SPINDLE GIKEN’ s Repair Services
Fuel Pump for M/E and G/ETo supply accurate metered amount of fuel with sufficientpressure to open fuel injector in correct timing.
The most common problem is fuel oil fired. The governor controls
the fuel pump delivery through a fuel rack, which is a combinationof mechanical links. Sometimes the fuel pump gets stuck leading
to lack of fuel supply in the concerned unit which results in either
fluctuation in the engine RPM if running or slow down/not start
the engine.

Fuel Pump Internal Parts
Puncture Valve
Suction ValveSpill Valve
Delivery/Discharge Valve
Plunger and Barrel

Fuel Line Parts
Fuel Injector
High Pressure Pipe
Roller Guide
Indicator Valve

Recommend / black Smoke:
All the fuel pump must be well overhauled and set
the timing before starting the main engine.
If incorrect timing difficult to start engine,abnormal exhaust temperature reading, block
smoke come out and irregular running of engine.

We recommend

periodicmaintenance.

Puncture Valve
It is fitted top cover of the pump and used to cut of the fuelinjector.
It’ s consist of piston which communicates with air controlsystem of the engine. In “STOP” is activated, compressed aircauses the piston pint to be pressed downwards and‘puncture’ the oil flow to the pump housing.

Suction Valve
Suction valve controls the ﬂow of fuel in to

Spill Valve
Spill valve controls the end of injection of fuel.

the pump and it also decides the beginningof fuel delivery.

Discharge/Delivery
The fuel is delivered to the cylinder
through discharge valve.

Plunger & Barrel
Barrel: It is a cylinder fixed in the pump’ s body to accommodate the plunger. It is a highsurface finish.
Plunger: Plunger reciprocates with minute clearance (in microns) inside the barrel topush the fuel out of the pump.
Fuel has to be injected into the engine at a high pressure so that it atomizes correctly. As
the plunger moves up the barrel, the pressure of the fuel in the barrel above the plunger
rises very quickly.

Recommend:
If the plunger and barrel clearance is not in the limit, it should need to be service.
• To check the barrel suction holes and the wear on the holes using both
endoscopic and photographic examinations• Grinding the barrel holes and renewal of the pump element with special
anticorrosion coating as required.
• We then proceed with grinding and lapping of the barrel contact plane, lubrification
hole cleaning using new generation multi-frequency ultrasonic equipment andreassembly at the required clearancesFuel valve/Injector
The purpose of the fuel injection system is to deliver fuel into the engine cylinders, while
precisely controlling the injection timing, fuel atomization, and other parameters. The
faulty fuel injectors are an extremely violent or rough engine. If fuel is not properly
provided to the engine cylinder, it will result in engine operation uneven or slowdown.

Recommend:
In this case Injector should be opened and overhauled for the below mentioned
items;
NozzleAtomizerSpindle Guide

Non-Return Valve• The assembly and the disassembly must be done as per the instructions given by
the engine manufacturer.
• The needle and the guide are always a pair and should not be interchanged withanother one.
• Cleanliness is the most important factor in making fuel valves. A clean fuel valve
lasts a longer time.
• To check nozzle seats using microscopic analysis.
• We then perform the grinding of the nozzle seat, replace the nozzle needle,calibrate the nozzle injection holes.
• Perform the necessary grinding and lapping of the contact plane.
Reassemble, test and calibrate on our specialized test benches to requested
specifications.

Exhaust Valve (4-Stroke)
The 4 stroke have multiple inlet and exhaust valves fitted to the cylinder heads. On
the medium speed engines this normally takes the form of two inlet and two exhaust
valves per unit.
The area of the valve openings must be large
enough to provide for an efficient gas exchange
process.
If the area is too small then not enough air will
be pushed/drawn into the cylinder during theinduction stroke, and on the exhaust stroke theengine will be doing work pushing the exhaustgas out of the cylinder.

Exhaust valves are subject to arduous conditions, and require regular overhaul.
To aid this, exhaust valves are often fitted in separate cages. This allows theexhaust valve to be changed and overhauled without removing the cylinder head.
The cages have water cooling passages connected to the cylinder head coolingwater.
The springs which ensure the valve closes will weaken with use and are liable tobreak.
Exhaust gas can leak up the spindle,
causing overheating and acceleratingwear. The springs which ensure the valve
closes will weaken with use and are liable
to break.
Inlet/Suction Valves are subject tomuch less arduous conditions and are notusually fitted in separate cages.

SIP (Swirl Injection Principle) ValveSIP may be controlled by ECL (Electronically Controlled Lubricating) system⇒ Reduction of running cost by lower cylinder oil consumption.
The principle of using the scavenging air inside the cylinder to distribute aspray of the lube oil as a thin and even oil film onto the cylinder wall.
Thereby, an optimum distribution of the lube oil is obtained at a minimum
lube oil consumption.
For each piston stroke of the engine, a small quantity of lube oil is sprayedout of the SIP Valve.

Recommend:
The function of the SIP Valve should be checked at appropriate intervals, e.g.
when renovating a cylinder or after operation hours.
We recommend that the spray, the closing pressure and the quantity of leak oil
are checked at appropriate intervals, for example every two years.
In addition, we recommend that the distance between the cylinders and the tip ofthe needle is measured to ensure that wear on the cylinders does not lead to anexposure of the tip of the valve, which may then be damaged by the piston rings

High Pressure Pipe
It helps to deliver the fuel from the high pressure pumpto the combustion engine without any loss of pressure,without any hindrance to the flow and without impairing
the functions of the fuel injection components.
FO leaks from the high-pressure pipe are dangerous
because of a risk of fire in the engine room. To prevent
FO leaks, the below actions should be followed:
Close Inspection: Clean & inspect by penetrating check. Chemicalflush.
Proper recondition: If any damage on the seat surface isobserved, the relevant seat surface is to be lab by the special tool
for all joints.
Proper Tightening: Pipe should be tightened to the proper torquein accordance with the manufacturer’ s instructions and test upto
1000 bars to check any leakage.

Indicator Valve
Indicator Valves are used to measure and monitor the cylinderpressure/power of diesel engine performance while the engine isrunning.
It indicates 4 types, such as Power card, Draw card, Compression
diagram and light spring diagram. With help of those 4 diagrams, wecan determine the following:i.

The compression pressure inside the cylinderii.

peak pressure generated inside the cylinderiii.

The actual power generated

iv.

Faulty combustion chamber parts (worn out piston, liner, rings,etc.) of theparticular unitv.

Faulty injection parts and wrong fuel timingvi.

Exhausting and scavenging process

It is therefore very important to read these diagrams correctly as they provide several details
about the cylinder working pressures and load.

Roller Guide
In the main engine with a camshaft, lubrication system
feeds to camshaft roller guides and bearings, which
actuates the exhaust valves and fuel pump.

G/E Governor

The main role of the governor is not to increase or decrease
the speed which can be done via fuel control system but oncethe speed of the engine has been set, the job of the governor
is to maintain that speed despite the variations in load.
Governor automatically adjusting the engine fuel pump settings
to meet the desired load at the set speed.

Recommend:
If found stuck and speed variations at running time, we should proceed to repairing.
Need to maintain proper periodic maintenance to extending the service life of these costly
components.

Alpha Lubricator (Electrical & Mechanical)
Lubrication of cylinders between liners and rings is one of the crucial
factors that affects the efficient operation of diesel engines.
Lubricating oil for a marine engine achieves two objectives; it mustcool and lubricate.
The main reason for cylinder lubrication system is to reduce the operational costs of the engine.
Moreover, the most expensive lubricating oil is generally used for the engine’ s combustion chamberas cylinder lube oil.

Recommend:
For the operational cost to a marine engine, besides fuel oil,cylinder oil also takes a big share. To carry out periodic overhauling
can reduce the cost.
Regular maintenance to reduce in cylinder oil feed rate.
Periodic maintenance BCU and MCU

M/E Main Air Starting Line / Main Air Starting Valve
Marine Engines are started using high pressure compressed air(pressure is 30 bar). The air is admitted into the cylinder andcontinued until the exhaust valve opens.
The main cause of starting airline explosion is the leaking
starting air valve or jamming at open position of the valve.
Initially, the oil which is discharged from the air compressor tostarting airline system.

Recommend:
Periodic inspection/maintenance of air starting system pipelines is to be carried out to ensurethat no build-up of oil is occurring.
Highly flammable cleaning fluids must never be used in any part of the starting air system.
Any residue of liquid or vapors could result in an explosion.

Pneumatic Actuator
A pneumatic actuator is a device that is capable of converting energy from a pressurized air
into motion (rotating the spindle and open the ball valve).
The actuator must withstand the temperature
range and other specific maker condition. Failureof an actuator the ball valve not to open and air
not flow to cylinder.

Recommend:
Carry out periodic maintenance.

M/E Air Distributor

Air distributor is responsible for maintaining the air
supply which opens the starting air valve in theengine cylinders. Since it’ s a mechanical part, it isdisposed to malfunctioning, especially getting stuck.
The main engine will not start if air distributor does
not supply air to open the starting air valves as no air
will be present in the cylinder to commence fuelcombustion.

Recommend:
If found stuck and maintain air
variations at running time, weshould proceed to repairing.

M/E Remote Control System
Pneumatic Maneuvering System
Governor Control UnitoADU (Actuator Drive Unit)oElectric Governor

Bridge Maneuvering System(Control and Safety System)
oControl SystemoSafety SystemoTelegraph Logger

Pneumatic and remote control system consists ofoverhauling of essential pneumatic valves/cylinders
involved in main engine control (start, stop,reversing ahead and astern, speed setting telegraph,from bridge, ECR and Emergency stand).

Recommend:
Maker recommend overhauling of pneumatic components every 2.5 years.
It is also recommended to check the functioning of the system regularly; air bottles should
be drained every day, filters cleaned regularly, automatic water traps emptied,compressors must be maintained in order to minimize the content of the oil and water inthe system.
Perform periodic maintenance to extending the service life of costly components.
Our technical team of experts is happy to work/technical assistance at any time to find theright solution for a perfect result.