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Diesel Technology: Fundamentals, Service, Repair

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

Diesel Technology: Fundamentals, Service, Repair

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

ISBN 13:
9781566377331
ISBN 10:
1566377331
Edition: 2nd
Format: Hardcover
Copyright: 07/01/2000
Publisher: Goodheart-Willcox Pub
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Summary

Diesel Technology provides up-to-date instruction on the construction, operation, service, and repair of two- and four-stroke diesel engines. The 2001 edition includes new information on electronic engine controls and fuel injection. Coverage ranges from fundamental operation to the latest in diesel engine technology. Content relates to on- and off-road vehicles, as well as marine, agricultural, and industrial applications.

Introduction to Diesel Engines	p. 11
Diesel Versus Gasoline Engines	p. 11
Diesel Engine Stroke Cycle
Supplying Air and Fuel
Compression Ratios
Durability
Diesel Drawbacks
Diesel Engine History	p. 14
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
Shop Safety	p. 23
Safety Notices	p. 23
Personal Safety	p. 23
Personal Protective Equipment
Shop Safety Rules	p. 24
Shop Cleanliness
Vehicle Safety Rules
Diesel Fuel Safety Precautions
Cleaning Equipment
Fire Prevention	p. 26
General Fire Safety Rules
Using a Fire Extinguisher
Right-to-Know Laws	p. 27
Hazardous Materials
Handling Hazardous Waste
Tools, Precision Tools, and Fasteners	p. 31
Hand Tools	p. 31
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	p. 38
Stationary Power Tools
Engine Measuring Tools	p. 41
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	p. 45
Injection Systems
Electrical Test Equipment	p. 48
Multimeters
Test Lights
Computer System Diagnostic Tools	p. 49
Fasteners	p. 49
Bolt and Screw Terminology
U.S. and Metric Nuts
Thread Repairs	p. 50
Applying Torque to a Fastener
Principles of Operation	p. 55
Major Engine Components	p. 55
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	p. 64
Engine Cycle Design
Four-Stroke Cycle Operation
Four-Cycle Engine Valve Timing
Two-Stroke Cycle Engines
Cylinder Number and Configuration	p. 69
Inline Engines
V-type Engines
W-type and Delta Engine Configurations
Radial Engines
Doubleacting Piston
Combustion Chamber Designs	p. 71
Direct Injection Chamber
Precombustion Chamber
Swirl Chamber
Energy (Lanova) Cells
Diesel Fuel Injection Systems	p. 73
Injection System Functions
Types of Fuel Injection Systems
Electronically Controlled Fuel Injection Systems
Engine Performance Terms and Formulas	p. 75
Bore and Stroke
Displacement
Compression Ratio
Pressure
Volumetric Efficiency
Specific Gravity
Mean Effective Pressure
Horsepower and Torque	p. 76
Horsepower
Torque
Engine Blocks	p. 81
Cylinder Blocks	p. 81
Accessing Diesel Engine Components	p. 81
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
Crankshafts	p. 103
Diesel Crankshafts	p. 103
Crankshaft Terminology
Crankshaft Lubrication
Crankshaft Classifications
Crankshaft Service
Crack Detection
Crankshaft Loads
Inspecting Journals
Reconditioning Crankshaft Journals
Bearing Inspection	p. 110
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
Pistons, Rings, and Connecting Rods	p. 125
Diesel Pistons	p. 125
Piston Designs
Types of Pistons
Cam Ground Pistons
Piston Cleaning
Inspecting Pistons
Checking Piston Wear
Checking Piston Clearance
Piston Rings	p. 129
Compression Rings
Oil Control Rings
Checking Ring Grooves for Wear
Piston Ring Installation
Piston Pins (Wrist Pins)	p. 134
Inspecting Piston Pins
Connecting Rods	p. 135
Connecting Rod Inspection
Connecting the Piston to the Rod
Assembling the Main Bearings
Checking Crankshaft Clearances
Connecting the Piston Assembly to the Crankshaft
Cylinder Heads and Related Components	p. 147
Cylinder Head	p. 147
Cylinder Head Studs and Gaskets
Disassembling a Cylinder Head
Cylinder Head Removal
Cylinder Head Inspection and Service
Checking for Cylinder Head Damage
Valves	p. 154
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
Camshaft and Valve Train Components	p. 173
Valve Train Operating Mechanisms	p. 173
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	p. 181
Camshaft Service
Cam Follower Service
Rocker Arm Service
Push Rod Service
Assembling the Valve Train Components	p. 186
Camshaft Installation
Assembling the Camshaft Gears
Installing the Cylinder Head
Adjusting Valve Clearance
Valve Cover
Lubrication Systems	p. 195
Lubricating Systems	p. 195
Lubrication System Components	p. 195
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	p. 217
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	p. 219
API Service Classification
Viscosity
Synthetic Oil
Oil Additives
Oil Analysis
Cooling Systems	p. 225
Cooling Systems	p. 225
Types of Cooling Systems
Coolants
Radiator Systems
Surge Tank
Radiators
Radiator Fan Shroud
Hoses	p. 233
Radiator Outlets
Cleaning and Replacing Cooling System Components	p. 234
Hose Replacement
Cleaning a Radiator
Inspecting and Testing the Cooling System
Coolant Filters
Thermostats
Cooling System Service
Water Manifolds	p. 241
Water Pumps	p. 241
V-Belt Drives	p. 243
Fans and Fan Clutches
Suction Fans	p. 244
Blower Fans	p. 244
Fan Clutch
Coolant Heaters
Industrial Engine Cooling Systems	p. 245
Radiator
Heat Exchanger
Cooling Tower
Expansion and Surge Tanks
Marine Engine Cooling System	p. 250
Raw-Water Cooling System
Materials Used in Marine Heat Exchangers
Salt Water Applications
Heat Exchanger Cooling Systems
Air Intake Systems	p. 257
Air Intakes	p. 257
Factors Affecting Air Intake Efficiency
Scavenging and Supercharging	p. 258
Scavenging Principles
Supercharging Principles
Four-Cycle Supercharging
Two-Cycle Supercharging
Air Cleaners	p. 261
Intake Air Cleaners	p. 263
Oil Bath Air Cleaners
Dry Air Filters
Filter Housing
Servicing Dry Type Filters
Additional Service Tips
Changing Air Filter Elements	p. 269
Intake Air Silencers	p. 269
Pipes and Hoses
Blowers	p. 270
Positive Displacement Blowers	p. 270
Roots Blower
Centrifugal Blowers
Intake Air Passages	p. 271
Intake Installation
Exhaust Systems	p. 275
Exhaust System	p. 275
Back Pressure
Exhaust System Components	p. 276
Exhaust Manifolds
Exhaust Manifold Service
Mufflers
Resonator
Exhaust Piping
Exhaust System Service	p. 285
Noise Levels
Reducing Exhaust Noise
Turbochargers	p. 287
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)	p. 292
Exhaust Pyrometers	p. 295
Exhaust Brakes	p. 295
Diesel Engine Emissions	p. 295
Water As a Performance Enhancer
Catalytic Converter/Silencer
Diesel Fuels	p. 303
Hydrocarbon Fuels	p. 303
Diesel Fuel Grades	p. 303
Diesel Fuel Properties
Fuel Additives	p. 308
Fuel Handling and Storage	p. 308
Storage Tanks
Alternative Fuels	p. 309
Compressed and Liquefied Natural Gas
Alcohol-Based Fuels
Biodiesel Fuels
Basic Fuel Systems	p. 315
Fuel System Components	p. 315
Fuel System Operating Fundamentals
Fuel Delivery System Types
Fuel Tanks	p. 317
Fuel Tank Material
Dual Fuel Tanks
Fuel System Problems
Fuel Gauge Systems
Analog and Digital Gauge Systems
Fuel Lines	p. 322
Heavyweight Fuel Lines
Fuel Flow Considerations
Fuel Transfer Pumps (Supply Pumps)	p. 325
Inspecting and Cleaning a Diaphragm Transfer Pump
Rebuilding Piston Fuel Transfer Pump
Gear Fuel Transfer Pump Service
Fuel Filters and Conditioners	p. 331
Damage by Dirt and Water	p. 331
Filtration Devices	p. 331
Sedimenters
Agglomerators
Fuel Filters
Filtration Systems
Servicing Filters	p. 336
Servicing Bolt-on Filters
Air Removal
Fuel Heaters
Fuel Coolers
Injection System Fundamentals	p. 343
Diesel Fuel Injection Systems	p. 343
Types of Fuel Injection Systems
Timing	p. 344
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	p. 353
Injection Nozzles	p. 355
Nozzle Holders	p. 355
Holder Construction
Types of Injector Nozzles
Hole Injector Nozzles
Pintle Nozzles
CAV Pentaux Nozzle
Spray Patterns
Servicing Fuel Injector Holders and Nozzles	p. 359
Factors that can Reduce Injector Life
Injector Removal
Disassembly
Cleaning
Reassembly and Installation
Reinstallation
Pencil Nozzles	p. 365
Pencil Nozzle Operation
Capped Pencil Nozzle
Pencil Nozzle Removal
Pencil Nozzle Testing and Adjustment
Pencil Nozzle Installation
Governors and Acceleration Controls	p. 373
Governing Engine Speed	p. 373
Classifications of Governors
Governor Terminology
Governor Designs
Gain and Proportional Control
Acceleration Smoke Controls	p. 384
Aneroid/Boost Compensator
Altitude-Pressure Compensator
Multiple Plunger Inline Injection Pumps	p. 391
Inline Injection Pumps	p. 391
Inline Injection Pump Components	p. 391
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	p. 396
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	p. 404
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
Lift-to-Port Closure
Plunger Head Clearance
Fuel Delivery Rate Calibration
Final Checks
Distributor Injection Pumps	p. 417
Distributor Injection Pumps	p. 417
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	p. 423
Opposed Plunger Pump Construction
Components
Pump Operation and Fuel Flow
Pressure Regulating Valve Operation
Electrical Shutoff
Distributor Injection Pump Removal and Installation	p. 429
Bosch VE Distributor Pump	p. 431
Pump Assembly
Construction
Unit Injector Fuel Injection Systems	p. 437
Basics of Unit Injection (Two-Stroke Engines)	p. 437
Mechanical Unit Injectors (MUI)
Mechanical Unit Injector Operation
Isolating a Faulty Injector
Injector Service (Two-Stroke Engines)	p. 442
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	p. 444
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	p. 452
Valve and Injector Timing
Injector Timing Height
Cummins Pressure-Time Injection Systems	p. 457
Pressure-Time (PT) Fuel Injection	p. 457
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	p. 462
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)	p. 472
Operation
Setting STC Top Stop Injectors
Mechanical Variable Timing	p. 474
Basics of Electricity	p. 477
Principles of Electricity	p. 477
Conventional versus Electron Theory
Measuring Electricity
Ohm's Law
Watt's Law
Conductors, Insulators, and Semiconductors
Electrical Circuits	p. 481
Series Circuits
Parallel Circuits
Series-Parallel Circuits
Ground Return Circuits
Basic Circuit Conditions
Electrical System Components	p. 483
Wiring
Circuit Protection
Switches
Relays and Solenoids
Resistors
Capacitors (Condensers)
Batteries	p. 486
Battery Design
Electrolyte Specific Gravity
Additional Battery Cell Materials
Battery Ratings
Battery Safety
Battery Preventive Maintenance	p. 489
Battery Testing and Service	p. 490
Battery Load Test
Battery Charging	p. 492
Battery Circuits
Jump Starting Diesel Engines
12- to 24-Volt Systems
Semiconductor Devices	p. 494
Doped Semiconductors
Diodes
Transistors
Transistor Operation
Integrated Circuits and Computer Chips
Electronic Engine Controls and Fuel Injection	p. 501
Diesel Engine Control Systems	p. 501
Electronic Control Module	p. 501
Voltage Signals
Analog-to-Digital (A/D) Converters
Binary Codes
Interface Circuits and Clock Chips
Control System Memory
EMI and RFI
Data Link Connectors and Serial Lines
Remote Data Retrieval Stations
Input Sensors	p. 506
Variable Resistor Sensors
Inductive (Pulse Counting) Sensors
Brake, Clutch, and Cruise Control Switches
Oil Pressure Sensor (OPS)
Air Pressure Sensor
Coolant Level Sensor
Turbocharger Boost Sensor (TBS)
Throttle Position Sensor (TPS)
Output Devices	p. 509
Fuel Injection Control
Tachometer/Speedometer Drive Outputs
Electronically Controlled Fuel Injection Pumps	p. 510
Electronic Unit Injectors (EUI)
Hydraulic Electronic Unit Injectors (HEUI)
Inline Injection Pumps
Electronically Controlled Distributor Pumps
Engine Control System Operation	p. 515
Open and Closed Loop Operation
Engine Diagnostics
Engine Protection (Shutdown) System
Viewing Diagnostic Codes
Self-Diagnostics
Software Programs
Factory and Customer Programmed Parameters	p. 519
Lifetime Totals and Maintenance Indicator Data
Security
Fuel Injection System Overviews	p. 520
Detroit Diesel Electronic Controls (DDEC)
Caterpillar Electronic Engine Control Systems
Mack V-MAC III Control System
Troubleshooting Electronic Controls	p. 528
Troubleshooting Procedures
Multimeter Checks
Oscilloscopes
Substitution
Service Precautions
Diesel Engine Charging Systems	p. 537
Charging System	p. 537
Principles of Magnetism
Alternators	p. 539
Alternator Design and Components
Brushless Alternators
Ac Rectification
Voltage Regulators	p. 543
Reverse Polarity Protection
A and B Field Circuits
Service Precautions	p. 545
Charging System Problems	p. 545
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	p. 548
Restoring Rotor Magnetism on Brushless Alternators
Diesel Starting Systems	p. 551
Starting System	p. 551
Electric Starter System Components	p. 551
Starter Motor Design and Operation
Starter Motor Components
Solenoid
Starter Motor Drives
Overrunning Clutches
Series-Parallel Starter Motor Switch
Electric Starting System Tests	p. 556
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	p. 560
System Components
Troubleshooting Air Starting Systems
Hydraulic Starting Systems	p. 561
Troubleshooting Hydraulic Starting Systems
Cold Starting Aids	p. 562
Coolant Heaters
Lubricating Oil Heaters
Glow Plugs
Fluid Starting Aids
Battery Warmers
Table of Contents provided by Syndetics. All Rights Reserved.

Amazon no longer offers textbook rentals. We do!

Diesel Technology: Fundamentals, Service, Repair

Diesel Technology: Fundamentals, Service, Repair

9781566377331

1566377331

Summary

Table of Contents

Supplemental Materials

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Amazon no longer offers textbook rentals. We do!

Diesel Technology: Fundamentals, Service, Repair

Diesel Technology: Fundamentals, Service, Repair

9781566377331

1566377331

Summary

Table of Contents

Supplemental Materials

Write a Review

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