DSL 120 Diesel Technology Introduction to Fuels

Lecture Hours: 2
Lab Hours: 8
Credits: 6

Covers fuel injection systems and how they relate to diesel engine performance and operation. Explores the operation of all major fuel injection devices including diesel fuels, fuel transfer pumps, fuel nozzles, filtration systems, metering systems and governing systems.

Prerequisite: DSL 110 and DSL 111 each with a grade of C or better; or consent of instructor.
Concurrent: DSL 121.
Student Learning Outcomes:

Apply diesel engine knowledge to diesel fuel injection systems functions and how they relate to engine operation and performance.
Troubleshoot, evaluate and repair diesel fuel injection systems.
Disassemble, test, and reassemble fuel injection components.
Test diesel engines for fuel system malfunctions.
Apply knowledge of diesel fuel, fuel injection systems, and how they relate to engine performance.
Research and locate repair literature.
Apply basic theory of diesel electricity, components, schematics, controls, and how they all relate to the fuel injection system.
Diagnose and repair injector electrical circuits.
Conduct repairs in an ethical and professional manner, respecting industry safety and environmental guidelines.
Communicate with co-workers, customers, management and general public in a professional and knowledgeable manner.

Content Outline

Diesel fuel properties and characteristics
- Calculate how much ignition accelerator is required to restore original CN valve
- Determine the calorific or heating value of a fuel
- Identify degraded diesel fuel
- Test several rigs for contaminated fuel
- Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system, hoses, lines, and fittings
Low-pressure fuel system
- Test the low side of a low pressure fuel system
- Test the charge side
- Functions of high-pressure fuel systems
- Troubleshoot a fuel sending unit
- Service primary and secondary fuel filters
- Service a water separator, prime a fuel subsystem
- Inspect high pressure fuel system components (fuel pump, pump drives, hoses, injection lines, filters, hold-downs, fittings, seals, and mounting hardware
Hydraulic nozzles
- Inspect high pressure fuel system components (fuel pump, pump drives, hoses, injection lines, filters, hold-downs, fittings, seals, and mounting hardware)
Hydraulic nozzles
- Identify the subcomponents of a nozzle assembly
- Identify gout types of injector nozzles
- Reprogram fuel flow codes to a engine control module (ECM)
- Bench test a hydraulic injector nozzle
- Disassemble, ultrasonic bathe, and reassemble an injector
- Test a nozzle for forward and back leakage
- Set interjector operating pressure (NOP)
Electronic unit injectors
- Describe the system layout and primary components in a typical single actuator electronically controlled unit injector (EUI)
- Describe the operation of a two terminal EUI, perform some basic troubleshooting on an EUI engine using OEM diagnostic routines
- Describe the system layout and the primary components in a full authority, dual actuator EUI system, identify the engines that use this system, sequence the injector phases of a Delphi E3 injector
- Describe how the ECM manages duty cycle, outline factors that govern the ECM fueling and engine management algorithm
- Outline the pre check and installation procedure for a Delphi E3 EUI
Hydraulic electronic unit injector (HEUI) fuel systems
- Describe the hydraulic electronic unit injector (HEUI) system layout and components
- Outline the role of the four primary HEUI subsystems
- Perform basic electrical troubleshooting on an HEUI system
- Use software to diagnose system problems with CAT and Navistar International HEUI fueled engines
Common rail (CR) systems
- Identify the subsystems on a CR system, trace fuel flow from tank to injectors, diagnose some typical CR fuel system malfunctions
- Outline the procedure to time a CR pump, and test EHI actuator resistance
- Diagnose some typical CR fuel system malfunctions
Amplified common rail (ACR) systems
- Identify ACRs on a diesel engine, trace the fuel routing, describe the operation of the inline piston pump and how it manages fuel pressure
- Perform come basic service routines on a Detroit DD series ACRS engine
- Change out a Hydraulic Amplifier (HADI) injector, reprogram HADI fuel injection quantity calibration codes using Detroit Diesel Diagnostic Link (DDDL)