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More than ten years have gone by since I wrote the second edition of this book. In this time, there have been significant changes in the diesel engine world. Whereas in the past such changes have occurred largely as a result of economic and competitive pressures, in recent years the motivation for change has come from what is known as "technology forcing" legislation, primarily in the form of ever-tightening emissions standards (see the Technology Forcing Legislation sidebar next page). When such legislation is first introduced, many in the industry argue that the new standards will be impossible to meet, but in fact, as each successive deadline has approached, manufacturers have invariably succeeded in exceeding the new requirements. Some will admit off the record that the legislative pressure has been good for the industry.
When first proposed, most of the tightened standards were not applicable to marine engines. But because of the relatively small size of the marine marketplace (approximately 50,000 diesel engines up to 800 horsepower worldwide each year, as opposed to millions of engines in the automotive and trucking industries), many marine diesel engines have always been adapted from other applications, and to the degree that the new standards applied to these applications, the technology found its way onto boats. From about 2004 onward, marine engines have been specifically included in both international and U.S. EPA regulations, with increasingly stringent emissions requirements being phased in over the five-year period from 2004 to 2009. This has resulted in numerous technological changes, most of which are invisible to boatowners, consisting of refinements in materials and design elements that have little impact on operating and maintenance practices. As such the changes have had, and continue to have, little practical impact on most boatowners. The two notable exceptions are electronic engine controls and common rail fuel injection.
Electronic engine controls and common rail fuel injection are different, with considerable practical implications, so I have worked them both into this new edition. Even so, it is worth noting that these technologies have typically not yet filtered down to marine diesel engines below 100 hp (76 kW), and in terms of the major players in this marketplace—Volvo Penta and Yanmar—are not likely to make their way into this horsepower range anytime soon. Thus, they can be ignored by the owners of most small auxiliary diesel engines.
The net result of this picture is that despite numerous modifications to diesel engines, as far as most boat-owners with an inboard diesel engine are concerned, there has been little change over the past ten years at the propulsion end of things. On the transmission side, things are a little different. We have seen major inroads into the sailboat market by saildrives, an innovation that replaces the conventional propeller shaft and shaft seal, and which consists of an inboard diesel engine connected to a drive leg that passes through the bottom of the boat. I look at saildrives in Chapter 8, Marine Transmissions.
Readers of earlier editions of this book will notice that many of the illustrations have been updated, and I have added a considerable number of new ones. I would particularly like to thank Jan Dahlsten at Volvo Penta and Greg Eck at Yanmar for helping me assemble this art. Scattered throughout the text are also numerous small pearls of wisdom and practical tips supplied by my readers over the years—my thanks to all of them.
Once again, it has been a pleasure to work with the crew at International Marine, especially Molly Mulhern, Janet Robbins, and Margaret Cook.
Nigel Calder
Cruising on Nada in Northern Europe, Summer 2006
См. также Дизельный двигатель + DVD на русском.
Содержание
LIST OF TROUBLESHOOTING CHARTS
PREFACE TO THE THIRD EDITION
PREFACE TO THE SECOND EDITION
INTRODUCTION
ONE
Principles of Operation
Compression Ignition
Converting Heat to Power
Expansion and Cooling
Gasoline Engines
Cost and Power-to-Weigh
Types of Diesels
Principal Engine Components
TWO
Details of Operation
Section One: The Air Supply
Volumetric Efficiency
Naturally Aspirated Engines
Superchargers and Turbochargers
Intercoolers and Aftercoolers
Section Two: Combustion
The Importance of Turbulence
Injector Spray Patterns
Techniques for Creating Turbulence
Section Three: Fuel Injection
Jerk (In-Line) Pumps
Distributor (Rotary) Pumps
Unit Injectors
Common Rail Systems
Injectors
Lift Pumps
Section Four: Governors
Simple Governors
Vacuum Governors
Section Five: Electronic Engine Controls
Networking
Limping Home
Section Six: Keeping Things Cool
Raw-Water Cooling
Heat Exchanger Cooling
Keel Cooling
Wet and Dry Exhausts
THREE
Routine Maintenance: Cleanliness is Next to Godliness
Section One: Clean Air
Routine Maintenance
Section Two: Clean Fuel
Lubrication
Contamination
Fuel Handling
Fuel Filters
Section Three: Clean Oil
The API "Donut"
Oil Changes
Changing Filters
Section Four: General Cleanliness
Clean Water
Clean Electrical Systems
A Clean Engine
Scheduled Overhauls
Section Five: Winterizing
FOUR
Troubleshooting, Part One: Failure to Start
Section One: Failure to Crank
Water in the Engine
Starter Motor Does Not Crank
Inertia and Preengaged Starters
Circuit Testing
Motor and Solenoid Disassembly, Inspection, and Repair
Section Two: Failure to Fire
An Unobstructed Airflow
Achieving Ignition Temperatures
Fuel Problems
FIVE
Troubleshooting, Part Two: Overheating, Smoke, Loss of Performance, and Other Problems
Overheating
Smoke
Loss of Performance
Oil-Related Problems
Inadequate Turbocharger Performance
Problems with Engine Instrumentation
SIX
Repair Procedures, Part One: Cooling, Exhaust, and Injection Systems
The Cooling System
Water Pumps
The Exhaust System
Governors
Fuel Injection Pumps
Injectors
Gaskets
SEVEN
Repair Procedures, Part Two: Decarbonizing
Preparatory Steps
Cylinder Head Removal
Valves
Cylinders
Pistons and Connecting Rods
Piston Rings
Replacing Pistons and Connecting Rods
Replacing Cylinder Heads
Retiming an Engine
Accessory Equipment
EIGHT
Marine Transmissions
Planetary Transmissions
Two-Shaft Transmissions
Variations on a Theme
Shaft Brakes
Transmission Maintenance
Troubleshooting and Repairs
NINE
Engine Selection and Installation
Section One: Engine Selection
Matching an Engine to Its Load
How Much Horsepower Do You Need?
ВНР, SHP, and Auxiliary Equipment
Section Two: Propeller Sizing and Selection
Propeller Sizing
Propeller Selection
Section Three: Connecting the Transmission to the Propeller
Couplings
Engine Alignment
Constant-Velocity Joints
Shaft Seals
Struts and Bearings
Section Four: Auxiliary Systems
Ventilation
Fuel Tanks
Cooling
Exhaust
Auxiliary Equipment
Some Electrical Considerations
Serviceability
Postscript: Diesel-Electric Propulsion