Heavy Duty Diesel Engine (HDD) Operation and Maintenance
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Heavy Duty Diesel Engine (HDD) Operation and Maintenance Course
Introduction:
Course Objectives:
At the end of this training course, you will learn 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 the quantity and timing of injected fuel can be controlled
Who Should Attend?
This training course is suitable for a wide range of professionals but will greatly benefit:
- Vehicles fleet maintenance engineers and technicians
- Fleet maintenance supervisors
- Automotive maintenance engineers
- Automotive maintenance technicians
- Diesel power generation plants engineers and technicians
Course Outlines:
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)
- 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 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