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)

1
Objectives
At 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



2
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'

3
Typical Diesel-Driven Generator
4
Typical Diesel-Driven Generator
5
Sound-Proof Diesel-Driven
Generator
6
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)

7
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 STROKE
Air is admitted into the cylinder. This air is often initially pressurized
by the turbo charger.



8
DIESEL ENGINES cont.d
2 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.

9
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.


10
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.
11
Induction
Intake (suction) of air alone (in a
diesel engine), or, air and gasoline
vapour in a gasoline engine.
12
Compression
13
Compressing of the above gases
POWER
14
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
15
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
16
FOUR STROKE ENGINES CYCLE
17
FOUR STROKE ENGINES CYCLE
18
FOUR STROKE ENGINES CYCLE
19
ENGINE-FLAT-4
ENGINE-INLINE-4
20
ENGINE-V-6
21
Engine Valve Train and Ignition
Systems
22
COMPARISM WITH TWO STROKE
ENGINE
23
BASIC COMPONENT OF TWO STROKE
ENGINE
24
BASIC COMPONENT OF TWO STROKE
ENGINE
25
TWO STROKE ENGINE
26
27
28
Identification of various parts of a
Diesel Engine
29
30

TYPES OF DIESEL ENGINE FUEL
SYSTEM
31
Distributor pump Fuel System
32
33
Fuel Transfer Pump Fuel Injector Pump
34
Fuel Injector Pump
Distributor Injector Nozzles
35
Distributor Fuel Pump System
36
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
37
Basic components of the modern
common-rail system
38
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
39
Common Rail Injector Nozzles
40
DIESEL ENGINE AIR SYSTEM -
OPERATION
41
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.
42
Turbocharger Assembly
43
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.

44
Engine Water Pump Assembly
45
Engine Coolant Circulation
46
Diesel Engine Cooling System
47
DIESEL ENGINE LUBRICATING SYSTEM -
OPERATION
48
49
50
51
52
53
Diesel Engine Internal Lubrication System
54
ENGINE TEST AND ADJUST
PROCEDURES
55
FUEL SYSTEM - TEST
56
57
AIR IN FUEL SYSTEM - TEST
58
59
60
Fuel Injector Pump Test
61
62
Injector Pump Assembly
63
Dial Indicator Installation
64
65
66
67
FUEL QUALITY- TEST
68
69
70
71
72
Fuel Transfer Pump - Test
73
Inlet And Exhaust System
74
75
Cylinder Compression - Test
76
77
Valves Adjustment - Test
78
79
80
81
LUBRICATING SYSTEM
82
ENGINE OIL PRESSURE -TEST
83
84
High Engine Oil Pressure - Test
85
86
ENGINE OIL PUMP ASSEMBLY
87
88
89
EXCESSIVE ENGINE OIL CONSUMPTION
90
91
92
ENGINE COOLING SYSTEM
93
ENGINE COOLING SYSTEM - INSPECT
94
95
96
97
98
99
100
FILLER CAP ASSEMBLY
101
ENGINE OIL COOLER - TEST
102
103
104
105
PISTON AND RINGS - INSPECT
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
ELECTRICAL SYSTEMS
122
ALTERNATOR - TEST
123
124
125
126
GENERATOR AUXILLARY SYSTEM
127
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.
128
AUXILLARY SYSTEM cont.d
Sound Attenuation
Generators 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.
129
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.
130
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 location
2. Floor loading
3. Vibration transmitted to building and equipment
4. Ventilation of room
5. Engine exhaust piping and insulation
6. Noise reduction
7. Method of engine cooling
8. Size and location of fuel tank
9. Smoke and emission requirements
131
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.
132
ENGINE BLOCK
133
Cylinder block
COMPONENTS OF THE ENGINE BLOCK
134
Piston and Piston Rod

135
Piston and Rings
136
Piston ,Pin and connecting Rod
137
Diesel Engine Crankshaft
138
Diesel Engine Crankshaft
139
Metal and main bearings
140
Metal and main bearings
141
Diesel Engine Valve
142
Diesel Engine Camshaft and
143
Diesel Engine Camshaft and
Drive Gear
144
145
Timing Marks on Engine
Diesel Engine Timing
146
Common Engine Malfunctions
147
148
149
150
Diagnosis By Exhaust Smoke Colour
151
Diagnosis By Exhaust Smoke Colour
152
153
THE END.
154