New Generation Volvo Diesel Engine Fundamentals Classroom Training en

Service training
Diesel Engine Fundamentals

Classroom training
Trainer booklet
Service training
Diesel Engine Fundamentals

Classroom training
Participant booklet
Diesel Engine Fundamentals Classroom training
Contents
Introduction
Course content........................................................................................................................... 1
Course objectives....................................................................................................................... 2
Engine history
The diesel engine, yesterday and today .................................................................................... 3
First diesel engine ...................................................................................................................... 4
Diesel engines in vehicles.......................................................................................................... 5
Engines for heavier vehicles ...................................................................................................... 6
Diesel engines in Volvo vehicles................................................................................................ 7
Engine range
Engine range.............................................................................................................................. 8
General and basic priciples
General and basic principles

Diesel engine ........................................................................................................................ 9
Internal combustion engine ............................................................................................... 10
Fuel-air mixture .................................................................................................................. 11
Rotating movement............................................................................................................. 12
Power from crankshaft........................................................................................................ 13
Diesel engine - petrol engine ............................................................................................. 14
Diesel engine - another approach ...................................................................................... 15
Sturdy engine components in the diesel engine................................................................. 16
Four strokes for a complete cycle....................................................................................... 17
Four stroke - six cylinder .................................................................................................... 18
Firing order ......................................................................................................................... 19
The diesel engine is miserly with its fuel ............................................................................ 20
Three diesel engine types .................................................................................................. 21
Precombustion indirect-injection engines........................................................................... 22
Swirl-chamber engine ......................................................................................................... 23
Different characteristics Direct injection ............................................................................. 24
Different characteristics Indirect-injection and swirl-chamber ............................................ 25
Diesel engine fundamentals. Test 1 ................................................................................... 26
Engine design ..................................................................................................................... 28
V-engine ............................................................................................................................. 29
Volvo - V8 engines.............................................................................................................. 30
The main engine components ............................................................................................ 31
Cylinder block ..................................................................................................................... 32
Cylinder block - inside ........................................................................................................ 33
Camshaft in cylinder block.................................................................................................. 34
Cylinder liner design ........................................................................................................... 35
Cylinder bore ...................................................................................................................... 36
Cylinder head...................................................................................................................... 37
Cylinder head - Inlet and exhaust ducts ............................................................................. 40
Cylinder head - Copper sleeve ........................................................................................... 41
Cylinder head - Details ....................................................................................................... 42
Cylinder head and cylinder liner seals................................................................................ 43
Cylinder head and cylinder liner seals................................................................................ 44
Cranking mechanism.......................................................................................................... 45
A few facts about loads ...................................................................................................... 46
Crankshaft .......................................................................................................................... 47
Power impulse .................................................................................................................... 48
Crankshaft - Oscillation ...................................................................................................... 49
Damper ............................................................................................................................... 50
The crankshaft is perfectly balanced .................................................................................. 51
Seven main bearings.......................................................................................................... 52
Seven main bearings - connecting rod ............................................................................... 53
V-engine, two connecting rods ........................................................................................... 54
Lubrication ducts ................................................................................................................ 55
What happens in an in-line six cylinder engine .................................................................. 56
Main bearing caps .............................................................................................................. 57
Main bearings screw........................................................................................................... 58
Support bearing .................................................................................................................. 59
Flywheel.............................................................................................................................. 60
Flywheel - other tasks......................................................................................................... 61
Connecting rod ................................................................................................................... 62
Connecting rod - details...................................................................................................... 63
Gudgeon pin ....................................................................................................................... 64
Gudgeon pin hole ............................................................................................................... 65
Gudgeon pin - journal led ................................................................................................... 66
Connecting rod bearing ...................................................................................................... 67

Piston.................................................................................................................................. 70
Piston - Thermal stress and mechanical stress.................................................................. 71
Piston - Materials ................................................................................................................ 72
Articulated piston ............................................................................................................... 73
Piston - Tolerance............................................................................................................... 74
Piston cooling ..................................................................................................................... 75
Piston rings ......................................................................................................................... 76
Piston rings material first ring ............................................................................................. 77
Piston rings material second ring ....................................................................................... 78
Piston rings material oil ring ............................................................................................... 79
Piston rings - Oil ring .......................................................................................................... 80
Valve mechanism ............................................................................................................... 83
Pushrod engine .................................................................................................................. 84
Overhead camshaft ............................................................................................................ 85
Camshaft ............................................................................................................................ 86
Camshaft - Design .............................................................................................................. 87
Engine timing mechanism .................................................................................................. 88
Engine timing mechanism - Sound insulation .................................................................... 89
Crankshaft seal................................................................................................................... 90
Valves, valve guides and valve seats................................................................................. 91
Valves ................................................................................................................................. 92
Valve stem .......................................................................................................................... 93
Valve springs ...................................................................................................................... 94
Valve seals ......................................................................................................................... 95
Pushrod and rocker arm ..................................................................................................... 96
Lubrication system
Lubrication system
Lubrication system.............................................................................................................. 99
Engine oil quality .............................................................................................................. 100
Splash lubrication - Pressure lubrication .......................................................................... 101
Pressure lubrication .......................................................................................................... 102
Lubrication system - Function........................................................................................... 103
Lubrication system - schematic ........................................................................................ 104
Oil pump - function............................................................................................................ 105
Oil pump - parts ................................................................................................................ 106

Oil filter housing ................................................................................................................ 107
Oil flows through the filter ................................................................................................. 108
Oil cooler........................................................................................................................... 109
Oil sump............................................................................................................................ 110
Diesel engine fundamentals. Test 6 ................................................................................. 111
Fuel system
Fuel system
Fuel injection system ........................................................................................................ 114
Injection pump .................................................................................................................. 115
Mechanical regulator or governor..................................................................................... 116
Supply pump..................................................................................................................... 117
Smoke limiter .................................................................................................................... 118
Fuel filter ........................................................................................................................... 119
Pressure pipes.................................................................................................................. 120
Injector - copper sleeve .................................................................................................... 121
Nozzle sleeve - needle ..................................................................................................... 122
Injector - function .............................................................................................................. 123
Diesel engine fundamentals. Test 7B............................................................................... 124
Fuel systems with unit injectors........................................................................................ 126
Unit injector - system function .......................................................................................... 127
Diesel engine fundamentals. Test 7C............................................................................... 128
Common rail ..................................................................................................................... 130
Injector .............................................................................................................................. 131
Diesel engine fundamentals. Test 7D............................................................................... 132
Engine management system
Engine management system

EMS - Engine Management System ................................................................................ 133
Engine control unit ............................................................................................................ 134
Sensors on the engine...................................................................................................... 135
Other sensors ................................................................................................................... 136
Example of communication .............................................................................................. 137
Diesel engine fundamentals. Test 7A............................................................................... 138
Intake and exhaust system

Intake and exhaust system............................................................................................... 140
Air filter ............................................................................................................................. 141

Cyclone filter .................................................................................................................... 142
Starter element ................................................................................................................. 143
Exhaust pressure governor .............................................................................................. 144
Compression brake VEB .................................................................................................. 145
Compression brake VEB+ ................................................................................................ 146
Compression brake JAK................................................................................................... 147
Engine brake function....................................................................................................... 148
Turbocharger
Turbocharger
Turbocharger history......................................................................................................... 151
Turbocharging................................................................................................................... 152
Turbocharger bearing ....................................................................................................... 153
Wastegate......................................................................................................................... 154
Turbocharger system........................................................................................................ 155
Exhaust pressure governor .............................................................................................. 156
Turbocharger type VGT .................................................................................................... 157
Charge air cooling............................................................................................................. 158
Air to air cooling ................................................................................................................ 159
Cooling system
Cooling system
Volvo coolant .................................................................................................................... 162
Cooling system ................................................................................................................ 163
External components of the cooling system..................................................................... 164
Thermostat ....................................................................................................................... 165
Schematic presentation of the cooling system ................................................................. 166
Radiator ............................................................................................................................ 167
Cooling fans in vehicles.................................................................................................... 168
Cooling fans in bus ........................................................................................................... 169
Cooling fans in VCE ......................................................................................................... 170
Diesel engine fundamentals. Test 10 ............................................................................... 171
Emissions
Emissions
Vehicle emissions and environmental impact .................................................................. 174
Engine emission ............................................................................................................... 175

Carbon dioxide and Hydrocarbons ................................................................................... 176
Nitrogen oxides (NOX) ..................................................................................................... 177
Particulate matter.............................................................................................................. 178
Diesel engine fundamentals. Test 11A............................................................................. 180
EGR
EGR
Emisson control, schematic description of the system..................................................... 181
EGR system...................................................................................................................... 182
I-EGR, Large engine platform........................................................................................... 183
I-EGR, Medium engine platform ....................................................................................... 184
I-EGR Function, Medium engine platform ........................................................................ 185
Diesel engine fundamentals. Test 11B............................................................................. 186
SCR
SCR
SCR - Selective Catalytic Reduction ................................................................................ 187
Main components in the Volvo SCR system .................................................................... 188
Solution principle for the Volvo SCR system.................................................................... 189
Overview of the exhaust gas processing system ............................................................. 190
Diesel engine fundamentals. Test 11C ............................................................................ 191
CCV
CCV
CCV - CrankCase Ventilation - Closed............................................................................. 193
Diesel engine fundamentals. Test 11D ............................................................................ 194
Introduction > Course content
Notes
GT120017A v.1.0.01_en Page 1

Introduction > Course content
Key points
 Course content
 Practical exercises
 Theoretical summary
 Course schedule
Working procedure
Go through Course content (overview).
Explain briefly what the different subjects will include - give examples.
Explain that each practical session will start with theory and after there it will be a practical
session.
Test questions are also included.
Remind the participants that later there will be a written test to complete the course.
Go through the schedule.
Additional information
Course guide
Start by welcoming the participants to the course.
Introduce yourself and let all the participants introduce themselves, e.g. give their name,
company, say where they come from, how long they have worked for Volvo and detail any
previous experience of other truck workshops they may have.
Present the course timetable and give a general idea of what is going to be covered over the
days (Course contents and objectives).
Also mention practical issues such as breaks, smoking, mobile phones, etc.
If this is the first time the participants have been on a Volvo course, tell them a little about the
Volvo Company.
Hand out the student material and inform the participants of the post test that will be held on the
last day. The use of the student material, including any personal notes the participants may have
made, will be allowed during the written post test.
Mention that some of the tasks from the practical training can be performed as individual tests.
Morning and afternoon breaks should be adapted to suit local times.
Trainer notes
Page 1 (trainer)
Introduction > Course objectives
Course objectives
After completing the course, you should be able to
• Select and use appropriate tools and equipment.
• Carry out jobs in a safe way, without causing damage to equipment, component, vehicle or
person.
• Check and adjust a range of engine components. e.g. valves, unit injectors, engine brake
system, fuel systems, belts etc.
• Verify proper operation after adjustment.
• The purpose of this training is to give you a good knowledge of the Basic Diesel Technology in
practical and theoretical.
Notes
Page 2 GT120017A v.1.0.01_en

Introduction > Course objectives
Key points
 Course objectives
 Check and adjust
 Appropriate tools and equipment.
 Damage
 Verify proper operation
Working procedure
Go through Course objectives (overview).
Course guide
Trainer notes
Page 2 (trainer)
Engine history > The diesel engine, yesterday and today
The diesel engine, yesterday and today

It all began in 1892 when Rudolf Diesel was granted a patent for a new type of engine. It was to
be far more efficient than all previously known engine types and it would be powered by a fuel
which was cheaper than petrol. Rudolf Diesel initially intended powering his new engine with coal
dust, but soon switched his attention to liquid fuel. Today, all diesel engines are driven by diesel
oil.
Diesel's first engine was completed in 1893. It suffered a host of problems and did not produce
enough power to keep itself running.
Not before 1897 did Diesel manage to produce an engine which functioned anything like he had
envisioned.
Since then, considerable effort has been invested in research and development to bring the
diesel engine to today's levels of superb efficiency and operational reliability.
The picture on the left shows one of the very earliest engines. It has a bore of 220 mm and a
stroke of 400 mm. And it's 3 metres tall.
The engine on the right is a Volvo TAD 1630. Roughly 80 years of development separate Rudolf
Diesel's first engine from this hyper-modern power unit.
Diesel engines today weigh less than half as much as their first ancestors, and they pump out
more than 30 times as much power.
GT120017A v.1.0.01_en Page 3

Engine history > The diesel engine, yesterday and today
Key points
 History
 Rudolf Diesel
 Frenchman
 Born 1858
 1876 Otto patent 4-stroke engine
 1892 patent diesel
 Coaldust
 First working engine = 4.5 ton - 20hp - 26% efficiency
 1913 suicide on the way to England
 The first engines were made for heavier vehicles
 First Volvo truck 1928
 Volvo truck engine 1946
 Turbocharger 1954
Working procedure
Go through the text in the student material and also add your own experience/knowledge.
Be sure that the participants have understood the main purpose of this information.
Ask question to be sure that the participants have understand the main purpose of this
chapter/slide/information/text.
Trainer notes
Page 3 (trainer)
Engine history > First diesel engine
First diesel engine

The first diesel engines were large and clumsy and they were certainly not designed for
installation in moving vehicles. Rather, they were intended as powerplants for industry or as
prime movers powering generators or pumps.
The two-cylinder engine in the picture to the right is from 1898 and it produced 50 hp (37 kW). It
was used to power industrial machines and was in regular operation until 1930. It was produced
by a German manufacturer, MAN in Augsburg.
Notes
Page 4 GT120017A v.1.0.01_en

Engine history > First diesel engine
Key points
 Large and clumsy
 For industry
 Powering generators or pumps
 1898
 50 hp (37 kW)
 MAN in Augsburg
Working procedure
Trainer notes
Page 4 (trainer)
Engine history > Diesel engines in vehicles
Diesel engines in vehicles

It took considerable research effort and innumerable trials before the diesel engine was ready for
installation in moving vehicles.
The very first vehicle engines came in the early 1920s. One of the first, a Benz from 1922, can be
seen here on the right. It had two cylinders and produced just 22 kW or 30 horsepower.
Notes
GT120017A v.1.0.01_en Page 5

Engine history > Diesel engines in vehicles
Key points
 Installation in moving vehicles
 Early 1920s
 Benz from 1922
 Two cylinders and produced just 22 kW or 30 horsepower
Working procedure
Trainer notes
Page 5 (trainer)
Engine history > Engines for heavier vehicles
Engines for heavier vehicles

The first engines were made for heavier vehicles such as trucks and tractors. The truck pictured
here is a Daimler-Benz made in 1923.
Lightweight series-manufactured diesel engines for passenger cars first made an entry about ten
years later. The first such engines bore the Daimler-Benz badge and they had a power output of
about 33 kW or 45 horsepower.
Rudolf Diesel, the inventor of the diesel engine, died in 1913, long before engines bearing his
name became a common sight in moving vehicles.
Volvo Penta launch diesel engine in 1958. The engine type was called MD1.
Volvo Construction Equipment launch diesel engine in 1954.
Volvos busses got a new diesel engine 1945 and one year later it was also introduce in the
trucks. The engine type was called VDA.
Notes
Page 6 GT120017A v.1.0.01_en

Engine history > Engines for heavier vehicles
Key points
 Truck Daimler-Benz made in 1923
 Lightweight series-manufactured diesel engines
 33 kW or 45 horsepower
 Rudolf Diesel, the inventor of the diesel engine, died in 1913
 Volvo Penta launch diesel engine in 1958. The engine type was called MD1
 Volvo Construction Equipment launch diesel engine in 1954
 Volvos busses got a new diesel engine 1945
 Volvo trucks got a new diesel engine 1946
 The engine type was called VDA
Working procedure
Trainer notes
Page 6 (trainer)
Engine history > Diesel engines in Volvo vehicles
Diesel engines in Volvo vehicles

Diesel engines were first fitted to Volvo trucks in 1946. The first engine was a six-cylinder unit
producing 71 kilowatts (96 horsepower). It carried the VDA designation (Volvo Diesel engine type
A).
More than a decade previously, however, in 1933, Volvo's trucks were powered by an engine
similar in concept to the diesel engine. It was known as the Hesselman engine and it ran on the
same fuel as the diesel engine, but featured an electrical ignition system. The Hesselman unit is
often referred to as a "semi-diesel" engine.
The latest generation of engines with which you work are developments of these early units.
Everyone concerned has invested enormous effort and expertise in making the diesel engine
better and better.
And the result can be seen if you compare the first VDA engine with a similarly-sized engine of
today.
Just look at the power outputs, for example. The VDA produced 71 kW and had a displacement
of 6.12 litres. A corresponding engine of today, the D6A (slightly smaller but with a turbocharger
and intercooler) produces more then 150 kW!
And there's more.
Fuel consumption is lower. Durability and service life are longer. Operating reliability is far higher.
So a lot has happened since 1946!

But what of the future?
Well, this is what it looks like in general terms: there is no other type of engine currently in
existence which can compete with the diesel engine in heavy-duty vehicles or as a power source
for large generators and pumps.
GT120017A v.1.0.01_en Page 7

Engine history > Diesel engines in Volvo vehicles
Key points
 71 kilowatts (96 horsepower)
 VDA (Volvo Diesel engine type A)
 Hesselman unit is often referred to as a "semi-diesel" engine
 VDA produced 71 kW and had a displacement of 6.12 litres
 D7E (slightly smaller but with a turbocharger and intercooler) produces more then 150 kW!
 Fuel consumption is lower
 Durability and service life are longer
 Operating reliability is far higher
 Future
Working procedure
Trainer notes
Page 7 (trainer)
Engine range > Engine range
Engine range
We shall look at the diesel engine range on the engine that we have today. Volvo have engines in
a range from approx. 240 horsepower and up to 700 horsepower. The cylinder volume is
between 7 litres and up to 16 litres.
The smallest engine is the D7E and it was launched in 2006...

_
...the next engine in range is the D9 engine and it was launched in 2001...
_
...and the D11 engine, launched in 2008...

_
... we have also the D13 engine. This engine was launched in 2005 and the biggest of them all
is...
_
...the D16 and this is also the most powerful of them all.
Notes
Page 8 GT120017A v.1.0.01_en

Engine range > Engine range
Key points
 Range
 D7E
 D9
 D11
 D13
 D16
Working procedure
Talk with the participants about the Volvo engine range.
Explain why we have overlap for different engines power and torque.
There is overlapping of different engine powers and torques. That has to do with different taxation
in different markets. Some markets have tax depending on power other markets set the tax
depending on volume.
Go through the information shown in the additional information.
Her it is possible to run the movie “AN INTRO TO DIESEL ENGINE”. This is like a teaser for the
participants. The movie going through the fundamentals estimated time 15 min. An another way
is to show each chapter where it belongs. This decision is up to the teacher to decide. In the
tranier notes under headline "Additional information" the trainer find information when it is time to
run each chapter.
Trainer notes
Page 8 (trainer)
General and basic priciples > General and basic principles > Diesel engine
Diesel engine
High demands are placed on modern engines.
They must meet demands for low fuel consumption combined with high performance, while at the
same time having low levels of noise and exhaust emissions.
There are few power sources on which so much research and development work is expended as
on the diesel engine, which is basically quite an old invention.
Development work has essentially been concentrated on refining existing technology, but a great
number of completely new solutions have been developed in recent years.
Electronic Management Systems (EMS) have been used for a number of years, and electronics
are steadily taking on a more central role in each new generation of engines.
The earlier fuel injection system EDC (Electronic Diesel Control), and Unit Injector have now
been developed into a more advanced EMS system that is integrated into the TEA (Truck
Electronic Architecture) vehicle electronic system.
Notes
GT120017A v.1.0.01_en Page 9

General and basic priciples > General and basic principles > Diesel engine
Key points
 Low fuel consumption combined
 High performance
 Low levels of noise
 Exhaust emissions
 Electronic Management Systems (EMS)
 Electronic Diesel Control (EDC)
 Unit Injector
 TEA vehicle electronic system
Working procedure
information/text.
Walk around different engines if it is possible and let the participants point out engine main part
on the outside.
Show the participants the engine parts and explain how they are connected to each other, do not
forget to tell them what is happen if they do not understand the basic when they shall e.g. fault
tracing.
Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter
"Introduction" and "Basic design". This is like a teaser for the participants.
Trainer notes
Page 9 (trainer)
General and basic priciples > General and basic principles > Internal combustion engine
The diesel engine is an internal combustion engine

 Combustion chamber
 Piston
 Cylinder
Notes
Page 10 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Internal combustion engine
Key points
 Internal combustion engine
 Piston
 Cylinder
Working procedure
information/text.
tracing.
Trainer notes
Page 10 (trainer)
General and basic priciples > General and basic principles > Fuel-air mixture
Fuel-air mixture
 Ignited
 Pressure
 Considerable force
 Rotate in a circle
Notes
GT120017A v.1.0.01_en Page 11

General and basic priciples > General and basic principles > Fuel-air mixture
Key points
 Fuel-air mixture
 High pressure
 Pushes the piston
 Force
 Rotate in a circle
Working procedure
information/text.
tracing.
Trainer notes
Page 11 (trainer)
General and basic priciples > General and basic principles > Rotating movement
Rotating movement
 Connecting rod
 Crankshaft
Notes
Page 12 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Rotating movement
Key points
 Movement of the piston
 Rotating movement
 Connecting rod
 Crankshaft.
 The force -piston-connecting rod-crankshaft
 Propel the vehicle
Working procedure
information/text.
tracing.
Trainer notes
Page 12 (trainer)
General and basic priciples > General and basic principles > Power from crankshaft
Power from crankshaft

 Vehicle
 Transmission components
 Driven wheels
 Driveline
Notes
GT120017A v.1.0.01_en Page 13

General and basic priciples > General and basic principles > Power from crankshaft
Key points
 Crankshaft-gearbox-rear axle-wheel
 Driveline
Working procedure
information/text.
tracing.
Trainer notes
Page 13 (trainer)
General and basic priciples > General and basic principles > Diesel engine - petrol engine
Diesel engine - petrol engine

 Petrol engine
 Ready-mixed blend of petrol and air
 Compressed
 Ignited
 Spark
Notes
Page 14 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Diesel engine - petrol engine
Key points
 Diesel engine
 Petrol engine
 Differences
 Petrol engine.
 Electrically generated spark
Working procedure
information/text.
tracing.
Trainer notes
Page 14 (trainer)
General and basic priciples > General and basic principles > Diesel engine - another approach
Diesel engine - another approach

 Unblended air
 Hot air
 Compressed
 Ignite the diesel fuel
 Compression ignition
 Peak pressure
 Diesel engine 7 and 20 MPa
 Petrol engine 3 to 5 MPa
Notes
GT120017A v.1.0.01_en Page 15

General and basic priciples > General and basic principles > Diesel engine - another approach
Key points
 Unblended air
 Compressed
 Hot - ignite the diesel fuel
 Fuel
 Hot air
 Ignited
 Compression ignition.
 Combustion pressure
 Diesel engine 7 to 20 MPa
 Petrol engine 3 to 5 MPa
 Peak pressure
Working procedure
information/text.
tracing.
Trainer notes
Page 15 (trainer)
General and basic priciples > General and basic principles > Sturdy engine components in the
diesel engine
Sturdy engine components in the diesel engine

 High working pressure
 Mechanical stress
 More expensive to produce
Notes
Page 16 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Sturdy engine components in the
diesel engine
Key points
 Sturdy components
 High working pressure
 More expensive
Working procedure
information/text.
tracing.
Trainer notes
Page 16 (trainer)
General and basic priciples > General and basic principles > Four strokes for a complete cycle
Four strokes for a complete cycle

 Inlet stroke
 Compression stroke
 Operating stroke
 Exhaust stroke
Notes
GT120017A v.1.0.01_en Page 17

General and basic priciples > General and basic principles > Four strokes for a complete cycle
Key points
 Four strokes for a complete cycle
 Inlet stroke
 The piston compresses the air
 2-3 MPa (20-30 bar)
 700-900°C
 Fuel injection occurs at the end of the compression stroke
 2000-2500°C
 Operating stroke
 Exhaust stroke
Working procedure
information/text.
tracing.
Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "4-
stroke principle". This is like a teaser for the participants.
Trainer notes
Page 17 (trainer)
General and basic priciples > General and basic principles > Four stroke - six cylinder
Four stroke - six cylinder

Firing order is 1 - 5 - 3 - 6 - 2 - 4
Cylinder 1
The compression stroke has just begun.
Cylinder 2
Operating stroke; the pressure is very high right now.
Cylinder 3
Exhaust stroke is completed, the inlet stroke begins.
Cylinder 4
End of compression stroke, fuel is sprayed in and ignited.
Cylinder 5
Inlet stroke has just begun and clean air is fed in.
Cylinder 6
The exhaust stroke has just begun.
Page 18 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Four stroke - six cylinder
Key points
 Four-stroke principle
 Firing order, 1 - 5 - 3 - 6 - 2 - 4
 Cylinder 1 the compression stroke has just begun
 Cylinder 2 operating stroke; the pressure is very high right now
 Cylinder 3 exhaust stroke is completed, the inlet stroke begins
 Cylinder 4 end of compression stroke, fuel is sprayed in and ignited
 Cylinder 5 inlet stroke has just begun and clean air is fed in
 Cylinder 6 the exhaust stroke has just begun
Working procedure
information/text.
tracing.
"Induction stroke", "Compression stroke", "Working stroke" and "Exhaust stroke".
This is like a teaser for the participants. After that you have run the four stroke
you can also run "Sum up 4-stroke principle" so the participants can see as a
sequence.
Trainer notes
Page 18 (trainer)
General and basic priciples > General and basic principles > Firing order
Firing order
 Direction the piston is moving
 Position of the valves
 A six-cylinder engine has a very close firing order
 Three operating strokes
 Once the crankshaft has rotated twice, combustion has taken place in all the cylinders
 Absolute precision is essential for the engine to run perfectly
Notes
GT120017A v.1.0.01_en Page 19

General and basic priciples > General and basic principles > Firing order
Key points
 Piston moving
 Position of the valves
 Each turn of the crankshaft-three operating strokes
 Once the crankshaft has rotated twice, combustion has taken place in all the cylinders
 One combustion stroke does not have time to be completed before the next starts
Working procedure
information/text.
tracing.
Operating strokes are coloured red.
With the engine operating at 2000 rpm. per minute, there are 6000 combustion strokes per
minute or 100 per second.
If the engine is run at that speed, it takes just three minutes to reach a million combustion
strokes.
Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Firing order". This is
like a teaser for the participants.
Trainer notes
Page 19 (trainer)
General and basic priciples > General and basic principles > The diesel engine is miserly with its
fuel
The diesel engine is miserly with its fuel

 Cooling losses
 Exhaust losses
 Friction losses
Notes
Page 20 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > The diesel engine is miserly with its
fuel
Key points
 Fuel-chemical energy
 Converts into mechanical effort.
 Sankey diagram
 Energy 100%.
 Cooling losses ca. 25% (diesel engine)
 Exhaust losses ca. 25% (diesel engine)
 Friction losses ca. 10% (diesel engine)
 Efficiency rating ca. 40% (diesel engine)
Working procedure
information/text.
tracing.
Diesel engines have the highest efficiency rating of all, up to 43-44% in a truck engine (D13 up to
47%).
Passenger-car diesels are somewhat less efficient, at about 38%, roughly the same level as two-
stroke diesel engines for vehicles. Petrol engines have an efficiency rating of about 30%.
The first engines from the end of the previous century had an efficiency rating of a mere 2-5%.
Trainer notes
Page 20 (trainer)
General and basic priciples > General and basic principles > Three diesel engine types
Three diesel engine types

 Direct-injection engines
 Precombustion indirect-injection engines
 Swirl-chamber engines
Notes
GT120017A v.1.0.01_en Page 21

General and basic priciples > General and basic principles > Three diesel engine types
Key points
 Three diesel engine types
 Direct-injection engines
 Swirl-chamber engines
 All Volvo diesel engines are direct-injection units
Working procedure
information/text.
tracing.
Trainer notes
Page 21 (trainer)
General and basic priciples > General and basic principles > Precombustion indirect-injection
engines
Precombustion indirect-injection engines

 Fuel
 Pre-chamber
 Combustion
 Glowplug
Notes
Page 22 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Precombustion indirect-injection
engines
Key points
 Roughly 25%, is separated into a pre-chamber
 Fuel into the pre-chamber
 Not sufficient air in the pre-chamber
 Mixture is pressed out into the combustion chamber
 Heated electrically
 VDA diesel engine-indirect-injection engine
Working procedure
information/text.
tracing.
Trainer notes
Page 22 (trainer)
General and basic priciples > General and basic principles > Swirl-chamber engine
Swirl-chamber engine
 Swirl-chamber
Notes
GT120017A v.1.0.01_en Page 23

General and basic priciples > General and basic principles > Swirl-chamber engine
Key points
 Swirl-chamber engine
 Lrger volume than the indirect-injection engine
 Roughly 50% in the swirl-chamber
 Same process as in the indirect-injection diesel
 Swirl-chamber engines-passenger-car diesels
Working procedure
information/text.
tracing.
Trainer notes
Page 23 (trainer)
General and basic priciples > General and basic principles > Different characteristics Direct
injection
Different characteristics
Direct injection
 Small losses
 Higher efficiency
 Lower fuel consumption
 Engine speeds, up to about 4000 rpm
Notes
Page 24 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Different characteristics Direct
injection
Key points
 Various engine types have different characteristics
 Direct injection-Small losses compared with the others
 Direct injection-Higher efficiency rating and lower fuel consumption
 Direct injection-Up to about 4000 rpm
Working procedure
information/text.
tracing.
Trainer notes
Page 24 (trainer)
General and basic priciples > General and basic principles > Different characteristics Indirect-
injection and swirl-chamber
Different characteristics
Indirect-injection and swirl-chamber
 Combustion is quick
 Operate at high speeds, up to about 6000 rpm.
 Greater losses
 Lower efficiency
 High fuel consumption
Notes
GT120017A v.1.0.01_en Page 25

General and basic priciples > General and basic principles > Different characteristics Indirect-
injection and swirl-chamber
Key points
 Indirect-injection and swirl-chamber
 Combustion is quick
 Operate at high speeds, up to about 6000 rpm
 Greater losses than for direct-injection engines
 Lower efficiency rating
 Higher fuel consumption
Working procedure
information/text.
tracing.
Trainer notes
Page 25 (trainer)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 1
Diesel engine fundamentals. Test 1

Decide which is correct.
A petrol engine takes in a ready-mixed blend of fuel and air.

The diesel engine works under higher pressure than a petrol engine.
The diesel engine is sometimes equipped with an electrical ignition system.
The highest pressure resulting from combustion is known as peak pressure.
In a diesel engine, finely atomised fuel is sprayed into the combustion chamber.
These parts are subjected to greater mechanical stresses in a diesel engine than in a
petrol engine.
True
False
State the correct sequence for the following processes (put the figures in the appropriate
boxes 1 -6 ).
The air is compressed

The fuel is ignited by the hot air
Clean air enters into the cylinders
Finely atomised fuel is sprayed in
Combustion produces high pressure
The exhaust gases leave the cylinder
State the correct sequence, putting the figures in the appropriate boxes ( 1 - 4 ).
Page 26 GT120017A v.1.0.01_en

Key points
• Question
• Answer
Working procedure
It is now time to hand out the question to the participants.
Let each participants work with the question for about 5-10 minutes. After that shall the trainer go
through the correct answer.
Discuss the answers with the participants if there have been any misunderstandings or linguistic
problems.
Questions that could help to improve the format of the questionnaire in the future may arise.
Introduction to diesel engines. Test 1 Key
*A petrol engine takes in a ready-mixed blend of fuel and air.

*The diesel engine works under higher pressure than a petrol engine.
The diesel engine is sometimes equipped with an electrical ignition system.
*The highest pressure resulting from combustion is known as peak pressure.
*In a diesel engine, finely atomised fuel is sprayed into the combustion chamber.
These parts are subjected to greater mechanical stresses in a diesel engine than in a petrol
engine.
*True
False
State the correct sequence for the following processes (put the figures in the appropriate boxes 1
-6 ).
The air is compressed 2

The fuel is ignited by the hot air 4
Clean air enters into the cylinders 1
Finely atomised fuel is sprayed in 3
Combustion produces high pressure 5
The exhaust gases leave the cylinder 6
State the correct sequence, putting the figures in the appropriate boxes ( 1 - 4 ).
Inlet stroke 1
Exhaust stroke 4
Operating stroke 3
Compression stroke 2
During one of the strokes in a diesel engine, the piston is on its way down and both valves are
shut. Which stroke is this?
Inlet stroke
Exhaust stroke
Compression stroke
*Opearating stroke
Page 26 (trainer)
nlet stroke
Exhaust stroke
Operating stroke
Compression stroke
During one of the strokes in a diesel engine, the piston is on its way down and both valves
are shut. Which stroke is this?
Inlet stroke
Exhaust stroke
Compression stroke
Opearating stroke
Peak pressure in a diesel engine can approach 20 MPa (200 bar).
No, not so high.

Yes, this is true.
No, much higher.
How many ignitions are there in a six-cylinder diesel engine for each turn of the
crankshaft?
Two
Three
Six
How many times does the crankshaft turn for all six cylinders to fire once?
One
Two
Six
You have to know both the direction in which the piston is moving and the positions of the
valves in order to determine exactly what is happening in a cylinder at any given moment
in time.
True
False
The firing order in a Volvo diesel engine is always:
1-5-4-2-3-6
1-2-3-4-5-6
1-5-3-6-2-4
Which of these engine types has the highest efficiency rating?
Petrol engine
Direct-injection diesel engine
Diesel engine with pre-chamber
All Volvo truck diesels as of 1986 are:
Pre-combustion chamber engines

Direct-injection engines
Swirl-chamber engines
GT120017A v.1.0.01_en Page 27

Peak pressure in a diesel engine can approach 20 MPa (200 bar).
No, not so high.

*Yes, this is true.
No, much higher.
How many ignitions are there in a six-cylinder diesel engine for each turn of the crankshaft?
Two
*Three
Six
How many times does the crankshaft turn for all six cylinders to fire once?
One
*Two
Six
You have to know both the direction in which the piston is moving and the positions of the valves
in order to determine exactly what is happening in a cylinder at any given moment in time.
*True
False
The firing order in a Volvo diesel engine is always:
1-5-4-2-3-6
1-2-3-4-5-6
*1 - 5 - 3 - 6 - 2 - 4
Which of these engine types has the highest efficiency rating?
Petrol engine
*Direct-injection diesel engine
Diesel engine with pre-chamber
All Volvo truck diesels as of 1986 are:
Pre-combustion chamber engines

*Direct-injection engines
Swirl-chamber engines
Trainer notes
Page 27 (trainer)
General and basic priciples > General and basic principles > Engine design
Engine design
 In-line engine or straight engine
 Turbocharged engines
 Reliable design
 Moving parts
 Low engine speeds
 Well-balanced
 Long service life
 Quiet
 Simple service
 Large crankshaft bearing surface
 Seven main bearings
 Ideal for turbocharging
Notes
Page 28 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Engine design
Key points
 Designed in different ways
 Cylinders are positioned
 Straight line-In-line engine or straight engine
 Turbocharged engines
 Volvo's diesel engines are 6-cylinder in-line engines or "straight-sixes"
 Volvo produced 6-cylinder in-line truck engines way back in the 1920s
 Semi-diesel
 Suitable for large-displacement engines
 Simple and it contains a relatively small number of moving parts
 Low engine speeds
 Well-balanced
 Long service life and quiet, smooth operation
 Service on this engine is simple
 Large crankshaft bearing surface
 Crankshaft is journalled in seven main bearings
Working procedure
information/text.
tracing.
Trainer notes
Page 28 (trainer)
General and basic priciples > General and basic principles > V-engine
V-engine
 Volvo 8-cylinder engine
Notes
GT120017A v.1.0.01_en Page 29

General and basic priciples > General and basic principles > V-engine
Key points
 V-engine
 Forties
 400 bhp
 Military vehicles
 Truck
 120 bhp
Working procedure
information/text.
tracing.
Trainer notes
Page 29 (trainer)
General and basic priciples > General and basic principles > Volvo - V8 engines
Volvo - V8 engines
Here are a few reasons why Volvo no longer builds V-engines:
 Five main bearings
 Two connecting rods - one crankshaft journal
 Service is much more difficult
Notes
Page 30 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Volvo - V8 engines
Key points
 Reasons why Volvo no longer builds V-engines
 The crankshaft only has five main bearings
 The in-line six has seven main bearings
 Two connecting rods
 On the same crankshaft journal
 The crankshaft bearing surfaces are not very large
 Service is much more difficult
Working procedure
information/text.
tracing.
Trainer notes
Page 30 (trainer)
General and basic priciples > General and basic principles > The main engine components
The main engine components
 Valve cover
 Cylinder head
 Cylinder head gasket
 Cylinder liner
 Timing gear casing
 Flywheel housing
 Cylinder block
 Vibration damper
 Crankshaft, Connecting rod, Piston, Flywheel
 Stiffening frame (on some engines)
 Oil sump
Notes
GT120017A v.1.0.01_en Page 31

General and basic priciples > General and basic principles > The main engine components
Key points
 Main engine components
 Essential for the engine
 Work in order for the engine to function safely and reliably.
 Cylinder block with cylinder liners, pistons, piston rings and gudgeon pins
 Crankshaft mechanism with all its relevant parts
 Timing mechanism
 Valve cover
 Cylinder head
 Cylinder head gasket
 Cylinder liner
 Timing gear casing
 Flywheel housing
 Cylinder block-Engine block
 Crankshaft, Connecting rod, Piston, Flywheel
 Stiffening frame (on some engines)
 Oil sump
Other components
 Inlet manifold
 Exhaust manifold
 Oil cooler
 Oil filter
 Coolant pump
 Injection equipment.
Working procedure
information/text.
tracing.
Trainer notes
Page 31 (trainer)
General and basic priciples > General and basic principles > Cylinder block
Cylinder block
 Cast in one piece
 Cast-iron
 Reinforcement ribs
Notes
Page 32 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Cylinder block
Key points
 Cast in one piece
 Cast-iron with a special alloy
 Reinforcement ribs on the inside
 Vibration in the block
 Quiet engine
Working procedure
information/text.
tracing.
Trainer notes
Page 32 (trainer)
General and basic priciples > General and basic principles > Cylinder block - inside
Cylinder block - inside

 Coolant jacket
 Cylinder liners
 O-rings
 Main bearings
 Bearings for the camshaft
 Lubricating oil ducts
 Piston cooling duct
Notes
GT120017A v.1.0.01_en Page 33

General and basic priciples > General and basic principles > Cylinder block - inside
Key points
 Coolant in the cylinder block
 Coolant jacket
 Cylinder liner recesses
 Grooves for sealing rings
 Main bearings
 Robust reinforcement ribs leading down to the main bearings
 Additional reinforcement around the holes for the cylinder head bolts
 Bearings for the camshaft
 Machined guides for the valve tappets
 Lubricating oil ducts
 Main duct (gallery duct)
 Piston cooling nozzles-one for each cylinder
Working procedure
information/text.
tracing.
Trainer notes
Page 33 (trainer)
General and basic priciples > General and basic principles > Camshaft in cylinder block
Camshaft in cylinder block
 Location
 Lifters
 Pushrods
 Rocker arms
 Transmission gears
Notes
Page 34 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Camshaft in cylinder block
Key points
 Location
 Lifters
 Pushrods
 Rocker arms
 Transmission gears
Working procedure
information/text.
tracing.
Trainer notes
Page 34 (trainer)
General and basic priciples > General and basic principles > Cylinder liner design
Cylinder liner design

 Directly in the block
 Pressed into recesses in the block
 Direct contact with the coolant
Notes
GT120017A v.1.0.01_en Page 35

General and basic priciples > General and basic principles > Cylinder liner design
Key points
 Cylinder bores directly in the lock
 Dry cylinder liners
 Wet cylinder liners
Working procedure
information/text.
tracing.
Trainer notes
Page 35 (trainer)
General and basic priciples > General and basic principles > Cylinder bore
Cylinder bore
 High degree of precision
 Cylinder bore
 Milled
 Honed
 Plateau honing
 Checked pattern
 Oil pockets
 Tapered profile
Notes
Page 36 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Cylinder bore
Key points
 High degree of precision
 Cylindrical throughout
 Smooth surface.
 Milled and honed
 Plateau honing
 Oil pockets
 Constant film of oil
 Shorter running-in period
 Tapered profile
 Prevents carbon on the piston
Working procedure
information/text.
tracing.
Trainer notes
Page 36 (trainer)
General and basic priciples > General and basic principles > Cylinder head
Cylinder head
 Cast-iron alloy
 Huge stresses
 Combustion process
Notes
GT120017A v.1.0.01_en Page 37

General and basic priciples > General and basic principles > Cylinder head
Key points
 Cylinder head
 Cast-iron alloy
 Huge stress
 High temperature
 High pressure
Working procedure
information/text.
tracing.
Trainer notes
Page 37 (trainer)

Place the right figure beside the appropriate name.
Flywheel casing
Vibration damper
Cylinder head
Timing cover
Flywheel
Cylinder liner
Cylinder block
Connecting rod
Valve cover
Crankshaft
Oil sump
Piston
This component in a Volvo diesel engine.
is cast in one piece

is known as the cylinder block
is made of silumin
features robust reinforcement ridges on the inside
is made of a special cast-iron alloy
Page 38 GT120017A v.1.0.01_en

Key points
 Question
 Answer
Working procedure
problems.
Let each participants work with the question for about 5-10 minutes.
After that shall the trainer go through the correct answer.
Place the right figure beside the appropriate name.
Flywheel casing 6
Vibration damper 7
Cylinder head 3
Timing cover 5
Flywheel 11
Cylinder liner 1
Cylinder block 4
Connecting rod 9
Valve cover 2
Crankshaft 8
Oil sump 12
Piston 10
This component in a Volvo diesel engine.
*is cast in one piece

*is known as the cylinder block
is made of silumin
*features robust reinforcement ridges on the inside
*is made of a special cast-iron alloy
*has space for coolant fluid
has cylinders drilled directly in it
Which of these figures shows a wet cylinder liner?
A
B
*C
Plateau honing helps ensure a permanent oil film on the cylinder wall and shortens the running-in
period.
*True
False
The diesel engine's cylinder head gasket is made of
a heat-resistant copper alloy
Page 38 (trainer)
as space for coolant fluid

has cylinders drilled directly in it
Which of these figures shows a wet cylinder liner?
A
B
C
Plateau honing helps ensure a permanent oil film on the cylinder wall and
shortens the running-in period.
True
False
The diesel engine's cylinder head gasket is made of
a heat-resistant copper alloy

an aluminium alloy
steel plate
a new ceramic material
The lower O-rings in the liner seal are made of rubber which hardens and
thus provides effective sealing.
True
False
Decide which is/are correct.
The upper liner seal is a thin O-ring.

The cylinder head gasket can withstand high peak pressures.
The lower cylinder liner gasket consists of two or three O-rings.
Notes
GT120017A v.1.0.01_en Page 39

an aluminium alloy
*steel plate
a new ceramic material
The lower O-rings in the liner seal are made of rubber which hardens and thus provides effective
sealing.
True
*False
*The upper liner seal is a thin O-ring.

*The cylinder head gasket can withstand high peak pressures.
*The lower cylinder liner gasket consists of two or three O-rings.
Trainer notes
Page 39 (trainer)
General and basic priciples > General and basic principles > Cylinder head - Inlet and exhaust
ducts
Cylinder head - Inlet and exhaust ducts

 Cooling jacket
 Exhaust outlet
 Injector sleeve
 Inlet and exhaust ducts
 Valve seat
 Valve guide
Notes
Page 40 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Cylinder head - Inlet and exhaust
ducts
Key points
 Direct contact
 Large cooling jacket
 The hottest areas
 Inlet duct
 Exhaust duct
 Valve seat
 Valve guide
Working procedure
information/text.
tracing.
Trainer notes
Page 40 (trainer)
General and basic priciples > General and basic principles > Cylinder head - Copper sleeve
Cylinder head - Copper sleeve

 Injector
 Copper sleeve
 Cooling jacket
Notes
GT120017A v.1.0.01_en Page 41

General and basic priciples > General and basic principles > Cylinder head - Copper sleeve
Key points
 Injector
 Copper sleeve
 Cooling jacket
Working procedure
information/text.
tracing.
Trainer notes
Page 41 (trainer)
General and basic priciples > General and basic principles > Cylinder head - Details
Cylinder head - Details

 Cylinder head
 Hole for injector
 Valve guide
 Injector sleeve
 Valve seat, exhaust
 Valve seat, inlet
Notes
Page 42 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Cylinder head - Details
Key points
 Cylinder head
 Hole for injector
 Valve guide
 Injector sleeve
 Valve seat, exhaust
 Valve seat, inlet
Working procedure
information/text.
tracing.
Trainer notes
Page 42 (trainer)
General and basic priciples > General and basic principles > Cylinder head and cylinder liner
seals
Cylinder head and cylinder liner seals

 High pressure in the cylinder
 Coolant, which also contains chemical additives
 Engine oil, which contains chemical additives
Notes
GT120017A v.1.0.01_en Page 43

seals
Key points
 Seals
 Cylinder head gasket-highest forces
 High pressure
 Coolant
 Engine oil
 Steel plate
 O-rings
 Ridges or grooves
Working procedure
information/text.
tracing.
Trainer notes
Page 43 (trainer)
seals
Cylinder head and cylinder liner seals
 Wet cylinder liner

 O-rings
 Upper end
 Liner collar
 Lower seal
 Different colours for securing correct mounting
Notes
Page 44 GT120017A v.1.0.01_en

seals
Key points
 Rubber O-rings
 Upper end-thin O-ring
 The silicon sealant-prevent friction
 Lower seal-two or three O-rings
 Different material
 Different colours
Working procedure
information/text.
tracing.
Trainer notes
Page 44 (trainer)
General and basic priciples > General and basic principles > Cranking mechanism
Cranking mechanism
 Gudgeon pin
 Piston
 Piston rings
 Connecting rods
 Main bearing
 Flywheel
 Connecting rod bearing
 Thrust washers (axial bearings)
 Crankshaft
Notes
GT120017A v.1.0.01_en Page 45

General and basic priciples > General and basic principles > Cranking mechanism
Key points
 Cranking mechanism
 Gudgeon pin
 Piston
 Piston rings
 Connecting rods
 Main bearing
 Flywheel
 Thrust washers (axial bearings)
 Crankshaft
Working procedure
information/text.
tracing.
Trainer notes
Page 45 (trainer)
General and basic priciples > General and basic principles > A few facts about loads
A few facts about loads

 High pressure
 Immense forces
 Peak pressure 11 MPa
 Piston surface - 130 cm2
 140 kN (kilo Newton), in other words about 14 tonnes
Notes
Page 46 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > A few facts about loads
Key points
 Peak pressure 11 MPa
 Piston surface 130 cm2
 Force 140 kN (kilo Newton)(14 tonnes)
 D13, the peak pressure is 20 MPa
Working procedure
information/text.
tracing.
Trainer notes
Page 46 (trainer)
General and basic priciples > General and basic principles > Crankshaft
Crankshaft
 Immense stress
 Stringent quality standards as regards both material and design
 Forged of special steel and undergo a special heat treatment
 Fatigue resistance and hard bearing surfaces
 Centrifugal forces
 Counterbalances
Notes
GT120017A v.1.0.01_en Page 47

General and basic priciples > General and basic principles > Crankshaft
Key points
 Crankshaft
 Immense stress
 Material
 Design
 Forged of special steel
 Special heat treatment
 Additional fatigue resistance
 Hard bearing surfaces
 Centrifugal forces
 Connecting rod's lower section
 Counterbalances
Working procedure
information/text.
tracing.
Trainer notes
Page 47 (trainer)
General and basic priciples > General and basic principles > Power impulse
Power impulse
 Power impulse
 Torsional tendencies
Notes
Page 48 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Power impulse
Key points
 Power impulse
 Torsional tendencies
Working procedure
information/text.
tracing.
Trainer notes
Page 48 (trainer)
General and basic priciples > General and basic principles > Crankshaft - Oscillation
Crankshaft - Oscillation
 Rapid oscillation
 Flywheel
Notes
GT120017A v.1.0.01_en Page 49

General and basic priciples > General and basic principles > Crankshaft - Oscillation
Key points
 Rapid oscillation
 Snap the crankshaft
 Flywheel
 Pulsationes and vibrations
Working procedure
information/text.
tracing.
Trainer notes
Page 49 (trainer)
General and basic priciples > General and basic principles > Damper
Damper
 Fluid-type damper
 The flywheel mass (damper ring)
 Bushing
 Sealed housing
 Viscous silicon oil
 Steady speed
Notes
Page 50 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Damper
Key points
 Fluid-type damper
 Very efficient
 Damper ring
 Bushing
 Sealed housing
 Viscous silicon oil
 Surrounds the flywheel mass
Working procedure
information/text.
tracing.
Trainer notes
Page 50 (trainer)
General and basic priciples > General and basic principles > The crankshaft is perfectly balanced
The crankshaft is perfectly balanced

 Imbalance
 Considerable stress
 Vibration in the engine
 Precisely balanced
Notes
GT120017A v.1.0.01_en Page 51

General and basic priciples > General and basic principles > The crankshaft is perfectly balanced
Key points
 Imbalance
 Provokes vibration
 Precisely balanced
 Balanced in a special machine
Working procedure
information/text.
tracing.
Trainer notes
Page 51 (trainer)
General and basic priciples > General and basic principles > Seven main bearings
Seven main bearings

 Renowned long service life
Notes
Page 52 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Seven main bearings
Key points
Working procedure
information/text.
tracing.
Trainer notes
Page 52 (trainer)
General and basic priciples > General and basic principles > Seven main bearings - connecting
rod
Seven main bearings - connecting rod

 Sturdy crankshaft bearing
 Large bearing surfaces
 High engine reliability
 One crankshaft bearing journal and connecting rod between the main bearings
Notes
GT120017A v.1.0.01_en Page 53

General and basic priciples > General and basic principles > Seven main bearings - connecting
rod
Key points
 Sturdy crankshaft bearing
 Large bearing surfaces
 High engine reliability
 One crankshaft bearing journal and connecting rod between the main bearings
Working procedure
information/text.
tracing.
Trainer notes
Page 53 (trainer)
General and basic priciples > General and basic principles > V-engine, two connecting rods
V-engine, two connecting rods

 Bearing
 Vital difference
 V-engine - two connecting rods
Notes
Page 54 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > V-engine, two connecting rods
Key points
 In-line six-V-engine
 Two connecting rods-same crankshaft bearing journal
 Not be as generously dimensioned
Working procedure
information/text.
tracing.
Trainer notes
Page 54 (trainer)
General and basic priciples > General and basic principles > Lubrication ducts
Crankshaft - Lubrication ducts

 Pressure-lubricated
 Drilled oil ducts in the crankshaft
Notes
GT120017A v.1.0.01_en Page 55

General and basic priciples > General and basic principles > Lubrication ducts
Key points
 Lubrication ducts-drilled in the cylinder block
 Oil under pressure-pressure lubricated
 Main bearing journals
 Crankshaft bearing journals
Working procedure
information/text.
tracing.
Trainer notes
Page 55 (trainer)
General and basic priciples > General and basic principles > What happens in an in-line six
cylinder engine
What happens in an in-line six cylinder engine

 Pistons 1 and 6 perform their upward and downward movements simultaneously.
 Pistons 2 and 5 move together.
 Pistons 3 and 4 move together.
 120 crankshaft degrees
 Ignition impulses
Notes
Page 56 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > What happens in an in-line six
cylinder engine
Key points
 Pistons 1 and 6
 Pistons 2 and 5
 Pistons 3 and 4.
 120 crankshaft degrees
Working procedure
information/text.
tracing.
Trainer notes
Page 56 (trainer)
General and basic priciples > General and basic principles > Main bearing caps
Main bearing caps

 Journal led
 Main bearing caps
 Replaceable
 Ready for installation
 Bearing shells
 Steel core
 Bearing-quality metal
Notes
GT120017A v.1.0.01_en Page 57

General and basic priciples > General and basic principles > Main bearing caps
Key points
 Main bearing caps
 Replaceable slider bearings
 Immense precision
 Manufacturer
 Bearing shells
 Steel core
 Bearing-quality metal
Working procedure
information/text.
tracing.
Trainer notes
Page 57 (trainer)
General and basic priciples > General and basic principles > Main bearings screw
Main bearings screw

 Upper bearing shell
 Lower shell
 Main bearing cap
Notes
Page 58 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Main bearings screw
Key points
 Main bearing screws
 Extremely robust
 Absorb considerable force during combustion
 The upper bearing shell
 The lower shell - main bearing cap
 Screwed to the cylinder block
Working procedure
information/text.
tracing.
Trainer notes
Page 58 (trainer)
General and basic priciples > General and basic principles > Support bearing
Support bearing
 Axial position
 Acceleration
 Retardation
 Axial movement
 Thrust washers
Notes
GT120017A v.1.0.01_en Page 59

General and basic priciples > General and basic principles > Support bearing
Key points
 Support bearing
 One main bearing
 Specific axial position
 Move back when the vehicle is under acceleration
 Move forth when the vehicle brakes are applied
 Controls the crankshaft's axial movement
 Loose thrust washers
 Coated with bearing alloy
 Precision-machined bearing surfaces
Working procedure
information/text.
tracing.
Trainer notes
Page 59 (trainer)
General and basic priciples > General and basic principles > Flywheel
Flywheel
 Power impulses
Notes
Page 60 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Flywheel
Key points
 Flywheel
 Fairly uneven
 Power impulses
 Crankshaft's speed increases and slows down every impulse
 Even out variations in speed
 Balancing
Working procedure
information/text.
tracing.
Trainer notes
Page 60 (trainer)
General and basic priciples > General and basic principles > Flywheel - other tasks
Flywheel - other tasks

 Starter ring
 Indication grooves
Notes
GT120017A v.1.0.01_en Page 61

General and basic priciples > General and basic principles > Flywheel - other tasks
Key points
 Starter ring
 Starter motor gear
 Electronic fuel injection control
 Indication grooves
Working procedure
information/text.
tracing.
Trainer notes
Page 61 (trainer)
General and basic priciples > General and basic principles > Connecting rod
Connecting rod
 Forged
 High-alloy steel
 Chrome-molybdenum steel
 Chrome manganese silicon steel
 Extremely durable
 Strong and lightweight
 I-shaped profile
 Flexing
 Big end
 Small end
 Bronze bushing
Notes
Page 62 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Connecting rod
Key points
 Connecting rod
 Forged from high-alloy steel
 Chrome-molybdenum steel
 Chrome manganese silicon steel
 Strong and lightweight
 I-shaped profile
 Tendency to flexing
 Big end
 Small end
 Gudgeon pin
Working procedure
information/text.
tracing.
Trainer notes
Page 62 (trainer)
General and basic priciples > General and basic principles > Connecting rod - details
Connecting rod - details

 Classified
 Marked
 Front marking
 Trapezoidal
 Lubricated via ducts
 Splash lubrication
 Diagonally split
Notes
GT120017A v.1.0.01_en Page 63

General and basic priciples > General and basic principles > Connecting rod - details
Key points
 Classified by weight
 Marked with number or letters
 Marking facing to the front
 Trapezoidal
 Piston more ridgit
 Lubricated via ducts
 Splash lubrication
 Gudgeon pin
 Diagonally split
 Serrations
 Split
Working procedure
information/text.
tracing.
Trainer notes
Page 63 (trainer)
General and basic priciples > General and basic principles > Gudgeon pin
Gudgeon pin
 Crankshaft mechanism
 High-quality material
 Chrome-manganese steel
 Chrome-molybdenum steel alloys
 Minimise weight
 Surface-hardened
 Finely-ground
Notes
Page 64 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Gudgeon pin
Key points
 Gudgeon pin
 Considerable stress and load
 High-quality material
 Chrome-manganese steel
 Chrome-molybdenum steel alloys
 Tubular
 Finely-ground
 Fine tolerances
Working procedure
information/text.
tracing.
Trainer notes
Page 64 (trainer)
General and basic priciples > General and basic principles > Gudgeon pin hole
Gudgeon pin hole

 Larger diameter
 Changes shape
 High load
Notes
GT120017A v.1.0.01_en Page 65

General and basic priciples > General and basic principles > Gudgeon pin hole
Key points
 Larger diameter at the recess
 Changes shape under high load
Working procedure
information/text.
tracing.
Gudgeon pin hole
The gudgeon pin hole has a larger diameter at the recess, providing space for the gudgeon pin
when it changes shape under high load.
Trainer notes
Page 65 (trainer)
General and basic priciples > General and basic principles > Gudgeon pin - journal led
Gudgeon pin - journal led

 Journal led
 Floating fit
 Locking rings
Notes
Page 66 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Gudgeon pin - journal led
Key points
 Journal led
 Floating fit
 Locking rings
Working procedure
information/text.
tracing.
Trainer notes
Page 66 (trainer)
General and basic priciples > General and basic principles > Connecting rod bearing
Connecting rod bearing

 Two bearing shells
 Machined big end
 Guide lugs
Notes
GT120017A v.1.0.01_en Page 67

General and basic priciples > General and basic principles > Connecting rod bearing
Key points
 Machined big end
 Guide lugs
 Fit properly
Working procedure
information/text.
tracing.
Trainer notes
Page 67 (trainer)
Place the right number beside the appropriate name.
Crank bearing
Vibration damper
Crankshaft
Thrust washers
Piston
Connecting rods
Flywheel
Main bearing
Piston rings
Gudgeon pin
Volvo diesel engines have fluid-type vibration dampers.

The crankshaft is balanced in a special machine.
Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine
or particularly heavy load on the crankshaft.
The ducts in the crankshaft's counterbalances are part of the lubrication system.
The crankshafts in Volvo diesel engines are forged from special steel.
True
False
Page 68 GT120017A v.1.0.01_en

Key points
 Question
 Answer
Working procedure
problems.
Crank bearing 8
Vibration damper 4
Crankshaft 5
Thrust washers 6
Piston 2
Connecting rods 10
Flywheel 9
Main bearing 7
Piston rings 1
Gudgeon pin 3
*Volvo diesel engines have fluid-type vibration dampers.

*The crankshaft is balanced in a special machine.
Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine
or particularly heavy load on the crankshaft.
The ducts in the crankshaft's counterbalances are part of the lubrication system.
The crankshafts in Volvo diesel engines are forged from special steel.
*True
False
Nitro-carburisation is a heat-treatment method for crankshafts.
*True
False
A bearing shell is made of a steel shell lined with bearing metal.
*True
False
The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing pins
as crankshaft pins.
True
*False
This illustration shows the crank weight positions in relation to each other.
Page 68 (trainer)
itro-carburisation is a heat-treatment method for crankshafts.
True
False
A bearing shell is made of a steel shell lined with bearing metal.
True
False
The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing
pins as crankshaft pins.
True
False
This illustration shows the crank weight positions in relation to each other.
Pistons 1 and 3 make their vertical movements at the same time.

There are 120:2 crankshaft degrees between ignition points.
There are 120 crankshaft degrees between ignition points.
The main bearings and crankshaft bearings are slider bearings.
True
False
The support bearing, the fourth main bearing, keeps the crankshaft in a pre-determined
axial position.
True
False
Decide what is correct.
The flywheel evens out variations in rpm.

The starter ring gear is on the flywheel.
The clutch acts on the flywheel's surface-ground face.
The connecting rod's big-end is split diagonally.
True
False
Notes
GT120017A v.1.0.01_en Page 69


*Pistons 2 and 5 make their vertical movements at the same time.
There are 120:2 crankshaft degrees between ignition points.
*There are 120 crankshaft degrees between ignition points.
The main bearings and crankshaft bearings are slider bearings.
*True
False
The support bearing, the fourth main bearing, keeps the crankshaft in a pre-determined axial
position.
*True
False
*The flywheel evens out variations in rpm.

*The starter ring gear is on the flywheel.
*The clutch acts on the flywheel's surface-ground face.
The connecting rod's big-end is split diagonally.
*True
False
Trainer notes
Page 69 (trainer)
General and basic priciples > General and basic principles > Piston
Piston
 Absorb combustion pressure
 Transfer considerable force
 Gudgeon pin
 Connecting rod
 Crankshaft
 Piston roof
 Perfect fit
 Loss of engine power
 Piston ring
 Piston ring groove
Notes
Page 70 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston
Key points
 Piston
 Immense load
 Transfer considerable force
 Gudgeon pin - connecting rod - crankshaft
 Piston roof
 Guide surface
 Combustion pressure leakage
 Piston and cylinder wall
 Piston rings
 Piston ring groove
Working procedure
information/text.
tracing.
Trainer notes
Page 70 (trainer)
General and basic priciples > General and basic principles > Piston - Thermal stress and
mechanical stress
Piston - Thermal stress and mechanical stress

 Thermal stress
 Combustion pressure load
 Wear against the cylinder wall
 Wear of the ring groove owing to piston ring movement
 Wear of the gudgeon pin bearing
Notes
GT120017A v.1.0.01_en Page 71

General and basic priciples > General and basic principles > Piston - Thermal stress and
mechanical stress
Key points
 Thermal stress
 Combustion pressure load
 Wear against the cylinder wall
 Wear of the ring groove
 Wear of the gudgeon pin bearing
Working procedure
information/text.
tracing.
Trainer notes
Page 71 (trainer)
General and basic priciples > General and basic principles > Piston - Materials
Piston - Materials
 Aluminium alloy
 Silicon
 Iron
 Nickel
 Manganese
 Copper
 Magnesium
 Thermal expansion
Notes
Page 72 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston - Materials
Key points
 Aluminium alloy
 Steel
 Diameter
Working procedure
information/text.
tracing.
Trainer notes
Page 72 (trainer)
General and basic priciples > General and basic principles > Articulated piston
Articulated piston
 Articulated pistons - split pistons
 Separately journal led
 Gudgeon pin
 Top section - steel
 Bottom section - aluminium
Notes
GT120017A v.1.0.01_en Page 73

General and basic priciples > General and basic principles > Articulated piston
Key points
 Articulated pistons (split pistons)
 Separately journal led
 Top section - steel
 Bottom section - aluminium
 Small gap prevent heat transference
 Higher temperature
 Higher co-efficient of efficiency
Working procedure
information/text.
tracing.
Trainer notes
Page 73 (trainer)
General and basic priciples > General and basic principles > Piston - Tolerance
Piston - Tolerance
 Dimensional tolerances
 Cylinder liner kits
 Piston heat
 Piston ring
 Piston ring carrier
Notes
Page 74 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston - Tolerance
Key points
 Tight dimensional tolerances
 Differences 0.07-0.08 mm
 Pistons and liners - complete kits
 Heat is transferred
 Vulnerable to wear
 Piston ring carrier made of cast-iron
Working procedure
information/text.
tracing.
Trainer notes
Page 74 (trainer)
General and basic priciples > General and basic principles > Piston cooling
Piston cooling
 Internal piston cooling
 Channel
 Oil sprayed into channel
 Efficient cooling
 Extremely hot
 High load
 Oil-borne piston cooling
 Piston cooling nozzles
 Inside of the piston
Notes
GT120017A v.1.0.01_en Page 75

General and basic priciples > General and basic principles > Piston cooling
Key points
 Internal piston cooling
 Piston crown- channel
 Very efficient cooling
Working procedure
information/text.
tracing.
Trainer notes
Page 75 (trainer)
General and basic priciples > General and basic principles > Piston rings
Piston rings
 Two types
 Compression ring
 Compression pressure
 High pressure
 Oil scraper ring
Notes
Page 76 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston rings
Key points
 Piston ring
 Ring grooves
 Compression rings
 Compression pressure
 High pressure
 Wear
 Forces stemming
 Oil scraper rings
 Oil on the cylinder walls
 Oil - back to the sump
Working procedure
information/text.
tracing.
Trainer notes
Page 76 (trainer)
General and basic priciples > General and basic principles > Piston rings material first ring
Piston rings material first ring

 Cast-iron
 Surface-treated
 Two compression rings
 One oil scraper ring
 Keystone ring
 Chrome-plated
 Molybdenum
Notes
GT120017A v.1.0.01_en Page 77

General and basic priciples > General and basic principles > Piston rings material first ring
Key points
 Cast-iron
 Surface-treated
 Two compression rings
 One oil scraper ring
 Different versions
 Trapezoidal cross-section - Keystone ring
 Ability to keep clean
 Chrome-plated
 Molybdenum
Working procedure
information/text.
tracing.
Trainer notes
Page 77 (trainer)
General and basic priciples > General and basic principles > Piston rings material second ring
Piston rings material second ring

 Chrome-plated
 Internal ridge
 Twistrings
Notes
Page 78 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston rings material second ring
Key points
 Chrome-plated
 Internal ridge
 Twist
 "Twistrings"
Working procedure
information/text.
tracing.
Trainer notes
Page 78 (trainer)
General and basic priciples > General and basic principles > Piston rings material oil ring
Piston rings material oil ring

 Chrome-plated
 Expanding spring
Notes
GT120017A v.1.0.01_en Page 79

General and basic priciples > General and basic principles > Piston rings material oil ring
Key points
 Chrome-plated
 Two scraper edges
 Spring
Working procedure
information/text.
tracing.
Trainer notes
Page 79 (trainer)
General and basic priciples > General and basic principles > Piston rings - Oil ring
Piston rings - Oil ring

 Oil
 Return holes
Notes
Page 80 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston rings - Oil ring
Key points
 Oil
 Led back
 Crankcase
 Oil sump
 Return holes
Working procedure
information/text.
tracing.
Trainer notes
Page 80 (trainer)
The gudgeon pin is prevented from moving towards the cylinder wall
by.
a screw which locks the pin to the connecting rod.

a decive which locks it to the small-end.
lock-rings in the piston.
Put the numbers in the appropriate boxes.
Piston rings
Piston crown
Piston ring groove
Piston shirt
Combustion chamber
Lock ring
Pistons and cylinder liners are classified according to diameter.

Piston and liner are matched together as per the classification letter.
GT120017A v.1.0.01_en Page 81

Key points
 Question
 Answer
Working procedure
problems.
The gudgeon pin is prevented from moving towards the cylinder wall by.
a screw which locks the pin to the connecting rod.

a decive which locks it to the small-end.
*lock-rings in the piston.
Piston rings 3
Piston crown 2
Piston ring groove 5
Piston shirt 6
Combustion chamber 1
Lock ring 4
*Pistons and cylinder liners are classified according to diameter.

*Piston and liner are matched together as per the classification letter.
Pistons are marked with classification figures 1, 2, 3 etc.
A twist-ring twists in the ring groove, thus scraping the oil as the piston moves downwards.
*True
False
The Keystone ring has a trapezoidal cross-section.
*True
False
A Keystone ring has the ability to keep clean because the chamfered surfaces work against the
ring carrier's surfaces.
*True
False
The oil scraper ring has two chrome-plated scraper edges which are pressed against the cylinder
wall.
*True
Page 81 (trainer)
istons are marked with classification figures 1, 2, 3 etc.
A twist-ring twists in the ring groove, thus scraping the oil as the
piston moves downwards.
True
False
The Keystone ring has a trapezoidal cross-section.
True
False
A Keystone ring has the ability to keep clean because the chamfered
surfaces work against the ring carrier's surfaces.
True
False
The oil scraper ring has two chrome-plated scraper edges which are
pressed against the cylinder wall.
True
False
Notes
Page 82 GT120017A v.1.0.01_en

False
Trainer notes
Page 82 (trainer)
General and basic priciples > General and basic principles > Valve mechanism
Valve mechanism
 Overhead valve
 Valve
 Rocker arm
 Pushrod
 Camshaft
Valve tappet
 Valve lifter (even called valve lifters)
 Robustly dimensioned
 Considerable loads
 Spherical
 The jacket
 Rotates
Notes
GT120017A v.1.0.01_en Page 83

General and basic priciples > General and basic principles > Valve mechanism
Key points
 Valve mechanism
 Overhead valve engines
 Valve
 Rocker arm
 Pushrod
 Camshaft
 Open and shut the valves
 Valve tappet
 Convert the camshaft's rotating
 Tappets (even called valve lifters)
 Bottom of the tappet
 The contact surface - cam
 Spherical
Working procedure
information/text.
tracing.
Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Valve
mechanism". This is like a teaser for the participants.
Trainer notes
Page 83 (trainer)
General and basic priciples > General and basic principles > Pushrod engine
Pushrod engine
 Pushrod act
 Rocker arm
 Valve yoke
Notes
Page 84 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Pushrod engine
Key points
 Pushrod engine
 Pushrod
 Rocker arm
 Valves
 Valve yoke
Working procedure
information/text.
tracing.
Trainer notes
Page 84 (trainer)
General and basic priciples > General and basic principles > Overhead camshaft
Overhead camshaft
 Rocker arm
 Directly
 Cam
Notes
GT120017A v.1.0.01_en Page 85

General and basic priciples > General and basic principles > Overhead camshaft
Key points
 Overhead camshaft
 Acted directly by the cam
 NO pushrods
 Few parts
 Valve mechanism
Working procedure
information/text.
tracing.
Trainer notes
Page 85 (trainer)
General and basic priciples > General and basic principles > Camshaft
Camshaft
 Forging
 Casting
 Steel alloy
 Special cast-iron alloy
 One cam for each valve
 Camshaft bearings
 Axial bearing - Thrust washer
Notes
Page 86 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Camshaft
Key points
 Camshaft
 Forging or casting
 Steel alloy
 Special cast-iron alloy
 One cam for each valve
 Seven bearing
 Two cams between
 Robust design
 Immense forces
 Axial bearing
 Axial bearing - thrust washer
Working procedure
information/text.
tracing.
Trainer notes
Page 86 (trainer)
General and basic priciples > General and basic principles > Camshaft - Design
Camshaft - Design
 Valves open and shut at exactly the right time

 Driven by the crankshaft
 Engine timing mechanism - Timing gears
 A = the total camheight
 B = called the basic circle
 C = the camlift
Notes
GT120017A v.1.0.01_en Page 87

General and basic priciples > General and basic principles > Camshaft - Design
Key points
 Precisely designed
 Valves open and shut
 Exactly the right time
 Engine's torque
 Exhaust gas values
 Opening and closing timing
 Driven by the crankshaft
 "Engine timing mechanism" - "Timing gears"
A - B = C
 A = the total camheight
 B = called the basic circle
 C = the camlift
Working procedure
information/text.
tracing.
Trainer notes
Page 87 (trainer)
General and basic priciples > General and basic principles > Engine timing mechanism
Engine timing mechanism
 Timing gear plate

 Crankshaft gear
 Idler gear, double
 Gear for power take off (extra equipment)
 Idler wheel, adjustable
 Camshaft gear
 Drive gear, air compressor
 Drive gear, power steering and fuel feed pump
 Intermediary gear, power steering and feed pump
 Drive gear, lubrication oil pump
 Flywheel damper with teeth for the inductive camshaft sensor
Notes
Page 88 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Engine timing mechanism
Key points
 Engine timing mechanism
 Drives the camshaft
 Fuel pump
 Other ancillaries
 1. Timing gear plate
 2. Crankshaft gear
 3. Idler gear, double
 4. Gear for power take off (extra equipment)
 5. Idler wheel, adjustable
 6. Camshaft gear
 7. Drive gear, air compressor
 8. Drive gear, power steering and fuel feed pump
 9. Intermediary gear, power steering and feed pump
 10. Drive gear, lubrication oil pump
 11. Flywheel damper with teeth for the inductive camshaft sensor
 Camshaft gear - positioned - crankshaft gear
 The gears are marked
 Helical teeth
 Quietly
 Less wear
Working procedure
information/text.
tracing.
Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Engine
timing gear". This is like a teaser for the participants.
Trainer notes
Page 88 (trainer)
General and basic priciples > General and basic principles > Engine timing mechanism - Sound
insulation
Engine timing mechanism - Sound insulation

 Timing gear casings
 Sound insulation
 Laminated steel
Notes
GT120017A v.1.0.01_en Page 89

General and basic priciples > General and basic principles > Engine timing mechanism - Sound
insulation
Key points
 timing gear casings
 Sound insulation
 Laminated steel layers with an intermediate plastic layer in between
Working procedure
information/text.
tracing.
Trainer notes
Page 89 (trainer)
General and basic priciples > General and basic principles > Crankshaft seal
Crankshaft seal
 Two different types of crankshaft seal
 The first one is a rubber overlap seal
 The second type is a Teflon overlap seal with two lips
Notes
Page 90 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Crankshaft seal
Key points
 Two different types
 Rubber overlap seal - radial sealing ring
 Two rubber lips
 Outer lip prevents dust
 Inner rubber lip is spring-loaded
 The second type is a Teflon overlap

 Two lips
 The outer lip prevents dust from
 The inner rubber lip is a Teflon seal
 This seal is not spring-loaded
Working procedure
information/text.
tracing.
Trainer notes
Page 90 (trainer)
General and basic priciples > General and basic principles > Valves, valve guides and valve
seats
Valves, valve guides and valve seats

 The job of the valve
 One or two valve springs
 Journal led
 Valve guide
 Valve's sealing
 Valve seat
Notes
GT120017A v.1.0.01_en Page 91

General and basic priciples > General and basic principles > Valves, valve guides and valve
seats
Key points
 Valves
 Valve guides
 Valve seats
 Open for precisely calculated periods
 Shut during the remaining time
 One or two valve springs
 Valve's sealing surface
 Valve leaks
 Different angle for inlet and exhaust
Working procedure
information/text.
tracing.
Trainer notes
Page 91 (trainer)
General and basic priciples > General and basic principles > Valves
Valves
 High temperatures
 800°C
 Cooled by the air which flow
 Force of the valve spring
 Nickel chromium steel
 Stellite
 Friction-welded
 Nimonic 80
 Chrome-plated
Notes
Page 92 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Valves
Key points
 Direct contact with the combustion process
 The exhaust valve
 800°C
 The inlet valve cooled by the air
 Valve spring
 Valve disc
 30 kilo Newton
 Nickel chromium steel
 Stellite
 Nimonic 80
 Chrome-plated valve stems
Working procedure
information/text.
tracing.
Trainer notes
Page 92 (trainer)
General and basic priciples > General and basic principles > Valve stem
Valve stem
 Journal led
 Cast-iron
 Replaceable
 Seals
 Valve seat rings
Notes
GT120017A v.1.0.01_en Page 93

General and basic priciples > General and basic principles > Valve stem
Key points
 Valve guide
 Cast-iron
 Replaceable
 The valve disc
 The valve seats
 Valve seat rings
 Heat-resist
 Durable material
Working procedure
information/text.
tracing.
Trainer notes
Page 93 (trainer)
General and basic priciples > General and basic principles > Valve springs
Valve springs
 Valve spring washer
 Valve locks
 Two halves
 Valve springs
 Guide washer
Notes
Page 94 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Valve springs
Key points
 Valve spring
 Valve spring washer
 Two valve locks
 Valve stem grooves
 Single valve springs
 Double valve springs
 Oscillation of the springs
Working procedure
information/text.
tracing.
Trainer notes
Page 94 (trainer)
General and basic priciples > General and basic principles > Valve seals
Valve seals
 Lubrication
 High oil consumption
 Rubber seals
Notes
GT120017A v.1.0.01_en Page 95

General and basic priciples > General and basic principles > Valve seals
Key points
 Seals
 Lubrication
 High oil consumption
 Inlet duct
 Rubber seals
 Valve guide
Working procedure
information/text.
tracing.
Trainer notes
Page 95 (trainer)
General and basic priciples > General and basic principles > Pushrod and rocker arm
Pushrod and rocker arm

 Strong
 Lightweight
 Tubular
 Pressed-in end-pieces
 Oil channel
 Adjustment screw
 Valve clearance
 Thermal expansion
 Journal led
 Bronze bushings
 Valve covers
Notes
Page 96 GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Pushrod and rocker arm
Key points
 Pushrod
 Rocker arm
 Strong
 Lightweight
 Tubular
 Pressed-in end-pieces
 The adjustment screw
 Valve clearance
 Increases in length
 The rocker arm shaft
 Bronze bushings
 Valve covers
Working procedure
information/text.
tracing.
Using the correct information from Impact for removing the cylinder head, Oil sump, piston and
connecting rod.
Trainer notes
Page 96 (trainer)
Camshaft
Valve lifter
Cam
Pushrod
Rocker arm shaft
Rocker arm
Lock-nut
Valve
Adjuster screw
Valve spring
Rocker arm bushing
The engine timing mechanism consists of a gear which drives the camshaft
and injection pump. It can also drive the...
oil pump
turbocharger
coolant pump
compressed air compressor
power steering servo pump
GT120017A v.1.0.01_en Page 97

Key points
 Question
 Answer
Working procedure
problems.
Camshaft 7
Valve lifter 6
Cam 8
Pushrod 5
Rocker arm shaft 11
Rocker arm 1
Lock-nut 3
Valve 9
Adjuster screw 4
Valve spring 10
Rocker arm bushing 2
The engine timing mechanism consists of a gear which drives the camshaft and injection pump. It
can also drive the...
*oil pump
turbocharger
*coolant pump
*compressed air compressor
*power steering servo pump
The valve lifter is found to one side of the cam's centre line so that
the lifter can be made lighter

the production process is simpler
*lifter wear is more evenly distributed
*The exhaust valve is much hotter than the inlet valve

*The valve's sealing surface can be coated with stellite
*Some valves are made in two pieces
The valve stem is made of Nimonic
*The valve stems in Volvo engines are chrome-plated
Page 97 (trainer)
The valve lifter is found to one side of the cam's centre line so that
the lifter can be made lighter

the production process is simpler
lifter wear is more evenly distributed
The exhaust valve is much hotter than the inlet valve

The valve's sealing surface can be coated with stellite
Some valves are made in two pieces
The valve stem is made of Nimonic
The valve stems in Volvo engines are chrome-plated
The valve seats are replaceable valve seat rings which are shrunk into
place.
True
False
A certain degree of valve clearance is essential since the valve increases in

length when it heats up during operation.
True
False
Place the figures in the appropriate boxes.
Duct
Valve
Sealing surface
Valve guide
Valve lock
Valve spring
Valve spring washer
Valve seat
Guide washer
If the camshaft gear incorrectly set by a single tooth, the valves will strike
the piston.
True
False
Notes
Page 98 GT120017A v.1.0.01_en

The valve seats are replaceable valve seat rings which are shrunk into place.
*True
False
A certain degree of valve clearance is essential since the valve increases in length when it heats
up during operation.
*True
False
Place the figures in the appropriate boxes.
Duct 3
Valve 4
Sealing surface 1
Valve guide 5
Valve lock 9
Valve spring 6
Valve spring washer 8
Valve seat 2
Guide washer 7
If the camshaft gear incorrectly set by a single tooth, the valves will strike the piston.
*True
False
Trainer notes
Page 98 (trainer)
Lubrication system > Lubrication system > Lubrication system
Lubrication system
If you were to ask anyone why there must be oil in an engine, the answer would almost certainly
be something like "Surely you must understand that the engine has to be lubricated!". And of
course it is true that engine components which rub against each other must be separated by a
thin film of oil. In other words, these components must be lubricated, and lubricated with clean oil
and the right sort of oil!
Notes
GT120017A v.1.0.01_en Page 99

Lubrication system > Lubrication system > Lubrication system
Key points
 Lubrication system
 Thin film of oil
 Clean oil
 Right sort of oil
 Lubricate all moving engine parts
 Wear and friction should be as little as possible
 Conduct heat away
 Sealing agent
 Plateau honing
 Clean
 Sludge
 Corrosion
 Oils require a very complex compound
 Base oil (refined mineral oil)
 Additives
 Synthetic oil
Working procedure
information/text.
tracing.
"Lubrication system". This is like a teaser for the participants.
Trainer notes
Page 99 (trainer)
Lubrication system > Lubrication system > Engine oil quality
Engine oil quality

 Oil change
 Engine oil quality
 The contents of sulphur in the fuel
Notes
Page 100 GT120017A v.1.0.01_en

Lubrication system > Lubrication system > Engine oil quality
Key points
 Specify oil
 Viscosity
 Different temperatures
 Impact
 Service schedule
 Oil grade
 Oil filter
 Oil change
 Engine oil quality
 VDS
 Sulphur
Working procedure
information/text.
tracing.
Trainer notes
Page 100 (trainer)

Lubrication system > Lubrication system > Splash lubrication - Pressure lubrication
Splash lubrication - Pressure lubrication

 Splash-lubrication
 Crankshaft's rotating motion
 Pressure lubrication
 Oil pump
 Lubrication points
 Cylinder walls
 Timing gears
Notes
GT120017A v.1.0.01_en Page 101

Lubrication system > Lubrication system > Splash lubrication - Pressure lubrication
Key points
 Required points
 Splash-lubrication
 Crankshaft's rotating motion
 Not sufficient for modern high-powered engines
 Pressure lubrication
 Oil pump
 Cylinder walls and timing gears are splash-lubricated
Working procedure
information/text.
tracing.
Trainer notes
Page 101 (trainer)

Lubrication system > Lubrication system > Pressure lubrication
Pressure lubrication
 Oil sump
 Oil pump
 Oil cooler
 Oil filter
 Oil ducts
 Lubricates
 Cools
 Cleans
 Seals
 Oil gallery
Notes
Page 102 GT120017A v.1.0.01_en

Lubrication system > Lubrication system > Pressure lubrication
Key points
 Pressure-lubrication system
 Circulating in a sealed system
 Block diagram
 Oil grade
 Oil sump
 Oil pump
 Oil cooler
 Oil filter
 Oil ducts
 Back to the oil sump
 100 litres a minute
 Gear pump
 Driven by the engine crankshaft
 Two longitudinal oil channels
 Main lubrication channel (oil gallery)
 Piston cooling oil gallery
 Timing gears
 VCB
 Valve
 Rocker arm shaft
 Camshaft bearings
 Rocker arm bearings
 Oil filter housing
 Full flow filter
 Bypass filter
Working procedure
information/text.
tracing.
Trainer notes
Page 102 (trainer)

Lubrication system > Lubrication system > Lubrication system - Function
Lubrication system - Function

The lubrication system shown on these two pages comes from a 13-litre engine.
The oil flow through the engine is regulated by six valves located inside the engine block, pump
and oil filter housing.
 Reduction valve
 Safety valve
 Thermostat valve for oil cooler
 By-pass valve for full flow filter
 Opening valve for piston cooling
 Control valve for piston cooling
Notes
GT120017A v.1.0.01_en Page 103

Lubrication system > Lubrication system > Lubrication system - Function
Key points
 A: Reduction valve
 B: Safety valve
 C: Thermostat valve for oil cooler
 D: By-pass valve for full flow filter
 E: Opening valve for piston cooling
 F: Control valve for piston cooling
Working procedure
information/text.
tracing.
Trainer notes
Page 103 (trainer)

Lubrication system > Lubrication system > Lubrication system - schematic
Lubrication system - schematic

 Strainer
 Plastic tube
 Oil pump
 Pressure pipe
 Oil cooler
 Filter housing
 Full flow filters
 Main lubrication gallery
 Separator turbine
 VCB valve
 Air compressor
 Turbocharger
 Bypass filter
 Nozzles
Notes
Page 104 GT120017A v.1.0.01_en

Lubrication system > Lubrication system > Lubrication system - schematic
Key points
 Strainer (1)
 Plastic tube (2)
 Oil pump (3)
 Pressure pipe (4)
 Oil cooler (5)
 Filter housing (6)
 Full flow filters (7)
 Main lubrication gallery (8)
 Separator turbine (9)
 VCB valve (10)
 Air compressor (11)
 Turbocharger (12)
 Bypass filter (13)
 Nozzles (14)
Working procedure
information/text.
tracing.
Trainer notes
Page 104 (trainer)

Lubrication system > Lubrication system > Oil pump - function
Oil pump - function
 Gear-driven pump
 Pump housing
 Negative pressure
 Gaps between the gear teeth
 Lubrication ducts
 Rotor pump
Notes
GT120017A v.1.0.01_en Page 105

Lubrication system > Lubrication system > Oil pump - function
Key points
 Oil pump
 Gear-driven pump
 Two gear wheels
 Pump housing
 Negative pressure
 Gaps between the gear teeth
 Lubrication ducts
 Rotor pump
 100-200 kPa (1-2 bar)
 300-500 kPa
Working procedure
information/text.
tracing.
Trainer notes
Page 105 (trainer)

Lubrication system > Lubrication system > Oil pump - parts
Oil pump - parts

 Idler gear
 Bearing sleeve
 Attachment bracket and pumping housing
 Bushing
 Driveshaft
 Drive gear
 Driven shaft
 Driving pump gear
 Driven pump gear
Notes
Page 106 GT120017A v.1.0.01_en

Lubrication system > Lubrication system > Oil pump - parts
Key points
 Dimensioned
 Driven by the engine timing mechanism
 Idler gear
 Bearing sleeve
 Attachment bracket and pumping housing
 Bushing
 Driveshaft
 Drive gear
 Driven shaft
 Driving pump gear
 Driven pump gear
Working procedure
information/text.
tracing.
Trainer notes
Page 106 (trainer)

Lubrication system > Lubrication system > Oil filter housing
Oil filter housing

 Number of valves - regulate oil flow
 Spin-on type
 10 bar without leaking
 Burst test
 Pressure up to 16 bar
 75,000 times from 0 to 8 bar
Notes
GT120017A v.1.0.01_en Page 107

Lubrication system > Lubrication system > Oil filter housing
Key points
 Oil filter housing
 Valves
 Spin-on type
 Rubber rings
 10 bar without leaking.
 75,000 times from 0 to 8 bar
Working procedure
information/text.
tracing.
Trainer notes
Page 107 (trainer)

Lubrication system > Lubrication system > Oil flows through the filter
Oil flows through the filter

 Filter insert
 Filter paper
 Particles down to approx. 40 thousandths of a millimetre (40 µm)
 Bypass filter - 10 µm
 Oil flow rate is approx. 7 litres/minute
 Oil filter replacement
 Clogged oil filters
Notes
Page 108 GT120017A v.1.0.01_en

Lubrication system > Lubrication system > Oil flows through the filter
Key points
 The oil flow
 Filter paper
 Particles down to approx. 40 thousandths of a millimetre (40 µm).
 Particles down to approx. 10 µm
 7 litres/minute
Working procedure
information/text.
tracing.
Trainer notes
Page 108 (trainer)

Lubrication system > Lubrication system > Oil cooler
Oil cooler
 10-15% heat
 130°C
 100°C
 Common type
Notes
GT120017A v.1.0.01_en Page 109

Lubrication system > Lubrication system > Oil cooler
Key points
 Oil cooler
 10-15%
 130°C
 100°C
 Flat oil cooler
Working procedure
information/text.
tracing.
Trainer notes
Page 109 (trainer)

Lubrication system > Lubrication system > Oil sump
Oil sump
 Moulded plastic (composite)
 Reducing engine noise levels
 Pressed steel variant
 Aluminum
 Sealing strip
 Dry sump
Notes
Page 110 GT120017A v.1.0.01_en

Lubrication system > Lubrication system > Oil sump
Key points
 Oil sump
 Moulded plastic (composite)
 Noise level
 Steel
 Aluminum
 Sealing strip
 Dry sump
 Lubricating oil tank
Working procedure
information/text.
tracing.
Point out main parts/valves and system layout in vehicle. Open an old oil pump.
If their is time you can also using VTT to read out oil pressure.
Trainer notes
Page 110 (trainer)

Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6
Oil has several vital functions, namely to:
lubricate by forming a thin film of oil between the moving parts

cool by leading away the heat
act as a seal between the pistons and cylinders
reduce coolant temperature by cooling the fluid
keep the engine clean by leding away soot particles and dirt
act as a noise-dampening material at the shaft seals
Volvo's VDS oil grade can withstand more operational hours than a simpler oil quality.
True
False
A high sulphur content in the fuel has no effect on the engine oil change frequency.
True
False
Oil flow through the engine can be 100 litres/minute in a large engine.
No, not so much

Yes, that is true
No, much more
In Volvo engines, piston cooling features its own oil duct in the cylinder block.
GT120017A v.1.0.01_en Page 111

Key points
 Question
 Answer
Working procedure
problems.
Oil has several vital functions, namely to:
*lubricate by forming a thin film of oil between the moving parts

*cool by leading away the heat
*act as a seal between the pistons and cylinders
reduce coolant temperature by cooling the fluid
*keep the engine clean by leding away soot particles and dirt
act as a noise-dampening material at the shaft seals
Volvo's VDS oil grade can withstand more operational hours than a simpler oil quality.
*True
False
A high sulphur content in the fuel has no effect on the engine oil change frequency.
True
*False
Oil flow through the engine can be 100 litres/minute in a large engine.
No, not so much

*Yes, that is true
No, much more
In Volvo engines, piston cooling features its own oil duct in the cylinder block.
*True
False
The reduction valve prevents oil pressure from rising too high.
*True
False
The piston cooling valve opens when oil pressure reaches a preset value.
*True
False
The oil cooler is a type of heat exchanger.
Page 111 (trainer)

True
False
The reduction valve prevents oil pressure from rising too high.
True
False
The piston cooling valve opens when oil pressure reaches a preset value.
True
False
The oil cooler is a type of heat exchanger.
True
False
Which is the pump's inlet and which is the outlet?
Inlet
Outlet
The pump in question 9 is a
Disc-type pump
Rotor pump
Crecent pump
Internal gear wheel pump
Gear wheel pump
Eccentric pump
What is this?
Piston lubrication
Piston cooling
Oil reduction
Return pipe for turbocharger oil
Is the following statement correct? If the driver does not replace the oil filters, the filters
become clogged. As a result, no oil will get to the lubrication points inside the engine.
True
False
All Volvo diesel engines have full-flow filters.
True
False
Oil filters must be replaced after a certain number of operational kilometers. How do you
find out the replacement interval?
I replacement them now and again.

I check in the maintenance instructions.
I ask a friend.
Page 112 GT120017A v.1.0.01_en

*True
False
Which is the pump's inlet and which is the outlet?
Inlet~2
Outlet~1
The pump in question 9 is a
Disc-type pump
Rotor pump
Crecent pump
Internal gear wheel pump
*Gear wheel pump
Eccentric pump
What is this?
Piston lubrication
*Piston cooling
Oil reduction
Return pipe for turbocharger oil
Is the following statement correct? If the driver does not replace the oil filters, the filters become
clogged. As a result, no oil will get to the lubrication points inside the engine.
True
*False
All Volvo diesel engines have full-flow filters.
*True
False
Oil filters must be replaced after a certain number of operational kilometers. How do you find out
the replacement interval?
I replacement them now and again.

*I check in the maintenance instructions.
I ask a friend.
Considerable amounts of heat must be directed away from the engine's interior. What proportion
does the oil manage to lead away?
Less than 5%
*10-15%
More than 25%
In one of the tests on a Volvo oil filter, the pressure in the filter rises 75,000 times from 0 to 8 bar.
*True
False
What is the name of the oil cooler type which Volvo uses in almost all its diesel engines?
Central radiator
Cyclone radiator
Page 112 (trainer)

onsiderable amounts of heat must be directed away from the engine's interior. What
proportion does the oil manage to lead away?
Less than 5%
10-15%
More than 25%
In one of the tests on a Volvo oil filter, the pressure in the filter rises 75,000 times from 0 to
8 bar.
True
False
What is the name of the oil cooler type which Volvo uses in almost all its diesel engines?
Central radiator
Cyclone radiator
Flat radiator
With the engine under high operating load, the oil temperature can reach 130°C.
True
False
Notes
GT120017A v.1.0.01_en Page 113

*Flat radiator
With the engine under high operating load, the oil temperature can reach 130°C.
*True
False
Trainer notes
Page 113 (trainer)

Fuel system > Fuel system > Fuel injection system
Fuel Injection system

 Injection pump
 Unit Injector system
 Common Rail system
 Injected at the right moment
 Tank
 Supply pump
 Fuel filters
 Pipe
 Overflow valve
 Return pipe
 High pressure pipe
 Injectors
Notes
Page 114 GT120017A v.1.0.01_en

Fuel system > Fuel system > Fuel injection system
Key points
 Fuel Injection system
 Different systems
 Injection pump
 Radial type
 In line type
 Unit Injector system
 Fuel quantity
 Milligrams of fuel
 Engine speeds
 Engine loads
 Incorrect fuel quantities
 Interference
 Impairing
 The right moment
 Top dead centre
 Injection sequence
 Extremely precise tolerances
 Tank
 Supply pump
 150 kPa (1.5 bar)
 Fuel filters
 Injection pump
 Overflow valve
 Return pipe
 High pressure
 Pressure pipe
 Injectors
 Atomised and sprayed into the combustion chamber
Working procedure
information/text.
tracing.
Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Fuel
system". This is like a teaser for the participants.
Page 114 (trainer)

Fuel system > Fuel system > Injection pump
Injection pump
 Older fuel system
 One pump element for each cylinder
 Pump-camshaft
 Pressure-valve
 Injector's pressure pipe
 Control rod
Notes
GT120017A v.1.0.01_en Page 115

Fuel system > Fuel system > Injection pump
Key points
 The injection pump
 Older fuel system
 Engine timing mechanism
 Six pump elements
 Piston
 Cam on the pump-camshaft
 Pressure-valve
 Injector's pressure pipe
Working procedure
information/text.
tracing.
Trainer notes
Page 115 (trainer)

Fuel system > Fuel system > Mechanical regulator or governor
Mechanical regulator or governor

 Mechanical regulator or governor
 Electronic regulators
 Linkage system
 Accelerator pedal
Notes
Page 116 GT120017A v.1.0.01_en

Fuel system > Fuel system > Mechanical regulator or governor
Key points
 Mechanical regulator or governor
 Electronic regulators
 Control rod's position
 Two spring-loaded weights
 Linkage system
 Throttle arm
Working procedure
information/text.
tracing.
Trainer notes
Page 116 (trainer)

Fuel system > Fuel system > Supply pump
Supply pump
 Piston pump
 Pump camshaft
 Hand-pump
Notes
GT120017A v.1.0.01_en Page 117

Fuel system > Fuel system > Supply pump
Key points
 Supply pump
 Specific pressure
 Piston pump
 Hand-pump
Working procedure
information/text.
tracing.
Trainer notes
Page 117 (trainer)

Fuel system > Fuel system > Smoke limiter
Smoke limiter
 Black smoke
 Legal limits
 Inlet manifold
 Turbocharger pressure
Notes
Page 118 GT120017A v.1.0.01_en

Fuel system > Fuel system > Smoke limiter
Key points
 Smoke limiter
 Fuel
 Black smoke
 Legal limits
 Inlet manifold
 Turbo pressure
 Less fuel means less smoke
Working procedure
information/text.
tracing.
Trainer notes
Page 118 (trainer)

Fuel system > Fuel system > Fuel filter
Fuel filter
 Clearance - 0.001 to 0.002 mm

 Hair - 20 times thicker
 Filter insert
 Filter housing
 Spin-on filter
 Box filter
 Fuel filter - fine filter
 Special paper
Notes
GT120017A v.1.0.01_en Page 119

Fuel system > Fuel system > Fuel filter
Key points
 Fuel filter
 Dirt particle
 Damage
 0.001 to 0.002 mm.
 Hair is about 20 times thicker
 Several different filters
 Filter insert
 Filter housing
 Spin-on or box filter
 Special type of paper
 Creased and coiled
Working procedure
information/text.
tracing.
Trainer notes
Page 119 (trainer)

Fuel system > Fuel system > Pressure pipes
Pressure pipes
 The pressure pipes - high-pressure leads

 Steel
 High pressures
 Clamps·
Notes
Page 120 GT120017A v.1.0.01_en

Fuel system > Fuel system > Pressure pipes
Key points
 Pressure pipes (high-pressure leads)
 Steel
 High pressures
 Thick, rigid walls
 Inner diameter
 Cylinder head's by clamps
Working procedure
information/text.
tracing.
Trainer notes
Page 120 (trainer)

Fuel system > Fuel system > Injector - copper sleeve
Injector - copper sleeve

 Cylinder head
 Copper sleeve
 Considerable heat
 Efficient heat dissipation
Notes
GT120017A v.1.0.01_en Page 121

Fuel system > Fuel system > Injector - copper sleeve
Key points
 Injector
 Inject
 Atomised fuel
 High pressure
 Copper sleeve
 Heat
Working procedure
information/text.
tracing.
The injector's job is to inject finely atomised fuel into the combustion chamber.
The fuel is atomised by being sprayed in under high pressure
Trainer notes
Page 121 (trainer)

Fuel system > Fuel system > Nozzle sleeve - needle
Nozzle sleeve - needle

 Shaped differently in different configurations
 The type of engine
 Shape of the combustion chamber
 Nozzle sleeve
 Ground needle
 Tapered sealing
 0.002-0.004 mm
 Lubricates
 Cools
Notes
Page 122 GT120017A v.1.0.01_en

Fuel system > Fuel system > Nozzle sleeve - needle
Key points
 Injector
 Nozzle
 Configurations
 Type of engine and the shape of the combustion chamber
 Nozzle sleeve
 Needle
 Tapered sealing surface
 Seat in the sleeve
 0.002-0.004 mm
 Lubricates
 Cools
Working procedure
information/text.
tracing.
Trainer notes
Page 122 (trainer)

Fuel system > Fuel system > Injector - function
Injector - function
 Nozzle holder
 Pressure pipe
 Return fuel pipe
 Spring
 Pressure pin
 Needle
 Pressure chamber
 Sleeve
 Adjusted
Notes
GT120017A v.1.0.01_en Page 123

Fuel system > Fuel system > Injector - function
Key points
 Nozzle holder
 Coupling
 Pressure pipe
 Return fuel pipe
 Force from the spring
 Pressure pin
 Needle
 Opening pressure
 Adjustment washers
 Adjustment screw
 Pressure chamber
 Increases sufficiently
 Four or five holes in the sleeve
Working procedure
information/text.
tracing.
Point out main parts/valves and system layout in vehicle. Read out feed pressure by using VTT.
Trainer notes
Page 123 (trainer)

Fuel system > Fuel system > Diesel engine fundamentals. Test 7B
Diesel engine fundamentals. Test 7B

The injection pump
ensures that the correct amount of fuel is injected into the engine
ensures that the fuel is injected into the inlet manifold
injects fuel at the correct point in time
is made to extremely high tolerance levels
The injection pump in Volvo engines
is lubricated from the engine's lubrication system

has a pump element which supplies fuel to all the injectors
has a regulator which meters the amount of fuel
is driven by a belt from the timing mechanism
varies the amount of fuel depending on the position of the control rod
The smoke limiter
reduces the grey and white smoke

regulates the amount of fuel so that black smoke stays within legal limits
is affected by turbo pressure
The injector
Page 124 GT120017A v.1.0.01_en

Key points
 Question
 Answer
Working procedure
problems.
Introduction to diesel engines. Test 7B Key
The injection pump
*ensures that the correct amount of fuel is injected into the engine
ensures that the fuel is injected into the inlet manifold
*injects fuel at the correct point in time
*is made to extremely high tolerance levels
The injection pump in Volvo engines
*is lubricated from the engine's lubrication system

has a pump element which supplies fuel to all the injectors
*has a regulator which meters the amount of fuel
is driven by a belt from the timing mechanism
*varies the amount of fuel depending on the position of the control rod
The smoke limiter.
reduces the grey and white smoke

*regulates the amount of fuel so that black smoke stays within legal limits
*is affected by turbo pressure
The injector
*has the job of injecting finely atomised fuel into the combustion chamber
*gets very hot and this heat is led away via the copper sleeve
has a lower section shaped like a pressure valve
*is connected to the injection pump via the pressure pipes
The fuel filter
must have an overflow valve

*is made such that fuel flows through a paper filter insert
*is of a type known as a spin-on or box filter
The diesel engine's exhaust gases
Page 124 (trainer)

as the job of injecting finely atomised fuel into the combustion chamber
gets very hot and this heat is led away via the copper sleeve
has a lower section shaped like a pressure valve
is connected to the injection pump via the pressure pipes
The fuel filter
must have an overflow valve

is made such that fuel flows through a paper filter insert
is of a type known as a spin-on or box filter
The diesel engine's exhaust gases
have a lower carbon monoxide content than in a petrol engine

contains no lead compounds
has a higher carbon monoxide content than in a petrol engine
contains nitrogen oxides, just like petrol engine exhaust gases
Notes
GT120017A v.1.0.01_en Page 125

*have a lower carbon monoxide content than in a petrol engine

*contains no lead compounds
has a higher carbon monoxide content than in a petrol engine
*contains nitrogen oxides, just like petrol engine exhaust gases
Trainer notes
Page 125 (trainer)

Fuel system > Fuel system > Fuel systems with unit injectors
Fuel systems with unit injectors
The unit injector system consists of:

 A pump section corresponding to the pump element in an in-line injection pump.
 A valve section with a fuel valve which is acted on by a solenoid valve.
 An injector section corresponding to the injector jets in a normal injector.
Notes
Page 126 GT120017A v.1.0.01_en

Fuel system > Fuel system > Fuel systems with unit injectors
Key points
 Unit injectors
 Pump element and injector are combined
 Electronic control
 Injection timing and fuel volume can be controlled for each injection by the control unit
 Control pulses
 Solenoid valve
 Mounted in the same place
 Overhead camshaft or high level camshaft
 A pump section corresponding to the pump element in an in-line injection pump
 A valve section with a fuel valve which is acted on by a solenoid valve
 An injector section corresponding to the injector jets in a normal injector
Working procedure
information/text.
tracing.
Trainer notes
Page 126 (trainer)

Fuel system > Fuel system > Unit injector - system function
Unit Injector - system function

 High pressure
 150-220 MPa (1500-2200bar)
 Fewer harmful exhaust emissions
 The feed section
 Control unit
 Cooled
 Galleries in the cylinder head
Notes
GT120017A v.1.0.01_en Page 127

Fuel system > Fuel system > Unit injector - system function
Key points
 Injection pressure is very high
 150-220 MPa (1500-2200bar)
 Achieve atomisation of the fuel and better combustion
 Fewer harmful exhaust emissions
 The feed section (low pressure section)
 Gear pump
 Hand pump
 Control unit
 Cooled by the fuel
 Galleries in the cylinder head
 Overflow valve
 Supply pressure
 Vents small amounts of air from the system
 Bleed screw for venting the fuel system
 Starting characteristics
 Reduce exhaust emissions
 Raises the temperature in the cylinder and combustion chamber
 Maximum is four revolutions at -20 ˚C
Working procedure
information/text.
tracing.
Trainer notes
Page 127 (trainer)

Fuel system > Fuel system > Diesel engine fundamentals. Test 7C
Diesel engine fundamentals. Test 7C
The start of an injection is controlled by ….

The fuel feed pressure
By the spill valve closing point
By the cam shaft lobe profile
The injected fuel quantity is determined by ….

The pumping element stroke
The return spring closing force
Electrical activation time, which is the length of time the spill valve remains
closed
The unit injector is supplied via

External pressure pipes
Integral ducts machined directly into the cylinder head.
Channels in the camshaft bearing brackets
Each unit injector has its own pumping element

False
True
The EUI pumping element is activated by….

The camshaft lobe via a rocker
Page 128 GT120017A v.1.0.01_en

Key points
 Question
 Answer
Working procedure
problems.
Diesel engine fundamentals. Test 7C Key
1. The start of an injection is controlled by ….

The fuel feed pressure
*By the spill valve closing point
By the cam shaft lobe profile
2. The injected fuel quantity is determined by ….

The pumping element stroke
The return spring closing force
*Electrical activation time, which is the length of time the spill valve remains closed
3. The unit injector is supplied via

External pressure pipes
*Integral ducts machined directly into the cylinder head.
Channels in the camshaft bearing brackets
4. Each unit injector has its own pumping element

False
*True
5. The EUI pumping element is activated by….

*The camshaft lobe via a rocker
Push rods
Connecting rods
Trainer notes
Page 128 (trainer)

Push rods
Connecting rods
Notes
GT120017A v.1.0.01_en Page 129

Trainer notes
Page 129 (trainer)

Fuel system > Fuel system > Common rail
Common rail
 Electronically controlled (EMS2)
 Injectors
 1600 bar
 Two unit pumps
 Sensors
 Low pressure side
 High pressure side
 Feed pump
 Fuel tank
 Pre-filter
 Fuel distributor
 Fuel filter housing
 Return line
Notes
Page 130 GT120017A v.1.0.01_en

Fuel system > Fuel system > Common rail
Key points
 EMS2
 Common rail
 Injectors
 High pressure
 1600 bar
 Engine control unit (EECU)
 Sensors
 Low pressure side (orange)
 High pressure side (red)
 Feed pump (1)
 Fuel tank (2)
 Pre-filter (3)
 Fuel distributor (4)
 Fuel filter housing (5)
 Unit pumps (6)
 Common rail (7)
 Injectors (8)
 Longitudinal channel (9)
Return line
Working procedure
information/text.
tracing.
Trainer notes
Page 130 (trainer)

Fuel system > Fuel system > Injector
Injector
 Injector body
 Nozzle holder
 Solenoid valve
 Preinjection
 Main injection
 Post-injection
Notes
GT120017A v.1.0.01_en Page 131

Fuel system > Fuel system > Injector
Key points
 Injector body
 Nozzle holder
 Solenoid valve
 Preinjection
 Main injection
 Post-injection
Working procedure
information/text.
tracing.
Trainer notes
Page 131 (trainer)

Fuel system > Fuel system > Diesel engine fundamentals. Test 7D
Diesel engine fundamentals. Test 7D
What is the part of the fuel system called the “common rail”?
A thick walled metal tube that serves as an accumulator that stores fuel at
high pressure
The return line common for all injectors for returning leak-off fuel back to tank
The part of the electrical cable harness used for activating all injector
solenoids simultaneously
In a common rail system….

There are two high pressure pumps for each cylinder
The injectors are mechanically activated by the engine timing gear
The injector needle is always subject to high pressure
Notes
Page 132 GT120017A v.1.0.01_en

Fuel system > Fuel system > Diesel engine fundamentals. Test 7D
Key points
 Question
 Answer

Working procedure
problems.
Diesel engine fundamentals. Test 7D Key
1. What is the part of the fuel system called the “common rail”?
*A thick walled metal tube that serves as an accumulator that stores fuel at
high pressure
The return line common for all injectors for returning leak-off fuel back to tank
The part of the electrical cable harness used for activating all injector
solenoids simultaneously
2. In a common rail system….

There are two high pressure pumps for each cylinder
The injectors are mechanically activated by the engine timing gear
*The injector needle is always subject to high pressure
Trainer notes
Page 132 (trainer)

Engine management system > Engine management system > EMS - Engine Management
System
EMS (Engine Management System)
 Low fuel consumption

 Noise
 Exhaust emissions
 EMS (Engine Management System)
 EDC (Electronic Diesel Control)
 Unit Injectors
 TEA (Truck Electronic Architecture)
 Electronic fuel injection
 Diagnostics
 Fault tracing
 Engine control unit
 Fault code
 Information link
 Display
 Stored
Notes
GT120017A v.1.0.01_en Page 133

Engine management system > Engine management system > EMS - Engine Management
System
Key points
 EMS (Engine Management System)
 EDC (Electronic Diesel Control)
 Unit Injectors
 TEA (Truck Electronic Architecture)
Working procedure
information/text.
tracing.
Trainer notes
Page 133 (trainer)

Engine management system > Engine management system > Engine control unit
Engine control unit

 Truck electronic architecture
 Data links
 Vehicle electronic control unit
 Sensors
 Cooled
 Starter element
 Unit injectors
 Exhaust pressure governor (EPG)
 Compression brake
Notes
Page 134 GT120017A v.1.0.01_en

Engine management system > Engine management system > Engine control unit
Key points
 1. Starter element
 2. Unit injectors
 3. Exhaust pressure governor (EPG)
 4. Compression brake
Working procedure
information/text.
tracing.
Trainer notes
Page 134 (trainer)

Engine management system > Engine management system > Sensors on the engine
Sensors on the engine

The engine control unit includes an atmospheric pressure sensor. Normally the engine is
equipped with the following sensors:
 Fuel pressure
 Charge air temperature and charge pressure
 Camshaft position
 Engine coolant level
 Air temperature and air pressure
 Engine coolant temperature
 Crankshaft position and engine speed
 Oil temperature and oil pressure
Notes
GT120017A v.1.0.01_en Page 135

Engine management system > Engine management system > Sensors on the engine
Key points
 1. Fuel pressure
 2. Charge air temperature and charge pressure
 3. Camshaft position
 4. Engine coolant level
 5. Air temperature and air pressure
 6. Engine coolant temperature
 7. Crankshaft position and engine speed
 8. Oil temperature and oil pressure
Working procedure
information/text.
tracing.
The following is a list of engine sensors that provide input to the EMS:
Ambient Air Temperature Sensor

Ambient Pressure sensor
Boost Air Pressure (BAP) Sensor
Camshaft Position (Engine Position) Sensor
Crankshaft Position (Engine Speed) Sensor
Differential Pressure DPF Sensor
EGR Differential Pressure Sensor
EGR Temperature Sensor
Engine Coolant Level (ECL) Sensor
Engine Coolant Temperature (ECT) Sensor
Engine Oil Pressure (EOP) Sensor
Engine Oil Level (EOL) Sensor
Engine Oil Temperature (EOT) Sensor
Exhaust Temperature Sensor (DPF Sensors)
Fuel Pressure Sensor
Intake Air Temperature And Humidity (IATH) Sensor
Intake Manifold (Boost) Temperature Sensor
Throttle Position (TP) Sensor
Turbo Speed Sensor
Variable Geometry Turbocharger (VGT) Position Sensor
Trainer notes
Page 135 (trainer)

Engine management system > Engine management system > Other sensors
Other sensors
 Vehicle speed (through sensors in the gearbox)

 Cruise control
 Retarder
 ABS system
 Brake, clutch and accelerator pedal
 Parking brake
 Engine brake
Notes
Page 136 GT120017A v.1.0.01_en

Engine management system > Engine management system > Other sensors
Key points
 3. Vehicle speed (through sensors in the gearbox)
 4. Cruise control
 5. Retarder
 6. ABS system
 7. Brake, clutch and accelerator pedal
 8. Parking brake
 9. Engine brake
Working procedure
information/text.
tracing.
The following is a list of engine sensors that provide input to the EMS:
Ambient Air Temperature Sensor

Ambient Pressure sensor
Boost Air Pressure (BAP) Sensor
Camshaft Position (Engine Position) Sensor
Crankshaft Position (Engine Speed) Sensor
Differential Pressure DPF Sensor
EGR Differential Pressure Sensor
EGR Temperature Sensor
Engine Coolant Level (ECL) Sensor
Engine Coolant Temperature (ECT) Sensor
Engine Oil Pressure (EOP) Sensor
Engine Oil Level (EOL) Sensor
Engine Oil Temperature (EOT) Sensor
Exhaust Temperature Sensor (DPF Sensors)
Fuel Pressure Sensor
Intake Air Temperature And Humidity (IATH) Sensor
Intake Manifold (Boost) Temperature Sensor
Throttle Position (TP) Sensor
Turbo Speed Sensor
Variable Geometry Turbocharger (VGT) Position Sensor
Trainer notes
Page 136 (trainer)

Engine management system > Engine management system > Example of communication
Example of communication
When the driver, for example, wants to increase speed and depresses the accelerator pedal, a
signal is transmitted from the accelerator pedal to the vehicle electronic control unit.
This signal is transmitted over the data link to the engine control unit.
The engine control unit checks the signals from its own sensors to ensure that it is possible to
increase the throttle setting. If there is no impediment the engine control unit activates the speed
increase.
The engine control unit then handles the control of the engine independently for as long as
conditions stay the same.
Notes
GT120017A v.1.0.01_en Page 137

Engine management system > Engine management system > Example of communication
Key points
 Communication
 Increase speed
 Signal
 Vehicle electronic control unit
 Data link
 Engine control unit
 Sensors
 Throttle setting
Working procedure
information/text.
tracing.
Point out the engine sensors. Run sensor test in VCADS Pro.
Trainer notes
Page 137 (trainer)

Engine management system > Engine management system > Diesel engine fundamentals. Test
7A
Diesel engine fundamentals. Test 7A

Which component is the EMS connected to
Unit injector
Sensors
Fuel filter
Oil pump
Can you use the EMS system for diagnostic and fault tracing
Yes
No
The engine control unit regulates different systems and components.

Which one below is correct?
Starter element
Unit injectors
Exhaust pressure governor (EPG)
Compression brake
Point out the following sensor on the engine/picture
Fuel pressure
Page 138 GT120017A v.1.0.01_en

7A
Key points
 Question
 Answer
Working procedure
problems.
Introduction to diesel engines. Test 7A Key
Which component is the EMS connected to

*Unit injector
*Sensors
Fuel filter
Oil pump
Can you use the EMS system for diagnostic and fault tracing
*Yes
No
The engine control unit regulates different systems and components.

Which one below is correct?
*Starter element
*Unit injectors
*Exhaust pressure governor (EPG)
*Compression brake
Point out the following sensor on the engine/picture

1. Fuel pressure
2. Charge air temperature and charge pressure
3. Camshaft position
4. Engine coolant level
5. Air temperature and air pressure
6. Engine coolant temperature
7. Crankshaft position and engine speed
8. Oil temperature and oil pressure
Trainer notes
Page 138 (trainer)

7A
Charge air temperature and charge pressure

Camshaft position
Engine coolant level
Air temperature and air pressure
Engine coolant temperature
Crankshaft position and engine speed
Oil temperature and oil pressure
Notes
GT120017A v.1.0.01_en Page 139

7A
Trainer notes
Page 139 (trainer)

Intake and exhaust system > Intake and exhaust system > Intake and exhaust system

 Separated from the fuel system
 Clean air through the intake system
 Inlet manifold - cast in aluminium
 O-rings - silicon-sealant
 Air filter
 Turbocharger
 Charge air cooler
 The exhaust manifold - heat-resistant material with high nickel content

 Two -or three piece unit
 Sealing rings
 Exhaust pipe
 Silencer
 All Volvo engines are boosted with a turbocharger
Notes
Page 140 GT120017A v.1.0.01_en

Intake and exhaust system > Intake and exhaust system > Intake and exhaust system
Key points
 Intake and exhaust system
 Separated from the fuel system
 Clean air through the intake system
 Fuel from a separate fuel system
 Intake manifold - cast in aluminium
 Sealing
 Rubber O-rings
 Silicon-sealant
 Air filter
 Turbocharger
 Charge air cooler
 Air resistance
 A large through-flow area is of prime importance
 Exhaust manifold
 Heat-resistant material with high nickel content
 Two -or three piece unit
 Sealed with sealing rings or a special sealing compound
Working procedure
information/text.
tracing.
Trainer notes
Page 140 (trainer)

Intake and exhaust system > Intake and exhaust system > Air filter
Air filter
 Reliability and life length
 Clean
 Pollutants
 20 cubic metres per minute
 Large through-flow area
 10 square metres
 Paper filter
 Air filter housing
Notes
GT120017A v.1.0.01_en Page 141

Intake and exhaust system > Intake and exhaust system > Air filter
Key points
 Air filter
 Reliability and life length
 Clean
 Pollutants
 20 cubic metres per minute
 Large through-flow area
 10 square metres
 Paper filter
 Air filter housing
Working procedure
information/text.
tracing.
Trainer notes
Page 141 (trainer)

Intake and exhaust system > Intake and exhaust system > Cyclone filter
Cyclone filter
 Difficult conditions
 Desert climate
 Option
 Cyclone tubes
 Air rotates
 Centrifugal force
 Dust particles
 Rubber valve
Notes
Page 142 GT120017A v.1.0.01_en

Intake and exhaust system > Intake and exhaust system > Cyclone filter
Key points
 Difficult conditions
 Desert climate
 Cyclone filter
 Cyclone tubes
 Air intake
 Air rotates
 Dust particles
 Centrifugal force
 Rubber valve
Working procedure
information/text.
tracing.
Trainer notes
Page 142 (trainer)

Intake and exhaust system > Intake and exhaust system > Starter element
Starter element
 Intake manifold
 Warm the air
 Helps the engine start
 White smoke
 Cold starts
 Starter element
 Electrically heated
Notes
GT120017A v.1.0.01_en Page 143

Intake and exhaust system > Intake and exhaust system > Starter element
Key points
 Starter element
 Intake manifold
 Warm the air
 White smoke
 Electrically heated
 Two or three heater coils
Working procedure
information/text.
tracing.
Trainer notes
Page 143 (trainer)

Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor
Exhaust pressure governor

 Compressed air
 Restricts the flow
 Back pressure
 Braking effect
Notes
Page 144 GT120017A v.1.0.01_en

Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor
Key points
 Engine brake
 Compressed air
 VEB - Volvo Engine Brake
Working procedure
information/text.
tracing.
Trainer notes
Page 144 (trainer)

Intake and exhaust system > Intake and exhaust system > Compression brake VEB
Compression brake - VEB

 Camshaft
 Rocker arms
 Hydraulic piston
 Hydraulic valve
 Rocker arm pistons
Notes
GT120017A v.1.0.01_en Page 145

Intake and exhaust system > Intake and exhaust system > Compression brake VEB
Key points
 Camshaft
 Rocker arms
 Hydraulic piston
 Hydraulic valve
 Rocker arm pistons
Working procedure
information/text.
tracing.
Trainer notes
Page 145 (trainer)

Intake and exhaust system > Intake and exhaust system > Compression brake VEB+
Compression brake - VEB+

 VEB+ Volvo Engine Brake
 Camshaft with four cam lobes
 Brake cam - VEB+ function
Notes
Page 146 GT120017A v.1.0.01_en

Intake and exhaust system > Intake and exhaust system > Compression brake VEB+
Key points
 VEB+
 EPG (Exhaust Pressure Governor).
 D16E EPG - butterfly type
 VEB+ Volvo Engine Brake
 Camshaft with four cam lobes
 Inlet cam
 Injector cam
 Exhaust cam
 Brake cam - VEB+ function
 VCB
 Engine braking control in position 2
 Engine speed above 900 rpm
 Vehicle speed above 5 km/h
 Clutch pedal released completely
 Engine oil temperature above 55°C
 Turbocharging pressure below 0.5 bar
 Accelerator pedal released completely
Working procedure
information/text.
tracing.
Trainer notes
Page 146 (trainer)

Intake and exhaust system > Intake and exhaust system > Compression brake JAK
Compression brake JAK

 Energy-absorbing air compressor
 Mounted above the rocker arm bridge
 Operate on the exhaust valves
 Always in combination with the exhaust brake
·
_
 Solenoid valve
 Control valve
 Pressure piston
Notes
GT120017A v.1.0.01_en Page 147

Intake and exhaust system > Intake and exhaust system > Compression brake JAK
Key points
 Compression brake - Jake brake
 1.Control valve
 2.Pressure piston
 3.Solenoid valve
 4.Adjustment screw, pressure piston
 Energy-absorbing air compressor

 Reducing the load on the service brakes
 Mounted above the rocker arm bridge
 Operate on the exhaust valves
 Always in combination with the exhaust brake
Working procedure
information/text.
tracing.
Trainer notes
Page 147 (trainer)

Intake and exhaust system > Intake and exhaust system > Engine brake function
Engine brake function

 Engine brake function
 Power stroke
 Exhaust stroke
Notes
Page 148 GT120017A v.1.0.01_en

Intake and exhaust system > Intake and exhaust system > Engine brake function
Key points
 Engine brake function
 Power stroke
 Exhaust stroke
Working procedure
information/text.
tracing
Trainer notes
Page 148 (trainer)

Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8
The inlet system of a diesel engine is entirely separated from the fuel
system.
True
False
The quantity of air to be cleaned in a large engine is:
approx. 5 m3/min.
approx. 10 m3/min.
approx. 20 m3/min.
An engine which has to work in surroundings where the air is

strongly polluted has an extra air filter known as a
centrifugal filter
cyclone filter
sand separator
What is this?
GT120017A v.1.0.01_en Page 149

Key points
 Question
 Answer
Working procedure
problems.
The inlet system of a diesel engine is entirely separated from the fuel
system.
*True
False
The quantity of air to be cleaned in a large engine is:
approx. 5 m3/min.
approx. 10 m3/min.
*approx. 20 m3/min.
An engine which has to work in surroundings where the air is

strongly polluted has an extra air filter known as a
centrifugal filter
*cyclone filter
sand separator
What is this?
a magnetic air filter

a cyclone filter
*a starter element
a filter cleaner
Page 149 (trainer)

a magnetic air filter

a cyclone filter
a starter element
a filter cleaner
The exhaust manifold is subjected to considerable thermal stress. It

is therefore made of a material with a high nickel content.
True
False
Notes
Page 150 GT120017A v.1.0.01_en

The exhaust manifold is subjected to considerable thermal stress. It

is therefore made of a material with a high nickel content.
*True
False
Trainer notes
Page 150 (trainer)

Turbocharger > Turbocharger > Turbocharger history
Turbocharger history
Notes
GT120017A v.1.0.01_en Page 151

Turbocharger > Turbocharger > Turbocharger history
Key points
Turbo charger history
Working procedure
Her it is time to run the movie “THE VOLVO TURBO HERITAGE 1954-2004”.
This is like a teaser for the participants.
The movie explains the development of the turbocharged engine through the
years.
Trainer notes
Page 151 (trainer)

Turbocharger > Turbocharger > Turbocharging
Turbocharging
 More air into the cylinder
 Not steal power
 Volvo turbo engines - 1954
 40 to 50% higher output
 Cleaner exhaust gases
 Quieter engine operation
 Turbocharger function
 Boost pressure - 150 kPa (1,5 bar)
 Speed - 1250-1670 rps (75,000-100,000 rpm)
 Top speed - 2200 rps (130,000 rpm)
Notes
Page 152 GT120017A v.1.0.01_en

Turbocharger > Turbocharger > Turbocharging
Key points
 Turbo charging
 Compressor air
 Turbocharger
 Powered by the flow
 1954
 Extending the engine's power
 40 to 50%
 Cleaner exhaust gases
 Quieter engine
 Turbine housing
 Exhaust system
 Turbine wheel
 Compressor wheel
 Shaft
 Compressor housing
 Air filter
 Inlet manifold
 150 kPa (1,5 bar)
 1250-1670 rps (75,000-100,000 rpm)
 2200 rps (130,000 rpm)
Working procedure
information/text.
tracing.
Trainer notes
Page 152 (trainer)

Turbocharger > Turbocharger > Turbocharger bearing
Turbocharger bearing
 Rotor shaft
 Bearing
 High speed
 Lubrication
 Cooled
 Clean oil
Notes
GT120017A v.1.0.01_en Page 153

Turbocharger > Turbocharger > Turbocharger bearing
Key points
 Rotor shaft
 Slider bearings
 Reliable lubrication
 Lubricated and cooled by engine oil
 Clean oil
Working procedure
information/text.
tracing.
Trainer notes
Page 153 (trainer)

Turbocharger > Turbocharger > Wastegate
Wastegate
 Engine torque requirements at low engine speeds

 Temperatures
 Emissions
 Boost pressure
 Bypass
 Overspeed
 Pneumatic actuator
Notes
Page 154 GT120017A v.1.0.01_en

Turbocharger > Turbocharger > Wastegate
Key points
 Wastegate
 Requirements at low engine speeds
 Producing good air flow
 Reduces exhaust temperatures
 Reduces emissions
 Boost pressure
 Bypass into the exhaust system
 Overspeed
 Pneumatic actuator
 Valve- bypass flap
Working procedure
information/text.
tracing.
Trainer notes
Page 154 (trainer)

Turbocharger > Turbocharger > Turbocharger system
Turbocharger system
 Intake system
 Exhaust system
 Turbocharger
 Starter element
 Exhaust pressure governor EPG
 Blue exhaust smoke
Notes
GT120017A v.1.0.01_en Page 155

Turbocharger > Turbocharger > Turbocharger system
Key points
 Intake
 Exhaust
 Turbocharger
 Starter element
 Exhaust pressure governor - EPG
 Reducing white and blue exhaust smoke
Working procedure
information/text.
tracing.
Trainer notes
Page 155 (trainer)

Turbocharger > Turbocharger > Exhaust pressure governor
Exhaust pressure governor

 Exhaust pressure governor EPG
 Turbocharger
 Two functions
 Pneumatic cylinder
 Vehicle's pneumatic system
 Solenoid
 Butterfly
Notes
Page 156 GT120017A v.1.0.01_en

Turbocharger > Turbocharger > Exhaust pressure governor
Key points
 Exhaust pressure governor - EPG
 Below the turbocharger
 Two functions
 Counterpressure
 Kept warm
 White exhaust smoke
 Shutter housing
 Shutter
 Pneumatic cylinder
 Compressed air
 Solenoid
Working procedure
information/text.
tracing.
Butterfly, see D16E, design and function.
Trainer notes
Page 156 (trainer)

Turbocharger > Turbocharger > Turbocharger type VGT
Turbocharger type VGT
 Variable Geometry Turbine, VGT

 EGR, Exhaust Gas Recirculation
 EMS
 Movable sleeve
 Lever
 Actuator
 Gear ratio
 Electric motor
Notes
GT120017A v.1.0.01_en Page 157

Turbocharger > Turbocharger > Turbocharger type VGT
Key points
 VGT - Variable Geometry Turbine
 EGR system
 Gas flow
 EGR-meter
 EMS system
 EGR-valve
 Axial movable sleeve (1)
 Lever (2)
 Actuator (3)
 Gear ratio (4)
 Electric motor (5)
Working procedure
information/text.
tracing.
Trainer notes
Page 157 (trainer)

Turbocharger > Turbocharger > Charge air cooling
Charge air cooling

There are two types of charge air cooler:
 Air to air cooling
 Fluid to air cooling
The charge air cooler principle
 Compressor
 Turbine
 Charge air cooler (Intercooler)
Notes
Page 158 GT120017A v.1.0.01_en

Turbocharger > Turbocharger > Charge air cooling
Key points
 Charge air cooling
 Fluid to air cooling
 Compressor
 Turbine
 Charge air cooler (Intercooler)
Working procedure
information/text.
tracing.
Trainer notes
Page 158 (trainer)

Turbocharger > Turbocharger > Air to air cooling
Air to air cooling
 Common type
 Charge air cooler (intercooler)
 Reduces the air temperature
 Raising engine power output
 Higher torque
 Positioned in front of the engine cooling radiator
Notes
GT120017A v.1.0.01_en Page 159

Turbocharger > Turbocharger > Air to air cooling
Key points
 Reduces the air temperature by roughly 100°C

 Raising engine power output by about 10%
 Torque is also higher
 Fuel consumption drops
 In front of the engine cooling radiator
Working procedure
information/text.
tracing.
Trainer notes
Page 159 (trainer)

Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9

Turbo pipe
Gasket
Sealing rings
Inlet duct
Exhaust manifold
Engine turbocharging means that

the air intake is positioned above the engine
the incoming air is pressed in from below
more air is pressed into the engine
There are several additional benefits to using a turbocharger.

Exhaust gases are cleaner
Fuel consumption is lower
Inlet noise is lower
Engine power increases
Exhaust noise is lower
Pipe routing is simpler
An exhaust pressure governor reduces the white and blue smoke in the
exhaust gases.
Page 160 GT120017A v.1.0.01_en

Key points
 Question
 Answer
Working procedure
problems.
Turbo pipe 4
Gasket 3
Sealing rings 1
Inlet duct 5
Exhaust manifold 2
Engine turbocharging means that
the air intake is positioned above the engine

the incoming air is pressed in from below
*more air is pressed into the engine
There are several additional benefits to using a turbocharger.
*Exhaust gases are cleaner

*Fuel consumption is lower
*Inlet noise is lower
*Engine power increases
*Exhaust noise is lower
Pipe routing is simpler
An exhaust pressure governor reduces the white and blue smoke in the exhaust gases.
*True
False
A diesel engine with a turbocharger and intercooler has the best possible efficiency rating.
*True
False
"Intercooler" is another name for charge air cooler.
Page 160 (trainer)

rue
False
A diesel engine with a turbocharger and intercooler has the best possible
efficiency rating.
True
False
"Intercooler" is another name for charge air cooler.

True
False
Notes
GT120017A v.1.0.01_en Page 161

*True
False
Trainer notes
Page 161 (trainer)

Cooling system > Cooling system > Volvo coolant
Volvo coolant
 Over heating
 Circulates the coolant
 Absorbs heat
 Radiator
 Fluid cooled
 Liquid coolant
 Glycol
 Water
Notes
Page 162 GT120017A v.1.0.01_en

Cooling system > Cooling system > Volvo coolant
Key points
 Over heating
 Circulates the coolant
 Absorbs heat
 Radiator
 Fluid cooled
 Liquid coolant
 Glycol
Water
Working procedure
information/text.
tracing.
Trainer notes
Page 162 (trainer)

Cooling system > Cooling system > Cooling system
Cooling system
 Heat
 Cylinder block
 Cylinder head
_
Coolant
When the ambient temperature is below 0°C, the coolant should consist of a mixture of water and
anti-freeze.
On markets where the ambient temperature never drops below 0°C, no anti-freeze is needed but
corrosion protection is still essential to prevent engine damage. In such cases, Volvo anti-
corrosion fluid is added in the ratio of 1:30 (1 litre of fluid to 30 litres of water).
All these fluids which circulate inside the cooling system are known as coolants. Referring to
them as "water" is incorrect since there is always something added to the water.
Notes
GT120017A v.1.0.01_en Page 163

Cooling system > Cooling system > Cooling system
Key points
 Cooling system
 10-15% - lubricating oil
 Radiated from the sides of the engine itself
 20-30% - cooling system
 Heat from the cylinder block and cylinder heads
 Cooling jacket
 Cylinders and combustion chambers have the same temperature
 Combustion to be as efficient and clean as possible
 Correct operational temperature
 Light or heavy load
 Low flow resistance
 Thermo-siphon principle
 Pump circulation
 Coolant pump
 Coolant
 0°C
 Mixture of water and anti-freeze
 Anti-corrosion fluid
 "water"
Working procedure
information/text.
tracing.
"Cooling system". This is like a teaser for the participants.
Trainer notes
Page 163 (trainer)

Cooling system > Cooling system > External components of the cooling system
External components of the cooling system

 Coolant filter
 Oil cooler
 Coolant pump
 Air compressor.
 Heating cell package in cab
 Expansion tank
 Level indicator.
 Filling cap.
 Thermostat
 Radiator
Notes
Page 164 GT120017A v.1.0.01_en

Cooling system > Cooling system > External components of the cooling system
Key points
 External components
 Coolant filter
 Oil cooler
 Coolant pump
 Air compressor
 Heating cell
 Expansion tank
 Level indicator.
 Warning lamp
 Filling cap - over pressure valves
 Thermostat
 Return pipe
 Radiator
Working procedure
information/text.
tracing.
Trainer notes
Page 164 (trainer)

Cooling system > Cooling system > Thermostat
Thermostat
Shut. (cold engine)
Coolant can only flow through the lower pipe.
Open. (warm engine)

Coolant can only flow through the upper pipe.
.
Notes
GT120017A v.1.0.01_en Page 165

Cooling system > Cooling system > Thermostat
Key points
 Thermostat regulates
 Shut. (cold engine)
 Open. (warm engine)
Working procedure
information/text.
tracing.
Trainer notes
Page 165 (trainer)

Cooling system > Cooling system > Schematic presentation of the cooling system
Schematic presentation of the cooling system.

 Inner circuit
 Outer circuit
Notes
Page 166 GT120017A v.1.0.01_en

Cooling system > Cooling system > Schematic presentation of the cooling system
Key points
 Schematic
 Inner circuit
 Outer circuit
Working procedure
information/text.
tracing.
Trainer notes
Page 166 (trainer)

Cooling system > Cooling system > Radiator
Radiator
 Heat exchanger
 Copper
 Brass
 Aluminium
 Plastic
 Upper tank
 Lower tank
 Honeycomb
 Pipes
 Thin steel fins
Notes
GT120017A v.1.0.01_en Page 167

Cooling system > Cooling system > Radiator
Key points
 Radiator
 Heat exchanger
 Copper
 Brass
 Aluminium
 Two containers
 Upper tank
 Lower tank
 Plastic
 Honeycomb
 Pipes
 Two up to four rows
 Steel
Working procedure
information/text.
tracing.
Trainer notes
Page 167 (trainer)

Cooling system > Cooling system > Cooling fans in vehicles
Cooling fans in vehicles

 Visco clutch
 Fan axle
 Fan
 Drive belt
 Automatic belt tensioners
Notes
Page 168 GT120017A v.1.0.01_en

Cooling system > Cooling system > Cooling fans in vehicles
Key points
 Cooling fan
 10 kW (14 bhp).
 Maximum flow
 Thermostat-regulated fan
 Fluid coupling which senses the temperature of the air which has flowed through the radiator.
 Low temperature 25% of full speed
 60°C - 95% of full speed
 5% slipping of the fluid coupling
 Reduces fuel consumption
 Less noise

Working procedure
information/text.
tracing.
Cooling fans in industrial engines
These engines feature fixed fans which are either pressure or suction fans. The former means
that the fan provides a thrust of air from behind the engine, out through the radiator. In a
generator set, this flow of air cools both the generator and the engine. Fixed fans are designed to
provide an ambient temperature of +50°
Trainer notes
Page 168 (trainer)

Cooling system > Cooling system > Cooling fans in bus
Cooling fans in bus
 Electro-hydraulic system
 Coolant temperature sensor
 PWM-signal
 Stepless regulation
 Rotational speed induction sensor
Notes
GT120017A v.1.0.01_en Page 169

Cooling system > Cooling system > Cooling fans in bus
Key points
 Electro-hydraulic system
 Coolant temperature sensor
 PWM-signal
 Stepless regulation
 Rotational speed induction sensor
Working procedure
information/text.
tracing.
Trainer notes
Page 169 (trainer)

Cooling system > Cooling system > Cooling fans in VCE
Cooling fans in VCE
 Articulated Haulers
 Wheel loaders
 Driven by hydraulic oil
 Hydraulic pump
 Hydraulic fan motor
 Vehicle ECU
 Sensors
 Valve
 Reversible fan
Notes
Page 170 GT120017A v.1.0.01_en

Cooling system > Cooling system > Cooling fans in VCE
Key points
 Articulated Haulers
 Wheel loaders
 Driven by hydraulic oil
 Hydraulic pump
 Hydraulic fan motor
 Vehicle ECU
 Sensors
 Valve
 Reversible fan
Working procedure
information/text.
tracing.
Point out main parts and system layout in vehicle
Trainer notes
Page 170 (trainer)

Cooling system > Cooling system > Diesel engine fundamentals. Test 10
Roughly 25% of the energy supplied to the engine is led away by the
cooling system.
True
False
How many degrees (roughly) does the coolant temperature drop on its way
through the radiator?
10°C
20°C
30°C
Since there is an over-pressure in the cooling system, the operational

temperature can be higher than 100°C without any risk of the system
boiling over.
True
False
It is the thermostat which provides the cooling system's over-pressure.

True
False
GT120017A v.1.0.01_en Page 171

Key points
 Question
 Answer
Working procedure
problems.
Roughly 25% of the energy supplied to the engine is led away by the cooling system.
*True
False
How many degrees (roughly) does the coolant temperature drop on its way through the
radiator?
*10°C
20°C
30°C
Since there is an over-pressure in the cooling system, the operational temperature can be
higher than 100°C without any risk of the system boiling over.
*True
False
It is the thermostat which provides the cooling system's over-pressure.
True
*False
Filling cap 10
Coolant pump 5
Air compressor 6
Expansion tank 8
Cab heating element 7
Coolant filter 3
Level indicator 9
Return pipe, Cylinder head 2
Thermostat 1
Oil cooler 4
Page 171 (trainer)

illing cap
Coolant pump
Air compressor
Expansion tank
Cab heating element
Coolant filter
Level indicator
Return pipe, Cylinder head
Thermostat
Oil cooler
The cooling mantle is in the cylinder block and cylinder head.

True
False
The thermostat keeps the pipe leading to the radiator shut until the engine
is sufficiently heated.
True
False
The coolant pump is a centrifugal pump. It can pump considerable

quantities of fluid at low pressure.
True
False
Decide what is correct as regards the coolant pump.

The pump is usually driven by the timing gear
Two rubber lip seals ensure pump shaft sealing
There is a ceramic slider ring in Volvo pumps
Pump shaft sealing consists of a slider ring seal
If the ambient temperature never drops below 0°C, there is no need for
glycol, but corrosion protection is necessary.
True
False
The piston thermostat has a low flow resistance.

True
False
A coolant filter contains anti-corrosion agent.

True
False
It is an advantage if the radiator fan does not work at all

when the vehicle is running at a low road speed or is at a standstill with the
engine operating
when the ambient air is cold and provides good cooling
when the engine is running under high load
Page 172 GT120017A v.1.0.01_en

The cooling mantle is in the cylinder block and cylinder head.
*True
False
The thermostat keeps the pipe leading to the radiator shut until the engine is sufficiently
heated.
*True
False
The coolant pump is a centrifugal pump. It can pump considerable quantities of fluid at
low pressure.
*True
False
Decide what is correct as regards the coolant pump.
*The pump is usually driven by the timing gear

Two rubber lip seals ensure pump shaft sealing
*There is a ceramic slider ring in Volvo pumps
*Pump shaft sealing consists of a slider ring seal
If the ambient temperature never drops below 0°C, there is no need for glycol, but
corrosion protection is necessary.
*True
False
The piston thermostat has a low flow resistance.
*True
False
A coolant filter contains anti-corrosion agent.
*True
False
It is an advantage if the radiator fan does not work at all
when the vehicle is running at a low road speed or is at a standstill with the engine operating
*when the ambient air is cold and provides good cooling
when the engine is running under high load
when the ambient air is hot
A thermostat fan reduces the engine's fuel consumption since it only steals a little power
from the engine when it spins at low speed.
*True
Page 172 (trainer)

hen the ambient air is hot
A thermostat fan reduces the engine's fuel consumption since it only steals
a little power from the engine when it spins at low speed.
True
False
Notes
GT120017A v.1.0.01_en Page 173

False
Trainer notes
Page 173 (trainer)

Emissions > Emissions > Vehicle emissions and environmental impact
Vehicle emissions and environmental impact
 Sulphur Oxides (SOx) from sulphur in fuel, engine emissions

 Carbon Monoxide (CO) from inefficient combustion
 Carbon dioxoide (CO2) from combustion, green house gas
 Particulate Matter (PM) from diesel engine emissions
 Nitrogen Oxides (NOx) from diesel engine emissions
 Hydrocarbons (HC) from inefficient combustion
Notes
Page 174 GT120017A v.1.0.01_en

Emissions > Emissions > Vehicle emissions and environmental impact
Key points
The most important air pollutants include:
- Sulphur Oxides (SOx) from sulphur in fuel, engine emissions
- Carbon Monoxide (CO) from inefficient combustion
- Carbon dioxoide (CO2) from combustion, green house gas
- Particulate Matter (PM) from diesel engine emissions
- Nitrogen Oxides (NOx) from diesel engine emissions
- Hydrocarbons (HC) from inefficient combustion
Working procedure
information/text.
tracing.
Trainer notes
Page 174 (trainer)

Emissions > Emissions > Engine emission
Engine emission
The diagram above shows the dramatic decrease in NOx and PM necessary to meet the Euro 4
and especially Euro 5 legislations.
Stricter emission legislation has caused an increased need for exhaust aftertreatment, in order to
remove harmful pollutants, such as NOx and particulates. The NOx emissions from a diesel
engine are lowered by adding a reducing agent to the exhaust gas flow, such as urea or diesel
fuel. The particulates are typically removed by collecting in a filter device, with continuous or
periodic regeneration of the filter.
 1st October 2006 - Euro 4

 1st October 2009 - Euro 5
 Nitrogen oxides (NOx)
 Particulate (PM)
Notes
GT120017A v.1.0.01_en Page 175

Emissions > Emissions > Engine emission
Key points
 Emission
 EGR
 SCR
Working procedure
Talk with the participants about the Volvo engine emission.
Go through the information shown below.
From 1st October 2007 all new trucks, buses and coaches will be required to be fitted with on-
board diagnostics which will monitor the performance of both SCR and EGR systems to ensure
emission compliance during use.
Enforcement authorities will be able to download faults recorded on the vehicle ECU.
Important to do the correct adjustment to get the correct emission.
There is more information about emissions on the violin link below.
http://violin.volvo.net/volvotechnology/corporate/en/business_functions/business_key_technology
_areas
Trainer notes
Page 175 (trainer)

Emissions > Emissions > Carbon dioxide and Hydrocarbons
Carbon dioxide and Hydrocarbons
Carbon dioxide contributes to the greenhouse effect, also called global warming. The
greenhouse effect is a natural phenomenon which means that the earth is heated when radiated
heat is captured by greenhouse gases in the atmosphere. Carbon dioxide is one of the most
important greenhouse gases. Since the industrial revolution human beings have added to the
greenhouse effect through increased greenhouse gas emissions.
This is expected to lead to climate change. Carbon dioxide is generated by burning material that
contains carbon, and is not poisonous. Diesel, the most common fuel for vehicles, consists of
hydrocarbons and during combustion generates carbon dioxide. Carbon dioxide emissions are
directly related to how much fuel is consumed. Compared with the petrol engine, the diesel
engine has a considerably greater degree of efficiency. This means that the energy content of the
fuel is utilised better, keeping down emissions of carbon dioxide.
Hydrocarbons are chemical compounds that contain hydrogen and carbon. Most motor vehicles
and engines are powered by hydrocarbon-based fuels such as gasoline and diesel.
Hydrocarbon pollution results when unburned or partially burned fuel is emitted from the engine
as exhaust, (or from the crankcase ventilation) and also when fuel evaporates directly into the
atmosphere. Hydrocarbons include many toxic compounds that cause cancer and other adverse
health effects. Hydrocarbons also react with nitrogen oxides in the presence of sunlight to form
ozone. Hydrocarbons, which may take the form of gases, tiny particles, or droplets, come from a
great variety of industrial and natural processes. In typical urban areas, a very significant fraction
comes from cars, buses, trucks, and non-road mobile sources such as construction vehicles and
boats.
Page 176 GT120017A v.1.0.01_en

Emissions > Emissions > Carbon dioxide and Hydrocarbons
Key points
 Carbon dioxide
 Greenhouse effect - global warming
 Greenhouse gases
 Industrial revolution
 Climate change
 Carbon - not poisonous
 Diesel
 Hydrocarbon
 Fuelconsumption
Working procedure
information/text.
tracing.
Trainer notes
Page 176 (trainer)

Emissions > Emissions > Nitrogen oxides (NOX)
Nitrogen oxides
Nitrogen oxides (NOx) is a collective name for nitrogen monoxide (NO) and nitrogen dioxide
(NO2). Nitrogen oxides contribute to a number of different environmental issues. These include
the formation of tropospheric ozone and the acidification of land and water. Nitrogen oxides are
also irritating when they are breathed in, and can in high concentrations cause damage to the
respiratory system.
Nitrogen oxides are formed during all combustion where air is present, as the oxygen and
nitrogen in the air react with each other.
At ambient temperatures, the oxygen and nitrogen gases in air will not react with each other. In
an internal combustion engine, combustion of a mixture of air and fuel produces combustion
temperatures high enough to drive endothermic reactions between atmospheric nitrogen and
oxygen in the flame, creating various oxides of nitrogen.
The high degree of efficiency of the diesel engine is achieved through high pressure, high
temperature and excess air during combustion. This increases the formation of NOx. However,
these characteristics also contribute to low emissions of carbon dioxide. Developments in engine
technology have lead to considerable reductions in NOx emissions from diesel engines.
In areas of high motor vehicle traffic, such as in large cities, the amount of nitrogen oxides
emitted into the atmosphere can be quite significant..
GT120017A v.1.0.01_en Page 177

Emissions > Emissions > Nitrogen oxides (NOX)
Key points
 Nitrogen oxides - NOX
 Nitrogen monoxide (NO)
 Nitrogen dioxide (NO2)
 Tropospheric ozone
 Irritating
 Respiratory system
Working procedure
information/text.
tracing.
Trainer notes
Page 177 (trainer)

Emissions > Emissions > Particulate matter
Particulate matter
Particulates, alternatively referred to as particulate matter (PM) or fine particles, are tiny particles
of solid or liquid suspended in a gas. In contrast, aerosol refers to particles and the gas together.
Sources of particulate matter can be man made or natural. Some particulates occur naturally,
originating from volcanoes, dust storms, forest and grassland fires, living vegetation, and sea
spray. Human activities, such as the burning of fossil fuels in vehicles, power plants and various
industrial processes also generate significant amounts of aerosols. Averaged over the globe,
anthropogenic aerosols -those made by human activities -currently account for about 10 percent
of the total amount of aerosols in our atmosphere. Increased levels of fine particles in the air are
linked to health hazards such as heart disease, altered lung function and lung cancer.
Particles from a diesel engine consist primarily of soot, various hydrocarbons and sulphur. When
they are breathed in the particles are transported into the lungs carrying with them harmful
substances. Particles can exacerbate existing respiratory problems and high concentrations can
probably lead to reduced pulmonary function. Particulate matter also contributes to poor visibility
and soot deposition. Particulate matter is generated by the incomplete combustion of fuel;
however engine lubricating oil is also a factor.
Various technical measures have reduced particulate formation in modern diesel engines. For
really good combustion good fuel must be used. Fuel with a low sulphur content reduces
particulate formation. Good fuel quality also provides greater opportunity for the use of
aftertreatment equipment.
From January 1, 2005 low sulphur fuel with a sulphur content of maximum 10 mg/kg (0.1%, 100
ppm) must be available in all member states of the EU. The USA is also introduced requirements
for greater access to low sulphur vehicle fuel from 2006. Low sulphur fuel does not only produce
lower emissions of particulates and oxides of sulphur, but is also a prerequisite for certain types
of exhaust after-treatment, e.g. particulate filters.
Page 178 GT120017A v.1.0.01_en

Key points
 Particles
 Soot
 Hydrocarbons
 Sulphur
 Harmful substances
 Respiratory problems
 Reduced pulmonary function
 Poor visibility
 Soot deposition
 Incomplete combustion of fuel
 Engine lubricating oil
 Good fuel
 Low sulphur
Working procedure
information/text.
tracing.
Trainer notes
Page 178 (trainer)

The recommended sulphur content for Euro 5 is 50 ppm, (0,05%).
Notes
GT120017A v.1.0.01_en Page 179

Trainer notes
Page 179 (trainer)

Emissions > Emissions > Diesel engine fundamentals. Test 11A
Diesel engine fundamentals. Test 11A
Which pollutants is lower in Euro 5 comparing to Euro 4.

Nitrogen oxides (NOx)
Particulate (PM)
Carbon monoxide (CO)
Carbon dioxide (CO2)
Sulphur oxide (SOx)
The recommended sulphur content for Euro 5 is

50 ppm, (0,05%)
30 ppm, (0,03%)
500 ppm, (0,50%)
5 ppm, (0,005%)
Notes
Page 180 GT120017A v.1.0.01_en

Emissions > Emissions > Diesel engine fundamentals. Test 11A
Key points
 Question
 Answer
Working procedure
problems.
Introduction to diesel engines. Test 11A Key
Which pollutants is lower in Euro 5 comparing to Euro 4.
*Nitrogen oxides (NOx)

*Particulate (PM)
Carbon monoxide (CO)
Carbon dioxide (CO2)
Sulphur oxide (SOx)
The recommended sulphur content for Euro 5 is
*50 ppm, (0,05%)

30 ppm, (0,03%)
500 ppm, (0,50%)
5 ppm, (0,005%)
Trainer notes
Page 180 (trainer)

EGR > EGR > Emisson control, schematic description of the system
Emisson control, schematic description of the system

 Emisson control
 Cooled-EGR
 EGR-valve
 EGR-cooler
 EGR-meter
 VGT turbocharger
 After treatment
 Stainless container
 Oxidizing catalytic converter
 Ceramic particulate filter
Notes
GT120017A v.1.0.01_en Page 181

EGR > EGR > Emisson control, schematic description of the system
Key points
 Emisson control
 Schematic
 Cooled-EGR
 Reducing of the nitrogen oxide
 EGR-valve (A)
 EGR-cooler (B)
 EGR-meter (C)
 VGT turbocharger (D)
 Good driveability
 Turbine geometry
 EMS system
 After treatment
 Muffler (E)
 Stainless container
 Oxidizing catalytic converter
 Ceramic particulate filter
Working procedure
information/text.
tracing.
Trainer notes
Page 181 (trainer)

EGR > EGR > EGR system
EGR system
 EGR valve
 Rear exhaust pipe
 EGR cooler
 Differential pressure sensor
 Venturi tube
 EGR temperature sensor
 EGR pipe
 Mixing chamber
 Charge air sensor
Notes
Page 182 GT120017A v.1.0.01_en

EGR > EGR > EGR system
Key points
 EGR system
 EGR valve
 Rear exhaust pipe
 EGR cooler
 Differential pressure sensor
 Venturi tube
 EGR temperature sensor
 EGR pipe
 Mixing chamber
 Charge air sensor
 EGR = Exhaust Gas Recirculation
 Nitrous oxide (NO x)
 Combustion temperature
 Cooled exhaust
 Maximum EGR
Working procedure
information/text.
tracing.
Trainer notes
Page 182 (trainer)

EGR > EGR > I-EGR, Large engine platform
I-EGR, Large engine platform
 Internal exhaust Gas Recirculation - I-EGR

 Reduce nitrogen oxide emissions - NOx
 Specially designed exhaust rocker - double rocker arm
 Controlled by the engine ECU
Notes
GT120017A v.1.0.01_en Page 183

EGR > EGR > I-EGR, Large engine platform
Key points
 Internal exhaust Gas Recirculation - I-EGR
 Added to the air-fuel mixture
 Reduce nitrogen oxide emissions - NOx
 Peak combustion temperature
 Specially designed exhaust rocker - double rocker arm
 Exhaust valve lift during the inlet stroke
 PWM controlled solenoid
Controlled by the engine ECU
Working procedure
Go through the text in the student material and also add your own
experience/knowledge.
Be sure that the participants have understood the main purpose of this
information.
Ask question to be sure that the participants have understand the main purpose
of this information/text.
Show the participants the engine parts and explain how they are connected to
each other, do not forget to tell them what is happen if they do not understand
the basic when they shall e.g. fault tracing.
Trainer notes
Page 183 (trainer)

EGR > EGR > I-EGR, Medium engine platform
I-EGR, Medium engine platform
 Medium range engines

 Construction equipment
 Mounted on top
Notes
Page 184 GT120017A v.1.0.01_en

EGR > EGR > I-EGR, Medium engine platform
Key points
 Medium range engines
 Construction equipment
 Mounted on top
Working procedure
information.
the basic when they shall e.g. fault tracing
Trainer notes
Page 184 (trainer)

EGR > EGR > I-EGR Function, Medium engine platform
I-EGR Function, Medium engine platform
 Inlet rocker arm

 Exhaust rocker arm
 Slave piston
 Control valve
 Low-pressure channel
 Solenoid valve
 From engine lubrication system
 High-pressure circuit
 Master piston
Notes
GT120017A v.1.0.01_en Page 185

EGR > EGR > I-EGR Function, Medium engine platform
Key points
 When the I-EGR is to be turned on/off is controlled by the engine ECU
 1. Inlet rocker arm
 2. Exhaust rocker arm
 3. Slave piston
 4. Control valve
 5. Low-pressure channel
 6. Solenoid valve
 7. From engine lubrication system
 8. High-pressure circuit
 9. Master piston
Working procedure
information.
the basic when they shall e.g. fault tracing
Trainer notes
Page 185 (trainer)

EGR > EGR > Diesel engine fundamentals. Test 11B
Diesel engine fundamentals. Test 11B
EGR valve
Rear exhaust pipe
EGR cooler
Differential pressure sensor
Venturi tube
EGR temperature sensor
EGR pipe
Mixing chamber
Charge air sensor
Notes
Page 186 GT120017A v.1.0.01_en

EGR > EGR > Diesel engine fundamentals. Test 11B
Key points
 Question
 Answer
Working procedure
problems.
Introduction to diesel engines. Test 11B Key
1. EGR valve
2. Rear exhaust pipe
3. EGR cooler
4. Differential pressure sensor
5. Venturi tube
6. EGR temperature sensor
7. EGR pipe
8. Mixing chamber
9. Charge air sensor
Trainer notes
Page 186 (trainer)

SCR > SCR > SCR - Selective Catalytic Reduction
SCR - Selective Catalytic Reduction

 SCR (Selective Catalytic Reduction) - catalytic exhaust gas cleaning
 Euro 4 - 1 October 2006
 Difference between Euro 4 and Euro 3
 Nitrogen oxides (NO x) reduced by 30%
 Particle emissions reduced 80%
 AdBlue
 Exhaust gases
 Catalytic converter
 Nitrous oxides - nitrogen gas and steam
 Euro 4 - 3-4% AdBlue
Notes
GT120017A v.1.0.01_en Page 187

SCR > SCR > SCR - Selective Catalytic Reduction
Key points
 SCR (Selective Catalytic Reduction) - catalytic exhaust gas cleaning
 Euro 4 - 1 October 2006
 Difference between Euro 4 and Euro 3
 Nitrogen oxides (NO x) reduced by 30%
 Particle emissions reduced 80%
 AdBlue
 Exhaust gases
 Nitrous oxides - nitrogen gas and steam
Working procedure
information/text.
tracing.
Trainer notes
Page 187 (trainer)

SCR > SCR > Main components in the Volvo SCR system
Main components in the Volvo SCR system

 Urea tank (AdBlue tank)
 Pump unit
 Dosing unit
Notes
Page 188 GT120017A v.1.0.01_en

SCR > SCR > Main components in the Volvo SCR system
Key points
 EU emission
 Reductions
 Emissions
 Particulates (PM)
 Nitrous oxides (NOx)
Working procedure
information/text.
tracing.
Trainer notes
Page 188 (trainer)

SCR > SCR > Solution principle for the Volvo SCR system
Solution principle for the Volvo SCR system

Exhaust gas cleaning in accordance with the SCR technology is a system with only a few
components.
 Solution principle
Notes
GT120017A v.1.0.01_en Page 189

SCR > SCR > Solution principle for the Volvo SCR system
Key points
 Main component
 SCR system
 Urea tank (1)
 Pump unit (2)
 Dosing unit (3)
 Silencer (4)
 SCR catalytic converter
 Solution principle
 Sprayed into the exhaust gases
 Atomised form
 Before the catalytic converter (5)
 Spraying is controlled by the EMS (Engine Management System)
 Optimal reduction of emissions
 Urea into ammonia and carbon dioxide
 Nitrous oxides (NO x) converted into harmless nitrogen gas and steam
 200°C
Working procedure
information/text.
tracing.
Trainer notes
Page 189 (trainer)

SCR > SCR > Overview of the exhaust gas processing system
Overview of the exhaust gas processing system

 Urea tank (AdBlue tank)
 Urea tank level sensor
 Urea tank temperature sensor
 Urea solution pump
 Urea solution filter
 Urea solution pressure sensor
 Urea solution temperature sensor
 MID233 control unit, urea dosing system
 Filter
 Flow direction valve
 Cooling control valve
 Non-return valve
 Dosing unit
 Exhaust temperature sensor
 NOx sensor (only used for OBD - On Board Diagnostics)
Notes
Page 190 GT120017A v.1.0.01_en

SCR > SCR > Overview of the exhaust gas processing system
Key points
 Principles diagram
 1. Urea tank (AdBlue tank)
 2. Urea tank level sensor
 3. Urea tank temperature sensor
 4. Urea solution pump
 5. Urea solution filter
 6. Urea solution pressure sensor
 7. Urea solution temperature sensor
 8. MID233 control unit, urea dosing system
 9. Filter
 10. Flow direction valve
 11. Cooling control valve
 12. Non-return valve
 13. Dosing unit
 14. Exhaust temperature sensor
 15. Catalytic converter
 16. NOx sensor (only used for OBD - On Board Diagnostics)
 MID128 (EECU - Engine Electronic Control Unit)
 Normal operation
 10°C
 15°C
Diesel Oxidation Catalyst, DOC (1)

Diesel Particulate Filter, DPF (2)
Muffler
Stainless steel
Carbon monoxide (CO) and Hydrocarbons (HC)
Carbon dioxide (CO2) and water
Nitrogen oxide (NO)
Nitrogen dioxide (NO2)
250 and 450 degrees.
Pressure sensor (3)
Temperature sensor (4)
Working procedure
information/text.
tracing.
Trainer notes
Page 190 (trainer)

SCR > SCR > Diesel engine fundamentals. Test 11C
Diesel engine fundamentals. Test 11C
Urea tank/AdBlue tank

Pump unit
Dosing/metering unit
Catalytic converter
Where in the exhaust system is the Adblue sprayed
Just before catalytic converter

Just before the turbocharger
Just before the outlet from the catalytic converter
Urea tank level sensor

Urea tank temperature sensor
Urea solution pump
Urea solution filter
Urea solution pressure sensor
GT120017A v.1.0.01_en Page 191

Key points
 Question
 Answer
Working procedure
problems.
Introduction to diesel engines. Test 11C Key
1. Urea tank/AdBlue tank

2. Pump unit
3. Dosing/metering unit
4. Catalytic converter
Where in the exhaust system is the Adblue sprayed
*Just before catalytic converter

Just before the turbocharger
Just before the outlet from the catalytic converter
2. Urea tank level sensor

3. Urea tank temperature sensor
4. Urea solution pump
5. Urea solution filter
6. Urea solution pressure sensor
7. Urea solution temperature sensor
8. MID233 control unit, urea dosing system
9. Filter
10. Flow direction valve
11. Cooling control valve
12. Non-return valve
14. Exhaust temperature sensor
16. NOx sensor (only used for OBD - On Board Diagnostics)
Page 191 (trainer)

Urea solution temperature sensor

MID233 control unit, urea dosing system
Filter
Flow direction valve
Cooling control valve
Non-return valve
Exhaust temperature sensor
NOx sensor (only used for OBD - On Board Diagnostics)
Notes
Page 192 GT120017A v.1.0.01_en

Trainer notes
Page 192 (trainer)

CCV > CCV > CCV - CrankCase Ventilation - Closed
CCV - CrankCase Ventilation - Closed

 Hose connection
 Connector
 Turbine
 Drive shaft
 Discs
 Pressure regulator
 Diaphragm
Notes
GT120017A v.1.0.01_en Page 193

CCV > CCV > CCV - CrankCase Ventilation - Closed
Key points
 CCV = Closed Crankcase Ventilation
 Hose connection (1)
 Connector (2)
 Turbine (3)
 Drive shaft (4)
 Discs (5)
 8 000 rpm
 Pressure regulator (6)
 Diaphragm (7)
 Clean gases
 Oil and heavier particles
 Function
Working procedure
information/text.
tracing.
Trainer notes
Page 193 (trainer)

CCV > CCV > Diesel engine fundamentals. Test 11D
Diesel engine fundamentals. Test 11D

Hose connection
Connector
Turbine
Drive shaft
Discs
Pressure regulator
Diaphragm
What is CCV stands for?
Closed crankcase ventilation

Clear combustion valve
Cooled crankcase by Volvo
What is the maximum revolution for the disc inside the separator?
8 000 rpm
18 000 rpm
6 000 rpm
Page 194 GT120017A v.1.0.01_en

Key points
 Question
 Answer
Working procedure
problems.
Introduction to diesel engines. Test 11D Key
Hose connection (1)

Connector (2)
Turbine (3)
Drive shaft (4)
Discs (5)
Pressure regulator (6)
Diaphragm (7)
What is CCV stands for?
*Closed crankcase ventilation

Clear combustion valve
Cooled crankcase by Volvo
What is the maximum revolution for the disc inside the separator?
*8 000 rpm
18 000 rpm
6 000 rpm
Where are the clean gases led after the CCV?
*The clean gases are led to the turbocharger inlet side via connector.
The clean gases are led to the turbocharger outlet side via connector.
The clean gases are led to the inlet side just before air filter.
Trainer notes
Page 194 (trainer)

Where are the clean gases led after the CCV?
The clean gases are led to the turbocharger inlet side via connector.
The clean gases are led to the turbocharger outlet side via connector.
The clean gases are led to the inlet side just before air filter.
Notes
GT120017A v.1.0.01_en Page 195

Trainer notes
Page 195 (trainer)

GT120017A v.1.0.01_en

New Generation Volvo Diesel Engine Fundamentals Classroom Training en

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Service training

Diesel Engine Fundamentals

Diesel Engine Fundamentals

General and basic priciples

General and basic principles

Diesel engine fundamentals. Test 3 ................................................................................... 68

Oil pump - parts ................................................................................................................ 106

Engine management system

Engine management system

Intake and exhaust system

Intake and exhaust system

Air filter ............................................................................................................................. 141

Engine emission ............................................................................................................... 175

GT120017A v.1.0.01_en Page 1

Start by welcoming the participants to the course.

Morning and afternoon breaks should be adapted to suit local times.

Page 2 GT120017A v.1.0.01_en

The diesel engine, yesterday and today

GT120017A v.1.0.01_en Page 3

First diesel engine

Page 4 GT120017A v.1.0.01_en

Diesel engines in vehicles

GT120017A v.1.0.01_en Page 5

Engines for heavier vehicles

Page 6 GT120017A v.1.0.01_en

Diesel engines in Volvo vehicles

So a lot has happened since 1946!

GT120017A v.1.0.01_en Page 7

The smallest engine is the D7E and it was launched in 2006...

...and the D11 engine, launched in 2008...

Page 8 GT120017A v.1.0.01_en

GT120017A v.1.0.01_en Page 9

The diesel engine is an internal combustion engine

Page 10 GT120017A v.1.0.01_en

GT120017A v.1.0.01_en Page 11

Page 12 GT120017A v.1.0.01_en

Power from crankshaft

GT120017A v.1.0.01_en Page 13

Diesel engine - petrol engine

Page 14 GT120017A v.1.0.01_en

Diesel engine - another approach

GT120017A v.1.0.01_en Page 15

Sturdy engine components in the diesel engine

Page 16 GT120017A v.1.0.01_en

Four strokes for a complete cycle

GT120017A v.1.0.01_en Page 17

Four stroke - six cylinder

Page 18 GT120017A v.1.0.01_en

GT120017A v.1.0.01_en Page 19

The diesel engine is miserly with its fuel

Page 20 GT120017A v.1.0.01_en

Three diesel engine types

GT120017A v.1.0.01_en Page 21

Precombustion indirect-injection engines

Page 22 GT120017A v.1.0.01_en

GT120017A v.1.0.01_en Page 23

Page 24 GT120017A v.1.0.01_en

GT120017A v.1.0.01_en Page 25

Diesel engine fundamentals. Test 1

A petrol engine takes in a ready-mixed blend of fuel and air.

The air is compressed

Page 26 GT120017A v.1.0.01_en

*A petrol engine takes in a ready-mixed blend of fuel and air.