RYA Diesel Engine Handbook

Andrew Simpson is a marine journalist, yacht surveyor and designer based in Poole. He has written a number of other books on boating and is a regular contributor to yachting magazines both at home and abroad. When not in the UK he can usually be found sailing Mediterranean and Atlantic waters in Shindig, a 12m light displacement cutter he designed himself.

• Introduction1 How Diesel Engines Work 6The four-stroke cycle 7Turbocharging 8How a turbocharger works 9Aftercooling or intercooling? 10The two-stroke cycle 10Indirect injection 112 Fuel 12What is diesel fuel? 12The basic system 13Troubles with tanks 14The diesel “bugs” 14The ideal tank 14Water separating filter (pre-filter) 16Bypass filters 16Fuel lift pump 17Fine filter 17The injection process 18Common rail systems 203 The Air System 21Air filters 22Exhaust 23Siphon breaks 24Watertrap silencers 25Exhaust temperature alarms 254 Engine Cooling 26Raw water cooling 26Indirect cooling 27Keel cooling 28Thermostats 29Of seacocks and strainers 30A pair of pumps 315 The Electrical System 32Ground return 32Insulated return 33Alternators 33Better charging 34Types of battery 34Engine starting 37Stopping the engine 376 Lubrication 38What is lubrication oil? 39Oil filters 39Oil pump 40Gearbox lubrication 40Oil Coolers 417 Transmission 42Direct drives 42Gearboxes 43Twin-shaft transmission 44Planetary or epicyclic transmission 45Shaft couplings 46Flexible couplings 46Stuffing boxes 47Modern shaft seals 48Shaft bearings 49Propellers 50Pitch and twist 50Slip 51Ventilation and cavitation 52Picking the right prop 53Folding and feathering 54Integrated drives 55Stern drives 55Sail drives 56Water jets 578 Engine Controls 58Cable systems 59Dual station controls 599 Starting and stopping your engine 60Pre-start check 60Starting 60A few running checks 61Stopping the engine 61If the engine won’t start 6210 Diagnostics and Troubleshooting 66Smoke signals 66Shake, rattle and roll 67General lack of performance 67The engine hunts or dies 67Possible mechanical causes 68Overheating alarm sounds 68Oil warning light or alarm activated 68Alternator charge alarm sounds 6811 Maintenance 69Basic maintenance intervals 69As recommended by the enginemanufacturer 70Scheduled by the seasons 70Tools 71Spares 7312 How to do it 74Taking care of fuel filters 74Draining a water tap 75Replacing filter elements 75Bleeding the fuel system 76Changing the oil and filter 78Changing gearbox oil 79Changing or adjusting thealternator belt 80Adjusting a packed gland 81Repacking a stern gland 82Changing a thermostatic valve 83Testing a thermostat 83Renewing the fresh water coolant 84Replacing raw water pump impeller 85Adjusting valve clearance 85Battery maintenance 86Replacing engine anodes 87Care of air filters 8713 Emergency procedures 88Engine overheats because ofthermostat failure 88Bypassing the ignition switch 89Stopping a “runaway” engine 90Dealing with an engine fire 90Carbon monoxide 91Index 92