• By the end of this Pioneers training seminar, participants will be able 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 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

• This Pioneers Maintenance Engineering training seminar on Heavy Duty Diesel Engine (HDD) Operation and Maintenance will utilise a variety of proven adult learning techniques to ensure maximum understanding, comprehension and retention of the information presented. The daily training seminar sections will be highly interactive and participative. It also involves detailed discussions accompanying the presentation of videos showing the recent development in HDD, their correct operation, control and and maintenance, and how to troubleshoot their common troubles. Delegates are strongly encouraged to bring and analyse data from their own work domain; this adds greater relevancy to the content.

• 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
•  

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)
• Combustion Process in Diesel Engines
• Compression Ratio
• Combustion Chambers Shapes
• Direct & Indirect Injection Methods
• Homogeneous 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 speed – Cruise speed – etc.)
• 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)

• Diesel Engines Troubleshooting
  • Forms of Diesel Engine Components Failure
  • Engines Troubleshooting and Fault Rectification
  • Testing of Injection Pumps, Injectors, Fuel Feed Pumps
  • Tests for Assessment of Engine Condition (compression, leakage tests)