Diesel Engine and Fuel System Repair

by Dagel, John F.; Brady, Robert N.

• ISBN13: 9780133996920
• ISBN10: 0133996921
• Edition: 4th
• Format: Hardcover
• Copyright: 1997-10-01
• Publisher: Prentice Hall

Summary

One of the only texts of its kind to devote chapters to the intricacies of electrical equipment in diesel engine and fuel system repair, this cutting-edge manual incorporates the latest in diesel engine technology, giving students a solid introduction to the technology, operation, and overhaul of heavy duty diesel engines and their respective fuel and electronics systems.

Table of Contents

Preface	vii	(2)
About the Author	ix
1 DEVELOPMENT OF THE DIESEL ENGINE	1	(15)
Overview	1	(1)
Historical Background	1	(1)
Diesel Engine Characteristics	2	(1)
Diesel Engine Components	2	(3)
Diesel Engine Designs and Classifications	5	(3)
Piston Designs	8	(3)
Piston Rings	11	(1)
Valves	12	(1)
Aftercooling	12	(2)
Summary	14	(1)
Self-Test Questions	14	(2)
2 DIESEL ENGINE OPERATING FUNDAMENTALS	16	(15)
Overview	16	(1)
Diesel Engine Classifications	16	(1)
Four-Stroke-Cycle Operation	16	(4)
Two-Stroke-Cycle Operation	20	(4)
Comparison of Two-and Four-Stroke-Cycle Designs	24	(2)
Engine Firing Orders	26
Summary	14	(1)
Self-Test Questions	14	(17)
3 UNDERSTANDING HORSEPOWER AND RELATED TERMS	31	(25)
Overview	31	(1)
Diesel Engineering Fundamentals	31	(1)
Understanding Power Terms	31	(21)
Heating Value Equivalents	52	(1)
ISO Standards	52	(1)
Summary	53	(1)
Self-Test Questions	53	(3)
4 COMBUSTION SYSTEMS	56	(12)
Overview	56	(1)
The Combustion Process	56	(1)
Types of Combustion Chambers	56	(3)
Combustion Dynamics	59	(3)
Fuel Injection Timing	62	(2)
Retarded versus Advanced Timing	64	(1)
Exhaust Emissions Limits	64	(2)
Summary	66	(1)
Self-Test Questions	66	(2)
5 ENGINE DISASSEMBLY	68	(18)
Overview	68	(1)
Overhaul Procedures	68	(13)
Engine Cleaning Procedures	81	(1)
Safe Work Habits When Cleaning	82	(2)
Summary	84	(1)
Self-Test Questions	84	(2)
6 THE CYLINDER BLOCK	86	(28)
Overview	86	(1)
Cylinder Block Structure	86	(1)
Diesel Engine Cylinder Blocks	86	(2)
Disassembly, Inspection, and Cleaning of the Cylinder Block	88	(4)
Final Inspection, Testing, Reconditioning, and Assembly	92	(9)
Cylinder Hones	101	(10)
Summary	111	(1)
Self-Test Questions	111	(3)
7 THE CYLINDER HEAD AND COMPONENTS	114	(30)
Overview	114	(1)
Cylinder Head Structure and Function	114	(1)
Service Recommendations	114	(26)
Summary	140	(1)
Self-Test Questions	140	(4)
8 CRANKSHAFT, MAIN BEARINGS, VIBRATION DAMPER, AND FLYWHEEL	144	(20)
Overview	144	(1)
Crankshaft Structure and Function	144	(2)
Crankshaft Cleaning and Inspection	146	(2)
Main Bearing Defects and Remedies	148	(7)
Main Bearing Specifications and Crankshaft Tolerances	155	(1)
Main Bearing and Crankshaft Installation	155	(1)
Rear Main Seal Installation	156	(2)
Vibration Dampers	158	(1)
Flywheels	159	(1)
Summary	160	(1)
Self-Test Questions	161	(3)
9 PISTONS, PISTON RINGS, AND CONNECTING-ROD ASSEMBLY	164	(20)
Overview	164	(1)
System Structure and Function	164	(5)
Inspection, Cleaning, and Removal of the Pistons	169	(3)
Inspecting the Connecting Rods	172	(1)
Piston Pin Inspection	173	(1)
Final Assembly of Pistons, Piston Rings, and Connecting Rods	174	(6)
Summary	180	(1)
Self-Test Questions	180	(4)
10 CAMSHAFT, CAM FOLLOWERS, PUSHRODS, ROCKER ARMS, AND TIMING GEAR TRAIN	184	(11)
Overview	184	(1)
System Structure and Function	184	(2)
Camshaft Cleaning and Inspection	186	(2)
Cam Follower Inspection	188	(2)
Pushrod Inspection	190	(1)
Inspection, Replacement, and Assembly of the Timing Gear Train	190	(3)
Summary	193	(1)
Self-Test Questions	193	(2)
11 LUBRICATION SYSTEMS AND LUBE OIL	195	(18)
Overview	195	(1)
Lubrication System Function	195	(2)
System Design	197	(1)
System Components	197	(5)
Engine Lube Oil	202	(4)
Inspection and Overhaul of Components	206	(3)
System Testing	209	(1)
Testing and Troubleshooting the Lube System	209	(1)
Summary	210	(1)
Self-Test Questions	210	(3)
12 COOLING SYSTEMS	213	(26)
Overview	213	(1)
Cooling System Function	213	(2)
Engine Heat Loads	215	(1)
Radiators	216	(2)
Radiator Shutters	218	(1)
Thermostats	219	(5)
Antifreeze	224	(1)
Testing the Coolant	225	(2)
Scale Buildup	227	(1)
Coolant Filters	227	(1)
Flushing the System	227	(2)
Pressure Caps	229	(1)
Pressure Checking the Cooling System	230	(1)
Expansion Tanks and Heat Exchangers	231	(2)
Raw Water Pumps	233	(2)
Keel Cooling Systems	235	(1)
Summary	236	(1)
Self-Test Questions	236	(3)
13 AIR INLET AND EXHAUST SYSTEMS	239	(42)
Overview	239	(1)
The Air Supply	239	(1)
Intake and Exhaust System Flow	240	(1)
Air Cleaners	240	(9)
Air Ducting Inspection	249	(1)
Aftercoolers	250	(3)
Turbochargers	253	(8)
Exhaust Mufflers and Particulate Traps	261	(4)
Gear-Driven Blowers	265	(5)
Marine Engine Applications	270	(2)
Troubleshooting Using Manometers	272	(3)
Exhaust Brake Devices	275	(2)
Summary	277	(1)
Self-Test Questions	277	(4)
14 TYPES OF FUEL SYSTEMS	281	(18)
Overview	281	(1)
System Types	281	(3)
Basic Fuel System Layout	284	(2)
Functions of a Fuel Injection System	286	(1)
High-versus Low-Pressure Fuel Systems	286	(1)
Distributor Pump System	287	(3)
Stanadyne DS Pump	290	(3)
Lucas Fuel Systems	293	(1)
Distributor Pumps	293	(3)
Summary	296	(1)
Self-Test Questions	296	(3)
15 THEORY OF ELECTRONIC FUEL SYSTEMS	299	(27)
Overview	299	(1)
System Development	299	(1)
Fuel System Structure and Function	300	(3)
Sensors	303	(5)
Electronic Unit Injectors	308	(4)
Electronic Control Modules	312	(7)
Diagnostic Tooling	319	(4)
Summary	323	(1)
Self-Test Questions	323	(3)
16 DIESEL FUEL, FILTERS, AND FUEL WATER SEPARATORS	326	(13)
Overview	326	(1)
Diesel Fuel Oil Grades	326	(1)
Specific Gravity of a Fuel	327	(1)
Heat Value of a Fuel	327	(1)
Fuel Filtration	328	(2)
Fuel Filters	330	(1)
Fuel Filter Water Separators	331	(3)
Fuel Heaters	334	(1)
Summary	335	(1)
Self-Test Questions	335	(4)
17 MECHANICAL AND ELECTRONIC GOVERNORS	339	(19)
Overview	339	(1)
Governor Function	339	(1)
Why a Governor is Required	339	(1)
Mechanical Governor Operation	340	(4)
Governor Terms	344	(2)
Types of Governors	346	(1)
Zero-Droop Governors	346	(1)
Adjustable-Droop Governors	347	(6)
Electronic Governors	353	(2)
Summary	355	(1)
Self-Test Questions	355	(3)
18 INJECTION NOZZLES	358	(16)
Overview	358	(1)
Nozzle Structure and Function	358	(3)
Nozzle Identification	361	(1)
Nozzle Components	361	(1)
Bosch Nozzles	362	(1)
Injector Nozzle Sac Volume	362	(1)
Nozzle Problems	362	(1)
Nozzle Removal	363	(2)
Testing Nozzles for Performance	365	(1)
Nozzle Disassembly and Cleaning	366	(6)
Injection Nozzle Reassembly	372	(1)
Nozzle Installation	373	(1)
Summary	373	(1)
Self-Test Questions	373	(1)
19 ROBERT BOSCH CORPORATION FUEL SYSTEMS	374	(73)
Company Background	374	(1)
Overview	374	(1)
Product Overview	375	(3)
Pump Features	378	(3)
Inline Pump Fuel System	381	(2)
Fuel Supply Pump Operation	383	(1)
Injection Pump Operation	384	(1)
Fuel Metering (Measurement)	384	(3)
Helix Shapes and Delivery Valves	387	(1)
Inline Pump-to-Engine Timing	388	(3)
Overview--Static Spill Timing	391	(3)
Air in the Fuel System	394	(1)
Cummins C Model Timing Check	395	(4)
Timing PF Jerk Pumps	399	(1)
Automatic Timing Advance Device	400	(1)
Basic Fuel System Troubleshooting	401	(5)
Robert Bosch Governors	406	(8)
Aneroid Boost Compensator Control	414	(1)
Altitude Pressure Compensator	415	(1)
Robert Bosch Electronic Diesel Control	416	(3)
Distributor Pumps	419	(15)
Robert Bosch VE Injection Pump Troubleshooting	434	(1)
Electronic Distributor Pump	434	(2)
Testing Setting Injection Pumps	436	(4)
Summary	440	(1)
Self-Test Questions	440	(7)
20 MACK ELECTRONIC FUEL SYSTEMS	447	(27)
Overview	447	(1)
System Structure and Function	447	(4)
V-MAC System Components	451	(5)
V-MAC System Troubleshooting	456	(4)
Injection Pump Removal	460	(3)
Injection Pump Installation	463	(3)
Electronic Unit Pump System	466	(1)
Mack Pump Timing Check	466	(1)
Pump Installation	466	(5)
Mack Intravance Econovance Systems	471	(1)
Summary	472	(1)
Self-Test Questions	473	(1)
21 DETROIT DIESEL CORPORATION FUEL SYSTEMS	474	(75)
Overview	474	(1)
Company Background	474	(1)
Engine Labels	475	(1)
Fuel System Functions	475	(1)
Fuel System Components	475	(3)
Fuel Pump	478	(3)
Minimum Fuel-Line Sizes Versus Restriction	481	(1)
Priming the Fuel System	481	(1)
Filter Replacement	482	(1)
Engine Runs Out of Fuel	482	(1)
Fuel Injectors	483	(8)
Fuel Jumper Line Reuse	491	(1)
Care and Testing of Unit Injectors	491	(1)
Mechanical Injector Tests	492	(3)
Fuel System Troubleshooting	495	(5)
Series 60 Compression Leakage	500	(3)
DDC Two-Stroke-Cycle Engine Tune-Up	503	(1)
Tune-Up Sequence	504	(17)
Detroit Diesel Four-Stroke-Cycle Engines	521	(1)
Detroit Diesel Electronic Systems	522	(10)
Diagnostic Tooling	532	(5)
Optimized Idle	537	(1)
Electronic Unit Pump System	538	(1)
Valve Adjustment for Mercedes-Benz Detroit Diesel Series 55 Engine Models	539	(2)
Summary	541	(1)
Self-Test Questions	541	(8)
22 CUMMINS FUEL SYSTEMS	549	(87)
Overview	549	(1)
Company Background	549	(1)
Engine Model Identification	549	(1)
PT Fuel System	549	(5)
PT Fuel Pumps	554	(9)
AFC Pumps	563	(1)
PTG-AFC Pump Flow Review	564	(2)
Manual Fuel Shutoff	566	(1)
PT Pump Checks and Adjustments	566	(4)
Basic PT Fuel System Troubleshooting	570	(6)
Fuel Rate: PTG-AFC Pump	576	(4)
Throttle Checks	580	(1)
PT Fuel Pump Removal and Installation	581	(1)
AFC No-Air Valve Setting	581	(2)
Installing the Cummins PT Pump to the Engine	583	(1)
Troubleshooting the Cummins Fuel Pump	583	(2)
PT Injectors	585	(11)
Engine-to-Injector Timing	596	(6)
Valve and Injector Adjustment	602	(6)
Step Timing Control System	608	(6)
Cummins Electronics	614	(11)
Diagnostic Tooling	625	(5)
Summary	630	(1)
Self-Test Questions	630	(6)
23 CATERPILLAR FUEL SYSTEMS	636	(70)
Overview	636	(1)
Company Background	636	(1)
System Structure and Function	636	(1)
New Scroll Fuel System: 3306 and 3406 Engines	637	(3)
Fuel Transfer Pump	640	(1)
Governor	640	(1)
Automatic Timing Advance Unit	641	(3)
Static Engine Timing	644	(3)
Dynamic Engine Timing	647	(6)
Governor Balance Point Check	653	(3)
Torque Control Group: 3406B 400-HP ATAAC	656	(1)
Air Fuel Ratio Control	656	(4)
Fuel Injection Pump Assembly: 3406B Engine	660	(2)
Valve Adjustment: 3406 Engine	662	(2)
3114 and 3116 Mechanical Model Engine	664	(14)
Caterpillar Electronic Fuel Systems	678	(17)
HEUI Fuel System	695	(7)
Summary	702	(1)
Self-Test Questions	702	(4)
24 ELECTRICAL FUNDAMENTALS AND BATTERIES	706	(23)
Overview	706	(1)
Electricity	706	(1)
Principles of Simple Electrical Circuits	707	(1)
Laws Relating to Voltage, Current Flow, and Circuit Resistance	708	(3)
Permanent Magnets and Electromagnets	711	(1)
Electromagnetic Induction	712	(1)
Test Instruments	713	(2)
Batteries	715	(8)
Summary	723	(1)
Self-Test Questions	723	(6)
25 ALTERNATOR CHARGING SYSTEMS	729	(20)
Overview	729	(1)
Electrical System Loads	729	(1)
Types of Alternators	729	(2)
Alternator Operation	731	(2)
Three-Phase Stator Winding	733	(1)
Stator Winding Designs	733	(1)
Rectification of AC Voltage	734	(1)
Generator Control Circuit	734	(1)
Brushless Generator Operation	735	(1)
Vat Tester	736	(1)
Heavy-Duty Alternator Test: On Vehicle	737	(1)
On-Vehicle Alternator Output Test	738	(1)
Troubleshooting Leece-Neville Alternators	739	(2)
Duvac (Dual-Voltage Alternator Control) Control System	741	(1)
Alternator Drive Belts	742	(1)
Inspection and Overhaul of System Components	743	(3)
Summary	746	(1)
Self-Test Questions	746	(3)
26 ELECTRIC STARTING MOTORS	749	(22)
Overview	749	(1)
Starter Motor Function	749	(1)
Electric Starter System Structure	749	(1)
12-and 24-Volt Circuits	750	(2)
Air Starter System	752	(1)
Electric Starter Motor Components	752	(4)
Solenoid Switch Components and Operating Principles	756	(2)
Electric Starter Troubleshooting	758	(9)
Summary	767	(1)
Self-Test Questions	767	(4)
INDEX	771