Troubleshooting and Repairing Diesel Engine Manual

Troubleshooting and Repairing Diesel Engines

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Troubleshooting and Repairing Diesel Engines Fourth Edition Paul Dempsey New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto

Copyright © 2008, 1995, 1991, 1975 by Paul Dempsey. All rights reserved. Manufactured in the United States of America. 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. 0-07-159518-X The material in this eBook also appears in the print version of this title: 0-07-149371-9. All trademarks are trademarks of their respective owners. Rather than put a trademark symbol after every occurrence of a trademarked name, we use names in an editorial fashion only, and to the benefit of the trademark owner, with no intention of infringement of the trademark. Where such designations appear in this book, they have been printed with initial caps. McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. For more information, please contact George Hoare, Special Sales, at george_hoare@mcgraw-hill.com or (212) 904-4069. TERMS OF USE This is a copyrighted work and The McGraw-Hill Companies, Inc. (“McGraw-Hill”) and its licensors reserve all rights in and to the work. Use of this work is subject to these terms. Except as permitted under the Copyright Act of 1976 and the right to store and retrieve one copy of the work, you may not decompile, disassemble, reverse engineer, reproduce, modify, create derivative works based upon, transmit, distribute, disseminate, sell, publish or sublicense the work or any part of it without McGraw-Hill’s prior cosent. You may use the work for your own noncommercial and personal use; any other use of the work is strictly prohibited. Your right to use the work may be terminated if you fail to comply with these terms. THE WORK IS PROVIDED “AS IS.” McGRAW-HILL AND ITS LICENSORS MAKE NO GUARANTEES OR WARRANTIES AS TO THE ACCURACY, ADEQUACY OR COMPLETENESS OF OR RESULTS TO BE OBTAINED FROM USING THE WORK, INCLUDING ANY INFORMATION THAT CAN BE ACCESSED THROUGH THE WORK VIA HYPERLINK OR OTHERWISE, AND EXPRESSLY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WAR- RANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. McGraw-Hill and its licensors do not warrant or guarantee that the functions contained in the work will meet your requirements or that its operation will be uninterrupted or error free. Neither McGraw-Hill nor its licensors shall be liable to you or anyone else for any inaccuracy, error or omission, regardless of cause, in the work or for any damages resulting therefrom. McGraw-Hill has no responsibility for the content of any information accessed through the work. Under no circumstances shall McGraw-Hill and/or its licensors be liable for any indirect, incidental, special, punitive, consequential or similar damages that result from the use of or inability to use the work, even if any of them has been advised of the possibility of such damages. This limitation of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract, tort or otherwise. DOI: 10.1036/0071493719

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About the author Paul Dempsey is a master mechanic and the author of more than 20 technical books, including Small Gas Engine Repair (now in its Second Edition) and How to Repair Briggs & Stratton Engines (now in its Fourth Edition), both available from McGraw-Hill. He has also written more than 100 magazine and journal articles on topics ranging from teach- ing techniques to maintenance management to petroleum-related subjects. Copyright © 2008, 1995, 1991, 1975 by Paul Dempsey. Click here for terms of use.

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vii Contents Foreword xi 1 Rudolf Diesel 1 2 Diesel basics 9 Compression ratio 9 Induction 12 Ignition and combustion 13 Two- and four-stroke-cycle 15 Power and torque 18 Fuel efficiency 18 Weight 19 Durability 19 Conventional fuels 20 3 Engine installation 23 Trucks and other motor vehicles 23 Stationary engines 26 Marine engines 30 4 Basic troubleshooting 39 Malfunctions 40 Tests 42 Air inlet system 50 Glow plugs 53 Exhaust backpressure 54 Engine mechanical 54 For more information about this title, click here

5 Mechanical fuel systems 61 Air blast 61 Early common-rail 61 Jerk pump system 62 Inline pumps 63 Distributor pumps 67 Delivery valves 74 Injectors 76 Timers 79 Diaphragm controls 81 Centrifugal governors 81 Pneumatic governors 85 Unit injection 87 Low-pressure system 90 Fuel filters and water separators 92 6 Electronic management systems 95 Background 95 Analog versus digital 100 Bosch CAN bus 101 On-board computer 102 Tools 107 Troubleshooting 108 Caterpillar EMS 111 Ford (International) 7.3L DI power stroke 124 Detroit Diesel 129 7 Cylinder heads and valves 139 Combustion chamber types 140 Valve configuration 144 Before you begin 147 8 Engine mechanics 177 Scope of work 177 Diagnosis 179 Rigging 179 Special considerations 181 Cleaning 188 Teardown 189 Lubrication system 189 Filters 195 Block casting 204 Pistons 217 Connecting rods 226 viii Contents

Troubleshooting and Repairing Diesel Engine Manual

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