Welcome to the P C Industries blog. We strive to be the best
there is in the diesel engine and parts industry. We go beyond industry standards
to ensure customer satisfaction and to produce quality products that last. We
understand that it’s the little things that matter and we have the experience
and commitment to be attentive to the details to get the job done right.
Our Goal in making this
blog is to share our passion for giving the best service to our customers in the
diesel engine industry.
In this first post we will be highlighting some of the processes and testing our
engines must go through and pass before they are shipped to our customers. For
a complete reference for the engine and component remanufacturing process you
can follow this link go to PDF.
Disassembly
The first stage the engine goes through is
the disassemble phase where the engine is disassembled down to the last nut and
bolt. Core plugs are removed from the crank shaft and cylinder block to ensure
thorough cleaning. All parts are inspected during the disassembly process to
look for any failures so special care can be taken in the repair of those
areas.
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| An engine block being magnafluxed |
Crankshafts are magnafluxed to test for cracks. They
are then checked for straightness and then main and rod journals are measured
with micrometers. Next they are demagnetized and polished to a fine finish and
then measured again. If required, crankshafts are ground to OEM undersize
specifications.
Camshafts are magnafluxed to test for cracks. The
main journals are measured with micrometers to ensure OEM specs. Once journals
are verified to be within OEM guidelines the camshaft lobes are ground to OEM
specifications.
Cylinder Heads are completely disassembled and then
magnafluxed to check for cracks. All bolt and threaded plug holes are inspected
and repaired as needed. The head is measured for proper thickness and recorded.
Cam follower/lifter bores are inspected and
measured. Cylinder heads are resurfaced
and measured again and recorded. Cross/bridge guides are inspected and measured
for proper diameter. Heads receive new copper
Injector tubes or a new/requalified
prechamber with new gaskets/o-rings. The heads are then pressured checked at
35psi to check for leaks. Valves are inspected for wear or fatigue and then the
valve stem diameter is measured with a micrometer. Valve and stem faces are then
ground to a fine finish. Valve head thickness is measured to meet or exceed
manufactures guidelines. New valve guides are installed and reamed to specs and
then valve seats are machined using a three angle relief system. Valves are then
installed and are inspected and measured for proper seat location and recession
or protrusion. Valves are then vacuumed tested to verify seating. Valve springs,
push rods, rocker arms are inspected and measured to ensure OEM specs, any parts
that do not meet qualification are discarded and new or remanufactured parts are
installed. Valve bridges are inspected and remanufactured. Final assembly is
preformed and the cylinder head is stamped with a serial
number.
Water pumps are completely disassembled and
inspected for cracks and wear. Main drive shafts are replaced with new as
recommended by OEM or as needed. New seals, bearings, impellers or impeller
seals are installed as the water pump is
reassembled.
Fuel pumps are disassembled and inspected for
cracks and wear. All seals and gaskets are replaced with new. Drive, driven
shafts and gears are replaced as necessary. Fuel Pumps are bench tested for
proper fuel pressure and to check for leaks.
Oil pumps are disassembled cleaned and flushed.
They are inspected for cracks and for wear. Rotor types are replaced with a new
rotor assembly. Gear types are inspected for wear and are replaced as necessary.
All shafts and bushings are measured to ensure proper specs. Parts that do not
meet OEM specs are replaced. When reassembled it is inspected and then approved.
Blowers are completely disassembled and washed and cleaned of
grease, oil and grime. Housings, end plates, rotors and gears are then carefully
inspected for defects, wear and fatigue. All components are refinished, then new
bearings, seals and sleeves are installed. Once reassembled it is inspected
tested and stamped with a serial number.
Injectors, blower drive supports, regulator and
relief valves, etc. are all remanufactured using OEM guidelines. Careful
consideration is given to ensure a high quality remanufactured
item.
New
Components
Engines are assembled always using all the
following new components: overhaul gasket set, rod bearings, main bearings, camshaft intermediate bearings, thrust bearings/washers, idler gear bearings/bushings, front and rear crankshaft seals and sleeves, camshaft seals and sleeves, liners, pistons, rings, liner seal rings, fuel jumper lines and valve cover gaskets. The sub-assemblies which are installed on the engine, listed previously above, are
always remanufactured.
Final Engine
Assembly
Final engine assembly is performed by top
qualified engine technicians, with each bolt being torqued using a calibrated
torque wrench. All critical procedures are inspected by a
QC Inspector and recorded on an engine
build sheet. All critical bolts and assemblies inside of the engine are torqued
and marked with a colored marker one-at-a-time. This procedure ensures that no
mistakes are made, which could cause critical failure. Upon completion of engine
assembly the fuel system and the cooling system is pressure tested to eliminate
any leaks or problems. The engine is then pre-lubed to avoid a dry
startup.
The Dyno
Test
All engines are then
dynamometer tested by top qualified engine technicians under the following
procedure: Engine is warmed up for 15 minutes while setting all speeds, checking
fuel and oil pressure, water temperature and checking for external fuel, water
and oil leaks. Any problems found are repaired at this time. Engine is then run
for 30 minutes under a full load while monitoring all pressures, temperatures,
horsepower and torque. Afterwards, a hot tune-up and inspection is performed.
The engine is run again for a full hour without interruption. All critical
information is observed and recorded on an engine dynamometer test
report.
The Final
Touch
Engines are then drained of all fluids,
steam cleaned, taped, rust proofed and painted. Extreme care is taken when
packaging the engine for shipment so that the engine stays safe and clean during
transportation to the customer.
