Part I Operational Issues
Tools 2.
Best Practices 3.
Proactive Attitudes 5.
Typical Exhaust Gas Components
Carbon Dioxide 7.
Carbon Monoxide 7.
Oxides of Nitrogen 7.
Hydrocarbons 7.
Particulate Matter 7.
Oxides of Sulfur 7.
Smoke 8.
Engine Systems and Conditions
That Affect Diesel Emissions
Combustion Chamber Design 9.
Intake Manifold System 10.
Operating Conditions 11.
Low Turbocharger Boost Pressure 11.
High Exhaust Backpressure 12.
High Crankcase Pressure 13.
Part II Overview of Six Engine Systems
Introduction 14.
1. Intake System
Introduction 15.
Dry Type Air Cleaners 16.
Air Induction Cooling 16.
Aftercoolers 16.
Air-to-Air Aftercoolers 17.
Water Aftercoolers 17.
Intake System Recommendations 17.
Servicing the Intake System 18.
Job Aid Checklist (Intake System) 19.
2. Exhaust System
Introduction 20.
Exhaust System Recommendations 21.
Exhaust After Treatment System Maintenance 21.
Job Aid Checklist (Exhaust System) 23.
Introduction to Tools used for Exhaust System Analysis
ECOM AC+ Gas Analyser 24.
UGAS Software Application 25.
Testing Protocol 25.
Pre-test Conditions 26.
Emissions Testing Protocol 26.
Basic Emission Equipment Operation
Undiluted Diesel Particulate Measurement 27.
Measurement Interpretation 28.
Analysis of Particulate Samples 28.
Thermal Optical Method 29.
Job Aid Checklist 30.
ECOM AC+ Gas Analyser 30.
Particulate Sampling - Gilian Pump 30.
Intake Testing 31.
Intake Restrictions and Exhaust Backpressure 32.
3. Fuel Injection System
Introduction 33.
Injection Pump or Injector Failure 33.
Inadequate Fuel Supply 34.
Incorrect Injection Pump or Injector Timing 34.
Advanced Timing 34.
Retarded Timing 34.
Fuel System Types 35.
Individual Unit Jerk Pumps 35.
Inline Pump System 36.
Distributor Pump System 37.
Cummins PT Fuel System 37.
Unit Injectors 38.
Electronically controlled Fuel Injection Systems 38.
Fuel Injection System Recommendations 39.
Job Aid Checklist (Fuel System) 40.
4. Cooling Systems
Cooling System Recommendations 41.
Cooling System Maintenance 42.
Cooling Mixture 42.
Conditioner and Inhibitors 42.
Cleaning and Flushing 43.
Troubleshooting 43.
Thermostats 43.
Aeration in Coolant 43.
Radiator Cap Relief Valve 44.
Temperature Probe (Cooling System) 44.
Job Aid Checklist (Cooling System) 45.
5. Diesel Fuel and Fuel Supply Systems
Introduction 46.
Best Practice Recommendations 46.
Sulfur Content 47.
Cetane Number 47.
Viscosity 47.
Flashpoint 47.
Fuel Quality and Handling Recommendations 48.
6. Lubrication
Lubrication Recommendations 49.
Lubrication Classification 50.
Combined Service Application 51.
Lubrication System Checks 51.
Conclusion 52.
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