basic disel engine technology
TRANSCRIPT
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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
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INTRODUCTION
• THE DIESEL ENGINE IS USED AS A SOURCE OF POWER FOR THOUSANDS OF APPLICATIONS.
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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.
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WHO DEVELOPED THE FIRST MASS PRODUCED
INJECTION PUMP?
• ROBERT BOSCH IN 1927
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USES OF DIESEL ENGINES
TODAY, DIESEL ENGINES ARE USED TO PROVIDE POWER IN A VARIETY OF APPLICATIONS IN
MANY INDUSTRIES
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THERE ARE SIX MAJOR USES OF DIESEL ENGINES
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AGRICULTURE/FARM
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TRANSPORTATION
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CONSTRUCTION
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FORESTRY
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MARINE
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ELECTRICAL GENERATION PLANTS
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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
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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
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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
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INTERNAL COMBUSTION ENGINE:
AN ENGINE THAT PRODUCES POWER BY BURNING FUEL INSIDE A COMBUSTION CHAMBER WITHIN THE ENGINE
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TWO TYPES OF INTERNAL COMBUSTION ENGINES
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SPARK IGNITION ENGINE
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COMPRESSION IGNITION ENGINE
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TRUE OR FALSE: SPARK PLUGS SHOULD BE CHANGED MORE OFTEN IN DIESEL ENGINES THAN IN GASOLINE ENGINES?
FALSE
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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.
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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.
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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
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TRUE OR FALSE: DIESEL ENGINES USE GREATER COMPRESSION RATIOS
THAN GASOLINE ENGINES?
TRUE
DIESEL ENGINES – 16:1 TO 22:1
GASOLINE ENGINES – 8:1
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TRUE OR FALSE: DIESEL ENGINES REQUIRE MORE
AIR THAN GASOLINE ENGINES
TRUE
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TRUE OR FALSE: DIESEL ENGINES HAVE NO IGNITION SYSTEM
COMPONENTS
TRUE
NO SPARK PLUGS, COIL, MAGNETO, DISTRIBUTOR, OR
WIRING
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TRUE OR FALSE: DIESEL ENGINES, LIKE GASOLINE ENGINES, DRAW IN FUEL AND AIR ON THE INTAKE
STROKE?
FALSE
ONLY AIR IN A DIESEL ENGINE
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WHAT IS THE PURPOSE OF A TURBOCHARGER ON A
DIESEL ENGINE?
TO INCREASE THE AIR INTAKE INTO THE CYLINDERS
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TRUE OR FALSE: DIESEL ENGINES REQUIRE A HIGH
PRESSURE PUMP TO INJECT THE FUEL INTO THE
COMPRESSED AIR IN THE CYLINDER?
TRUE
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WHAT IS THE NAME OF THE ENGINE PART THAT SPRAYS FUEL INTO THE CYLINDER
OF A DIESEL ENGINE?
INJECTOR NOZZEL
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WHAT TYPE MATERIAL ARE FUEL LINES MADE OF IN A
DIESEL ENGINE? WHY?
STEEL
PRESSURES FROM 5,000 TO 20,000 PSI ARE INVOLVED
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TRUE OR FALSE: GASOLINE IS LESS VOLATILE THAN
DIESEL FUELS
FALSE
GASOLINE EVAPORATES READILY AND IS VERY
EXPLOSIVE
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TRUE OR FALSE: GASOLINE ENGINES ARE HEAVIER
THAN DIESEL ENGINES OF THE SAME HORSEPOWER?
FALSE
HIGH DIESEL CYLINDER PRESSURES REQUIRE HEAVIER
MATERIALS
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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
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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
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HOW AN ENGINE WORKS
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WHAT ARE THE FIVE BASIC PARTS OF ANY ENGINE?
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NAME THE TWO BASIC TYPES OF ENGINES
• FOUR STROKE CYCLE ENGINE
• TWO STROKE CYCLE ENGINE
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WHAT SEQUENCE OF EVENTS MAKE UP A
CYCLE?• INTAKE
• COMPRESSION
• POWER
• EXHAUST
• WHAT IS A STROKE?
• ONE MOVEMENT OF THE PISTON
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FOUR STROKES OF AN ENGINE
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HOW MANY TIMES DOES THE CRANKSHAFT
REVOLVE DURING A CYCLE IN A FOUR STROKE CYCLE
ENGINE?
TWO
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WHAT ARE THE MAJOR DIFFERENCES IN EACH
STROKE WHEN COMPARING A DIESEL
ENGINE WITH A GASOLINE ENGINE?
• INTAKE – AIR VS. AIR/FUEL MIXTURE
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DIFFERENCES CONTINUED
• COMPRESSION STROKE– COMPRESSION RATIO
• POWER STROKE– SPARK PLUG VS. HEAT OF
COMPRESSION
• EXHAUST STROKE– SAME FOR BOTH
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TWO-STROKE CYCLE ENGINES
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HOW MANY STROKES OF THE PISTON ARE REQUIRED
FOR A CYCLE TO BE COMPLETED IN A TWO
STROKE CYCLE ENGINE?
TWO
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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 AIR-FUEL MIXTURE IS DRAWN INTO THE CRANKCASE. (INTAKE STROKE)
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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
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TWO-STROKE CYCLE GASOLINE ENGINES
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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
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TWO-STROKE DIESEL ENGINE
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THE DIESEL AIR SYSTEM
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BASIC PARTS OF THE DIESEL AIR SYSTEM
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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
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HOW IMPORTANT IS KEEPING AIR FILTERS
CLEAN?
VERY IMPORTANT
A DIESEL ENGINE USES 12-15,000 GALLONS OF AIR TO
EACH GALLON OF FUEL
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NAME THREE TYPES OF AIR CLEANERS
• OIL-BATH TYPE CLEANER
• PRE-CLEANER
• DRY-TYPE AIR CLEANER
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THE DIESEL FUEL SYSTEM
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WHAT ARE THE FIVE BASIC PARTS OF A DIESEL FUEL
SYSTEM?
• INJECTION NOZZLES
• INJECTION PUMP
• FILTERS
• TRANSFER PUMP
• FUEL TANK
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THE DIESEL FUEL SYSTEM
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DIESEL FUEL, LIKE GASOLINE IS A PRODUCT OF
THE DISTILLATION OF-
CRUDE OIL
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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
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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
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THE DIESEL COOLING SYSTEM
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WHAT ARE TWO PRIMARY TYPES OF COOLING
SYSTEMS FOR DIESEL ENGINES?
LIQUID COOLING
AIR-COOLING
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LIQUID COOLING ENGINE
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AIR-COOLED DIESEL ENGINE
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WHAT IS THE IDEAL OPERATING TEMPERATURE
FOR MOST DIESEL ENGINES?
165 – 185 DEGREES F.
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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
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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
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WHAT ARE SOME ADVANTAGES OF AIR-
COOLED 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
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WHAT ARE SOME DISADVANTAGES TO AIR-
COOLED ENGINES?
• LENGTH OF THE ENGINE
• LESS TEMPERATURE CONTROL
• HIGHER OPERATING TEMPERATURES
• GREATER NOISE
• MORE FREQUENT CLEANING
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THE DIESEL LUBRICATION SYSTEM
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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
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TRUE OR FALSE: MOST OF THE LUBRICANTS USED IN
DIESEL ENGINES COME FROM PETROLEUM?
TRUE
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WHAT ARE LUBRICANTS DERIVED FROM ANIMAL OR VEGETABLE OILS CALLED?
SYNTHETIC OILS
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WHAT TWO CHARACTERISTICS ARE
MOST IMPORTANT IN CHOOSING PROPER OIL?
VISCOSITY
SERVICE CLASSIFICATION
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WHAT IS VISCOSITY?
• A MEASURE OF A LIQUID’S RESISTANCE TO FLOW
• HIGHER TEMPERATURE – DECREASE IN VISCOSITY
• SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) DEVELOPED NUMBERING SYSTEM
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WHAT ARE THE VISCOSITY GRADES?
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API ENGINE OIL SERVICE CATEGORIES
AMERICAN PETROLEUM INSTITUTE
TABLE 1: (HANDOUT)
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WHAT ARE THE THREE MOST COMMON OIL
ADDITIVES?• OXIDATION INHIBITORS
• CORROSION AND RUST INHIBITORS
• DETERGENT DISPERSANTS
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HOW DO DETERGENT ADDITIVES WORK?
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PRINCIPLES OF FLUID HYDRAULICS
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HYDRAULIC SYSTEMS ON A TRACTOR
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WHAT IS PASCAL’S LAW OF HYDRAULICS?
• PRESSURE ON A LIQUID IN A CONTAINER IS TRANSFERRED EQUALLY TO ALL SURFACES
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PASCAL’S LAW
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PRESSURE TRANSFER IN HYDRAULIC BRAKES
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CHANGING THE PRESSURE IN A HYDRAULIC SYSTEM