Supervise Overhaul of an Internal Combustion Engine Flashcards by Richard Hill

Where would you find guidance for diesel engine operating hour overhaul intervals?

COMDTINST M9000.6 in Table 233-1

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WHO is the final authority for determining the timing of overhauls?

MLC Atlantic and Pacific

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At approximately 80% of the operating hour overhaul interval, the supervisor shall assess the condition of the engine. What guidance would you reference to accomplish this?

NEM 9000.6, Chapter 233, Paragraph B.2

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Who will the supervisor initiate a discussion with to report the condition of the engine and recommend when to conduct the overhaul?

The MLC type desk manager

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What additional inspections will MLC complete when deciding whether or not to extend (or shorten) the overhaul based on engine condition?

OEM Technical Representative Inspection
MLC ASSIST or NESU/MAT Inspection
Navy (Fleet Technical Support Command) Inspection

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Where would you record adjustments to overhaul intervals?

The cutter’s Naval Engineering Projects List (NEPL)

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MLC shall provide specific guidance such as limitations on operating the engine and the plan for monitoring and reassessing the engines condition. Where shall this specific guidance be incorporated?

The cutter’s Long Range Maintenance Plan (LRMP)

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MLC may also fund a limited number of OEM technical representative cutter visits and onsite labor hours to assist the ships force with:

Critical Measurements
Inspections

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When scheduling and planning an overhaul, what items will the supervisor be responsible for ensuring are ordered for the overhaul?

Flexible hoses
Valves
Gauges
All consumable items required for the overhaul.

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What funds will be used for travel cost for MAT assistance to non MAT-supported cutters?

The cutter AFC-30 fund

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The ________ shall conduct weekly progress meetings with all key personnel and provide progress reports to MLC type desk.

Supervisor

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The ______ shall be responsible for receipt, inventory and inspection of parts and long lead-time material.

Supervisor

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The _____ will be responsible for ensuring all post-overhaul test, inspections and break-in procedures are conducted.

Supervisor

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Where would you find guidance for documenting the overhaul in the next Cutter Engineer Report?

NEM M9000.6

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Who shall document completion of the overhaul in the fleet logistics system, which will be reflected in the cutter’s Naval Engineering Project List (NEPL)?

MLC type desk

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Name four things you want to pay particular attention to when preparing to complete an overhaul?

Installation tolerences
Wear limits
Adjustments
Safety procedures

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What must you do before attempting to jack the engine over by hand?

Disable the starter circuit

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Remove and upon completion of work, reinstall all interferences in way of work for the main diesel engine overhaul in the engine room IAW _______.

MLCA Standard Specification 0700C0490.STD

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Prior to disassembly of the MDE what do you want to check?

Check the face and bore alignment between the engine flywheel and flex coupling.

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Cleaning and inspection On the basis of the disassembly and inspection of th engine, submit to the supervisor a condition report of all components with recommendations for _________.

Reuse, repair and/or renewal

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Clean, inspect and repair/recondition as specified the following components of each engine per the manufactures tolerances and standards:

Cylinder block
Crankshaft
Pushrods and rocker shafts
Camshaft and followers
Cam bearings and bushings
Gear train

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What guidance would you reference for checking alignment after installing a new flexible couple?

CAT special instruction, Form SEH7456-01

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The following components for the engine shall be renewed in the after cooler group:

core assembly
after core assembly
packing
seal
gasket

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The following components for the engine shall be renewed in the crankshaft group:

thrower
baffles
rings
bearing

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What psi would you hydrostatically test a manifold to?

50 psi

**Chemically clean** the **Lubricating Oil Cooler** per applicable sections of \_\_\_\_\_\_\_\_\_.

Table I of MLC Standard Specification

Visually inspect and hydrostatically test each of the Oil Cooler per \_\_\_\_\_\_\_.

ASTM E1003

When would you take the Crankshaft Deflection Test?

Before starting the overhauled engine, after alignment (cold) and after running the engine for trials (hot).

Upon completion of any major overhaul or repair, as a supevisor, what must you do prior to placing machinery back into operational status?

Test and Operate Machinery

What might you be doing when accomplishing the following task? * Start ventilation in the main engine room * charge the pneumatic starting system * check cooling system valves for porper position * Ensure MDE fluids are topped off * Visually check fuel lines/fuel system

Pre-starting check

Check all systems for leaks by turing the MDE in the direction of rotation using the jacking bar to ensure it rotates freely.

**PRE-STARTING CHECKS** **AFTER AN ICE OVERHAUL**

Test run the propulsion for a minimum of __ hour at idle.

1 hour

Run-in MDE dockside, for a period of approximately ___ hours, per manufactures instructions.

5 hours

After completion of the final run-in, the following items shall be inspected and corrected as necessary:

* lubricating oil leaks * water leaks * F/O leaks all external bolts secure

The test data obtained during the run-in shall be recorded and submitted to appropriate authority within ____ hours after completion of the test.

48 hours

A sea trial for a period of 4 to 6 hours may be required to demonstrate proper operation of the overhauled MDE, in all modes of operation, as per \_\_\_\_\_\_\_\_.

COMDTINST M9000.6, Chapter 094.1.4

What is piston wear characterized by?

An excessive clearance between the piston and the cylinder

What are symptoms of excessive clearance between a piston and cylinder?

Piston Slap and Excessive Oil Consumption

When does piston slap occur?

After TDC and BDC, as the piston shifts its thrust from one side to the other.

What will accumulation of carbon deposits cause?

Erratic operation and greatly reduce engine efficiency

What is one of the factors controlling piston wear?

Lubrication

What will inadequate lubrication cause?

* Piston wear * Piston seizure * Land breakage * Piston pin bushing wear

What is lack of lubrication caused by?

Lack of L/O pressure or restricted oil passages

There should be _____ on all pistons at all times.

Load Balance

What will cause excessive wear on the piston and piston pin bushing?

An overload or unbalanced load

How is the balance of an engine determined?

By checking the exhaust gas temperature at each cylinder, the rack settings and the firing and compression pressures.

What causes cracking of the lands of a piston?

Insufficient ring groove clearance

Of the causes listed under "Other factors which may cause low compression pressure", which causes would affect the pressure in only one cylinder assembly of a multicylinder engine?

* A: Leaking cylinder valves * B: Faulty injector gasket * C: Faulty head gasket * D: Leaking after-chamber valves

What causes of "low compression pressure" may effect a group of cylinders or posibly all cylinders.

* Intake air header leakage * faulty blower * clogged air filter

What is excessive oil consumption generally associated with?

Worn oil rings

What is caused by excessive operating temperatures?

Oxidation

Name two factors that cause improper ring clearance:

* Abnormal amount of carbon deposits on rings and grooves * Improper dimensions, new rings must have proper thickness, width, diameter and gap

One cause of undue loads on a ring could be\_\_\_\_\_.

Insufficient gap clearance

What does a bright spot found on each end of a broken ring indicate?

Insufficient gap clearance

\_\_\_\_\_\_\_\_\_ may result from insufficient ring pressure.

Sticking and binding

What indicates the leakage of gases past the rings?

Discoloration (usually appearing as black lines)

What conditions cause piston rings to stick in the grooves, wear excessively or break?

Improper lube oil

What is the greatest factor affecting the wearing of piston rings?

Worn cylinder liner

What must be considered when new piston rings are installed?

* Surface condition * Amount of taper * Out-of-roundness of the liner

How should you stagger adjacent rings to reduce gas leakage?

180 degrees

What type of metal are piston pins made of?

Hardened steel alloy

What type of metal is piston sleeve bearings and bushings made of?

Bronze or a similar material

Wear of a pin or bearing is normal, but what factors can increase the rate of wear?

* Inadequate or improper lubrication * Overloading * Misalignment of parts * Failure of adjacent parts

What should you measure piston pins and bushings with to determine if wear is excessive?

Micrometer

What will result of misalignment of connecting rods?

Uneven loading on piston pins and bearings

\_\_\_\_\_\_ may be caused by improper reaming of the bushing for proper clearance.

Misalignment

Connecting rod troubles usually involve either the ______ or the \_\_\_\_\_\_\_\_.

connecting rod bearing or the piston pin bearing

Connecting rods must be checked for proper alignment before being installed in an engine and after any derangement involving the \_\_\_\_\_\_\_\_\_.

piston, cylinder or crankshaft

Whenever rod bolts are removed, they should be carefully inspected for \_\_\_\_\_\_\_\_\_\_\_.

Stripped or damaged threads or elongation

What are some common troubles of crankshafts, camshafts, journal bearings and antifriction bearings?

Metal fatigue, inadequate lubrication and operation of the engine at critical speeds

What are some lubrication difficulties you should watch out for?

* low L/O pressure * High temperatures * Lube oil contamination by water, fuel and foreign particles

* Corrosion of bearing materials * Surface pitting of bearings * Inadequate bond between bearing material and bearing shell * Out of round journals * Rough spots * Fautly installation * Poor contact * Misalignment of parts * Failure to follow recommended procedures in the care of L/O

What are a few causes of journal bearing failure?

What are a few causes of poor contact between a bearing shell and a connecting rod on journal bearings?

* Foreign particles * excessive clearance * rough surface

\_\_\_\_\_\_\_\_ of main bearings can be cause by warped or bent crankshaft.

Misalignment

If there is no manual available to provide guidance on the proper L/O temperature to be maintained, what temperature should you maintain the L/O leaving the engine?

The engine should be mainatined between 160 degrees and 200 degrees fahrenheit if no manual is available.

Dirt in a bearing which has been improperly or insufficiently cleaned may be detected by\_\_\_\_\_\_\_.

* Noise when the bearing is rotated * Difficulty in rotating * Visual inspection

Spalled or pitted rollers or races may be first recognized by \_\_\_\_\_\_\_.

The noisy operation of the bearing

Brinelled or dented races are most easily recognized by\_\_\_\_\_.

Inspection after thorough cleaning

Where does brinelling receive it's name from?

It's from the similarity to the **_BRINNELL HARDNESS TEST._**

Can Brinelled Bearings be placed back in service?

**NO**, they must not be placed back in service!

What is **_CREEP_**?

A very gradual rotation of the race.

Cracked races will usually be recognized by a definite \_\_\_\_\_\_\_\_\_.

thump or clicking noise in the bearing during operation

The principle type of ______ for timing and accessary drives in most diesel engines is a system of gears.

Power Transmission

What are some causes of gear failure?

* Improper lubrication * Corrosion * Misalignment of parts * Torsional vibration * Excessive backlash * Wiped gear bearings and bushings * Metal obstructions * Improper manufacturing procedures

\_\_\_\_\_\_\_\_\_ of gear trains involve a thorough check of gear shafts, bushings and bearings, and gear teeth during each periodic inspection.

Maintenance and Repair

One of the most important parts of a _______ is the set of gears that drives and sychronize the two rotors.

Root Type Blower

The most direct method for checking gear clearance is by the use of \_\_\_\_\_\_.

feeler gauges

What are the principle causes of drive chain failure?

* Improper chain tension * Lack of lubrication * Sheared cotter pins or improperly riveted joint pins * misalignment of parts, especially idler gears

What is used on most engines to adjust chain tension?

An idler sprocket and chain tensioner

During operation, chain increase slightly in length because of \_\_\_\_\_\_.

stretch and wear

Turbo chargers used in the CG today may operate with temperatures as high as ______ degrees and speeds up to ______ RPM's.

1200 degrees Fahrenheit, 75,000 RPM's

List six supervisor responsibilities associated with planning, scheduling, executing and completing a maintenance or repair task.

* Size up the job before starting * Check on materials required * Check on priority of the job * Consider capabilities and experience of personnel when assigning work * Keep track of work being done * Carefully inspect after the job has been completed

Who is responsible for ordering flexible hoses, gauges and all consumable materials required for an internal combustion engine overhaul?

The Supervisor

What four task is the supervisor responsible for during the execution stage of an overhaul?

* Managing * Supervising all work * Inspections * Tests

Upon completion of an overhaul, the supervisor will ensure the completion is documented in what two reporting systems?

* Next Cutter Engineering Report * CMplus

What two conditons must be maintained in tanks or compartments or when conducting hotwork in an area in conjuction with an overhaul?

* **SAFE FOR PERSONNEL** * **SAFE FOR HOTWORK**

What is the wear criteria and critical dimension data of components based on when cleaning and inspecting a disassembled engine?

Manufactures service/Technical manual

What is a sea trial period intended to demonstrate?

Proper operation of an overhaul MDE

Characterized by presence of abnormal amount of carbon.

Improper piston ring clearance

Characterized by improper functioning of a torsion vibration damper.

Bent or broken crankshaft

Characterized by improper valve tappet adjustment.

Camshaft and bearing trouble

Characterized by fine abrasives in lubricants

Bearing wear causing looseness without apparent surface disintegaration

Characterized by misalignment of idler gears.

Drive chain failure

The lubricating oil temperature shall be maintained at ___________ or below during bearing checks.

48.9° C (120° F)

Insufficient lubrication to any bearing or bushing, improper installation of bearings or bushings, or defective bearings or bushings normally will be indicated by a noticeable overheating of the affected part by the end of the \_\_\_\_\_\_\_\_\_\_\_\_,

15 minute run at 40 percent speed, no load

Diesel engine log readings shall be recorded every __ minutes during run.

Supervise Overhaul of an Internal Combustion Engine Flashcards

(106 cards)