SMART DMU Engine Replacement Procedure

for Crankshaft Replacement

DPM/Engine Replacement

Due to the engine crankshaft issue, all of engines need to be replaced to the engine which uses updated crankshaft in SMART. When engine/transmission set is uninstalled from the carbody, carbody need to be lifted by carjacks and need the caster Jig and engine Jig. Therefore this document shows how to lift the carbody and swing the engine.

DPM Jig & Caster Jig Picture

Caster jig DPM jig

Engine jig

DPM sit on DPM jig

Caster Jig & Engine Jig Picture

Caster jig

Engine jig

Engine/transmission sit on Engine jig/caster jig

Engine Exchange Procedure

Procedure of Engine & Transmission Installation/Uninstallaion

(1) Move car to pit. Drain engine coolant. Disconnect cardan shaft, auxiliary coupling, Engine & transmission connectors, battery cable and coolant hoses.

DPM

Cardan Shaft Auxiliary Shaft

DPM a

Caster Jig (2) Move car to flat place. Place engine jig on Caster jig, and set those aside the car

Top View

Side View

Engine Jig

Car

Transmission

Engine

Caster Jig (blue)

Engine Jig (orange)

Procedure of Engine & Transmission Installation/Uninstallaion

DPM a

(3) Use carjacks to lift the car, and slide the jigs into underneath the engine. Lower the car until contacting the engine jig to engine bracket. Uninstall the engine and transmission.

Engine

Caster Jig (blue)

Engine Jig (orange)

Procedure of Engine & Transmission Installation/Uninstallaion

(4) Fix the engine to the engine jig. Then, Lift the car and support truck frame by tripods as well as car jacks for the safety. Slide the engine and jigs out of the car.

DPM a Engine

Caster Jig (blue)

Engine Jig (orange)

Procedure of Engine & Transmission Installation/Uninstallaion

Car lifted and engine is located side of the car on the engine/caster jig

Tripod

(5) Exchange engine transmission set to new set with engine jig.

Engine

Procedure of Engine & Transmission Installation/Uninstallaion

Mod. Engine

New engine & transmission set with engine jig delivered from Cummins. (if the engine brackets, rubber mounts, oil/coolant/fuel filters, hoses are already attached to new set, the preparation work on site can be so reduced)

(6) Lift the car. Slide the new engine and jigs underneath the car.

Procedure of Engine & Transmission Installation/Uninstallaion

DPM a Mod. Engine

Caster Jig (blue)

Engine Jig (orange)

(7) lower car until contacting engine bracket to DPM frame. Install engine and transmission. Lift the car and slide jigs to side of the car.

Procedure of Engine & Transmission Installation/Uninstallaion

DPM a New Engine

Caster Jig (blue)

Engine Jig (orange)

Procedure of Engine & Transmission Installation/Uninstallaion

(8) Move car to pit. Connect cardan shaft, auxiliary coupling, engine & transmission connectors, battery cable and engine coolant hoses. Align the auxiliary shaft. Refill engine coolant. Keep engine high idle more than 10 minutes and top off the coolant.

DPM

Cardan Shaft Auxiliary Shaft

(9) Ship 2 engine/ transmission sets to Cummins to replace the crankshaft and oil gaskets. Test by dyno and couple engine and transmission. Cummins ship back the engine to SMART.

Ship engine to Cummins (w/ engine jig)

Procedure of Engine & Transmission Installation/Uninstallaion

Engine Transmission

Engine Uncoupling

Modify engine (crankshaft, gaskets)

Mod. Engine Dyno test

Mod. Engine Coupling

Mod. Engine

Ship engine to SMART (w/ engine jig)

Cummins

SMART

Engine jig

There are 2 spare transmission and 4 sets of diaphragms at NPower.

There is 1 engine jig at SMART and Npower is estimating 3 engine jig sets now.

Problem

Diaphragms (ZF)