December 1999 Question 7 a.

Describe the procedure for taking crankshaft deflections, explaining all precautions that must be observed. (5) b. Explain what deflection readings actually mean and suggest the action which taken 2nd Classmust be by the should readings be outside Motor Examination Questions values recommended engine manufacturer. (5) c. Describe a safe procedure for checking wear down at a bearing. (6) a. Before taking a set of crankcase deflections observe the following precautions: Carry out a risk assessment procedure. Most companies now have this preloaded on a computer in the form of a checklist. It will include: Permission granted to immobilize engine. Starting air shut off and locked off. Open the indicator cocks. Engine cooled down sufficiently to allow LO pumps to be shut down. On large engines where it is possible to climb inside the crankcase or to put head and shoulders inside while working, it should be treated as an enclosed space, and a permit to work is required. Ensure that no-one else is working elsewhere on the engine (e.g. cleaning the scavenge space). Check that no-one is working in the vicinity of the shafting system, and that the bridge has confirmed that it is OK to turn the engine. If the deflections are being taken after working on the engine ensure that all tools and lifting gear are removed from the engine. Only the person in charge of the operation is to operate the turning gear.

Deflections are taken by placing a dial indicator or remote reading gauge into a pop marked position between the two crankwebs of a crankshaft throw. The engine is turned to just after bottom dead centre, and the gauge is zeroed. The engine is then turned, and the gauge reading taken when the engine is 90 before TDC, TDC, 90 after TDC and then lastly just before BDC. (Note: on some engines, the manufacturer may recommend turning the engine astern to take the readings). It is normal practice to turn the engine to just after the gauge position and then reverse the turning gear to negate the lifting effect of the turning gear. It is important that the crankshaft journals are sitting on the bottom bearing shells when taking the readings. This can be checked using feeler gauges. The readings are recorded on a chart as shown. Unit No (A) BDC (1) (B) Port (C) TDC 1 2 3 4