the inspection of the cylinder assembly is carried out as per instructions given in
manufacturer’s maintenance manual.