Heavy Duty Diesel Engine (HDD) Operation and Maintenance

Introduction

This interactive, application-driven 5-day training course will highlight the added value that Heavy-Duty Diesel Engines can offer to support engineers and technicians working in power plants, petroleum industries, and fleet management and maintenance. It will show how to safely use such engines economically, safely and environment-friendly.

The training course will emphasize the application of related recommended operation and maintenance practices advised by the most reputable manufacturers and by the relevant standards, focus on proper HD Diesel engine selection for specific jobs, retrieval and interpretation of data from HD Diesel engines manuals.

This training course will feature:

• Discussions on the benefits and applications of heavy-duty Diesel HDD engines
• The importance of correct operation and maintenance of HDD for better reliability
• The detailed description of HDD systems and characteristic performance
• Focusing on electronic control of HDD for economy and environment-friendly

Objectives

At the end of this training course, you will learn to:

• Outline the principle of operation of diesel engines
• Specify the difference between Heavy Duty Diesel Engines and normal Diesel engines
• Describe how combustion occurs in diesel engines
• Explain the reason of air charging in diesel engines
• List and explain the principle of operation of air charging systems in diesel engines
• List and explain the operation principle of various types of fuel injection systems used in HDD
• Describe the layout and components of various fuel injection systems used in HDD
• Explain how the quantity and timing of injected fuel can be controlled
• State the benefits of Diesel Electronic Control (DEC)
• List and explain the principle of operation of various HDD emission control systems
• Outline the procedure and requirements for servicing HDD
• Outline the HDD basic routine maintenance operations
• List and explain how to fix the common HDD troubles

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

This training course is suitable for a wide range of professionals but will greatly benefit:

• Vehicles fleet maintenance engineers and technicians
• Fleet maintenance supervisors
• Automotive maintenance engineers
• Automotive maintenance technicians
• Diesel power generation plants engineers and technicians

Course Outline

Day 1: Introduction to Heavy-Duty Diesel (HDD) engines

• Meaning of HDD engine: Rating – Load factor – Operation duration

• HDD engine glossary of terms

• International standards for HDD engine

• HDD engine Internal and external characteristic performance curves

• Design considerations of HDD engine

• HDD engine construction features and materials

• HDD engine Applications

Day 2: Work Cycle and Combustion in HDD Engines

• Work cycle, internal and external characteristic curves of HDD engines

• Diesel fuel (Classification – Fuel properties – Fuel tests)

• The combustion process in Diesel engines

• Compression ratio

• Combustion chambers shapes

• Direct & indirect injection methods

• Homogenous Charge Compression Ignition (HCCI)

• Air charging in heavy-duty diesel engines:

• Types (Mechanical – Turbo – Pressure wave)

• Turbocharger configuration (Combined – Two-stage - Variable geometry – Sequential)

• Turbocharger control (Pressure – Fuel compensation)

• Turbocharger performance characteristics

Day 3: Fuel Injection Systems in HDD Engines

• Types and principle of operation of fuel injection systems:

  • Cummins systems: (PT – CELECT unit injector – Accumulator – HPI – XPI)

  • Caterpillar systems: (HUEI/A – HUEI/B – Navistar – MEUI/A – MEUI/B)

  • In-line or multi-plungers systems.

  • Common rail systems

• HDD engines fuel injection systems layout and components.

• Methods of control of injected fuel quantity and timing: (Hydraulic, pneumatic, electronic)

• Diesel fuel filtration and water separation.

Day 4: Electronic Diesel Control (EDC)

• Advantages of EDC

• EDC basic layout and components (ECU – Sensors – Actuators – Layout for various types of fuel injection systems)

• Open& Closed loops and data processing

• Controlled quantities: Start – Drive mode – Idle speed – Maximum speed – Intermediate speeds – Cruise speed - ….)

• Injected fuel quantity limits

• Emission control systems;

  • Diesel Oxidation Catalyst (DOC)

  • Diesel Particulate Filter (DPF)

  • Selective catalyst reduction (SCR)

  • Urea Injection (UI)

  • Exhaust gas recirculation (EGR)

  • Closed Crankcase Ventilation (CCV)

Day 5: Operation and Maintenance of HDD Engine

• Operation Tips for HDD engine

  • Indicator lamps

  • On-Board diagnostics

  • Fuel type

  • Items to be noticed

  • Tips for efficient operation

• Maintenance of diesel engines

• Basics of mechanical maintenance

• Servicing of diesel fuel injection systems 

• Diesel engine tune-up

• Diesel engine routine maintenance operations (time-based, distance-based)

• Forms of diesel engine components failure

• Engines troubleshooting and fault rectification

• Testing of injection pumps, injectors, fuel feed pumps

• Tests for the assessment of engine condition (compression, leakage tests)

• Diesel engines troubleshooting