By the end of this course, delegates will be able to:

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

• Introduction to Heavy Duty Diesel Engines (HDD)

  • Meaning of HDD: Rating, Load factor, Operation duration
  • HDD glossary of terms
  • Standards for HDD
  • Design consideration of HDD
  • HDD construction features and materials
  • HDD Characteristic performance
  • HDD Applications

  Work Cycle and Combustion in Diesel Engines

  • Work cycle
  • Diesel fuel (Classification, Fuel properties, Fuel tests)
  • Combustion in Diesel engines
  • Compression ratio
  • Combustion chambers
  • Direct & indirect injection
  • 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

  Fuel Injection Systems in HDD

  • 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 systems
  • Common rail systems
  • HDD fuel injection systems layout and components
  • Control of injected fuel quantity and timing (hydraulic, pneumatic, electronic)

  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)

  Operation and Maintenance of HDD

  • Operation Tips for HDD
  • 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)