1. 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

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

3. 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.

4. WHO DEVELOPED THE FIRST MASS PRODUCED INJECTION PUMP? ROBERT BOSCH IN 1927

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

6. THERE ARE SIX MAJOR USES OF DIESEL ENGINES

7. AGRICULTURE/FARM

8. TRANSPORTATION

9. CONSTRUCTION

10. FORESTRY

11. MARINE

12. ELECTRICAL GENERATION PLANTS

13. 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

14. 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

15. 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

16. INTERNAL COMBUSTION ENGINE: AN ENGINE THAT PRODUCES POWER BY BURNING FUEL INSIDE A COMBUSTION CHAMBER WITHIN THE ENGINE

17. TWO TYPES OF INTERNAL COMBUSTION ENGINES

18. SPARK IGNITION ENGINE

19. COMPRESSION IGNITION ENGINE

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

21. 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.

22. 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.

23. 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

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

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

26. TRUE OR FALSE: DIESEL ENGINES HAVE NO IGNITION SYSTEM COMPONENTS TRUE NO SPARK PLUGS, COIL, MAGNETO, DISTRIBUTOR, OR WIRING

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

28. WHAT IS THE PURPOSE OF A TURBOCHARGER ON A DIESEL ENGINE? TO INCREASE THE AIR INTAKE INTO THE CYLINDERS

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

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

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

32. TRUE OR FALSE: GASOLINE IS LESS VOLATILE THAN DIESEL FUELS FALSE GASOLINE EVAPORATES READILY AND IS VERY EXPLOSIVE

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

34. 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

35. 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

36. HOW AN ENGINE WORKS

37. WHAT ARE THE FIVE BASIC PARTS OF ANY ENGINE?

38. NAME THE TWO BASIC TYPES OF ENGINES FOUR STROKE CYCLE ENGINE TWO STROKE CYCLE ENGINE

39. WHAT SEQUENCE OF EVENTS MAKE UP A CYCLE? INTAKE COMPRESSION POWER EXHAUST WHAT IS A STROKE? ONE MOVEMENT OF THE PISTON

40. FOUR STROKES OF AN ENGINE

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

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

43. DIFFERENCES CONTINUED COMPRESSION STROKE –COMPRESSION RATIO POWER STROKE –SPARK PLUG VS. HEAT OF COMPRESSION EXHAUST STROKE –SAME FOR BOTH

44. TWO-STROKE CYCLE ENGINES

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

46. 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)

47. 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

48. TWO-STROKE CYCLE GASOLINE ENGINES

49. 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

50. TWO-STROKE DIESEL ENGINE

51. THE DIESEL AIR SYSTEM

52. BASIC PARTS OF THE DIESEL AIR SYSTEM

53. 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

54. HOW IMPORTANT IS KEEPING AIR FILTERS CLEAN? VERY IMPORTANT A DIESEL ENGINE USES 12- 15,000 GALLONS OF AIR TO EACH GALLON OF FUEL

55. NAME THREE TYPES OF AIR CLEANERS OIL-BATH TYPE CLEANER PRE-CLEANER DRY-TYPE AIR CLEANER

56. THE DIESEL FUEL SYSTEM

57. WHAT ARE THE FIVE BASIC PARTS OF A DIESEL FUEL SYSTEM? INJECTION NOZZLES INJECTION PUMP FILTERS TRANSFER PUMP FUEL TANK

58. THE DIESEL FUEL SYSTEM

59. DIESEL FUEL, LIKE GASOLINE IS A PRODUCT OF THE DISTILLATION OF- CRUDE OIL

60. 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

61. 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

62. THE DIESEL COOLING SYSTEM

63. WHAT ARE TWO PRIMARY TYPES OF COOLING SYSTEMS FOR DIESEL ENGINES? LIQUID COOLING AIR-COOLING

64. LIQUID COOLING ENGINE

65. AIR-COOLED DIESEL ENGINE

66. WHAT IS THE IDEAL OPERATING TEMPERATURE FOR MOST DIESEL ENGINES? 165 – 185 DEGREES F.

67. 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

68. 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

69. 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

70. WHAT ARE SOME DISADVANTAGES TO AIR- COOLED ENGINES? LENGTH OF THE ENGINE LESS TEMPERATURE CONTROL HIGHER OPERATING TEMPERATURES GREATER NOISE MORE FREQUENT CLEANING

71. THE DIESEL LUBRICATION SYSTEM

72. 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

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

74. WHAT ARE LUBRICANTS DERIVED FROM ANIMAL OR VEGETABLE OILS CALLED? SYNTHETIC OILS

75. WHAT TWO CHARACTERISTICS ARE MOST IMPORTANT IN CHOOSING PROPER OIL? VISCOSITY SERVICE CLASSIFICATION

76. 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

77. WHAT ARE THE VISCOSITY GRADES?

78. API ENGINE OIL SERVICE CATEGORIES AMERICAN PETROLEUM INSTITUTE TABLE 1: (HANDOUT)

79. WHAT ARE THE THREE MOST COMMON OIL ADDITIVES? OXIDATION INHIBITORS CORROSION AND RUST INHIBITORS DETERGENT DISPERSANTS

80. HOW DO DETERGENT ADDITIVES WORK?

81. PRINCIPLES OF FLUID HYDRAULICS

82. HYDRAULIC SYSTEMS ON A TRACTOR

83. WHAT IS PASCAL’S LAW OF HYDRAULICS? PRESSURE ON A LIQUID IN A CONTAINER IS TRANSFERRED EQUALLY TO ALL SURFACES

84. PASCAL’S LAW

85. PRESSURE TRANSFER IN HYDRAULIC BRAKES

86. CHANGING THE PRESSURE IN A HYDRAULIC SYSTEM