This document provides an overview of basic diesel engine technology. It discusses the history of the diesel engine and its invention by Rudolf Diesel in 1895. The document outlines the major uses of diesel engines in agriculture, transportation, construction, forestry, marine, and electrical generation applications. It also summarizes the advantages and disadvantages of diesel engines compared to gasoline engines. The core components and operating principles of diesel engines are explained, including the combustion process, fuel and air systems, cooling systems, and lubrication systems.

1. BASIC DIESEL ENGINE
TECHNOLOGY
By
Engr. Muhd. Hasanuzzaman
MUSLIM
ENGINEERS & SHIP BUILDERS LTD.

2. INTRODUCTION
• THE DIESEL ENGINE IS USED AS A
SOURCE OF POWER FOR
THOUSANDS OF APPLICATIONS.

3. WHO INVENTED THE
DIESEL ENGINE?
• 1895 – RUDOLPH DIESEL
SUCCESSFULLY INVENTED AN
ENGINE THAT BURNED COAL DUST
INJECTED BY PRESSURIZED AIR.
THE DIESEL ENGINE WAS BORN.

4. WHO DEVELOPED THE
FIRST MASS PRODUCED
INJECTION PUMP?
• ROBERT BOSCH IN 1927

5. USES OF DIESEL ENGINES
TODAY, DIESEL ENGINES ARE
USED TO PROVIDE POWER IN A
VARIETY OF APPLICATIONS IN
MANY INDUSTRIES

6. THERE ARE SIX MAJOR
USES OF DIESEL ENGINES

7. AGRICULTURE/FARM

8. TRANSPORTATION

9. CONSTRUCTION

10. FORESTRY

11. MARINE

12. ELECTRICAL GENERATION
PLANTS

13. SEVEN ADVANTAGES OF
DIESEL ENGINES
• MORE EFFICIENT AND
ECONOMICAL TO USE
• FUEL VAPOR IS NOT EXPLOSIVE
• EXHAUST GASES ARE LESS
POISONOUS – LESS CARBON
MONOXIDE
• GREATER LUGGING POWER AND
TORQUE

14. ADVANTAGES CONTINUED
• ENGINES ARE DURABLE AND IF
PROPERLY CARED FOR WILL
MAINTAIN THEIR ECONOMY
• FUEL IS LESS VOLATILE – NO
VAPOR LOCK PROBLEMS
• CAN USE A VARIETY OF FUELS AND
MIXTURES

15. FIVE DISADVANTAGES OF
DIESEL ENGINES
• ENGINES MUST BE STONGER AND
HEAVIER BECAUSE OF HIGHER
COMPRESSION RATES
• INITIALLY MORE EXPENSIVE
• FUEL COULD GEL IN COLDER
CLIMATES
• GENERALLY NOISER OPERATION
• VERY PUNGENT EXHAUST ODOR

16. INTERNAL COMBUSTION
ENGINE:
AN ENGINE THAT PRODUCES
POWER BY BURNING FUEL
INSIDE A COMBUSTION
CHAMBER WITHIN THE ENGINE

17. TWO TYPES OF INTERNAL
COMBUSTION ENGINES

18. SPARK IGNITION ENGINE

19. COMPRESSION IGNITION
ENGINE

20. TRUE OR FALSE: SPARK
PLUGS SHOULD BE
CHANGED MORE OFTEN IN
DIESEL ENGINES THAN IN
GASOLINE ENGINES?
FALSE

21. BASICALLY, HOW DOES A
SPARK-IGNITION ENGINE
WORK?
• LIQUID FUEL BROKEN DOWN INTO
A FINE SPRAY AND MIXED WITH
AIR IN THE CARBURETOR.
• FUEL-AIR MIXTURE PIPED TO THE
CYLINDER WHERE IT IS IGNITED BY
AN ELECTRIC SPARK FROM THE
SPARK PLUG.

22. HOW DOES A
COMPRESSION-IGNITION
ENGINE WORK?
• NO SPARK IS NEEDED
• LIQUID FUEL UNDER VERY HIGH
PRESSURE IS INJECTED DIRECTLY INTO
THE CYLINDER WHICH IS FILLED WITH
HIGHLY COMPRESSED AIR.
• IGNITION BEGINS WHEN THE FUEL HITS
THE AIR THAT IS AT A TEMPERATURE OF
777 DEGREES F.

23. WHAT DOES A
COMPRESSION RATIO OF
16:1 MEAN?
THE AIR IN A CYLINDER IS
COMPRESSED INTO 1/16 THE
SPACE AT THE TOP OF THE
STROKE AS COMPARED TO THE
BOTTOM OF THE STROKE

24. TRUE OR FALSE: DIESEL
ENGINES USE GREATER
COMPRESSION RATIOS
THAN GASOLINE ENGINES?
TRUE
DIESEL ENGINES – 16:1 TO 22:1
GASOLINE ENGINES – 8:1

25. TRUE OR FALSE: DIESEL
ENGINES REQUIRE MORE
AIR THAN GASOLINE
ENGINES
TRUE

26. TRUE OR FALSE: DIESEL
ENGINES HAVE NO
IGNITION SYSTEM
COMPONENTS
TRUE
NO SPARK PLUGS, COIL,
MAGNETO, DISTRIBUTOR, OR
WIRING

27. TRUE OR FALSE: DIESEL
ENGINES, LIKE GASOLINE
ENGINES, DRAW IN FUEL
AND AIR ON THE INTAKE
STROKE?
FALSE
ONLY AIR IN A DIESEL ENGINE

28. WHAT IS THE PURPOSE OF A
TURBOCHARGER ON A
DIESEL ENGINE?
TO INCREASE THE AIR INTAKE
INTO THE CYLINDERS

29. TRUE OR FALSE: DIESEL
ENGINES REQUIRE A HIGH
PRESSURE PUMP TO INJECT
THE FUEL INTO THE
COMPRESSED AIR IN THE
CYLINDER?
TRUE

30. WHAT IS THE NAME OF THE
ENGINE PART THAT SPRAYS
FUEL INTO THE CYLINDER
OF A DIESEL ENGINE?
INJECTOR NOZZEL

31. WHAT TYPE MATERIAL ARE
FUEL LINES MADE OF IN A
DIESEL ENGINE? WHY?
STEEL
PRESSURES FROM 5,000 TO
20,000 PSI ARE INVOLVED

32. TRUE OR FALSE: GASOLINE
IS LESS VOLATILE THAN
DIESEL FUELS
FALSE
GASOLINE EVAPORATES
READILY AND IS VERY
EXPLOSIVE

33. TRUE OR FALSE: GASOLINE
ENGINES ARE HEAVIER
THAN DIESEL ENGINES OF
THE SAME HORSEPOWER?
FALSE
HIGH DIESEL CYLINDER
PRESSURES REQUIRE HEAVIER
MATERIALS

34. HOW IS ENGINE SPEED
CONTROLLED IN A DIESEL
ENGINE?
• THE THROTTLE CONTROL REGULATES
ONLY THE AMOUNT OF FUEL INJECTED
INTO THE CYLINDER
• THE THROTTLE CONTROL IN A GASOLINE
ENGINE REGULATES THE AMOUNT OF
AIR/FUEL MIXTURE ALLOWED INTO THE
CYLINDER

35. HOW ARE DIESEL ENGINES
STOPPED?
• BY SHUTTING OFF THE FUEL TO
THE CYLINDERS BY A MANUAL
CONTROL OR SOLENOID SWITCH
• GASOLINE ENGINES ARE STOPPED
BY CUTTING OFF THE SPARK FROM
THE SPARK PLUGS TO THE
CYLINDERS

36. HOW AN ENGINE WORKS

37. WHAT ARE THE FIVE BASIC
PARTS OF ANY ENGINE?

38. NAME THE TWO BASIC
TYPES OF ENGINES
• FOUR STROKE CYCLE ENGINE
• TWO STROKE CYCLE ENGINE

39. WHAT SEQUENCE OF
EVENTS MAKE UP A
CYCLE?
• INTAKE
• COMPRESSION
• POWER
• EXHAUST
• WHAT IS A STROKE?
• ONE MOVEMENT OF THE PISTON

40. FOUR STROKES OF AN
ENGINE

41. HOW MANY TIMES DOES
THE CRANKSHAFT
REVOLVE DURING A CYCLE
IN A FOUR STROKE CYCLE
ENGINE?
TWO

42. WHAT ARE THE MAJOR
DIFFERENCES IN EACH
STROKE WHEN
COMPARING A DIESEL
ENGINE WITH A GASOLINE
ENGINE?
• INTAKE
– AIR VS. AIR/FUEL MIXTURE

43. DIFFERENCES CONTINUED
• COMPRESSION STROKE
– COMPRESSION RATIO
• POWER STROKE
– SPARK PLUG VS. HEAT OF
COMPRESSION
• EXHAUST STROKE
– SAME FOR BOTH

44. TWO-STROKE CYCLE
ENGINES

45. HOW MANY STROKES OF
THE PISTON ARE REQUIRED
FOR A CYCLE TO BE
COMPLETED IN A TWO
STROKE CYCLE ENGINE?
TWO

46. WHAT HAPPENS DURING
STROKE 1 IN A TWO
STROKE CYCLE GASOLINE
ENGINE?
• THE UPSTROKE OF THE PISTON
COMPRESSES THE AIR/FUEL
MIXTURE. (COMPRESSION STROKE)
• AT THE SAME TIME, A NEW AIR-
FUEL MIXTURE IS DRAWN INTO THE
CRANKCASE. (INTAKE STROKE)

47. WHAT HAPPENS DURING
STROKE 2 OF A TWO
STROKE CYCLE GASOLINE
ENGINE?
• THE DOWNWARD STROKE (POWER
STROKE) OF THE PISTON CAUSES THE
BURNED GASES TO ESCAPE THROUGH
THE EXHAUST PORT. (EXHAUST STROKE)
• NEW FUEL-AIR IS FORCED INTO THE
CYLINDER

48. TWO-STROKE CYCLE
GASOLINE ENGINES

49. WHAT ARE THE
DIFFERENCES BETWEEN A
DIESEL AND GASOLINE
TWO-STROKE CYCLE
ENGINE?
• DIESEL ENGINES INJECT FUEL INTO THE
CYLINDER THROUGH A FUEL INJECTOR
• A BLOWER IS OFTEN USED TO FORCE AIR
INTO THE CYLINDER
• DIESEL ENGINES HAVE EXHAUST
VALVES, GAS ENGINES HAVE A PORT

50. TWO-STROKE DIESEL
ENGINE

51. THE DIESEL AIR SYSTEM

52. BASIC PARTS OF THE
DIESEL AIR SYSTEM

53. WHAT IS A TURBOCHARGER
ON A DIESEL ENGINE?
A CENTRIFUGAL BLOWER
THAT IS DRIVEN BY EXHAUST
GASES WHICH FORCES MORE
AIR INTO THE CYLINDER.
INCREASES POWER

54. HOW IMPORTANT IS
KEEPING AIR FILTERS
CLEAN?
VERY IMPORTANT
A DIESEL ENGINE USES 12-
15,000 GALLONS OF AIR TO
EACH GALLON OF FUEL

55. NAME THREE TYPES OF AIR
CLEANERS
• OIL-BATH TYPE CLEANER
• PRE-CLEANER
• DRY-TYPE AIR CLEANER

56. THE DIESEL FUEL SYSTEM

57. WHAT ARE THE FIVE BASIC
PARTS OF A DIESEL FUEL
SYSTEM?
• INJECTION NOZZLES
• INJECTION PUMP
• FILTERS
• TRANSFER PUMP
• FUEL TANK

58. THE DIESEL FUEL SYSTEM

59. DIESEL FUEL, LIKE
GASOLINE IS A PRODUCT OF
THE DISTILLATION OF-
CRUDE OIL

60. 100 GALLONS OF CRUDE
OIL WILL YIELD WHAT
PRODUCTS?
• GASOLINE = 44 GALLONS
• DIESEL FUEL = 36 GALLONS
• MISC. = 9 GALLONS
• KEROSENE = 6 GALLONS
• LUBRICANTS = 3 GALLONS
• LOSS = 3 GALLONS

61. WHAT ARE THE THREE
GRADES OF DIESEL FUEL?
• NUMBER 1 DIESEL FUEL (NO. 1-D)
– RECOMMENDED FOR COLD WEATHER.
REMAINS FLUID FOR EASIER STARTING
– BUSES, CARS, TRUCKS, FARM TRACTORS
• NUMBER 2 DIESEL FUEL (NO. 2-D)
– HEAVY WORK LOADS. BUSES, TRUCKS,
FARM EQUIPMENT
• NUMBER 4 DIESEL FUEL (NO. 4-D)
– OCEAN GOING VESSELS WITH LOW-MEDIUM
SPEED ENGINES

62. THE DIESEL COOLING
SYSTEM

63. WHAT ARE TWO PRIMARY
TYPES OF COOLING
SYSTEMS FOR DIESEL
ENGINES?
LIQUID COOLING
AIR-COOLING

64. LIQUID COOLING ENGINE

65. AIR-COOLED DIESEL
ENGINE

66. WHAT IS THE IDEAL
OPERATING TEMPERATURE
FOR MOST DIESEL
ENGINES?
165 – 185 DEGREES F.

67. WHAT ARE SOME EFFECTS
OF ENGINE OVERHEATING?
• CYLINDER HEAD AND BLOCK CAN
CRACK OR WARP
• RINGS AND VALVES MAY SEIZE OR STICK
DUE TO GUMS, LAQUERS, AND
VARNISHES FORMING FROM
OVERHEATED OIL AND CARBON
FORMATION
• BEARINGS MAY BE DAMAGED CAUSING
EXCESSIVE WEAR

68. WHAT ARE SOME EFFECTS
OF OVERCOOLING?
• INCREASED ENGINE WEAR
• IMPROPER LUBRICATION
• INCREASED FUEL CONSUMPTION
• INCREASED SLUDGE FORMATION
• INCREASED ENGINE CORROSION
– MOISTURE CONDENSES IF BELOW 140
DEGREES IN THE ENGINE CRANKCASE

69. WHAT ARE SOME
ADVANTAGES OF AIR-
COOLED ENGINES
• LESS WEIGHT
• LESS MAINTENANCE
• LESS DOWN-TIME
• NO CAVITATION EROSION
• NO COOLANT CONCERNS
• MORE EFFICIENT USE OF POWER
• LESS VULNERABLE TO DAMAGE
• LESS BULK
• QUICKER WARM-UP

70. WHAT ARE SOME
DISADVANTAGES TO AIR-
COOLED ENGINES?
• LENGTH OF THE ENGINE
• LESS TEMPERATURE CONTROL
• HIGHER OPERATING
TEMPERATURES
• GREATER NOISE
• MORE FREQUENT CLEANING

71. THE DIESEL LUBRICATION
SYSTEM

72. WHAT ARE THE
FUNCTIONS FOR THE
LUBRICATION SYSTEM?
• REDUCES SHOCK, WEAR, AND
FRICTION
• SEALS COMPRESSION
• PROVIDES SOME CLEANING
• HELPS COOL THE ENGINE
• QUIETS THE ENGINE OPERATION

73. TRUE OR FALSE: MOST OF
THE LUBRICANTS USED IN
DIESEL ENGINES COME
FROM PETROLEUM?
TRUE

74. WHAT ARE LUBRICANTS
DERIVED FROM ANIMAL OR
VEGETABLE OILS CALLED?
SYNTHETIC OILS

75. WHAT TWO
CHARACTERISTICS ARE
MOST IMPORTANT IN
CHOOSING PROPER OIL?
VISCOSITY
SERVICE CLASSIFICATION

76. WHAT IS VISCOSITY?
• A MEASURE OF A LIQUID’S
RESISTANCE TO FLOW
• HIGHER TEMPERATURE –
DECREASE IN VISCOSITY
• SOCIETY OF AUTOMOTIVE
ENGINEERS (SAE) DEVELOPED
NUMBERING SYSTEM

77. WHAT ARE THE VISCOSITY
GRADES?

78. API ENGINE OIL SERVICE
CATEGORIES
AMERICAN PETROLEUM
INSTITUTE
TABLE 1: (HANDOUT)

79. WHAT ARE THE THREE
MOST COMMON OIL
ADDITIVES?
• OXIDATION INHIBITORS
• CORROSION AND RUST INHIBITORS
• DETERGENT DISPERSANTS

80. HOW DO DETERGENT
ADDITIVES WORK?

81. PRINCIPLES OF FLUID
HYDRAULICS

82. HYDRAULIC SYSTEMS ON
A TRACTOR

83. WHAT IS PASCAL’S LAW OF
HYDRAULICS?
• PRESSURE ON A LIQUID IN A
CONTAINER IS TRANSFERRED
EQUALLY TO ALL SURFACES

84. PASCAL’S LAW

85. PRESSURE TRANSFER IN
HYDRAULIC BRAKES

86. CHANGING THE PRESSURE
IN A HYDRAULIC SYSTEM