Diesel Technology

by Norman, Andrew; Corinchock, John; Scharff, Robert

• ISBN13: 9781566370141
• ISBN10: 1566370140
• Format: Hardcover
• Copyright: 1997-12-01
• Publisher: Goodheart-Willcox Pub

Summary

Diesel Technology provides up-to-date instruction on the construction, operation, service, and repair of two- and four-stroke diesel engines. Coverage ranges from the fundamentals of diesel operation to the latest developments in diesel technology Content relates to both on- and off-road vehicles, as well as marine, agricultural, and industrial applications.

Table of Contents

Chapter 1: Introduction to Diesel Engines	11	(12)
Diesel Versus Gasoline Engines	11	(3)
Diesel Engine Stroke Cycle
Supplying Air and Fuel
Compression Ratios
Durability
Diesel Drawbacks
Diesel Engine History	14	(9)
Early Theories and Successes
The Silent Otto Engine
The Development of the Diesel Engine
Continued Development of the Diesel Engine
Modern Diesel Applications
Modifications to Increase Diesel Engine Efficiency
Chapter 2: Shop Safety	23	(8)
Safety Notices	23	(1)
Personal Safety	23	(1)
Personal Protective Equipment
Shop Safety Rules	24	(2)
Shop Cleanliness
Vehicle Safety Rules
Diesel Fuel Safety Precautions
Cleaning Equipment
Fire Prevention	26	(1)
General Fire Safety Rules
Using a Fire Extinguisher
Right-to-Know Laws	27	(4)
Hazardous Materials
Handling Hazardous Waste
Chapter 3: Tools, Precision Tools, and Fasteners	31	(24)
Hand Tools	31	(7)
Chisels and Punches
Saws and Knives
Files
Screwdrivers
Hammers
Wrenches
Sockets and Socket Drivers
Allen Wrenches
Pliers and Cutters
Vise and C-Clamps
Torque Wrench
Other Hand Tools
Power Tools	38	(3)
Stationary Power Tools
Engine Measuring Tools	41	(4)
Micrometers
Reading a Micrometer
Depth Gauge
Vernier Calipers
Telescoping and Small Hole Gauges
Feeler Gauges
Dial Indicator
Cylinder Bore Dial Gauge
Digital Tachometer
Infrared Thermometer
Cylinder Compression Gauge
Manometer
Specialized Diesel Tools and Equipment	45	(3)
Injection Systems
Electrical Test Equipment	48	(1)
Multimeters
Test Lights
Computer System Diagnostic Tools Fasteners	49	(1)
Fasteners	49	(1)
Bolt and Screw Terminology
U.S. and Metric Nuts
Thread Repairs	50	(5)
Applying Torque to a Fastener
Chapter 4: Principles of Operation	55	(26)
Major Engine Components	55	(9)
Cylinder Block and Cylinder Liners
Pistons
Crankshaft
Connecting Rods
Oil Pan
Flywheel
Vibration Dampers
Camshaft
Valve Train Components
Cylinder Head
Valves
Intake and Exhaust Manifolds
Superchargers
Turbochargers
Aftercoolers
Diesel Engine Classifications	64	(5)
Engine Cycle Design
Four-Stroke Cycle Operation
Four-Cycle Engine Valve Timing
Two-Stroke Cycle Engines
Cylinder Number and Configuration	69	(2)
Inline Engines
V-type Engines
W-type and Delta Engine Configurations
Radial Engines
Double-acting Piston
Combustion Chamber Designs	71	(2)
Direct Injection Chamber
Precombustion Chamber
Swirl Chamber
Energy (Lanova) Cells
Diesel Fuel Injection Systems	73	(2)
Injection System Functions
Types of Fuel Injection Systems
Electronically Controlled Fuel Injection Systems
Engine Performance Terms and Formulas	75	(1)
Bore and Stroke
Displacement
Compression Ratio
Pressure
Volumetric Efficiency
Specific Gravity
Mean Effective Pressure
Horsepower and Torque	76	(5)
Horsepower
Torque
Chapter 5: Engine Blocks	81	(22)
Cylinder Blocks	81	(1)
Accessing Diesel Engine Components	81	(22)
Accessing Components in a Stationary Engine
Accessing Components in a Mobile Engine
Engine Block Cleaning
Cylinder Block Inspection
Cylinder Bores and Liners
Inspection of Cylinder Bores and Liners
Types of Cylinder Liners
Installing Cylinder Liners
Cylinder Liner Safety Features
Chapter 6: Crankshafts	103	(22)
Diesel Crankshafts	103	(7)
Crankshaft Terminology
Crankshaft Lubrication
Crankshaft Classifications
Crankshaft Service
Crack Detection
Crankshaft Loads
Inspecting Journals
Reconditioning Crankshaft Journals
Bearing Inspection	110	(15)
Bearing Material
Types of Diesel Engine Bearings
Bearing Crush and Spread
Bearing Distress
Checking Bearing Clearance
Crankshaft Oil Seals
Crankshaft Gears
Flywheel
Starter Gear Inspection
Vibration Dampers
Chapter 7: Pistons, Rings, and Connecting Rods	125	(22)
Diesel Pistons	125	(4)
Piston Designs
Types of Pistons
Cam Ground Pistons
Piston Cleaning
Inspecting Pistons
Checking Piston Wear
Checking Piston Clearance
Piston Rings	129	(5)
Compression Rings
Oil Control Rings
Checking Ring Grooves for Wear
Piston Ring Installation
Piston Pins (Wrist Pins)	134	(1)
Inspecting Piston Pins
Connecting Rods	135	(12)
Connecting Rod Inspection
Connecting the Piston to the Rod
Assembling the Main Bearings
Checking Crankshaft Clearances
Connecting the Piston Assembly to the Crankshaft
Chapter 8: Cylinder Heads and Related Components	147	(26)
Cylinder Head	147	(7)
Cylinder Head Studs and Gaskets
Disassembling a Cylinder Head
Cylinder Head Removal
Cylinder Head Inspection and Service
Checking for Cylinder Head Damage
Valves	154	(19)
Valve Stem and Seat
Valve Construction
Valve Guides
Valve Guide Reconditioning
Valve Seats
Valve Stem Seals
Valve Springs
Valve Rotators
Valve Keepers
Injection Nozzle Holder Inserts
Chapter 9: Camshaft and Valve Train Components	173	(22)
Valve Train Operating Mechanisms	173	(8)
Camshafts
Cam Lobes
Camshaft Gear
Valve Operation
Camshaft Location
Camshaft Drive Systems
Engine Timing
Cam Follower Assemblies
Rocker Arms
Rocker Housing Cover
Inspecting and Servicing the Valve Train	181	(5)
Camshaft Service
Cam Follower Service
Rocker Arm Service
Push Rod Service
Assembling the Valve Train Components	186	(9)
Camshaft Installation
Assembling the Camshaft Gears
Installing the Cylinder Head
Adjusting Valve Clearance
Valve Cover
Chapter 10: Lubrication Systems	195	(30)
Lubricating Systems	195	(1)
Lubrication System Components	195	(22)
Types of Lubrication Systems
Oil Pans and Sumps
Dipstick
Oil Pumps
Oil Cooler
Maintenance of Oil Coolers
Oil Pressure Relief Valve
Oil Filters
Oil Filter Maintenance
Oil Pressure Indication Systems	217	(2)
Oil Pressure Warning Light
Mechanical Indicating System
Electrical Indicating System
Electromagnetic Coil Indicating System
Heating Coil Indicating System
Pressure Switch Indicating System
Electronic Indicating System
Ventilation Systems
Engine Oils	219	(6)
API Service Classification
Viscosity
Synthetic Oil
Oil Additives
Oil Analysis
Chapter 11: Cooling Systems	225	(32)
Cooling Systems	225	(8)
Types of Cooling Systems
Coolants
Radiator Systems
Surge Tank
Radiators
Radiator Fan Shroud
Hoses	233	(1)
Radiator Outlets
Cleaning and Replacing Cooling System Components	234	(7)
Hose Replacement
Cleaning a Radiator
Inspecting and Testing the Cooling System
Coolant Filters
Thermostats
Cooling System Service
Water Manifolds	241	(1)
Water Pumps	241	(2)
V-Belt Drives	243	(1)
Fans and Fan Clutches
Suction Fans	244	(1)
Blower Fans	244	(1)
Fan Clutch
Coolant Heaters
Industrial Engine Cooling Systems	245	(5)
Radiator
Heat Exchanger
Cooling Tower
Expansion and Surge Tanks
Marine Engine Cooling System	250	(7)
Raw-Water Cooling System
Materials Used in Marine Heat Exchangers
Salt Water Applications
Heat Exchanger Cooling Systems
Chapter 12: Air Intake Systems	257	(18)
Air Intakes	257	(1)
Factors Affecting Air Intake Efficiency
Scavenging and Supercharging	258	(3)
Scavenging Principles
Supercharging Principles
Four-Cycle Supercharging
Two-Cycle Supercharging
Air Cleaners	261	(2)
Intake Air Cleaners	263	(6)
Oil Bath Air Cleaners
Dry Air Filters
Filter Housing
Servicing Dry Type Filters
Additional Service Tips
Changing Air Filter Elements	269	(1)
Intake Air Silencers	269	(1)
Pipes and Hoses
Blowers	270	(1)
Positive Displacement Blowers	270	(1)
Roots Blower
Centrifugal Blowers
Intake Air Passages	271	(4)
Intake Installation
Chapter 13: Exhaust Systems	275	(28)
Exhaust System	275	(1)
Back Pressure
Exhaust System Components	276	(9)
Exhaust Manifolds
Exhaust Manifold Service
Mufflers
Resonator
Exhaust Piping
Exhaust System Service	285	(2)
Noise Levels
Reducing Exhaust Noise
Turbochargers	287	(5)
Turbocharger Components
Turbocharger Operation
Turbocharger Advantages
Turbocharger Lubrication
Turbocharger Controls
Scavenging Pump and the Turbocharger
Two-or Four-Stage Turbocharging
Turbocharger Inspection and Troubleshooting
Turbocharger Removal and Installation
Aftercoolers (Intercoolers)	292	(3)
Exhaust Pyrometers	295	(1)
Exhaust Brakes	295	(1)
Diesel Engine Emissions	295	(8)
Water As a Performance Enhancer
Catalytic Converter
Silencer
Chapter 14: Diesel Fuels	303	(12)
Hydrocarbon Fuels	303	(1)
Diesel Fuel Grades	303	(5)
Diesel Fuel Properties
Fuel Additives	308	(1)
Fuel Handling and Storage	308	(1)
Storage Tanks
Alternative Fuels	309	(6)
Compressed and Liquefied Natural Gas
Alcohol-Based Fuels
Biodiesel Fuels
Chapter 15: Basic Fuel Systems	315	(16)
Fuel System Components	315	(2)
Fuel System Operating Fundamentals
Fuel Delivery System Types
Fuel Tanks	317	(5)
Fuel Tank Material
Dual Fuel Tanks
Fuel System Problems
Fuel Gauge Systems
Analog and Digital Gauge Systems
Fuel Lines	322	(3)
Heavyweight Fuel Lines
Fuel Flow Considerations
Fuel Transfer Pumps (Supply Pumps)	325	(6)
Inspecting and Cleaning a Diaphragm Transfer Pump
Rebuilding Piston Fuel Transfer Pump
Gear Fuel Transfer Pump Service
Chapter 16: Fuel Filters and Conditioners	331	(12)
Damage by Dirt and Water	331	(1)
Filtration Devices	331	(5)
Sedimenters
Agglomerators
Fuel Filters
Filtration Systems
Servicing Filters	336	(7)
Servicing Bolt-on Filters
Air Removal
Fuel Heaters
Fuel Coolers
Chapter 17: Injection System Fundamentals	343	(12)
Diesel Fuel Injection Systems	343	(1)
Types of Fuel Injection Systems
Timing	344	(9)
Fuel Metering
Port and Helix Fuel Metering
Sleeve Metering System
Inlet Metering System
Pressure-Time Fuel Metering Systems
Unit Injector Metering System
Electronic Metering Systems	353	(2)
Chapter 18: Injection Nozzles	355	(18)
Nozzle Holders	355	(4)
Holder Construction
Types of Injector Nozzles
Hole Injector Nozzles
Pintle Nozzles
CAV Pentaux^R Nozzle
Spray Patterns
Servicing Fuel Injector Holders and Nozzles	359	(6)
Factors that can Reduce Injector Life
Injector Removal
Disassembly
Cleaning
Reassembly and Installation
Reinstallation
Pencil Nozzles	365	(8)
Pencil Nozzle Operation
Capped Pencil Nozzle
Pencil Nozzle Removal
Pencil Nozzle Testing and Adjustment
Pencil Nozzle Installation
Chapter 19: Governors and Acceleration Controls	373	(18)
Governing Engine Speed	373	(11)
Classifications of Governors
Governor Terminology
Governor Designs
Gain and Proportional Control
Acceleration Smoke Controls	384	(7)
Aneroid
Boost Compensator
Altitude-Pressure Compensator
Chapter 20: Multiple Plunger Inline Injection Pumps	391	(26)
Inline Injection Pumps	391	(1)
Inline Injection Pump Components	391	(5)
Inline Pump Components
Inline Pump Operation
Pump and Governor Identification
Inline Injection Pump Sizes and Features
Automatic Timing Advance Device
Inline Pump Testing and Service	396	(8)
Inline Pump Removal
Injection Pump Installation
Static Spill Timing Check
Timing with Fixed Timing Sensor
Light
High Pressure Port Closure Test
Assembled Engine Spill Timing Check
Low Air Pressure Method
Bleeding the Injection System
Basic Troubleshooting	404	(13)
Relief Valve Pressure Check
Transfer Pump Restriction Check
Secondary Fuel Filter Pressure Check
Inline Injection Pump Service and Calibration
Disassembly
Cleaning and Inspection
Reassembly
Testing and Calibration of Inline Pumps
Life-to-Port Closure
Plunger Head Clearance
Fuel Delivery Rate Calibration
Final Checks
Chapter 21: Distributor Injection Pumps	417	(20)
Distributor Injection Pumps	417	(6)
Distributor Pump Components
Delivery Valve Operation
Governor Operation
Excess Fuel and Aneroid Devices
Intravance Camshaft
Distributor Pump Removal
Distributor Pump Installation
Distributor Pump Calibration
Opposed Plunger Inlet Metered Pumps	423	(6)
Opposed Plunger Pump Construction
Components
Pump Operation and Fuel Flow
Pressure Regulating Valve Operation
Electrical Shutoff
Distributor Injection Pump Removal and Installation	429	(2)
Bosch VE Distributor Pump	431	(6)
Pump Assembly Construction
Chapter 22: Unit Injector Fuel Injection Systems	437	(20)
Basics of Unit Injection (Two-Stroke Engines)	437	(5)
Mechanical Unit Injectors (MUI)
Mechanical Unit Injector Operation
Isolating a Faulty Injector
Injector Service (Two-Stroke Engines)	442	(2)
Inspection and Testing
Plunger and Control Rack Movement Test
Spray Pattern Test
Pressure and Leakage Test
Fuel Output Test
Injector Installation
Fuel Spill Back Check
Engine Tune-Up Procedure	444	(8)
Exhaust Valve Bridge Check
Setting Exhaust Valve Clearance
Injector Timing
Governor Gap Adjustment
Injector Control Racks
Setting Maximum No-load Speed
Idle Speed
Buffer Screw
Starting Aid Screw Adjustment
Throttle Delay Cylinder Adjustment
Fuel Modulator Adjustment
Final Tune-Up Checks
Detroit Diesel Series 60 Engines	452	(5)
Valve and Injector Timing
Injector Timing Height
Chapter 23: Cummins Pressure-Time Injection Systems	457	(20)
Pressure-Time (PT) Fuel Injection	457	(5)
PT Fuel System Operation
Pressure-Time Governed (PTG) Fuel Pump Functions
Governor
PTG Air-Fuel Control (AFC)
Shutdown Valve
Cooling Kit
Injector Operation
PT Pump Checks and Adjustments	462	(10)
Idle Speed Adjustments
Basic Fuel System Checks
PT Fuel Pump Removal and Installation
Injector Removal
Injector Installation
Engine-to-Injector Timing
Performing Timing Checks
Valve and Injector Adjustments
Top Stop Injector Timing Adjustment
Step Timing Control (STC)	472	(2)
Operation
Setting STC Top Stop Injectors
Mechanical Variable Timing	474	(3)
Chapter 24: Basics of Electricity	477	(24)
Atomic Structure and Electricity	477	(1)
Principles of Electricity	478	(4)
Conventional versus Electron Theory
Measuring Electricity
Ohm's Law
Watt's Law
Conductors, Insulators, and Semiconductors
Electrical Circuits	482	(3)
Series Circuits
Parallel Circuits
Series-Parallel Circuits
Ground Return Circuits
Basic Circuit Conditions
Electrical System Components	485	(4)
Wiring
Circuit Protection
Switches
Relays and Solenoids
Resistors
Capacitors (Condensers)
Batteries	489	(3)
Battery Design
Electrolyte Specific Gravity
Additional Battery Cell Materials
Battery Ratings
Battery Safety
Battery Preventive Maintenance	492	(1)
Battery Testing and Service	492	(3)
Battery Load Test
Battery Charging	495	(6)
Battery Circuits
Jump Starting Diesel Engines
12-to 24-Volt Systems
Chapter 25: Electronic Engine Controls and Fuel Injection	501	(36)
Electronic Fuel Injection	501	(1)
Semiconductor Devices	501	(4)
Doped Semiconductors
Diodes
Transistors
Integrated Circuits
Diesel Engine Control Systems	505	(1)
Input Sensors	505	(3)
Variable Resistor Sensors
Three-Wire Sensors
Pulse Counters
Coolant Temperature Sensor
Oil Temperature Sensor (OTS)
Fuel Temperature Sensors (FTS)
Coolant Level Sensor
Intake Air Temperature and Air Pressure Sensors
Turbocharger Boost Sensor (TBS)
Oil Pressure Sensor (OPS)
Throttle Position Sensor
Engine Position Sensor
Timing Reference Sensor
Vehicle Speed Sensor (VSS)
Brake and Clutch Switches
Electronic Control Module	508	(3)
Voltage Signals
Analog
Digital (A/D) Converters
Binary Codes
Memory
Interfaces and Clock Pulses
Open and Closed Loop Operation
Data Link Connector
Output Devices	511	(3)
Malfunction Indicator Lamp (MIL)
Stop Engine Lamp (SEL)
Engine Protection System
Computer-Controlled Fuel Injection Pumps
Electronically Controlled Inline Injection Pump
Distributor Pump Electronic Controls
Fuel Injection
Ether Starting Systems
Fuel Injection System Overviews	514	(1)
Detroit Diesel Electronic Controls (DDEC)	515	(5)
System Components and Operation
Electronically Controlled Unit Injectors
Unit Injector Operation
Diagnostic and Control Systems
Cruise Control
Engine Fan Braking
Engine Brake
Vehicle Speed Limiting
Idle Timer Shutdown
Vehicle Power Shutdown
ProDriver^(TM)
Optimized Idle
Idle Adjustment
Electronically Controlled Ether Start
Progressive Shifting
Engine Protection System
Caterpillar 3100 HEUI Electronic Engine Control System	520	(3)
Governing Functions
Hydraulic Electronic Unit Injectors (HEUI)
Injection Timing
Fuel Injection
Customer Parameters' Effect on Engine Governing
Engine Monitoring
Lifetime Totals and Maintenance Indicator Data
Programmable Parameters
Caterpillar Programmable Electronic Engine Control (PEEC)	523	(2)
Electronic Control Module
Timing Advance Unit
Rack Actuator and Transducer Module
Caterpillar Electronic Unit Injection	525	(1)
Cummins PACE and Celect Systems	525	(2)
Compulink System
Mack Vehicle Management and Control (V-MAC)	527	(3)
Fuel Injection Control (FIC) Module
V-MAC II Control System
Co-Pilot^(TM)
Security
Enhanced Overspeed Tracking
Vehicle Management
On-Command Fast Idle
Genie Relay
V-MAC III Control System
Troubleshooting Electronic Controls	530	(7)
Checking Components
Service Precautions
Chapter 26: Diesel Engine Charging Systems	537	(14)
Charging System	537	(2)
Principles of Magnetism
Alternators	539	(4)
Alternator Design and Components
Brushless Alternators
Ac Rectification
Voltage Regulators	543	(2)
Reverse Polarity Protection
A and B Field Circuits
Service Precautions	545	(1)
Charging System Problems	545	(3)
Alternator Problems
Voltage Regulator Adjustment
Alternator Output Test
Full Field Testing
Stator Winding Test
Testing Diodes and Brushes
Regulator Circuit Test
Charging Circuit Resistance Test
Alternator Removal and Installation	548	(3)
Restoring Rotor Magnetism on Brushless Alternators
Chapter 27: Diesel Starting Systems	551	(16)
Starting System	551	(1)
Electric Starter System Components	551	(5)
Starter Motor Design and Operation
Starter Motor Components
Solenoid
Starter Motor Drives
Overrunning Clutches
Series-Parallel Starter Motor Switch
Electric Starting System Tests	556	(4)
Cranking Current Test
Available Voltage Check
Relay Bypass Test
Control Circuit Tests
Starter Circuit Resistance Tests
Removing and Installing the Starter Motor
Air Powered Starting Systems	560	(1)
System Components
Troubleshooting Air Starting Systems
Hydraulic Starting Systems	561	(1)
Troubleshooting Hydraulic Starting Systems
Cold Starting Aids	562	(5)
Coolant Heaters
Lubricating Oil Heaters
Glow Plugs
Fluid Starting Aids
Battery Warmers
Chapter 28: Engine Reassembly and Installation	567	(14)
Establish Good Work Habits	567	(1)
Cylinder Block, Sleeves and Crankshaft Assembly	568	(7)
Installing Bearings and Crankshaft
Gear Housing
Installing Pistons and Connecting Rods
Oil Pump and Oil Pan
Flywheel and Crankshaft Rear Seal
Camshaft Installation
Inline or Distributor Injection Pumps
Timing Gear Cover
Lifter Assemblies (Cam Roller Followers)
Cylinder Head Reassembly and Installation
Unit Fuel Injectors
Air Inlet Manifold
Push Rods and Rocker Arms
Fuel Injectors
Valve Cover
Vibration Damper, Crankshaft Pulley and Crankshaft Front Seal
Exhaust Manifold
Fuel Transfer Pump
Fuel and Oil Filters
Power Steering Pump and Water Pump
Air Compressor
Final Assembly
Rebuilt Engine Run-In Procedures	575	(6)
Engine Preparation
Engine Dynamometer Run-In
Dynamometer Check
Engine Installation into Vehicle
Chassis Dynamometer Operation
Highway Run-In Procedures
Chapter 29: Preventive Maintenance and Troubleshooting	581	(20)
Setting Up a Preventive Maintenance (PM) Program	581	(8)
Daily Walk-Around Inspection
Level One Maintenance
Level Two Maintenance
Level Three Maintenance
Records and Forms
Oil Changes
Oil Analysis
Analysis Data
Winterizing Engines	589	(1)
Coolant System
Starting Aids
Batteries and Electrical System
Fuel System
Troubleshooting	590	(2)
Electronic Diagnostics
Primary Engine Checks	592	(1)
General Test Procedures	593	(5)
Locating a Misfiring Cylinder
Cylinder Compression Check
Pressure Checks
Crankcase Pressure
Exhaust Back Pressure
Air Inlet Restrictions
Storage of Diesel Engines	598	(3)
Short Storage Preparation
Extended Storage Preparation
Chapter 30: Career Oppertunities	601	(8)
The Diesel Field	601	(3)
Diesel Engine and Equipment Manufacturers
Diesel Technician
Shop Supervisors
Service Manager
Self-Employment
Educational Requirements
Employment Availability and Wages
Teaching
ASE Certification	604	(2)
ASE Test Content
Taking ASE Tests
A Few Final Words	606	(3)
Working in the Field
Appendix A: Troubleshooting Engine and Fuel System Problems	609	(7)
Appendix B: Conversion Tables	616	(12)
Acknowledgments	628	(1)
Glossary	629	(22)
Index	651