Lesson 2: Diesel Engine Components

Lesson 2: Identify Caterpillar Diesel Engine

Components and Explain Principles
of Diesel Engine Operation

Objective:

The student will be able to identify diesel engine components and

explain the principles of diesel engine operation.

References:

The Engine Book LEBQ9801

Introduction to Diesel Engines TECB6005
3400 Engine Major Component Performance Guide SEBD0794
3406 Engine Components and Systems CD-ROM

Introduction:

Caterpillar develops and builds four-stroke-cycle diesel engines to

satisfy the requirements of Caterpillar-built equipment as well as a
wide variety of equipment built by other manufacturers.

To effectively perform diagnosis, repair, and service, it is necessary

to have a complete understanding of the operating principles and
construction of diesel engines.
Unit 1 1-2-3 Engine Fundamentals
Lesson 2

This CD-ROM presentation will review the major engine components

and systems of the Caterpillar 3406B diesel engine.

Fig. 1.2.1 Caterpillar 3406B Engine

Caterpillar 3406B Engine

Years of diesel experience have provided Caterpillar with the
technology necessary to design and build high quality engines that
offer maximum performance at a low overall cost. The specific
design considerations for the 3406B include:

• Reliability
• Serviceability
• Long Life before Overhaul is Needed
• Low Overhaul costs
• Application Flexibility
• Fuel Economy
• Oil Control
• Performance

Caterpillar has always emphasized strength and quality, and continues

to do so with the 3406B. The 3406B is a heavy-duty, in line, 6-
cylinder, diesel engine. The engine has a 5.4 inch bore, 6.5 inch
stroke and a displacement of 893 cu. in.
Unit 1 1-2-4 Engine Fundamentals
Lesson 2

The major engine components will now be discussed in detail.

Fig. 1.2.2 Cylinder Block

Cylinder Block

One of the major components in a diesel engine that must exhibit

maximum strength is the cylinder block. To provide maximum
strength, the block is precision cast using a combination of alloys.

Fig. 1.2.3 Cylinder Head

Cylinder Head

The cylinder head is designed to have excellent structural strength

and ridgidity. The cylinder head has passed rigorous, deep thermal
cycle shock testing for assured durability. This results in a cylinder
head with significant resistance to cracking.

The steel or aluminum spacer plate that is used between the cylinder
head and the block eliminates the need for deep counterbores in the
cylinder block. Deep counterbores decrease the structural integrity of
the block and are prone to cracking.
Unit 1 1-2-5 Engine Fundamentals
Lesson 2

Fig. 1.2.4 3406B Crankshaft

3406B Crankshaft

The crankshaft is a carbon steel forging that is total hardened. Many

other diesel engine manufacturers induction harden their crankshafts
only at the journals and fillets. This process can leave a stress riser at
the boundary between the hardened and unhardened areas. The
patented Caterpillar total-hardening process hardens the entire surface
of the crankshaft, creating a longer wearing and stronger crankshaft.
With the entire surface of the crankshaft hardened, the possibility of
cracking is reduced.

Fig. 1.2.5 3406C Crankshaft

3406C Crankshaft
With the introduction of the 3406C, the size of the rod bearing has
been significantly increased (projected area by 19%). The wider
bearing spreads the load over a greater surface area, dramatically
decreasing the bearing load while increasing the bearing life. This
photo shows a former rod bearing on the new crankshaft to
demonstrate the increase in bearing area. Additionally, this change
increases the oil film thickness by 50% and gives the 3406C the
largest rod bearing capacity in its class, eliminating mid-life bearing
roll-ins.
Unit 1 1-2-6 Engine Fundamentals
Lesson 2

Fig. 1.2.6 Connecting Rods

Connecting Rods

The forged boron steel connecting rod is hardened and shot peened
for stress relief. The tapered-end design provides additional pin to
bore contact area during the power stroke. This results in extra
strength and durability of the piston and rod assembly.

New with the 3406C is a larger, stronger connecting rod with a much
larger rod bearing. In fact, the wider 3406C rod bearing has the
greatest load carrying capacity of any heavy duty engine in its class.
By spreading the firing loads over a larger surface area, load carrying
capacity, bearing reliability, and service life are all dramatically
increased for all ratings.
Unit 1 1-2-7 Engine Fundamentals
Lesson 2

Fig. 1.2.7 Pistons

Pistons

Pistons are critical to the design, life, and overall performance of an

engine. The Caterpillar 3406B Engine's three-ring piston is an
aluminum alloy casting with a cast-in nickel iron band for the
compression rings. The nickel iron band provides improved groove
strength and resists wear.

The three-ring piston design provides excellent compression and oil

control while reducing friction and heat buildup. This results in
extended piston, ring and liner life and reduces maintenance cost at
overhaul time.

The piston rings are nodular iron for strength and durability. The oil
and intermediate rings are chrome coated, while the top ring is
plasma coated. Both coatings provide excellent wear and scuff-
resistant properties.
Unit 1 1-2-8 Engine Fundamentals
Lesson 2

Fig. 1.2.8 Cylinder Liners

Cylinder Liners

Cylinder liners are made of a cast molybdenum alloy iron for an extra
margin of hardness. The internal surface of each liner is induction
hardened, then ground in a cross-hatched pattern to aid in oil control.
O-rings are used to seal the liner to block coolant cavity. A liner band
is used to seal the top of the liner. Because the engine is rigid, these
seals remain seated and provide excellent liner sealing.

Fig. 1.2.9 Valves

Valves

Exhaust and intake valves in the 3406B Engine are extremely wear
resistant for long life. Three materials are used in the exhaust valves.
The stems are made of a hardened stainless steel. A special alloy is
used for the heads to provide high temperature strength. The seating
faces of the valve are made of Stellite for high temperature wear
resistance. Intake valve heads and stems are made from stainless
steel and are hardened for resistance to wear.
Unit 1 1-2-9 Engine Fundamentals
Lesson 2

Fig. 1.2.10 Valve Seat Inserts

Valve Seat Inserts

When the valve seats become worn or damaged, valve seat inserts are
replaceable. Intake inserts are a stainless steel alloy and the exhaust
inserts are a nickel base alloy.

Each valve has a rotator which moves the valve face 3° relative to the
valve seat during one complete cycle of the engine. This assures
uniform wear for longer valve life and helps prevent burned valves.

Fig. 1.2.11 Camshaft

Camshaft

The camshaft is made of a special alloy steel that is drop forged and
hardened for reliability and durability. The camshaft gear is heated
and pressed on during installation.
Unit 1 1-2-10 Engine Fundamentals
Lesson 2

Fig. 1.2.12 BrakeSaver

BrakeSaver

The 3406B has an optional BrakeSaver hydraulic retarder that

provides smooth, quiet and efficient vehicle braking. The BrakeSaver
develops a retarding capability of 360 hp and maintains normal
engine temperatures on long downhill grades. The hydraulic
operation of the BrakeSaver provides smooth, gradual engagement,
reducing the possibility of skids or jackknives.

By relieving the service brakes of the severe wear caused by downhill

braking, the BrakeSaver extends brake lining, drum, and tire life.
This reduces user maintenance costs.

Fig. 1.2.13 Fuel System

Fuel System

The 3406B utilizes a direct injection, scroll type, high pressure fuel
system. The system is very efficient, allowing short injection
duration and excellent fuel atomization. This results in lower
emissions and improved fuel economy.
Unit 1 1-2-11 Engine Fundamentals
Lesson 2

Fig. 1.2.14 Fuel Injection Nozzle

Fuel Injection Nozzle

Injection nozzles can be replaced in the field. The six hole tip
atomizes the high pressure fuel flow in the combustion chamber for
complete, efficient combustion.

Fig. 1.2.15 Fuel Injection Pump

Fuel Injection Pump

Individual scroll-type fuel pumps for each cylinder require no
balancing and maintain fuel efficiency without periodic adjustment.
Unit 1 1-2-12 Engine Fundamentals
Lesson 2

Fig. 1.2.16 Spring/Hydraulic Timing Advance

Spring Hydraulic Timing Advance

The speed sensitive timing advance mechanism optimizes

performance and makes starting easy. Earlier 3406B Engines used a
spring/hydraulic system. As engine speed increases, timing is
advanced hydraulically using engine oil. As engine speed decreases,
a large spring pushes the timing mechanism toward the retarded
position. The spring/hydraulic system has a timing advance
capability of 9 degrees.

Fig. 1.2.17 Hydraulic Timing Advance

Hydraulic Timing Advance

A double hydraulic automatic timing advance was introduced on the
3406B Engines, serial number 4MG3600 and up. In this system, the
timing mechanism advances and retards hydraulically using engine
oil. A spool valve actuated by flyweights controls the flow of oil in
the timing mechanism. This fully hydraulic system has a timing
advance capability of 12 degrees.
Unit 1 1-2-13 Engine Fundamentals
Lesson 2

Fig. 1.2.18 Governor

Governor

The Caterpillar 3406B features a full range governor. The

hydraulically assisted governor maintains nearly constant speed over
rolling terrain similar in effect to automatic speed control in
automobiles. This reduces gear shifts and accelerator changes,
resulting in improved trip times and less driver fatigue.

Fig. 1.2.19 Turbocharger

Turbocharger

3406B turbochargers are performance matched for each horsepower

rating. Their low inertia design reacts rapidly to load demands while
delivering full-rated power to the altitude limit appropriate for the
application of the engine. This results in improved combustion
efficiency and more work per gallon of fuel.
Unit 1 1-2-14 Engine Fundamentals
Lesson 2

Component Locations

Fig. 1.2.20 Engine Component Locations

Engine Component Locations

Located on the front of the engine are:
• Air compressor drive cover
• Timing advance cover
• Vibration damper
• Coolant pump

Fig. 1.2.21 Engine Component Locations

Engine Component Locations

On the right side of the engine are the:
• Turbocharger
• Exhaust manifold
• Oil filter
• Oil cooler
• Breather and tube assembly
Unit 1 1-2-15 Engine Fundamentals
Lesson 2

Fig. 1.2.22 Engine Component Locations

Engine Component Locations

Located on the left side are the:
• Air compressor mounting location
• Injection lines
• Hand priming pump
• Starter location
• Fuel filter
• Fuel transfer pump
• Fuel injection pump

Depending on the application, the engine may also be equipped with

a different arrangement on the fuel filter and priming pump locations.
Some engines will also have an aftercooler.

Fig. 1.2.23 Transmission Oil Cooler

Transmission Oil Cooler

If used, the transmission oil cooler is installed on the right side of the
engine.
Unit 1 1 Engine Fundamentals
Lesson 2, Exercise 1.2.1

Student Copy: Exercise 1.2.1

Unit 1, Exercise 1.2.1

Using handouts, "Introduction to Diesel Engines" (Form No. TECB6005), and "The Engine Book"
(Form No. LEBQ9801) write a brief explanation of the function of the following components.

Cylinder Block:

Crankshaft:

Connecting Rod:

Piston:

Piston Rings:

Piston Pin:

Bearings:

Cylinder Liner/Sleeve:

Turbocharger:

Pushrod:

Lifter:

Camshaft:

Valves:

Rocker Arm:

Cylinder Head:

Fuel Injector:

Aftercooler:

Vibration Damper: