Cy - Head 2stroke

‫‪CYLINDER HEAD OVERHAUL‬‬
‫( ‪) TOW STROKE ENGINE‬‬
‫أعداد الطالب ‪ -:‬غازي علي فيصل الجبر‬

‫عباس مؤيد محمد‬
‫حسين أكرم لفته‬
SAFETY PRECAUTIONS
• Stopped engine.
• Shut off starting air supply At starting air
receiver.
• Block the main starting valve.
• Shut off starting air distributor/distributing
system supply.
• Shut off safety air supply Not ME-engines.
• Shut off control air supply.
SAFETY PRECAUTIONS
• Shut off air supply to exhaust valve - Only with

stopped lubriating oil pumps.
• Engage turning gear.
• Shut off cooling water.
• Shut off fuel oil.
• Stop lubricating oil supply.
• Lock the turbocharger rotors.
CYLINDER COVER
DISMANTLING
• Close fuel oil inlet valve.
• Close cooling water inlet valve.
• Close cooling water outlet valve.
• Open cooling water drain cocks.
• Shut off the air supply for the pneumatic exhaust valve
spring
and vent the system.
• Dismount the hydraulic high-pressure pipe to the exhaust
Valve.
CYLINDER COVER
DISMANTLING
• Remove the cooling water outlet pipe from the exhaust valve.
• Dismount the drain oil pipe between the exhaust valve and
the hydraulic actuator, and the air pipe for the pneumatic
exhaust valve spring.
• Remove the outlet oil pipe from the exh.valve.
• Remove the starting air pipe (30bar)
• Remove the starting air pipe (7bar).
• Remove the expansion joint (belows) between exh.valve &exh.
Manifold.
CYLINDER COVER
DISMANTLING
• Remove The high pressure pipe of fuel between the inj.p/p
and the injector .( 2 or 3 pipe depending on type of engine).
• Remove the protective caps from the cylinder cover nuts.
• Loosen the Nuts (8 nut or 6 nut) by the hydraulic jack at
Pressure (2000_ 1500bar).After complete release the pressure
And remove the conections of hydraulic jackLoosen and
remove The nuts.
CYLINDER COVER
DISMANTLING
• Hook the engine room crane on to the lifting attachment on
top of the exhaust valve. Lift away the cylinder cover complete.
• If the cylinder cover is to be overhauled it is recommended
instead to land the cylinder cover on a couple of wooden
planks.
CYLINDER COVER
DISMANTLING
• Remove and discard the sealing ring between cylinder cover

and cylinder liner.
WORK TO BE DONE ON
CY.COVER
• Cylinder cover in tow stroke engine including 3 parts:

-Cooling jacket.
- Cylinder head.
-Exhaust valve.
• Put the cylinder head in horizontal position to cleaning the
cooling jacket because it’s a part from the combustion
chambers and after cleaning replay the cylinder cover to the
vertical position.
CY.COVER PARTS
DISMANTLING
• Injector
remove the pipe that come from circulating pump(8_ 7bar)
that the fuel continuously passed in it to prevent blockage
occurred and remove the injector and injector stud.
CY.COVER PARTS
DISMANTLING
• Exhaust valve :
• Remove the protective caps from the exh.valve nuts.
• In same way when we remove nuts in cy.cover we apply it
to remove the nuts of exh.valve.
• Lifting the exhaust valve.
CY.COVER PARTS
DISMANTLING
• Remove the indicator cocks.
• Remove the air starting valve and it’s studs.
• Put I bolt in the cy.cover to lifting it and separate from
Cooling jacket.
• Loosen the screw bolts that tight the cy.cover with
cooling Jacket and start lifting the cy.cover.
• Lift the cylinder cover free of the cooling jacket and land it on
a couple of planks.
WORK TO BE DONE ON
CY.COVER
• Remove and discard the O-rings from the cover, and carefully
clean the cooling jacket and the cylinder cover.
• Provide the cylinder cover with newO-rings, well lubricated
with vaseline.
• Lift the cylinder cover and guide the jacket/ cover into
position, using the guide pin as reference (manoeuvre side).
• Mount and tighten the screws for the cooling jacket.
WORK TO BE DONE ON
CY.COVER
• Grinding of Bores :
A_Fuel valve bore
The tool consists of a common spindle with handle, and of a
guide, a carbon cutter, a seating face cutter, and a grinding
mandrel.
Clean the fuel valve bores, using the carbon cutter. If required ,
recondition the fuel valve seating with the appropriate
cutter.
• Grind the seating with the grinding mandrel and a grinding
compound (e.g.Carbo-rundum No. 200).
After the milling/grinding, clean the bore and seating carefully,
and check that the seating is not damaged.
B_EXHAUST VALVE BORE
• The tool consists of a spindle with handle and a grinding

disC.
• AFTER cleaning the valve bore and seating, grind the seating
with the grinding disc and a grinding compound
(e.g. CarborundumNo. 200).
• After the grinding, clean the bore and seating carefully, and
check that the seating is not damaged.
C_STARTING VALVE BORE
• The tool consists of a guide, a cutter, and a grinding

disc.
• Recondition the starting valve bore and seating in the same
way as described for the fuel valve bore.
• When replacing valves on a cylinder cover that is mounted on
the engine, recondition the valve bores/seating in the same
way as described here, but without dismounting the studsS.
WORK TO BE DONE ON
CY.COVER
• Clean the bores for safety valve/indicator cock.
MOUNTING OF CYLINDER
COVER PARTS
• Lubricate the threads with 'Never Seize’ or Molybdenum

Disulphide (Mos2) and Put the exhaust valve in it’s postion.
• Tighten the nuts of exh.valve , before the tight we put
molybdenum disulphide to the thread.( The way of the tight
similar to the way of the loose we also use hydraulic jack and
raise the pressure then we tight the nuts.(
• Put the cap of the nuts on it.
COVER PARTS
• Lubricat the stud of the air start valve with molybdenum and
mount the air Start valve in it’s postion the tight the nuts with
tourq spanner(Force of the tight depend on manual. (
• Lubricate the studs of the injector and the outer casing with
molybdenum and put it in it postion and tight the nuts with
Tourq spanner.
COVER PARTS
• Mount the indicator cock with it gasket.
• Mount the cooling water pipe.
• Place a new sealing ring on top of the cylinder liner.
COVER PARTS
• Put the cylinder head in it position and take attention to two

Things first the connection pipe of cooling water that passed
The water from linear to cy.head and the second is drain pipe
Of exh.valve (maybe need to replace the O ring ).
• Lubricate the thread of the cylinder head before tight the
Nuts .(the way of the tight similar to the way of the loose)
COVER PARTS
• Check with a 0.05mm feeler gauge that there is no clearance
between bottom of cyl. cover stud nut and top surface of
cyl. cover.
• Put the protective caps on the nuts.
COVER PARTS
• Mount the connect drain exhaust valve.

• Mount the starting air pipe and control air pipe for the
starting valve.
• Mount the intermediate pipe between the exhaust valve
• And exhaust manifold.
• Mount the cooling water outlet.
• Mount the return oil pipe and the air pipe for pneumatic
closing of the exhaust valve.
COVER PARTS
• Mount the exhaust high pressure pipe.

• Mount high pressure pipe of fuel.
THANKA YOU FOR
READING

Cy - Head 2stroke

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‫‪CYLINDER HEAD OVERHAUL‬‬

‫( ‪) TOW STROKE ENGINE‬‬

‫أعداد الطالب ‪ -:‬غازي علي فيصل الجبر‬

• Shut off air supply to exhaust valve - Only with

• Remove and discard the sealing ring between cylinder cover

• Cylinder cover in tow stroke engine including 3 parts:

• The tool consists of a spindle with handle and a grinding

• The tool consists of a guide, a cutter, and a grinding

• Lubricate the threads with 'Never Seize’ or Molybdenum

• Put the cylinder head in it position and take attention to two

• Mount the connect drain exhaust valve.

• Mount the exhaust high pressure pipe.

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