RIRI YOANDA 4216105007 (ENGINE REPAIRING RESUME)

Introduction (Maintenance)
MAINTENANCE
All activities that maintain facilities and equipment in good working order so that a system can perform as intended
Two basic categories
Building and grounds
Equipment maintenance
GOAL OF MAINTENANCE
To keep production/service systems in good working order at minimal cost
Reasons for maintenance
To avoid production or service disruptions
To not add production or service costs
To maintain high quality
To avoid missed delivery dates
REACTIVE VS PROACTIVE
Reactive Maintenance:
Breakdown maintenance
Reactive approach; dealing with breakdowns or problems when they occur
Proactive Maintenance:
Preventive maintenance
Proactive approach; reducing breakdowns through a program of lubrication, adjustment, cleaning, inspection, and replacement
of worn parts
MAINTENANCE REASONS
Reasons for keeping equipment running
Avoid production/ service disruptions
Not add to production/service costs
Maintain high quality
Avoid missed delivery dates
BREAKDOWN CONSEQUENCES
Production capacity or service quality is reduced
Orders are delayed
No production/ service
Overhead continues
Cost per unit increases
Quality issues
Product may be damaged
Safety issues
Injury to employees
Injury to customers
Preventive maintenance : goal is to reduce the incidence of breakdowns or failures in the plant or equipment to avoid the associated costs
Preventive maintenance is periodic
Result of planned inspections
According to calendar
After predetermined number of hours
Predictive maintenance :An attempt to determine when best to perform preventive maintenance activities
Total productive maintenance
JIT approach where workers perform preventive maintenance on the machines they operate
BREAKDOWN PROGRAMS
Standby or backup equipment that can be quickly pressed into service
Inventories of spare parts that can be installed as needed
Operators who are able to perform minor repairs
Repair people who are well trained and readily available to diagnose and correct problems with equipment
REPLACEMENT
Trade-off decisions
Cost of replacement vs cost of continued maintenance
New equipment with new features vs maintenance
Installation of new equipment may cause disruptions
Training costs of employees on new equipment
Forecasts for demand on equipment may require new equipment capacity
When is it time for replacement?
DIESEL ENGINE COMPONENTS
Main parts
structural parts (stationary part)
running parts
Systems
STRUCTURAL PARTS PURPOSE:
to support running parts
to keep them in position and line
to provide jackets and passages for cooling water, sumps, for lube oil
 to form protective casing for running parts
to support auxiliaries (valves, camshaft, turbo blowers)
RUNNING PARTS PURPOSE : - to convert the power of combustion in the cylinders to mechanical work
SYSTEMS PURPOSE : Supply of air, Removal of exhaust, Turbocharging, Supply and injection of fuel, Lubrication, Cooling
STURCTURAL PARTS : BEDPLATE (foundation on which the engine is built, must be rigid enough to support the rest of the engine and hold
the crankshaft which sits on the bearing housing in alignment with transverse girders, at the same time, the bedplate has to be flexible
enough to hog and sag with the foundation plate to which it is attached and which forms part of the ship structure). FRAME (load-carrying
part of an engine, it may include parts as the cylinder block,base, sump and end plates, in two-stroke engines, frames are sometimes known
as A-frames). CYLINDER BLOCK/ENGINE BLOCK(part of the engine frame that supports the engine cylinder liners, heads and crankshafts,
cylinder blocks for most large engines are made of castings and plates that are welded horizontally and vertically for strength and rigidity
(stiffener), entablature = cylinder block which incorporates the scavenge air spaces in two-stroke engines). CYLINDERLINER(a bore in which
an engine piston moves back and forth, replaceable, the material of the liner must withstand extreme heat and pressure developed within
the combustion space at the top of the cylinder, and at the same time must permit the piston and its sealing rings to move with a minimum
of friction). CYLINDERHEAD/CYLINDERCOVER(the space at the combustion chamber top is formed and sealed by a cylinder head, the
cylinder head of a four-stroke engine houses intake and exhaust valves, the fuel injection valve, air starting vale, safety valve(the two-stroke
engine lacks the intake valve). MAJOR RUNNING PARTS : PISTON(one of the major moving parts, crown, skirt, must be designed to
withstand extreme heat and combustion pressure, made of cast iron or aluminium (to reduce weight)). PISTONROD (connects the piston
with the crosshead). CROSSHEAD(the crosshead pin connects the piston rod to the connecting rod, crosshead slippers are mounted on
either side of the crosshead pin, the slippers run up and down in the crosshead guides and prevent the connecting rod from moving
sideways as the piston and rod reciprocate). CONNECTINGROD (it is fitted between the crosshead and the crankshaft, it transmits the firing
force, and together with the crankshaft converts the reciprocating motion to a rotary motion). CRANKSHAFT&BEARINGS(one of the largest
moving parts, it consists of a series of cranks formed in a shaft, converts reciprocating motion of the piston into rotary motion,
counterweights for balancing purposes). ARRANGEMENT FOR THE AIR SUPPLY AND GAS EXHAUST( valves (inlet & exhaust), valve gear
(camshaft & camshaft drive, push rod, rocker arm, spring), manifolds, scavenging and supercharging (turboblower systems)). FUEL
INJECTION SYSTEM(fuel pump, high pressure piping, injector, nozzle).
ENGINE PARAMETERS: (Cylinder bore inner diameter of the cylinder (in mm or cm); Stroke the distance the piston travels between top
and bottom dead centers (in mm or cm); Engine speed speed at which the crankshaft rotates (measured in revolutions per minute);
Maximum Continuous Rating (MCR) the designed maximum power which a diesel engine is capable of delivering continuously, at nominal
maximum speed, in the period between two consecutive overhaulings).
TROUBLESHOOTING
AN ABNORMAL ENGINE INDICATION (Abnormal circumstances will disrupt the operation of an engine.
Good engine operation depends on the main things including :
The supply of air compression until high pressure is reached.
Sufficient fuel injection at the right time.
Loss of power is caused by several factors: Unstable of Engine speed; excessive vibration,faltering (too long) idle time; The
engine difficult to start is an indication that the compression pressure is too low; Poor quality of Injection on one or more
cylinders, or Supply of air is very poor.
LOOKING FOR MISFIRING LOC : Start engine and turn on the part load to normal engine temperature conditions; Stop the engine and
open the valve rocker cover; Check the clearance of valve (follow manual guide); Start engine. Press the follower injector with screw driver
to prevent injector operation. If the cylinder happens misfire then there will be no change of engine sound and engine operation.
Conversely, if there is a change in sound and operation then the cylinder in a normal working condition;Check injector follower wit screw
driver; If the first cylinder is running normally, repeat again on the next cylinder until the cylinder is found misfire; In case of misfire then it
needs to be checked : Check the timings of injectors,Check the compression pressure.,Replace the new injector if it is damaged, If there is
still a jam, loose cam follower and check worn cam roller, camshaft lobe , bent rod or worn cocker arm bushing.;CHECK COMPRESSION
PRESSURE (Start engine and turn on the part load to normal engine temperature conditions.;Turn off the engine and remove the fuel pipe
from the fuel injector and connector on the cylinder no 1.;Remove the injector and plug in the adapter and pressure gage.;Use one of the
fuel pipes as the connecting jumper between the fuel inlet and the return manifold connector. To return the fuel flow to the return
manifold.;Start engine, turn the engine at 600 rpm. Observe and note the compression pressure on the indicator. Remember do not rotate
engine with starting motor to measure compression pressure!; Repeat processes 2 to 5. Pressure should be adjusted to the table on the
reference project guide. If anyone does not meet the requirement then it needs to be checked.Low pressure may be caused by: a. Possible
piston ring stuck (sticky?) Or damaged. Inspection of piston ring. For checking depending of the engine brand. Open the air box cover, and
check each one and check with the blunt tool.b.Possible damage from gaskets (torn, perforated etc.).