Lesson 7. Diesel engine maintenance

Notes:

 

maintenance	содержание и техническое обслуживание, техническая эксплуатация, уход, (текущий) ремонт
daily	ежедневно
dipstick	футшток
to stand still	находиться не в рабочей состоянии
at least	по крайней мере
draining	слив
to unscrew	отвинчивать
to screw	завинчивать
drain plug	сливная пробка
bottom	дно, днище
crankcase	картер двигателя
to fill	наполнять
to refill	наполнять вновь
refilling	повторное наполнение
to wipe	протирать
inside	внутри, внутренняя сторона
rag	ветошь
fluff	пух, пушок, ворс
cotton waste	зд. хлопчатобумажная ветошь
to dip	погружать, окунать
lube oil suction strainer	фильтр масла на входе
sump	отстойник, сборник, сточная цистерна
to examine	проверять
frequently	часто
crack	трещина
upper	верхний
piston ring	поршневое кольцо
depending on	в зависимости от
condition	состояние
deposits	отложения
carbon	нагар
excessive	излишний
externally	с наружной стороны
scale	накипь
wear	износ
to renew	заменять
top	верхняя часть
to adjust	регулировать
clearance	зазор
also	также
joint	соединение
lever	рычаг
alignment	регулировка, выравнивающая
bearing	центровка, настройка, просветка (линий вала)
readings	подшипник показания, данные, замеры

Check the lube oil pressure daily. The pressure should be 1,5 Kg per sq.cm = 21 Ibs/sq. in (psi). Keep the oil level up to the full mark of the dipstick. Make control when the engine stands still. The lube oil should be changed the first time after 50 working hours, the next time after another 150 working hours and then at least once a year. Draining is made by unscrewing the drain plug at the bottom of the crankcase just after stopping the engine when the oil is warm and easy to drain. Before refilling with fresh oil wipe out the inside of the crankcase with a clean rag (use material free from fluff, do not use cotton waste). Dip the rag in gas oil and clean the lube oil suction strainer placed on the drain plug and clean the sump. When changing the lube oil, clean the lubricating oil filter with petrol or gas oil. Refill the sump with fresh lube oil.

Pistons should be examined frequently for cracks. The upper piston rings should be examined once a month during the first six months service and than as necessary depending on their condition. At intervals of six months piston heads if cooled mast be examined for deposits of carbon in cooling spaces -and cooling pipes. Exhaust valves, manifold and cylinder ports should also be examined and excessive carbon deposits should be removed. Cylinder liners must be examined externally for deposits of scale. The liners should also be examined for wear and renewed if necessary. The clearance of the connecting rod - top and bottom ends should also be examined and adjusted if necessary. At intervals of one year the manoeuvring gear should be examined for wear at the joints of levers and rods. The alignment of the crankshaft should be checked and corrected if necessary. The main bearings, should be examined and readings taken for wear.

 

Exercise 1. Answer the questions.

1) How often should the lube oil pressure be checked?

2) What should be the pressure?

3) When should the lube oil be changed the first time?

4) How is draining made?

5) Where is the drain plug positioned?

6) When is the oil easiest to drain?

7) When is it necessary to wipe out the inside of the crankcase?

8) What should the pistons be examined for?

9) Where is usually carbon deposited?

10) What should be done with carbon deposits?

11) How often should the maneuvering gear be examined?

 

Exercise 2. Give the Russian equivalents of the following.

1) lube oil pressure

2) drain plug

3) inside of the crankcase

4) lube oil suction strainer

5) deposits of scale

 

Exercise 3. Use the correct words from the text.

1) Check the lube oil … daily.

2) Keep the oil level up to the full … of the …

3) Dip the rag in gas … and clean the lube oil … strainer placed on the … plug and clean the …

4) … valves, manifold and cylinder … should also be examined and excessive carbon … should be removed.

5) The … of the connecting rod-top and bottom … should also be examined and … if necessary.

 

Exercise 4. Translate into English.

1) Производите контроль, когда двигатель остановлен.

2) Перед заполнением свежим маслом, протрите внутреннюю сторону картера чистой ветошью.

3) При замене масла, очистите масляный фильтр.

4) Поршни следует часто осматривать на наличие трещин.

5) Следует проверять и корректировать по мере необходимости центровку коленвала.

 

Exercise 5. Made up a dialogue of your own based on the one given below.

 

THE CYLINDER LINERS AND THE CAMSHAFT

 

Mr. Wilson - Why do you want to replace only 3 cylinder liners I wonder?

Ch.Eng - You see these liners are badly damaged through erosion on the cooling water side and have some ellipsoidal wear. That's why they are to be replaced. As to the other liners they require checking. Then we'll see what should be done.

Mr. Wilson - We must know the exact number of cylinder liners to be renewed because the delivery takes rather much time. So we'll speed up the dismantling of the cylinder liners and carry out the necessary survey of defects as quick as possible.

Ch.Eng. - We'd like to have your opinion about the other three liners in two days. Can you manage it?

Mr. Wilson - You see, it's necessary to grind the camshaft journals, other wise it's impossible to replace the bearings. The camshaft labyrinth packing should be renewed too, I think.

Ch. Eng. - Yes, they should. But look it is stipulated in the list of repairs.

Mr. Wilson - So, we shall make a complete repair of the camshaft drive, shan't we? Sorry we have not all necessary spare parts for the-main starting valve repair in our repair hit at present. Ch, Eng. - Don't worry. The main starting valve repair requires only minor repair. We try to do it by our engine room stuff.

 

Notes:

 

cylinder liner	цилиндровая втулка
packing	набивка
wear	износ
to repack	перенабить
wear-wore-worn	изнашиваться
drive	привод
delivery	поставка
repair kit	ремонт, комплект
exact	точный
quality	качество
speed up	ускоряться
quantity	количество
to be badly damaged of	быть сильно поврежденным из-за...
dimension	размер
shape	форма
to grind	шлифовать
camshaft	распредвал
journal	щенка
sorry but I am not satisfied with the quality (results) of repair	Простите, но я не удовлетворен качеством (результатом) ремонта

 

 

Exercise 6. Speak on the following.

1) The lube oil changing.

2) Refilling with fresh lube oil.

3) Piston examination

Lesson 8. IRREGULARITIES IN OPERATION, CAUSES AND REMEDIES I

 

Notes

regardless of	Невзирая на
both... and...	н то, и другое, как... так... e.g. Both above and below the piston
because of	из-за чего-либо
instead of	Вместо чего-либо
to consist of	Состоять из
to include smth (into)	Включать что-либо
to draw into (drew, drawn)	Втягивать (направлять) в
to push out of	Выталкивать из
to reach smth	Достигать, доходить до чего-либо
as long as	так долго, как (пока)
as soon as	как можно скорее
twice as many (much)	вдвое больше
twice less	вдвое меньше
shortly after	Вскоре (сразу) после
just before	Непосредственно перед
to start	Начинать
to continue	Продолжать
to stop, complete	Завершать
to communicate with	Связываться с
although	Хотя
moreover	более того
nevertheless	тем не менее
however	Однако
thus	таким образом
under the favorable conditions	при благоприятных условиях
to be available	иметь в наличии

REMEMBER THE FOLLOWING ABBREVIATIONS

 

BDC (bottom dead center)	Нижняя мертвая точка
TDC (top dead center)	Верхняя мертвая точка
cpp (controllable pitch propeller)	винт регулируемого шага (ВРШ)
cst (centistoke)	Сантистокс
С (Centigrade)	по шкале Цельсия
F (Fahrenheit)	по шкале Фаренгейта
HFO (Heavy Fuel Oil)	Тяжелое топливо
ECR (economic continuous rating)	Длительная экономическая мощность
MCR (maximum continuous rating)	Максимальная длительная мощность

 

Irregularities in Operation, Causes and Remedies

Symptom:	Cause:	Remedy:
1. Starting difficulties.
Insufficient or no compression.	a) Inlet and exhaust valves leaking.	Grind or replace valves, mill the seats.
''	b) Inlet and exhaust valves sticking.	Oil the valve spindles with gas oil, or remove valves for cleaning.
''	c) Insufficient rocker arm clearance.	Adjust valves.
''	d) Piston rings sticking in grooves, or worn.	Loosen rings and replace them if necessary.
''	e) Valve springs broken or slack.	Replace springs.
''	f) Cylinder liner worn.	Replace.
''	g) Cylinder liner scratched.	Replace.
Fuel valve out of order.	Nozzle needle valve sticking or leaking.	Release it, grind or replace if required.
Fuel pumps give no or insufficient pressure.	a) Pressure valve sticking or leaking	Clean it, replace if required.
''	b) Pressure valve holder loose.	Tighten.
''	c) Piston and lining worn.	Replace.
Insufficient or no fuel supply.	a) Air in fuel system.	Ventilate
''	b) Fuel lift pump defective.	Repair pump and ventilate fuel system.
2. Engine starts, but stops shortly afterwards.
Engine starts, but stops after a while	a) Fuel tank empty	Fill tank and remove air from fuel system.
''	b) Air in fuel system	Airate.
''	c) Fuel filter choked	Clean the filter.
3. Engine does not reach maximum capacity
Insufficient or no compression.		See under "Starting difficulties".
Fuel valves out of order.		''
Excessive waste of oil from fuel pumps.	Fuel pump plungers worn.	Replace plungers and sleeves.
Engine takes load only momentarily.	Fuel supply blocked, fuel pump out of order.	Check the whole fuel system thoroughly.
Engine does not reach full speed.	Governor drive broken.	Adjust or replace governor spring.
Engine loses too much speed under load.	Incorrect adjustment of governor, or something in the system works sluggishly.	Adjust governor. Check governor system, and correct the defect.
Smell of heat.	Insufficient cooling water.	Stop engine, fill in cooling water when the engine has cooled off.
4. Engine speed too high.
Languid movements of governor arm.	Governor arm has become oblique by blows or the like.	Stop engine quickly by interrupting the fuel supply and check the governor system.
Incorrect adjust­ment of governor.		Adjust governor.
5. Engine knocks.
Ignition too advanced.	Incorrect adjustment of fuel oil pumps.	Adjust correctly.
Mechanical faults.	Connecting rod bolls loose.	Check connecting rod bolts thoroughly. If cracked or defect, replace them. Tighten nuts.
Mechanical faults.	a) Hot or worn bearings.	Replace bearing lining, check lube oil system, correct fault if any before restarting.
''	b) Flywheel loose.	Tighten nut and lock it.
''	c) Worn pistons and linings.	Replace them.
6. Engine smokes.
Black smoke from engine.	a) Air filter choked.	Clean filter.
''	b) Fuel valve out of order.	See under "Starting difficulties".
''	c) Insufficient compression.
''	d) Engine overloaded.	Reduce load. Never overload.
''	e) Thermostat valve leaking.	Replace valve.
Black smoke from engine.	Lube oil forces its way past leaky piston and oil rings into combustion chamber.	Replace oil and piston rings.
7. Excessive fuel oil consumption.
Engine runs hot.	Engine overloaded.	Reduce load(never overload).
Insufficient compression.		See under "Starting difficulties".
Leaky fuel system.	a) Fuel pipes leaking.	Repair or replace.
''	b) Fuel pump plungers and linings worn.	Replace defective parts.
Increasing oil level.	Fuel lift pump diaphragm defective.	Replace diaphragm.
Engine smokes.	a) Fuel valves out of order.	Clean and adjust valves.
''	b) Thermostat valve leaks.	Replace valve.
8. Excessive lubricating oil consumption.
Lube oil enters combustion chamber.	Oil piston rings worm.	Replace rings.
''	Pistons and cylinder linings worm.	Replace defective parts.
Lube oil leaks out of crank shaft end bearings.	Oil seal rings and bearings worn.	Replace seal rings and repair bearings.
9. Engine runs hot.
Smell of heat.	a) No cooling water.	Stop engine, fill up with cooling water when engine cooled off.
''	b) Engine overloaded.	Unload engine.
Cooling water temperature too high.	Lack of cooling water owing to defective cooling water pump or escape of water from leakage.	Remedy the fault.
Cooling water too high.	a) Defective thermostat.	Replace thermostat.
''	b) Fan belt too loose.	Tighten belt.
''	c) Radiator choked.	Clean radiator.
''	d) Pressure vacuum valve out of order.	Repair valve.
Lube oil pressure insufficient.	a) Lube oil filter choked.	Clean filter.
''	b) Lube oil pump defective.	Repair pump.
''	c) Lube oil pressure line leaks.	Repair or replace line.
''	d) Defective lube oil overflow valve.	Repair valve.
10. Engine jars.
Engine misfires.	a) Air in fuel system.	Ventilate. See under "Starting difficulties" and "Engine does not reach maximum capacity".
''	b) Fuel valves out of order.

Exercise 1. Answer the following questions:

1) What is a diesel engine?

2) How is the diesel engine power expressed?

3) What are the characteristics of slow-speed diesel engine? (name the cylinder bore, rpm, power output).

4) What kind of engine is called a directly-coupled engine, slow or medium-speed?

5) In what kind of ships are medium-speed engines applied? What are their particulars?

6) What are the advantages of slow-speed engines and benefits of medium-speed ones?

7) Where is high-speed diesel engine installed and what are its characteristics?

8) What fuel does each of these types of diesel engines burn?

9) How else can diesel engines be classified?

10)Where is combustion chamber in the double-acting engine situated?

11) Why are double-acting engines obsolete now?

12) What cycles do diesel engines have? Describe them.

13) During what period does the complete cycle of operation take place in the two-stroke engine?

14) What are the advantages of the four-stroke engines over the two-stroke ones?

 

Exercise 2. Give synonyms to the following words.

To spray, to drive, to pass, to open, to leave, to fall, to occur, to develop, to obtain, to increase, to start, to reach, to include, to finish, to work.

Exercise 3. Give antonyms to the following words.

Low, upward stroke, inlet valve, scavenging port, to reduce, to expand, to drop, to absorb, to stop, above, popular, before, light.

Exercise 4. Explain in English what is meant by:

Combustion chamber, suction stroke, compression stroke, combustion and expansion stroke, exhaust stroke, upward stroke, downward stroke, scavenging port, exhaust valve, fuel injection valve, uniflow scavenging, air charge, burned gases.

Exercise 5. Explain the difference between

1) Single-acting and double-acting principles;

2) Trunk-piston, cross head and opposed-piston types;

3) Two-stroke and four-stroke engines;

4) Upward and downward strokes;

5) Exhaust valve and exhaust port;

6) Air inlet valve and scavenging port;

7) Heavy fuel oil and light fuel oil;

8) Slow, medium and high-speed diesel engines.

Exercise 6. Describe the engine installed abroad your vessel using the following words. Mention its raying (output power and RPM).

Slow, medium, high-speed, two or four-stroke, single or double acting, in-line or V-shape, with cross head or trunk piston, direct, coupled or connected, to the propeller bу gear.

 

Exercise 7. Made up a dialogue of your own based on the dialogues given below.

THE CYLINDER AND PISTON ASSEMBLY I

 

Notes:

cylinder head (cover)	крышка цилиндра
surface	поверхность
scraping	шабровка
to scrape	шаброватъ
machining	машин. обработка
to renew	заменять
safety valve	предохранительный клапан
rocker	коромысло
indicating cock	индикаторный кран
rod	штанга
valve disk	тарелка клапана
bush	втулка
valve stem	шток клапана
pin	палец
turn	обтачивать
to cut off	вырубать
rod	штанга
valve disk	тарелка клапана
bush	втулка
valve stem	шток клапана
pin	палец
turn	обтачивать
to cut off	вырубать
fitting	арматура, пригонка, установка
to weld	заваривать
to fit into position	устанавливать по месту
exhaust valve	выхлопной клапан
cylinder assembly	цилиндр в сборе
we have to... we Should...	Нам следует (надо)

The Cylinder Heads

Mr. Wilson - What about the cylinder heads? Do the contract surfaces of the cylinder heads require machining or just scraping?

Ch. Eng. - They need both.

Mr. Wilson - Must all.the cylinder head be renewed or can some of them be repaired?

Ch.Eng. - Well, the. starting valves are to be overhauled with later pressure testing. But all the other' fittings (the safety valves, the indicating cocks, etc) should be renewed.

Mr. Wilson - Very well. According to the list of repairs you'd like to replace only four exhaust valves. Why not all of them?

Ch.Eng. - The other exhaust valves are O.K. But their disks and stems should be turned.

Mr. Wilson - Do you think that all exhaust valve rockers and rods should be replaced too?

Ch.Eng. - No,-I don't think so. But the rocker bronze bushes and pins should be renewed.

Mr. Wilson-Well, I see.

 

THE CYLINDER AND PISTON ASSEMBLY II

 

Notes:

piston	поршень
repair size	ремонт, размер
plasma - jet hard facing	плазменная наплавка
piston pin	поршневой палец
pressure test	опрессовка
groove	канавка
main bearing	рамовый подшипник
ring	кольцо
top-end bearing	головной подшипник
renewal	замена
measure	измерять
bottom-end bearing	мотылевый подшипник
adjust	регулировать
measurement	измерение
clearance	зазор
adjustment	регулировка
to rebabbit	перезалить
babbit = white metal = antifrictional metal	заливка подшипника
to bore	растачивать
boring	расточка

 

- Mr. Wilson - Well, let's pass on to the piston. Can you tell me. What should be done about them?

Ch. Eng. - according, to the list of repairs two piston assemblies are to be replaced. The rest require the following repairs, namely:

- plasma jet hard facing and cutting the grooves for the piston rings;

- renewal of the piston rings on all the piston;

- measuring the clearances in the top-end bearings. If required they should be rebabbited and then fitted into position with necessary clearances.

Mr. Wilson - I see. By.the way do you want the top end bearings to be rebabbited and adjusted to the new repair sizes of the piston pins or to the old ones?

Ch. Eng. - To the old ones. The pistons will require the pressure testing.

Mr. Wilson - What arc you plans about the piston telescopic system?

Ch. Eng. - Unfortunately it should be completely replaced.

Mr. Wilson - And what about the main bearings?

Ch. Engineer - The main bearings which have big cracks in babbit should be remetalled and then fitted into position. The other bearings should be used depending on their conditions and clearances.

Mr. Wilson - Shall we repair the bottom - end bearings according to the list of repairs?

Ch.Eng. - Oh, yes. Rebabbiting, boring, scraping, fitting and all that I'm sure you know what should be done.

Mr. Wilson - Well, we'll try to do our best.

 

Exercise 8. Придумайте ответные реплики:

A: Do the contact surfaces of the cylinder heads require machining or just scraping?

B:......................

A: What are you planning to do with the starting valves?

B:......................

A: What valves should be replaced?

B:......................

A: What are your plans about the piston telescopic system?

B:......................

A: And what about the main bearings?

B:......................

A: Shall we repair the bottom end bearing according to the list of repairs?

B:......................

A: How many cylinder liners should be replaced?

B:......................

Exercise 9. Translate the sentences.

1. Объясните, что главному двигателю необходим кап. Ремонт. Вся дополнительная работа по демонтажу и сборке главного двигателя включена в ремонтную ведомость. Телефоны, датчики и индикаторы будут сняты силами машинной команды.

2. Объясните, что крышки цилиндров требуют машинной чистки и шабровки. Вся их арматура, кроме выхлопных клапанов должна быть заменена. Трещины надо вырубить и перезаварить. Диски и штоки выхлопных клапанов должны быть проточены.

3. Объясните, что вы хотите заменить 2 поршня в сборе и отремонтировать остальные. Объясните, какой ремонт им необходим. Мотылевые подшипники должны быть перезалиты, проточены, отшаброваны и установлены по месту.

4. Объясните что головка одного из поршней прогорела.

5. Скажите, какой ремонт необходимо сделать. На поршне цилиндра №2 кольца защемлены в канавках. Замерьте, зазоры и прорубите канавки точно по размеру. На поршне цилиндра №3большие отложения накипи, которые необходимо удалить.

 

Lesson 11. PUMPS

Notes: