HDD 202 - Heavy Duty Diesel Engines Level III

Credits: 4
Instructional Contact Hours: 4

     A.         Check engine no cranking, cranks but fails to start, hard starting, and starts but does not continue to run problems; determine needed
                  action.

     B.          Identify engine surging, rough operation, misfiring, low power, slow deceleration, slow acceleration, and shutdown problems; determine
                  needed action.

2.    Complete NATEF tasks related to Engine Block of heavy duty diesel engine as  listed below.

     A.          Remove, inspect, service, and install pans, covers, gaskets, seals, wear rings, and crankcase ventilation components.

     B.          Disassemble, clean, and inspect engine block for cracks/damage; measure mating surfaces for warpage; check condition of passages,
                   core/expansion and gallery plugs; inspect threaded holes, studs, dowel pins, and bolts for serviceability; determine needed action.

     C.          Inspect cylinder sleeve counter bore and lower bore; check bore distortion; determine needed action.

     D.          Clean, inspect, and measure cylinder walls or liners for wear and damage; determine needed action.

     E.          Replace/reinstall cylinder liners and seals; check and adjust liner height (protrusion).

     F.           Inspect in-block camshaft bearings for wear and damage; determine needed action.

     G.          Inspect, measure, and replace/reinstall in-block camshaft; measure/adjust end play.

     H.          Clean and inspect crankshaft for surface cracks and journal damage; check condition of oil passages; check passage plugs; measure
                   journal diameter; determine needed action.

     I.            Inspect main bearings for wear patterns and damage; replace as needed; check bearing clearances; check and correct crankshaft end
                   play.

     J.           Inspect, install, and time gear train; measure gear backlash; determine needed action.

     K.          Inspect connecting rod and bearings for wear patterns; measure pistons, pins, retainers, and bushings; perform needed action.

     L.          Determine piston-to-cylinder wall clearance; check ring-to-groove fit and end gap; install rings on pistons.

     M.         Assemble pistons and connecting rods; install in block; install rod bearings and check clearances.

     N.         Check condition of piston cooling jets (nozzles); determine needed action.

3.    Complete NATEF tasks related to Lubrication Systems of heavy duty diesel engines as listed below.

     A.          Inspect and measure oil pump, drives, inlet pipes, and pick-up screens; check drive gear clearances; determine needed action.

     B.          Inspect oil pressure regulator valve(s), by-pass and pressure relief valve(s), oil thermostat, and filters; determine needed action.

4.    Complete NATEF tasks related to Air Induction and Exhause Systems of heavy duty diesel engines as listed below.

     A.          Remove and reinstall turbocharger/wastegate assembly.

     B.          Inspect intake manifold, gaskets, and connections; replace as needed.

     C.          Inspect and test preheater/inlet air heater, or glow plug system and controls; perform needed action.

     D.          Inspect exhaust gas recirculation (EGR) system including EGR valve, cooler, piping, filter, electronic sensors, controls, and wiring;
                  determine needed action.

5.    Complete NATEF tasks related to Fuel System of heavy duty diesel engines as listed below.

     A.          Fuel System Supply

                  1.    Inspect, clean, and test fuel transfer (lift) pump, pump drives, screens, fuel/water separators/indicators, filters, heaters, coolers, ECM
                         cooling plates, and mounting hardware; determine needed action.

                  2.    Inspect and test pressure regulator systems (check valves, pressure regulator valves, and restrictive fittings); determine needed
                         action.

                  3.    Check fuel system for air; determine needed action; prime and bleed fuel system; check primer pump.

                  4.    Inspect, test, and adjust engine compression/exhaust brake control circuits, switches, and solenoids; determine needed action.

     B.          Electronic Fuel Management System

                  1.    Inspect and test power and ground circuits and connections; measure and interpret voltage, voltage drop, amperage, and resistance
                         readings using a digital multimeter (DMM); determine needed action.

                  2.    Inspect and test switches, sensors, controls, actuator components, and circuits; adjust or replace as needed.

                  3.    Using electronic service tool(s) access and interpret customer programmable parameters.

                  4.    Perform on-engine inspections, tests and adjustments on electronic unit injectors (EUI); determine needed action.

                  5.    Remove and install electronic unit injectors (EUI) and related components; recalibrate ECM (if applicable).

                  6.    Perform cylinder contribution test utilizing electronic service tool(s).

                  7.    Perform on-engine inspections and tests on hydraulic electronic unit injectors (HEUI) and system electronic controls; determine
                         needed action.

                  8.    Perform on-engine inspections and tests on hydraulic electronic unit injector (HEUI) high pressure oil supply and control systems;
                         determine needed action.

                  9.    Perform on-engine inspections and tests on high pressure common rail (HPCR) type injection systems; determine needed action.