This densely illustrated, hands-on guide to diesel engine maintenance, troubleshooting, and repair renders its subject more user-friendly than ever before. Finally, boatowners who grew up with gas engines can set aside their fears about tinkering with diesels, which are safer and increasingly more prevalent. As in other volumes in the International Marine Sailboat Library, every step of every procedure is illustrated, so that users can work from the illustrations alone. The troubleshooting charts in the second chapter--probably the most comprehensive ever published--are followed by system-specific chapters, allowing readers to quickly diagnose problems, then turn to the chapter with solutions. Diesel engine systems covered include: mechanical; oil; fresh- and raw-water cooling; low- and high-pressure fuel; exhaust; starting; charging; transmission and stern gear.
Acknowledgements
Introduction
Maintaining Your Diesel
Good Operating Procedures
Routine Maintenance
Surveying the Engine
The Initial Inspection
The Startup
The Sea Trial
Preventing Corrosion
Laying Up or "Winterizing" a Diesel
Troubleshooting Marine Diesels
Main Menu
Check Crankshaft Turns Freely
Performance Problems
Oil Problems
Excessive Exhaust Smoke
Temperature Problems
Noise and Vibration Problems
Starting System Problems
Charging System Problems
Turbocharger Problems
Fuel System Functional Check
Engine Fails to Stop
The Mechanical System
Engine Block
Cylinder Head
Crankshaft
Timing Gears
Valves
Pistons and Cylinders
Engine Mounts
Engine Alignment
Table of Mechanical System Faults
The Lubrication System
Oil
Oil Pump
Oil Pressure - Regulating Valve
Oil Filter
Priming the Oil System
Oil Contamination
Table of Lubrication System Faults
The Raw-Water Circuit
Raw-Water Strainer
Raw-Water Pump
Reconditioning a Raw-Water Pump
Heat Exchangers and Oil Coolers
Sacrificial Anodes, or "Zincs"
Antisiphon Valves
Raw-Water Hoses
Hose Clamps
Raw-Water Thermostats
Table of Raw-Water Circuit Faults
The Coolant Circuit
Coolant
Header Tank
Thermostat
Circulating Pump
V-Belt
Coolant-Circuit Hoses
Table of Coolant Circuit Faults
The Fuel System
Fuel
Fuel Tanks
Primary Filter
Fuel Lift Pump
Secondary Fuel Filter
Governor
Injector Pump
Cold-Starting Aids
Fuel Injectors
Air in the Fuel System
Table of Fuel System Faults
The Intake and Exhaust System
Air-Intake Filter
Exhaust Manifold
Exhaust Injection Elbow
Exhaust Hose
Mufflers and Lift Boxes
Exhaust Backpressure
Turbochargers
Intercoolers
Table of Intake and Exhaust System Faults
The Electrical System
Batteries
Battery Switches
Alternator
Starter Motor
Typical Engine-Installation Circuit Diagram
Table of Electrical System Faults
Controls and Instruments
Throttle Controls
Gear-Selector Controls
Engine-Stop Controls
Control Cables
Tachometers
Engine-Panel Gauges
Warning Circuits
Table of Control and Instrument Faults
Appendix: Diesel Engine Toolkit
Index
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