www.jntuworld.

com

www.jwjobs.net

THERMAL ENGINEERING
LAB MANUAL

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

LIST OF EXPERIMENTS

1. I.C ENGINES PERFORMANCE TEST (4-STROKE DIESEL ENGINE

2. I.C ENGINES HEAT BALANCE
3. ECONAMICAL SPPED TEST (4-STROKE DIESEL ENGINE)
4. PERFORMANCE TEST ON RECIPROCATING AIR COMPRESSOR
5. PORT TIMING DIAGRAM OF A 2-STROKE PETROL ENGINE
6. VALVE TIMING DIAGRAM OF A 4-STROKE DIESEL ENGINE
7.. DIS-ASSEMBLY AND ASSEMBLY OF A ENGINE.

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

I.C ENGINES PERFORMANCE TEST (4-STROKE DIESEL ENGINE)

AIM:
To conduct performance test on 4-Stroke diesel engine (Single cylinder) and to
draw the following graphs.
1. B.P Vs S.F.C
2. Mechanical efficiency Vs B.P
3. B.P Vs Indicated thermal efficiency
4. B.P Vs Indicated thermal efficiency
5. Air fuel Ratio Vs B.P
6. Air fuel Ratio Vs S.F.C
THEORY:
The Test Ring consists of Four-Stroke Diesel Engine, to be tested for
performance, is connected to Rope Brake Drum with Spring Balace (Mechanical
Dynamometer) with Exhaust Gas Calorimeter. The arrangement is made for the
following measurements of the Set-up :
1) The Rate of Fuel Consumption is measured by using the pipette reading againt the
known time.
2) Air Flow is measured by Manometer connected to Air Box.
3) The different mechanical loading is achieved by operating the spring balance of
dynamometer in steps.
4) The different mechanical energy is measured by spring balance and radius of
brake drum.
5) The Engine Speed (RPM) is measured by electronic digital RPM Counter.
6) Temperature at different points is measured by electronic digital Temperature
Indicator.
7) Water Flow Rate through the engine & calorimeter is measured by Watermeter.
The whole instrumentation is mounted on a self contained unit ready for table
operation.

PROCEDURE:
www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

1. Check the diesel in the diesel tank.

2. Allow diesel, start the engine by using hand cranking.
3. The engine is set to the speed of 1500 RPM.
4. Apply load from the spring balance of dynamometer.
5. Allow some time so that the speed stabilizes.
6. Now take down spring balance readings.
7. Put tank valve in to pipette position and note down the time taken for
particular quantity of fuel consumed by the engine.
8. Note down the temperature readings at different points.
9. Note down the water readings.
10. Repeat the procedure (4)&(7) for different loads.
11. Tabulate the readings as shown in the enclosed list.
12. After the experiment is over ,keep the diesel control valve at mains position.

OBSERVATIONS:

Spring
balance
Readings

Fuel
pipette
readings

Caloriemeter
Water
Temperature

Engine head
water
temperature

Exhaust gas
Air
Engine
temperature inlet
Speed
in
RPM F1 F2
Time
In
Inlet Outlet Inlet Outlet Inlet Outlet
In
In
in
T6C
Ml
T2C T3C T1C T2C T4C T5C
Kgs Kgs
Secs.
1
2(a) 2(b) 3(a) 3(b) 4(a)
4(b)
5(a)
5(b)
6(a)
6(b)
7

www.jntuworld.com

Air flow
Water
Manometer flow
readings in rate
mm of
in
water
lpm

www.jntuworld.com

www.jwjobs.net

CALCULATIONS
1.FUEL CONSUMPTION IN Kg/Hr

WF =

Column(3a)oftablereadings
x 3.06
Column(3b)oftablereadings

2. ENGINE OUT PUT BHP:

BP=

2 N ( F 1 F 2) r
KW
4500

Where, N- Speed of engine in RPM

rRadius of brake drum in mts =0.185 mt
F1&F2- Force indicated on spring balance in KGs

3.SPECIFIC FUEL CONSUMPTION (SFC):

SFC =

WF
Kg/BHP. Hr
BHP

4. FUEL HP(THERMAL HORSE POWER),

FHP=

WF x CV x J
60 X 4500

Where, Cv = Calorific value of diesel= 10000 K.Cal /Kg

J= Mechanical equivalent of heat=427 kg.m / K.Cal

5. PERCENTAGE THERMAL EFFICIENCY.

% th =

BHP
x 100
FHP

6. AIR CONSUMPTION IN Kg/ Hr Wa

Wa = 0.6 x A0 x Va x 1.29 x 60 x 60
Where, Ao = Area of the orifice in m2 =

d2

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

Where d= Dia.of the orifice in m = 0.015 mt

Va = 2g (hm/1000) x [( w a ) - 1]
Where g = 9.81 m/ sce2
hm = Manometer reading in mm (column 5)
w = Density of water = 1000 Kg/ m3
a = Density of air = 1.29 Kg/ m3
7.AIR TO FUEL CONSUMPTION RATIO.
Air to fuel consumption ratio =

Wa
WF

Fuel
Air
Engine
Air to Fuel Engine
Consumed Consumed
Sl.NO RPM
Ratio
output
Wf
Wa
N
Wa / Wf BHP
In Kg/Hr
In Kg/Hr
1

Specific fuel
consumption
SFC

Fuel HP
FHP

2
3
4
5
6

RESULT;
Performance test on 4-Stroke diesel engine(Single cylinder) is conducted and the
following graphs are plotted.
1. B.P Vs S.F.C
2. Mechanical efficiency Vs B.P
3. B.P Vs Indicated thermal efficiency
4. B.P Vs Indicated thermal efficiency
5. Air fuel Ratio Vs B.P
6. Air fuel Ratio Vs S.F.C

www.jntuworld.com

Brake %
thermal
efficiency

www.jntuworld.com

www.jwjobs.net

I.C ENGINES HEAT BALANCE

AIM:
To conduct performance test on 4-Stroke diesel engine(Single cylinder) and to
check the heat balance of I.C engine.

THEORY:
The Test Ring consists of Four-Stroke Diesel Engine, to be tested for
performance, is connected to Rope Brake Drum with Spring Balance (Mechanical
Dynamometer) with Exhaust Gas Calorimeter. The arrangement is made for the
following measurements of the Set-up :
1) The Rate of Fuel Consumption is measured by using the pipette reading against
the known time.
2) Air Flow is measured by Manometer connected to Air Box.
3) The different mechanical loading is achieved by operating the spring balance of
dynamometer in steps.
4) The different mechanical energy is measured by spring balance and radius of
brake drum.
5) The Engine Speed (RPM) is measured by electronic digital RPM Counter.
6) Temperature at different points is measured by electronic digital Temperature
Indicator.
7) Water Flow Rate through the engine & calorimeter is measured by Wattmeter.
The whole instrumentation is mounted on a self contained unit ready for table
operation.

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

PROCEDURE:
1. Check the diesel in the diesel tank.
2. Allow diesel, start the engine by using hand cranking.
3. The engine is set to the speed of 1500 RPM.
4. Apply load from the spring balance of dynamometer.
5. Allow some time so that the speed stabilizes.
6. Now take down spring balance readings.
7. Put tank valve in to pipette position and note down the time taken for particular
quantity of fuel consumed by the engine.
8. Note down the temperature readings at different points.
9. Note down the water readings.
10. Repeat the procedure (4)&(7) for different loads.
11. Tabulate the readings as shown in the enclosed list.
12. After the experiment is over ,keep the diesel control valve at mains position.

OBSERVATIONS:

Spring
Fuel
Caloriemeter Engine head
Exhaust gas
Air
balance
pipette
Water
water
Engine
temperature inlet
readings
Temperature temperature
Speed Readings
in
RPM F1 F2
Time
In
Inlet Outlet Inlet Outlet Inlet Outlet
In
In
in
T6C
Ml
T2C T3C T1C T2C T4C T5C
Kgs Kgs
Secs.
1
2(a) 2(b) 3(a) 3(b) 4(a)
4(b)
5(a)
5(b)
6(a)
6(b)
7

www.jntuworld.com

Air flow
Water
Manometer flow
readings in rate
mm of
in
water
lpm

www.jntuworld.com

www.jwjobs.net

CALCULATIONS:
1.FUEL CONSUMPTION IN Kg/Hr

WF =

Column(3a)oftablereadings
x 3.06
Column(3b)oftablereadings

2. ENGINE OUT PUT BHP:

BP=

2 N ( F 1 F 2) r
KW
4500

Where, N- Speed of engine in RPM

rRadius of brake drum in mts =0.185 mt
F1&F2- Force indicated on spring balance in KGs
3.SPECIFIC FUEL CONSUMPTION (SFC):

SFC =

WF
Kg/BHP. Hr
BHP

4. FUEL HP(THERMAL HORSE POWER),

FHP=

WF x CV x J
60 X 4500

Where, Cv = Calorific value of diesel= 10000 K.Cal /Kg

J= Mechanical equivalent of heat=427 kg.m / K.Cal

5. PERCENTAGE THERMAL EFFICIENCY.

% th =

BHP
x 100
FHP

6. AIR CONSUMPTION IN Kg/ Hr Wa

Wa = 0.6 x A0 x Va x 1.29 x 60 x 60

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

Where, Ao = Area of the orifice in m2 =

d2

4
Where d= Dia.of the orifice in m = 0.015 mt
Va = 2g (hm/1000) x [( w a ) - 1]
Where g = 9.81 m/ sce2

hm = Manometer reading in mm (column 5)

w = Density of water = 1000 Kg/ m3
a = Density of air = 1.29 Kg/ m3
7.AIR TO FUEL CONSUMPTION RATIO.
Air to fuel consumption ratio =

Wa
WF

8.. TABLE OF CALCULATIONS.

Fuel
Air
Engine
Air to Fuel Engine
Consumed Consumed
Sl.NO RPM
Ratio
output
Wf
Wa
N
Wa / Wf BHP
In Kg/Hr
In Kg/Hr
1
2
3
4
5
6

www.jntuworld.com

Specific fuel
consumption
SFC

Fuel HP
FHP

Brake %
thermal
efficiency

www.jntuworld.com

www.jwjobs.net

9. HEAT BALANCE SHHET ON MINUTE BASIS:

1. Heat supplied in fuel = Fuel consumed in Kg/min x Cv

WF x 10000
=
K.Cal / min-------------------I
60
2. Heat carried away by engine head cooling water
= mw x Cw x (T1-T2) K.Cal / min------------------------II
3. Heat carried away by calorie meter water
= mw x Cw x (T3-T2) K.Cal / min------------------------III
4. Heat carried away by the exhaust gasses
=mg x Cp x [T5-T4] K.Cal / min------------------------IV
mg = Mass of gas = Wa + WF
5.Radiation & un Accounted = I-[ BHP+ II + III+IV] K.Cal/minV

RESULT:
Heat balance sheet is as follows
CREDIT

Kilo
Calories

DEBIT
1.Brake power

Heat
supplied in
fuel

100

Kilo
Calories

BHP

BHP
x 100
I

2.Engine head water

II

II
x 100
I

3.Calorie meter water

III

III
x 100
I

4.Exhaust gasses

IV

IV
x 100
I

5.Radiation and unaccounted

( by difference)

100

V
x 100
I

100

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

ECONAMICAL SPPED TEST (4-STROKE DIESEL ENGINE)

AIM:
To conduct economical speed test on 4-Stroke diesel engine(Single cylinder)

THEORY:
The Test Ring consists of Four-Stroke Diesel Engine, to be tested for
performance, is connected to Rope Brake Drum with Spring Balance (Mechanical
Dynamometer) with Exhaust Gas Calorimeter. The arrangement is made for the
following measurements of the Set-up :

1) The Rate of Fuel Consumption is measured by using the pipette reading against
the known time.
2) Air Flow is measured by Manometer connected to Air Box.
3) The different mechanical loading is achieved by operating the spring balance of
dynamometer in steps.
4) The different mechanical energy is measured by spring balance and radius of
brake drum.
5) The Engine Speed (RPM) is measured by electronic digital RPM Counter.
6) Temperature at different points is measured by electronic digital Temperature
Indicator.
7) Water Flow Rate through the engine & calorimeter is measured by Water meter.
The whole instrumentation is mounted on a self contained unit ready for table
operation.

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

PROCEDURE:
1. Check the diesel in the diesel tank.
2. Allow diesel, start the engine by using hand cranking.
3. The engine is set to the speed of 1500 RPM.
4. Apply load from the spring balance of dynamometer.
5. Allow some time so that the speed stabilizes.
6. Now take down spring balance readings.
7. Put tank valve in to pipette position and note down the time taken for
particular quantity of fuel consumed by the engine.
8. Note down the temperature readings at different points.
9. Note down the water readings.
10. Repeat the procedure (4)&(7) for different loads.
11. Tabulate the readings as shown in the enclosed list.
12. After the experiment is over ,keep the diesel control valve at mains position.
OBSERVATIONS:
Engine
Speed
in
RPM

Spring balance
Readings
F1
F2
In Kgs
In Kgs

Fuel pipette readings

In ml

Time in Secs.

www.jntuworld.com

Air flow Manometer readings

in mm of water
H1

H2

www.jntuworld.com

www.jwjobs.net

CALCULATIONS
1.FUEL CONSUMPTION IN Kg/Hr

WF =

Column(3a)oftablereadings
x 3.06
Column(3b)oftablereadings

2. ENGINE OUT PUT BHP:

BP=

2 N ( F 1 F 2) r
KW
4500

Where, N- Speed of engine in RPM

rRadius of brake drum in mts =0.185 mt
F1&F2- Force indicated on spring balance in KGs

3.SPECIFIC FUEL CONSUMPTION (SFC):

SFC =

WF
Kg/BHP. hr
BHP

4. FUEL HP(THERMAL HORSE POWER),

FHP=

WF x CV x J
60 X 4500

Where, Cv = Calorific value of diesel= 10000 K.Cal /Kg

J= Mechanical equivalent of heat=427 kg.m / K.Cal

5. PERCENTAGE THERMAL EFFICIENCY.

% th =

BHP
x 100
FHP

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

6. AIR CONSUMPTION IN Kg/ Hr Wa

Wa = 0.6 x A0 x Va x 1.29 x 60 x 60
Where, Ao = Area of the orifice in m2 =

d2

4
Where d= Dia.of the orifice in m = 0.015 mt
Va = 2g (hm/1000) x [( w a ) - 1]
Where g = 9.81 m/ sce2
hm = Manometer reading in mm (column 5)
w = Density of water = 1000 Kg/ m3
a = Density of air = 1.29 Kg/ m3

7. AIR TO FUEL CONSUMPTION RATIO.

Air to fuel consumption ratio =

Wa
WF

Fuel
Air
Engine
Air to Fuel Engine
Consumed Consumed
Sl.NO RPM
Ratio
output
Wf
Wa
N
Wa / Wf BHP
In Kg/Hr
In Kg/Hr
1

Specific fuel
consumption
SFC

Fuel HP
FHP

Brake %
thermal
efficiency

2
3
4
5
6

RESULT;
Economical speed test on 4-Stroke diesel engine(Single cylinder) is conducted. From
the graph economical speed of engine is---------------RPM @---------HP

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

PERFORMANCE TEST ON RECIPROCATING AIR COMPRESSOR

AIM:
To study the working of double stage air compressor and determination of volumetric
efficiency, mechanical efficiency.
THEORY:
When the motor is started, air is sucked from the atmosphere through the
inlet air filter and orifice meter and compressed in the LP Cylinder. The hot and
compressed air is colled in the intercooler and again compressed in the HP
Cylinder.Finnally, high pressure air passes into air receiver tank through after coller and
non-return valve.
The compressor motor unit consists of a AC motor. The AC motor body
frame is mounted on trunnion bearing which swivels on application of load/torque on the
motor. The torque/load developed is measured at the torque arm of 0.2m using a spring
balance. The encoders (speed pick-ups) are provided for both motor and compressor
shafts for measurement of RPM. A toggle switch and digital RPM indicator are provided
in the control panel
The control console consists of digital speed indicator, temperature
indicator, double column manometer for air flow measurement, pressure gauges for
pressure rise measurement after each stage separately,energy meter to measure electrical
input to the motor. The neccssary mains ON indicators and switches are provided for
completeness of the instrumentation.
The complete unit is built-in. Foundation is not neccssary for installation
of the test rig. The pressure tappings and temperature sensors after each stage are
connected to pressure gauges and indicators in the control panel. Air volume measuring
chamber with orifice of 15mm diameter is fixed beneath the control console and tappings
connected to double column manometer for air intake measurements.
PROCEDURE;
1. Release the pressure of air fully from tank, if previously pressurized.
2. Check zero level in the double column.
3. Switch ON the mains and observe the light indicators ON.
4. Keep the outlet valve closed.
5. Switch-ON the starter and allow motor to run full speed.

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

6. As the pressure in the receiver tank increases , set the pressure by obtaining the
delivery valve to 1,2,3 Kg/ cm2 as observed from the pressure gauge and note the
readings.
7. Note down the flow rate manometer readings at different pressures.
8. Note down pressure after LP cylinder, after HP cylinder, temperatures after LP
cylinder, after inter cooler , after HP cylinder and at the inlet.
9. Note down the energy meter reading, speed and air temperature.
10. Tabulate the above readings as shown.
11. Stop the compressor and release the pressure from the tank after the experiment is
completed.
OBSERVATIONS:

T1= Air inlet temperature

T2= After first stage
T3=After inter cooler
T4=After second Stage
E.M Constant=150 Rev/ KWH
Orifice Dia=15mm
Torque arm=0.2m

www.jntuworld.com

www.jntuworld.com

Sl.
No

P1(LP)
Pressure
after first
stage in
Kg/ cm2

www.jwjobs.net

Energy
P2(HP)
meter
Pressure reading
after
No.of
second revns./
stage in
Time
Kg/ cm2
in
Secs.

Air flow
across
Orifice in
mm of
water
hw

RPM of RPM
compre
of
ssor
motor

Temperature
Points

Swinging field
Spring balance
readings inKg
T1

1
2
3
4
5

CALCULATIONS:
1. Density of Air at 30 C (a)

= 1.293 Kg/ m3

2. Water Density (w)

= 1000 Kg/ m3

3. Acceleration due to gravity,g = 9.81 m/sec2

4. Orifice diameter

= 15 mm

5. Co-efficient of discharge of orifice, Cd= 0.64

6. Torque arm distance
7. INPUT TO COMPRESSOR

= 0.2m
=Energy meter reading
=

5
60 x 60 1000
x
x
hp
150
736
t
( where t is time in Secs.for 5 revns)

Wa Q H
736
Where, Wa = 1.293 Kg/ m3 = 12.68 N/ m3
P
H(Head in meters of water) =
x 104
Wa
P is read on after HP cylinder pressure in Kg/ cm2

8. COMPRESSOR OUTPUT

www.jntuworld.com

T2

T3

T4

www.jntuworld.com

www.jwjobs.net

Q(Flow rate) = Cd A

A (Area of orifice) =
Ha =

hw
1000

m3/ sec

2 g Ha
4

x d2 = 1.766 x 10 -4 m2

1 = 0.772 hw

Q = 0.62 x1.766 x 10 -4 m2 x
Q = 4.2612x10 -4 x hw

2 x 9.81 x 0.772 hw

Where hw = Head measured in mm of water across orifice plate.

9. % EFFICIENCY OF COMPRESSOR (MECHANICAL)
%

compressor

Compressor output
x 100
Electrical input

10. SWEPT VOLUME OF PISTON (LP) = Area of Piston x Stroke

Vs1=

x (0.07)2 x 0.085 = 3.2711 x 10 -4 m3

11. SWEPT VOLUME OF PISTON (LP) = Area of Piston x Stroke

Vs2=

x (0.05)2 x 0.085 = 1.6689 x 10 -4 m3

Vs = Vs1+ Vs2
12. ACTUAL AIR SWEPT

Q x 60
m3
RPM of compressor

Va =

13.VOLUMETRIC EFFICIENCY

Va
x 100
Vs

www.jntuworld.com

www.jntuworld.com

Sl.No Electrical Discharge H

Input in
Q
In mts
HP
In m3/sec of air
1

www.jwjobs.net

Compressor
Output in
HP

Theoretical
swept
volume

Actual
swept
volume

%
efficiency
(Mechanical)

2
3
4
5

RESULT:
Volumetric efficiency, mechanical efficiency of double stage air compressor is
calculated.

www.jntuworld.com

%
volumetric
efficiency

www.jntuworld.com

www.jwjobs.net

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

PORT TIMING DIAGRAM OF A 2-STROKE PETROL ENGINE

AIM:
To draw the port timing diagram of a 2-stroke petrol engine by studying given out
section model
THEORY:
Port timing diagram is a graphical representation of exact model is the
sequence of operations at which inlet exhaust and transfer port open and closes as well as
firing of fuel. It is generally exposed in terms of angular position of crank shaft.
In theoretical port timing diagram of 2-stroke petrol engine. The fuel is
fired at A i.e., spark advances takes places from TDC to BDC at B both inlet & exhaust
ports are open and motion as well as exhaust port are takes place from B to C position
moves first to BDC and then slightly upwards to C. Both the plates parts are closed and
compression takes place from C to A. The crank shaft revolves through 1200
appproximately and piston moves to TDC in 2-stroke engine crank revolves through 3600
In actual port timing diagram the expansion of the change starts as
position of piston moves from TDC towards BDC first of all burnt gases leaving the
cylinders after a small revolution of crank revolution. The transfer port also opens and
fresh fuel air mixture center into engine cylinder now piston reaches BDC and then starts
moving up wards. As crank moves a little and BDC. The first transfer port closes and
then exhaust port closes. Now the change is compressed with both parts closed & then
ignited with help of spark plug before the end of compression stroke. This is done as the
change required same time to ignite by the time position reaches to TDC. The burnt
gasses push the position downwards with fire and the expansion of burnt gasses takes
place opens and close at equal angle on either side of BDC position.
TPC: Transfer port closed 640 after BDC
EPC: Exhaust port closed 830 after BDC
EPO: Exhaust port opens 680 before BDC
TPO: Transfer port opens 480 before BDC

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

PROCEDURE:
1. First observe the various parts of a 2-stroke petrol engine at given section model
2. Now set up the pointer which placed on the flywheel to 00 and position at BDC
3. Slowly move the flywheel after some time before reaching TDC. Then inlet port
opens measure of angle at which pointer shows
4. The inlet port opens at 300 before TDC. now position reaches TDC and BDC the
inlet valve closes 700 before BDC
5. The spark advance takes places 450 before TDC the exhaust port closes at800
after BDC and transfer port closes at 600 after BDC
6. Now position moves from TDC towards BDC suction and compression starts in
previous stroke which the piston reaches BDC. And again inlet port closer at 700
before BDC
7. Transfer port is closed at 600 after BDC and and exhaust port closes at 800 after
BDC
RESULT:
1. Scavenging suction process covered =
2. Compression process covered=
3. Expansion process covered=
4. Exhaust process covered=

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

VALVE TIMING DIAGRAM OF 4-STROKE DISEL ENGINE

AIM:
To draw the valve timing diagram of 4-stroke engine by studying the cut section
model
THEORY:
1. The Theoretical valve timing diagram for 4-stroke diesel engine is shown in
figure. In this the diagram inlet valve opens at A.
2. The solution takes place from A to B. The crank shaft revolves through 1800 &
the piston moves from TDC to BDC.
3. It B the inlet valve closes and the compression revolves through 1800 and the
piston moves from BD to TDC.
4. A C the fuel injection takes places i.e. injection valve opens and fuel is fixed by
the compression
IVO: Inlet Valve open
IVC: Inlet valve close
FVO: Fuel valve open
FVC: Fuel valve close
EVO: Exhaust valve open
EVC: Exhaust valve close

PROCEDURE:
1. Observe the various parts of4-stroke diesel engine and various strokes of engine.
After this set the pointer at flywheel at zero
2. Now position at BDC on moving slowly the flywheel inlet valve opens before the
position reaching to TDC. Reading are noted
3. Inlet valve opens before TDC and after slowly moved flywheel in the same
direction. The position reaches TDC and then BDC
4. After BDC the inlet valve closes note the position of the inlet valve closes 130
after BDC
5. Slowly move the flywheel in same direction after closing of inlet valve suction
stroke is completed

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

6. Exhaust valve is opens at 350 before BDC exhaust valve closes 80 after TDC.
Same time exhaust stroke completes and cycle is completed
PRECAUTIONS:
1. Readings should be taking without parallax error
2. Observe carefully the valves are closed or in open
RESULT:
The valve timing diagram of 4-stroke diesel engine is studied with the help of given
cut section model
1. Suction covered =
2. Compression covered =
3. Expansion covered =
4. Exhaust covered =
5. Overlap =

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

DIS-ASSEMBLY AND ASSEMBLY OF A ENGINE.

AIM:

To study the procedure for dis-assembly and assembly of a specific engine by

making a practical trail on it.

THEORY: The main parts of any engine are,

Cylinder Block:
1. It forms the basic frame work of the engine.
2. It houses the engine cylinders.
3. Serves as bearing or support and guides the piston reciprocating in it.
4. Block contains passengers for circulation of cooling water and lubricating oil.
There are two types of rings
a) Compression ring
b) Oil control ring

Connecting rod:
It connects the piston with the crank shaft thus facilitative the transmission
of power combustion chamber to the crank shaft it also converts the reciprocating motion
of the piston into rotary motion of crank shaft.
Fly wheel:
The fly wheel absorbs the energy power source and gives out this energy the other
3-strokes keeping the crank shaft rotating at uniform speed through out.
Cam shaft :
A shaft is responsible for opening the valves on addition the crank shaft operates.
Cylinder head:
1. The head is a mano block casting.
2. It contains spark plug notes and cooling water Sackets, valve opening
mechanism is mounted.
3. Complete valve opening mechanism is mounted on the head.

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

Piston:
The top of the piston is called head or crown it may be either done are may
specially to form a desired shape of combustion chamber jointly with the cylinder block.

Piston pin:
It provides a seal b/w the piston fuel pump. Oil pump and distributor valves.
Valves:
These are accurate by the cams which in turn are operated by crank shaft and
perform following functions.

PROCEDURE FOR ENGINE DIS-ASSEMBLY.

For dis-assembly the engine,it should be mounted in a suitable stand.Engine disassembly is carried out in a sequence as follows and engine is out of the vehicle and all
the accessories have been removed and oil has been drained.
Remove water pump.
Remove exhaust manifold
Remove oil filter
Remove water outlet fitting
Remove thermostat
Remove crank shaft pulley
Remove oil pump
Remove crank case ventilation valve
Remove rocker arm assembly
Remove cylinder head.
Remove oil pan.
Remove piston rod and connecting rod.
Remove timing gear cover.
Remove front end plate.
Remove fly wheel housing.
Remove fly wheel, clutch
Remove crank shaft.
Remove exhaust valve and springs.

www.jntuworld.com

www.jntuworld.com

www.jwjobs.net

Remove cam shaft, valve tappers.

Remove oil gallery plugs.

PROCEDURE FOR ENGINE DIS-ASSEMBLY.

First clean the cylinder block with fresh oils. Piston is connected to connecting
rod with gudge pin .This piston have the piston rings.
After fixing the rings piston is inserted in to the cylinder block with help of ring
compressor.
These rings are fitted in the piston grooves with help of calipers.
The crank shaft has been placed on the bottom of the cylinder block the
connecting rod is connected to its crank.
The fly wheel is attached to the crank shaft one side.
On the other side of the crank shaft timing gear is fitted. It is for valve operating.
This equipment is placed on the sump of the engine.
After fixing on the sump the cam shafts are fitted in the cylinder head in the inlet
valve & exhaust valves are fitted with help of G-clamp
To this cylinder the intake manifold and injectors are fitted one side.
Other side of the cylinder head the exhaust manifold is fitted.
Fill the sump with new oil.
After fill up the oil the water pump is fitted.
The thermostat is also fitted to this engine then the re assembly of the given
engine is completed.

RESULT:
Thus the procedure of the assembling of a engine is studied and recorded.

www.jntuworld.com