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MK1 EOCT Propulsion Machinery > Supervise Overhaul of an Internal Combustion Engine > Flashcards

Supervise Overhaul of an Internal Combustion Engine Flashcards

67
Q

Where would you find guidance for diesel engine operating hour overhaul intervals?

A

COMDTINST M9000.6 in Table 233-1

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68
Q

WHO is the final authority for determining the timing of overhauls?

A

MLC Atlantic and Pacific

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69
Q

At approximately 80% of the operating hour overhaul interval, the supervisor shall assess the condition of the engine. What guidance would you reference to accomplish this?

A

NEM 9000.6, Chapter 233, Paragraph B.2

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70
Q

Who will the supervisor initiate a discussion with to report the condition of the engine and recommend when to conduct the overhaul?

A

The MLC type desk manager

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71
Q

What additional inspections will MLC complete when deciding whether or not to extend (or shorten) the overhaul based on engine condition?

A
  • OEM Technical Representative Inspection
  • MLC ASSIST or NESU/MAT Inspection
  • Navy (Fleet Technical Support Command) Inspection
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72
Q

Where would you record adjustments to overhaul intervals?

A

The cutter’s Naval Engineering Projects List (NEPL)

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73
Q

MLC shall provide specific guidance such as limitations on operating the engine and the plan for monitoring and reassessing the engines condition. Where shall this specific guidance be incorporated?

A

The cutter’s Long Range Maintenance Plan (LRMP)

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74
Q

MLC may also fund a limited number of OEM technical representative cutter visits and onsite labor hours to assist the ships force with:

A
  • Critical Measurements
  • Inspections
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75
Q

When scheduling and planning an overhaul, what items will the supervisor be responsible for ensuring are ordered for the overhaul?

A
  • Flexible hoses
  • Valves
  • Gauges
  • All consumable items required for the overhaul.
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76
Q

What funds will be used for travel cost for MAT assistance to non MAT-supported cutters?

A

The cutter AFC-30 fund

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77
Q

The ________ shall conduct weekly progress meetings with all key personnel and provide progress reports to MLC type desk.

A

Supervisor

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78
Q

The ______ shall be responsible for receipt, inventory and inspection of parts and long lead-time material.

A

Supervisor

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79
Q

The _____ will be responsible for ensuring all post-overhaul test, inspections and break-in procedures are conducted.

A

Supervisor

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80
Q

Where would you find guidance for documenting the overhaul in the next Cutter Engineer Report?

A

NEM M9000.6

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81
Q

Who shall document completion of the overhaul in the fleet logistics system, which will be reflected in the cutter’s Naval Engineering Project List (NEPL)?

A

MLC type desk

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82
Q

Name four things you want to pay particular attention to when preparing to complete an overhaul?

A
  • Installation tolerences
  • Wear limits
  • Adjustments
  • Safety procedures
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83
Q

What must you do before attempting to jack the engine over by hand?

A

Disable the starter circuit

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84
Q

Remove and upon completion of work, reinstall all interferences in way of work for the main diesel engine overhaul in the engine room IAW _______.

A

MLCA Standard Specification 0700C0490.STD

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85
Q

Prior to disassembly of the MDE what do you want to check?

A

Check the face and bore alignment between the engine flywheel and flex coupling.

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86
Q

Cleaning and inspection On the basis of the disassembly and inspection of th engine, submit to the supervisor a condition report of all components with recommendations for _________.

A

Reuse, repair and/or renewal

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87
Q

Clean, inspect and repair/recondition as specified the following components of each engine per the manufactures tolerances and standards:

A
  • Cylinder block
  • Crankshaft
  • Pushrods and rocker shafts
  • Camshaft and followers
  • Cam bearings and bushings
  • Gear train
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88
Q

What guidance would you reference for checking alignment after installing a new flexible couple?

A

CAT special instruction, Form SEH7456-01

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89
Q

The following components for the engine shall be renewed in the after cooler group:

A
  • core assembly
  • after core assembly
  • packing
  • seal
  • gasket
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90
Q

The following components for the engine shall be renewed in the crankshaft group:

A
  • thrower
  • baffles
  • rings
  • bearing
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91
Q

What psi would you hydrostatically test a manifold to?

A

50 psi

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92
Q

Chemically clean the Lubricating Oil Cooler per applicable sections of _________.

A

Table I of MLC Standard Specification

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93
Q

Visually inspect and hydrostatically test each of the Oil Cooler per _______.

A

ASTM E1003

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94
Q

When would you take the Crankshaft Deflection Test?

A

Before starting the overhauled engine, after alignment (cold) and after running the engine for trials (hot).

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95
Q

Upon completion of any major overhaul or repair, as a supevisor, what must you do prior to placing machinery back into operational status?

A

Test and Operate Machinery

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96
Q

What might you be doing when accomplishing the following task?

  • Start ventilation in the main engine room
  • charge the pneumatic starting system
  • check cooling system valves for porper position
  • Ensure MDE fluids are topped off
  • Visually check fuel lines/fuel system
A

Pre-starting check

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97
Q

Check all systems for leaks by turing the MDE in the direction of rotation using the jacking bar to ensure it rotates freely.

A

PRE-STARTING CHECKS AFTER AN ICE OVERHAUL

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98
Q

Test run the propulsion for a minimum of __ hour at idle.

A

1 hour

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99
Q

Run-in MDE dockside, for a period of approximately ___ hours, per manufactures instructions.

A

5 hours

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100
Q

After completion of the final run-in, the following items shall be inspected and corrected as necessary:

A
  • lubricating oil leaks
  • water leaks
  • F/O leaks all external bolts secure
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101
Q

The test data obtained during the run-in shall be recorded and submitted to appropriate authority within ____ hours after completion of the test.

A

48 hours

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102
Q

A sea trial for a period of 4 to 6 hours may be required to demonstrate proper operation of the overhauled MDE, in all modes of operation, as per ________.

A

COMDTINST M9000.6, Chapter 094.1.4

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103
Q

What is piston wear characterized by?

A

An excessive clearance between the piston and the cylinder

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104
Q

What are symptoms of excessive clearance between a piston and cylinder?

A

Piston Slap and Excessive Oil Consumption

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105
Q

When does piston slap occur?

A

After TDC and BDC, as the piston shifts its thrust from one side to the other.

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106
Q

What will accumulation of carbon deposits cause?

A

Erratic operation and greatly reduce engine efficiency

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107
Q

What is one of the factors controlling piston wear?

A

Lubrication

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108
Q

What will inadequate lubrication cause?

A
  • Piston wear
  • Piston seizure
  • Land breakage
  • Piston pin bushing wear
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109
Q

What is lack of lubrication caused by?

A

Lack of L/O pressure or restricted oil passages

110
Q

There should be _____ on all pistons at all times.

A

Load Balance

111
Q

What will cause excessive wear on the piston and piston pin bushing?

A

An overload or unbalanced load

112
Q

How is the balance of an engine determined?

A

By checking the exhaust gas temperature at each cylinder, the rack settings and the firing and compression pressures.

113
Q

What causes cracking of the lands of a piston?

A

Insufficient ring groove clearance

114
Q

Of the causes listed under “Other factors which may cause low compression pressure”, which causes would affect the pressure in only one cylinder assembly of a multicylinder engine?

A
  • A: Leaking cylinder valves
  • B: Faulty injector gasket
  • C: Faulty head gasket
  • D: Leaking after-chamber valves
115
Q

What causes of “low compression pressure” may effect a group of cylinders or posibly all cylinders.

A
  • Intake air header leakage
  • faulty blower
  • clogged air filter
116
Q

What is excessive oil consumption generally associated with?

A

Worn oil rings

117
Q

What is caused by excessive operating temperatures?

A

Oxidation

118
Q

Name two factors that cause improper ring clearance:

A
  • Abnormal amount of carbon deposits on rings and grooves
  • Improper dimensions, new rings must have proper thickness, width, diameter and gap
119
Q

One cause of undue loads on a ring could be_____.

A

Insufficient gap clearance

120
Q

What does a bright spot found on each end of a broken ring indicate?

A

Insufficient gap clearance

121
Q

_________ may result from insufficient ring pressure.

A

Sticking and binding

122
Q

What indicates the leakage of gases past the rings?

A

Discoloration (usually appearing as black lines)

123
Q

What conditions cause piston rings to stick in the grooves, wear excessively or break?

A

Improper lube oil

124
Q

What is the greatest factor affecting the wearing of piston rings?

A

Worn cylinder liner

125
Q

What must be considered when new piston rings are installed?

A
  • Surface condition
  • Amount of taper
  • Out-of-roundness of the liner
126
Q

How should you stagger adjacent rings to reduce gas leakage?

A

180 degrees

127
Q

What type of metal are piston pins made of?

A

Hardened steel alloy

128
Q

What type of metal is piston sleeve bearings and bushings made of?

A

Bronze or a similar material

129
Q

Wear of a pin or bearing is normal, but what factors can increase the rate of wear?

A
  • Inadequate or improper lubrication
  • Overloading
  • Misalignment of parts
  • Failure of adjacent parts
130
Q

What should you measure piston pins and bushings with to determine if wear is excessive?

A

Micrometer

131
Q

What will result of misalignment of connecting rods?

A

Uneven loading on piston pins and bearings

132
Q

______ may be caused by improper reaming of the bushing for proper clearance.

A

Misalignment

133
Q

Connecting rod troubles usually involve either the ______ or the ________.

A

connecting rod bearing or the piston pin bearing

134
Q

Connecting rods must be checked for proper alignment before being installed in an engine and after any derangement involving the _________.

A

piston, cylinder or crankshaft

135
Q

Whenever rod bolts are removed, they should be carefully inspected for ___________.

A

Stripped or damaged threads or elongation

136
Q

What are some common troubles of crankshafts, camshafts, journal bearings and antifriction bearings?

A

Metal fatigue, inadequate lubrication and operation of the engine at critical speeds

137
Q

What are some lubrication difficulties you should watch out for?

A
  • low L/O pressure
  • High temperatures
  • Lube oil contamination by water, fuel and foreign particles
138
Q
  • Corrosion of bearing materials
  • Surface pitting of bearings
  • Inadequate bond between bearing material and bearing shell
  • Out of round journals
  • Rough spots
  • Fautly installation
  • Poor contact
  • Misalignment of parts
  • Failure to follow recommended procedures in the care of L/O
A

What are a few causes of journal bearing failure?

139
Q

What are a few causes of poor contact between a bearing shell and a connecting rod on journal bearings?

A
  • Foreign particles
  • excessive clearance
  • rough surface
140
Q

________ of main bearings can be cause by warped or bent crankshaft.

A

Misalignment

141
Q

If there is no manual available to provide guidance on the proper L/O temperature to be maintained, what temperature should you maintain the L/O leaving the engine?

A

The engine should be mainatined between 160 degrees and 200 degrees fahrenheit if no manual is available.

142
Q

Dirt in a bearing which has been improperly or insufficiently cleaned may be detected by_______.

A
  • Noise when the bearing is rotated
  • Difficulty in rotating
  • Visual inspection
143
Q

Spalled or pitted rollers or races may be first recognized by _______.

A

The noisy operation of the bearing

144
Q

Brinelled or dented races are most easily recognized by_____.

A

Inspection after thorough cleaning

145
Q

Where does brinelling receive it’s name from?

A

It’s from the similarity to the BRINNELL HARDNESS TEST.

146
Q

Can Brinelled Bearings be placed back in service?

A

NO, they must not be placed back in service!

147
Q

What is CREEP?

A

A very gradual rotation of the race.

148
Q

Cracked races will usually be recognized by a definite _________.

A

thump or clicking noise in the bearing during operation

149
Q

The principle type of ______ for timing and accessary drives in most diesel engines is a system of gears.

A

Power Transmission

150
Q

What are some causes of gear failure?

A
  • Improper lubrication
  • Corrosion
  • Misalignment of parts
  • Torsional vibration
  • Excessive backlash
  • Wiped gear bearings and bushings
  • Metal obstructions
  • Improper manufacturing procedures
151
Q

_________ of gear trains involve a thorough check of gear shafts, bushings and bearings, and gear teeth during each periodic inspection.

A

Maintenance and Repair

152
Q

One of the most important parts of a _______ is the set of gears that drives and sychronize the two rotors.

A

Root Type Blower

153
Q

The most direct method for checking gear clearance is by the use of ______.

A

feeler gauges

154
Q

What are the principle causes of drive chain failure?

A
  • Improper chain tension
  • Lack of lubrication
  • Sheared cotter pins or improperly riveted joint pins
  • misalignment of parts, especially idler gears
155
Q

What is used on most engines to adjust chain tension?

A

An idler sprocket and chain tensioner

156
Q

During operation, chain increase slightly in length because of ______.

A

stretch and wear

157
Q

Turbo chargers used in the CG today may operate with temperatures as high as ______ degrees and speeds up to ______ RPM’s.

A

1200 degrees Fahrenheit, 75,000 RPM’s

158
Q

List six supervisor responsibilities associated with planning, scheduling, executing and completing a maintenance or repair task.

A
  • Size up the job before starting
  • Check on materials required
  • Check on priority of the job
  • Consider capabilities and experience of personnel when assigning work
  • Keep track of work being done
  • Carefully inspect after the job has been completed
159
Q

Who is responsible for ordering flexible hoses, gauges and all consumable materials required for an internal combustion engine overhaul?

A

The Supervisor

160
Q

What four task is the supervisor responsible for during the execution stage of an overhaul?

A
  • Managing
  • Supervising all work
  • Inspections
  • Tests
161
Q

Upon completion of an overhaul, the supervisor will ensure the completion is documented in what two reporting systems?

A
  • Next Cutter Engineering Report
  • CMplus
162
Q

What two conditons must be maintained in tanks or compartments or when conducting hotwork in an area in conjuction with an overhaul?

A
  • SAFE FOR PERSONNEL
  • SAFE FOR HOTWORK
163
Q

What is the wear criteria and critical dimension data of components based on when cleaning and inspecting a disassembled engine?

A

Manufactures service/Technical manual

164
Q

What is a sea trial period intended to demonstrate?

A

Proper operation of an overhaul MDE

165
Q

Characterized by presence of abnormal amount of carbon.

A

Improper piston ring clearance

166
Q

Characterized by improper functioning of a torsion vibration damper.

A

Bent or broken crankshaft

167
Q

Characterized by improper valve tappet adjustment.

A

Camshaft and bearing trouble

168
Q

Characterized by fine abrasives in lubricants

A

Bearing wear causing looseness without apparent surface disintegaration

169
Q

Characterized by misalignment of idler gears.

A

Drive chain failure

170
Q

The lubricating oil temperature shall be maintained at ___________ or below during bearing
checks.

A

48.9° C (120° F)

171
Q

Insufficient lubrication to any bearing or bushing, improper installation of bearings or bushings, or defective bearings or bushings normally will be indicated by a noticeable overheating of the affected part by the end of the ____________,

A

15 minute run at 40 percent speed, no load

172
Q

Diesel engine log readings shall be recorded every __ minutes during run.

A

15

MK1 EOCT Propulsion Machinery (3 decks)

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