1 Abstract

The training was in Suez Canal authority dredging

department, which contains a workshops to make maintenance
.for it and other tugs, boats and ferry
At motor workshop we have seen total overhauling to Volvo
diesel motor and total assembly and disassembly of it also
during the overhauling the engineer explained the machine
parts and its function, mechanism of motors and problems and
.its remedy
At the machinery workshop where the motor parts and boats
and dredger parts are made, and we have some information
.about the production machines and how to work on them

2 Table of Contents
1

Abstract........................................................................................................... 1

Table of Contents............................................................................................. 2
2.1

List of figures :.......................................................................................... 3

Main text......................................................................................................... 4
3.1

Introducton................................................................................................ 4

3.2

Historical background............................................................................... 6

3.2.1

Suez Canal Construction History.........................................................6

3.2.2

Suez Canal Use and Control................................................................7

3.2.3

The Suez Canal Today.........................................................................8

3.2.4

Significance of the Suez Canal............................................................8

3.3

Main component of Diesel engine:............................................................9

3.3.1

Cylinder Head:-................................................................................... 9

3.3.2

Cylinder Head Gasket:-.....................................................................10

3.3.3

Valves:-............................................................................................. 11

3.3.4

Piston:-.............................................................................................. 11

3.3.5

Piston Ring:-...................................................................................... 12

3.3.6

Connecting Rod:-.............................................................................. 13

3.3.7

Crank Shaft:-..................................................................................... 14

3.3.8

Camshaft:-........................................................................................ 15

3.3.9

Cooling system:-............................................................................... 15

3.3.10 Fuel injection:-.................................................................................. 16

3.3.11 Turbo Charger:-................................................................................. 17
3.3.12 Lubrication System:-.........................................................................18
3.4

3.4.1

The Intake Stroke:............................................................................. 19

3.4.2

The Compression Stroke:..................................................................19

3.4.3

The Power Stroke:............................................................................. 20

3.4.4

The Exhaust Stroke:..........................................................................20

3.5
4

4 stroke................................................................................................... 19

2 stroke:.................................................................................................. 21

References..................................................................................................... 22

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2.1 List of figures :

Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure

1 ( cylinder head)........................................................................................ 9
2 (studs).................................................................................................... 10
3 (gasket).................................................................................................. 10
4 (valves).................................................................................................. 11
5 (piston ).................................................................................................. 12
6 (piston rings).......................................................................................... 13
7 (connecting rod)..................................................................................... 14
8 (crank shaft)........................................................................................... 14
9 (camshaft).............................................................................................. 15
10 (fuel injector)........................................................................................ 16
11 (turbo charger)..................................................................................... 17
12 ( intake stroke)..................................................................................... 19
13 (compession stroke)............................................................................. 19
14 (power stroke)...................................................................................... 20
15 (exhaust stroke)................................................................................... 20
16 (two stroke )......................................................................................... 21

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3 Main text
3.1 Introducton
The diesel engine has been the engine of choice for heavy-duty
applications in agriculture, construction, industrial, marine unit
and on high way.
The diesel engine has no spark plug, that it intakes air and
compresses it, and that it then injects the fuel directly into the
combustion chamber (direct injection). It is the heat of the
compressed air that lights the fuel in a diesel engine.
The injector on a diesel engine is its most complex component
and has been the subject of a great deal of experimentation -in any particular engine it may be located in a variety of places.
The injector has to be able to withstand the temperature and
pressure inside the cylinder and still deliver the fuel in a fine
mist. Getting the mist circulated in the cylinder so that it is
evenly distributed is also a problem, so some diesel engines
employ special induction valves, pre-combustion chambers or
other devices to swirl the air in the combustion chamber or
otherwise improve the ignition and combustion process.
The main differences between the gasoline engine and the
diesel engine are:
A gasoline engine intakes a mixture of gas and air, compresses
it and ignites the mixture with a spark. A diesel engine takes in
just air, compresses it and then injects fuel into the compressed
air. The heat of the compressed air lights the fuel
spontaneously.
A gasoline engine compresses at a ratio of 8:1 to 12:1, while a
diesel engine compresses at a ratio of 14:1 to as high as 25:1.
The higher compression ratio of the diesel engine leads to
better efficiency.
Gasoline engines generally use either carburetion, in which the
air and fuel is mixed long before the air enters the cylinder, or
port fuel injection, in which the fuel is injected just prior to the
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intake stroke (outside the cylinder). Diesel engines use direct

fuel injection -- the diesel fuel is injected directly into the
cylinder.
One big difference between a diesel engine and a gas engine is
in the injection process. Most car engines use port injection or a
carburetor rather than direct injection. In a car engine,
therefore, all of the fuel is loaded into the cylinder during the
intake stroke and then compressed. The compression of the
fuel/air mixture limits the compression ratio of the engine -- if it
compresses the air too much, the fuel/air mixture
spontaneously ignites and causes knocking. A diesel
compresses only air, so the compression ratio can be much
higher. The higher the compression ratio, the more power is
generated.
The four strokes of the internal combustion engine are as
follows (and in order): Intake, Compression, Power, and
Exhaust. These four strokes require two revolutions of the
crankshaft. The process continuously repeats itself during the
operation of the engine. So, if a four-cylinder engine requires
two complete revolutions of the crankshaft to ignite all of its
cylinders.

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3.2 Historical background

The Suez Canal , located in Egypt, is a 101 mile (163 km) long
canal that connects the Mediterranean Sea with the Gulf of
Suez, a northern branch of the Red Sea. It officially opened in
November 1869.

3.2.1

Suez Canal Construction History

Although the Suez Canal wasn't officially completed until 1869,

there is a long history of interest in connecting both the Nile
River in Egypt and the Mediterranean Sea to the Red Sea. It is
believed that the first canal in the area was constructed
between the Nile River delta and the Red Sea in the 13th
Century B.C.E. During the 1,000 years following its
construction, the original canal was neglected and its use
finally stopped in the 8th Century.
The first modern attempts to build a canal came in the late
1700s when Napoleon Bonaparte conducted an expedition to
Egypt. He believed that building a French controlled canal on
the Isthmus of Suez would cause trade problems for the British
as they would either have to pay dues to France or continue
sending goods over land or around the southern part of Africa.
Studies for Napoleon's canal plan began in 1799 but a
miscalculation in measurement showed the sea levels between
the Mediterranean and the Red Seas as being too different for a
canal to be feasible and construction immediately stopped.
The next attempt to build a canal in the area occurred in the
mid-1800s when a French diplomat and engineer, Ferdinand de
Lesseps, convinced the Egyptian viceroy Said Pasha to support
the building of a canal. In 1858, the Universal Suez Ship Canal
Company was formed and given the right to begin construction
of the canal and operate it for 99 years, after which time, the
Egyptian government would take over control of the canal. At
its founding, the Universal Suez Ship Canal Company was
owned by French and Egyptian interests.

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Construction of the Suez Canal officially began on April 25,

1859. It opened ten years later on November 17, 1869 at a cost
of $100 million.

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3.2.2

Suez Canal Use and Control

Almost immediately after its opening, the Suez Canal had a

significant impact on world trade as goods were moved around
the world in record time. In 1875, debt forced Egypt to sell its
shares in ownership of the Suez Canal to the United Kingdom.
However, an international convention in 1888 made the canal
available for all ships from any nation to use.
Shortly thereafter, conflicts began to arise over use and control
of the Suez Canal. In 1936 for example, the U.K. was given the
right to maintain military forces in the Suez Canal Zone and
control entry points. In 1954, Egypt and the U.K. signed a seven
year contract that resulted in the withdrawal of British forces
from the canal area and allowed Egypt to take control of the
former British installations. In addition, with the creation of
Israel in 1948, the Egyptian government prohibited the use of
the canal by ships coming and going from the country.
Also in the 1950s, the Egyptian government was working on a
way to finance the Aswan High Dam. Initially it had support
from the United States and the U.K. but in July 1956, both
nations withdrew their support and the Egyptian government
seized and nationalized the canal so passage fees could be
used to pay for the dam. On October 29 of that same year,
Israel invaded Egypt and two days later Britain and France
followed on grounds that passage through the canal was to be
free. In retaliation, Egypt blocked the canal by intentionally
sinking 40 ships. These events were known as the Suez Crisis.
In November 1956, the Suez Crisis ended when the United
Nations arranged a truce between the four nations. The Suez
Canal then reopened in March 1957 when the sunken ships
were removed. Throughout the 1960s and 1970s, the Suez
Canal was closed several more times because of conflicts
between Egypt and Israel.
In 1962, Egypt made its final payments for the canal to its
original owners (the Universal Suez Ship Canal Company) and
the nation took full control of the Suez Canal.

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3.2.3

The Suez Canal Today

Today, the Suez Canal is operated by the Suez Canal Authority.

The canal itself is 101 miles (163 km) long and 984 feet (300
m) wide. It begins at the Mediterranean Sea at Point Said flows
through Ismailia in Egypt, and ends at Suez on the Gulf of Suez.
It also has a railroad running its entire length parallel to its west
bank.
The Suez Canal can accommodate ships with a vertical height
(draft) of 62 feet (19 m) or 210,000 deadweight tons. Most of
the Suez Canal is not wide enough for two ships to pass side by
side. To accommodate this, there is one shipping lane and
several passing bays where ships can wait for others to pass.
The Suez Canal has no locks because Mediterranean Sea and
the Red Sea's Gulf of Suez have approximately the same water
level. It takes around 11 to 16 hours to pass through the canal
and ships must travel at a low speed to prevent erosion of the
canal's banks by the ships' waves.

3.2.4

Significance of the Suez Canal

In addition to dramatically reducing transit time for trade

worldwide, the Suez Canal is one of the world's most significant
waterways as it supports 8% of the world's shipping traffic and
almost 50 ships pass through the canal daily. Because of its
narrow width, the canal is also considered a
significant geographic chokepoint as it could easily be blocked
and disrupt this flow of trade.
Future plans for the Suez Canal include a project to widen and
deepen the canal to accommodate the passage of larger and
more ships at one time.

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3.3 Main component of Diesel engine:

3.3.1
Cylinder Head:The cylinder head (or cylinder cover) is bolted to the top of the
engine block and forms a gas tight seal over the end of each
cylinder. The head may be cast as a separate head to cover
each cylinder as is usual with the larger engines or in the case
of smaller engines a single casting covering all cylinders. A
number of engine parts that are essential to engine operation
may be found in or attached to the cylinder head. The cylinder
head for a 4-stroke cycle engine will house intake and exhaust
valves, valve guides, and valve seats. The cylinder head will
also carry the valve rocker arm assembly, fuel injection valves,
heater plugs, the cover for the rocker gear as well as providing
for the flow of:- cooling water to essential areas of the head, air
supply for combustion and discharged exhaust gases.
Maintenance:Remove cylinder by sliding it up over the four stud.
In the case of v-twin engines, the cylinders used on air cooled
units are interchangeable as a new part, but if they are to be
used again, the should be suitably marked to ensure they will
be replaced in their respective left and right hand position.
Remove the gudgeon pin cylinder and push gudgeon pin out of
the piston, remove piston from connecting rod, in the case of vtwin engines, mark the piston to ensure correct replacement in
their respective bores.

Figure 1( cylinder head)

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3.3.2

Cylinder Head Gasket:-

A gas tight seal between the cylinder head and the block
depends upon surfaces being level and smooth, good quality
gaskets, and the correct tightness (torque settings) of the head
studs.

3.3.2.1

Stud:-

Cylinder head studs are manufactured from round rod,

generally of alloy steel. Threads are cut on both ends. The
threads that screw into the block are generally made with finer
threads than those on the nut end. This design allows for a
tighter fit in the block, which keeps the stud from loosening
when the stud nut is removed.

Figure 2 (studs)

3.3.2.2

Gasket:-

Gaskets are used to provide a seal between two surfaces. The

type of duty may vary greatly from the somewhat rough
surfaces of water pipe flanges to the carefully ground faces of
high pressure superheated steam pipes; from the valve cover
on a cylinder head to the highly polished surfaces of hydraulic
pump components. Each duty requires the correct type and
thickness of material so it is important to understand the
properties of the various gasket materials and the exact nature
of the duty

Figure 3 (gasket)

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Maintenance:When the gasket has leakage it must be removed and replaced

and must be ensured, and stud are replaced when it
brokedown.

3.3.3

Valves:-

All four-stroke internal combustion engines employ valves to

control the admittance of fuel and air into the combustion
chamber. Two-stroke engines use ports in the cylinder bore,
covered and uncovered by the piston, though there have been
variations such as exhaust valves.

Figure 4 (valves)

3.3.3.1

Piston Engine Valve:-

In piston engines, the valves are grouped into 'inlet valves'

which admit the entrance of fuel and air and 'outlet valves'
which allow the exhaust gases to escape. Each valve opens
once per cycle and the ones that are subject to extreme
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accelerations are held closed by springs that are typically

opened by rods running on a camshaft rotating with the
engines' crankshaft.

3.3.3.2

Control Valve:-

Continuous combustion enginesas well as piston engines

usually have valves that open and close to admit the fuel
and/or air at the startup and shutdown. Some valves feather to
adjust the flow to control power or engine speed as well.

3.3.4

Piston:-

A piston is a component of reciprocating engines. It is located in

a cylinder and is made gas-tight by piston rings. Its purpose is
to transfer force from expanding gas in the cylinder to
the crankshaft via a piston rod and or connecting rod. In twostroke engines the piston also acts as a valve by covering and
uncovering ports in the cylinder wall.

Figure 5 (piston )

Maintenance:If the piston has breakdown and has a leak, it must be replaced
with another piston with the same dimension to ensure that the
piston will work normally.
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3.3.5

PistonRing:-

Piston rings perform three functions: seal the cylinder,

distribute and control lubricating oil on the cylinder wall, and
transfer heat from the piston to the cylinder wall. All rings on a
piston perform the latter function, but two general types of
rings compression and oil are required to perform the first two
functions.

Figure 6 (piston rings)

3.3.5.1

Oil Ring:-

Although oil rings come in a large variety of designs, they must

all do two things:
1. Distribute enough oil to the cylinder wall to prevent metal to
metal contact.
2. Control the amount of oil distributed.

3.3.5.2

CompressionRing:-

The principal function of compression rings is to seal the

cylinder and combustion space so that the gases within the
space cannot escape until they have performed their function.
Some oil is carried with the compression rings as they travel up
and down the cylinder for lubrication. Most compression rings
are made of gray cast iron.
Maintenance:When the piston ring leak it must be removed and replaced and
must ensure when replaced that it has the same dimension of

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the old ring and ensure it is put at the right place on the piston
and two ring opening are opposite to each other.

3.3.6

Connecting Rod:-

The connecting rod or connecting rod connects the piston to

the crank or crankshaft. Together with the crank, they form a
simple mechanism that converts reciprocating motion into
rotating motion.
As a connecting rod is rigid, it may transmit either a push or a
pull and so the rod may rotate the crank through both halves of
a revolution, Piston pushing and piston pulling. Earlier
mechanisms, such as chains, could only pull. In a few twostroke engines, the connecting rod is only
required to push.
Maintenance:Remove the inspection cover on the side of
the crank case which provides access to
connecting rod big end.

Figure 7 (connecting rod)

Replace the connecting rod bolts through the

exposed opening in the cover and remove them, then remove
the connecting rod upwards through the cylinder bore.

3.3.7

Crank Shaft:-

The crankshaft changes the movement of the piston and the

connecting rod into the rotary motion required to drive such
items as reduction gears, propeller shafts, generators, or
pumps. As the name implies, the crankshaft consists of a series
of cranks (throws) formed as offsets in a shaft. The crankshaft
is subjected to all the forces developed in an engine. Because
of this, the shaft must be of especially strong construction. It is
usually machined from forged alloy or high carbon steel. The
shafts of some engines are made of cast-iron alloy. Forged
crankshafts are nitride (heat-treated) to increase the strength
of the shafts and to minimize wear.

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Figure 8 (crank shaft)

Maintenance:Remove the nuts holding the main bearing plate flywheel side
and remove the plate using two forcing screws .
At the first time we used the lathe to repair the shaft and put it
back in the engine, and more over until it reaches the minimum
allowable thickness so, it will be replaced in its next overhaul

3.3.8

Camshaft:-

Figure 9 (camshaft)

It transmit the cam action of the crankshaft for the valves to

open and close in the right time as needed. The relationship of
camshaft and crankshaft is very important to an engine. The
valves control the flow of air intake and exhaust gasses. For this
purpose camshaft is connected to crankshaft either directly by
a timing gear, by a timing belt or by a timing chain. Depending
on the position of the camshaft, the cams operate the valves
directly or by the use of a push rod and rocker arm. Direct
operation of the cam to the valve is much simpler valve
mechanism. It leads to fewer parts needed and which means
fewer mechanism to fail. It will require that the camshaft is to
be positioned at the top of the cylinder.

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Maintenance:The camshaft replace after a long time of using because it is

not broke down easily as there are no high stress on it.

3.3.9

Cooling system:-

Combustion generates a great deal of heat, and some of these

transfers to the walls of the engine. Failure will occur if the body
of the engine is allowed to reach too high a temperature; either
the engine will physically fail, or any lubricants used will
degrade to the point that they no longer protect the engine.
The lubricants must be clean as dirty lubricants may lead to
over formation of sludge in the engines, Cooling systems
usually employ air (air-cooled) or liquid (usually water) cooling.

3.3.10

Fuel injection:-

Fuel injection is a system for admitting fuel into an internal

combustion engine. It has become the primary fuel delivery
system used in automotive engines, direct injection diesel
engines have injectors mounted at the top of the combustion
chamber. The injectors are activated using one of two methods
- hydraulic pressure from the fuel pump, or an electronic signal
from an engine controller.

Figure 10 (fuel injector)

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Maintenance:Remove the injector form the engine and then replace it, If its
tested and found not spraying well

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3.3.11

Turbo Charger:-

A turbocharger is a turbine-driven forced induction device that

increases an engine's efficiency and power by forcing extra air
into the combustion chamber. This improvement over
a naturally aspirated engine's output results because the
turbine can force more air, and proportionately more fuel, into
the combustion chamber than atmospheric pressure alone.

Figure 11 (turbo charger)

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3.3.12

Lubrication System:-

The movement of various engine parts under high speed and

load conditions creates the requirement for an engine
lubrication system. Without some lubricant, friction between
parts would quickly wear and generate heat causing severe
engine damage and eventually seizure. A number of other
lubrication system functions, while not obvious, are critical to
good engine operation and durability. Lubrication systems in a
diesel engine accomplish the following tasks:
1) Maintain oil film between piston rings and cylinder wall
2) Provide proper lubrication of camshaft valve gear
3) 3) Provide oil film between shafts and bearing surfaces at
main, crank pin wrist pin thrust bearings and all other
bearing.
4) 4. Assists sealing of the combustion chamber by forming a
film between the piston rings and the cylinder wall.
5) 5. Absorbs shock loads between bearings and gears thus,
cushioning and protecting engine parts while minimizing
engine noise production.
6) 6. Stores an adequate supply of oil for lubricating internal
engine parts.
7) 7. Minimizes corrosion of internal engine components
lubrication system components.
o Oil pan : it is the reservoir for the oil, located in the
bottom cover of the engine.
o Oil Pump : it supply oil under pressure. It draws oil from
the reservoir to the oil nozzles. bearings, and other parts
that needs lubrication.

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3.4 4 stroke
3.4.1

The Intake Stroke:

On the intake stroke, the intake valve has

opened. The piston is moving down, and a
mixture of air and vaporized fuel is being
pushed by atmospheric pressure into the
cylinder through the intake valve port.

Figure 12 ( intake stroke)

3.4.2

The Compression Stroke:

After the piston reaches the lower limit of its

travel, it begins to move upward. As this
happens, the intake valve closes. The exhaust
valve is also closed, so the cylinder is sealed. As
the
piston moves upward, the air/fuel mixture is
compressed. On some small high compression
engines, by the time the piston reaches the
top of its travel, the mixture is compressed to
as little as one-tenth its original volume.
Thus, the compression of the air/fuel mixture
increases the pressure in the cylinder. The
compression process also creates the
Figure 13 (compession stroke)
air/fuel mixture to increase in
temperature.

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3.4.3

The Power Stroke:

As the piston reaches the top of its travel on the

compression stroke, an electric spark is
produced at the spark plug. The ignition system
delivers a high voltage surge of electricity to the
spark plug to create the spark. The spark ignites
air/fuel mixture. The mixture burns rapidly and
cylinder pressure increases to as much as
(600psi). All of this pressure against the
piston forces it down in the cylinder. The
power impulse is transmitted down through
the piston, through the piston rod (connecting
rod), and to the crankshaft. The crankshaft is
rotated due to the force.

the

Figure 14 (power stroke)

3.4.4

The Exhaust Stroke:

As the piston reaches the bottom of its travel,

exhaust valve opens. Now, as the piston
moves up on the exhaust stroke, it forces the
burned gases out of the cylinder through the
exhaust port. When the piston reaches the top
travel, the exhaust valve closes, and the
valve opens. The cycle repeats again with the
stroke. The four strokes are continuously
repeated during the operation of the
engine.

the

of its
intake
intake

Figure 15 (exhaust stroke)

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3.5 2 stroke:
A two-stroke or two-cycle engine is a type of internal
combustion engine which completes a power cycle in only one
crankshaft revolution and with two strokes, or up and down
movements, of the piston in comparison to a four-stroke engine
which uses four strokes. This is accomplished by the end of the
combustion stroke and the beginning of the compression stroke
happening simultaneously and performing the intake and
exhaust or scavenging functions at the same time.

Figure 16 (two stroke )

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4 References
1. Volvo Marine Diesel Engine
2. http://actualrepair.com/how-to-overhaul-a-diesel-engine/
(20/11/2014)
3. Diesel workshop at Suez Canal Authority
4. http://geography.about.com/od/specificplacesofinterest/a/s
uezcanal.htm (20/11/2014)
5. http://www.suezcanal.gov.eg/ (20/11/2014)
6. http://en.wikipedia.org/wiki/Component_parts_of_internal_
combustion_engines (20/11/2014)

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