Department of Mechanical Technology Heavy Equipment

- 1 -

Heavy Equipment Major Mechanical Technology Department

HEQ251 Code Diesel Engine Fuel Systems Course Title

HEQ172 Prerequisites

5 4 3 2 1 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.

3 Credit Hours (Hour/week)

1 L

Contact Hours

(Hour/week) 4 W

T

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.

Department of Mechanical Technology Heavy Equipment

- 2 -

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

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

References:

Department of Mechanical Technology Heavy Equipment

- 3 -

Detailed Curriculum (Theory)

Behavioral Objectives Contents Hrs The trainees should be able to: • Explain different types of diesel

fuel injection systems and components.

1-Diesel fuel injection system: • Fuel supply systems (gravity-system-

pressurized system) • Diesel fuel injection system (fuel tank-

supply pump-fuel filters-injection pump-piping-injectors)

2

• Explain different types of diesel

fuel supply pumps and operation • Determine faults in supply pumps

2-Fuel supply pumps: • Types of fuel supply pumps (piston-

diaphragm-electric pumps) • Construction and operation of supply

pumps • Faults in diesel fuel supply pumps

2

• Explain types of fuel filters and

operation and the effect of filter faults on diesel injection system performance.

3-Fuel filters: • Types of fuel filters • Filter element materials • Fuel paths in filters • Effect of fuel filters on faults in injection

systems

1

Department of Mechanical Technology Heavy Equipment

- 4 -

Detailed Curriculum (Theory)

Behavioral Objectives Contents Hrs 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.

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-hydraulic-

pneumatic)

4

• Identify injector parts and

operation. • Test injectors on specialized testers.

5-Diesel fuel injectors: • Types of diesel fuel injectors • Construction and operation of diesel fuel

injectors

2

• Identify the components of an

electronic diesel control system. • Explain the theory of operation of

electronic diesel control systems.

6-Electronic diesel control (EDC): • Electronic control system for inline and

distributor pumps • Electronic control system components

(sensors-actuators-control unit)

2

Department of Mechanical Technology Heavy Equipment

- 5 -

Detailed Curriculum (Practice)

Behavioral Objectives Contents Hrs The trainees should be able to: • Identify the components of diesel

fuel injection system parts. • Dismantle and install injection

system components.

1-Diesel fuel injection system parts: • Safety precaution in diesel workshops • Dismantle and installation of injection

system parts (fuel tank-supply pump-fuel filters-injection pump-piping-injectors)

4

• Replace fuel filters. • Repair fuel supply pump.

2-Adjustment, repair, and replacement of: • Fuel filters • Supply pumps

6

• Identify diesel injection system

faults and possible causes. • Inspect fuel injection circuits. • Bleed air from injection circuits.

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)

10

Department of Mechanical Technology Heavy Equipment

- 6 -

Detailed Curriculum (Practice)

Behavioral Objectives Contents Hrs The trainees should be able to: • Inspect, repair, test, and adjust

injectors.

4-Adjustment, repair, and testing of injectors:

• Disassemble, cleaning repair and reassembly of injector

• Inspection and repair of injector • Injector testing (leakage-injection

pressure-dribble-atomization tests)

8

• Adjust inline injection pump on

high pressure pump test stand.

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

6

• Adjust distributor 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 advance-maximum fuel delivery-fuel cut off-governor setting-injection timing

• Compare results with manufacturer data

6

Department of Mechanical Technology Heavy Equipment

- 7 -

Detailed Curriculum (Practice)

Behavioral Objectives Contents Hrs The trainees should be able to: • Replace the inline and distributor

injection pump elements.

7-Repair of inline and distributor injection pumps: • Replacement of defective parts in diesel

injection pumps such as: injection elements-cam plate-springs-injection timer spring-bearings-delivery valves

8

• Inspect and replace the components

of electronic diesel control systems.

8-Inspection and replacement of electronic diesel control systems:

• Inspection of EDC elements (sensors-actuators-controller)

• Replacement of the components of diesel injection electronic control systems

8