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Millwright 4th Year > Engines (All Modules) > Flashcards

Engines (All Modules) Flashcards

1
Q

What is it called when the main bearing caps are under the crank shaft?

A

An underslung crankshaft

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2
Q

What is it called when the crankshaft is laid on a bed plate and the main bearing caps are on top of the crankshaft?

A

An overslung crankshaft

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3
Q

What should you not use when cleaning aluminium?

A

Caustics

Strong corrosive

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4
Q

What measurements change if the block deck is resurfaced?

A

The piston to head clearance and the block deck height changes

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5
Q

How can you check for crankshaft deflection if the crankshaft is still in the housing?

A

You can use a deflection gauge placed between the webs and rotate the crank to see if the space between changes.

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6
Q

What is line boring?

A

A procedure that uses a boring bar to machine the main bearing bores

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7
Q

What are other names for cylinders?

A

Liners or sleeves

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8
Q

What are the main functions of a cylinder? (Liners, sleeves)

A

To be able to,

Withstand high heat And high pressures from combustion.

Dissipate heat and keep the coolant out of the crankcase.

Cylinders also have a large affect on sealing the combustion gases.

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9
Q

Where is the highest wear area on a cylinder?

A

Near the top of the line due to high temperatures, pressures and minimum lubrication

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10
Q

What are some of the methods used to treat the inside of cylinder liners in order to reduce the rate of wear?

A

Induction hardening

Hard chrome

Nitriding

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11
Q

What are dry liners?

A

They are sleeves that fit inside the cylinder bore and do not contact the engine coolant

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12
Q

What are wet liners?

A

Liners that are in contact with the coolant and form part of the water jacket

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13
Q

Why should you measure a liner while it is still in the block before you remove it?

A

It may warp or expand when removed from the block. So take measurements while it is still in the block to see if it can be reused.

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14
Q

What is the best tool for taking bore measurements?

A

Dial bore gauge

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15
Q

What is scoring of a cylinder?

A

Severe scratches and abrasions along the cylinder walls

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16
Q

What usually causes liner cracking?

A

Over heating, hot spots or piston seizure

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17
Q

What is cavitation of a cylinder liner?

A

Where small pinholes appear on the coolant side of the liner, if the holes get deep enough, the coolant enters the cylinder and mixes with the lube oil

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18
Q

What is deglazing of a cylinder?

A

If a cylinder measures within specifications for reuse, deglazing is done with a flexible hone or ball deglazed. This removes polished or glazed surfaces and produces a cross-hatch pattern in the cylinder.

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19
Q

What angles should a cylinder cross hatch patter be?

A

40° - 60°

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20
Q

What should you use to clean the cylinder after honing or deglazing?

What should you not use?

A

You should use a bristle brush and hot soapy water

Don’t use a solvent because it does throughly flush the material and abrasives from the microscopic grooves.

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21
Q

What is honing? (Rigid honing)

A

Rigid honing is done to make the cylinder straight and round

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22
Q

Misaligned main bearing bores could cause what?

A

Excessive bearing wear or a broken crankshaft

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23
Q

Why do you use alloy cast iron for an engine block material?

A

The alloy cast iron is very strong

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24
Q

What do leaking o-rings on a wet liner cause?

A

Coolant to enter the crankcase

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25
Q

What is the purpose of the crankshaft?

A

To convert downward linear motion of the piston to usable rotary motion

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26
Q

What are the parts of a crankshaft?

A

Main bearing journals

Connecting rod journals/throws

Webs

Counterweights

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27
Q

What is a flywheel for?

A

To stabilize speed fluctuations and store energy during power pulses to carry the engine to the next stroke

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28
Q

What are vibration dampeners?

Balancers, harmonic balancers

A

To reduce crankshaft torsional vibration

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29
Q

What are the 3 different types of vibration dampeners?

A

Rubber mounted

Viscous-type dampeners

Spring-type

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30
Q

What is fatigue strength of a plain bearing?

A

The ability of the bearing to withstand shock loads without flaking or cracking prematurely

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31
Q

What is conformability of a plain bearing?

A

The ability of the bearing to mould itself to the imperfections of the crank journal

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32
Q

What is embeddability of a plain bearing?

A

The ability of the bearing to absorb small particles of dirt, thereby preventing damage to the shaft

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33
Q

What is bearing spread?

A

When the bearing half is wider the the bore that is going to be installed. This gives the bearing a tight fit in the bearing cap and housing during installation

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34
Q

What is bearing crush?

A

When the bearing inserts are machined to protrude out from the bearing cap and housing. This is to achieve a tight fit during installation by forcing the bearings against the bearing cap and housing when it is torqued together

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35
Q

What are 4 ways of measuring bearing clearance?

A

Measurement of the shaft and the bearings inside diameter

Plastigauge

Lead wire

Bearing lift checks

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36
Q

What are the most common causes of bearing failure?

A

Lack of lubrication

Contaminated oil

Misalignment

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37
Q

What are connecting rods?

A

They form the link that transmits the force of combustion in the cylinder from the piston to the crankshaft

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38
Q

What are the 2 types of connecting rods? What is the difference?

A

Straight cut, has a parting line that is 90° to the rod beam

Bias cut, this is cut at an angle to reduce the with when the 2 parts are separated

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39
Q

If you don’t see match marks when removing rod caps, what should you do?

A

Match mark them!

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40
Q

What are the various piston rod cap alignment devices?

A

Rod bolts which have a close fit

Dowels

Tongue and groove

Serrated (saw tooth)

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41
Q

What is the purpose of a piston?

A

To receive and withstand the high temperature-high pressure force of the expanding gases caused by the combustion

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42
Q

What are the purpose of piston rings?

A

To make a dynamic seal between the piston and the cylinder walls and to dissipate heat from the piston to the cylinder walls

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43
Q

Why might the top of a piston be irregularly shaped?

A

To create turbulence within the cylinder to mix the air and fuel

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44
Q

What is a trunk type piston?

A

A one piece piston that can be forged or cast, it has a longer skirt to provide more support and quieter operation

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45
Q

What is a cross head type piston head?

A

It’s a 2 piece piston where the top part of the piston with the ring lands is one part and the skirt is the second

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46
Q

What are the various ways for piston cooling and lubrication?

A

Spray oil from a nozzle that is directed at the underside of the piston

Oil that is pumped through the rod lubrication passage to a compartment in the top of the piston

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47
Q

What are the 3 types of piston pins?

A

Full floating pins, free in the rod and piston

Locked-to rod pins, that turn in the piston only

Locked-on piston, pins are held in the piston while the rod turns on the pin

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48
Q

What are the 2 types of rings used on a piston?

A

Compression rings

Oil control rings

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49
Q

How are compression rings activated?

A

By gas pressure that forces the ring outward and down to seal

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50
Q

What are the common types of ring joints for compression rings?

A

Angle joint

Step joint

Straight butt joint

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51
Q

How should ring gaps on compression rings be lined up when installed?

A

They must be staggered to prevent leakage

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52
Q

What is a camshaft and what does it control?

A

It’s a loved shade that changes rotary motion into reciprocating morning, the camshaft controls the opening and closing of the intake and exhaust valves

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53
Q

How fast does the camshaft on a 4-stroke engine spin compared to the crankshaft?

A

The speed of the camshaft is 1/2 crankshaft speed on a 4-stroke engine

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54
Q

What are the 3 types of lifters?

A

Solid

Roller

Hydraulic

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55
Q

What is the purpose of the camshaft lifter?

A

To transfer motion to the pushrod

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56
Q

What is a pushrods purpose?

A

It serves as a link between the lifter and the rocker arm in a camshaft-in-block engine.

It may be a solid rod or a hollow tube that carries oil to the rocker arm and pivot

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57
Q

What us a rocker arm and what is it’s purpose?

A

It’s a mechanical link between the pushrod and the valve, changing the upward motion of the lifter and pushrod into a downward motion of the valve.

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58
Q

What is a valve bridge/cross head?

A

It is a bridge that spans a pair of intake or exhaust valves and allows one rocker arm to open both valves simultaneously

59
Q

What is the function of the cylinder head?

A

It forms and seals the top of the cylinder that includes a combustion chamber where the compressed air/fuel mixture is burned.

It also incorporates passages for the flow of coolant and lubricating oil

60
Q

How are engine valves primarily cooled?

A

Through heat stranded to the valve sear and guide

61
Q

What is a valve rotator and what is it’s purpose?

A

It cause the valve to rotate slightly every time the valve actuated, it is used to help break carbon deposits on the valve seat and promotes even wear on the valve and seat

62
Q

What is valve clearance? (Lash)

A

It is small a gap between the rocker arm and the top of the valve

It is there to provide clearances for component expansion as engine temperatures rise and to compensate for wear in the valve operating system

63
Q

When you adjust valve clearance what position must the valves be in?

A

A closed position

64
Q

When compared to an integral valve seat, valve seat inserts provide a replaceable wear surface with improved ______

A

Wear characteristics

65
Q

Why is an exhaust valve usually made of higher quality material then an intake valve?

A

It operates at a higher temperature and is subject to corrosive gases flowing through

66
Q

What are the 2 types of cam arrangements?

A

Can in block arrangement

Overhead cam arrangement

67
Q

Valve seals control valve guide and stem lubrication to prevent what?

A

Oil consumption

68
Q

What is a BTU?

A

A British Thermal Unit

Amount of head required to head 1 lb of water by 1°F

69
Q

What is a calorie?

A

Amount of heat necessary to heat 1g of water by 1°C

70
Q

What does octane rating refer too?

A

The ability of the fuel to resist ignition due to compression

71
Q

What does a higher octane number show?

A

The more the fuel can resist

self-ignition

72
Q

What does Cetane refer too?

A

The ability of a fuel to ignite easily under compression

73
Q

What is pre-ignition?

A

This occurs before there is a spark from the ignition system to the spark plug, it is caused by hot spots in the combustion chamber

74
Q

What is detonation?

A

Occurs later then pre-ignition in the combustion process, the flame travels from the plug across the combustion chamber, as the fuel is burning the flame causes the fuel mixture on the opposite side of the combustion chamber to be compressed even higher then it is already compressed from compression.

75
Q

What are the two basic methods of gasoline fuel systems?

A

Carburetor

Electronic fuel injection

76
Q

What does a carburetor do?

A

Atomizes the fuel and mixes it with the air in the proper ratio

77
Q

What is a Venturi on a carburetor?

A

A restriction in the air horn that creates a low pressure area in the carburetor.

78
Q

How does the main discharge tube of a carburetor allow fuel to enter the air horn?

A

It has atmospheric pressure in the bowl where the fuel is and a low pressure area at the end of the fuel causing the fuel to flow through the tube because of the difference in pressure

79
Q

What are the 2 basic methods used to meter the fuel in a computer controlled electronic fuel injection system?

A

Varying the fuel pressure

Opening the injector in pulses

80
Q

What is a knock sensor?

A

A sensor that is attached to the block or the head to indicate whether there is pre-ignition or detonation

81
Q

Where is the fuel injected in a gasoline engine?

A

The intake manifold or the intake port

82
Q

What are the 2 basic types of natural gas fuel systems?

A

Carbureted

Fuel injected

83
Q

What is needed between the fuel and air inlet pressure at the carburetor?

A

The gas must always have a higher pressure then the air pressure to ensure there is always gas entering the engine

84
Q

How is carburetor linkage setup?

A

It is set up so that a very small movement of the governor does not cause a large initial movement of the throttle in its most sensitive positions

85
Q

What is the issue with throttle shaft seal leaks?

A

It allows unfiltered wire into the engine which can cause significant wear

86
Q

Where is the fuel mixed on a two stroke

Natural gas engine that uses a low pressure fuel injection system?

A

In the engine cylinder. The air and fuel are not premixed before entering the cylinders

The air enters the cylinder at bdc and the fuel is not injected into the cylinder until the piston moves up and covers the exhaust ports.

87
Q

What does LPG stand for?

A

Liquid petroleum gas

88
Q

Between gasoline, natural gas, propane and diesel. Which of these has the highest heat value?

A

Diesel has the highest heat value

89
Q

How much should you a propane tank be filled to and why?

A

80% because propane expands very rapidly when there is a temperature increase

90
Q

What are the 2 types of carburetors used when using propane?

A

Air valve carburetors

Spray bar carburetors

91
Q

What does the metering valve control and what does the throttle plate control on a spray bar mixer?

A

The metering plate controls the fuel

The throttle plate controls the air

92
Q

How does a diesel fuel system ignite the fuel?

A

Using the heat of compression

93
Q

What is a necessary thing a diesel fuel injection pump must do?

A

Inject a high enough pressure to overcome and penetrate the highly compressed air

94
Q

What are the two basic types of diesel fuel injection systems?

A

Mechanical injection/mechanical control

Mechanical injection/electronic control

95
Q

How does a distributor fuel injection system work?

A

It has one high pressure pumping plunger the distributed and pumps fuel to a distribution head. The distribution head than diverts fuel to each of the injector nozzles

96
Q

How does an inline fuel injection system work?

A

It is a self contained unit that has its own cam and plunger for each cylinder

97
Q

What is the port and helix metering method?

A

When each plunger pump is feared to a rack that is controlled by the governor. The position of the governor linkage adjusts the rack, which then rotates the plungers in their bore. This changes the position of the plunger helix port for when fuel is delivered to the injector.

98
Q

How does a unit fuel injection work?

A

Is has the injector pump and injector mounted in the head of the engine

99
Q

What are the primary functions of an air induction system?

A
  • To clean the air so that it is free of abrasive particles
  • Ensures a sufficient quantity of air is supplied
  • Ensures air is at the correct temperature
  • Also aids in cooling the valves and other internal parts
100
Q

What’s the most common way an oil bath air cleaner works?

A

It directs the air to make a sharp corner, at which point the air encounters the oil, the first particles are then caught in the oil.

101
Q

What is a u-tube manometer used for?

A

A primary measuring device the indicates pressures or vacuums by the difference in the height of two columns of fluid.

102
Q

What are the most common ways of induction?

A

Natural aspiration
- relies on atmospheric pressure to push air into the cylinders

Artificially aspirated
- uses some mechanic means to push the air into the cylinder

Piston-type scavenging pumps
- uses the underside of the piston and a sealed crankcase to push air into the cylinder

Blowers
- lobed blowers, centrifugal blowers

103
Q

What is supercharging?

A

Process of increasing the mass of air in the engine cylinders by raising the air density and pressure in the cylinder to above atmospheric pressure, this allows more fuel to be burned.

104
Q

What is turbo charging?

A

Uses the exhaust gases to spin a turbocharger exhaust wheel that is attached to the intake compressor wheel. This causes both wheels to spin at the same high rate of speed.

105
Q

What is the term used for pressure produced by the turbo charger?

A

Boost

106
Q

What is a ignition system distributor?

A

A device that distributed electrical power to each system in the correct sequence and at evenly spaced intervals

107
Q

What is a diode?

A

A solid state decides that allows current to flow in only one direction

108
Q

What is a zener diode?

A

A solid state voltage-regulating device that can be specified for a specific voltage or voltage rating

109
Q

What is a transistor?

A

An electronic switch that is turned on by a small current to one of its connections.

110
Q

What is a bridge rectifier?

A

A solid state device that changes AC current into DC current

111
Q

What is a magneto ignition system?

A

An ignition system that produces its own power by using permanent magnets in its own generating system

112
Q

What is a microprocessor-type ignition system?

A

An ignition system that has no moving parts and are fully computerized

113
Q

What are the 2 distinct circuits of all ignition systems?

A

The low voltage primary circuit

The high voltage secondary circuit

114
Q

What is an ignition coil?

A

A step-up transformer that converts low voltage, high current electrical energy into high voltage, low current electrical energy

115
Q

Which component do you use to control boost on a turbocharger?

A

The waste gate

116
Q

How do you determine the heat range of a spark plug?

A

The heat path is from the tip of the centre electrode, through the ceramic insulator to the steel shell. The shorter the length of this path, the cooler the spark plug operates.

117
Q

What 2 components do you use in a compression ignition (CI) system for cold starting?

A

Glow plugs

Intake manifold heaters

118
Q

What are the 4 methods you can crank an engine over for starting?

A

Use an electric motor

Air start with an air rotor

Air start with direct air injection

Hydraulic motor

119
Q

What is the main function of an engine cooling system?

A

To regulate engine temperature

120
Q

What are the three methods an engine cooling system uses to reject heat?

A

Conduction

Convection

Radiation

121
Q

What are the three types of cooling systems?

A

Air cooled engines

Liquid cooling open system
(Coolant is not recirculated)

Liquid cooling closes system
(Coolant is recirculated)

122
Q

What is the function of a thermostat?

A

To sense engine temperature and maintain operating limits by controlling coolant flow

123
Q

Where most a cooling system expansion tank be located?

A

Above the engine

124
Q

What type of pump is a water pump?

A

A centrifugal, non-positive, displacement type pump

125
Q

What are the 2 main types of coolant and which one is safer for the environment?

A 
Ethylene Glycol 
(High boiling point)

Propylene Glycol
(Safer for the environment)
(Lower boiling point)

126
Q

What happens if glycol is introduced into the lubrication system?

A

The oil/glycol mixture becomes acidic and damages engine parts and surfaces

127
Q

What are 2 tools used to test antifreeze strength?

A

A hydrometer

A refractometer

128
Q

What are the 3 types of lubrication methods?

A

Splash system

Splash/pressure system

Full pressure system

129
Q

What type of pump is used on an engines main lubrication system?

A

Positive displacement rotary pump

Ex. 
External gear type 
Vane 
Internal gear 
Gerotor pumps
130
Q

What are the 2 types of oil filtration systems?

A

Full-flow filtration

Bypass filtration system

131
Q

What are some of the considerations that affect oil and filter changes?

A

Type of fuel burned and the quality of the fuel

The environmental conditions in which the engine operates

The amount of oil in the sump and the extent of the filtration systems

132
Q

What is the purpose of a crankcase ventilation system?

A

To remove combustion gases and water vapours from the crankcase

133
Q

What is it called when combustion gases escape past the piston rings and enter the crankcase?

A

Blow-by

134
Q

What is the purpose of the exhaust manifold?

A

To collect the exhaust gas

135
Q

How does a muffler accomplish sound silencing?

A

By changing the direction of gas flow multiple times

136
Q

What are the 5 functions of a lubrication system?

A 
To reduce friction 
To cool 
To seal 
To clean 
To absorb loads
137
Q

What instrument is commonly used to check the crankcase ventilation system?

A

Manometer

138
Q

What should the mass be of a complete engine foundation?

A

2.5 times the mass of the complete engine

139
Q

Typically, How thick are the rubber separators places between the building foundation and the engine mounting block?

A

3/4” thick

140
Q

What are the 2 basic types of engine mounting?

A

Skid mount

Block mount

141
Q

What are sole plates?

A

The load bearing steel plates grouted into the foundation around the mounting area of the foundation

142
Q

What are the 2 types of engine control systems?

A

Electronic

Pneumatic

143
Q

What are the three types of maintenance programs?

A

Reactive

Preventative

Predictive

144
Q

What is the main purpose of an engine control system?

A

To monitor and control the engine and to shut down an engine in the event of a critical alarm

Millwright 4th Year (15 decks)

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