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You are welcome to a 5 day training programme on PRACTICAL DIESEL ENGINE MAINTENANCE COURSE

Organised for The Staff of

APM TERMINALS APAPA LIMITED BY

APPLIED ENGINEERING TECHNOLOGY INITIATIVE (...total engineering solutions)

ObjectivesAt the end of this course, participants will be able to; • Have proper understanding of prime movers• Utilize common terminology of diesel engine• Effectively apply the principle of two stroke and four stroke engines• Understand the basis of diesel engine fuel system, air system, lubricating

system and cooling system• Perform engine test and adjust procedures for fuel injector pump &

injector nozzles, cylinder compression, valve adjustment, engine oil pressure test, piston and rings, connecting rods & bearings, as well as cylinder block.

• Acquire troubleshooting skill/techniques to solve basic and complex problems of a diesel engine

• Work confidently during engine overhauling and routine engine service

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COURSE CONTENT

• Generator Prime Movers, • Diesel Engine Fuel System, • Air System, • Cooling System, • Lubricating System, • Engine Test And Adjust Procedures, • Engine Electrical System, • Generator Auxiliary System,• Components Of An Engine Block, • Common Engine Malfunctions'

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Typical Diesel-Driven Generator

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Typical Diesel-Driven Generator

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Sound-Proof Diesel-Driven Generator

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GENERATOR PRIME MOVERS

• The generation of electricity involves the rotation of the alternator. This rotary motion will require a mechanical device (prime mover) to accomplish it.

• There are different types of prime movers;• Steam Turbine• Gas Turbine• Gas Generator• Wind Turbine• Hydro Generator• Internal Combustion Engine (Diesel, Petrol, Gas etc)

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DIESEL ENGINES• The diesel engine was invented in 1892 by a German engineer

named Rudolf Diesel.• It is a compression ignition internal combustion engine. The

principle of a compression ignition internal combustion engine is described below;

There are four cycles.

• INDUCTION STROKEAir is admitted into the cylinder. This air is often initially pressurized by the turbo charger.

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DIESEL ENGINES cont.d2 COMPRESSION STROKE The air is compressed to a ratio of between 15:1 and 20:1,and towards the

end of the stroke, atomized fuel is sprayed into the cylinder via the injector nozzles.

3 POWER OR EXPANSION STROKE

4 As the fuel, which is sprayed at controlled rate, ignites in the cylinder, power is developed which forces down the piston. The connecting rod rotates the crankshaft.

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DIESEL ENGINES cont,d• EXHAUST STROKE

At the end of the power stroke, the piston gradually comes up, while the exhaust valve opens to discharge the products of combustion. This is the end of one cycle, and another cycle starts.

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FOUR-STROKE cycle ?

• To derive it's power from the heat of the burning fuel the four stroke engine (whether diesel or gasoline) has to complete four separate cycles. The completion of four piston cycles takes 2 complete crankshaft revolutions.

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Induction

• Intake (suction) of air alone (in a diesel engine), or, air and gasoline vapour in a gasoline engine.

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Compression

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Compressing of the above gases

POWER

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Igniting of the compressed gasoline vapour by a spark within a gasoline engine, or, the injection of a diesel mist through an injector, which then self ignites due to the heat, generated by compressing the air. This produces a rapid expansion and therefore power.

EXHAUST

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The blowing out of the spent gases. And then the process starts all over. This completes the second revolution of the crankshaft.

FOUR STROKE ENGINES COMPLETE DUTY CYCLE

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FOUR STROKE ENGINES CYCLE

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FOUR STROKE ENGINES CYCLE

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FOUR STROKE ENGINES CYCLE

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ENGINE-INLINE-4

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ENGINE-V-6

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Engine Valve Train and Ignition Systems

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COMPARISM WITH TWO STROKE ENGINE

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BASIC COMPONENT OF TWO STROKE ENGINE

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BASIC COMPONENT OF TWO STROKE ENGINE

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TWO STROKE ENGINE

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Identification of various parts of a Diesel Engine

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TYPES OF DIESEL ENGINE FUEL SYSTEM

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Distributor pump Fuel System

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Fuel Transfer Pump

Fuel Injector Pump

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Distributor Injector Nozzles

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Distributor Fuel Pump System

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Common Rail Fuel System• HYDRAULICALLY ACTUATED ELECTRONICALLY CONTRLLED UNIT

INJECTION (HEUI)• It is the system used in place of mechanical high pressure fuel injection

pump and nozzle.• The features are;• Hydraulic actuation using engine oil as power medium.• Injection is controlled by solenoid.• Solenoid is controlled by ECM.

HEUI Fuel Injection Gives Control of • Injection Pressure• Injection Rate • Injection Timing

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Basic components of the modern common-rail system

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Basic components of the modern common-rail system are a high-pressure pump (1), common rail (2), electronic injectors (3), and onboard computer (4). Courtesy Bosch

Diesel Engine Fuel Flowpath

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Common Rail Injector Nozzles

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DIESEL ENGINE AIR SYSTEM - OPERATION

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TURBOCHARGERS

• A turbocharger, or turbo is a turbine driven forced induction device used to allow more power to be produced by an engine of a given size. A turbocharged engine can be more powerful and efficient than a naturally aspirated engine because the turbine forces more air, and proportionately more fuel, into the combustion chamber than atmospheric pressure alone.

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Turbocharger Assembly

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Engine Cooling System - Operation

• The cooling system consists of the coolant circulation pump, the radiator and the radiator cooling fan.

• The radiator exposes the hot coolant to a large surface area for cooling.

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Engine Water Pump Assembly

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Engine Coolant Circulation

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Diesel Engine Cooling System

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DIESEL ENGINE LUBRICATING SYSTEM - OPERATION

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Diesel Engine Internal Lubrication System 54

ENGINE TEST AND ADJUST PROCEDURES

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FUEL SYSTEM - TEST

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AIR IN FUEL SYSTEM - TEST

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Fuel Injector Pump – Test

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Injector Pump Assembly

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Dial Indicator Installation

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FUEL QUALITY- TEST

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Fuel Transfer Pump - Test

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Inlet And Exhaust System

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Cylinder Compression - Test

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Valves Adjustment - Test

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LUBRICATING SYSTEM82

ENGINE OIL PRESSURE -TEST

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High Engine Oil Pressure - Test

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ENGINE OIL PUMP ASSEMBLY

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EXCESSIVE ENGINE OIL CONSUMPTION

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ENGINE COOLING SYSTEM

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ENGINE COOLING SYSTEM - INSPECT

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FILLER CAP ASSEMBLY

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ENGINE OIL COOLER - TEST

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PISTON AND RINGS - INSPECT

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ELECTRICAL SYSTEMS

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ALTERNATOR - TEST

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GENERATOR AUXILLARY SYSTEM

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AUXILLARY SYSTEMS cont.d

• VIBRATION ATTENUATION• Anti-vibration mountings and dampers are installed in various locations to

prevent vibration from transferring to nearby structures.They are located between;

• Engine/alternator feet and the base frame to prevent engine vibration from transferring to the foundation and the generator house.

• Between generator and its external connections e.g. flexible connections in the exhaust system.

• Radiator and main engine frame.

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AUXILLARY SYSTEM cont.d

• Sound AttenuationGenerators are often sound-proofed to reduce noise to a tolerable level.This is achieved by encasing it in an acoustically insulated cabin. The silencer of such generator is also made bigger to reduce the sound further.

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GENERATOR INSTALLATION PROCEDURES

There are things to consider while planning to install a generator.• Size of room• Ventilation and air flow• Engine cooling water supply• Radiator location• Exhaust outlet• Fuel tank and fuel transfer system

By following correct installation procedures you will be able to plan an economical, efficient installation with operating characteristics suitable for each particular application.

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GENERATOR INSTALLATION PROCEDURES cont.d

• It is necessary to pay attention to some mechanical engineering and electrical engineering details while installing the generator. Such details include;

1. Access and maintenance location2. Floor loading3. Vibration transmitted to building and equipment 4. Ventilation of room5. Engine exhaust piping and insulation6. Noise reduction7. Method of engine cooling8. Size and location of fuel tank9. Smoke and emission requirements

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INSTALLATION CONT,D• Moving The Set• The generating set can be moved with forklift, rollers or can be lifted by a crane.

• Generating Set Location• Most of the time, a concrete basement is cast, then the ventilated house is made

around it after the generator had been installed.• All the other procedures should be adhered to for the installation to be effective.

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ENGINE BLOCK

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Cylinder block

COMPONENTS OF THE ENGINE BLOCK

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Piston and Piston Rod

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Piston and Rings

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Piston ,Pin and connecting Rod

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Diesel Engine Crankshaft

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Diesel Engine Crankshaft

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Metal and main bearings

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Metal and main bearings

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Diesel Engine Valve

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Diesel Engine Camshaft and

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Diesel Engine Camshaft and Drive Gear

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Timing Marks on Engine

Diesel Engine Timing

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Common Engine Malfunctions

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Diagnosis By Exhaust Smoke Colour

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Diagnosis By Exhaust Smoke Colour

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THE END.

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