Diesel Engine and Crane Maintenance

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Diesel Engine and Crane Maintenance Course
Introduction:
Diesel engines have emerged as the preferred choice for a wide range of commercial and industrial applications worldwide. They dominate the field of propulsion engines due to their exceptional performance and reliability. Diesel engines are extensively utilized in off-highway construction equipment, powering them efficiently. Furthermore, deepwater commercial freighters and containerships predominantly rely on diesel engines for their propulsion. Passenger ships, on the other hand, primarily employ either diesel engines or a combination of diesel and gas turbines.
Course Objectives:
Upon the completion of this course, the participants will be able to:
· Recognize the different diesel engine types such as inline engines, v-type engines, slant engines, opposed engines and various numbers of cylinders according to classification by title, speed, piston format and the fuel used
· Familiarize the basic terminology of force, torque, power, top, and bottom dead center and determine the aspects of 2-stroke and 4-stroke by learning the various engine cycles
· Practice the various diesel engine maintenance exercises & discussion given during the course and recognize the principles of timing gear timing chain and sprocket according to timing mechanism construction
· Illustrate the different engine indicator diagrams and detail the methods of engine construction maintenance
· Characterize the different HP fuel pumps and maintenance such as delivery valves, rack & pinion, barrel & plunger and injection pump timing as well as recognize the importance of fuel injectors and maintenance in actuations (hydraulic, mechanical, and electronic) and injector faults
Who Should Attend?
This course is intended for maintenance, plant & PMV, operation & production, engineering & project and utility managers, superintendents, engineers, supervisors, foremen and technicians.
Course Outlines:
Introduction to 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 Diesel Engines
- Work cycle, internal and external characteristic curves of HDD engines
- Diesel fuel (Classification – Fuel properties – Fuel tests)
- The 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 Diesel 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
- Diesel 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 Diesel 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)
- Forms of diesel engine components failure
- Engines troubleshooting and fault rectification
- Testing of injection pumps, injectors, fuel feed pumps
- Tests for the assessment of engine condition (compression, leakage tests)