BASIC DIESEL ENGINE TECHNOLOGY

TRI-CO. YOUNG FARMERS DECEMBER 4, 2001

Original Power Point created By Joey Wells Modified by Georgia Agricultural Education Curriculum Office June 2002

INTRODUCTION
THE DIESEL ENGINE IS USED AS A SOURCE OF POWER FOR THOUSANDS OF APPLICATIONS.

WHO INVENTED THE DIESEL ENGINE?

1895 RUDOLPH DIESEL SUCCESSFULLY INVENTED AN ENGINE THAT BURNED COAL DUST INJECTED BY PRESSURIZED AIR. THE DIESEL ENGINE WAS BORN.

WHO DEVELOPED THE FIRST MASS PRODUCED INJECTION PUMP?

ROBERT BOSCH IN 1927

USES OF DIESEL ENGINES

TODAY, DIESEL ENGINES ARE USED TO PROVIDE POWER IN A VARIETY OF APPLICATIONS IN MANY INDUSTRIES

THERE ARE SIX MAJOR USES OF DIESEL ENGINES

AGRICULTURE/FARM

TRANSPORTATION

CONSTRUCTION

FORESTRY

MARINE

ELECTRICAL GENERATION PLANTS

SEVEN ADVANTAGES OF DIESEL ENGINES

MORE EFFICIENT AND ECONOMICAL TO USE FUEL VAPOR IS NOT EXPLOSIVE EXHAUST GASES ARE LESS POISONOUS LESS CARBON MONOXIDE GREATER LUGGING POWER AND TORQUE

ADVANTAGES CONTINUED
ENGINES ARE DURABLE AND IF PROPERLY CARED FOR WILL MAINTAIN THEIR ECONOMY FUEL IS LESS VOLATILE NO VAPOR LOCK PROBLEMS CAN USE A VARIETY OF FUELS AND MIXTURES

FIVE DISADVANTAGES OF DIESEL ENGINES

ENGINES MUST BE STONGER AND HEAVIER BECAUSE OF HIGHER COMPRESSION RATES INITIALLY MORE EXPENSIVE FUEL COULD GEL IN COLDER CLIMATES GENERALLY NOISER OPERATION VERY PUNGENT EXHAUST ODOR

INTERNAL COMBUSTION ENGINE:

AN ENGINE THAT PRODUCES POWER BY BURNING FUEL INSIDE A COMBUSTION CHAMBER WITHIN THE ENGINE

TWO TYPES OF INTERNAL COMBUSTION ENGINES

SPARK IGNITION ENGINE

COMPRESSION IGNITION ENGINE

TRUE OR FALSE: SPARK PLUGS SHOULD BE CHANGED MORE OFTEN IN DIESEL ENGINES THAN IN GASOLINE ENGINES?
FALSE

BASICALLY, HOW DOES A SPARK-IGNITION ENGINE WORK?

LIQUID FUEL BROKEN DOWN INTO A FINE SPRAY AND MIXED WITH AIR IN THE CARBURETOR. FUEL-AIR MIXTURE PIPED TO THE CYLINDER WHERE IT IS IGNITED BY AN ELECTRIC SPARK FROM THE SPARK PLUG.

HOW DOES A COMPRESSION-IGNITION ENGINE WORK?

NO SPARK IS NEEDED LIQUID FUEL UNDER VERY HIGH PRESSURE IS INJECTED DIRECTLY INTO THE CYLINDER WHICH IS FILLED WITH HIGHLY COMPRESSED AIR. IGNITION BEGINS WHEN THE FUEL HITS THE AIR THAT IS AT A TEMPERATURE OF 777 DEGREES F.

WHAT DOES A COMPRESSION RATIO OF 16:1 MEAN?

THE AIR IN A CYLINDER IS COMPRESSED INTO 1/16 THE SPACE AT THE TOP OF THE STROKE AS COMPARED TO THE BOTTOM OF THE STROKE

TRUE OR FALSE: DIESEL ENGINES USE GREATER COMPRESSION RATIOS THAN GASOLINE ENGINES?
TRUE DIESEL ENGINES 16:1 TO 22:1 GASOLINE ENGINES 8:1

TRUE OR FALSE: DIESEL ENGINES REQUIRE MORE AIR THAN GASOLINE ENGINES
TRUE

TRUE OR FALSE: DIESEL ENGINES HAVE NO IGNITION SYSTEM COMPONENTS

TRUE NO SPARK PLUGS, COIL, MAGNETO, DISTRIBUTOR, OR WIRING

TRUE OR FALSE: DIESEL ENGINES, LIKE GASOLINE ENGINES, DRAW IN FUEL AND AIR ON THE INTAKE STROKE?
FALSE ONLY AIR IN A DIESEL ENGINE

WHAT IS THE PURPOSE OF A TURBOCHARGER ON A DIESEL ENGINE?

TO INCREASE THE AIR INTAKE INTO THE CYLINDERS

TRUE OR FALSE: DIESEL ENGINES REQUIRE A HIGH PRESSURE PUMP TO INJECT THE FUEL INTO THE COMPRESSED AIR IN THE CYLINDER?
TRUE

WHAT IS THE NAME OF THE ENGINE PART THAT SPRAYS FUEL INTO THE CYLINDER OF A DIESEL ENGINE?
INJECTOR NOZZEL

WHAT TYPE MATERIAL ARE FUEL LINES MADE OF IN A DIESEL ENGINE? WHY?
STEEL PRESSURES FROM 5,000 TO 20,000 PSI ARE INVOLVED

TRUE OR FALSE: GASOLINE IS LESS VOLATILE THAN DIESEL FUELS

FALSE GASOLINE EVAPORATES READILY AND IS VERY EXPLOSIVE

TRUE OR FALSE: GASOLINE ENGINES ARE HEAVIER THAN DIESEL ENGINES OF THE SAME HORSEPOWER?
FALSE HIGH DIESEL CYLINDER PRESSURES REQUIRE HEAVIER MATERIALS

HOW IS ENGINE SPEED CONTROLLED IN A DIESEL ENGINE?

THE THROTTLE CONTROL REGULATES ONLY THE AMOUNT OF FUEL INJECTED INTO THE CYLINDER THE THROTTLE CONTROL IN A GASOLINE ENGINE REGULATES THE AMOUNT OF AIR/FUEL MIXTURE ALLOWED INTO THE CYLINDER

HOW ARE DIESEL ENGINES STOPPED?

BY SHUTTING OFF THE FUEL TO THE CYLINDERS BY A MANUAL CONTROL OR SOLENOID SWITCH GASOLINE ENGINES ARE STOPPED BY CUTTING OFF THE SPARK FROM THE SPARK PLUGS TO THE CYLINDERS

HOW AN ENGINE WORKS

WHAT ARE THE FIVE BASIC PARTS OF ANY ENGINE?

NAME THE TWO BASIC TYPES OF ENGINES

FOUR STROKE CYCLE ENGINE TWO STROKE CYCLE ENGINE

WHAT SEQUENCE OF EVENTS MAKE UP A CYCLE?

INTAKE COMPRESSION POWER EXHAUST WHAT IS A STROKE? ONE MOVEMENT OF THE PISTON

FOUR STROKES OF AN ENGINE

HOW MANY TIMES DOES THE CRANKSHAFT REVOLVE DURING A CYCLE IN A FOUR STROKE CYCLE ENGINE?
TWO

WHAT ARE THE MAJOR DIFFERENCES IN EACH STROKE WHEN COMPARING A DIESEL ENGINE WITH A GASOLINE ENGINE?
INTAKE
AIR VS. AIR/FUEL MIXTURE

DIFFERENCES CONTINUED
COMPRESSION STROKE
COMPRESSION RATIO

POWER STROKE
SPARK PLUG VS. HEAT OF COMPRESSION

EXHAUST STROKE
SAME FOR BOTH

TWO-STROKE CYCLE ENGINES

HOW MANY STROKES OF THE PISTON ARE REQUIRED FOR A CYCLE TO BE COMPLETED IN A TWO STROKE CYCLE ENGINE?
TWO

WHAT HAPPENS DURING STROKE 1 IN A TWO STROKE CYCLE GASOLINE ENGINE?

THE UPSTROKE OF THE PISTON COMPRESSES THE AIR/FUEL MIXTURE. (COMPRESSION STROKE) AT THE SAME TIME, A NEW AIRFUEL MIXTURE IS DRAWN INTO THE CRANKCASE. (INTAKE STROKE)

WHAT HAPPENS DURING STROKE 2 OF A TWO STROKE CYCLE GASOLINE ENGINE?

THE DOWNWARD STROKE (POWER STROKE) OF THE PISTON CAUSES THE BURNED GASES TO ESCAPE THROUGH THE EXHAUST PORT. (EXHAUST STROKE) NEW FUEL-AIR IS FORCED INTO THE CYLINDER

TWO-STROKE CYCLE GASOLINE ENGINES

WHAT ARE THE DIFFERENCES BETWEEN A DIESEL AND GASOLINE TWO-STROKE CYCLE ENGINE?
DIESEL ENGINES INJECT FUEL INTO THE CYLINDER THROUGH A FUEL INJECTOR A BLOWER IS OFTEN USED TO FORCE AIR INTO THE CYLINDER DIESEL ENGINES HAVE EXHAUST VALVES, GAS ENGINES HAVE A PORT

TWO-STROKE DIESEL ENGINE

THE DIESEL AIR SYSTEM

BASIC PARTS OF THE DIESEL AIR SYSTEM

WHAT IS A TURBOCHARGER ON A DIESEL ENGINE?

A CENTRIFUGAL BLOWER THAT IS DRIVEN BY EXHAUST GASES WHICH FORCES MORE AIR INTO THE CYLINDER. INCREASES POWER

HOW IMPORTANT IS KEEPING AIR FILTERS CLEAN?

VERY IMPORTANT A DIESEL ENGINE USES 1215,000 GALLONS OF AIR TO EACH GALLON OF FUEL

NAME THREE TYPES OF AIR CLEANERS

OIL-BATH TYPE CLEANER PRE-CLEANER DRY-TYPE AIR CLEANER

THE DIESEL FUEL SYSTEM

WHAT ARE THE FIVE BASIC PARTS OF A DIESEL FUEL SYSTEM?

INJECTION NOZZLES INJECTION PUMP FILTERS TRANSFER PUMP FUEL TANK

THE DIESEL FUEL SYSTEM

DIESEL FUEL, LIKE GASOLINE IS A PRODUCT OF THE DISTILLATION OFCRUDE OIL

100 GALLONS OF CRUDE OIL WILL YIELD WHAT PRODUCTS?

GASOLINE = 44 GALLONS DIESEL FUEL = 36 GALLONS MISC. = 9 GALLONS KEROSENE = 6 GALLONS LUBRICANTS = 3 GALLONS LOSS = 3 GALLONS

WHAT ARE THE THREE GRADES OF DIESEL FUEL?

NUMBER 1 DIESEL FUEL (NO. 1-D)
RECOMMENDED FOR COLD WEATHER. REMAINS FLUID FOR EASIER STARTING BUSES, CARS, TRUCKS, FARM TRACTORS

NUMBER 2 DIESEL FUEL (NO. 2-D)

HEAVY WORK LOADS. BUSES, TRUCKS, FARM EQUIPMENT

NUMBER 4 DIESEL FUEL (NO. 4-D)

OCEAN GOING VESSELS WITH LOW-MEDIUM SPEED ENGINES

THE DIESEL COOLING SYSTEM

WHAT ARE TWO PRIMARY TYPES OF COOLING SYSTEMS FOR DIESEL ENGINES?

LIQUID COOLING AIR-COOLING

LIQUID COOLING ENGINE

AIR-COOLED DIESEL ENGINE

WHAT IS THE IDEAL OPERATING TEMPERATURE FOR MOST DIESEL ENGINES?

165 185 DEGREES F.

WHAT ARE SOME EFFECTS OF ENGINE OVERHEATING?

CYLINDER HEAD AND BLOCK CAN CRACK OR WARP RINGS AND VALVES MAY SEIZE OR STICK DUE TO GUMS, LAQUERS, AND VARNISHES FORMING FROM OVERHEATED OIL AND CARBON FORMATION BEARINGS MAY BE DAMAGED CAUSING EXCESSIVE WEAR

WHAT ARE SOME EFFECTS OF OVERCOOLING?

INCREASED ENGINE WEAR IMPROPER LUBRICATION INCREASED FUEL CONSUMPTION INCREASED SLUDGE FORMATION INCREASED ENGINE CORROSION
MOISTURE CONDENSES IF BELOW 140 DEGREES IN THE ENGINE CRANKCASE

WHAT ARE SOME ADVANTAGES OF AIRCOOLED ENGINES

LESS WEIGHT LESS MAINTENANCE LESS DOWN-TIME NO CAVITATION EROSION NO COOLANT CONCERNS MORE EFFICIENT USE OF POWER LESS VULNERABLE TO DAMAGE LESS BULK QUICKER WARM-UP

WHAT ARE SOME DISADVANTAGES TO AIRCOOLED ENGINES?

LENGTH OF THE ENGINE LESS TEMPERATURE CONTROL HIGHER OPERATING TEMPERATURES GREATER NOISE MORE FREQUENT CLEANING

THE DIESEL LUBRICATION SYSTEM

WHAT ARE THE FUNCTIONS FOR THE LUBRICATION SYSTEM?

REDUCES SHOCK, WEAR, AND FRICTION SEALS COMPRESSION PROVIDES SOME CLEANING HELPS COOL THE ENGINE QUIETS THE ENGINE OPERATION

TRUE OR FALSE: MOST OF THE LUBRICANTS USED IN DIESEL ENGINES COME FROM PETROLEUM?
TRUE

WHAT ARE LUBRICANTS DERIVED FROM ANIMAL OR VEGETABLE OILS CALLED?

SYNTHETIC OILS

WHAT TWO CHARACTERISTICS ARE MOST IMPORTANT IN CHOOSING PROPER OIL?

VISCOSITY SERVICE CLASSIFICATION

WHAT IS VISCOSITY?
A MEASURE OF A LIQUIDS RESISTANCE TO FLOW HIGHER TEMPERATURE DECREASE IN VISCOSITY SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) DEVELOPED NUMBERING SYSTEM

WHAT ARE THE VISCOSITY GRADES?

API ENGINE OIL SERVICE CATEGORIES

AMERICAN PETROLEUM INSTITUTE TABLE 1: (HANDOUT)

WHAT ARE THE THREE MOST COMMON OIL ADDITIVES?

OXIDATION INHIBITORS CORROSION AND RUST INHIBITORS DETERGENT DISPERSANTS

HOW DO DETERGENT ADDITIVES WORK?

PRINCIPLES OF FLUID HYDRAULICS

HYDRAULIC SYSTEMS ON A TRACTOR

WHAT IS PASCALS LAW OF HYDRAULICS?

PRESSURE ON A LIQUID IN A CONTAINER IS TRANSFERRED EQUALLY TO ALL SURFACES

PASCALS LAW
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PRESSURE TRANSFER IN HYDRAULIC BRAKES

CHANGING THE PRESSURE IN A HYDRAULIC SYSTEM