Global Business Power Corporation
Toledo Power Co.
Barangay Daanlungsod, 6038 Toledo City, Cebu
Attn:
Welmar Geresola / Armando Tabada
Initial report on the overhauling of Clarke diesel engine
No valve seal found upon
opening, carbon slug
deposit on the rocker arm
surface area and on the
injector seating
Cylinder head
5
Pistons are damaged; some are shown seizure on the body
Piston # 5; found crack on the crown and detached portion on one side
Piston pin showed blackened due to overheating of the engine
“Cylinder Liners”
Found seizure mark on
Inside surface, stained
due to water enter on
the cylinder
Connecting rods are in good condition
No found damaged on the bearing shell and
bushing
Connecting rods bearing housing ovality are
within the standard
Crank shaft
Stain / corrosion mark shown of main journal, deep and rough surface due to water soaking for
a longer period of time
Couple water pump
Stuck bearing due to corrosion
Broken seating of mechanical seal
Brittle oil seal
O.D (Old Cylinder Liner)
Length = 228mm
F. A
P. S
a.135.15
c.128.12
a.135.10
c.128.12
b.129.13
d.125.10
B.129.12
d.125.08
O.D (New Cylinder Liner)
Length = 228mm
F. A
P. S
a.135.14
c.128.13
a.135.16
c.128.15
b.129.10
d.125.10
B.129.13
d.125.10
I.D (Old Cylinder Liner)
F. A
a.115.84
c.115.85
b.115.85
P. S
a.115.89
c.115.88
B.115.88
I.D (New Cylinder Liner)
F. A
a.115.88
c.115.89
b.115.88
P. S
a.115.88
c.115.89
B.115.88
OLD PISTON BODY
F. A
a.115.12
c.115.56
b.115.55
P. S
a.115.13
c.115.88
B.115.88
NEW PISTON BODY
F. A
a.115.19
b.115.75
c.115.77
P. S
a.115.19
B.115.75
c.115.77
OLD PISTON PIN
Length = 91mm
F. A
a.47.75
P. S
c.47.75
a.47.75
b.47.75
c.47.75
B.47.75
NEW PISTON PIN
Length = 67mm
F. A
a.47.74
P. S
c.47.74
a.47.74
b.47.74
c.47.74
B.47.74
OLD PISTON HOLE
T.B
F.47.79
P. S
A.47.79
F.47.78
A.47.78
NEW PISTON HOLE
T.B
F.47.83
P. S
A.47.83
F.47.83
A.47.83
I.D (OLD CON ROD BIG END)
a.81.10
b.81.10
c.81.10
I.D (CON ROD BUSHING SMALL END)
T.B
P.S
1.)47.07
1.)47.06
2.)47.06
2.)47.06
3.)47.06
3.)47.06
4.)47.07
4.)47.06
5.)47.82
5.)47.82
6.)47.81
6.)47.81
Note: all measurements are in millimeters (mm)
Weight Comparison between old and new piston supplied with pin
Old piston = 2.8kg
New piston = 3.2kg
Findings:
1.
2.
3.
4.
5.
Cylinder head warping surface due to over heating
Excessive wear of piston
Minimal wear at cylinder liner wall, piston rings, piston pin bushing, connecting rod bearing
Corrosion mark on crankshaft main journal numbers 2, 3 and 4
Water pump totally damaged
Service Recommendations:
1.
2.
3.
4.
Surface grinding and conduct hydro test of cylinder head
Piston replacement
Replacement of cylinder liner, piston pin, piston rings, piston pin bushing and connecting rod bearing
Under size machining of crankshaft main journal
• Crankshaft main journal under size up to 0.010”
• Crankshaft main journal bearing oversize to 0.010”
5. Replacement of water pump assembly
Prepared by:
A2Z Marine & Industrial Services Inc.