Heavy Duty Diesel Engine (HDD) Operation and Maintenance

What are the Goals?

By the end of this training course, 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

Who is this Training Course for?

This training course is suitable to 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

Daily Agenda

Day One: 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 Two: 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
• 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 Three: 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 Four: 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 Five: 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 trouble shooting
• Forms of diesel engine components failure
• Engines trouble shooting and fault rectification
• Testing of injection pumps, injectors, fuel feed pumps
• Tests for assessment of engine condition (compression, leakage tests)