ICEs OVERHAUL

1. INTRODUCTION
Overhaul consist on restoring every component and system of an equipment
so its functionality is recovered optimally. Normally some components must be
replaced and others just required to be fixed or just cleaned, but it depends on
their actual condition checked when disassembling the equipment.

In this document, the general considerations for executing an overhaul of an

ICE are exposed.

2. GOALS

After reading this document, the reader should be able to:

• Understand the importance of scheduled maintenance for the combustion
engine reliability.
• Learn the basic maintenance task procedures of a general ICE scheduled
maintenance

3. PRERREQUISITOS

4. CONTENTS

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 1. PLANNING AN OVERHAUL
1.1. Responsibilities.
Statement of the required staff for all the procedure and their own tasks and
responsibilities.
- Supervisor: Person in charge of required planning, performing and tools
supply. Asses the involved risks. Counseling on lifting plans. Look after staff
security and integrity.
- Massy Energy HSE: Check the planning and accomplishment of: risk
assessment, lifting planning, etc. Avoid or minimize accidents and
environmental impact. etc.
- Mechanical technician 1A: person in charge of the field work accomplishment.
Organizes the else working staff to carry out a safe dismantling. Responsible
for order and cleanliness. Make records and fill out required forms.
- Operator: Submit the engine ready to start the overhaul procedure. Performs
and endorses the required isolations.
- AA (Area Authority): Approves working permissions.
- Technicians (Mechanical, electrical, instrumentation): Perform the overhaul
procedures following the established overhaul plan and 1A technician
guidelines.
- EA (Executing authority): Carry out the handwork.

1.2. Tools statement.

The required machinery, tools, supplies and protection equipment are declared.
• Tools and machinery
• Spare parts and consumable sources.
• Personal Protective Equipment. (PPE).
• REPORTES DE MANTENIMIENTOS PREVIOS REPORTES CVM

1.3. Safety and health cautions.

Identify risks related to: ergonomics, physical, mechanical, chemical, biologic,
electrical, locations, social etc. Found risks must be referred into the corresponding
working permissions.
Working permissions must be discussed by performer staff before start in order
to make known the risks and controls and avoid accidents.

ASP. Fichas de seguridad de equipos. Carpeta para HSI

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 2. OVERHAUL PROCEDURE
Waukesha L7042GU (F3521) Engine overhaul procedure

2.1. Out of service

- Withdraw from operation the engine.
- Test hydraulic jacks, bridge cranes and other lifting tools and machinery.
2.2. Disassemble.
- Close manual control valves: gas suply, air suply, coolant suply
- Set all switches to OFF: engine start, emergency stop,
- Place warning signs in the control panel: OUT OF SERVICE. DON’T
OPERATE
- Disconnect starter.
- Remove intake ducts
- Drain oil from pan, oil cooler and oil filters.
- Remove oil filter
- Drain oil from strainers
- Drain coolant from system
2.2.1. Remove electrical wiring and control instruments.
- Disconnect cylinder and head thermocouples
- Remove exhaust thermocouples
- Disconnect primary harness. (coils)
- Remove coils and high-tension wires.
- Remove detonation sensor harness, and detonation sensors.
- Remove oxygen sensors and their harness.
- Remove water temp thermocouple and oil temp thermocouple
- Remove speed pick-up harness.
- Remove over speed control harness.
- Remove over speed pick-up
- Remove TB6 box input wiring.
- Remove temperature control breakers
- Remove Murphy coolant level indicator (switch)
2.2.2. Remove filter and exhaust piping
2.2.3. Dismount cylinder heads.
- Remove exhaust ducts clamps.
- Remove exhaust ducts
- Remove flex sleeves
- Remove exhaust Y.
- Remove thermostats
- Remove block-to-radiator pipe.
- Remove coolant manifold
- Remove head-to-exhaust coolant elbows.

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 - Remove exhaust manifold
- Remove cylinder heads oil piping.
- Remove rocker arm caps.
- Remove spark plugs
- Remove rockers
- Remove pushrods.
- Remove gas pressure regulator.
- Remove throttle control linkage.
- Remove manual-stop lever linkage
- Remove carburetor.
- Remove intake manifolds
- Remove cylinder heads screws.
- Remove cylinder heads. Use a separation bar to separate gasket from head.
Use the bridge crane
2.2.4. Remove pulley covers from engine and fan.
- Remove rex coupling
- Remove fan belts, main and auxiliary coolant pumps.
- Remove starter
2.2.5. Remove air cleaners case.
- Remove oil pan inspection lids.
2.2.6. Uncouple compressor, pump and generator.
- Remove covers.
- Remove coupling
2.2.7. Remove flywheel coupling plate
Dismount flywheel

- Loosen fastener bolts.

- Fasten a lifting montage.
- Remove two fasteners (9 and 3 clock spots)
- Introduce two pins about 6 inches’ length and the same bolts diameter into the
removed bolts positions.
- Remove the other fasteners.
- With a lifting machine, remove the flywheel from crankcase. Flywheel weights
about 480 kg. Adequate fastening stuff and lifting machine must be used.
- Remove the flywheel pins
Remove back sheet

- Loosen fastener bolts.

- Loosen and remove retainer
- Fasten to a lifting montage. Back sheet weights about 80 kg. Adequate
fastening stuff and lifting machine must be used.

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 - With a detachment rod remove seal between gear case and back sheet.
- Remove the case back sheet with adequate fastening and lifting equipment.
- Remove the gears
- Remove conical gear bolt and washer.
- Remove gears and shafts from case
- Remove shafts and gear back washer.
- Mark gear pairs as reference to assemble.
Remove camshaft case

- Remove pushrods
- Remove the bolts from the case ends.
Clean up all the components

Electrical works.

- Check the ground connections. Look for poor condition wires and isolations.
- Check coils and high tension wires.
Dismantled-engine Inspections and checks.

Instruments work.

An instruments technician is required to check: ignition system, heads and block

thermocouples, transistors, control panel wiring, protection elements; to clean:
micros, connections; To calibrate: every instrument that needs.

Connecting rod bushings inspection.

- Visual inspection to bushings and crankshaft.

- Replace bushings.
- Record metrology data and generate reports.
- Tighten fasteners to 190 ft.lb torque in two steps, first to 100 ft.lb and second
to 190 ft.lb
Crankcase bushings inspection

- Remove oil strainer

- Release crankcase cover lateral fasteners.
- Remove cover with proper lifting equipment. Cover weights about 21 kg.
- Visual inspection to bushings and crankshaft. Replace bushings if necessary.
- Record metrology data and generate reports.
- Install top bushing. Add clean oil.
- Install the cover tightening fasteners to 250 lb.ft in three steps.

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 Crankshaft Deflection test

A deflection gauge is used.

Thermostats inspection and cleanup

- Clean thermostats.
- Check valve position to be totally closed. If defective, must be replaced.
- Test the thermostat introducing it into a water container and warming the water.
Thermostat must open progressively and be totally open at specified
temperature.
Oil pan cleanup.

Pumps drivetrain

- Replace or repair coolant pump

- Replace or repair auxiliary coolant pump
- Replace or repair oil pump
Cylinder heads

- Cylinder heads replacement (Lifetime end)

Intake system

- Turbochargers replacement (Lifetime end)

Driving set

- Replace pistons
- Replace cylinders
- Replace piston rings
- Connecting rods metrology
- Replace connecting rod bushings
Rockers

- Replace rocker hubs

- Replace pushrods
- Replace valve adjustment screws
Camshaft

- Check camshaft stumps condition

- Camcase (cylinder head) metrology
- Replace valve followers

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 Crankshaft

- Metrology
- Replace rod bushings, crankcase bushings and main caps.
- Asses crankshaft stumps condition
- Crankshaft metrology
- Crankshaft machining (polishing)
- Crankcase metrology
- Asses cylinder-block clearances.
- Block machining if necessary
- Gaskets kit replacement
Cooling system

- Radiator assesment
- Oil cooler assement
- Replace belts
- Replace short shaft and bearings of fan
- Measure fan blades angle.
- Chech pulleys and tensioner
Control panel.

- Check PLC software and hardware

- Check instruments and manifolds.
- Check instruments connections.
- Test electric protections.
Auxiliary systems

- Starting system repair

- Regulators repair
- Carburetors repair
- Solenoids repair
- Governor repair
Manufacturer mandates

- Head screws torque check

- Connecting rods bolts torque check
- Crankshaft deflection measurement
- Crankshaft axial clearance assessment

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 2.3. Engine Assembly

2.3.1. Alignments.
- Engine-generator alignment.
2.3.2. Engine start tests

3. RECORDS AND DOCUMENTS

Service bulletins

- Manufacturer references and serials data of the components.

- List of components and their condition before overhaul
- Test and metrology results
- Photo book and condition report.
- Corrective actions taken and recommendations
Crankcase lower bore restoration

crankcase lower bore cylinder sleeve sealing areas are subject to deterioration if
cooling system maintenance is neglected.

- Restoration sleeve machining: Restoration sleeve should be machined to a

length of 1.75 in.
- Lower crankcase bore machining: interference with restored sleeve: 0.006-
0.008 in.
Mahchined surfaces of the restoration sleeve ant the machined surface of the
crankcase lower bore must be clean and dry before installation of the
restoration sleeve

Retorquing crankshaft endplate and front pulley capscrews

crankshaft endplate screws and front pulley capscrews must be retorqued annually.
Loose crankshaft endplate or damper capscrews may prevent the vibration damper
from absorving the torsional vibrations. It may lead to crankshaft failure.

Gear backlash measurement if backlash on a new gear is not within specification,

recheck part reference. Using tight (bound) or excessively worn gears can lead to
severe engine damage

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 Important Tests for Major Overhauling of Ship’s Generator

Following a step-by-step procedure backed by systematic planning is the base of a

successful generator overhauling procedure.

Test hydraulic jacks: In order to ensure a smooth overhaul process, proper testing
of hydraulic jacks and pumps is done before using them for the overhauling procedure.

Cylinder head test: The cylinder heads are overhauled and reused. Hence it is
important to test the heads for any leakage by means of pressure testing. Pressure
testing of the engine cylinder head is done by means of water and air.

Bearing cap test: The serration provided in the bearing housing holds the two caps
against each other along with the con-rod bolts. Hence any damage to bolts will also
result in damage to the bearing cap. The bearing caps serrations are checked for
cracks by using Die Penetrant test kit.

Connecting Rod bolts test: The bottom cap holds the con-rod bearing by means of
bottom end bolts which are subjected to reversal stresses. Crack test of Con-rod bolts
is also to be done during every overhauling by using die penetrant test kit.

Connecting Rod Bend Test: The connecting rod is subjected to extreme pressures.
When overhauling the engine, the con-rod is checked for straightness by inserting
brass rod in the oil hole of the con-rod having slightly less diameter than the oil bore.
If the con-rod is slightly bent (which cannot be seen with naked eye), the brass rod
will not pass through the bore.

Starting air valve testing: Like fuel injectors, air starting valves are also overhauled
and reused. Hence to check the proper operation of the same, all starting air valves
are tested by using service air for any leakage before installing into the cylinder head.

Relief valve test: The relief valve of the cylinder head is pressure tested to check
proper functioning. It is an important part which prevents explosion of the head or
damage to the combustion chamber because of overpressure. Pressure testing is

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 carried out on a bench mounted test rig consisting of a high-pressure air, pressure
control valve, and calibrated gauges. The relief valve is bolted to the accumulator
flange and the air pressure is increased until the valve lifts. Settings are done
accordingly.

The current test: This is an important test which is done before trying out the
generator with fuel after the completion of d’carb procedure. Once the d’carb is
finished, the turning gear is engaged and with indicator cock open, the engine is
turned. The current is continuously monitored. Any fluctuation or increase in the
current value indicates obstruction or some problem in the rotating shaft.

Alarm and Trips test: The alarm and trips of the generator are electrical system with
wiring and contacts. To check their correct operation, testing of all the alarms and trips
of the prime mover including lube oil trip, cooling water high temperature trip, over
speed trip etc. is done.

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 5. REFERENCES

1. Moran, Michael J., y otros. Fundamental of Engineering Thermodynamics. s.l. : Wiley, 2014.

2. Stone, Richard. Introduction To Internal Combustion Engines. 2nd. s.l. : MACMILLAN, 1992.

3. Heywood, John B. Internal Combustion Engine Fundamental. s.l. : McGraw-Hill, 1988.

4. Pulkrabek, Willard W. Engineering Fundamentals of The Internal Combustion Engine. s.l. :

Prentice Hall, 2003.

5. Waukesha-Dresser. Tecnología de Motores a Gas - COMBUSTION. 1997.

6. Waukesha - Dresser . Tecnología de Motres a Gas - SISTEMA DE COMBUSTIBLE . 1997.

Rev. Fecha Motivo de Preparado Revisado Aprobado Cliente

su emisión
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