Cylinder Piston Overhaul

All the engines mentioned in the table below are fitted with composite type pistons. 

Pistons

 The piston assembly must be dismantled for inspection of mating surfaces between piston skirt and piston crown and for inspection and cleaning of cooling oil spaces.

Piston crown

 Visual inspection: The combustion space must be checked for corrosion and/or burning
marks. If marks deeper than 2 mm are found the piston crown should be replaced. Deposits in the cooling oil space thicker than 0.5 mm is an indication of contaminated lubricating oil. Such extensive deposit layers can cause overheating of the piston crown.
Crack detection test: A crack detection test by use of liquid penetrant or, preferably, magnetic particle detection method should be performed, comprising all surfaces. No cracks are allowed.
 
 
 

 

Engine Oil Sump

The light, welded oil sump is attached to the engine block and is sealed off by a rubber sealing. Suction pipes to the lube oil pump and if used, for the separator, as well as for the main lube oil distributing pipe for crankshaft bearings, are incorporated in the oil sump. From the main distributing pipe the lube oil is led up to the main bearing through a hydraulic jack, by means of which the bearing cap can be lowered and lifted, e.g. when inspecting the bearings. An oil dipstick is located in the engine block. The oil dipstick indicates the maximum and minimum limits between which the oil level may vary. Keep the oil level near the max. mark and never allow the level to go below the min. mark. The limits apply to the oil level in a running engine. One side of the dipstick is graduated in centimeter. This scale can be used when checking the lubricating oil consumption.

Instrument Dryer Operational Procedure

 Operational Procedure:

1.  Make sure all valves are in proper position.

2.  Check the low refrigeration pressure gauge, it should indicate higher than 0∙4 Mpa (g)/(4∙1 Kg/cm²).

3.  If the voltage is at normal range, open electric control box and close air switch.

4.  Press the control button “ON” to start.

5.  Take note of refrigerant gauge indication at normal range. The low refrigeration pressure gauge should indicate 0∙4~0∙55 Mpa (g) / (4∙1 Kg/cm² ~ 5∙6 Kg/cm²). If pressure is below this range, take necessary steps.

6.  The high refrigeration pressure gauge should indicate 1∙4~2∙5 Mpa (g) / (14∙3 Kg/cm² ~ 25∙5 Kg/cm²). If the indication falls below this range, check and adjust fan motor high and low pressures setting value.

7.  Do not start up and shutdown frequently, Dryers should restarted after 6~10 minutes.

Instrument Air Compressor Operational Procedure

Before Starting:

1.  Make visual check of the machine, ensure that all guards secure and that nothing is obstructing the proper ventilation of, or free access to the machine.

2.  Check coolant level. Add if necessary.

3.  Make sure main discharge valve is open.

4.  Turn on electrical isolator. The power on indicator will light, indicating that line and control voltages are available.

5.  Check direction of rotation at initial start, after maintenance of the motor or following interruption in power supply.

6.  Check the auto drain out system of condense.

During Starting:

1.  Push the reset button

2.  The fault indication will extinguish

3.  Switch the ON/OFF switch to the ON position

4.  The compressor will start and then load automatically.

During Running:

1. Check all operational data are normal as per Instruction Manual

2. Check for any abnormal noise, vibration or leakage.

Stopping / Emergency:

1.  Switch the ON / OFF switch to the OFF position. The compressor will unload and stop.

2.  Press Emergency Stop button and the compressor will stop immediately.

3.  Turn off electrical isolator or disconnect.

After Stopping:

1.  Check for Auto/Manual switch in demand mode

2.  Check the drain out system for condensation.

Note: This is a consolidated operating instruction. Detail operating procedure is available at Maker’s instruction manual, kept in control room, Plant Manager’s office and Maintenance Engineer’s office room.