Heavy Duty Diesel Engine (HDD) Operation and Maintenance Course
Maintenance, Reliability and Rotating Equipment
-Electrical and Power Engineering

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Heavy Duty Diesel Engine (HDD) Operation and Maintenance Course
Course Overview:
The course covers the workings of Heavy-duty diesel engines along with design, theory, technology, and maintenance. Furthermore, it aims at developing maintenance skills of HDD engines amongst its target audience such as diesel power generation personnel.
Additionally the students will be trained in performing combustion, air charging, and fuel injections with the use of combustion processes.
Moreover, studying the utilization of advanced electronic diesel control units and emission control devices such as DPF, EGR, and SCR will also be a part of the curriculum.
Instructors will ensure step by step guidance on servicing, engine diagnostics and testing. Most importantly, performance and certification for optimal engine cost will be emphasized.
Course Objectives:
At the end of this training course, you will learn to:
§ Outline the principle of operation of diesel engines
§ Specify the difference between Heavy Duty Diesel Engines and normal Diesel engines
§ Describe how combustion occurs in diesel engines
§ Explain the reason of air charging in diesel engines
§ List and explain the principle of operation of air charging systems in diesel engines
· List and explain the operation principle of various types of fuel injection systems used in HDD
§ Describe the layout and components of various fuel injection systems used in HDD
§ Explain how the quantity and timing of injected fuel can be controlled
Who Should Attend?
This training course is suitable for a wide range of professionals but will greatly benefit:
- Vehicles fleet maintenance engineers and technicians
- Fleet maintenance supervisors
- Automotive maintenance engineers
- Automotive maintenance technicians
- Diesel power generation plants engineers and technicians
Course Outlines:
Introduction to Heavy-Duty Diesel (HDD) engines
- Meaning of HDD engine: Rating – Load factor – Operation duration
- HDD engine glossary of terms
- International standards for HDD engine
- HDD engine Internal and external characteristic performance curves
- Design considerations of HDD engine
- HDD engine construction features and materials
- HDD engine Applications
Work Cycle and Combustion in HDD Engines
- Work cycle, internal and external characteristic curves of HDD engines
- Diesel fuel (Classification – Fuel properties – Fuel tests)
- The combustion process in Diesel engines
- Compression ratio
- Combustion chambers shapes
- Direct & indirect injection methods
- Homogenous Charge Compression Ignition (HCCI)
- Air charging in heavy-duty diesel engines:
- Types (Mechanical – Turbo – Pressure wave)
- Turbocharger configuration (Combined – Two-stage - Variable geometry – Sequential)
- Turbocharger control (Pressure – Fuel compensation)
- Turbocharger performance characteristics
Fuel Injection Systems in HDD Engines
- Types and principle of operation of fuel injection systems:
- Cummins systems: (PT – CELECT unit injector – Accumulator – HPI – XPI)
- Caterpillar systems: (HUEI/A – HUEI/B – Navistar – MEUI/A – MEUI/B)
- In-line or multi-plungers systems.
- Common rail systems
- HDD engines fuel injection systems layout and components.
- Methods of control of injected fuel quantity and timing: (Hydraulic, pneumatic, electronic)
- Diesel fuel filtration and water separation.
Electronic Diesel Control (EDC)
- Advantages of EDC
- EDC basic layout and components (ECU – Sensors – Actuators – Layout for various types of fuel injection systems)
- Open& Closed loops and data processing
- Controlled quantities: Start – Drive mode – Idle speed – Maximum speed – Intermediate speeds – Cruise speed - ….)
- Injected fuel quantity limits
- Emission control systems;
- Diesel Oxidation Catalyst (DOC)
- Diesel Particulate Filter (DPF)
- Selective catalyst reduction (SCR)
- Urea Injection (UI)
- Exhaust gas recirculation (EGR)
- Closed Crankcase Ventilation (CCV)
Operation and Maintenance of HDD Engine
- Operation Tips for HDD engine
- Indicator lamps
- On-Board diagnostics
- Fuel type
- Items to be noticed
- Tips for efficient operation
- Maintenance of diesel engines
- Basics of mechanical maintenance
- Servicing of diesel fuel injection systems
- Diesel engine tune-up
- Diesel engine routine maintenance operations (time-based, distance-based)
- Forms of diesel engine components failure
- Engines troubleshooting and fault rectification
- Testing of injection pumps, injectors, fuel feed pumps
- Tests for the assessment of engine condition (compression, leakage tests)
- Diesel engines troubleshooting