2 - Diesel Engine Training

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The key takeaways are that diesel engines operate on compression ignition rather than a spark plug, and were invented by Rudolf Diesel in 1892.

Diesel engines operate on compression ignition rather than a spark plug. The fuel is ignited by heat of compression rather than an external spark.

Rudolf Diesel invented the diesel engine in 1892 based on the hot bulb engine. He received a patent on February 23, 1893 and intended it to use a variety of fuels including coal dust.

DIESEL ENGINE TRAINING

TRAINING DEPARTMENT
2016 Ihsan Yavuz ERMIS
DIESEL ENGINE TRAINING

Diesel Engine Description :

• Diesel engine is type of internal cumbustion


egine. Diesel engine is mechanics system
integral for converting from chemical energy
(intake fuel) to thermo energy, from thermo
energy to mechanical energy.

• More specifically, it is a compression ignition


engine, in which the fuel is ignited solely by
the high temperature created by compression
of the air-fuel mixture.

• After all, the gasoline liquid is ignited by an


outside source (a spark plug).
DIESEL ENGINE TRAINING

Diesel Engine History :


The engine is named after
German engineer Rudolf Diesel,
who invented it in 1892 based on
the hot bulb engine and received
the patent on February 23, 1893.
Diesel intended the engine to use
a variety of fuels including coal
dust. He demonstrated it at the
1900 Exposition Universelle
(World's Fair) using peanut oil A Diesel engine built by
(biodiesel). MAN AG in 1906
DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Principle :


DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Principle :


DIESEL ENGINE TRAINING

Engine Terms :

 Top Dead Center (TDC) : Point of uppermost travel of the


piston and crankshaft.
 Bottom Dead Center (BDC) : Point of lowermost travel of
the piston and crankshaft.
 Bore : Diameter of the cylinder.
 Stroke : Distance the piston travels on a stroke, or the
distance from TDC to BDC. The stroke is twice the distance
of the throw.
 Throw : The distance from the center of the main journal of
the crankshaft to its rod journal. The throw is one half the
distance of the stroke.
DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Principle :

1. Intake Stroke

Rotation of the crankshaft pulls the


piston down. At this time, the intake
valve is opened, allowing the piston
to draw an air charge into the
combustion chamber. As the piston
nears the bottom of the stroke, the
intake valve closes, sealing the
charge in the combustion chamber.
DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Principle :

2. Compression Stroke

 The piston moves up to TDC


during the compression stroke
raising the pressure by as much as
20:1.
 As the crankshaft rotation
continuoues, the piston is pushed
up towards the top of the cylinder,
compressing the air.
DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Principle :

3. POWER STROKE

 Typically, just before the piston reaches


its top most position (Top Dead Center or
TDC) , fuel is forced into the cylinder by
an injector. The temperature of the air
has been raised far above the ignition
point for the fuel by the compression
process, and the fuel ignites when it is
injected
 The pressure inside the cylinder
increases dramatically because of the
combustion taking place and this pressure
forces the piston down, which causes the
crankshaft to rotate providing usable
power output.
DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Principle :

4. EXHAUST STROKE
By the time the piston is forced most of
the way down the cylinder, nearly all of
the usable energy created from the
burning fuel has been used. At this
point, the exhaust valve begins to open
and as the crankshaft rotation
continues, the rising piston forces the
spent gases out of the cylinder and into
the exhaust system. Just prior to the
piston reaching TDC, the exhaust valve
closes and shortly thereafter, the intake
valve reopens to start the process over.
DIESEL ENGINE TRAINING

Firing Order In Diesel Engine :

If diesel engine has got 4 cylinder :


1-3-4-2

If diesel engine has got 6 cylinder :


1-5-3-6-2-4
DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Animation :


DIESEL ENGINE TRAINING

Four Stroke Cycle Diesel Engine Operation Animation :


DIESEL ENGINE TRAINING

Four Stroke Cycle Engine Operation Animation :


DIESEL ENGINE TRAINING

Engines That We Use in AKSA :


DIESEL ENGINE TRAINING

General Engine Overview :


DIESEL ENGINE TRAINING

Cylinder Block :
Cylinder block supports the
cylinder liners and the cylinder
head or heads..
DIESEL ENGINE TRAINING

Flywhell :

• Flywheel is a significant mass at


the end of the crankshaft that
stores energy during a power
stroke and release energy during
the rest of the cycle.
• It helps to stabilize the shaft
rotation.
DIESEL ENGINE TRAINING

Crank Shaft :
Crank case serves as the housing for the crankshaft; may be
an integral part of the cylinder block with an oil pan, sump, or
base to complete the housing, or it may be a separate section
bolted to the block.
DIESEL ENGINE TRAINING

Camshaft :
 Camshaft has eccentric projections called cams.
Controls the operation of valves..

 The camshaft uses lobes (called cams) that push against


the valves to open them as the camshaft rotates; springs on
the valves return them to their closed position.
DIESEL ENGINE TRAINING

Piston :

 Piston serves as the unit that


transmits the force of the combustion
of the diesel fuel. May act as a valve
(e.g., in 2 stroke engines).

 Piston Pin (and bearing) transmits the


force on the piston to the connecting
rod. Must be especially strong. The
pin is the pivot point where the
straight-line or reciprocating motion
changes to the reciprocating and
rotating motion of the connecting rod.
DIESEL ENGINE TRAINING

Piston Rings :

There are three functions of


piston rings :

1) Seal the cylinder


(compression rings)

2) Distribute and control


lubricating oil on the cylinder
wall (oil rings)

3) Transfer heat from the


piston to the cylinder wall (all
rings)
DIESEL ENGINE TRAINING

Connection Roads :

• It provides the connecting link between the


piston and the crankshaft..
• Transmits the reciprocating motion of the
piston to the rotating motion of the crankshaft.
DIESEL ENGINE TRAINING

Intake and Exhaust Valves :

 Intake and exhaust valves allow air


into the cylinder and allow exhaust
gases to flow out. Depending on the
design they may be integral parts of
the cylinder liner (essentially just
holes).
 Actuating mechanism the cams
engage cam rollers that push on push
rods to move the rocker arms that are
attached to the valves and injectors.
The cams are designed such that hold
the valves open as long as necessary
for a particular portion of the cycle.
DIESEL ENGINE TRAINING

Injector :
• Diesel engines use direct fuel injection. The diesel fuel
is injected directly into the cylinder by injector.
• Fuel injection atomizes the fuel by forcibly pumping it
through a small nozzle under high pressure.
DIESEL ENGINE TRAINING

Radiator :
 Radiator is base part of engine
cooling system.
 Coming hot water from
cylinder block sends again
engine after cooling.
 It adjusts requested rating the
cooling water
DIESEL ENGINE TRAINING

Mechanical Governor :

• Type of mechanical governor


provides to adjust engine speed
by manually.
• Mechanical governor uses gears
and flyweights inside the
crankcase to sense speed and
detect changes in the load, John Deere Standyne Type of
adjusting the throttle to Mechanical Govarnor
compensate.
• Engine speed has to adjust 1560
rpm (52 Hz) on zero load because
of engine speed will be 1500 rpm
(50 Hz) on full load (droop 4%).
DIESEL ENGINE TRAINING

Electronics Governor :
• Calculating engine speed,
adjusting requested engine speed by
opening and closing the quantity of
fuel.
• It has got 3 parts: electronic unit,
magnetic pick-up (MPU) and
actuator.
DIESEL ENGINE TRAINING

Electronic Governor - Magnetic Pick-Up (MPU) :

• MPU calculates the flywhell


gears, senses engine speed (rpm)
as frequence and sends it to the
electronic control unit.
DIESEL ENGINE TRAINING

Electronic Governor - Actuator :

 According to coming
signals from electronic
control unit; opening or
closing the quantity of
fuel.
DIESEL ENGINE TRAINING

GCS (Generator-Drive Control System) :


 For Cummins “Q” series engine.

Diagnostic LEDs
Overspeed
Low Oil Pressure
High Engine Temp
Shutdown
Warning
DIESEL ENGINE TRAINING

Starter :

 It gives first movement to the engine.


 It takes supply from battery (DC supply). It produces mechanical
energy and forwards it to the flywhell. Thus Engine will be cranked.
DIESEL ENGINE TRAINING

Charging Alternator :

• It is a dynamo to generate DC current as mechanical energy.


• It provides to supply battery in the operation.
DIESEL ENGINE TRAINING

Fuel Transfer Pump and Fuel Filter :

•Fuel transfer pump adsorbs fuel


from fuel tank and it sends fuel
pump.

• Fuel filter separates fuel and water or


impurity by centrifugal power. It keeps
them from fuel system.
• Fuel filter should place beetwen fuel
transfer pump and fuel tank.
DIESEL ENGINE TRAINING

Fuel Pump :

• Fuel pump increases fuel pressure and measures fuel level.


• It sends fuel to the injection according to firing order and timing.
• It pro-rates the fuel to the cylinders.

Stanadyne Type Bosch Type of Order Lucas Type of Turnable


DIESEL ENGINE TRAINING

Cooling Water Pump :

• This pump takes movement from crank case by


disangaging gear. It provides to run around cooling
water in the cylinder block.
DIESEL ENGINE TRAINING

Thermostat :
• Thermostat is used in diesel engine to regulate the flow of coolant. When
the thermostat is open, coolant passes through the cylinder head where it
gets hot. It is then led from the engine into the radiator where it loses the
heat to the air flowing through it. A “water pump” driven from the engine
propels the coolant around the system. When the thermostat is closed the
flow is prevented and so the engine is allowed to heat up to its optimum
operating temperature.
• The operating temperature is fixed, typically in the range of 76,5 to 82 °C.
But, for cold places it can be range of 88ºC.
DIESEL ENGINE TRAINING

Oil Pan :

 Oil pan covers engine’s bottom side, protects moving parts of


engine from out side.Generally oil pan is made from steel sheet
 At the same time, oil pan covers bottom of krankshaft case,
contains lubrication oil, provides resting and cooling lubrication oil.
DIESEL ENGINE TRAINING

Exhaust Silencer and Suspention :


Exhaust silencers are 3 types depends
on reducing sound level :
• Industrial type (Non-Critical) (12-18 dBA)
• Residential (18-25 dBA)
• Critical (Critical) (25-35 dBA)

Exhaust suspentions are


used for prevent harming to
exhaust pipe system that
caused by engine’s vibration.
DIESEL ENGINE TRAINING

Oil Pump :

• Oil pump sends oil to engine’s other sides such as oil


inlet from oil pan.
• Oil pump takes ıt’s transaction from cam shaft
DIESEL ENGINE TRAINING

Oil Filter :

• It’s a filter that prevents mixing


dust and filth with lubrication system
by filtering engine oil.

• It protects oil characteristic by


filtering soot, carbon, metal particles,
other chemical items which caused
by friction surfaces.
DIESEL ENGINE TRAINING

Fuel System :
It contains fuel that is required for runing engine and
cleans fuel. It increases fuel’s pressure and sends fuel to
cylinders as depending on ignition time and returning.
DIESEL ENGINE TRAINING

Fuel System :

 Fuel system’s parts :

• Low pressure pipes


• Feeding pump
• Fuel tank
• Filters
• Fuel pumps
• Regulators
• İnjectors
DIESEL ENGINE TRAINING

Lubrication System :

• Lubrication system prevents


direct friction between diesel
engine’s moving parts. It provides
oil circulation in engine’s moving
parts for easing moving.
• It reduces friction for decreasing
power looses.
• It prevents frictions and warming.
• It helps engine’s cooling and
provides cleaning of runing parts.
DIESEL ENGINE TRAINING

Lubrication System :

Parts of lubrication
system:

• Oil pump
• Filter
• Indicator
• Level bar
• Oil canal
• Oil pan
DIESEL ENGINE TRAINING

Cooling System :

It adjusts heat gap for the most efficiant of engine’s


runing on the all conditions and all engine cycle.
DIESEL ENGINE TRAINING

Cooling System :

 Parts of cooling
system:

• Circulation water pump


• Radiator
• Water canal
• Thermostat
• Temperature sensor
• Fan engine
• Ventilator
• Heater
DIESEL ENGINE TRAINING

Cooling System :
1. Water inlet to pump
2. Water inlet to engine
3. Water transition
around the oil
coolant.
4. Water flowing to
cylinder jacket.
5. Water flowing
around the cylinders.
6. Water flowing from
cylinder head.
7. Water flowing from
water manifold to
thermostat body.
8. Water return from
turbocharge.
9. Water way to
turbocharge.
DIESEL ENGINE TRAINING

Air Intake Systems :


Intake system provides air (oxygen) that is required for
combustion of fuel in cylinder.
DIESEL ENGINE TRAINING

Air Intake Systems :


DIESEL ENGINE TRAINING

Air Intake Systems :


Naturally Aspirated System; It directly intakes air that is
required by diesel engine.
DIESEL ENGINE TRAINING

Air Intake Systems :


Turbocharged system; provides more power from engine by giving
air, that is above atmospheric pressure (more oxygen), to cylinders. This
is a pump system and it takes it’s motion from outlate pressure of
exhaust gas.
• It has got 2 fans; turbine and compressor. Turbine is in exhaust side
and compressor is in intake side.
DIESEL ENGINE TRAINING

Turbocharged System :

Air Intake

Exhaust Gas
DIESEL ENGINE TRAINING

Air Intake Systems :

 Naturally Aspirated  Turbocharged


System System
DIESEL ENGINE TRAINING

Turbocharged System :

 Air intake temperature to cylinder;


 Cummins Air Intake (Bottom of Air Filter) + 25°C
 J. Deere Air Intake (Bottom of Air Filter) + 35°C
DIESEL ENGINE TRAINING

Turbocharged System :
Turbocharged-Aftercooled Charge Air-Cooled
DIESEL ENGINE TRAINING

Turbocharged System :
DIESEL ENGINE TRAINING

Turbocharged System :
Heat Exchanger Cooled
Heat exchanger cooling systems flow
engine coolant in a closed circuit system
and provides a passage for raw water
through the heat exchanger tubes to
remove heat from that closed circuit. The
system requires a cool water supply to
remove heat as it passes through the
heat exchanger, then dumped as waste
water. The raw water can come from city
water supply, sea water, a well, or any
unlimited freshwater supply.
Check engine data sheets for Raw Water
Flow, System Restriction, and Heat
Rejection Value requirements and
maximum limits.
DIESEL ENGINE TRAINING

Exhaust System :
 Exhaust system throws exhaust gas from
engine cylinder to atmosphere with minimum
resistivty.

 Exhaust system
functions :
• Reducing noise of exhaust
gas.
• Absorbing sparks in
exhaust.
DIESEL ENGINE TRAINING

Engine Assembly Animation :


DIESEL ENGINE TRAINING

Diesel Engine Preferences :

Diesel engines are using in many industrial


places. Because of following that ;

• Fuel economy.
• Diesel fuel is cheaper than the others.
• More efficiency (~% 37).
• Less exhaust gas impressiveness (CO2 in diesel
engine, CO in gasoline engine).
• Less fire dangerous (ignition point at 65°C).
DIESEL ENGINE TRAINING

Efficiency In Diesel Engine :

% 100
%2
% 32

% 20
% 37

Ambient Heat Rejection Energy


2035 btu/min % 9
DIESEL ENGINE TRAINING

Efficiently Operation In Diesel Engine :

Air Intake Temperature 0°C (32°F)


Exhaust Temperature 177°C (350°F)
Cooling Water Temperature 60°C (140°F)
DIESEL ENGINE TRAINING

Fuel Recommendation :

• Fuel should be suitable according to


EN 590 and ASTM D975 standard
which we’ll use.

• Sulphur rate in fuel should be less


than rate of 0,5%. Or Carbon
damages metal surface which is
become chemical reaction with liquid
sulhur.

• Minumun cetane number of fuel


should be 40. Cetane number of fuel
should be upper than 50 in place of
over 1500 meters altitude or under -
20°C temperature. Cetane number is
ignition temperature.
DIESEL ENGINE TRAINING

Fuel Storage :

 Fuel tank should be cleanly.


 Don’t use galvanized material in fuel tank.
 Zinc coats cause peeling by chemical reaction between
zinc and diesel fuel in galvanized tank. It causes jelling
If fuel has got water. This jelling is damaged fuel
system, fuel filters, fuel pump, fuel injectors and other
materials of fuel system.
 Don’t use brass material in fuel system (brass has got
zinc and copper).
 Don’t use less ciculation and storaged more than 1
month fuel .
DIESEL ENGINE TRAINING

Requested Features Of Engine Oils :

 Viscosity :
• Viscosity is a measure of the resistance of a fluid to deform
under shear stress. It is commonly perceived as
"thickness", or resistance to pouring.
 SAE Viscosity :
• Engine oil is decided according to viscosity of “Society Of
Automotive Engineers”.
 Adhesion and Cohesion :
• Adhesion is the molecular attraction exerted between
bodies in contact. Cohesion or cohesive attraction or
cohesive force is the intermolecular attraction between like-
molecules. Cohesion explains phenomena such as surface
tension. Adhesion and cohesion is decided viscosity of oil.
DIESEL ENGINE TRAINING

Recommended SAE Oil Viscosity Grades & Ambient Temperatures :


DIESEL ENGINE TRAINING

Over Oil Combustion Causes In Engine :

• Using incorrect oil.


• No operation engine as long
time.
• Operation engine by low load.
• Operation engine at over speed.
• External creepage.
• Low compression pressure of
combustion chamber (Piston
rings and cylinder block is
damaged).
• Over warming of valves.
• Bearing of connecting rod is
damaged.
DIESEL ENGINE TRAINING

Damaging Causes In Engine Oil :

• Carbon goes to crank case after each combustion (oil is dirtied,


thickened, more density).
• Metal dusts from friction parts.
• Water vapour (after exhaust stroke) is mixed oil system by
concentration. It causes to become corrosion and sedimentation
(more than 1 liter water becomes after 1 liter diesel fuel
combustion).
• Acids (by combustion) cause to become oil acid.
• Oil and water vapour can not eject by air-condition system, it
collects by concentration in carter case, it is mixed oil and thin
down oil, when the engine operation by chilly. Thus it becomes filth.
Those filths plug the oil filter. Oil system doesn’t work by stability.
DIESEL ENGINE TRAINING

Harms Of Damaged Oil :

Acids damage which is mixed oil.

Carbon dusts cause to reduce


engine oil quantity, to increase oil
density, to block oil lines, to
damage cylinder and bearings
which is collected in crank case.

Unsuitable (thick or thin density)


oil damages oil system.
DIESEL ENGINE TRAINING

Effects Of Engine Temperature :

If over temperature :

 Reducing mechanical endurance


 Causing to change obligatory spaces
between piston, bearing, piston ring.
 Oil density is reduced by
temperature, losed adhesion and
cohesion features and con not work
by stability.
 It is damaged because of over
temperature of cylinder block and
cylinder head .
 Damaging movement parts and out
of order.
DIESEL ENGINE TRAINING

Effects Of Engine Temperature :

If low temperature :

 Reduceing thermic efficiency of engine.


 Increasing fuel consumption.
 Engine oil is dirty. So ;
 Incorrect oil lubrication
 Causing corrosion
 Changing spaces on movement parts.
 Cylinders is rusted and CO density in water is
increased If cooling water lower than normal value.
DIESEL ENGINE TRAINING

Coolant Water :

 Protection liquids is suggested via manufactoring


companies to reduce damaging effects to cylinder block
(Cummins is suggested DCA4 protection liquid).

 Effecting To Cylinder Block Of Water In Cooling


System ;

• Corrosion (Rusting)
• Cavitation
DIESEL ENGINE TRAINING

Cavitation :

Cavitation is description that to become voids and bubbles


in a liquid (cooling water) by reducing pressure when the
pistons move. These voids and bubbles will be exploded at
10.000 bar. So this exploding is damaged cylinder block.
Cooling Water

Cylinder Cylinder
Block Block
Cylinder Bubbles
and Piston
DIESEL ENGINE TRAINING

Anti-freeze Using Rate According To


Ambient Conditions :

 0 – (-15) °C % 30

 (-15) – (-25) °C % 40

 (-25) – (-40) °C % 50
DIESEL ENGINE TRAINING

Anti-Freeze Rate – Freezing Point Diagram :

0
0 10 20 30 40 50 60 70 80 90 100

-10

-20
Freezing Point °C

-30

-40 Boiling
DonmaPoint
Noktası

-50

-60

-70

-80

% Anti-freeze Rate
DIESEL ENGINE TRAINING

Noise Sources In Generator :

Exhaust Noise
 Causing diffusion of exhaust gases by vibration.
Mechanical Noise
 Causing parts of engine, alternator and cabin.
Radiator Noise
 Causing air cooling flow via radiator fins by fan.
Cunstructional Noise
 Vibration, flabby assembly.
DIESEL ENGINE TRAINING

Noise Effect In Generator :

 90 dB noise more than 8 hours per 1 day is


damaged human health according to Europen
standards.

 Therefore ;
 Using silencer for exhaust.
 Using silencer for radiator and mechanical parts.
 Using anti-vibration dowel to reduce constructional
noise.
DIESEL ENGINE TRAINING

Carefully read all safety


messages in your
engines manual and on
your machine safety
signs .

Don’t start engine by


shorting across starter
terminal.
DIESEL ENGINE TRAINING

Handle fuel with care;


it’s highly flammable.
Do not refuel the
machine while smoking
or when near open
flame or sparks.

Keep a first aid kit


and fire extingisher
handy.
DIESEL ENGINE TRAINING

Keep all sparks and flame


away when using it. Keep
starting fluid away from
batteries and cables.

Wear close fitting


clothing and safety
aquipment appropriate
to the job.
DIESEL ENGINE TRAINING

Keep area clean and dry.


Never lubricate, service or
adjust machine while it is
moving.

Entanglement in rotation
driveline can couse serious
injury or death. Keep master
shields and driveline shields in
place at all times. Make sure
rotation shields turn freely.
DIESEL ENGINE TRAINING

Avoid heating near


pressurized fluid
lines.
Work in vantilated area.
Engine exhaust fumes can
cause sickness or death.

Avoid high-pressure fluids.


Escaping fluid under pressure
can penetrate the skin causing
serious injury.
DIESEL ENGINE TRAINING

Follow the suggestions below for troubleshooting :

• Study the problem thoroughly before acting.


• Refer to the engine system diagrams.
• Do the easiest and most logical things first.
• Find and correct the cause of the problem.
DIESEL ENGINE TRAINING

Causing of Stop The Engine By Instantly :

 Suddenly oil pressure reduction


 Abnormal engine warmness
 Abnormal noise and vibration
 Suddenly power losing
 More black exhaust fumes
 More fuel spending
 More oil spending
 Oil - water - fuel creepage
DIESEL ENGINE TRAINING

Engine does not crank or cranks slowly ? :

• External or internal conditions affecting


engine crankshaft rotation
• Battery connections broken, loose or
corroded
• Incorrect oil
• Oil temperature low
• Battery rating too low
• Battery temperature too low
• Battery charge low
• Starting circuit component malfunction
DIESEL ENGINE TRAINING

Battery Charge Condition :

Terminal Voltage (Vdc) % Charge Condition Application

V < 11.6 0
Battery must
11.6 < V < 11.9 0 - 25 be charged.
11.9 < V < 12.2 25 - 50
12.2 < V < 12.4 50 - 75

Battery charge
12.4 < V < 12.7 75 - 100 is enough.
Warning:
V > 12.8 100 Battery is
unbalanced
or damaged.
DIESEL ENGINE TRAINING

Engine hard to start or does not start


(exhaust fumes present) ?:

• Engine cranking speed low (below 150 rpm)


• Engine driven units engaged
• Cold start aid needed or not working correctly
• Fuel filter plugged
• Air in the fuel system
• Fuel sucting line restricted
• Intake air system restricted
• Fuel contaminated
DIESEL ENGINE TRAINING

Engine cranks but does not start


(no exhaust fumes)? :

• No fuel in tank
• Shut off valve closed
• No fuel to injectors
• Fuel connections loose on
suction side of fuel pump
• Fuel filter plugged or suction
line restricted
• No fuel in pump
• Intake or exhaust system
restricted
DIESEL ENGINE TRAINING

Engine starts but does not keep running ? :

• Air in the fuel system


• Engine driven units engaged
• Fuel filter plugged or fuel waxing
due to cold weather
• Fuel suction line restricted
• Fuel contaminated
• Intake or exhaust system
restricted
DIESEL ENGINE TRAINING

Lubrication oil pressure low? :

• Incorrect oil level


• Oil pressure gauge
malfunctioning
• Oil diluted with fuel
• Incorrect oil specifications
• Oil temperature above normal
(>120°C)
DIESEL ENGINE TRAINING

Coolant temperature below normal ? :

• Radiator shutters stuck in open position


or opening early
• Temperature gauge malfunctioning
DIESEL ENGINE TRAINING

Coolant temperature above normal ? :

 Low coolant level


 Radiator fins damaged or obstructed with
debris
 Collapsed or restricted radiator hose
 Loose fan drive belt
 Incorrect oil level
 Cooling fan shroud damaged or missing
 Incorrect or mulfunctioning radiator cap
 Temperature gauge malfunctioning
 Thermostats are not opening completely
or cold weather radiator cover closed
DIESEL ENGINE TRAINING

Exhaust fumes excessive under load ? :

• Intake air system restricted


• Intake air leaks between
turbocharger and cylinder head
• Fuel specifications wrong
• Valves or injections adjusted wrong
• Fuel drain line restricted
DIESEL ENGINE TRAINING

Engine power output low ? :


• Excessive load for engine horsepower rating
• Low power due to altitude
• Fuel suction line or fuel filter restricted
• Lubrication oil level too high
• Throttle linkage adjustment wrong
• Intake or exhaust systems restricted
• Air in fuel-spongy throttle is symptom
• Fuel drain line restricted or fuel tank vents plugged
• Valves or injectors adjusted wrong
• Fuel quality poor
• High intake air temperature (above 38°C)
• Low intake air temperature (below 0°C)
• High fuel temperatures (above 70°C)
DIESEL ENGINE TRAINING

Engine will not reach rated speed when loaded ? :

• Excessive load for engine


horsepower rating
• Tachometer has a malfunction
• Throttle linlage adjustment wrong
• Fuel suction line restricted
DIESEL ENGINE TRAINING

White smoke or rough running at idle


(After warmup period) ? :

• Low coolant temperature


• Fuel quality poor
DIESEL ENGINE TRAINING
DIESEL ENGINE TRAINING FINISHED

THANKS

QUESTIONS

ANSWERS

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