Operation and Maintenance of SUZUKI

Generator SV1400L
Abstract:
IC engine is a heat engine where the combustion of the air-fuel mixture occurs inside the combustion
chamber that produces high temperature and high gas pressure. This gas pressure pushes the piston over a
distance and transforms the chemical energy into thermal energy which is used for performing the
mechanical work. The report will cover the operation, maintenance activities and trouble-shooting of petrol
engine cars through a broad knowledge of different kinds of mechanical systems. Technical operating
systems, their routine maintenance and trouble diagnosis of different mechanical systems were learned, and
it is the main scope of discussion in this report. Many of the technical processes those can be utilized in
petrol engine cars for improvement and decreasing extra cost and difficulties will be also discussed. To
apply this technical knowledge, the scope is limited in Bangladesh. But hopefully, in near future the scope is
going to be widened.

Introduction:
We are given a four stroke SUZUKI SV1400L petrol engine for maintenance purpose. 4-stroke engines have
become the standard in power generation due mostly to how much cleaner they run than the 2-stroke
engines. Separating the intake from the exhaust stroke reduces the amount of unburnt fuel and expanding
gases released through the exhaust system. It also reduces the overall operating temperature, decreasing the
wear and tear on engine components. In the 4-stroke engine, the piston completes four separate strokes while
turning the crankshaft
 Intake
 Compression
 Combustion
 Exhaust
The downside is the extra strokes reduce the available power significantly. A 2-stroke engine produces
power on each revolution, whereas the 4-stroke produces power on every other revolution. This reduces the
efficiency of the engine in exchange for more manageable emissions and longer life.

Problem Statement:
A SUZUKI Generator SV1400L which was not in working condition. We wanted to bring it into proper
working condition by fixing all the problems remaining within available resources.

Aim
Our aim was to bring the SUZUKI Generator SV1400L in working condition so that we can get desired
output

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Objectives

The main objectives of the report has been done to show the total operation, maintenance and
trouble-shooting procedure and the related other aspects of Toyota and Nissan cars.

 To study working principles of petrol engines

 To study all other systems of petrol engine

 To study maintenance of petrol engine

 To study trouble-shooting of petrol engine

Background

Engineering applications are often interdisciplinary, involving the interrelationship of several of

the basic engineering science. Therefore the modern engineer must have a fundamental knowledge in
each of these theoretical and practical areas. To make a bridge between theoretical knowledge to the
practical knowledge by arranging this type of industrial training results an engineer build up own
criteria very much widely in practical life.

Methodology

A qualitative research method has been used to conduct this study of practicum in Toyota and
Nissan cars of Central Government Motor Vehicle Workshop. The information of this report
has been collected from the following sources:

 Information source of the company

 Official documents of the company

 Industrial unit management handbook

 Servicing manual handbook

 Machinery maintenance handbook
 Quality management handbook
 Textbooks
Besides the above sources some of the information is collected through related reports,
publications, journals, articles, magazines and online resources.

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SYSTEM OVERVIEW
Typically, vehicles are propelled by engines, also known as prime movers, which are mechanical devices
capable of converting the chemical energy contained in a fuel to mechanical energy. The chemical energy
contained in the fuel is first transformed to heat by combustion, and then to mechanical work via the use of
a working medium. This medium of operation might be either a liquid or a gas. Indeed, the heat generated
by burning raises its pressure or specific volume, which results in mechanical effort. (Romain Nicolas, 2019)
The movement of a piston into a cylinder, which is closed at one end by the cylinder head, results in a cyclic
fluctuation in the cylinder volume in reciprocating ICE. The piston is attached to a rod and the crank is
connected to the shaft, causing the piston to cycle between two extreme locations, the Top Dead Center
(TDC, closest to the cylinder head) and the Bottom Dead Center. (BDC, furthest from the cylinder head)
(BDC, largest distance from the cylinder head).

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2.1-Working of Petrol Engine (Otto Cycle):

The Otto Cycle is a term that refers to the process through which heat engines convert fuel to

motion. As is the case with other thermodynamic cycles, this one convert chemical energy to

thermal energy, which is subsequently converted to motion. The Otto cycle explains how internal

combustion engines (such as vehicles and lawn mowers) operate.

Figure depicts the ideal Otto cycle's PV diagram (pressure-volume diagram). This graphic illustrates

how the pressure and volume of the working fluid (gasoline and air fuel) vary as a result of the

combustion of hydrocarbons, which drives the movement of a piston and generates heat to propel a

vehicle. There are expansion (increased volume chamber) piston movements that occur as a result of

the thermal energy generated during combustion, causing work to be done by the gas and the

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 piston. In comparison, as the piston compresses the gas, the engine chamber is expanded

(decreasing in volume).

Figure 4: The pressure-volume diagram of an ideal Otto Cycle process. It consists of two isochoric, two adiabatic
and two isobaric processes (for intake and exhaust)

Green line: During the intake phase, the piston is pushed down to the bottom of the chamber, allowing

the volume of the chamber to expand enough to enable the piston to "intake" a fuelair solution. This is

referred to as an isobaric process in thermodynamics.

i. Process 1 to 2: The piston will be pushed up during this phase in order to compress the

fuel-air combination that has entered the chamber. Compression increases the pressure

and temperature of the mixture slightly—but no heat is exchanged. This is referred to as

an adiabatic process in thermodynamics. When the cycle reaches point 2, the spark plug

comes into contact with the fuel and is ignited.

ii. Processes 2 to 3: This is where combustion occurs as a result of the spark plug igniting

the fuel. At point 3, the gas is completely combustible, resulting in a highly pressurized

chamber that generates a great deal of heat (thermal energy).

This is referred to as an isochoric process in thermodynamics.

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iii. Processes 3 to 4: The heat energy generated by combustion is utilized to exert force on the piston, which

pulls the piston downward, so expanding the chamber's capacity. This is also referred to as the

power stoke because it occurs when thermal energy is converted to mechanical energy and

used to power the machine or

vehicle.
iv. Purple line (Process 4 to 1 and exhaust phase): All waste heat is expelled from the engine chamber during

process 4 to 1. As heat escapes from the gas, the molecules lose kinetic energy, resulting in the

pressure decrease. The exhaust phase then begins, during which the residual mixture in the

chamber is compressed by the piston and "exhausted" without increasing the pressure. ( Dinçer

and C. Zamfirescu, 2014)

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 Figure 5:Visual illustration of working mechanism

The geometry of IC Engine is composed of complex parts. The description of the

major parts ofIC engine is given below:

F
i
g
u
r
e

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:

Figure 6: Labelled diagram of Engine

• It generateselectricity for

• It consists of magnet and

• Magnet rotates around

changing
magnetic field produces

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 2.2-Parts of IC Engine:

2.2.1 Generator

spark plug, lights and

horn coil static

coil, current.

2.2.2 Cylinder
• It consists of bore in which piston reciprocates linearly

• Its outer surface acts as heat exchanger (fins) • It is made up of cast

Iron (Aluminum alloy in new models).

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 2.2.3 Cylinder Head:
• It covers cylinder

• It is made up of aluminum alloy and consists of heat exchanger on its exterior surface

• It consists of tappet cover

• In its interior, there are cam shaft, inlet valve, exhaust valve

• On left side, there is also a hole for spark plug

• It also accommodates Carburetor

2..2.4 Cam Shaft:

• It controls inlet and Exhaust valves

• It is coupled with crank shaft using timing chain

• It is made of malleable cast iron

• It consists of two noses in center and a bearing on each end of shaft

2.2.5 Crank Shaft

• It converts the reciprocating motion of a Piston into the rotational motion

• It is connected to the other end of connecting rod.

• It is made up of structured steel alloy

2.2.6 Piston
• Piston is fixed on another end of connecting
rod using piston pin.

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• It is made up of aluminum alloy

• It compresses the air-fuel mixture

• It consists of rings

2.2.7 Piston Rings

• Piston consists of five rings

• Two are compression rings and three are oil rings

• Function of compression rings is to prevent leakage of AF mixture

• Function of oil rings is to prevent upward movement of engine ring

2.2.8 Timing Chain

• It consists of a chain and two sprockets which connect crank shaft and cam shaft to each
other.

• It decides the timing for opening and closing of valves based on crankshaft’s movement

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 2.2.9 Crank Case Cover (Right)
• It covers clutch box and contains oil gauge hole and clutch hole.

• It is made up of aluminum alloy

2.2.10 Clutch Box

• Clutch box helps in shifting gears

• It temporarily disconnects engine from transmission which drives rear wheel

2.2.11 Drum Gear Shifter

• It fits between main and counter gear shaft

• It has two fingers; one fits on main gear shaft and other fits on counter gear shaft

• It engages and disengages transmission

2.2.12 Carburetor
• It is one of the most important components of a bike

• It prepares the air fuel mixture for combustion

• It is connected to air filter, fuel tank and cylinder head

Maintenance Strategy:
 Preventive Maintenance
 Corrective Maintenance
 Troubleshooting

Preventive Maintenance
Preventive maintenance is applied in distribution networks to prevent failures by performing
maintenance actions on components that are at risk. Distributed generators (DGs) and batteries
can be used to support power to nearby loads when they are isolated due to maintenance. In this
paper, a novel short-term preventive maintenance method is proposed that explicitly considers
the support potential of DGs and batteries as well as uncertainties in the power generated by the
DGs. Two major issues are addressed. To deal with the large-scale complexity of the network, a
depth-first-search clustering method is used to divide the network into zones. Moreover, a
method is proposed to capture the influence of maintenance decisions in the model of the served

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load from DGs and batteries via generation of topological constraints. Then a stochastic
scenario-based mixed-integer non-linear programming problem is formulated to determine the
short-term maintenance schedule. We show the effectiveness and efficiency of the proposed
approach via a case study based on a modified IEEE-34 bus distribution network, where we also
compare a branch-and-bound and a particle swarm optimization solver. The results also show
that the supporting potential of DGs and batteries in preventive maintenance scheduling allows a
significant reduction of load losses.
Preventive maintenance reduces the possibility of unexpected stops. So much so that even
the lifespan the engine is benefited, resulting in lower costs in the medium-long term.

we usually divide preventive maintenance into three categories:

Minor Preventive Maintenance: 

Basic maintenance tasks are performed such as replacing oil filters, renewing air filters, adjusting
valve clearance, replacing spark plug washers, replacing rocker arm cover gaskets, and other
minor parts. Usually, the execution time of minor preventive maintenances does not exceed four
or five hours.
Medium preventive maintenance: 
In addition to the works previously described, in this case the spare parts of the upper part of the
engine are reconditioned, such as, for example, intercoolers and cylinder heads. Depending on
the size of the engine, a medium preventive maintenance takes around 4-7 days of execution
between stop and commissioning.
Major preventive maintenance (Overhaul): 
On the basis that an Overhaul is a complete maintenance of the engine, in which all its wear parts
are renewed both in its upper part and in its lower part, RS Motor on certain occasions has the
ability to adapt to the conditions that end customers may have. Overhaul can be carried out at RS
Motor’s facilities or at the customer’s power plant. Sometimes, if the delivery time is a limiting
factor, there is the possibility of supplying an exchange “short block”, an exchange “long block”
or a complete engine previously assembled at RS Motor and with the Overhaul previously
performed.

Preventive maintenance duration:

The duration of preventive maintenance depends on the type of power plant. The same maintenance
duration is assumed to be one period on average for all power plants. This is a typical duration in real
cases.
For Suzuki SV1400L
For First time, we will change lubrication oil after 24 hours and after 100 hours and goes on like this
We have to change filter after 500 hours

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0 Operation good as new
1 Rated operation
2 Derated operation
3 Obsolescence
4 Not in Operation
I Policy of replacement
II Overloaded operation

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Operation good as new and policy of replacement:
The infant mortality is considered as a period of guarantee given by the manufacturer’s policy. In this
stage, the component is in a state denominated as “operation good as new”. If a failure occurs, the
component is subjected to the policy of replacement and the component’s lifetime is reset to zero. This
process is repeated until the guarantee period ends .

Non-operating, derated and rated operation:

To perform a reliability evaluation, it is common to represent the components of the system in two basic
states:
1. Operating (On).
2. Non-Operating (Off).
Although this model is simple to use, it lacks competence in modelling a real system. Indeed, there are
systems that present redundancy between its components, and if a failure occurs in a certain component, it
may not necessarily lead the system to a nonoperating state. For instance, thermal unit generation is
designed to have a main and an auxiliary component working in parallel. Whenever the auxiliary unit
fails, the output power of the system is reduced by a certain amount, resulting in a derated power. A
schematic representation of the given example is presented shows the individual impact of the states
between the main and auxiliary unit over the thermal generation unit.

Advantages of preventive maintenance

The advantages of a good preventive maintenance are more than the disadvantages. Next, we
will highlight the most important ones:

 Plant stop forecast: This allows the client to know when the plant will stop and for
how long, being able therefore to make its internal planning and adapt its needs
moments prior to the intervention.
 Fewer unforeseen events: Unscheduled engine stops are considerably reduced since,
during preventive maintenance, it is much better to see if the engine has a fault that
must be corrected by taking advantage of this stop.
 Longer useful life of the engine: Preventive maintenance avoids and protects the
engine in the long term, resulting in a longer useful life.
 Long-term costs are lower: By reducing unscheduled downtime and increasing the
useful life of the engine, the long-term investments will be lower and, as a
consequence, the end customer will have the engine available for longer.

 Maintenance philosophies
 Running hour based
 Condition based
 Corrective maintenance
 Review of the maintenance tasks and intervals recommended by the engine manufacturer
 Assessment of engine condition
 Maintenance planning
 Safety hazards and precautions

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  Special tools
 Measuring tools
 Review of dismantling, inspection, measurements, evaluation assembling, and adjustment of the
engine components.
 Cylinder cover with valves
 Piston complete
 Cylinder liner
 Fuel injection equipment
 Bearings
 Mechanical control gear
 Turbocharger and air cooler
 Instrumentation
 Safety systems
 Running-in procedures
 Reconditioning of parts

Corrective maintenance:
Corrective maintenance is a type of work that must be carried out as soon as possible in the event
of an unscheduled engine stop due to various causes (piston seizure, high temperatures, high
pressures, electronic failures …).

This is the most basic maintenance, as it simply involves repairing what has broken down. In this
sense, corrective maintenance is a process that basically consists of locating and correcting faults
or defects that are preventing the engine from running properly.

Corrective maintenance is a type of work that must be avoided as much as possible, since it
implies that the end customer reduces the production and the operation of its power plant. The
number of corrective maintenances can be decreased as long as the preventive maintenance of
the engine is carried out according to the operating hours provided by the engine manufacturer
and installing quality spare parts on these.

Unscheduled corrective maintenance:

As its name indicates, unscheduled corrective maintenance is the one on which unscheduled
failures or breakdowns arise that make the power plant unable to operate (seizures, electrical
failures…).

In unscheduled corrective maintenances, the main goal is to correct any breakdowns that occur.
Therefore, all work is focused on getting the engine running as soon as possible.

Advantages and disadvantages of corrective maintenance

Although there are few, corrective maintenance can have advantages (although this is not
recommended):

 Short-term costs are lower: As this type of maintenance is a reactive activity, it is only
carried out when a problem occurs in the engine or in the power plant.
 Planning is minimal: Corrective maintenance consists of correcting an identified fault in a
particular engine component. As a result, you don’t need to plan anything in advance.

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The disadvantages of corrective maintenance are much more numerous than the
advantages. We highlight the following:

 It is unpredictable: This can affect the reaction time if the stock of spare parts to carry out
the repair is not enough, resulting in a longer stop than is desirable.
 You will have paused operations: You never know when the engine will stop running, so
availability must always be maximum, and the maintenance company and plant operators
must always be alert.
 Less lifespan of the equipment: Corrective maintenance does not prevent or protect the
engine at all, nor does it make its useful life longer. As a conclusion, the most likely is that
the engine will have to be renewed much earlier than scheduled.
 Long-term costs can be higher: When a breakdown occurs, it can become very costly now
and in the future. This can be detrimental to the company’s reputation, customer satisfaction,
and plant safety. In addition to the above, it would be impossible to plan any type of annual
expense or manage purchases or production efficiently.

Fault Analysis:
Following steps were followed to analyze faults and apply relevant maintenance techniques.

Problem No. 1
 Carburetor was not in working condition. As, there were tiny particles inside the float valve.
 Also, the fuel supply control valve was not working. Because it was turning through 180 degrees.
But it should rotate through 90.

Solution:
 Installed a new carburetor, that has given better performance.

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Problem No. 2
 The recoil spring had deformed permanently. And it was coming out of its seat.

Solution
 Replaced the old recoil spring with the new one.

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Problem No. 3
 Missing of Fuel Supply Pipe and Its Clamps

Solution
 Purchased and installed the new Fuel supply pipe and its clamps.

Troubleshooting:

Troubleshooting is a systematic approach to problem solving that is often used to find and
correct issues with complex machines, electronics, computers and software systems.

The first step in troubleshooting is gathering information on the issue, such as an undesired
behavior or a lack of expected functionality. Other important information includes related
symptoms and special circumstances that may be required to reproduce the issue.

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Once the issue and how to reproduce it are understood, the next step might be to eliminate
unnecessary components in the system and verify that the issue persists, to rule out
incompatibility and third-party causes. 

Continuing, assuming the issue remains, one might next check common causes. Depending on
the particular issue and the troubleshooter’s experience, they may have some ideas. They may
also check product documentation and/or conduct research on a support database or through
a search engine.

Engine Oil Changing:

The old oil was removed and replaced with new engine oil It

has following benefits:

• Keeps the engine clean internally

• Increases the mileage

• Better engine life

TOOLS USED FOR ASSEMBLING AND DISASSEMBLING

• Screw drivers
• Spanners
• Ring spanners
• Combination spanners
• Socket spanner
• Torque wrench
• Pliers
• nose plier
• Hammers
• Chisels
• Files

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Working images:

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 CONCLUSION
Engine is the heart of every automobile and machinery depending upon mechanical energy
and power. So, its maintenance should be ensured to avoid any unpleasant situation. The life of the
engine also depends on how much importance we gave to the maintenance tasks. Therefore,
regular, weekly, monthly, and yearly checking of the engine should be ensured to keep the engine
running on its optimum power.

After disassembling the engine, the following faults were found that was causing difficulties for the
engine's operationality.

➢ Spark Plug was not performing its task. So, it was replaced with the new one.

➢ The cleaning of the carburetor was done to remove the dust particles and other
contamination.
➢ The piston ring was broken because of some wear and tear. So, it was replaced as well.
➢ Intake valve was adjusted by grinding it.
But we managed to get rid of all those measures and sprayed the whole engine to give it a new
look.

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