13

RECONDITIONING
 Introduction

• Maintenance is the management, control, execution

and quality of those activities which will ensure that
optimum levels of availability and overall
performance of plant are achieved, in order to meet
business objectives.
 Introduction

• Maintenance strategies can be characterized as

a) general purpose,

b) essential and

c) critical
 A. General Purpose

• Failure does not affect plant safety

• Not critical to plant production
• Machine has an installed spare or can operate on
demand
• These machines require low to moderate
expenditure, expertise and time to repair
• Secondary damage does not occur or is minimal
 Run-to-failure Maintenance

• This applies to non essential equipment and

machinery where shutdowns do not affect
production, materials and replacement are readily
available.
• It allows the machinery to run to failure and only
repair or replace damaged components when the
machine comes to a complete stop.
 Disadvantages

• Interrupt production
• Large inventory of spare parts
• Maintenance personnel have to work at odd time
and interrupt normal activities and tend to work
overtime.
 B. Essential Equipment
• Failure can affect plant safety
• Machine that are essential for plant operation and
where shutdown will curtail a unit operation or part of
the process
• They may or may not have an installed spare available
• Start-up is possible but may affect production process
• High power and speed might not be running
continuously
• Some machines that demand time-based maintenance
• These machines require moderate expenditure,
expertise and time to repair
 C. Critical Equipment

• If their failure can affect plant safety

• Machines that are essential for plant operation and
where a shut-down will curtail the production
process
• Machines which do not have spare parts
• These machines have high capital cost, they are
very expensive to repair or take a long time to
repair
 Preventive Maintenance

Preventive or time-based maintenance is to schedule

maintenance at predetermined time intervals,
based on running hours of machines.
• In this case replacement of damaged equipment is
carried out before problems occur.
• This allows the machine to run continuously and
where the personnel have enough skill, knowledge
and time to perform the preventive work.
 Disadvantages:
• Performing maintenance tasks either too early or too
late
• Replacement of components before the end of
residual life
• Reduced production due to unnecessary
maintenance
• Possibility of diminished performance due to
incorrect repair methods
• Possibility of good parts being disassembled and
discarded and improper fixing of replaced parts can
lead to other problems
 Condition-based Maintenance
• Condition-based or predictive maintenance periodic
monitoring involves periodic monitoring on the health
of the machine and scheduling maintenance only when a
functional failure is detected.
• This allows trends of the machine component be
constructed and time to failure be estimated.
Maintenance can be conveniently planned and allows
lead-time for organization of parts and maintenance
personnel and be scheduled.
• This leads to full utilization of the machine and possible
increase in production capacity.
 Disadvantages

• Incorrect assessment of the deterioration of

machines
• Inaccurate prediction of the lead-time
• Requires specialized equipment to monitor the
trend and highly skilled personnel.
 14.1.4 Proactive Maintenance

• Proactive or prevention maintenance involves tracing

all failures to their root cause and to ensure that
failures are not repeated.
• It utilises predictive/preventive maintenance
techniques in conjunction with root cause failure
analysis (RCFA).
• RCFA detects and identify the cause of failure and
ensures that proper installation and repair techniques
are used.
• It also identifies need for redesign of machine to
avoid future occurrence of the same problems and
improve the reliability of the machine.
 Disadvantages

• Needs highly skill personnel with a vast

knowledge of all aspects of maintenance
• May require outsourcing to private consultants
and problems with confidentiality
• Requires specialized monitoring equipment and
management support.
 13.2 Introduction to Condition Monitoring
• according to ISO, Sub-committee 9 ISO/TC/108/SC5
• Standardization of the procedures, process and
equipment requirement uniquely related to the technical
activity of condition monitoring and diagnosis of
machines .
• selected parameters associated with an operating are
periodically or continuously sensed, measured and
recorded
• for interim purpose of reducing, analyzing, comparing
and displaying the data and information so obtained
• for the ultimate purpose of using this results to support
decisions related to the operation and maintenance of the
machine.
 Condition monitoring(cont…)
• Attempts to detect symptoms of eminent failure
and approximates time of a functional failure.
• It utilizes a combination of techniques to obtain the
actual operating condition of the machines based on
collected data such as vibration analysis, oil and
wear debris analysis, ultrasound, temperature and
performance evaluation.
• The specific techniques used depend on the type
and operation of the machines.
 Examples condition monitoring techniques
• (a) Vibration monitoring – this is the most commonly used
and effective technique to detect internal defects in rotating
machinery.
• (b) Acoustic emission monitoring – this involves detection
and location of cracks in bearings, structures, pressure vessels
and pipelines.
• (c) Oil analysis – lubrication oil is analysed and the
occurrence of certain microscopic particles in it can be
connected to the condition of bearings and gears.
• (d) Particle analysis – worn machinery components, whether
in reciprocating machinery, gearboxes or hydraulic systems,
release debris. Collection and analysis of this debris provides
vital information on the deterioration of these
• components.
• (e) Ultrasonic monitoring – this is used to
measure thickness of corrosion or crack on
.
pipelines, offshore structures, pressure vessels.
• (f) Thermography – this is used to detect thermal
or mechanical defects in generators, overhead
lines, boilers, misaligned coupling and cell
damage in carbon fiber structures on aircrafts.
• (g) Performance monitoring – this is used to
determine the performance problems in
equipment. The efficiency of machines provides a
good inside on their internal conditions.
 13.3 Relevant Industrial Standards
a) ISO 18436-1 Condition monitoring and diagnostics of
machines
• This part of ISO 18436 defines the requirements for
bodies operating certification systems in no-intrusive
machine condition monitoring, diagnostics and
correction technologies
b) ISO 18436-2 Condition monitoring and diagnostics of
machines
• Vibration condition monitoring and diagnostics.
 STD (Cont…)

c) ISO 17359:2003(E) Condition monitoring and

diagnostics of machines
• It introduces the concept of directing condition
monitoring activities towards root cause failure
modes,
• It describes the generic approach to setting alarm
criteria, carrying out diagnosis and prognosis and
improving the confidence in diagnosis and
prognosis.
 STD (cont…)

d) ISO 13379:2003(E) Condition monitoring and diagnostics

of machines
• General guidelines on data interpretation and diagnostics
techniques.
• contains general procedures that can be used to determine
the condition of a machine relative to a set of baseline
parameters.
• Changes fro the baseline values and comparison to alarm
criteria are used to indicate anomalous behaviour and to
generate alarms
• procedures that identify the cause(s) of the anomalous
behavior are given
 Cont…

e) ISO 13380:2002(E)
• General guidelines on using performance parameters
• provides guidelines for condition monitoring and
diagnostics of machines using parameters such as
• temperature
• flow rates
• contamination
• power and speed
• typically associated with the performance, condition,
safety and quality criteria.
 STD (Cont…)

f) ISO 13374-1:2003(E) part-I

• Establishes general guidelines for software

specifications related to data processing,
• communication and presentation of machine
condition monitoring and diagnostics information.
THANKS
 Chapter 13 - Reconditioning engine blocks
Topics to be covered

• Line honing or boring

• Honing cylinders for overhaul
• Boring and honing oversize
• Installing sleeves
• Reconditioning connecting rods
• Preparing piston and rod assemblies
• Grinding and polishing crankshafts
• Grinding flywheels
• Overhauling oil pumps
Copyright 2003 Gary Lewis – Dave Capitolo
Reconditioning engine blocks
Line honing and boring

• Purpose
• Advantages of line boring
• Advantages of line honing
• Procedure
• Changes crankshaft centerline
Reconditioning engine blocks
Reconditioning cylinders

• Measuring wear
• Overhaul limits for taper & out of round
• Honing for overhauls
• If ring ridge remains…
 Reconditioning engine blocks
Reconditioning cylinders for oversize pistons

Boring and honing cylinders oversize

• Boring machine vs. boring bar
• Common sizes of oversize pistons
• Bore cylinders .003” to .005” under final size
• Hone to final size and surface finish
 Reconditioning engine blocks
Reconditioning cylinders for oversize pistons

Honing cylinders oversize

• Cylinder alignment stays original
• Rough hone & leave .002” to .003”
• Finish hone to size and surface finish
• Stone selection
 Reconditioning engine blocks
Surface finishes for cylinders

RMS, AA, & RA

• Range is 15 to 40 micro-inches
• Crosshatch pattern
• Chrome & cast iron rings = 25AA micro-inches
Moly rings = 15AA micro-inches
 Reconditioning engine blocks
Dry sleeves

Purpose
• Repair cracks or damage
• Restore bore to standard diameter
• Strength comparable to original
Sizes available
• 3/32”, used for standard bore
• 1/8”, used for +.030” & up
 Reconditioning engine blocks
Dry sleeves

Setting the boring bar

• Measure sleeve in 6 spots
• Average measurements
• .0005” to .001” press for each inch of bore
• 3/16” step at bottom of cylinder
 Reconditioning engine blocks
Dry sleeves

Preparation
• Lightly deburr top & bottom of cylinder
• Chamfer bottom of sleeve
• Clean sleeve
Installing sleeves
• Hammer & driver
• Chill sleeve & heat block
• Hydraulic press
 Reconditioning engine blocks
Dry sleeves

Finishing the sleeve

• Trim top with boring bar and file/surface
• Bore ID, and leave .003” to .005” to hone
 Reconditioning engine blocks
Piston rings

Stresses on rings
• Do pistons ever stop while the engine is running?
• Long stroke & high RPM
• High compression
 Reconditioning engine blocks
Piston rings

Oil control rings

• Wipe excess oil from cylinder walls
• Excess oil is returned through rings & pistons
• Rails conform to shape of cylinder
• Expanders are required for thin rails
 Reconditioning engine blocks
Piston rings

Compression rings
• Top 2 grooves
• 5/64” & 1.5mm are standard sizes
• 1/16” rings for performance
• .040” rings with “gas ported pistons”
• 2nd ring is oil scraper
• Top ring must seal to protect other rings from gas
 Reconditioning engine blocks
Piston rings

Ring material & coating

• Compression rings are iron or ductile iron
• Oil control rails are chrome plated steel
• Iron oxide used to resist scuffing on iron rings
• Molybdenum used to improve scuff resistance
• Chromium plating for resistance to embedding
 Reconditioning engine blocks
Piston rings

More ring materials

• Carbon steel
• Stainless steel
• Tool steel
More coatings
• Chromium Nitride, Titanium Nitride
• Diamondlike Carbon
 Reconditioning engine blocks
Piston rings

Ring assembly
• Oil control expander lined up with center of pin
• Oil control rails 2” either side
• Bottom compression ring lined up at end of pin
• Top ring lined up at opposite end of pin
• Watch for overlapping expanders
• Watch for proper end gap offset
 Reconditioning engine blocks
Connecting Rods

Pin fit for press-fit piston pins

• Can be checked by feel
• .001” press fit in rod
• .0005” clearance in piston pin bores
• Replace pistons, pins, or oversize pins if needed
 Reconditioning engine blocks
Connecting Rods

Pin fit for full-floating piston pins

• Can be disassembled and gauged
• .0004” clearance in rod bores
• .0002” clearance in piston pin bores
 Reconditioning engine blocks
Connecting Rods

Measuring pin fits

• Two pins used to set gauge
• Measure rod bore
• Measure piston pin bore
 Reconditioning engine blocks
Connecting Rods

Replacing bushings
• Bushings are pressed into small end of rod
• Line up oil hole/drill if not present
• Expand bushing into bore and face off excess bushing
 Reconditioning engine blocks
Connecting Rods

Replacing bushings
• Rough hone to within .002” of finished size
• Finish hone to size with finishing stones
 Reconditioning engine blocks
Connecting Rods

Sizing with a boring machine

• Corrects for bend and twist
• Center-to-center can be equalized
 Reconditioning engine blocks
Connecting Rods

Resizing housing bores

• To restore bearing crush
• To restore proper oil clearance
 Reconditioning engine blocks
Connecting Rods

Resizing housing bores

• Stretched housing bores are common
• Should be resized to within .0003” roundness
 Reconditioning engine blocks
Connecting Rods

Procedure for resizing rods

• Remove rod bolts
• Grind .002” from both cap and rod, or until clean
• Keep grinding equal for each set of rods
 Reconditioning engine blocks
Connecting Rods

Preparation for resizing rods

• Clean and reassemble – May need new hardware
• Torque to specs
• Set gauge to specs
• Hone to size
 Reconditioning engine blocks
Connecting Rods

Honing housing bores

• With power-stroking attachment
Set RPM and stroke rate
• RPM, stroke rate, &
overstroke help stone life
 Reconditioning engine blocks
Connecting Rods

Honing housing bores

• Without attachment, hone two rods at a time
• Reverse position of rods for quality
 Reconditioning engine blocks
Connecting Rods

Honing housing bores with diamond tools

• Minimal abrasive wear
• Better size control
• Methods similar to abrasive
stones
 Reconditioning engine blocks
Connecting Rods
Center-to-center distances
• Keep length within .003”
• Shortest rod becomes standard
• Recut rod caps that are > .003” longer
• Excessive honing may damage bearing grooves
 Reconditioning engine blocks
Connecting Rods
More reconditioning

• Deburr sides of rods with file

• Rechamfering may be required
 Reconditioning engine blocks
Connecting Rods
Assembling piston & rod assemblies
• Check position of pistons & rods in the engine
 Reconditioning engine blocks
Connecting Rods
Assembling full floating assemblies

• Clean, oil, and assemble

• Inspect/replace locks
 Reconditioning engine blocks
Connecting Rods
Assembling oscillating assemblies
• Assemble with press in one direction or . . .
• Use rod heater -
Heat small end to 425°F
Center pin into piston & rod
 Reconditioning engine blocks
Connecting Rods
Checking rod alignment

• Bend and twist

 Reconditioning engine blocks
Connecting Rods
Correcting press-fit assemblies

• Assemble piston & rod first

• Check & correct bend first
 Reconditioning engine blocks
Connecting Rods
Correcting press-fit assemblies

• Turn piston to one side

• Check & correct twist
 Reconditioning engine blocks
Connecting Rods
Correcting full floating assemblies

• Check bend, then twist using piston pin

 Reconditioning engine blocks
Connecting Rods
Checking rod offset

• Measure difference between each side of rod

and face of aligner
Reconditioning engine blocks
Flywheels
• Used on standard transmission
• Used with clutch assembly to couple & uncouple
engine and transmission
 Reconditioning engine blocks
Flywheels
Resurfacing
• To restore flatness
• To remove heat checking
• To restore parallelism
 Reconditioning engine blocks
Flywheels
Set up
• Magna-flux back of flywheel
• Parallelism should be less than .005” TIR
 Reconditioning engine blocks
Flywheels
Set up
• Remove dowel pins as needed
• Deburr & index on crankshaft surface
• Grind & spark out for flatness
 Reconditioning engine blocks
Crankshaft fitting
Housing bores
• Diameters within tolerance
• Round within .0003”
Bearings
• Specified thickness
• Installed to specified clearance
Crankshaft
• Diameters within tolerance
• Round within .0005”
• Straight within ½ of oil clearance
• Surface finish 10Ra or better
 Reconditioning engine blocks
Crankshafts
Inspection
• Clean
• Check for cracks (wet mag)
• Size & out of round
• Straightness
 Reconditioning engine blocks
Crankshafts
If ground while bent, crankshafts . . .
• Become out of balance
• Cause stroke length differences
• Cause alignment problems
 Reconditioning engine blocks
Crankshafts
Welding crankshafts
• To keep undersize to a minimum
• Gas shield method
Welding is covered by Argon or CO2
• Submerged arc method
Welding is covered by flux powder
 Reconditioning engine blocks
Crankshafts
Welding crankshafts
• Journals are built up
• Then ground to size
 Reconditioning engine blocks
Crankshafts
If fillets were welded
• Crank is straightened after welding
• Roughed to within .030”
• Re-straightened
• Finish grind, and then grind mains last
 Reconditioning engine blocks
Crankshafts
Stress relieving after welding several journals
• Heated to 900°F – 1100°F
• Soak for a few hours
• Shot blast after to remove scaling
 Reconditioning engine blocks
Crankshaft hardening
Nitriding
• Heat treatment for crankshaft hardness
• Salt bath (Tuff-Triding) or gas atmosphere
• Nitriding causes journal diameters to grow
 Reconditioning engine blocks
Crankshaft hardening
Chrome plating
• Journals are ground .006” undersize
• Plate with hard chrome
• Dry at 350°F & slowly grind to size
 Reconditioning engine blocks
Crankshaft grinding
Common undersizes
• .010”, .020”, & .030” for domestic crankshafts
• .25mm, .50mm, & .75mm for import crankshafts
 Reconditioning engine blocks
Crankshaft grinding
Crankshaft must be within limits of . . .
• Taper, roundness, size, fillet radius, stroke length, &
surface finish
 Reconditioning engine blocks
Crankshaft grinding
Set up
• In chucks or between centers
 Reconditioning engine blocks
Crankshaft grinding
Set up
• Grinding wheel is dressed with specified radius
 Reconditioning engine blocks
Crankshaft grinding
Set up
• Crankshaft is offset to ½ the stroke length
• Other journals are indexed
• Mains are ground on center of rotation
• Positioning is done from seal surface &
gear/sprocket surface
 Reconditioning engine blocks
Oil pumps
Overhauling
• End clearance limit is .003” for both pumps
• Sand pump body to reduce clearance
• Gear teeth to body clearance limit is .005”
• Scrap gear type pumps if scored
 Reconditioning engine blocks
Oil pumps
Overhauling
• Clearance limit between rotors is .014”
• Clearance limit for outer rotor to body is .010”