Though we have had the engine up and running for several weeks now, it is important that we keep the engine cool while operating for long periods of time. Determining a solution to our broken fan belt sheave became the top priority for the start of the quarter. There were three primary options for consideration with regard to the fan:
- Reconnect the fan belt system to the engine and run on one V-belt (since the current sheave was cracked).
- Buy a new shaft and replace the cracked one.
- Cool the engine with an external electric fan with a directed flow.
First, we decided to assess the feasibility of using the existing fan belt system. Last week, we removed the fan and attempted to reconnect the shaft and sheave to the engine. While doing so, we discovered the probable cause of the crack in the sheave: the initial bolts were broken and lodged in the engine’s damper. The flange was taken to a shop to have the bolts removed by Electric Discharge Machining (EDM). While awaiting completion, we determined and obtained the necessary dimensions and fan belt as well as the engine’s oil specifications and suppliers.
In addition, we needed to remove the muffler in order to unbolt the fan from its mount. Upon inspection, we discovered rusty water build-up within the exhaust exit. This may be the cause of the steam we were observing in the exhaust while operating. We suspect the water isn’t indicative of an engine problem, but instead because of condensation and the lack of an exhaust stack cover.
By Katie Leong, Engine Test Bed