DSL 366 - Diesel Engines II

1. Identify, define and analyze fuel injection components and principles
   1. Define fuel injection terms
   2. Identify fuel sub-systems and components
   3. Troubleshoot possible fuel injection problems
2. Identify, define and analyze the lubrication system and components
   1. Define properties and classifications of oil
   2. Identify and measure components
   3. Interpret oil analysis and define oil change intervals
   4. Troubleshoot lubrication system problems
3. Identify, define and analyze cooling system components
   1. Define properties and classifications of coolant, supplemental coolant additive, and anti-freeze
   2. Identify and measure coolant system components
   3. Troubleshoot coolant system problems
4. Identify, define and analyze engine breathing systems and components
   1. Identify and measure intake and exhaust components
   2. compare toots blower and turbo chargers
   3. Identify variable geometry turbochargers and explain operation
   4. Identify and test charge air heat exchangers
   5. Troubleshoot engine breathing systems
   6. Demonstrate wastegate adjustment
   7. Identify exhaust and emission components
5. Identify, define and analyze engine exhaust brake, compression brake and retarding systems
   1. Identify electrical components and read electrical schematics fro braking systems
   2. Identify components and trace oil and air flow in the braking systems
   3. Demonstrate adjustments for proper operation
   4. Troubleshoot engine braking systems
   5. Operate compression brake and brakesaver hydraulic retarder
6. Demonstrate the ability to rebuild a cylinder head
   1. Dissemble a cylinder head
   2. Inspect head for cracks
   3. Measure valve guides, valves, seats and springs for wear
   4. Resurface valves correctly
   5. Use valve seat grinder correctly
   6. Examine valve for proper contact
   7. Assemble cylinder head
7. Perform Cummins fuel injection timing
   1. Demonstrate the correct procedure
   2. Explain each step of the procedure
   3. Read the gauges correctly
   4. Change the reading per instructor’s direction
8. Demonstrate proper bridge, valve and injector adjustment on assigned engines: Detroit 60 series, Cummins M-11 and N-14, caterpillar 3176, 3406 E, C-11, Mack and seven other engines
   1. Demonstrate correct procedure from the appropriate service manual
   2. Demonstrate correct bridge, (crosshead, yoke) adjustment
   3. Demonstrate correct unit injector adjustment
   4. Demonstrate correct valve adjustment
9. Demonstrate how to time and in-line fuel pump
   1. Remove fuel pump
   2. Position the engine for fuel pump timing
   3. turn the fuel pump for proper fuel pump timing
   4. Explain the importance of the engine and fuel pump positions
   5. Install the fuel pump correctly timed to the engine
   6. Instructor verification
10. Demonstrate how to time a rotary fuel pump
    1. Remove fuel pump
    2. Position the engine for fuel pump timing
    3. turn the fuel pump for proper fuel pump timing
    4. Explain the importance of the engine and fuel pump positions
    5. Install the fuel pump correctly timed to the engine
    6. Instructor verification
11. Demonstrate correct crankshaft and flywheel housing removal and installation
    1. Remove and install flywheel housing
    2. Demonstrate proper measurement of flywheel housing total indicated runout (TIR).
    3. Demonstrate removal and installation of crankshaft in block
    4. Demonstrate removal and installation of main bearings, in-chassis and out of chassis
    5. Demonstrate correct measurement techniques of crankshaft using plastigage, outside mic and dial indicator
    6. Instructor verification
12. Demonstrate trouble shooting techniques
    1. Identify a cylinder with a miss
    2. Show the uses of a monometer
    3. Use a compression tester
    4. Use spill port timing to confirm correct fuel pump to engine timing
    5. Demonstrate ability to follow troubleshooting charts, manuals and logic to solve problems
13. Disassemble a diesel engine
    1. Remove cylinder head correctly
    2. Remove all pistons correctly
    3. Remove wet liners correctly
    4. Remove camshaft and gear train correctly
    5. Remove flywheel correctly
    6. Inspect engine parts for reuse
    7. Measure parts per measurement sheet and service manual
    8. Prepare engine parts and surfaces for assembly
14. Assemble a diesel engine per engine manual
    1. Install wet liners correctly
    2. Demonstrate the correct use of plastigage
    3. Install camshaft and gear train correctly
    4. Install all pistons and rods correctly
    5. Install cylinder head correctly
    6. Demonstrate ability to check flywheel housing concentricity
    7. Install flywheel correctly
15. Start a diesel engine
    1. Demonstrate engine pre-lube process
    2. Demonstrate starter hook-up
    3. Identify engine leaks
    4. Analyze engine for proper operation