CHAPTER-7

Diesel Fuel Filters And Water Sedimenter:

• Since the injection pump and the injectors are manufactured to very high standards of precision
(1 /1000 mm ), even the smallest particle of dirt or other foreign body would cause severe wear or
damage within a short time, and render the item concerned unserviceable.
• It is therefore a more economical proposition in the long run to keep the fuel filter in good working
order than to be obliged to renew expensive pump elements or injectors.
i. Box type fuel filters and replaceable filter element type filters
• In addition to filters with replaceable elements, box-type filters are being used increasingly today. A
sheet-metal box containing the paper element is screwed to the filter cover.
• The filter box has inlet holes for the unfiltered fuel, and 1 outlet hole for the filtered fuel.
• The outlet hole is tapped, and is also used to screw the filter box to the cover. The complete box is
renewed when the filter element becomes unserviceable. It is unscrewed from the cover and
discarded, after which a new box is screwed on hand tight until the sealing ring makes firm contact.
• It is then given another quarter-turn to tighten it finally. The old filter elements must be scrapped,
as they cannot be cleaned.
 Fig. 7.1 Box type filter
• This also eliminates the risk of damage to the fuel injection system if replaceable filter
elements were to be installed again after incorrect or careless cleaning.
Filter Element:
• Paper is the material mostly used for filter elements. Depending on the arrangement of
the paper for the filter element, we distinguish between wrapped filter elements and star-
shaped filter elements (see Figure above). The paper of a wrapped-type element is
wound round a tube .
• The fuel flows through the filter axially, from top to bottom, so that dirt particles are
trapped in the V-shaped pockets. After purification, the fuel flows back up through the
central tube.
 Fig.7.2 Wrapped filter

• The star-shaped filter element is placed in position round a perforated tube.

• The fuel flows radially through the filter, from the outside inwards, so that dirt particles
are trapped in the folds of the element or drop to the bottom.
• The filtered fuel flows through the perforations and up the central tube.

Fig. 7.3 Star pattern filter

 Single and multi-stage fuel filters

• Single stage filter consists of the filter cover with tapped holes for the fuel
IN and OUT a center bolt for the filter can.

Fig.7.4 Fuel filter (single stage) Fig. 7.5 Fuel filter and sedimenter (Two stage filter)
 Cont…
• To eliminate water, which may have entered the fuel as a result of careless refueling, incorrect
storage of the fuel or the formation of condensate in the fuel tank, a water trap is provided on the
filter.

• The water, which collects here, can be removed from the system by unscrewing a drain plug.

• In the two-stage fuel filter the fuel first passes through the course filter to the fine filter.

• The fuel filter for the distributor type injection pumps is often combined with a priming pump
and a water sedimenter.

• The priming pump is a manual unit containing a reciprocating piston used to draw in diesel fuel
to bleed air or water from the fuel system. It is normally locked to prevent it from operating while
the engine is running.
 Water Sedimenter

• The water sedimenter separates water from the diesel fuel by using the difference in
specific gravities between it and the diesel fuel.

• When the water level and the float rise beyond a specified limit, a magnet inside the float
closes a reed switch. This lights an indicator lamp on the combination meter to warn the
driver that water has accumulated in the water sedimenter. The sedimenter has a cock
underneath.

Fig. 7.6 Water level detection switch

 Cont…
• Water can be removed by un tightening the cock and operating the priming pump. Water is heavier than the
diesel fuel and so sinks to the bottom. The float is lighter than water but heavier than the diesel fuel.
Therefore, the float rises as the water level under the fuel increases. When it reaches the water level
detection switch (a reed switch), the magnet inside the float turns the switch on to issue a warning.

7.2. Intake system

The purpose of an intake system is to clean the incoming air, mix it in proper proportion with fuel, vaporizing
and directing the mixture into the engine cylinder.

Component parts of an intake system

The gasoline (carbureted) intake system consists of the air cleaner, part of a carburetor, intake manifold and
then intake valve. Air cleaners are employed in the intake system to purify the air drawn in for combustion
effectively without impeding the incoming airflow rate.
Air cleaners also perform the following functions:-
• It captures moisture and carbon soot that are present in the atmospheric air.

• It acts as a silencer and reduces the noise caused by the intake air as the intake valves open
and close.

• It acts as a flame arrestor if the engine backfires through the air-intake systems. Backfiring
causes a momentary flashback through the carburetor. Without air cleaner, the flame could
erupt from the carburetor or air intake system and cause a fire in the engine compartment.

• The common types of air cleaners available in the market are dry paper type and oil wetted
wire mesh type of air cleaners.
 1. The paper type of air cleaners:
• This type of air cleaners contains three main parts, cover, cleaning element and main housing (case). These are
assembled into one unit. The main housing contains the cleaning element, usually of multi-wire netting, but some
are made of nylon hair or paper. The air from the atmosphere passes through the cleaning element and goes to the
inlet manifold.

• The paper filter element is cleaned after 50-100 hours of service. Dry air cleaners are mounted (i) vertically in
front of the tractor radiator and (ii) horizontally on the overhead engines. It is most often used type of air cleaners.

• The dry types of air cleaners have the following advantages:

1. Easy to service.

2. Good performance in gradient and in rough fields.

3. More efficient at high speeds.

4. Straw and chaff cause less restriction to air passage.

Its main disadvantages of dry air cleaners are:
1. It is costlier to maintain than an oil bath because the filter elements require replacements
very often.
2. Sometimes, dust particles enter the cylinder

Fig. 7.7 Paper type air cleaner

 Inspecting procedure for air cleaner

1. Remove the air cleaner element.

2. Clean the element by blowing compressed air from inside if it is dry-paper type. Otherwise
refer to the repair manual.
3. If the element is torn or excessively dirty, replace it with a new one.
4. Check the carburetor mountings and gaskets for leakage (if it is carbureted).
5. Check the intake manifold mountings and gaskets for leakage.

Fig. 7.8 cleaning the air cleaner element

 2. Oil wetted wire mesh type of air cleaners.
• It consists of a copper mesh or nylon wire wetted with oil to catch the dust particles from
the air which are made to pass through it.
• This type, however, gets clogged with dust quickly, thus, seriously affecting the air flow
through it and rendering it inefficient in removing the fine particles of dust from the air.

Fig. 7.9 Wetted type of air cleaner

 Chapter - 9
Servicing of Vehicle Controlling Systems
i. Air bleeding from hydraulic brakes:
• Fluids cannot be compressed, whereas gases are compressible. Any air in the brake hydraulic
system is compressed as the pressure increases.

• This action reduces the amount of force that can be transmitted by the fluid, therefore it is very
important to keep all air out of the hydraulic system. To do this, air must be bled from brakes.

• This action is called bleeding the brake system.

• Bleeding is a process of forcing fluid through the brake lines and out through a bleeder valve or
bleeder screw (Figure 9.1 ). The fluid eliminates any air that might be in the system. Bleeder
screws and valves are fastened to the wheel cylinders or calipers. The bleeder must be cleaned.
 Cont…
• A drain hose then is connected from the bleeder to a glass jar (Figure 9.1 ).
• Two types of brake bleeding procedures are used: manual bleeding (vacuum bleeding) and
pressure bleeding.
• Always follow the manufacturer’s recommendations when bleeding brakes. The sequence
in which bleeding is performed can be critical. To remove vacuum, the engine must be off.
• Pump the brake pedal several times.

Fig. 9.1 Bleeding hydraulic brake system

 a. Manual Bleeding
• A manual bleeding procedure requires two people. One person operates the bleeder; the other, the brake
pedal. Bleed only one wheel at a time. Follow the following procedures.

1. Fill the master cylinder reservoir.

2. Place the bleeder hose and jar in position.

3. Have a helper pump the brake pedal several times and then hold it down with moderate pressure.

4. Slowly open the bleeder valve. After fluid/air has stopped flowing, close the bleeder valve. Have the helper
slowly release the pedal. Repeat this procedure until fluid that flows from the bleeder is clear and free of
bubbles. Discard all used brake fluid.

5. Fill the master cylinder reservoir.

6. Check the brakes for proper operation.

• The other that is very essential for brake system is checking and adjusting its pedal free play.
 Cont…

Fig. 9.2 The recommended bleeding sequence for a diagonally split brake system.
 ii. Clutch Linkage Adjustment
• Except for systems with self-adjusting mechanisms, the release bearing should not touch
the pressure plate release levers when the clutch is engaged (pedal up).
• Clearance between these parts prevents premature clutch plate, pressure plate, and release
bearing wear. As the clutch disc wears and becomes thinner, this clearance is reduced.
• Clearance can be ensured by adjusting the clutch linkage, so the pedal has a specified
amount of play, or free travel. Free travel is the distance a clutch pedal moves when
depressed before the release bearing contacts the clutch release lever or diaphragm spring
of the pressure plate.
• To check pedal play, use a tape measure or ruler.
1. Place the tape measure or ruler beside the clutch pedal and the end against the floor of the
vehicle and note the reading (Figure 9.3).
2. Then depress the clutch pedal just enough to take up the pedal play and note the reading
again.
3. The difference between the two readings is the amount of pedal play.
 Cont…

Fig. 9.3 Checking clutch pedal play

 Cont…
• Adjustment should be performed when pedal play is not correct or when the clutch does
not engage or disengage properly.

• To adjust clutch pedal play, refer to the manufacturer’s service manual for the correct
procedure and adjustment point locations.

• Often pedal play can be increased or decreased by turning a threaded fastener located
either under the dash at the clutch pedal or where the linkage attaches to the clutch fork.

• Check hydraulic-operated linkage systems for leaks at the clutch master cylinder,
hydraulic hose, and slave cylinder. Then adjust the linkage to provide the manufacturer’s
specified clutch pedal play.