last year,WE CAME TO SMK PELAYARAN DEMAK WITH

ALL OF OUR STUPIDNESS

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC .
05

WE KNEW NOTHING

OUR SENIORS & LECTURES TEACH US

PATIENTLY
TO BE

A REAL MARINE ENGINEER

I DEDICATE IT

THANKS
TO TO
OUR DIRECTOR,
ENGINEERS,
BELOVED CADETS
OFFICERS, AND SENIORS
SEMARANG MERCHANT MARINE POLYTECHNIC

DIESEL ENGINE PRESENTATION

DESND by : BUDI RIYANTO
CHEKD by : Mr.ENDRODI MM
APPD by : Mr.ACHMAD WAHYUDIONO MM

Main Diesel
Engine

Main Diesel
Engine
overhouled
Piston &
Con.rod
For 4 stroke
Diesel Engine

Turbocharger
overhouled

Piston crown &

con.rod
for 2 stroke
diesel engine
Turbocharger

COMBUSTION ENGINE
IN LINE & V-TYPE

---

INDICATOR POWER OF 4 STROKE DIESEL

1ST THE
INLET STROKE
ENGINE-by

BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

AIR VALVE OPENS,PERMITING

AIR TO BEIKW
DRAWN INTO THE CYLINDER B
Ni = Pi.L.A.N.Z
THE DOWNWARD STROKE OF THE PISTON

Ni

: Daya IndikatorIKW.

Pi

2 Indikator
THE COMPRESSION
STROKE
: Tekanan rata-rata
pada cylinder...Bar =1
bar x 105 N/m2=1 bar x102
2
KN/m2
ND

-BOTH OF THE VALVE dIS CLOSED & THE PISTON START

4 AIR FOR PRODUCING THE HEAT NEEDED
: langkah pistonMeter.
UPWARD,COMPRESSING
THE
TO IGNITE THE FUEL.
: Luas penampang Piston
Meter.

L
A
d

: diameter cylinder..Meter.

: Banyaknya putaran porosRPS.putaran/detik

-THE
FUEL VALVE OPENS & THE FUEL OIL IS INJECTED INTO THE HOT AIR
Z
: Banyaknya cylinder
WHERE IT IGNITES.

3RD THE POWER STOKE

---EFECTIF
OF
4 STROKE
DIESEL
ENGINE---THE BURNINGPOWER
FUEL FORM
GASES
WHICH CREATE
PRESSURE
& SEND
THE PISTON DOWNWARD,THIS
IS THE
POWER STROKE OFENGINE.
Ne = Pe.L.A.N.Z
EKW
2
Ne

: Daya EfektifEKW.
TH

Pe

: Tekanan rata-rata Efektif pada poros...Bar =1 bar x 105 N/m2=1 bar x102 KN/m

4 THE EXHAUST SROKE

-WHEN THE PISTON HAS COMPLETED ITS POWER STROKE ,THE EXHAUS
: langkah pistonMeter.
VALVE OPEN & PERMITS
2THE BURNED GASES TO ESCAPE.
d
A
: Luas penampang Piston.
Meter.
4
-THE PISTON RETURNING UPWARD FORCES OUT THE REMAINING GASES
d
: diameter cylinder..Meter.
IN THE CYLINDER.
L

: Banyaknya putaran porosRPS.putaran/detik

: Banyaknya cylinder

4 stroke PISTON DIAGRAM

Pressure & Volume Diagram

ad

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

---- INDICATOR POWER OF 2 STROKE DIESEL ENGINE

by

Ni
Ni

= Pi.L.A.N.ZIKW

BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

: Daya IndikatorI KW.

Pi
: Tekanan rata-rata Indikator pada cylinder...Bar =1 bar x 105 N/m2=1 bar
x102 KN/m2
L

2
: langkah pistonMeter.

4
ST
: Luas penampang Piston

: diameter cylinder..Meter.

STROKE

Meter.

COMPRESSES
AIR IN
THE CYLINDER TO IGNITE THE
N
: Banyaknya putaran
porosRPS.putaran/detik
FUEL OIL
Z
: Banyaknya cylinder

---EFECTIF POWER OF 2 STROKE DIESEL ENGINE--Ne = Pe.L.A.N.ZEKW

Ne

: Daya EfektifEND
KW.

STROKE

Pe
: Tekanan rata-rata Efektif pada poros...Bar =1 bar x 105 N/m2=1 bar x102
KN/m2

IS PRODUCED BY THE BURNING GASESIT IS POWER

2
L
: langkah pistonMeter.
d
STROKE
A

4
: Luas penampang Piston.

: diameter cylinder..Meter.

: Banyaknya putaran porosRPS.putaran/detik

Meter.

2 STROKE ENGINE
CROSSHEAD TYPE

STARTING VALVE
OPEN

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC .
05

STARTING AIR SYSTEM

STARTING VALVE
CLOSE

Main air 30 Kg/cm

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

7 Kg/cm
Starting Air systemControl
forairMain
Diesel Engine

cam

Main starting
valve

Pilot starting air

pipe

Main Air
valve

1
5

starting
Before
starting
Distributor
valve

starting

2
3

reducer

Air
pressure
Receiver
30 Kg/cm

Engine runing
Main starting air pipe

Air Starting
Valve

Cyl.#.1

Cyl.#.2

Cyl.#.3

Cyl.#.4

Cyl.#.5

LOOP SCAVENGING
In the Loop scavenging the intake &
exhaust portout
are located
at one
Pushing
exhaust
gases
side,the exhaust over the intake
ports.The flow part of air from theair is
intake port across to the opposite
side & up towards the cylinder head
& then make a loop to the exhaust
ports above the intake ports.

DIRECT/CROSS
Scavenging
SCAVENGING

UNIFLOW SCAVENGING

by

BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

In the uniflow intake ports are located

at theso
sidethat
of thea
cylinder
at
with the
of fresh the
air intake
fresh& exhaust
charge
In thehelp
direct scavenging
the cylinder head.the air enters the
inlet ports
arecompression
located on one
available
for
that
follows.
intake
& moves up towards the
side of the cylinder opposite
cylinder head where the exhaust valve
the exhaust ports.the flow
are installed
part of the scavenging air is

of pure
exhaust
manifold

from one side to the other

side.

exhaust
manifold

exhaust
manifold

Scavenging
manifold

LOOP SCAVENGING types

examples of use:
M.A.N, RND-M SULZER

Scavenging
manifold

CROSS SCAVENGING types

example of use :
SULZER,RD,RND

Scavenging
manifold

UNIFLOW SCAVENGING types

examples of use :
B & w,SULZER-RTA

Scavenging
manifold

LUBRICATING OIL SYSTEM FOR MAIN DIESEL ENGINE

Lo.cooler

Lo.

Lo.

Storage

Heating

tank

tank

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

Fungsi pelumasan untuk motor

diesel :
a.

Memperkecil koefisien
gesek,sehingga bagian yang
bergesekan tdk menjadi
aus,motor bekerja lebih lancar
& suara lebih halus.

b.

Mendinginkan bagian-bagian
mesin yg saling
bergesekan,selanjutnya
panas yang terkandung dalam
minyak lumas diserahkan ke
air laut pendingin dalam
Lo.cooler.

c.

Membersihkan bagian-bagian
dalam dari mesin yang
selanjutnya ditahan di filter
atau dibersihkan didalam
Lo.purifier.

Pressure
filter

Main
Diesel
engine

Lo.heater

Lo.pump
Lo.purifier
Suction
filter

L.O SUMP. TANK

Minyak lumas juga berfungsi untuk

membersihkan
bagin-bagian
dalam
motor
diesel:(jelaga,& metal sediment) yang
Lubricating
oil system
untuk main
diesel
engine
selanjutnya akan ditahan difilter/strainer atau dibersihkan didalam Lo.Purifier/Separator.
Minyak lumas didalam sumptank dipompa oleh Lo.pump melalui filter isap,kemudian didinginkan oleh air laut didalam Lo
Kotoran dalam minyak lumas akan dibersihkan oleh purifier :
cooler,setelah panas pada minyak lumas hilang maka akan diteruskan ke filter tekan untuk masuk menuju ke Main
Diesel Engine
untukLo.purifier
melumasipump
bagian-bagian
yang bergerak.
Minyak lumas didalam sumptank
di isap oleh
dan dipanaskan
oleh Lo.heater untuk dipanaskan
sebelum dibersihkan oleh purifier.
Setelah mengadakan pelumasan pada bagian-bagian Mesin,minyak lumas turun ke sumptank,selanjutnya akan
lagi untuk
& dilanjutkan
untuk
berikutnya.
Setelah minyakdipompakan
lumas dibersihkan
olehdidinginkan
purifier akan
dikembalikan
lagi pelumasan
ke sumptank
dalam keadaan bersih.

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

PERAWATAN MINYAK LUMAS DALAM SYSTEM :

Minyak Pelumas dalam system harus dijaga :
a.Jumlah/volumenya,jika sewaktu jaga ternyata kurang agar segera ditambah.

b.Viscositas/kekentalan,apabila sudah terlalu encer/jam kerjanya sudah habis agar segera diganti yang baru.

c. Jangan sampai tercampur dengan air tawar/air laut ataupun oleh bahan-bakar.

Tercampur dengan air mengakibatkan proses korosi.

Tercampur dengan bahan-bakar mengakibatkan turunnya kekentalan sehingga hilangnya oil film & metal-metal
akan segera hancur.

INDIKATOR MINYAK PELUMAS

SUDAH MENJADI RUSAK & TIDAK BOLEH DIPAKAI LAGI

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

1
Minyak pelumas system berwarna keputih-putihan seperti susu di mungkinkan tercampur dengan air tawar, agar diperiksa
keadaan silinder liner (mungkin ada yang bocor) atau air tawar pendingin injector ada yang bocor

2
Minyak pelumas system berwarna kehijauan seperti lumpur cair,dimungkinkan bercampur air laut,agar diperiksa got kamar mesin
mungkin banjir & masuk ke Lo.sumptank atau periksa Lo.cooler mungkin bocor.

3
Minyak pelumas system dalam sumptank terlalu banyak,tetapi encer & berbau solar, agar diperiksa pengabut bahan-bakar/
injector yang mungkin bocor pada nozzlenya selanjutnya bahan-bakar tidak terbakar & mengalir ke sumptank karena ditarik oleh
scrap oil ring.

4
Minyak pelumas system cepat berwarna hitam & cepat encer dimungkinkan ring-ring piston yang sudah lemah/ aus/ bocor
ataupun jumlah/volume minyak lumas dalam sumptank sering kurang & selalu menambah jumlahnya.

by

HEAVY FUEL OIL SYSTEM FOR MAIN DIESEL

Bunker station
Port.side

BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

Bunker station
strbd.side
HFO.

HFO.

MDO.

Settling
tank

Service
tank

Service
tank
Flow meter

heater

Fo.chamber

Cyl
Cyl
headCyl
head
Cyl
head
head

Main
Main
Main
Main
Diesel
Diesel
Diesel
Diesel
engine
HFO Purifier
HFO transfer
Filling
pumpline

Fuel.pump

Suction line

Double bottom TK.Port side

heater

engine
engine
engine

HFO.circ.
pump

Double bottom TK.Centre

HFO.Booster.
pump

Double bottom TK.Strbrd side

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

COOLING SYSTEM FOR MAIN DIESEL ENGINE

Fw.expansion Tk

to. Over board

70.C

Cyl
head

55.C

Main
Diesel
engine

Fw.cooler

70.C

High sea
chest

Lo.cooler
SW.cooling
pump

55.C

FW.cooling
pump

Low sea
chest
GS.cooling
pump

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

NW=Ni-Ne
NW = daya hilang
(kehilangan mekanis=

utk menggerakan pompa-pompa & hambatan-hambatan gesekan)

Ni: daya yang dihasilkan dalam silinder.IKW

Ne : daya pada poros..EKW

 rendemen

daya yg berguna

Panas yg diubah menjadi usaha berguna

th

Panas yg terkandung dalam bahan bakar

Ni 0
th
B.NP 0

th

th

3600 0
0
B
.NP
Ni

th

3600
bi.NP

bi

Ni
B
.NP
3600
B
kg / kw. jam
Ni

= Rendemen thermis %
Ni = Daya indikator..IKW
B

= Pemakaian bahan-bakar dalam... kg/jam

NP = Nilai Pembakaran bahan-bakar kj/kg

bi = pemakaian bahan-bakar spesifik indikator..Kg/kw.jam

1 kw=1 kJ/detik

Daya pada poros

m
Daya pada silinder
m

Ne Pe 0

NI Pi 0

= Rendemen mekanik..................... %

Ne = Daya efectif.eKW
Ni = Daya indikator.....iKW
Pe = Tekanan efectif rata-ratabar.x 100 KN/meter
Pi = Tekanan indicator rata-rata. bar.x 100 KN/meter.

total
total

Daya pada poros

Daya yg terkandung dalam bahan bakar

Ne

B.Np

total

3600 Ne
B.Np

B
be
Kg kw
jam
Ne

tot th . m

total = Rendemen total (rendemen seluruh motor).. %

be = pemakaian bahan bakar spesifik efektifKg/kw.jam

th = Rendemen thermis %
B

= Pemakaian bahan-bakar dalam... kg/jam

NP = Nilai Pembakaran bahan-bakar kj/kg

bi = pemakaian bahan-bakar spesifik indikator..Kg/kw.jam

m= Rendemen mekanik..................... %
Ne = Daya efectif.eKW
Ni = Daya indikator.....iKW
Pe = Tekanan efectif rata-ratabar.x 100 KN/meter
Pi = Tekanan indicator rata-rata. bar.x 100
KN/meter.

 rendemen pada Motor

th
th

Panas yg diubah menjadi usaha berguna

Panas yg terkandung dalam bahan bakar

Ni
B.NP

th

3600
bi.NP

bi

B jumlah bahan bakar yg digunakan

Nilai pembakaran NP NP. Kj
Kg

Ne
Pe

NI
Pi

total

B
be
Kg Ekw
jam
Ne

3600 Ne
B.Np

B
kg / kw
Ni
B B.Kg

total

bi

Ne
B.Np

B
Kg Ikw
jam
Ni

tot th . m

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

Cooling system / sistem pendinginan

Selama motor diesel bekerja memerlukan pendinginan.
-panas yang diterima oleh komponen-komponen motor diesel dipindahkan/diserahkan kepada zat pendingin.
Panas pada motor diesel terjadi karena pembakaran bahan-bakar & akibat pergesekan antara 2 logam (poros dengan metal,
piston ring dengan cyl liner, kepala silang dengan peluncurnya)

Tujuan pendinginan :
1. menjaga suhu dalam keadaan optimal
( kondisi aman = tidak boleh terlalu tinggi & tidak boleh terlalu rendah)
tidak boleh terlalu tinggi karena akan menyebabkan pelumas encer/oil film hilang berakibat metal-metal akan rusak.
tidak boleh terlalu rendah karena akan merugikan bahan akibat pemuaian yang mendadak.
2.agar motor diesel dapat bekerja terus-menerus dengan aman & awet.
Bagian-bagian motor diesel yang mendapat pendinginan :
a.Cylinder liner.
b.Cylinder head.
c.Klep gas buang.

Jenis-jenis Sistem Pendinginan

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

A. Sistem Terbuka
Keuntungan :
- Sistem cukup sederhana, tidak perlu tangki ekspansi,& cooler, sehingga biaya lebih murah.
- Media pendingin / air laut selalu tersedia
Kekurangannya :
- Pada suhu lebih dari 50 C akan terjadi kerak-kerak garam yang akan mempersempit pipa.
- Resiko terhadap poros korosi sangat besar sehingga motor akan lebih cepat rusak.
- Resiko berlayar di daerah dingin maka pengaturan suhu air masuk motor sulit diatur karena suhu air laut terlalu rendah
sehingga silinder liner dapat retak karena perbedaan suhu yang tinggi antara didalam silinder liner dan suhu air laut diluar
silinder liner.

B. Sistem Tertutup
Keuntungan :
- Dengan media air tawar, maka resiko terhadap korosi dapat dicegah / dihindari.
- Pengaturan suhu masuk dan suhu keluar dari air pendingin lebih mudah diatur lewat cooler.

Kekurangan:
- Ketergantungan terhadap persediaan air tawar pendingin.
- Sistem penataan pipa menjadi lebih mahal, karena adanya cooler, tangki ekspansi, dan pipa-pipanya.

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

A.THE ENGINE DOES NOT TURN WHEN STARTING AIR APPLIED

POSSIBLE CAUSES :

STARTING DIFICULTIES
&
TROUBLE SHOOTING
AIR PRESSURE TOO LOW
ONE OR MORE STARTING AIR VALVE HAVE STUCK
THE STARTING VALVE LEAKING IN CYLINDER
CLOGGING FUEL NOZZLES
PILOT VALVE SHUT
STARTING DISTRIBUTOR VALVE SHUT

B.THE ENGINE DOES NOT IGNITE OR FIRING

POSSIBLE CAUSES :
*AIR IN THE FUEL SYSTEM
*THE FUEL OIL OR THE FUEL PIPES ARE BLOCKED
*INCORRECT ADJUSTMENT OF THE FUEL INJECTION PUMPS.
*CLOGGED FUEL NOZZLES
*FUELS BY-PASS OPEN
*BOOSTER FUEL PUMP FAILURE
*AIR COMPRESSION PRESSURE TOO LOW

by

THE COMPRESSION PRESSURE IS TOO LOW CAUSED BY :

*WORN OR BROKEN PISTON RINGS
*LEAKING VALVES IN CYLINDER COVER
*LEAKING GASKET BETWEEN THE CYLINDER COVERS & THE CYLINDER LINERS
*TOO THICK GASKETS BETWEEN THE CYLINDER LINERS & THE CYLINDER BLOCK

THE ENGINE STOPS

*WATER IN THE FUEL OIL
*AIR IN THE FUEL OIL SYSTEM
*FAULTS IN THE FUEL SUPPLY
*A PISTON HAS SEIZED
*CLOGGED PIPE LINES OR FUEL OIL FILTER

BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

BLACK EXHAUST GAS

POSSIBLE CAUSES :
-ENGINE IS OVERLOADED
-SOME CYLINDERS ARE OVERLOADED
-INLET OR EXHAUST GAS OUTLET VALVE IS LEAKING
-FAULTS IN THE FUEL INJECTION PUMPS OR VALVES
-IGNITION TIMING FAULTY
-FUEL TEMPERATURE TOO HIGH

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

ENGINE RPM DROPS

3.

1.
ENGINE IS OVERLOADED
2.
INJECTION PUMPS ARE WORKING IRREGULARLY.AIR IN FUEL SYSTEM
A PISTON OR A BERAING HAS A BREAKDOWN DUE TO INSUFFICIENT LUBRICATION OR DIRT IN LUBE OIL

POSSIBLE CAUSES
ONE CYLINDER FALLS OUT
LEAKAGE BETWEEN THE CYLINDER LINER & THE PISTON
LEAKAGE IN TOP GASKET
CLOGGED FUEL OIL FILTER
THE INLET AND/OR THE EXHAUST VALVES ARE LEAKING
THE VALVE CLEARANCES ARE TOO SMALL
FILTER FOR TURBO-CHARGE IS CLOGGED

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

TURBOCHARGER SURGING

SURGING CAN BE DEVIDED INTO TWO MAIN CATEGORIES

I.RESTRICTION IN THE AIR/GAS SYSTEM
II.VARITION IN CYLINDER LOAD

CHECK THE FOLOWING :

1.FUEL OIL SYSTEM SUCH AS FILTERS,FUL PUMP,FUEL INJECTOR,FUEL TIMING,AIR IN FUEL
2.EXHAUST SYSTEM ,BACK PRESSURE,VALVE OPENING& TIMING,PRESSURE FLUCTUATION,ETC
3.TURBOCHARGER.FOULED OR DAMAGED TURBINE OR COMPRESSOR SIDE,FOULED FILTER.
4.SCAVENGE AIR SYSTEM.FOULED AIR COOLER,CHOKED SCAVENGE PORTS,HIGH SCAVENGE
5.GOVERNOR.HUNTING.

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

THE ENGINE KNOCKS

POSSIBLE CAUSES :

INJECTION IS TOO EARLY,DUE TO INCORRECT PRE-INJECTION ANGLE.

2. FAULTS IN INJECTION VALVES
3. A PISTON BECOME TOO HOT AND SEIZE
4. THE GUDGEON PIN OR BIG END BEARING HAVE TOO BIG CLEARANCES
5. TOO BIG PISTON CLEARANCE.WORN CYLINDER LINER
6. OVERLOADING
7. POOR FUEL/AIR ATOMIZATION

by
BUDI RIYANTO
ENGINE HALL CLUB
SEMARANG
MERCHANT MARINE POLYTECHNIC
05

KNOWLEDGE IS POWER BUT

CARACTER IS EVERYTHING

INLET
COMPRESSION
POWER
EXSHAUST