Heavy Duty Diesel Engine (HDD) Operation and Maintenance

This training workshop will feature:

• Discussions on the benefits and applications of heavy duty Diesel HDD engines

• The importance of correct operation and maintenance of HDD for better reliability

• The detailed description of HDD systems and characteristic performance

• Focusing on electronic control of HDD for economy and environment friendly operation

Objectives

By the end of this training seminar, participants will be able to:

• Outline the principle of operation of diesel engines

• Specify the difference between Heavy Duty Diesel Engines and normal Diesel engines

• Describe how combustion occurs in diesel engines

• Explain the reason of air charging in diesel engines

• List and explain the principle of operation of air charging systems in diesel engines

• List and explain the operation principle of various types of fuel injection systems used in HDD

• Describe the layout and components of various fuel injection systems used in HDD

• Explain how quantity and timing of injected fuel can be controlled

• State the benefits of Diesel Electronic Control (DEC)

• List and explain the principle of operation of various HDD emission control systems

• Outline the procedure and requirements for servicing HDD

• Outline the HDD basic routine maintenance operations

• List and explain how to fix the common HDD troubles

Programme  Outline

Introduction to Heavy Duty Diesel (HDD) engines

• Meaning of HDD engine: Rating – Load factor – Operation duration

• HDD engine glossary of terms

• International standards for HDD engine

• HDD engine Internal and external characteristic performance curves

• Design considerations of HDD engine

• HDD engine construction features and materials

• HDD engine Applications

Work Cycle and Combustion in HDD Engines

• Work cycle, internal and external characteristic curves of HDD engines

• Diesel fuel (Classification – Fuel properties – Fuel tests)

• Combustion process in Diesel engines

• Compression ratio

• Combustion chambers shapes

• Direct & indirect injection methods

• Homogenous Charge Compression Ignition (HCCI)

• Air charging in heavy duty diesel engines:

• Types (Mechanical – Turbo – Pressure wave)

• Turbocharger configuration (Combined – Two stage - Variable geometry – Sequential)

• Turbocharger control (Pressure – Fuel compensation)

• Turbocharger performance characteristics

Fuel Injection Systems in HDD Engines

• Types and principle of operation of fuel injection systems:

◦ Cummins systems: (PT – CELECT unit injector – Accumulator – HPI – XPI)

◦ Caterpillar systems: (HUEI/A – HUEI/B – Navistar – MEUI/A – MEUI/B)

◦ In-line or multi-plungers systems.

◦ Common rail systems

• HDD engines fuel injection systems layout and components.

• Methods of control of injected fuel quantity and timing: (Hydraulic, pneumatic, electronic)

• Diesel fuel filtration and water separation.

Electronic Diesel Control (EDC)

• Advantages of EDC

• EDC basic layout and components (ECU – Sensors – Actuators – Layout for various types of fuel injection systems)

• Open & Closed loops and data processing

• Controlled quantities: Start – Drive mode – Idle speed – Maximum speed – Intermediate speeds – Cruise speed - ….)

• Injected fuel quantity limits

• Emission control systems;

◦ Diesel Oxidation catalyst (DOC)

◦ Diesel Particulate Filter (DPF)

◦ Selective catalyst Reduction (SCR)

◦ Urea Injection (UI)

◦ Exhaust gas recirculation (EGR)

◦ Closed Crankcase Ventilation (CCV)

Operation and Maintenance of HDD Engine

• Operation Tips for HDD engine

◦ Indicator lamps

◦ On-Board diagnostics

◦ Fuel type

◦ Items to be noticed

◦ Tips for efficient operation

• Maintenance of diesel engines

◦ Basics of mechanical maintenance

◦ Servicing of diesel fuel injection systems 

◦ Diesel engine tune up

◦ Diesel engine routine maintenance operations (time-based, distance- based)

• Diesel engines troubleshooting

◦ Forms of diesel engine components failure

◦ Engines trouble shooting and fault rectification

◦ Testing of injection pumps, injectors, fuel feed pumps

◦ Tests for assessment of engine condition (compression, leakage tests)