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Diesel Technology

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

Diesel Technology

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

ISBN 13:
9781566370141
ISBN 10:
1566370140
Format: Hardcover
Copyright: 12/01/1997
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. 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.

Chapter 1: Introduction to Diesel Engines

(12)

Diesel Versus Gasoline Engines

(3)

Diesel Engine Stroke Cycle

Supplying Air and Fuel

Compression Ratios

Durability

Diesel Drawbacks

Diesel Engine History

(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

(8)

Safety Notices

(1)

Personal Safety

(1)

Personal Protective Equipment

Shop Safety Rules

(2)

Shop Cleanliness

Vehicle Safety Rules

Diesel Fuel Safety Precautions

Cleaning Equipment

Fire Prevention

(1)

General Fire Safety Rules

Using a Fire Extinguisher

Right-to-Know Laws

(4)

Hazardous Materials

Handling Hazardous Waste

Chapter 3: Tools, Precision Tools, and Fasteners

(24)

Hand Tools

(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

(3)

Stationary Power Tools

Engine Measuring Tools

(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

(3)

Injection Systems

Electrical Test Equipment

(1)

Multimeters

Test Lights

Computer System Diagnostic Tools Fasteners

(1)

Fasteners

(1)

Bolt and Screw Terminology

U.S. and Metric Nuts

Thread Repairs

(5)

Applying Torque to a Fastener

Chapter 4: Principles of Operation

(26)

Major Engine Components

(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

(5)

Engine Cycle Design

Four-Stroke Cycle Operation

Four-Cycle Engine Valve Timing

Two-Stroke Cycle Engines

Cylinder Number and Configuration

(2)

Inline Engines

V-type Engines

W-type and Delta Engine Configurations

Radial Engines

Double-acting Piston

Combustion Chamber Designs

(2)

Direct Injection Chamber

Precombustion Chamber

Swirl Chamber

Energy (Lanova) Cells

Diesel Fuel Injection Systems

(2)

Injection System Functions

Types of Fuel Injection Systems

Electronically Controlled Fuel Injection Systems

Engine Performance Terms and Formulas

(1)

Bore and Stroke

Displacement

Compression Ratio

Pressure

Volumetric Efficiency

Specific Gravity

Mean Effective Pressure

Horsepower and Torque

(5)

Horsepower

Torque

Chapter 5: Engine Blocks

(22)

Cylinder Blocks

(1)

Accessing Diesel Engine Components

(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

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Diesel Technology

Diesel Technology

9781566370141

1566370140

Summary

Table of Contents

Supplemental Materials

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Amazon no longer offers textbook rentals. We do!

Diesel Technology

Diesel Technology

9781566370141

1566370140

Summary

Table of Contents

Supplemental Materials

Write a Review

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