Department of Mechanical Technology

Heavy Equipment

Department Course Title Prerequisites

Mechanical Technology Diesel Engine Fuel Systems HEQ172

Major Code

Heavy Equipment HEQ251

Trimester Course Description: This course presents the study of different types of diesel fuel injection systems and components including; fuel tank, supply pump, injection pump, injectors, and electronic diesel controls. The practical sessions include; methods of fault diagnosis, repair and adjustment of system components. Credit Hours (Hour/week) L Contact Hours (Hour/week) W T

4 3 1 4

General Goal: The course gives the trainees the understanding of different types of diesel fuel injection systems and components, as well as the construction and operation of system parts. In addition to hands on experience of faultfinding, inspection, repair, and adjustment of system components.

Behavioral Objectives: The trainees should be able to: Identify components of a diesel fuel injection system. Explain the construction and operation of injection system elements. Locate faults and adjust an injection system without disassembly. Adjust and calibrate different types of injection pumps on a test bench. Adjust and calibrate injectors. Repair injection pumps and injectors through replacement of defective parts.

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Department of Mechanical Technology

Heavy Equipment

Topics
Diesel fuel injection systems Fuel supply pumps Fuel filters Diesel fuel injection pumps (high pressure pumps) Diesel fuel injectors Electronic diesel control (EDC) Fault diagnosing, repair, and adjustment of diesel fuel injection system components

References:

Diesel Engine and Fuel Systems, Barry Wellington and Alan Asmus Diesel and Mobile Plant Technology, Clifford M. Tempest

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Department of Mechanical Technology

Heavy Equipment

Detailed Curriculum (Theory)

Hrs Contents 1-Diesel fuel injection system: Fuel supply systems (gravity-systempressurized system) Diesel fuel injection system (fuel tanksupply pump-fuel filters-injection pumppiping-injectors) Behavioral Objectives The trainees should be able to: Explain different types of diesel fuel injection systems and components.

2-Fuel supply pumps: Types of fuel supply pumps (pistondiaphragm-electric pumps) Construction and operation of supply pumps Faults in diesel fuel supply pumps Explain different types of diesel fuel supply pumps and operation Determine faults in supply pumps

3-Fuel filters: Types of fuel filters Filter element materials Fuel paths in filters Effect of fuel filters on faults in injection systems Explain types of fuel filters and operation and the effect of filter faults on diesel injection system performance.

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Department of Mechanical Technology

Heavy Equipment

Detailed Curriculum (Theory)

Hrs Contents 4-Diesel fuel injection pump (high pressure pump): Types of inline and distributor pumps Assembly and operation of inline injection pump Assembly and operation of distributor injection pump Methods of injection control in inline pump Methods of injection control in distributor pump Testing and adjustment of inline pump Testing and adjustment of distributor pump Speed governors (mechanical-hydraulicpneumatic) Behavioral Objectives The trainees should be able to: Identify different types of diesel injection pumps, parts, and operation. Explain methods of control of diesel fuel injection for inline and distributor pumps. Test and adjust injection pump on specialized test benches. Identify different types of speed governors.

5-Diesel fuel injectors: Types of diesel fuel injectors Construction and operation of diesel fuel injectors Identify injector parts and operation. Test injectors on specialized testers.

6-Electronic diesel control (EDC): Electronic control system for inline and distributor pumps Electronic control system components (sensors-actuators-control unit) Identify the components of an electronic diesel control system. Explain the theory of operation of electronic diesel control systems.

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Department of Mechanical Technology

Heavy Equipment

Detailed Curriculum (Practice)

Hrs Contents 1-Diesel fuel injection system parts: Safety precaution in diesel workshops Dismantle and installation of injection system parts (fuel tank-supply pumpfuel filters-injection pump-pipinginjectors) Behavioral Objectives The trainees should be able to: Identify the components of diesel fuel injection system parts. Dismantle and install injection system components.

2-Adjustment, repair, and replacement of: Fuel filters Supply pumps Replace fuel filters. Repair fuel supply pump.

3-Testing of diesel fuel injection system on test bench: Simulation of fuel system faults and relating these faults to possible causes such as hard starting, loss of engine power, irregular engine running, engine knock...etc. Apparent inspection of piping, hoses, electrical connections, to determine leakage and faults. Injection timing Smoke testing Bleeding injection system Repair and replacement of supply lines (high pressure tubes-return pipes-filters) Identify diesel injection system faults and possible causes. Inspect fuel injection circuits. Bleed air from injection circuits.

10

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Department of Mechanical Technology

Heavy Equipment

Detailed Curriculum (Practice)

Hrs Contents 4-Adjustment, repair, and testing of injectors:

Behavioral Objectives The trainees should be able to: Inspect, repair, test, and adjust injectors.

Disassemble, cleaning repair and reassembly of injector Inspection and repair of injector Injector testing (leakage-injection pressure-dribble-atomization tests)

5-Testing and adjustment of inline injection pump:

Use of high pressure pump test bench to determine: leaks-rack position-fuel spill off-fuel quantity at different rpm and positions of control rack Compare results with manufacturer data

Adjust inline injection pump on high pressure pump test stand.

6-Testing and adjustment of distributor injection pump:

Use of high pressure pump test bench to test: transfer pump-automatic advancemaximum fuel delivery-fuel cut offgovernor setting-injection timing Compare results with manufacturer data

Adjust distributor injection pump on high pressure pump test stand.

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Department of Mechanical Technology

Heavy Equipment

Detailed Curriculum (Practice)

Hrs Contents 7-Repair of inline and distributor injection pumps: 8 Replacement of defective parts in diesel injection pumps such as: injection elements-cam plate-springs-injection timer spring-bearings-delivery valves Behavioral Objectives The trainees should be able to: Replace the inline and distributor injection pump elements.

8-Inspection and replacement of electronic diesel control systems:

Inspection of EDC elements (sensorsactuators-controller) Replacement of the components of diesel injection electronic control systems

Inspect and replace the components of electronic diesel control systems.

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