Diesel engines

A diesel engine is an
internal combustion
engine that uses diesel
fuel instead of gasoline.
 Diesel engines use
heat developed by
compressing air to
burn the fuel and air
mixture instead of
spark plug used in
gasoline engines.
Diesel Engine Principle:

 The Diesel cycle is a combustion process of a

reciprocating internal combustion engine.
 Ignition of Fuel takes place by the heat of
compression of air in the combustion chamber
into which fuel is injected.
 Diesel engines are used in automobiles, power
generation, diesel-electric locomotives,
ships and submarines.
Diesel engines
 Work In (Win) is done by the Piston
Compressing the Air System.
 Heat In is (Qin) is done by the
Combustion of Fuel.
 Work Out (Wout) is done by the working
fluid expanding and pushing a Piston-
Usable work
 Heat Out is done by exhausting the air.
 Net work done Qin- Qout, the net work
produced per cycle and is also called the
useful work.
 The Diesel engine has the
highest thermal efficiency (engine
efficiency) due to its very high expansion
ratio and lean burning mixture.
 In the Diesel engine, only air is initially
introduced into the combustion chamber. The
air is compressed with a compression ratio
typically between 15:1 and 23:1. This high
compression causes the temperature of the air
to rise.
 Near to the top of the compression stroke, fuel
is injected into the compressed air in the
combustion chamber.
 Diesel engines have the lowest specific
fuel consumption of any large internal
combustion engine in a single cycle-
0.16 kg/kWh
 Diesel cycle is also termed as Constant
Pressure cycle due to heat addition at
constant pressure.
Diesel Engine Power Plant
DIESEL COMPONENTS
 The main
components of a
typical diesel engine
include a cylinder, a
cylinder head, a fuel
injector, an exhaust
valve, a piston ,piston
rings, air intake ports,
a connecting rod, a
crankshaft, a flywheel
and a ring gear.
 CYLINDER BLOCK

 The cylinder block is generally a single

unit made from cast iron
 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 and crankshaft bearing
 CYLINDER

 A round hole in which the piston reciprocates.

Also known as engine bore.
FUEL INJECTOR

 A device, such as a
nozzle, used to spray
fuel into an engine
cylinder so that
combustion can occur.
 The piston transforms the energy of the
expanding gasses into mechanical energy.
 The piston rides in the cylinder liner or sleeve.
 Pistons are commonly made of aluminum or
cast alloys.
 CYLINDER LINER

A sleeve or liner between

the piston and cylinder wall
or provide an easily
replaceable surface for the
cylinder.
 PISTON

The piston transforms the energy of the

expanding gasses into mechanical energy.
The piston rides in the cylinder liner or sleeve.
Pistons are commonly made of aluminum or cast
alloys.
 PISTON RINGS
Rings used to seal the gap between a piston and
a cylinder wall.
The rings are usually made of cast iron and
coated with chrome or molybdenum
 CONNECTING ROD
A component in a
diesel engine that
changes the up and
down motion of the
crankshaft
The rods are made
from drop-forged,
heat-treated steel to
provide the required
strength.
 CRANKSHAFT
A shaft used to transfer the power of a diesel
engine to the equipment that the diesel operates.
Crankshafts are made of forged steel
 CAMSHAFT
A shaft that has cams and is rotated by gears,
belts or chains that connect it with the
crankshaft.
 CAM
A projecting part on a camshaft, shaped to move a
push rod up down.
POSH ROD

 Component that is
attached to rocker arm
and rides on a cam ;
operates the rocker arm.
 ROCKER ARM

 A center-pivoted lever that moves up and down

and can be used to operate a valve or a fuel
injector.
 FLYWHEEL
A heavy wheel connected to
the end of a diesel engine's
crankshaft that turns as the
crankshaft rotates and builds
sufficient speed to help
smooth out the operation of
the engine.
The vibration damper smoothes the vibrations caused by
the power strokes.
It has a pulley on it the run auxiliary systems.
It may contain timing marks or crankshaft timing sensors
 CYLINDER HEAD

 A detachable portion of an engine which

covers the upper end of the cylinder bores and
includes fuel injectors and exhaust valves.
Diesel Engine Valve
Diesel Engine Camshaft and Drive
Gear
 AIR BLOWER
 A device used to
supply pressurized
air to a diesel
engine.
CLASSIFICATION OF DIESEL
ENGINES
 Diesel engine are classified as follows by:
Diesel engine are classified as
follows by
 Developed power, horsepower from 3 –
40000 hp
 Number of cylinders from one up to 24
 Cycles of operation two or four-cycle
 Arrangement of the cylinders in-line or
V arrangement
 Action of the piston
Arrangement of the cylinders
 ACTION OF THE PISTON

 Single-acting,
double- acting and
opposed pistons.
 SINGLE-ACTING PISTON

 An engine with Single-acting pistons, has one

piston per cylinder.
DOUBLE- ACTING PISTON

 An engine with double-

acting pistons, also has
one piston per cylinder.
 OPPOSED PISTONS
 An engine with opposed pistons, has two pistons per
cylinder.
 BASIC CYCLES

 There are two basic

types of diesel
engines; two-stroke
cycle engine and
four-stroke cycle
engine.
FOUR-STROKE CYCLES ENGINE
 In a four-stroke
diesel engine, one
out of every four
strokes of the piston
produces power. It
contains many of
the same
components as a
two stroke-diesel
engine, but there
are differences.
FOUR-STROKE CYCLES ENGINE

ANIMATIONS\1-Basic Principles four Stroke

Diesel.flv
 TURBOCHARGER

 A turbocharger supplies the diesel cylinder

with fresh air ; it is driven by the exhaust
gases leaving the engine.
TURBOCHARGER

TURBOCHARGER
TURBOCHARGER
 INTAKE STROKE

 The intake stroke begins when the piston is it the top of

the cylinder and air intake valve is open.
 COMPRESSION STROKE

 The compression stroke starts with the upward

stroke of the piston.
 POWER STROKE

 The power stroke is the second downward

stroke.
 EXHAUST STROKE

 The exhaust stroke is the second upstroke

of the piston.
TWO-STROKE CYCLE ENGINE

 In a two- stroke
diesel engine, all of
the events in the
operating cycle take
place during the two
stroke of the piston.
TWO-STROKE CYCLE ENGINE

 TWO-STROKE CYCLE ENGINE

TWO-STROKE CYCLE ENGINE
TWO-STROKE CYCLE ENGINE

 One stroke down, one stroke up,

resulting in one turn of the crankshaft.
 As opposed to the four stroke where the
piston performs four strokes in two crank
rotations in order to achieve one cycle

 The power stroke occurs at every down

stroke, which would lead us to believe
the two stroke to be twice as efficient
TWO-STROKE CYCLE ENGINE

 On large plants, the two stroke is about

1.8:1 more powerful than a four stroke
engine of similar weight.
 On smaller application, I,e. a bus, the
power/pound gap closes, and the
effective horsepower of similar sized
engines will be about the same for the
two and four stroke.
 AIR INTAKE PORTS
Are holes in the bottom
of the cylinder wall .They
allow air to enter the
cylinder so that
compression and
combustion can occur.
 EXHAUST VALVES
Valves that open to
allow exhaust gases
to escape from the
cylinder after
combustion occurs.
DIESEL ENGINE SUPPORT
SYSTEM
 FUEL SYSTEM
 The purpose of the fuel system is to deliver the
proper amount of clean fuel to the cylinder of the
system must also provide a safe place to store
the fuel and a safe method of transferring it from
storage to the cylinder.
FUEL SYSTEM
The Major Parts of a diesel fuel
system are the:
1- Fuel Tank, which stores the fuel
2- Fuel Transfer Pump, which moves the fuel from
the tank to the fuel nozzles

3- Fuel Filters, which help keep the fuel clean

4- Injection Pump, which times and meters the fuel
delivered under pressure to the fuel nozzles
5- Injection Nozzles, which atomize and inject the
fuel into the cylinders
 INTAKE SYSTEM

 The function of the intake system is to

supply the proper amount of air, at the
proper temperature for good combustion.
Oil bath Air Filter
 Oil bath Air Filter

 Air intake systems vary greatly from

vendor to vendor but are usually one of
two types, wet or dry
 In a wet filter intake system the air is
sucked or bubbled through a housing that
holds a bath of oil such that the dirt in the air is
removed by the oil in the filter
 Turbocharging

An engine occurs when the engine is own

exhaust gasses are forced through a
turbine (impeller), which rotates and is
connected to a second impeller located
in the fresh air.
Exhaust gas turbocharged engine

The compressed air serves two functions:

1- First, it increases the engines available power
by increasing the maximum amount of air that is
forced into each cylinder.
2- Second function is to increase intake pressure
 Supercharging

An engine performs the same function as

turbocharging an engine.
The difference in source of power used to drive
the device that compresses the incoming fresh air
EXHAUST SYSTEM
The exhaust system performs three
functions:
1- Removing heat from the engine
2- Muffling engine noises
3- Carrying the burned gases from the
cylinder ands exhausting them into the
atmosphere.
The basic parts of the exhaust
system are:
 The exhaust valves
 The exhaust manifold collects the burned
exhaust gases and carries them away from the
cylinder during the exhaust stroke.
 The muffler muffles or reduces the sounds of
the engine during the exhaust period.
LUBRICATION SYSTEM
The Lubrication system has five
functions:

1- Reduces friction between the moving parts

2- Absorbs and dissipates heat
3- Seals the piston rings and cylinder walls
4- Cleans and flushes moving parts
COOLING SYSTEM
The Cooling System Performs Two
Functions:

1- Prevents the engine from overheating

2- Regulates the temperature of the
engine
 Valve Timing

Is the adjustment of the valves to open and

close at the proper time for smooth and
efficient operation of the engine.
 Governing System
The governing system keeps the engine
performing at a constant speed by regulating
the amount of fuel supplied to the combustion
chambers.
The mechanism that operates the governor
may be mechanical, hydraulic, or electric.
A governor is essentially a speed-sensitive
device, designed to maintain a constant
engine speed regardless of load variation.
Governing System
Routine Diesel Engine Inspection

 Many of the routine inspection checks

are the same to those conducted during
a pre-start inspection.
1- Leaks
2- Proper oil level (lube oil system)
3- Proper water level (cooling water sys)
4- Starting System
5- Fuel System
 Proper oil level

 The proper oil level is checked while the diesel

engine is not operating and make sure that
there is enough oil for lubrication.
 Improper oil levels can lead to problems:
1- Too much oil can result in foamy oil or oil
leaks.
2- Low oil levels can cause the oil to lose its
cleaning and lubricating properties.
3- If the oil is completely gone, the engine will
probably sizes.
 Proper oil level

 Dipstick, is used to determine the oil level.

 Most dipsticks have several oil level bands
marked off.
 Common bands include:
High Full Add Low
Proper oil level
Cooling system maintenance
 Water level is important because the
cooling system requires a certain amount
of water to cool the diesel engine
properly.
1- a sight glass on the mixing tank indicates
water level and the amount of cooling water
available to the diesel engine..
2- The cooling system is usually checked by
reading a water jacket temperature gauge
Starting system maintenance
If a diesel engine has an electric starting
system, the batteries are checked
1. The electrolyte level is checked & distilled
water must be added to raise the level.

If a diesel engine has an air starting system, the

air pressure can be checked by reading air
pressure gauges.
1. If air pressure is low, the compressed air must
be recharged
 Fuel system maintenance
 Fuel system requires periodic
maintenance to ensure efficient engine
operation.
1- A small amount of fuel is drained periodically
from storage tank.
2- The filters need to be cleaned or replaced
periodically, depending on the design of the
engine.
3- Typical injector maintenance includes
checking the injector timing
 Lube oil system

 Some maintenance job include:

1- Checking oil level
2- Adding or changing oil
3- Cleaning out sludge buildup
4- Oil filters require periodic cleaning or
replacement
Serving the Diesel Engine

 1- Cylinder Blocks
The block should be cleaned and thoroughly
checked for cracks by the following methods:
1- By sealing off all passages and applying air
pressure while the block is submerged in water.
2- A magnetic crack detector
3- Dye penetrates can be used to locate porous
spots or cracks.
Serving the Diesel Engine

 2- Cylinder Head
Cylinder head is checked for warpage using a
straight edge and feeler gauge
Serving the Diesel Engine
 2- Cylinder Head

Use proper
tightening
sequence for
cylinder head
bolts
Serving the Diesel Engine

 3- Valves
Check the valves for the following damages
- Distortion
- Deposits
- Burning marks
- Erosion of valve stem
- Valve crack
- Broken valve stem
- Worn valve guide
Serving the Diesel Engine

 4- Valve Seats
Valve seat inserts are used for high speed
engines
- Check for wear and resurface or replace
Serving the Diesel Engine

 5- Camshaft
Camshaft journals should be checked for signs
of wear or out of round condition using outside
micrometer

 6- Pushrods
Pushrods should be examined to see if they are
bent. Any bent rod should be replaced.
Serving the Diesel Engine
 7- Valve Springs
Check the valve spring ends for wear
If the tension loss exceeds 10 percent, the spring
should be replaced
 8- Rocker Arms
Rocker arms and springs should be removed in a
definite sequence and replaced in the reverse
order.
The point at which the rocker arm contacts, the
valve stem tip should be inspected for wear
Serving the Diesel Engine

 9- Cylinder Liners
Most high speed,
high performance
diesel engines use
wet liners
Servicing the Diesel Engine

 Checking the cylinder for roundness & taper

 Checking Piston Pins for roundness
 Checking the Piston for wear
 Checking piston ring to groove clearance
 Checking the piston ring for wear
 Checking Connecting Rod and Crankshaft
Bearings for healthiness & clearance
 Inspecting the Crankshaft for wear & fatigue
cracks
Servicing the Diesel Engine

The three methods of locating the

microscopic fatigue cracks are:
 1. Magnetic Particle Method
 2. Fluorescent Magnetic Particle
Method
 3. Fluorescent Penetrant Method
Servicing the Diesel Engine

Precaution for bearings

Never replace only the upper or lower shell. If

new bearing shells are needed, replace both
halves

Do not reverse the positions of the bearing

shells.
Servicing the Diesel Engine

Checking cylinder bore

Servicing the Diesel Engine

Checking piston wear

Servicing the Diesel Engine

Checking piston ring to groove clearance