Stationary Engine Flashcards
What is needed before using an open flame or tools that creates sparks?
Secured Hot permits
What seals and confines the expanding gas and is situated on the top of the cylinder?
Cylinder head
What is another name for Block?
Frame
Engine Cylinders are also known as?
Liner or Sleeves
What is the component that changes the downward linear motion of the piston to usable rotary motion?
Crankshaft
Balancer also known as?
- Vibration Damperner
- Harmonic balancer
- Torsional vibration dampener
What Balancer does?
To absorbs torsional vibrations.
What is leakage of burned and unburned gases past the compression rings is called?
Blowby
What strokes that the piston travels down from TDC on both are?
Intake and Power
What strokes that the piston travels up towards TDC on both are?
Compression and exhaust strokes
The number one cylinder on an inline engine is usually _____ the fly wheel?
Opposite
What determines the firing order of the engine?
By crankshft throws and the arrangement of the lobes on the camshaft.
What are running mates and what type of engine has them?
Having pistons reaching TDC and applies to 4-stroke engines
What is an integral engine arrangement?
Sharing the crankshaft with others
What power required to overcome engine frictional and pumping losses?
Friction Horsepower - (FHP)
Formula for Friction Horse Power (FHP)
Friction HP = Indicated HP - Brake HP
The ratio of the total volume of the cylinder (Swept volume/Displacement) and combustion chamber (clearance volume) when the piston is at BDC to the clearance volume when the piston is at TDC?
Compression Ratio
Formula for Compression Ratio (CR)
CR = Swept volume + Clearance Vol. / Clearance vol.
What are the 2 types of cranking motors and how do you lock them out?
- Pneumatic starts - Close, lock and tag the valves
2. Electric starts - disconnect, lock and tag power source
What device do large engines have for manually rotating the engine and should be locked out prior to entry of the crankcase?
Barring Gear
3 main functions of piston rings?
- Sealing compressed
- Sealing oil
- Transferred heat/cooling
A/F ratio?
Air to fuel ratio
BMEP?
Brake mean effective pressure
IMEP?
Indicated mean effective pressure
B?
Bore (cylinder)
OHC?
Overhead cam
OHV?
Overhead valve
DOHC?
Dual overhead cam
EGR?
Exhaust gas recirculation
ft-lb?
foot-pound (work done)
lb-ft?
pound-foot (torque)
N/m
Newton meter (torque)
HC?
Hydrocarbon
NOx?
Oxides of nitrogen
SAE?
Society of Automotive Engineers
3 functions of flywheel?
- Store energy
- Smooth out vibration/impulse
- attached coupling/shaft to transferring power
What type of engine arrangement is strong reliable and easier to produce?
In-line engine
Engines have high compression ratios in order to heat and ignite the fuel. They also have a high-pressure fuel injection system to overcome and penetrate the highly compressed air?
Compression Ignition (CI) - Diesel
Engines have high-voltage electricity to ignite the fuel?
Spark Ignition (SI) - Gas engine
What are the two independent load arrangements?
- Closed couple load means - Sharing a bearing
2. Remote mounted means - not sharing a bearing
Low speed engines operate below ___rpm?
500 rpm
Medium speed engines operate between ___rpm?
500 to 1000 rpm
High speed engines operate over ___rpm?
1000 rpm
This fuel on Spark ignition engines has the most inconsistent character, due to this reason a computer needed to tweet the inconsistency character?
Methane
4 main parts of the crankshaft?
- Main bearing journals (shaft)
- Connecting rod journals (throws)
- Webs
- Counterweights
What feature on a crankshaft is opposite of the rod throws?
Counterweights
3 designs for damperner?
- Rubber-mounted damperners
- Viscous type
- Spring type
Which type of damperner is repairable?
Spring type
What bearing characteristic allows the bearing to absorb small particles?
Embeddability
Engine bearing shells are manufactured with 2 distinct features to ensure good contact with the bearing bore. These features are?
- Bearing crush
2. Bearing spread
What is the most accurate way to check the bearing clearances?
Measurement
4 ways to check bearing clearance?
- By Plastigage
- Lead wire
- Bearing lift check
- Measurements
One-piece block is also called an?
Under slung crankshaft
The one-piece block has an underslung crankshaft and is commonly used in ______ and _____ speed engines?
smaller size and medium-high speed engines
Multi piece blocks are common for ____ and ____ speed engines?
Larger and low and medium speed engines
What is the purpose of the cross-bolt and multi bolt main bearing cap?
To strengthen more the block/frame
What pressure should not be exceeded when checking for coolant leaks?
45 psi
Aluminum blocks should be cleaned with caustics (capable of destroying or eating away by chemical action) True/False?
False
How much can bearing bores deviate from true alignment?
1/2 the maximum allowable main bearing clearance in new condition
2 ways to check the main bearing alignment.
- if the crankshaft is removed?
- if crankshaft is in place?
- Using piano wire, laser or optical methods
2. Using deflection gauge
Where is the deflection placed to determine if a crankshaft is sitting straight?
between counterweights
What machining process is used to make the bearing bores true again?
Line Boring
What type of liners are thicker? Dry/Wet
Wet
What is the major thrust side of a cylinder?
Opposite of the crankshaft throw on the combustion stroke/power stroke (combustion pressure)
What is the minor thrust side of a cylinder?
Opposite of the crankshaft throw on the compression stroke (compression pressure)
What designs on the large engines to minimize or eliminate the sides wear (major thrust side and minor thrust side) of the liner?
Cross-head design
Where is the highest amount of wear found in a cylinder?
Top of the liner near the upper limit of the ring travel
3 methods to decrease the inside wear of a cylinder?
- Induction hardening
- Hard chrome
- Nitriding
3 styles of liners?
- dry liners
- wet liners
- air-cooled liners
What type liner transmitting heat thru piston rings and block before it reached the coolant. The liner and the block fitting should be closed as much as possible?
Dry liners
To prevent rotation in engines that have had the flywheel removed or that have no provisions for locking?
By block the engine under the throws of the crankshaft
The camshaft open and closes the intake and exhaust valves. The cam can have extra lobes on it to operate?
- Gas Valves
- Air Valves or
- Fuel Injectors
The function of the _____ is to link the crankshaft, camshaft, balance shafts, ignition system and other accessories so that all the events in the engine occurs at the correct time?
Timing Gear
Force x Distance ( a turning distance)
Torque
The torque produced by an engine is dependent on the?
Break Mean Effective pressure (BMEP)
The rate at which work is being done?
Power
Kw x 1.341?
HP
The theoretical power of an engine. It is calculated using information from an indicator card and does not take any friction or pumping losses into consideration?
Indicated Horsepower (IHP)
How to measure BRAKE HORSEPOWER on large engines?
Brake horsepower is the actual power measured at the end of the crankshaft
How to measure Brake horsepower on a small engines?
A dynamometer measure BHP. The dynamometer calculates the BHP after measuring the torque applied by the engine and the rpm.
3 kinds of friction?
- Sliding friction
- Rolling friction and
- fluid friction
Type of friction exists on the engine bearings and cylinder walls when there is metal to metal contact?
Sliding friction
sliding friction changes to ______ friction when the surfaces become separately by a film of oil?
Fluid friction
Zero gauge pressure equals to?
14.7 psia
Gauge pressure below atmospheric is?
negative
All absolute pressure readings are?
Positive
When working on engines, you need to refer to pressure below as well as above___ pressure?
Atmospheric pressure
Refers to pressure that is below atmospheric pressure?
Vacuum
Use this term for measuring pressure in intake manifolds or other low-pressure systems?
Vacuum
A vacuum gauge measures ___ at atmospheric pressure?
Zero (0)
A vacuum gauge measures ___ mercury at absolute pressure?
29.92 in.
Atmospheric pressure is a result of the weight of the atmospheric on the earth’s surface at sea level?
14.7 psia (absolute)
A engine has the same dimensions for bore diameter and stroke length?
Square Engine
An Engine has a larger bore diameter that the stroke length?
Oversquare Engine
An Engine has a longer stroke length than the bore diameter?
Undersquare Engine
Total _______ of an engine cylinder is the volume swept by the piston when making one complete stroke?
Piston displacement
Area of bore x Length of stroke =?
Piston displacement
The volume swept by all the pistons in the engine is?
Engine displacement
Area of bore x length of stroke x Number of cylinders?
Engine displacement
It is the ratio (expressed as a percent) of the volume of atmospheric air drawn into the cylinder on the intake stroke to the cylinder displacement? usually applies to four-stroke engines.
Volumetric Efficiency
Shows how well an engine converts the energy in the fuel into mechanical energy.
Thermal Efficiency. Most engines are from 25% to 35% efficient.
The fuel cannot burn alone and must _____ and mix with oxygen?
atomize
In compression ignition (CI) engines (diesel) and some natural gas engines, only ____ is introduced on intake stroke?
Air
In gasoline, some natural gas and propane engines, a charge of _____mixture is introduced into cylinder on intake stroke?
Air-fuel mixture
As the piston reaches a few degrees BTDC, ignition takes place
Compression stroke
In a Compression ignition (diesel) engine, ____ is injected on compression stroke?
Fuel
In a spark ignition (Gas) engine, a ___ ignites the air-fuel mixture?
Spark plug
The number of degrees the crankshaft travels when both intake and exhaust valves are open at the same time is called?
Valve overlap.
Overlap aids in scavenging means - On intake fresh air pushing out the gasses without Oxygen.
On 2-stroke Cycle Operation;
Power and Exhaust Stroke - as the piston travels down, the top of the piston moves past the exhaust ports. This ends the power stroke and is called?
Blow down
Comparison of 2-stroke & 4-stroke engines
For a given of displacement, a 2-stroke engine produces more power because it has twice as many power strokes per unit of time. The 2-stroke engine does not have twice the power because the effective power stroke is shorter due to the ports in the cylinder.
This method of determining crankshaft rotation is the standard method set by the?
Society of Automotive Engineers (SAE)
To install a distributor and to set the engine valves correctly, you need to know?
The cylinder numbering and firing order.
A typical firing order for CCW running inline-six-cylinder engine is?
1-5-3-6-2-4
In-Line arrangement, each side of each cylinder has a ____bearing, therefore, the bearing area per cylinder on the in-line engine is considerably more.
Main bearing
Common angles for the V-style are?
90 degree and 60 degree
This arrangement consists of the in-line design and can have a varying number of cylinders. This arrangement has two crankshaft, one above the block and one below, which makes this type of arrangement uncommon?
Opposed Piston
This arrangement are common in automotive (Volkswagen, Subaru, Porsche) and aircraft applications. usually in a flat position. They have one crankshaft with cylinders located 180 degrees from each other, which usually results in a high power-to-weight ratio unit.
Horizontal Opposed also called Pancake Engines
The cylinder on this arrangement engines are located around the circumference of the block?
Radial
3 Valves arrangement are:
- Overhead Valve (I head)
- Multi-Valve and
- Flat Head (L head)
The valve design and its variations is the most efficient because the combustion chamber has minimum surface are for its volume. This means that less energy is lost to the cooling system and can used to drive the piston down?
Overhead Valve (I Head)
This valve arrangement are in the block.The position of the piston centreline and the valve head position form an upside-down L. Therefore, limited valve lift due to compression ratio?
Flat head (L Head)
2 Camshaft positions are?
- Overhead cams (OHC)
2. Cam in the block (pushrod engine)
This camshaft design solves the problem of excessive valve train mass. Are used on small and intermediate-size engines with one head. They are not practical on larger engines with multiple heads?
Overhead Cams (OHC)
This camshaft design have all the advantages of the single OHC engines. Advantage over Cam in block (Pushrod engine) is less linkages less friction
Double overhead cams (DOHC)
This cam arrangement , the crankshaft drives the cam directly with gear and pinion. Therefore many engines have the cam close to the crank. Although this design may eliminate extensive gear trains, it requires lengthy push rods. The disadvantage is that long pushrods add to the weight and inertia of the valve train.
Cam in the block (Pushrod Engine)
Air-cooled industrial engines are rare and are usually small engines that have less than ___hp.
200 hp
This cooling methods can keep the temperature difference from the liner to the water jacket smaller. Can regulate the temperature of the engine more efficiently. Advantage, temperature stays constantly even change in loads
Liquid cooled
This cooling methods engines do not achieve 100% volumetric efficiency because of the restriction the air must overcome on its way to the cylinder.
Naturally Aspirated
Only _____ stroke engines can be either naturally aspirated or artificially aspirated?
4-stroke engines
Spark and comparison ignition engines
Spark Ignition Compression Ignition
- CR 6:1 to 10:1 14:1 to 23:1
- Comp. Temp. 500 F & higher Approx. 1000 F
- Comp. Press. 100 to 260 psi 300 to 500 psi
Independent Load Arrangements are:
- Close-Coupled Load
2. Remote-Mounted Load
Arrangement when the driven unit attaches directly to the engine flywheel and flywheel housing. They may use the engine’s main bearing as a support for part of the load.
Closed-coupled load
This load arrangement is when the load has independent bearing supports on each end of its shaft
Remote-Mounted Load
These blocks provide more rigidity than multi-piece block configurations and the main bearing caps are under the crankshaft
One-Piece Block or Underslung Crankshaft
These blocks usually have overslung crankshafts, where the main bearing caps are on top of the crankshaft. This is because the crankshaft mounts in the bed plate. Common in the larger low-and medium speed engines with bores approximately 10” and larger?
Multi-Piece Block also called overslung
Engine blocks service do not use ___ (Like oven Cleaner) for cleaning aluminum engine components because this solution attack and erode aluminum?
Cautics
Some type of cracks on block can be repair by?
Welding or cold stitching
Check the alignment of the main bearing bores. On high-speed engines, the alignment can be checked with a ____ and ___?
Straight edge and feeler gauge
To fix main bearing misalignment on high-speed, one piece block engines, _____ is recommended?
line boring is recommended
Main bearing bore alignment, using deflection gauge should discriminate to?
To 0.0001 inch
When taking readings with the connecting rods removed, the crank is place at _______ (___) for the journal, the dial is zeroed and the crank is rotated. Readings are recorded at each 90 degree interval. If the crankshaft is not running straight, You should shim the engine base to correct this condition?
Top dead center and should shim the engine base
Main bearing bore size and concentricity. You also need to check each bore for ____, ____ and ____ using inside micrometer or a dial bore guage. This is done with the crankshaft removed and the main bearing caps in lace and torqued to specs?
for size, taper and out-of-round
Cylinders must be able to withstand the following, they also must be able to dissipate ____ and keep the ____ out of the crankcase?
withstand high pressures and high temperatures of compression and combustion.
to dissipate heat and keep the coolant out of the crankcase.
Different types of removable cylinder liner?
- Dry cylinder liner
- Wet cylinder liner
- Air-cooled cylinder liner
The highest wear area in the cylinder is near the top of the liner due to following:
- High temperatures
- High pressures and
- Minimum lubrication
Some methods used to treat the inside of cylinder liners in order to reduce the rate of wear are:
- Induction hardening
- Hard chrome and
- Nitriding
_____ Liners are sleeves may have a slide fit (transition) or interference fit and require good contact with the bore in the block for premium heat transfer. Theses liners have thinner walls than wet liner and have constant outside diameter.
Dry Liner
This liners must be thick walled in order to withstand combustion pressures. They have a flange top that seals and o-rings at the bottom to keep the water out of the crankcase.
Wet Liners
Cause of cavitation on wet liners?
Once temperature of coolant nearing to boil and adds to that is vibration of the piston will cause cavitation.
Air-cooled liners limits to ___HP?
200 hp
Liners that feature porting on them near the middle of the cylinder are used on _____ stroke engines, Some features porting is flange mounted cylinder. These are used on very large engines with 12-inch and larger bores and have dry liners?
Two-stroke engines
The liner bores should be measured for wear while they are ____ the cylinder block in order to determine whether they are reusable. If the liners out the block, some liners are easily distorted and measurements can be inaccurate.
While they are inside the block.
Liner inspection. On smaller bores of 6 inches or less, if the liner has a ridge near the top of ring travel the thickness of a ____, it has considerably wear and should not be reused.
Thickness of a fingernails.
The dial bore gauge can be used to measure size as long as it is ___ to a known dimensions; otherwise, it can used only to compare sizes and measure taper.
As long as it is ZEROED to a known dimensions.
Liner wear inspection should be done for the following steps?
- Size 2. Taper
3. Out of round 3. Scratches
Number of steps to determine if the cylinder is out-of-round or tapered?
Total of 6 measurement.
After removal, liners that are to be reused should be marked so they can be reinstalled in the same position during assembly. Liners should be stored _____ and not on their _____ as they can become distorted or egg shaped over time.
Should be stored vertically and not on their side as they can become distorted or egg shaped over time.
Liner problems, _____ is when there are severe scratches and abrasions along the cylinder walls. This is caused by the cylinder rings becoming too hot, which results in compression loss and oil consumption.
Scoring
Liner problems on wet liners, _______ is the loss of metal on the outside of the liner, which affects heat transfer.
Corrosion
Liner problems, _____ is the wearing of the outside of the liner by abrasive particles in the coolant, which then reduces the rate of heat transfer.
Erosion
Liner problems, ___ are caused by a distorted block, over torquing the head bolts and wrong liners protrusion
Flange cracks
Liner problems, ___ is usually caused by overheating, hot spots or piston seizure.
Liner cracking
Liner problems, ____ causes discoloration of liners. This is commonly caused by poorly fitted liners.
Overheating
Liner problems, excessive or premature liner wear can often be attributed to ____ or ___ coming through the air filter or leaks in the intake system.
Attributed to DUST or FINE PARTICLES
Removing the ridge on the cylinders under ____ inches in diameter is accomplished with a hand operated ridge reamer. On large engines, use a rotary burr and/or hone.
under 6 inches (150mm)
If the cylinders measure within specifications for reuse, , removing polished and deglazing surfaces is done with a _____ or ____.
With a flexible hone or ball deglazer.
Using flexible hone or ball deglazer will produces a ____ pattern from ___ to ___degree.
A cross-hatch pattern from 40 to 60 degree
This ___ pattern is made up of microscopic grooves in the cylinder wall, which retain oil for lubrication of the rings and aids new ring seating.
The cross-hatch pattern
Honing with a drill speed of ___ to ___ rpm, while making one complete vertical stroke per second, produces the correct crosshatch angle.
speed of 300 to 400 rpm
Surface finish is normally specified in micro-inches, selecting a ___ to ___ grit stone produces a surface finish of approximately ____ micro inches
Selecting a 180 to 200 grit stone produces a surface finish of approximately 20 micro inches
After honing or deglazing, use a ___ and ___water to clean the cylinders before installing the pistons.
use a BRISTLE BRUSH and HOT SOAPY WATER
To check cleanliness of the bores, wipe with a lightly ___, _____ -free, ____cloth.
Wipe with a lightly oiled, lint-free, white cloth.
____ honing is done to make the cylinder straight and round.
Rigid honing
If the taper and wear of the cylinder are not excessive _____ inches maximum, the cylinder can be made straight with a rigid or fixed honing.
Are not excessive 0.002 inches maximum
Rigid honing must used with __ so the stone won’t breaking.
Used with oil so the stone won’t breaking.
The liner protrusion should also be checked on each cylinder without the ___-rings in place.
Without the O-RINGS in place
usually sealing under the top liner flange depend on pressure from the cylinder head pushing down on the liner, to ensure a leak proof seal, You should put a bead of high temperature ____ (___) sealant under the top liner flange.
You should put a bead of high temperature ROOM TEMPERATURE VULCANIZING (RTV) sealant under the top liner flange.
Most crankshafts are made from _____ steel, which either ___ or ___ hardened.
Made from FORGED ALLOY steel, which either FLAME or INDUCTION hardened.
Some less durable crankshafts are made from ___ steel or ___ iron.
Made from CAST steel or NODULAR iron.
Some small engines have the counterweights as part of the forged mas, but on larger engines the weights are ___ to the crankshaft.
The weights are BOLTED to the crankshaft.
