Lesson 1Running-in and engine test procedures: no-load, incremental loading, vibration measurement, and oil system checksThis lesson covers running-in and testing of overhauled engines, including no-load checks, staged loading, vibration monitoring, and oil system verification, teaching learners to log data and confirm safe readiness for service in Eritrean maritime settings.
Pre-start checks and priming proceduresInitial no-load start and safety monitoringIncremental loading and parameter loggingVibration and noise checks during run-inOil pressure, flow, and contamination checksFinal inspection and test report completionLesson 2Vibration analysis basics: frequency, amplitude, causes, and handheld toolsThis lesson introduces vibration analysis for marine fitters, covering basic terms, common vibration sources, and use of handheld meters, linking frequency and amplitude patterns to misalignment, imbalance, and combustion issues on Eritrean ships.
Frequency, amplitude, and phase explainedCommon engine and shaft vibration sourcesRecognizing imbalance and misalignment signsTorsional and combustion-related vibrationUsing handheld vibration meters onboardTrend logging and alarm threshold settingLesson 3Gasket, stud, and torque practices: surface cleaning, torque patterns, and torque wrench useThis lesson explains correct handling of gaskets and studs, surface preparation, torque patterns, and torque wrench use, emphasizing prevention of leaks, distortion, and fastener failure during cylinder head and manifold work in Eritrean engine rooms.
Surface cleaning and flatness verificationGasket selection, handling, and positioningStud inspection, renewal, and lubricationTorque patterns and staged tighteningUsing and calibrating torque wrenchesRetorque procedures after initial runningLesson 4Visual and borescope inspection techniques for cylinders, liners, and piston crownsThis lesson focuses on visual and borescope inspection of cylinders, liners, and piston crowns, helping learners identify wear patterns, deposits, cracks, and scuffing, relating findings to combustion quality, lubrication, and cooling issues on Eritrean vessels.
Lighting, access, and safety precautionsReading liner wear, polishing, and scuff marksRecognizing crown burning, erosion, and crackingIdentifying carbon buildup and wet stackingBorescope setup and image interpretationDocumenting findings for maintenance planningLesson 5Fundamentals of medium-speed diesel engine operation and combustion dynamicsThis lesson covers operating principles of medium-speed marine diesels, including air handling, fuel injection, combustion phases, and load response, emphasizing how combustion dynamics affect efficiency, emissions, and component stresses in Eritrean shipping.
Engine cycle review and timing diagramsAir charging, scavenging, and turbochargingFuel injection stages and spray formationIgnition delay and controlled combustion phaseEffects of load, speed, and fuel qualityCombustion issues: smoke, misfire, and rough runningLesson 6Measuring clearances: valve lash, guide wear, piston-to-cylinder clearance, and liner runout measurementsThis lesson details measuring valve lash, valve guide wear, piston-to-cylinder clearance, and liner runout, emphasizing correct tools, measurement points, recording methods, and interpreting results against maker’s tolerances for Eritrean diesel engines.
Selection and care of measuring instrumentsSetting and checking valve lash hot and coldMeasuring valve stem and guide clearancePiston skirt and ring land measurementsPiston-to-cylinder clearance assessmentLiner runout and ovality measurement stepsLesson 7Cylinder head reassembly: valve timing, injector seating, injection pump timing checksThis lesson explains correct cylinder head reassembly after overhaul, focusing on valve timing, injector seating, and injection pump timing checks to ensure proper combustion, safe starting, and long-term reliability of marine diesel engines in Eritrea.
Pre-assembly cleaning and component identificationSetting camshaft and crankshaft reference marksValve timing alignment and verification stepsInjector seating, torque, and leak checksInjection pump timing and phasing checksPost-assembly rotation and interference checksLesson 8Cylinder head removal procedure: preparation, sequence, and safe liftingThis lesson describes safe, stepwise cylinder head removal on marine diesels, including preparation, isolation, loosening sequence, lifting gear selection, and protecting sealing surfaces and components from damage in Eritrean ship maintenance.
Pre-removal checks and system isolationDraining fluids and disconnecting auxiliariesBolt loosening sequence and patternRigging, slings, and lifting point selectionGuiding, landing, and storing cylinder headsPost-removal inspection of deck and studsLesson 9Acoustic/knock diagnosis: distinguishing detonation, piston slap, and bearing knockThis lesson teaches recognizing abnormal engine sounds and relating them to faults, focusing on differentiating detonation, piston slap, and bearing knock using location, rhythm, intensity, and operating condition for accurate diagnosis on Eritrean vessels.
Safe listening practices and basic toolsCharacteristics of combustion knock and detonationIdentifying piston slap under varying loadsRecognizing main and rod bearing knockUsing a mechanic’s stethoscope effectivelyCorrelating sound patterns with engine data
