BASIC DIESEL ENGINE TECHNOLOGY

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BASIC DIESEL ENGINE TECHNOLOGY

• DECEMBER 16, 2007

BY MR. GERBITZ

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INTRODUCTION

• THE DIESEL ENGINE IS USED AS A SOURCE OF POWER
  FOR THOUSANDS OF APPLICATIONS.

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WHO INVENTED THE DIESEL ENGINE?

• 1895 RUDOLPH DIESEL SUCCESSFULLY INVENTED AN
  ENGINE THAT BURNED COAL DUST INJECTED BY
  PRESSURIZED AIR. THE DIESEL ENGINE WAS BORN.

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WHO DEVELOPED THE FIRST MASS PRODUCED INJECTION
PUMP?

• ROBERT BOSCH IN 1927

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USES OF DIESEL ENGINES

• TODAY, DIESEL ENGINES ARE USED TO PROVIDE POWER
  IN A VARIETY OF APPLICATIONS IN MANY INDUSTRIES

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THERE ARE SIX MAJOR USES OF DIESEL ENGINES
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AGRICULTURE/FARM
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TRANSPORTATION
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CONSTRUCTION
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FORESTRY
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MARINE
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ELECTRICAL GENERATION PLANTS
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SEVEN ADVANTAGES OF DIESEL ENGINES

• MORE EFFICIENT AND ECONOMICAL TO USE
• FUEL VAPOR IS NOT EXPLOSIVE
• EXHAUST GASES ARE LESS POISONOUS LESS CARBON
  MONOXIDE
• GREATER LUGGING POWER AND TORQUE

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ADVANTAGES CONTINUED

• ENGINES ARE DURABLE AND IF PROPERLY CARED FOR
  WILL MAINTAIN THEIR ECONOMY
• FUEL IS LESS VOLATILE NO VAPOR LOCK PROBLEMS
• CAN USE A VARIETY OF FUELS AND MIXTURES

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FIVE DISADVANTAGES OF DIESEL ENGINES

• ENGINES MUST BE STONGER AND HEAVIER BECAUSE OF
  HIGHER COMPRESSION RATES
• INITIALLY MORE EXPENSIVE
• FUEL COULD GEL IN COLDER CLIMATES
• GENERALLY NOISER OPERATION
• VERY PUNGENT EXHAUST ODOR

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INTERNAL COMBUSTION ENGINE

• AN ENGINE THAT PRODUCES POWER BY BURNING FUEL
  INSIDE A COMBUSTION CHAMBER WITHIN THE ENGINE

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TWO TYPES OF INTERNAL COMBUSTION ENGINES
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SPARK IGNITION ENGINE
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COMPRESSION IGNITION ENGINE
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TRUE OR FALSE SPARK PLUGS SHOULD BE CHANGED
MORE OFTEN IN DIESEL ENGINES THAN IN GASOLINE
ENGINES?

• FALSE

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BASICALLY, HOW DOES A SPARK-IGNITION ENGINE WORK?

• LIQUID FUEL BROKEN DOWN INTO A FINE SPRAY AND
  MIXED WITH AIR IN THE CARBURETOR.
• FUEL-AIR MIXTURE PIPED TO THE CYLINDER WHERE IT
  IS IGNITED BY AN ELECTRIC SPARK FROM THE SPARK
  PLUG.

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HOW DOES A COMPRESSION-IGNITION ENGINE WORK?

• NO SPARK IS NEEDED
• LIQUID FUEL UNDER VERY HIGH PRESSURE IS INJECTED
  DIRECTLY INTO THE CYLINDER WHICH IS FILLED WITH
  HIGHLY COMPRESSED AIR.
• IGNITION BEGINS WHEN THE FUEL HITS THE AIR THAT
  IS AT A TEMPERATURE OF 777 DEGREES F.

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WHAT DOES A COMPRESSION RATIO OF 161 MEAN?

• THE AIR IN A CYLINDER IS COMPRESSED INTO 1/16 THE
  SPACE AT THE TOP OF THE STROKE AS COMPARED TO THE
  BOTTOM OF THE STROKE

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TRUE OR FALSE DIESEL ENGINES USE GREATER
COMPRESSION RATIOS THAN GASOLINE ENGINES?

• TRUE
• DIESEL ENGINES 161 TO 221
• GASOLINE ENGINES 81

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TRUE OR FALSE DIESEL ENGINES REQUIRE MORE AIR
THAN GASOLINE ENGINES

• TRUE

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TRUE OR FALSE DIESEL ENGINES HAVE NO IGNITION
SYSTEM COMPONENTS

• TRUE
• NO SPARK PLUGS, COIL, MAGNETO, DISTRIBUTOR, OR
  WIRING

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TRUE OR FALSE DIESEL ENGINES, LIKE GASOLINE
ENGINES, DRAW IN FUEL AND AIR ON THE INTAKE
STROKE?

• FALSE
• ONLY AIR IN A DIESEL ENGINE

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WHAT IS THE PURPOSE OF A TURBOCHARGER ON A DIESEL
ENGINE?

• TO INCREASE THE AIR INTAKE INTO THE CYLINDERS

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TRUE OR FALSE DIESEL ENGINES REQUIRE A HIGH
PRESSURE PUMP TO INJECT THE FUEL INTO THE
COMPRESSED AIR IN THE CYLINDER?

• TRUE

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WHAT IS THE NAME OF THE ENGINE PART THAT SPRAYS
FUEL INTO THE CYLINDER OF A DIESEL ENGINE?

• INJECTOR NOZZEL

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WHAT TYPE MATERIAL ARE FUEL LINES MADE OF IN A
DIESEL ENGINE? WHY?

• STEEL
• PRESSURES FROM 5,000 TO 20,000 PSI ARE INVOLVED

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TRUE OR FALSE GASOLINE IS LESS VOLATILE THAN
DIESEL FUELS

• FALSE
• GASOLINE EVAPORATES READILY AND IS VERY EXPLOSIVE

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TRUE OR FALSE GASOLINE ENGINES ARE HEAVIER THAN
DIESEL ENGINES OF THE SAME HORSEPOWER?

• FALSE
• HIGH DIESEL CYLINDER PRESSURES REQUIRE HEAVIER
  MATERIALS

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HOW IS ENGINE SPEED CONTROLLED IN A DIESEL
ENGINE?

• THE THROTTLE CONTROL REGULATES ONLY THE AMOUNT OF
  FUEL INJECTED INTO THE CYLINDER
• THE THROTTLE CONTROL IN A GASOLINE ENGINE
  REGULATES THE AMOUNT OF AIR/FUEL MIXTURE ALLOWED
  INTO THE CYLINDER

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HOW ARE DIESEL ENGINES STOPPED?

• BY SHUTTING OFF THE FUEL TO THE CYLINDERS BY A
  MANUAL CONTROL OR SOLENOID SWITCH
• GASOLINE ENGINES ARE STOPPED BY CUTTING OFF THE
  SPARK FROM THE SPARK PLUGS TO THE CYLINDERS

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HOW AN ENGINE WORKS
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WHAT ARE THE FIVE BASIC PARTS OF ANY ENGINE?
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NAME THE TWO BASIC TYPES OF ENGINES

• FOUR STROKE CYCLE ENGINE
• TWO STROKE CYCLE ENGINE

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WHAT SEQUENCE OF EVENTS MAKE UP A CYCLE?

• INTAKE
• COMPRESSION
• POWER
• EXHAUST
• WHAT IS A STROKE?
• ONE MOVEMENT OF THE PISTON

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FOUR STROKES OF AN ENGINE
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HOW MANY TIMES DOES THE CRANKSHAFT REVOLVE DURING
A CYCLE IN A FOUR STROKE CYCLE ENGINE?

• TWO

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WHAT ARE THE MAJOR DIFFERENCES IN EACH
STROKE WHEN COMPARING A DIESEL ENGINE WITH A
GASOLINE ENGINE?

• INTAKE
• AIR VS. AIR/FUEL MIXTURE

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DIFFERENCES CONTINUED

• COMPRESSION STROKE
• COMPRESSION RATIO
• POWER STROKE
• SPARK PLUG VS. HEAT OF COMPRESSION
• EXHAUST STROKE
• SAME FOR BOTH

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TWO-STROKE CYCLE ENGINES
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HOW MANY STROKES OF THE PISTON ARE REQUIRED FOR A
CYCLE TO BE COMPLETED IN A TWO STROKE CYCLE
ENGINE?

• TWO

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WHAT HAPPENS DURING STROKE 1 IN A TWO STROKE
CYCLE GASOLINE ENGINE?

• THE UPSTROKE OF THE PISTON COMPRESSES THE
  AIR/FUEL MIXTURE. (COMPRESSION STROKE)
• AT THE SAME TIME, A NEW AIR-FUEL MIXTURE IS DRAWN
  INTO THE CRANKCASE. (INTAKE STROKE)

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WHAT HAPPENS DURING STROKE 2 OF A TWO STROKE
CYCLE GASOLINE ENGINE?

• THE DOWNWARD STROKE (POWER STROKE) OF THE PISTON
  CAUSES THE BURNED GASES TO ESCAPE THROUGH THE
  EXHAUST PORT. (EXHAUST STROKE)
• NEW FUEL-AIR IS FORCED INTO THE CYLINDER

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TWO-STROKE CYCLE GASOLINE ENGINES
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WHAT ARE THE DIFFERENCES BETWEEN A DIESEL AND
GASOLINE TWO-STROKE CYCLE ENGINE?

• DIESEL ENGINES INJECT FUEL INTO THE CYLINDER
  THROUGH A FUEL INJECTOR
• A BLOWER IS OFTEN USED TO FORCE AIR INTO THE
  CYLINDER
• DIESEL ENGINES HAVE EXHAUST VALVES, GAS ENGINES
  HAVE A PORT

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TWO-STROKE DIESEL ENGINE
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THE DIESEL AIR SYSTEM
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BASIC PARTS OF THE DIESEL AIR SYSTEM
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WHAT IS A TURBOCHARGER ON A DIESEL ENGINE?

• A CENTRIFUGAL BLOWER THAT IS DRIVEN BY EXHAUST
  GASES WHICH FORCES MORE AIR INTO THE CYLINDER.
  INCREASES POWER

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HOW IMPORTANT IS KEEPING AIR FILTERS CLEAN?

• VERY IMPORTANT
• A DIESEL ENGINE USES 12-15,000 GALLONS OF AIR TO
  EACH GALLON OF FUEL

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NAME THREE TYPES OF AIR CLEANERS

• OIL-BATH TYPE CLEANER
• PRE-CLEANER
• DRY-TYPE AIR CLEANER

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THE DIESEL FUEL SYSTEM
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WHAT ARE THE FIVE BASIC PARTS OF A DIESEL FUEL
SYSTEM?

• INJECTION NOZZLES
• INJECTION PUMP
• FILTERS
• TRANSFER PUMP
• FUEL TANK

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THE DIESEL FUEL SYSTEM
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DIESEL FUEL, LIKE GASOLINE IS A PRODUCT OF THE
DISTILLATION OF-

• CRUDE OIL

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100 GALLONS OF CRUDE OIL WILL YIELD WHAT
PRODUCTS?

• GASOLINE 44 GALLONS
• DIESEL FUEL 36 GALLONS
• MISC. 9 GALLONS
• KEROSENE 6 GALLONS
• LUBRICANTS 3 GALLONS
• LOSS 3 GALLONS

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WHAT ARE THE THREE GRADES OF DIESEL FUEL?

• NUMBER 1 DIESEL FUEL (NO. 1-D)
• RECOMMENDED FOR COLD WEATHER. REMAINS FLUID FOR
  EASIER STARTING
• BUSES, CARS, TRUCKS, FARM TRACTORS
• NUMBER 2 DIESEL FUEL (NO. 2-D)
• HEAVY WORK LOADS. BUSES, TRUCKS, FARM EQUIPMENT
• NUMBER 4 DIESEL FUEL (NO. 4-D)
• OCEAN GOING VESSELS WITH LOW-MEDIUM SPEED ENGINES

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THE DIESEL COOLING SYSTEM
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WHAT ARE TWO PRIMARY TYPES OF COOLING SYSTEMS FOR
DIESEL ENGINES?

• LIQUID COOLING
• AIR-COOLING

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LIQUID COOLING ENGINE
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AIR-COOLED DIESEL ENGINE
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WHAT IS THE IDEAL OPERATING TEMPERATURE FOR
MOST DIESEL ENGINES?

• 165 185 DEGREES F.

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WHAT ARE SOME EFFECTS OF ENGINE OVERHEATING?

• CYLINDER HEAD AND BLOCK CAN CRACK OR WARP
• RINGS AND VALVES MAY SEIZE OR STICK DUE TO GUMS,
  LAQUERS, AND VARNISHES FORMING FROM OVERHEATED
  OIL AND CARBON FORMATION
• BEARINGS MAY BE DAMAGED CAUSING EXCESSIVE WEAR

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WHAT ARE SOME EFFECTS OF OVERCOOLING?

• INCREASED ENGINE WEAR
• IMPROPER LUBRICATION
• INCREASED FUEL CONSUMPTION
• INCREASED SLUDGE FORMATION
• INCREASED ENGINE CORROSION
• MOISTURE CONDENSES IF BELOW 140 DEGREES IN THE
  ENGINE CRANKCASE

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WHAT ARE SOME ADVANTAGES OF AIR-COOLED ENGINES

• LESS WEIGHT
• LESS MAINTENANCE
• LESS DOWN-TIME
• NO CAVITATION EROSION
• NO COOLANT CONCERNS
• MORE EFFICIENT USE OF POWER
• LESS VULNERABLE TO DAMAGE
• LESS BULK
• QUICKER WARM-UP

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WHAT ARE SOME DISADVANTAGES TO AIR-COOLED
ENGINES?

• LENGTH OF THE ENGINE
• LESS TEMPERATURE CONTROL
• HIGHER OPERATING TEMPERATURES
• GREATER NOISE
• MORE FREQUENT CLEANING

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THE DIESEL LUBRICATION SYSTEM
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WHAT ARE THE FUNCTIONS FOR THE LUBRICATION
SYSTEM?

• REDUCES SHOCK, WEAR, AND FRICTION
• SEALS COMPRESSION
• PROVIDES SOME CLEANING
• HELPS COOL THE ENGINE
• QUIETS THE ENGINE OPERATION

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TRUE OR FALSE MOST OF THE LUBRICANTS USED IN
DIESEL ENGINES COME FROM PETROLEUM?

• TRUE

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WHAT ARE LUBRICANTS DERIVED FROM ANIMAL OR
VEGETABLE OILS CALLED?

• SYNTHETIC OILS

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WHAT TWO CHARACTERISTICS ARE MOST IMPORTANT IN
CHOOSING PROPER OIL?

• VISCOSITY
• SERVICE CLASSIFICATION

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WHAT IS VISCOSITY?

• A MEASURE OF A LIQUIDS RESISTANCE TO FLOW
• HIGHER TEMPERATURE DECREASE IN VISCOSITY
• SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) DEVELOPED
  NUMBERING SYSTEM

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WHAT ARE THE VISCOSITY GRADES?
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API ENGINE OIL SERVICE CATEGORIES

• AMERICAN PETROLEUM INSTITUTE
• TABLE 1 (HANDOUT)

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WHAT ARE THE THREE MOST COMMON OIL ADDITIVES?

• OXIDATION INHIBITORS
• CORROSION AND RUST INHIBITORS
• DETERGENT DISPERSANTS

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HOW DO DETERGENT ADDITIVES WORK?
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PRINCIPLES OF FLUID HYDRAULICS
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HYDRAULIC SYSTEMS ON A TRACTOR
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WHAT IS PASCALS LAW OF HYDRAULICS?

• PRESSURE ON A LIQUID IN A CONTAINER IS
  TRANSFERRED EQUALLY TO ALL SURFACES

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PASCALS LAW
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PRESSURE TRANSFER IN HYDRAULIC BRAKES
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CHANGING THE PRESSURE IN A HYDRAULIC SYSTEM