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Copyright © 2018 by McGraw-Hill Education. All rights reserved.
Except as permitted under the United States Copyright Act of 1976,
no part of this publication may be reproduced or distributed in any
form or by any means, or stored in a database or retrieval system,
without the prior written permission of the publisher.
ISBN: 978-1-26-011644-1
MHID: 1-26-011644-1
The material in this eBook also appears in the print version of this
title: ISBN: 978-1-26-011643-4,
MHID: 1-26-011643-3.
TERMS OF USE
1 Rudolf Diesel
2 Diesel basics
Compression ratio
Induction
Ignition and combustion
Two- and four-stroke-cycle
Power and torque
Fuel efficiency
Weight
Durability
Conventional fuels
3 Engine installation
Trucks and other motor vehicles
Stationary engines
Marine engines
4 Basic troubleshooting
Malfunctions
Tests
Air inlet system
Glow plugs
Exhaust backpressure
Engine mechanical
8 Engine mechanics
Scope of work
Diagnosis
Rigging
Special considerations
Cleaning
Teardown
Lubrication system
Filters
Block casting
Pistons
Connecting rods
Crankshafts
Camshafts and related parts
Harmonic balancers
Crankshaft bearings
Assembly—major components
9 Air systems
Air cleaners
Turbochargers
Compressor map
VGTs
Aftercoolers
Troubleshooting
10 Electrical fundamentals
Electrons
Circuits
Electrical measurements
Ohm’s law
Direct and alternating current
Magnetism
Electromagnets
Voltage sources
Generator principles
Direct-current motors
Storage batteries
Switches
Diodes
12 Cooling systems
Air cooling
Liquid cooling
13 Greener diesels
Diesel emissions
Emissions controls
Diesel debacle
Biodiesel
Straight vegetable oil
Natural gas
Compressed natural gas (CNG)
LNG
Renewable natural gas (RNG)
Index
Foreword
In a world of throwaway consumer products, diesel engines are an
exception. Industrial engines, those built by established
manufacturers such as Caterpillar, Cummins, Deutz and Daimler run
for decades with only occasional repairs. Several of these have been
used in American pickup trucks, although car makers prefer in-house
power. The Ford-designed 6.7L Power Stroke follows industrial
practice and, as a result, is in process of receiving a B10 rating,
which means that 90% of them should run for 500,000 miles
without having the cylinder heads or oil pan disturbed. Smaller
engines intended for commercial use have something of the same
durability.
The subjects covered include:
• Diesel operation (what distinguishes diesel engines from spark-
ignition engines)
• How to install stationary and marine engines
• Basic troubleshooting
• Cylinder head and engine rebuilding
• Mechanical fuel systems
• Electricity for those who are new to the subject
• Electronic fuel systems
• Turbochargers and associated air systems
• Starting and generating systems
• Air and liquid cooling systems
• Emission controls
This book is intended to supplement factory shop manuals, most
of which are written cook-book style with little or nothing by way of
explanation. Cook books are okay, if the only engine you will ever
work on is the one you have a manual for. My aim in writing was to
combine “how-to” instructions with theory. Understanding is the
best, most essential tool a mechanic can have.
The more you know the easier the work becomes and the less
money you waste on throwing parts at the problem. And should the
job appear too demanding, an understanding of what’s involved and
a familiarity of the vocabulary puts shop mechanics on notice that
they are dealing with a knowledgeable customer who will not be
taken advantage of.
That said, diesel engines are simple mechanical devices, differing
from gasoline engines only in the precision of their parts. Most
repairs can be accomplished with no more than a good set of hand
tools. Things get complicated when dealing with fuel systems.
Special tools are needed together with an appreciation of how these
systems work. You must also be aware of the hazards presented by
high-pressure fuel and the lethal voltages that are sometimes
present. But the rewards of working on these beautiful engines are
real. Not only will you save money—shop labor charges can top $150
an hour—you will have the satisfaction that comes with
accomplishment.
Paul Dempsey
Houston, TX
1
CHAPTER
Rudolf Diesel
Rudolf Diesel was born of German parentage in Paris in 1858. His
father was a self-employed leather worker who, by all accounts,
managed to provide only a meager income for his wife and three
children. Their stay in the City of Light was punctuated by frequent
moves from one shabby flat to another. Upon the outbreak of the
Franco-Prussian War in 1870, the family became political
undesirables and was forced to emigrate to England. Work was
almost impossible to find, and in desperation, Rudolf’s parents sent
the boy to Augsburg to live with an uncle. There he was enrolled in
school.
Diesel’s natural bent was for mathematics and mechanics. He
graduated as the head of his class, and on the basis of his teachers’
recommendations and a personal interview by the Bavarian director
of education, he received a scholarship to the prestigious
Polytechnikum in Munich.
His professor of theoretical engineering was the renowned Carl
von Linde, who invented the ammonia refrigeration machine and
devised the first practical method of liquefying air. Linde was an
authority on thermodynamics and high-compression phenomena.
During one of his lectures he remarked that the steam engine had a
thermal efficiency of 6–10%; that is, one-tenth or less of the heat
energy of its fuel was used to turn the crankshaft, and the rest was
wasted. Diesel made special note of this fact. In 1879 he asked
himself whether heat could not be directly converted into mechanical
energy instead of first passing through a working fluid such as
steam.
On the final examination at the Polytechnikum, Diesel achieved
the highest honors yet attained at the school. Professor Linde
arranged a position for the young diploma engineer in Paris, where,
in few months, he was promoted to general manager of the city’s
first ice-making plant. Soon he took charge of distribution of Linde
machines over southern Europe.
By the time he was thirty, Diesel had married, fathered three
children, and was recognized throughout the European scientific
community as one of the most gifted engineers of the period. He
presented a paper at the Universal Exposition held in Paris in 1889—
the only German so honored. When he received the first of several
citations of merit from German universities, he announced wryly in
his acceptance speech: “I am an iceman. . .”
The basis of his acclaim was his preeminence in the new
technology of refrigeration, his several patents, and a certain
indefinable air about the young man that marked him as
extraordinary. He had a shy, self-deprecating humor and an absolute
passion for factuality. Diesel could be abrupt when faced with
incompetence and was described by relatives as “proud.” At the
same time, he was sympathetic to his workers and made friends
among them. It was not unusual for Diesel to wear the blue cotton
twill that was the symbol of manual labor in the machine trades.
He had been granted several patents for a method of producing
clear ice, which, because it looked like natural ice, was much in
demand by the upper classes. Professor Linde did not approve of
such frivolity, and Diesel turned to more serious concerns. He spent
several years in Paris, working on an ammonia engine, but was
defeated by the corrosive nature of this gas at pressure and high
temperatures.
The theoretical basis of this research was a paper published by
N.L.S. Carnot in 1824. Carnot set himself to the problem of
determining how much work could be accomplished by a heat
engine employing repeatable cycles. He conceived the engine drawn
in Figure 1-1. Body 1 is a boiler or other heat source that raises the
temperature of the working fluid A. The piston is at position C in the
drawing. As the air in the cylinder is heated, it expands in
correspondence to Boyle’s law. If we assume a frictionless engine,
the temperature of the air does not rise. Instead, expansion will take
place, driving the piston to D. Then A is removed, and momentum
takes the piston to E. The air column is now placed into contact with
2, which can be a radiator or cooling tank. At this point the
temperature of the air falls until it exactly matches cold surface 2.
The piston falls because cooled air occupies less volume than heated
air. Note, however, that the temperature of the air does not change.
The increase in compression as the piston falls restores heat to the
air to hold its temperature constant. At B cold body 2 is removed,
and the piston falls to A. During this phase the air gains temperature
until it is equal to the heat source 1. The piston climbs back into the
cylinder.
Diesel basics
At first glance, a diesel engine looks like a heavy-duty gasoline
engine, minus spark plugs and ignition wiring (Figure 2-1). Some
manufacturers build compression ignition (CI) and spark ignition (SI)
versions of the same engine. Caterpillar G3500 and G3600 SI
natural-gas fueled engines are built on diesel frames and use the
same blocks, crankshafts, heads, liners, and connecting rods.
2-1 The Yanmar 1GM10, shown with a marine transmission, provides auxiliary
power for small sailboats. The 19.4 CID unit develops 9 hp and forms the basic
module for two- and three-cylinder versions.
Compression ratio
When air is compressed, collisions between molecules produce
heat that ignites the diesel fuel. The compression ratio (c/r) is the
measure of how much the air is compressed (Figure 2-2).
2-2 Compression ratio is a simple concept, but one that mathematics and pictures
express better than words.
Induction
Most SI engines mix air and fuel in the intake manifold by way of
one or more low-pressure (50-psi or so) injectors. A throttle valve
regulates the amount of air admitted, which is only slightly in excess
of the air needed for combustion. As the throttle opens, the injectors
remain open longer to increase fuel delivery. For a gasoline engine,
the optimum mixture is roughly 15 parts air to 1 part fuel. The air-
fuel mixture then passes into the cylinder for compression and
ignition.
In a CI engine, air undergoes compression before fuel is admitted.
Injectors open late during the compression stroke as the piston
approaches tdc. Compressing air, rather than a mix of air and fuel,
improves the thermal efficiency of diesel engines. To understand
why would require a course in thermodynamics; suffice to say that
air contains more latent heat than does a mixture of air and
vaporized fuel.
Forcing fuel into a column of highly compressed air requires high
injection pressures. These pressures range from about 6000 psi for
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value. veritable and inestimable rallying-points of which
our History should be little more than a reasoned catalogue,
connected by summary of less important phenomena. Referring duly
to it, we find ourselves at the standpoint of a man who has really
wide knowledge, and who, when his general assumptions do not
interfere, has a real critical grasp. But the chief of these assumptions
is not merely that the vernaculars have not attained equality with
the classics—this, allowing for inevitable defects of perspective and
other things, would not be fatal—but that they cannot attain such
equality, much less any superiority. The point of view—to us plain
common-sense—that if Sannazar and others wrote in Latin about
Christian subjects, they should use Christian Latin, seems to Giraldus
the point of view of a kind of maniac. Without the details and
developments of Vida, he is apparently in exact accordance with that
excellent Bishop. Cicero and Virgil, not to mention others, have
achieved for literature a medium which cannot be improved upon,
and all those who adopt any other are, if not exactly wicked,
hopelessly deceived and deluded. This is the major premiss for
practically every syllogism of our critic. Where it does not come in—
between vernacular and vernacular, between Latin and Latin of the
classical type—he can judge just judgment. Where it comes in, the
more perfect his logic, the more inevitably vitiated is his conclusion.
19. Since I wrote this, an obliging correspondent, Mr P.G. Thomas
of Liverpool, has suggested actual quotation of a passage of Bruni’s
on prose style in his De Studiis et Literis. If I do not give this it is,
first, because indulgence in quotation here is as the letting out of
waters; and, secondly, because the tractate is translated in Mr W. H.
Woodward’s well-known and excellent book on Vittorino da Feltre
(Cambridge, 1897), where other matter of interest to us will also be
found.
23. Or, “a pretty old woman that of a girl,” the position of the
epithet between the two nouns being ambiguous.
28.
32. I have used the Opera, 2 vols., Lugduni, 1531, 8vo. The
passages cited will be found at ii. 14 sq.
34. This, which is very amusing, opens the ed. of Berni’s Opere in
the Sonzogno collection (Milan, 1888).
35. For the Latin I use Pope’s Selecta Poemata Italorum (2 vols.,
London, 1740), i. 131-189, and the anonymous Poemata Selecta
Italorum (Oxford, 1808), 207-266; for Pitt’s Englishing, Chalmers’s
Poets, xix. 633-651. The original is Rome, 1527, 4to.
39.
41. Cf. Poet., ii. 162. Semper nutu rationis eant res.
49. But most of this latter part had been written in 1548-49, and
all must have been before 1550, when Trissino died. Even this,
however, leaves a twenty years’ gap, which Trissino attributes to the
composition of his great (or at any rate large) poem on the Goths.
56. The discussion occupies nearly four quarto pages, ii. 127-130.
Trissino, of course, does not neglect Quintilian’s handling of the
subject in Inst., vi. 3, and he quotes modern as well as ancient
examples.
57. Dolce had translated the Ars Poetica of Horace into Italian the
year before.
La catena
Di Dante non e leggiadra, se non
Fa punto con la terza sua rima.
67. Delia Lingua Toscana. The four Books of this are rather empty
things. The first goes to show that Philosophy is necessary to the
perfect orator; the second that it is equally necessary to the perfect
poet; the third that Rhetoric is useful for writing and speaking with
eloquence; while the fourth discusses oratorical diction and its
ornaments. Few of the books cited here better justify De Quincey’s
too sweeping ban.
69. Venice, 1562. It is very short and very general. There are
some literary touches in his Lettere (2 vols., Venice, 1562), especially
a correspondence with Cinthio on the Amadigi.
71. His volume appears to be almost introuvable for sale; but the
British Museum has no less than three copies. I wish it would give
me one of them.
79. Perhaps, if this be true, the Irish got it from their French
friends of the seventeenth century, among whom, according to the
Ménagiana, poeta regius was the correct title of the King’s Fool.
89. For the neat little edition of this by Karl Wotke (Berlin, 1894)
one must be thankful, and also for the careful bibliographical
introduction on recent work concerning Renaissance Literature.
90. Op. cit., pp. 62, 63, 70. Giraldus also knows Colet, Grocyn,
and others of the set.
94. He allows him (p. 18, ed. cit.) “sweetness and wit,” but says
nescio quare as to the contemporary praise of the Hermaphroditus,
and adds plumply, nec poeta bonus nec bonus orator. The simple
fact is that, if the subjects of this notorious book were decent,
nobody would see anything but quite ordinary merit in their
treatment.
“Come nasca dalla tristitia, che si sente del male del giusto, e del
bene del malvagio.
oblica, che si prende dalla miseria, o dalla felicita altrui qual sia,”
&c. &c.
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