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Unit 3
Lubrication Systems and Oil
Unit Objectives:
Unit References:
Tooling:
Objectives:
References:
Introduction:
Oil Passages
The lubrication system inside the engine includes the following
components:
1. Oil manifold (gallery) in block
2. Piston cooling jet
3. Oil passage to main and cam bearings
4. Camshaft and main bearing oil passage
5. Front oil supply for lifters
6. Rear oil supply for lifters
7. Front oil supply to rocker shaft
8. Rear oil supply to rocker shaft
9. Oil supply to fuel pump
HOUSING
DRIVE GEAR
The basic gear pump is the type most commonly found on Caterpillar
engines. This pump has two gears in mesh. One gear is driven by
the engine and the other is an idler gear. The two gears rotate in
opposite directions capturing the engine oil, and drawing it around
the inside of the housing. When the teeth come together in mesh the
oil is forced out of the teeth and flows through the pump outlet to the
rest of the lubrication system.
INNER OUTER
GEAR GEAR
OUTLET
INLET
PORT
PORT
Some Perkins engines use a rotor type pump. This pump has an inner
gear and a outer gear that are in mesh with one another. The inner
gear is driven by the engine. The centerline of the outer gear is offset
from the inner gear and is free to turn. As the inner gear is turned it
causes the outer gear to rotate. Engine oil is drawn into the pump
through the inlet and carried in the space between the two rotating
parts to the outlet. On the outlet side the inner gear and the outer
gear come into mesh with one another and force the oil to be pushed
out the outlet port of the pump.
Unit 3 3-1-6 Engine Fundamentals
Lesson 1
As pressure in the system nears the maximum, it will force the valve
off its seat and allow some oil to bypass to the low pressure side of
the pump. If the pressure in the system continues to rise, the valve
plunger will move farther down allowing more flow to bypass.
When the engine oil is cold it will be thick or have a high viscosity,
and will resist flowing. During cold engine start ups the oil will
resist flowing through the engine. Pressure will build quickly,
causing the valve to open.
Unit 3 3-1-7 Engine Fundamentals
Lesson 1
Oil Cooler
Many engines are equipped with an oil cooler assembly. The cooler
utilizes an engine oil to coolant heat exchanger. Hot engine oil
passing through the cooler element transfers heat to the engine
coolant. This cooling of the oil helps to maintain the lubricating
properties of the oil under heavy engine load.
Oil Filter
The oil filter base mounts at least one filter element. Most Caterpillar
engines use spin-on style full flow filters in order to remove
damaging foreign materials from the engine oil.
Turbocharger Lubrication
The turbocharger oil supply line is connected to the outlet of the filter
base. An adequate supply of cooled, clean oil is essential to
turbocharger life. Thus, the turbocharger receives oil flow before
other engine components. Oil cools, and lubricates the bearings of
the turbocharger. Oil flow from the turbocharger is returned to the oil
pan. This is also why hot shutdowns or high rpm shutdowns of the
engine are bad. Insufficient oil flow under these conditions could
lead to premature failure of the turbocharger. The turbocharger needs
the oil to cool and to lubricate its bearings.
Drilled passages in the rocker shafts supply the upper valve train with
oil flow. This is also used to supply oil to the compression release
brake (Jake Brake), if equipped.
Unit 3 3-1-12 Engine Fundamentals
Lesson 1
BrakeSaver Option
Since the BrakeSaver retarder option becomes an integral part of the
lubrication system, we will review the operation of the BrakeSaver
along with the changes to the lubrication system the option requires.
The rear section of the oil pump supplies oil for BrakeSaver operation
and oil cooling.
BrakeSaver Control
BrakeSaver Control
When the BrakeSaver retarder is in operation, the braking force
available is in direct relation to the amount of oil in the compartment.
The BrakeSaver control valve determines the amount of oil delivered
to the unit.
Unit 3 3-1-16 Engine Fundamentals
Lesson 1
BrakeSaver Operation
When the oil is warm, the oil is sent to the BrakeSaver control valve.
If the BrakeSaver control lever is in the OFF position, spring force
holds the valve spool against the cover at the air inlet end of the
control valve. With the valve spool in this position, the valve directs
the warm oil to the oil cooler. From the oil cooler the oil goes back
through the BrakeSaver control valve and returns to the oil pan.
BrakeSaver Operation
If the BrakeSaver control lever is in the ON position, air pressure
moves the valve spool to the right against the spring force. Engine
oil from the oil pump is sent through the control valve to the
BrakeSaver. After the oil goes through the BrakeSaver, it returns to
the BrakeSaver control valve. The valve then directs the oil to the oil
cooler. From the cooler, the oil again returns to the control valve and
is sent back to the oil pan.
Unit 3 3-1-17 Engine Fundamentals
Lesson 1
BrakeSaver Lubrication
Lubrication for the BrakeSaver retarder is provided by an outside oil
line from the engine lubrication system. This oil lubricates the piston
ring seals and the lip-type seals under all conditions of BrakeSaver
retarder operation. The drain line returns the oil to the oil pan.
BrakeSaver Components
The BrakeSaver housing is fastened directly to the rear face of the
flywheel housing. The BrakeSaver retarder consists of the housing,
stator and rotor. The rotor is attached to the crankshaft and rotates in
a space between the stator and the housing.
Unit 3 3-1-18 Engine Fundamentals
Lesson 1
BrakeSaver Rotor
The rotor has pockets on the outer circumference of both sides and
four holes to permit equal oil flow to both sides.
BrakeSaver Housing
The BrakeSaver housing and the stator are fastened to the flywheel
housing and cannot turn. Both the housing and the stator have
pockets on their inside surfaces in alignment with the pockets in the
rotor.
Unit 3 3-1-19 Engine Fundamentals
Lesson 1
BrakeSaver Operation
When the BrakeSaver retarder is in operation, engine oil comes into
this compartment from a passage in the bottom of the housing. The
rotor, turning with the crankshaft, throws this oil outward into the
stator and the housing compartment. The pockets or vanes on the
turning rotor, force the oil to flow in the BrakeSaver compartment.
BrakeSaver Operation
If the area in the stator and housing were smooth, the rotor and oil
would turn inside the compartment with little opposition. However,
both the stator and housing have vanes which are opposite the rotor.
These vanes oppose the flow of the oil in the compartment induced
by the rotor. It is this resistance of the oil flow that creates the
retarding action of the BrakeSaver retarder.
This resistance to the oil flow creates heat in the oil which is removed
by the oil cooler.
3-1-20
In the modern diesel engine, engine oil must perform four basic tasks
without having a negative impact on engine performance and
longevity of the engine. These functions of the oil are discussed
here.
Lubrication
Cooling
Cleaning
Sealing
The engine oil creates a film between the piston rings and the
cylinder walls. This film not only lubricates, but also helps to seal
the combustion chamber of the engine off from the crankcase. This
helps to prevent blowby.
Unit 3 3-1-21 Engine Fundamentals
Student Handout 1
Lubricating oil used in the first Caterpillar Diesel, introduced in 1931, was straight mineral crankcase
oil. When the engines began experiencing ring sticking and cylinder liner scratching, it became
apparent that a more effective oil was needed. In 1935, the first additive crankcase oil was developed
in a cooperative effort of several U.S. oil companies and Caterpillar.
The performance standards for this and subsequent oil were established by tests performed on a single
cylinder test engine designed and built by Caterpillar specifically for oil testing. This initial crankcase
oil was named "Superior Lubricants for Caterpillar Engines" and was sold only through Caterpillar
Dealers.
The test, run by engine manufacturers, required that the single cylinder test engine be disassembled
after it had run for a designated period of time at a pre-determined load and speed. Pistons were
inspected, and the color change caused by lacquering was observed and recorded. Other critical factors
such as ring wear and deposits were measured. In 1958, Caterpillar established the Series 3
classification.
It wasn’t until 1970, that the API (American Petroleum Institute) recognized the need to revise its
classification system. The API, SAE, and ASTM collaborated in this effort. Their new system was
based on the same type of performance specifications which Caterpillar and others had been using.
Caterpillar was able to drop its classification system in 1972. The new API/SAE system established
CD, CC and other SAE letter designations for oil classifications. These referred to performance levels
in engine tests. A list of all brand name API-rated oils is included in the Engine Manufacturers
Association Lubricating Oils-Data Book, available from your Caterpillar Dealer, Caterpillar form
number SEBU5939.
Caterpillar recommends that you use (SOS) Fluid Sampling, a service offered by most Caterpillar
Dealers. An analysis of your engine oil can show the presence of metal wear particles which can
indicate acid attack or other abnormal wear. Before taking an oil sample, operate the engine until it is
at the normal operating temperature. A sampling valve and adapter is available to take an oil sample
while the engine is running. Fill the new sample bottle approximately 75% full. If a sample is taken
from the oil drain stream do not get the sample from the first part or the last part of the oil drain. Use
caution to prevent burns or injuries caused by the hot oil. Fill out the sample and shipment labels.
Make sure engine serial number, miles on oil, and unit number are indicated.
Lesson 2: Remove, Inspect and Install
Lesson 2: Remove, Inspect, and Install
Lubrication System Components
Objectives:
References:
Introduction:
Tooling:
Lab Exercises:
Install the engine onto a 1U5750 repair stand with 1U5749 adapter.
Remove oil cooler taking note of core and circulation path of oil and
path of coolant.
Remove oil pan and oil pump. Disassemble oil pump taking note of
gears and relief valve. Inspect oil pump using specifications from the
Service Manual.