Operation and Maintenance MCQ Quiz - Objective Question with Answer for Operation and Maintenance - Download Free PDF

Concept:

TOTAL PRODUCTIVE MAINTENANCE:

TPM is a maintenance program that involves a newly defined concept of maintaining plants and equipment. The goal of the TPM program is to significantly increase production, at the same time increasing employee morale and job satisfaction.

TPM philosophically resembles TQM in many aspects such as a long-range plan on any ongoing process.

Various pillars of TPM:

• 5'S Principle
• Jishu Hozen(JH)
• Kaizen
• Planned Maintenance
• Quality Maintenance.
• Training
• Office TPM
• Safety, Health, and Environment

The five S principles are used for implementations of TPM.

1. SEIRI – Sort out
2. SEITON –Organize
3. SEISO – Shine workplace
4. SEIKETSU – Standardization
5. SHITSUKE – Self-discipline

Explanation:

Poor starting of diesel engines can be due to:

• Low fuel in the tank
• Choked fuel hose
• Clogged fuel filter
• Air lock in the fuel system
• Air in the fuel injection pump
• Clogged exhaust ports
• Raptured cylinder head gasket
• Worn piston rings
• Broken valve timing belt/chain
• Poor valve seating
• Valve seat pitted
• The main fuse is blown off
• Defective starting relay
• Main ignition switch open circuited
• Defective brushes in the starter
• Open in-field or armature circuit of the starter
• Loose battery terminal connection
• Run down battery

Explanation:

Oil filter:

• Before entering the main oil gallery, the oil is allowed to pass through the filter.
• If the filter becomes clogged, one bypass valve in the filter permits the oil to enter the main oil gallery directly.
• Felt, cotton waste, fabric, and paper are used as filter element materials.
• Oil filters must be changed after an engine has run a particular distance, as per the manufacturer's recommendation.
• There are two types of Fuel Filters. 

1. Full-flow oil filter system 
2. Bypass oil filter system

Full-flow oil filter system 

• In this system, all the oil passes through the filter before reaching the main oil gallery.
• One bypass valve is provided in the filter which allows oil to reach the main oil gallery directly if the filter is choked.

Bypass oil filter system

• In this system, only a part of the engine oil enters the filter.
• After filtering, the oil goes to the oil sump.
• The remaining oil goes directly to the main oil gallery.

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Additional Information

Fuel filter:

• The most crucial factor in maintaining an engine's long-term trouble-free operation is effective fuel and oil filtration.
• There is a danger that water, dirt, germs, and wax crystals will contaminate diesel fuel when it is being transported and handled. The worst enemy of fuel injection machinery is dirt.
• For these reasons, removing these contaminants requires a very effective fuel filtering system.
• There are two types of fuel filtering systems:
  1. Single filter system
  2. Two-stage filter system

Air filter:

• There is a lot of dust and dirt in the atmosphere. Air is filtered before entering the cylinder bore because dirty air will damage and wear down engine parts more quickly.
• The functions of air filter are:
  • cleans the intake air
  • during engine backfiring, it acts as a flame arrester
  • minimize the intake air noise.
• It is fitted at the top of the air intake manifold.

Thus, option (2) is the correct answer.

Explanation:

Dial gauge:

• The dial gauge is a precision measuring instrument that is used to measure internal dimensions. The bore of the cylinder is measured by a dial gauge.
• Generally, the dial gauge is available as a two-point self-centering type.
• It consists of a stem, plunger, centering shoes, dial, and fixed anvil insert.
• The accuracy of the dial gauge lies in the range of 0.001 mm to 0.01 mm.

Thus, option (3) is the correct answer.

Explanation:

Ovality of bore:

• The ovality of the cylinder bore is measured by using an inside micrometer.
• The ovality of abore is the difference between the thrust side diameter and the non-thrust side diameter of the cylinder.
• The ovality of the cylinder is typically induced by wear over time in the piston of the engine.
• Usually, it results from a little difference in pressure inside the cylinder.
• This pressure is connected to how the crank moves while it is under load.
• Over several cycles, the piston's up-and-down motion can wear out the cylinder, giving it a slightly oval shape.

Thus, option (2) is the correct answer.

Most likely causes of engine over heating are

• Less air drafts
• Less circulation of water
• No water circulation of water in cylinder block
• Incomplete combustion of fuel
• Cylinder block water passage blocked/scale formation

For a mechanic, initial and most likely check for engine overheating will be loose fan belt as this is common for less air draft or less circulation of water.

• Piston slap is the rocking of the piston in the cylinder (as opposed to the desired movement of the piston up and down the cylinder)
• It happens when there is "too much" room for the piston in the cylinder and the skirt of the piston hits the cylinder wall
• It can be a design flaw, or it can be due to excessive wear over time

The opening and closing of the valves in an IC engine in relation to the movement of the piston and flywheel is called valve timing.

High consumption of oil occurs due to the following reasons and the remedies for the cause is also given in the table.

Following are the causes and remedies for engine overeat

Following are the causes of the starter motor does not rotate/rotate slowly.

1. Defective Starter
2. No supply to started motor (Discharged Battery)
3. Less supply to starter motor

These are the following reasons for low power generation

1. Less supply of fuel
2. Less supply of air
3. Incomplete combustion of fuel
4. Exhaust gases not going out of cylinder completely
5. Weak compression

Explanation:

Malfunction indicator lamp (MIL):

• A check engine lamp or a data scanner is used to indicate problems in the engine management system.
• A code indicates where the fault may be.
• The MIL is that terrible little light in the dash that indicates a problem with the car.
• There are a few variations, but they all indicate an error found by the OBD -II protocol.
• OBD-II stands for on-board diagnostics second generation.
• OBD II is a system that was mandated by the federal EPA (Environmental Protection Agency) and was developed by the society of automotive electronic diagnostics, so technicians can use the scan tool to test all models of automobiles with a special adopter or factory seamer.

Explanation:

Not starting an engine can be due to:

• Low or no fuel in the tank
• Choked fuel hose
• Clogged fuel filter
• Air lock in the fuel system
• Air in the fuel injection pump
• Clogged exhaust ports
• Raptured cylinder head gasket
• Worn piston rings
• Broken valve timing belt/chain
• Poor valve seating
• Valve seat pitted
• Main fuse is blown off
• Defective starting relay
• Main ignition switch open circuited
• Defective brushes in the starter
• Open in-field or armature circuit of the starter
• Loose battery terminal connection
• Run down the battery

Following are the reasons for high fuel consumption. Out of given options, leakage of fuel is one of the main reasons for excess fuel consumption.

High fuel consumption