INTERNAL COMBUSTION ENGINES Section 4 Control of Operation Of The Internal Combustion EngineSECTION FOUR CONTROL OF OPERATION OF THE IC ENGINE The Instrument Panel 1, The instrument panel provides a central location for ‘the controls and gayes needed to operate an IC engine. The engine is operated by the operator from the (J instrument: panel/] engine itselz). instrument panel 2. Here is a drawing of a simplified instrument panel. WATER WATER LEVEL TEMPERATURE OL LeveL OIL PRESSURE: \ IGNITION SWITCH THROTTLE Gages on this instrument panel show the oil __, evel the oi] ______, the water and pressure, level the water temperature 3. The ignition switch (7 opens/} closes) the electrical closes circuit when the engine is to be started. 4. Engine speed is controlled by the Sans throttle 5. Engine speed may also be automatically controlled by ——— governor 6. To check on the operation of the cooling system, you look at the gage. ‘water temperature 7. If the oil-pressure gage shows an excessively high reading, the system is malfunctioning, Jubrieating 8. An oil filter may be - blocked, or clogged 9. Sight gages show the —_____of il in the Iu level bricating system and the of water in level the cooling system, 65,Prestart Procedures 10. 1, 12, 13, 14, a 18. Manufacturers always furnish operation and mainte: nance manuals for their engine: ‘Phe manuel contains starting, procedures. Every operator these procedures before he ti engine. stopping, and control should study and know to 5 ‘The operator who is familiar with the manual and the engine can usually detect malfunctions before they cause serious trouble, Once a malfunction is detected, the operator must know how to____the engine before damage is caused to the engine. A new engine, an overhauled engine, or one that has been idle for a long time should be thoroughly before startup. Aji experienced operator knows how to procee Dut a new onerator may need to use a PRESTART. CHECKLIST to get the engine ready to start. Each company has its own checklist. Exhibit 1 shows a typical checklist Now pull the exhibits out of the bock On this PRESTART CHECKLIST for a stationary enigine, one of the first considerations is whethor or not this is a — engine. ‘To be able to start the engine without damaging it and to be able to ———the engine in an emergency, you must know the location of all valves, piping, and controls. ‘To prevent an accidental startup, the ignition switch ia turned Tf the engine has been worked on, or if it is new, piccos of weld metal or other obstructions may be lying in the fuel tine, If the fuel line — the engine can’t start, When engines are new or have been worked on, the is checked for block- ing, material ‘There is less strain on the engine if it is started when it (CF) is] is not) coupled to the load. “7 start stop checked new stop blocked, or plugged fuel Jine is not19. 20. 21. 24, 21, 28. 30. For example, if the engine is used as a pump driver ihe pump should be (C] unloaded from/[} londed to) the engine. Unload the driven unit, following instructions. For proper engine operation, the lubricating system ‘valves aire adjusted to deliver ofl to the engine, and the engine oil reservoir should be filled. If water is present in the engine crankease, the erank- case is____, the water souree found, and necessary repairs are made. ‘The oil strainer and oil filters are —____, if, nocessary. ‘The governor and throttle are checked, ‘The throttle must move freely to give rapid control of the engine's ‘The cooling system must be filled, and heat exchangers: filled with coolant When the cooling system is full, cheek carefully for any coolant from the system, ‘The cooling water should remain turned on if the cooling system is an (TJ open/{_] recirculating) system, On a new engine, the oil lines are empty, Since the oil pump is run by the engine crankshaft, the pump will not fill them until the engine ‘Thus, before starting the engine the pump must be operated ___until the system is full, and until the engine is up te epocd. Large industrial engines may be equipped with motor- driven lubricating pamps. ‘hen it is not necessary to operate 2 motor-driven lubricating pump by: — before starting ‘the engine, tors, the On engines equipped with separate lub reservoir oil level must be checked and added if necessary. ‘The engine should be turned manually (cranked) throuzh one complete revolution to make sure that, all parts moye freely. Fuel valves are ___________and ignition switches are (C] an] off) while the engine is being cranked. 68 unloaded from ‘manufacturer drained cleaned speed leaking open starts manually, or by hand hand oil, or lubricant. closed oft31, If the engine is equipped with an electric starting motor, it is not necessary to turn the engine over manually. Movement can be chosked by simply engaging the motor for a few seconds, 82. Some engines are started by foreing air into the cylinders, ‘Whe air forces the ________to move. When the engine has an air-motor starter, the air valves must be (C] open] closed) so that the air can turn the engine over. 34, Moisture may be present in the starting motor’s air tank, Drains to this tank are opened to force out any in the tank, 35. In this way, the air entering the eylinder is, 36. All fuel-supply valves except the one which lets gas into the header line should now be ‘37, With this header-line valve closed, no fuel can enter ‘the 38 In engines using naturel ges, the gas pressure at the header should be checked. When gas pressure is high enough for engine opera- tion, the overspeed trip switch may be aot ta — 89, Other automatic safety devices may also be set to Engine Starting Procedures The engine is now ready to be started. Starting procedures vary from manufacturer to manufae- turer and for cach particular installation, The starting procedure given here is intended for a spark-ignition engine using natural gas as 4 fuel. 40. ‘To be sure that: all auxiliary systems of the engine and the driven unit are ready for —, the items listed on the prestart checklist should be accom- plished, 69 starting pistons open moisture, or water ary opened cylinder on on, ‘operation41 43. 44 4, 46. 40, 48. If the engine has heon operated recently it may have some unburned gas left in it from the previous operation. ‘This unburned gas can explode in the in- take manifold or in the muifier Tt must be ___ hefore starting the engine, If the engine has a magneto-ignition system it ia wise to “ground” the magneto to prevent sparking, which ean cause gases to in the muffler or in the intake manifold. If the engine is equipped with an air-motor starter, the air valve is now opened. If it is equipped with an electric starting motor, the starter is to turn the engine over. ‘The engine should be allowed to make 10 or 15 revo- lutions to purge any unburned gases from the intake or exhaust system, When the engine has been pursed, it should be stopped ; the oil-pressure safety switch and the switch should be turned “ON,” As soon as the ignition switch is turned “ON,” thon the gas valve in the header line should be opened to admit___to the header line, ‘The air valve remains open or the electric starting motor is engaged until the —______begins to fire. If the engine fails to start before the fuel gage 5 psi pressure the engine is shut down immediately to find and — __ the trouble. ‘The engine is allowed to warm up to operating tem- perature before it is loaded. ‘The engine is warmed up at reduced speeds and with- out load until the temperature gage on the aa shows that the temperature is within the operating range, If the oil pressure sage shows no pressure within a few seconds after the engine is started the engine is immediately to prevent serious dam- age from having no lubricant. 70 purged, or removed explode engaged. ignition fuel engine correct, or fix instrument panel stopped, or shut down49, When an engine is being started for the first time, it should be run for only 10 or 15 minutes and then stopped for an inspection to check for overheating. Inspection covers are removed, and the crankshaft and bearings are touched to see that they are not getting i eee 50. Some of the lubricating oil may have flowed into parts of the system whieh wore empty when oil was first pat in ‘This flow the amount of oil in the reservoir, 51. If the oil level indieator shows a low oil level, oll is 52. After inspection, addition of oil, and replacement of inspection covers, the engine is ready to operate, ‘The cil-pressure safety switch end the ignition switch should be turned on again, and the mechanism turned on again, 58. New engines require very little breaking in, because the manufacturer breaks them in at the factory. ‘The new engine needs to be run for a few hours at (Cj amrtial/C] tant) spoods before it is fully loaded. 54, Before fully loading the engine, check to see that Iu- bricant is reaching all parts. If the lubricating system is functioning, the engine is ready for. load. 55, ‘The engine can now be fully loaded to the manufac- turer's rated TP. You watch the controls and indicators to make sure that no—_ develops, Procedures for Stopping 56, ‘The stopping procedures for a stationary spark-ignition engine are simple, But the right sequence of steps must be followed to —_______ niisfiring, hot decreases added starting partial full ‘trouble, or problem preventon. 58, bs, 60. 61. 62. 63, 64, 60. 66. {f there is no emergency, the engine should bo allowed to run unloaded for 8 to 5 minutes. ‘This cannot be done in an emergency or when one of tie: sfety —__ slops the engine automati- cally. If the engine has not been stopped by a safety device, it can be stopped hy hand. ‘To stop the engine manually, the frst thing to do is ut off the fuel at the main fuel gas line and let the tine continue to________until it stops by itselt. ‘To burn any fuel left in the engine, the ignition switch should be left “ON” after the fuel ia cut off, After the engine has stopped, the next thing to do is turn the ignition switch An engrine that has been running for a few hours may be hot enough to ignite fuel without a spark. ‘Turning off the ignition switch does not alvays stop) a____ engine. Uncontrolled burning of fuel is dangerous, because it can cause backfiring or explosions that damage equip- ment and injure personnel. Burning fuel by engine heat in « spark-ignition engine is uncontrolled —__ ‘To burn all fuel, keep the ignition switch on during the entire time —___ is coming into the engine. In @ gas system, the shutoff valve at the gas head is closed to keep fuel from ——________ into the cylinders during long shutdowns. Pressure is relieved on integral compressors during Jong shutdowns, s0 that combustible gases can't Ieak back into the crankcase and cylinders of the engin« Any combustible gas in the engine can cause serious explosions when the engine is again. If the engine is to be idle for any length of time, and there is danger of freeving, the cooling syatem is -, unless it is protected with anti-freeze, Ti the engine is shut down for only a short time, it is inspected and then prepared for starting by going, through the procedures in the ________cheek- list again. 12 devices, or switches run OFF hot burning fuel getting, or flowing started drained prestartPreventive Maintenance Engine operating efficioney ean be maintained for longer periods of time by performing periodic engine checks like those shown in Ixhibit 2, at least once every day. 67. The best source of information about engine operation is the Daily Log Sheet which is prepared by the —_______ running the engine, 68. The Daily Log Sheet also gives information ahout maintenance performed on the engine. ‘Che operator who makes out his Daily Log Sheet care fully gives a complete history of the 69. An engine needs little attention when it is new, but it must be checked periodically to keep it operating 70. The operator should check often enough to keep the fuel pressure ____ enough for efficient operation, TL. The operator must also check the air pressure in a 2. engine to be sure that enough — is getting into the engine. 72. Oil levels are checked Lo be sure that there Is enough oil to reach all moving parts, ‘The temperature of the oil is checked periodically to assure that moving parts are properly 18. Proper lubrication prevents and over. heating, 74. Governors must be lubricated properly and must have enough oil for hydraulic units to maintain proper eon- trol of the engine's 16. Cooling system temperatures show how well the engine is working. ‘These temperatures should be checked frequently to see that the engine is not getting too _____. 76. To assure continuous engine operation without mal- functions, the operator should make the checks shown on the Daily Log Sheet and show them in the space when he makes the check, 8 operator engine cfliciently, or properly high, or constant air lubricated friction, or wear speed hot hour, or timeDaily and Weekly Preventive Maintenance Checks Preventive maintenance checks should be made following the manufacturer's instructions, Some inspections, like those on the Daily Log Sheet, should be made more than once a day. Other in- speetions need to be made only ence a day er onee a week, 17. Water level in the cooling system and ____ level in the oil reservoir need to be checked daily. 78. Oil filter handles on cleanable filters or strainers should be turned at least every 4 hours, All other filters should be checked at least once ev week to soe if they need to be 79. In diesel engrinos, the fucl-gas injector valves mast be lubricated at least once a week with a small amount of greuse to be sure that they can admit the proper amount of to the engine. 80, Daily und weekly lubrication of valve rocker arms, rocker arm shafts, and connecting linkage is needed to be sure of proper —___. 81. All lines in the system should be checked at least once every day to make sure there are no losses of fuel, oil, water, or air asa result of in the lines, Monthly Preventive Maintenance Checks 82. Some parts of the engine can function longer then others without special attention, The air cleaner can go for as long as a month under normal conditions without having to be — 85. Oil condition should be checked every month to see if the strainers or the —____ should be eloaned or changed. 84. The fuel-was injector valye may begin to erode by the end of a month of operation, ‘To keep these injector-valve nozzles from causing in- urate fuel injections, they should be = every month. 85. Unless pure water is used, or rust and seale inhibitors are added to the cooling water, rust and scale form quickly in the engine water jacket. When no inhibitors are used, the engine water jackets should be checked for —______and____ formation at least once a month, 4 cleaned, or changed fuel, or seas operation, or action leaks, or holes, or obstructions cleaned, or changed filtera choekedPILOT SIX — INSTRUMENTATION FOR OPERATORS UNIT ONE ~ MEASURING INSTRUMENTS, PRESSURE AND TEMPERATURE An Introduction to Instrumentation for Operators Section One Pressure Instruments... pegs: aa What is Pressure How Pressure is Measured The Barometer ‘The Manometer ‘The Bourdon Tube Spiral and Helix Bourdon Tubes, Using the Bourdon Tube The Diaphragm Gage ‘The Bellows Gage... : Operating Problems with Pressure Gages |. How Are Gages Sealed Interpreting Pressure Readings yand Sumunary Re Section Two ‘Temperature Instruments What is Temperature .., Poe Capitary Tube Filled-System Thermometers . eee How Are Thermometers Protected ....)... 1.0... Bimetallic Thermometers Electric Thermometers What is Electricity How Does a Tiesosconle We Work Thermopiles . * The Portable Pyrometer, sor Resistance Elements Thermistor . , Review and Summary Page 10 10 7 7 19 22 24 26 21 29 38 40 42