DIESEL POWER PLANT

FUNDAMENTALS

EE 150(OJT/PRACTICUM)
 Power Plant System

A power plant may be defined as a machine or assembly of

equipment for the generation of electric power. When coupling it
to a prime mover runs the generator, The electricity is generated.

The type of prime mover determines the type of power plant.

These major plants are:
1.Diesel Power Plant 4.Nuclear Power Plant
2.Steam Power Plant 5.Hydro Electric Power Plant
3.Gas Turbine Power Plant
 Introduction

Although several types of prime movers are available (gasoline engines, steam
and gas turbines), The diesel engine is the most commonly used to supply
electrical power generation and act as a back up electrical generator for
emergency use during loss of the normal power supply.

Diesel engine provide a self reliant energy source that is available in sizes from
few to 10000 horsepower. Relatively speaking, diesel engine are small,
inexpensive, powerful, fuel efficient and extremely reliable if maintained
properly. Because of the widespread use of diesel engines, a basic
understanding of the operation of a diesel engine will help ensure they are
properly operated and maintained properly.

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 History

The modern diesel engine came about as a result of the internal combustion
principles first proposed by Sadi Carnot in early 19th century. Dr. Rudolf Diesel
applied Sadi Carnot’s principles into a patented cycle or method of combustion
that has become known as “diesel” cycle.
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His patented engine operated when the heat generated during the compression
of the air fuel charge caused ignition of the mixture, when then expanded at a
constant pressure during the full power stroke of the engine.
Diesel Cycle
 DieselEngines

A diesel engineis an internal combustion engine in which air is compressed to a

sufficiently high temperature to ignite diesel fuel injected into the cylinders
where combustion and expansion actuate the piston

Diesel engines are not self-speed limiting because the air (oxygen) entering the
engine is always the maximum amount. Therefore, engine speed is limited solely
by the amount of fuel injected into the engine cylinders.
 Major Components of a Diesel Engine

The Cylinder Block

The cylinder block is generally a single unit made from cast iron. In a liquid-
cooled diesel, the block also provides the structure and rigid frame for the
engine’s cylinders, water coolant and oil passages and support for the crankshaft
and camshaft bearings.
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Crankcase and Oil Pan

The crankcase is usually located on the bottom of the cylinder block. The
crankcase is defined as the area around the crankshaft bearings. This area
encloses the rotating crankshaft and crankshaft counter weights and direct
returning oil into the oil pan. The oil pan is located at the bottom of the
crankcase. The oil pan collects and stores the engine supply of lubricating oil.
Cylinder Sleeve or Bore

Diesel engine use two types of cylinders. A Machined or bored into the block
casting, making the block and cylinders an integral part. And other is a machined
steel sleeve is pressed into the block casting to form the cylinder.

The cylinder sleeve or bore provides the engine with the cylindrical structure
needed to confine the combustion gasses and to act as a guide for the engine’s
piston.
In engine using sleeves, there are two types of sleeves, wet and dry. A dry sleeve is
surrounded by the metal of the block and does not come in direct contact with
the engine’s coolant(water).
A wet sleeve comes in direct contact with the engine’s coolant. The volume
enclosed by the sleeve or bore is called the combustion chamber and is the space
where the fuel is burned. The diameter of the cylinder is called bore of the engine.
Piston and Piston Rings

The piston transforms the energy of the expanding gasses into mechanical energy.
The piston rides in the cylinder liner or sleeve. Piston are commonly made of
aluminum or cast iron alloys.

To prevent the combustion gasses from bypassing the piston and to keep friction to
a minimum, each piston has several metal rings around it. This rings function as the
seal between the piston and the cylinder wall and also act to reduce friction by
minimizing the contact area between the piston and the cylinder wall.

The rings are usually made of cast iron and coated with chrome . The top ring acts
primarily as the pressure seal. The intermediate ring acts as a wiper ring to remove
and control the amount of oil film on the cylinder walls. The bottom ring is an oiler
ring and ensures that a supply of lubricating oil is evenly deposited on the cylinder
walls.
Connecting Rod

The connecting rodconnects the piston to the crankshaft. The rods are made
from drop-forged, heat-treated steel to provide the required strength. Each end
of rod is bored, with the smaller top bore connecting to the piston pin in the
piston. The large bore end of the rod is split in half and bolted and allow the rod
to be attached to the crankshaft.
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Some diesel engine connecting rods are drilled down the center to allow oil to
travel up from the crankshaft and into the piston pin and piston for lubrication .
Crankshaft

The crankshaft transforms the linear motion of the piston into a rotational motion
that is transmitted to the load. Crankshaft are made of forged steel. The forged
crankshaft is machined to produce the crankshaft bearing and connecting rod
bearing surfaces.
The rod bearings are eccentric or offset, from the center of the crankshaft. This
offset converts the reciprocating(up and down) motion of the piston into the
rotary motion of the crankshaft. The amount of offset determines the stroke
(distance the piston travels) of the engine.
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The crankshaft does not ride directly on the cast iron block crankshaft supports,
but rides on a special bearing material. The connecting rods also have bearings
inserted between the crankshaft and the connecting rods. The bearing material is
a soft alloy metals that provides replaceable wear surface and prevents galling
between two similar metals(i.e. crankshaft and connecting rod)
Crankshaft cont.

Each bearing is split into halves to allow assembly of the engine. The crankshaft
is drilled with oil passages that allow the engine to feed oil to each of the
crankshaft bearings and connecting rod bearings and up into the connecting rod
itself. The crankshaft has large counter weights that balance the weight of the
connecting rods. These weights ensure an even(balance) force during the
rotation of moving parts.
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Flywheel
The flywheelis located on one end of the crankshaft and serves three purposes.
First through it’s inertia, it reduces vibration by smoothing out the power stroke
as each cylinder fires. Second, it is the mounting surface used to bolt the engine
up to its load. Third, the flywheel has gear teeth around its perimeter that the
starter motors to engage and crank the diesel.
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Cylinder Heads and Valves

A diesel engine’s cylinder headsperform several functions. First, they provide the
top seal for the cylinder bore or sleeve. Second, they the provide structure holding
exhaust valves (and intake valves where applicable), the fuel injector, and
necessary linkages.
A diesel engine’s head are manufactured in one of two ways. In one method, each
cylinder has its own head casting, which is bolted to the block. This method is used
primarily on the larger diesel engines. In the second method, which used on
smaller engines, the engine’s head is cast as one piece (multi-cylinder head).

Diesel engines have two methods of admitting and exhausting gasses from the
cylinder. They can used either ports or valves or a combination of both. Ports are
slots in the cylinder walls located in the lower 1/3 of bore. When the piston travels
below the level of the ports, the ports are opened and fresh air or exhaust gasses
are able to enter or leave, depending on the type of port.
Valves cont.

The ports are then closed when the piston travels back above the level of the
port. Valves are mechanically opened and closed to admit or exhaust the gasses
as needed. The valves are located in the head casting of the engine. The point at
which the valve seals against the head is called valve seat. Most medium-sized
diesels have either intake ports or exhaust valves or both intake and exhaust
valves.
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Timing Gears, Camshaft and Valve Mechanism

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In order for a diesel engine to operate, all of its components must perform their
functions at very precise intervals in relation to the motion of the piston. To
accomplish this, a component called camshaft is used.
Timing gears cont.

A camshaft is a long bar with egg-shaped eccentric lobes, one lobe for each valve
and fuel injector. Each lobe has a follower or tappet. As camshaft is rotated, the
tappet is forced up and down as it follows the profile of the cam lobe.

The tappets are connected to the engine’s valves and fuel injectors through various
types of linkages called pushrods and rocker arms. As the pushrods and rocker arms
transfer the reciprocating motion generated by the camshaft lobes to the valves
and injectors, opening and closing them as needed.
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The camshaft is driven by the engine’s crankshaft through a series of gears called
idler gears and timing gears. The gears allow the rotation of the camshaft to
correspond or be in time with, the rotation of the crankshaft and thereby allows the
valve opening, valve closing, and injection of fuel to be timed to occur at precise
intervals in the piston’s travel.
Blower (Turbocharger)

The diesel engine’s blower is part of the air intake system and serves to
compress the incoming fresh air for delivery to the cylinders for combustion.
Turbocharging occurs when the engine’s own exhaust gasses are forced through
a turbine(impeller) which rotates and is connected to a second impeller located
in the fresh air intake system. The impeller in the fresh air intake system
compresses the fresh air.
The compressed air increases the engine’s available power by increasing the
maximum amount of air (oxygen) that is forced into each cylinder and increases
intake pressure that improves the scavenging of the exhaust gasses out of the
cylinder.
Fuel Injection pump and Unit Injector

Fuel injection pumpis the device that pumps fuel into the cylinders of a
diesel engine. Precisely delivered fuel, maintains a rhythm or timing that keeps
the engine running smoothly. Simultaneously the pump also controls the
amount of fuel needed to gain the desired power. It is driven indirectly from the
crankshaft by gears. Its timing is such that the fuel is injected before top dead
center of that cylinder’s compression stroke.
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Unit injectorsis a compact fuel injection design in which the pump plunger
creates high pressure by a mechanical force applied by the engine. The plunger
and injectors blend into one unit where job is to deliver fuel spray to the
combustion chamber. The plunger pump used is usually driven by a shared
camshaft.
 Diesel Engine Support System

Cooling System
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Nearly all diesel engines rely on a liquid cooling system to transfer waste heat
out of block and internals.
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The cooling systemconsist of a closed loop similar to that of a car engine and
contains the following major components: water pump, radiator, water jacket
(which consist of coolant passages in the block and heads) and thermostat.
Lubrication System

An internal combustion would not run for even a few minutes if the moving
parts were allowed to make metal to metal contact. The heat generated due to
the tremendous amount of friction would melt the metals, leading to the
destruction of the engine.
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To prevent this, all moving parts ride on a thin film of oil that is pumped
between all the moving parts of the engine. The oil lubricate the bearing
surfaces and cool the bearings by absorbing the friction generated heat.
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The flow of oil to the moving parts is accomplished by the engine’s internal
lubricating system.
Fuel System

All diesel engines require a method to store and deliver fuel to the engine.
Because diesel engines rely on injectors which are precision components with
extremely tight tolerances and very small injection holes.
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The fuel delivered to the engine must be extremely clean and free from
contaminants. Commonly, the fuel will be filtered once outside the engine and
then the fuel will pass through at least one more filter internal to the engine.
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It serves two purposes, obviously supply the fuel to run the engine and the
other is to act as coolant to the injectors.
Air Intake System

Diesel enginerequires close tolerances to achieve its compression ratio, because

most diesel engines are either turbocharged the air entering the engine must be
clean, free of debris and cool as possible.
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There are two types of filter, the wet typeand dry type of filter system. In wet
type, the air is sucked that holds a bath of oil such that the dirt in the air is
removed by the oil in the filter.
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In dry type, paper cloth or metal screen type material is used to catch and trap
dirt before it enters the engine. The reason for ensuring that an engine’s air
supply is as cool as possible is that cool air is more dense than hot air. This
means that, per unit volume, cool air has more oxygen than hot air. More
oxygen means a more efficient fuel burn and more power.
Exhaust System

The exhaust system of a diesel engine performs three functions. First, the
exhaust system routes the spent combustion gasses away from the engine,
where they are diluted by the atmosphere. This keeps the area around the
engine habitable.
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Second, the exhaust system confines and routes the gasses to the turbocharger.
Third, the exhaust system allows mufflers to be used to reduce the engine noise.
 The Basic Diesel Cycle

The Four stroke cycle

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A four strokeengine is an internal combustion engine that utilizes four distinct piston
strokes (intake, compression, power and exhaust ) to complete one operating cycle.
The piston make two complete passes in the cylinder to complete one operating
cycle. An operation cycle requires two revolution (720%) of the crankshaft.
Intake Stroke
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The intake stroke begins at top dead center, and as the piston moves down the intake
valve opens. The downward movement of the piston creates a vacuum in the cylinder
causing a fuel mixture to be drawn through the intake port into the combustion
chamber, as the piston reaches bottom dead center the intake valve closes.
Compression Stroke

The compression stroke begins with the piston at bottom dead center and rising
up to compress the fuel and air mixture. Since both the intake and exhaust
valves are closed, there is no escape for fuel and air mixture and it is
compressed to a fraction of its volume. At this point, the fuel and air mixture is
ignited.
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Power Stroke
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The power stroke begins when the fuel and air mixture is ignited, burns and
expands and forces the piston down. The valves remain closed so that all of the
force is exerted to the piston. The power stroke ends as the piston reaches
bottom dead center.
Exhaust Stroke

The exhaust stroke begins when the piston nears the end of the power stroke
and the exhaust valve is opened.

As the piston moves upwards top dead center, it pushes the burnt gasses,
resulting from the ignition of the fuel and air mixture out of the combustion
chamber and through the exhaust port.
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As the piston reaches top dead center ending the exhaust stroke, the exhaust
valve closes and intake valve opens to begin the intake stroke for the next cycle.
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 Cycle Operation
Four Stroke-Cycle Diesel Engine
Two Stroke Engine

A two stroke engine requires one rotation of the crankshaft to complete one cycle. This
events as follows:
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Intake – The intake ports open and the fresh air is forced in and exhaust ports are
closed and intake continues.
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Compression – Intake and exhaust ports closed, piston travel upwards TDC. Fresh air
heated by the compression.
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Power – piston passes TDC and expanding gasses force the piston down, rotating the
crankshaft.
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Exhaust – piston approaches BDC the exhaust ports open and exhaust gasses start to
flow out of the cylinder.
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Two Stroke Cycle Engine Operation
Engine Performance Terminology

Bore and Stroke

Bore and stroke refer to

the cylinder size of an engine.
The bore is the diameter of the
cylinder. The stroke is the
distance that the piston travels
from bottom dead center (BDC)
to top dead center (TDC).
Engine Displacement

Engine displacement is the volume that is displaced by all the pistons during
one upward stroke. Engine displacement is expressed in cubic inches (in.³) or
liters (L). To find the engine displacement, multiply the volume of one
cylinder by the total number of engine cylinders.
bore x bore x stroke x 0.7854 x number of cylinders = engine displacement

Suppose that the bore is 6.25 in., the stroke is 6.25 in., and that there are six
cylinders. The engine displacement is:
6.25 x 6.25 x 6.25 x 0.7854 x 6 = 1,150 in.³ or 18 L

Compression Ratio and Clearance Volume

The amount of compression developed by a cylinder is expressed as the

compression ratio. The compression ratio compares the cylinder volume
when the piston is at the bottom of its stroke (BDC) and the volume when the
piston is at the top of its stroke (TDC).
The volume to which the air is compressed is the clearance volume (the
space remaining in the combustion chamber).

To calculate compression ratio, you need to know the displacement volume,

the clearance volume, and the following formula:

Compression ratio = displacement volume + clearance volume

clearance volume

Torque

Torque also called moment of force is the tendency of a force to rotate an

object about an axis, fulcrum, or pivot. Just as a force is a push or a pull, a
torque can be thought of as a twist.

Loosely speaking, a torque is a measure of the turning force on an object

such as a bolt or a flywheel. For example, pushing or pulling the handle of a
wrench connected to a nut or bolt produces a torque (turning force) that
loosens or tightens the nut or bolt.
Horse power

Power is the amount of work done per unit time or the rate of
doing work. For a diesel engine, power is rated in units of
horsepower.
Indicated horsepower is the power transmitted to the pistons by
the gas in the cylinders and is mathematically calculated.

Brake horsepower refers to the amount of usable power delivered

by the engine to the crankshaft. Mechanical efficiency of the
engine is the ratio of an engine brake horsepower and its indicated
horsepower.
 Engine Oil & Diesel Fuel
Engine Oil Requirements

Effectiveness of the engine oil ultimately extends the life of the engine. To
achieve maximum effectiveness the engine oil should possess the following
qualities:
ØGood wetting ability
ØCorrect viscosity
ØMinimum evaporation during service
Ø Relative non-toxicity
ØNo damaging sediments
ØNo tendency to deposit varnish, gum, or sludge deposits

However, unless the air-intake system, the coolant system, and the fuel-
injection system are maintained properly; the oil and filters changed regularly;
and the engine coolant temperature maintained between 185 and 205 ºF (85
and 96 ºC), the engine oil will not perform satisfactorily.
Viscosity

Viscosity is the physical property of an engine oil with which the technician is
most concerned. Viscosity is a measurement of fluidity or resistance to flow.
Fluidity or resistance to flow changes with temperature; therefore its
measurement is always related to temperature.

Diesel Fuel

Fuel Classification

Diesel engine fuel ranges from a highly refined distillate fuel obtained
from fractional distillation of crude oils, to a product of residual materials
obtained from crude-oil distillation, cracking processes, and fractions
removed during the production of crankcase oil. However, the fuels with
which the diesel technician is most concerned are those known as middle
distillates, that is, grades 1D, 2D, and occasionally 4D.
 Cetane Number (Ignition Quality)

The cetane number of a diesel fuel expresses its igniting quality.

The higher the cetane number, the shorter the ignition delay period.
 Seals, Gaskets, and
Fasteners
Purpose of Seals and Gaskets

Manufacturers have made great efforts to combat sealing problems

caused by high or low temperatures, expansion, contraction, vibration,
pressure or vacuum, corrosion, and oxidation. However, even today with
the great variety of seals available, it is difficult to find a seal which will
be 100 percent effective under all operating conditions.

Classification of Seals

1. Static Seals – The seals which are used between two

stationary components.
2. Dynamic Seals – Seals capable of sealing two components which
move in relation to each other.
 Mechanical Seals
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Mechanical seals are found in fuel-injection systems, in coolant
systems, and in hydraulic motors and pumps. The two lapped mating
surfaces (stator and rotor) are forced together through a hold-down
device or by spring force to form the sealing surface. The stator is
fastened to the non-rotating element, and the rotor is fastened to the
rotating element.

A Simple Mechanical Seal

 O-Ring Seals

The construction of material of today’s O-ring seals is such that they can
be used as either static or dynamic seals. To identify the various
synthetic materials from which O-ring seals are made, a lettering system
is used. The color has no bearing on the proper selection. However, SAE
recommends a yellow stripe marking for oil-resistant O-rings and a red
marking for fuel-resistant O-rings.
Ø Removing and Installing O-rings

1. When you remove an O-ring, you must be careful not to damage the
grooves or corners. Check the O-ring by rolling it inside out.
Stretching it lightly will help to reveal any small cracks or other
irregularities.
2. During installation, make certain that the O-ring is well lubricated,
that it is not twisted, and that it is properly inserted into the
groove.
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Gaskets

The most common static seal is the gasket. Gaskets are designed to suit
particular needs and, therefore, are manufactured from many different
materials. When you select a gasket material, you must consider pressure,
temperature, hole size, flexibility, smoothness, and the material of the
mating surface. You must also consider the function of the gasket, such as
whether or not it must seal off oil, water, dirt, and /or air, or whether it is
needed to support a vacuum.
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► Gasket Material
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Copper, aluminum, steel, cork,
fiber, asbestos, Nobestos, synthetic
rubber, paper, and various
combinations of these materials are
used to make gaskets. Copper,
aluminum, steel, cork, fiber, asbestos,
synthetic rubber, paper, and various
combinations of these materials are
used to make gaskets.
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► Head Gaskets
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Cylinder-head gaskets are the most
complicated in design and construction
because they must withstand extreme
pressure, vibration, high temperature,
and expansion changes. They must seal
against compression, gases, oil, and
coolant. They must resist extrusion,
elongation, oxidation, and chemicals,
and in fact, must possess the same
strength requirements as the other
combustion chamber components.
 Antiseizure Compounds

The function of an antiseizure compound is to prevent seizure

of bolts, nuts, or shafts. It also prevents corrosion, oxidation,
galling, and chemical reaction between two elements and reduces
friction. This compound should be applied to exhaust-manifold
bolts and to pipes where a corrosive condition or chemical reaction
is likely to occur. Where a precise torquing is important, a light coat
should be applied on the bolts and nuts to reduce friction.

Fasteners

Two metals can be joined together by four basic methods:

Ø Welding (brazing or soldering)

Ø Riveting
Ø Interference fit or press-fit
Ø Threaded fasteners (screws, hex bolts, and nuts).
Bolt -is used to join two metals
when there is room to screw a
nut onto the end of the bolt.
The bolt is inserted through the
holes, then a nut is screwed
onto the bolt’s threaded end
and torque to force the metals
together.
Screw - is used to join two pieces
of metal when one side is
inaccessible and therefore a
nut could not be threaded onto
the bolt. The screw is inserted
through one hole and threaded
into the other hole, and the
metal pieces are forced
together as the screw is torque.
Stud Bolts – have thread on both
ends. They are used when a
bolt or screw would not
provide satisfactory clamping
force.
► Causes of Bolt or Cap-Screw Failure
1. Excessive residual tension (adds to
the stress on the bolt or screw)
2. Improper torque, improper grade, or
improper installation (creates
stress changes which in time lead
to fatigue and failure)
3. Exposure to extreme heat (reduces
tensile strength of bolts)
4. Improper mating of fastener
components (causes
decarburization and stripping of
the nuts and bolts)
5. Cracked or dished washers (cause
the fasteners to fail)
6. Improper material, heat treatment,
or excessive hardness (causes the
head to pop off or the nut to
crack)
7. Excessive vibrations (causes fracture
failure)
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 Safety
Safety Rules for the Mechanic

1. Keep your mind on your work. If you day dream or allow your personal
problems to divide your attention you become an easy mark for an accident.
2. Keep fit, and do not continue to work when you are overtired.
3. Do not wear an open jacket or shirt when coveralls should be worn. Either one
could get caught in a machine or vehicle and cause injury to the wearer.
4. Do not wear unclean coveralls. They should be free of oil, grease, or fuel to
prevent skin irritation.
5. Wear safety shoes and make certain they are in good condition.
6. Do not wear any type of jewelry.
7. Wear a hard hat when this is recommended.
8. Keep the shop clean.
Safety Rules – Explosion and Fire

1. Know where the fire alarm switches are located.

2. Know where the different fire extinguishers are located.
3. Know which type of fire extinguisher to use.
4. Keep your workshop clean and immediately discard all rubbish and
combustibles.
5. Keep all inflammable fluid and material in a safe container and whenever
possible store them in a separate area.
6. Make certain that all electrical equipment is properly connected and
grounded.
7. Do not connect the charger cables to the battery when the charger is
switched on, or an explosion may result.
8. Disconnect the battery ground cable first when removing batteries; when
reconnecting the batteries, connect the ground cable last.
Safety Rules for Lifting

1. When selecting a lifting device, a chain block, a come-along a crane, a

loader, a forklift, etc., make certain that the lifting capacity of the unit is
higher than the load to be lifted.
2. When selecting a wire rope sling, make certain the eyes are spliced
properly and that there are no wire breaks or sharp kinks.
3. When using a rope, make certain that it is properly hitched or knotted to
the object.
4. When lifting, stay clear of the load and lift it no higher than required,
then swing it free and lower it to the minimum height. Do not leave the
load suspended in the air.
5. When placing the object on the bench, jack, or floor, make certain it is
supported by wooden blocks so that it cannot tip over.
6. Never attempt to lift heavy parts without a lifting device. If you must
manually lift an object, lift it with your legs, keeping your back straight.
Safety Rules – Tools

To avoid injury to yourself or to others, always use the tool designed for
the job. (i.e., do not use a pair of pliers to tighten a nut or fittings, do not
use screwdrivers in place of chisel, do not use a file without a handle)
Safety Rules for Cleaning

1. Never use compressed air to clean your clothes, hands, or body. The
pressure could cause the cleaning fluid or dirt particles to penetrate
your skin, resulting in infection and/or blood poisoning.
2. If a job or cleaning task requires the use of gloves, use the appropriate
gloves.
 Tools and Equipment
Selection of Hand Tools

Purchase of top-grade tools. These are made from high-quality steel and manufactured to precision.
Special consideration is given to balance so that tool will feel comfortable in your hand.

Care of Tools

Your tools should always be cleaned before you return them to your toolbox. Ideally, each type of tool
should have its own tray or drawer, primarily to protect the tools but also to allow you to locate them
quickly.

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Combination, Box-End, and Open-End Wrenches
►
4 Socket Wrenches

Without a complete socket

wrench set in 3/8- and ½-in.
drives, your technician’s tool box
is not complete. Also if the work
you intend to do requires the
larger size bolts and nuts, then
you must acquire a ¾-in. drive
socket set.
Torque Wrenches

Precision Tools

To determine exact measurements of engine components

Straightedge

Feeler Gauge
 Precision Measuring Instruments
Instruments used for precision measurements in thousandths or ten-
thousandths of an inch (or in hundredths or thousandths of a millimeter)

10 Dial Indicators
 Pointers for Using Dial Indicators

1. Make certain that you have selected the best mounting attachment and
a suitable contact point.
2. Make certain that the dial indicator and base are firmly attached and
that the measuring rod is parallel to the object being measured.
3. Check that the rod, spindle, and dial needle move freely and that the
dial range is adjusted so that the full movement of the object can
be measured.
4. Always turn the dial face so that the zero line is placed over the dial
needle.
5. Take at least two readings. Move or turn the object against its stop or
end of travel to ensure accuracy of measurement.
6. Store the measuring tool in a protective case. Do not oil the spindle or
gear mechanism.
 Engine Technical Data
Engine Technical Data (Perkins):
Make Perkins
Model 2006TG1
Type Vertical, 6-Cylinder
4 Stroke Diesel, Turbocharged
Bore 130.17 mm (5.125 inches)
Stroke 152.40 mm (6.000 inches)
Capacity 12.17 liters (742.64 cubic inches)
Compression Ratio 15.9 to 1
Tappet Clearance (Engine Stop, Hot or Cold):
Inlet (All Engines) 0.254 mm (0.010 inch)
Exhaust 0.508 mm (0.020 inch)
Injection Timing 22 degrees btdc.
Cylinder Numbering from front (fan end) to rear (flywheel end)
Engine Firing Order 1, 4, 2, 6, 3, 5
Direction of rotation Anti-clockwise (viewed on flywheel)

Lubricating Oil Capacity:

Total System 29.5 liters
Lubricating Oil Pressure:
Normal at Rated Pressure 3.45 to 4.83 bars
Min. at Rated speed 2.07 bars
Protection Switch Setting 1.72 bars
Shutdown Switch Setting 1.24 bars

Lubricating Oil Temperature:

Normal 95 degrees C
Maximum 118 degrees C
Cooling System:
Radiator IMI Radiators Ltd.
Total Coolant Capacity 45.6 liters
Pressure Capacity Setting 0.69 bar
Maximum Top Rank Temp. 103 degrees C
Minimum Temperature
Entering Engine 70 degrees C
Temperature Rise
Across Engine (100%) 5.8 degrees C
Thermostat Operating Range 78 to 94 degrees C
Protection Switch Setting 100 degrees C
Shutdown Switch Setting 106 degrees C
Perkins 1300 Series
 Post test
I - Fill – In the correct word.

1._____________provides the engine with the cylindrical structure needed to confine the combustion
gasses and to act as a guide for the engine’s piston.
2._____________is the device that pumps fuel into the cylinders of a diesel engine.
3._____________part of the air intake system and serves to compress the incoming fresh air for delivery to
the cylinders for combustion.
4._____________transforms the linear motion of the piston into a rotational motion that is transmitted to
the load.
5._____________provide the top seal for the cylinder bore or sleeve and provide structure holding exhaust
(and intake valves where applicable),the fuel injector and necessary linkages.
6._____________transform the energy of the expanding gasses into a mechanical energy. It rides in the
cylinder sleeve or liner.
7._____________connects the piston to the crankshaft. Are made from drop-forged, heat-treated steel to
provide the required strength.
8._____________is located on one end of the crankshaft, has gear teeth around its perimeter that the
starter motor to engage and the engine.
9._____________is the amount of work done per unit time or the rate of doing work.
10.____________is the tendency of a force to rotate an object about an axis, fulcrum or pivot.
II - True or False

1._____ Intake stroke begins at top dead center, and as the piston moves down the intake valve opens.
The downward movement of the piston creates a vacuum in the cylinder causing a fuel
mixture to be drawn through the intake port into the combustion chamber.
2._____ Power stroke begins when fuel and air mixture is ignited, burns and expands and forces the
piston down. The valves remain closed so that all of the force is exerted to the piston.
3._____ Compression stroke begins with the piston at bottom dead center and rising up to compress the
fuel and air mixture with intake and exhaust valves closed.
4._____ Exhaust stroke begins when the piston nears the end of the power stroke and the exhaust valve
is opened.
5._____ Four stroke cycle engine is an internal combustion engine that utilizes four distinct piston strokes
to complete one operating cycle. The piston make two complete passes in the cylinder to complete
one operating cycle.
6._____ Diesel engine is an internal combustion engine in which air is compressed to a sufficiently high
temperature to ignite diesel fuel injected into the cylinders, where combustion and expansion
actuate the piston.
7._____ A power plant may be defined as a machined or assembly of equipment for the generation of
electric power.
8._____ Piston rings act as a seal between the piston and cylinder wall and also reduce friction by
minimizing the contact area between the piston and the cylinder wall.
9._____ The bore is the diameter of the cylinder liner or sleeve of an engine.
10._____The stroke is the distance that piston travels from bottom dead center (BDC) to top dead center
(TDC).
III - Explain each of the following engine support system:

1. Cooling System
2. Lubrication System
3. Fuel System
4. Air Intake System
5. Exhaust System