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Complete Engine Reconditioning
Key Benefits
- All moving parts replaced
- All running tolerances kept to rigid Deutz Specifications
- Extended dynamometer run time to insure reliability right from start up
Scope of work
- Engine is completely dismantled and a failure analysis is completed as applicable
- Cleaning
- All parts are high pressure cleaned in environmentally friendly pressure washing cabinets
- All parts are mechanically cleaned to base metal
Crankcase
- Complete crankcase checked for cracks
- All machined surfaces polished and checked
- Bearing bores for ball or cylindrical bearings checked
- All threaded holes cleaned and inspected
- Cylinder seating surfaces checked and counter bored as required
- Main bearing bores checked for size, taper, out of round and alignment
- Camshaft bearings replaced and camshaft running clearances checked
- New core hole plugs installed
Crankshaft
- Checked for straightness, plugs removed, threads checked
- Checked for cracks using magnetic particle inspection
- Seal runs ground and built up using submerged arc welding
- Shaft ground to next undersize as required, seal runs ground to nominal
- Hardness checked on all seal runs and journals
- Checked for cracks using magnetic particle inspection
- Shaft pressure cleaned including all oil passages
- Shaft oiled for preservation, new plugs installed
Connecting rods
- Checked for cracks or damage
- Big end bore checked for size, taper, out of round, resize as required
- New small end bushing installed, checked for installed size
- Check rod for bend and twist
- New bolts installed
Camshaft
- Checked for straightness
- Checked for wear or pitting
Cylinder head
- Checked for cracks
- Small cosmetic cracks at pre combustion chamber ground out and welded
- Threaded holes inspected and repaired
- Studs inspected or replaced, pull tested for retention
- Valve seats and guides replaced, checked for retention
- Valve guide to valve clearance checked
- Valves ground or replaced as required
- Seating surface to cylinder machined
- Valve seats cut to nominal depth using three angle cutters
- Valve protrusion checked, head dish depth checked
- Valve springs tested to nominal
- New valve collets installed
- Vacuum tested
Gear train, Valve drive
- Gears checked for cracks, wear
- Proper gears selected for application
- Push rods inspected for straightness
- Rocker arm tips and bushings replaced as applicable
- Valve tappets inspected for wear and pitting
- Rocker shafts inspected for wear and scoring
- Rocker arm to shaft fit checked
Cooling blower
- Fan inspected for wear, damage, balance
- Stator inspected for wear, damage, bearing fit
- Stator to housing checked for alignment and shifting
Fuel system
- Injector body sealing surface lapped
- Edge filters cleaned with ultrasonics
- New nozzles installed
- Nozzle opening pressure set
- Tested for leakage, spray pattern, atomization
- Injection pump completely dismantled
- All worn or damaged parts replaced
- Calibration to manufacturers specification
Coolers
- Contaminated coolers discarded
- Pressure tested, leaking coolers discarded
Sheet metal
- Replaced or repaired with m.i.g. welding equipment
- Individually painted on all surfaces
Dynamometer
- Extended engine break in time of 6-8 hours for engines over 30 h.p.
- Valve train retorqued, valves reset
- Engine tested for power, torque curve, with computerized acquisition system
- Emissions checked with gastec tubes
- All pressures and temperatures monitored with electronic data acquisition
- Leaks checked with ultra violet light
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