Service Training

MALAGA

CAT Diesel Engines

Thorben
November 1997
 CAT DIESEL ENGINES
CHAPTER : Introduction

Caterpillar produces engines for various applications:

EPG

MARINE
INDUSTRIAL

CAPTIVE

The engines are divided in three categories:

Small engines (3000 - 3300)

Medium engines (3400 - 3500)

Large engines (3600 - MAK)

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 CAT DIESEL ENGINES
CHAPTER : Introduction

Caterpillar engines can be divided in two types:

IN-LINE ENGINES

ES
VE

IN
E

G
-

EN

Those two types of engines are running on two different

types of fuel:

GAS DIESEL

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 CAT DIESEL ENGINES
CHAPTER : Introduction

If you know one, you know them all !

The difference from one engine to another is the fuel

system.

All other systems (cooling , lubrication , air) are fitted to

the different fuel systems.

The fuel system is the heart of an engine. It gives the

engine its power.

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 CAT DIESEL ENGINES
CHAPTER : Engine systems

AIR INTAKE & EXHAUST

LUBRICATION
OIL

COOLING

FUEL

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 CAT DIESEL ENGINES

Air intake & exhaust

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 CAT DIESEL ENGINES
CHAPTER : Air intake systems

Natural Aspirated Turbocharged

Turbocharged Turbocharged Aftercooled

JWAC

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 CAT DIESEL ENGINES
CHAPTER : T & TA

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 CAT DIESEL ENGINES
CHAPTER : NA & ATAAC

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 CAT DIESEL ENGINES
CHAPTER : JWAC & SCAC

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 CAT DIESEL ENGINES
CHAPTER : Air intake & exhaus

The use of a turbocharger is to get more power out of an

engine.

More air in the cylinder...

More fuel can be burned...

More horsepower output !

Aftercooling is an addition to turbocharging - this

increases the horsepower again !!

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 CAT DIESEL ENGINES
CHAPTER : 4-stroke system

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 CAT DIESEL ENGINES

Lubrication system

OIL

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 CAT DIESEL ENGINES
CHAPTER : Lub. system functions

An engine oil serves 5 vital functions in a modern diesel

engine:

1. Lubricates friction surfaces by forming a fluid film

2. Cools internal engine parts by absorbing heat.

3. Cleans the engine by flushing away dirt and wear

particles

4. Supprts the crankshaft and bearing

5. Protects the engine from harmfull acids, rust and

deposits

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 CAT DIESEL ENGINES
CHAPTER : Lubrication

Viscosity
Internal resistance felt as one layer of liquid moves relative
to another layer - ie: internal liquid friction.

SAE 20 weight 20 at 100C (212F)

SAE 20W weight 20 at -18C (0F)

SAE 20W - 30 weight 20 at -18C (0F)

&

weight 30 at 100C (212F)

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 CAT DIESEL ENGINES
CHAPTER : External & internal comp.

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 CAT DIESEL ENGINES
CHAPTER : Cross drillings & camshaft lub.

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 CAT DIESEL ENGINES
CHAPTER : Oil flow 3406 engine

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 CAT DIESEL ENGINES
CHAPTER : Oil pressure relief valve

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 CAT DIESEL ENGINES

Cooling system

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 CAT DIESEL ENGINES
CHAPTER : Heat transfer

Fuel burning temperature can reach 1927C (3500F).

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 CAT DIESEL ENGINES
CHAPTER : Heat sources

Other heat gernerating sources:

- transmission oil coolers

- hydraulic oil coolers

- aftercoolers

- water-cooled exhaust manifolds

- water-cooled turbocharger shields and

housings

- marine gear oil coolers

- torque converter / retarder coolers

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 CAT DIESEL ENGINES
CHAPTER : Systems & components

Cooling systems:
- radiator

- keel cooler

- shunt cooling

- heat exchanger cooling

Basic components:
- radiator

- fan

- coolant

- water pump

- engine oil cooler

- water temperature regulator

- pressure cap

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 CAT DIESEL ENGINES
CHAPTER : Keel/shunt/heat ex. system

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 CAT DIESEL ENGINES
CHAPTER : Coolant flow

Coolant flow:
water pump

oil cooler

cylinder block

cylinder head

(radiator)

water pump

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 CAT DIESEL ENGINES
CHAPTER : Pressure cap

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 CAT DIESEL ENGINES
CHAPTER : Altitude compensation

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 CAT DIESEL ENGINES

Fuel system

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 CAT DIESEL ENGINES
CHAPTER : CAT fuel systems

Pump & lines - Multiple plunger pump

- High pressure fuel lines
- Injection nozzles
- Limited injection pressure (18.000 PSI)*
- Limited injection timing
- Limited injection rate capabilities

MUI - Mainly used on large engines to eliminate the need

for long high pressure lines and the related problems
inherent with controlling pressure in these lines.
- Requires an additional cam lobe, lifter, push rod
and rocker arm for each cylinder.

*Current engine emissions and performance requirements demand injection

pressure in excess of 20.000 PSI and greater timing flexibility.

PEEC (Programmable Electronic Engine Control)

- ECM takes over of the functions of the mechanical
governor.
- Fuel pump is still used.
- Throttle linkage replaced by electronic throttle.
- Air fuel ratio control electronically controlled.
- Engine is equipped with various sensors for monitoring.

EUI / MEUI (Mechanical Electronic Unit Injectors )

- Fuel is metered electronically by means of a solenoid
operated poppet valve.
- System still requires a mechanical valve train to
actuate the plunger.
(Mechanically actuated , electronically controlled)
- Fuel transfer pump replaces the "pump & lines".

HEUI (Hydraulic Electronic Unit Injectors )

- Plunger movement is not limited to speed or duration

of a cam lobe.
- Plunger speed is a function of actuation pressure
versus fuel pumping resistance.
(Hydraulically actuated , electronically controlled)
- Injection pressure is +20.000 PSI
 CAT DIESEL ENGINES
CHAPTER : Fuel pumps (pump & lines)

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 CAT DIESEL ENGINES
CHAPTER : System components

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 ORIFICE
CHECK VALVE TRANSFER PUMP FUEL FILTER

LIFT PUMP
VENT
WIRE
WATER
AUTOMATIC SEPARATOR
ADVANCE

GOVERNOR PRESSURE
SPRING REGULATOR
RETURN

CHAPTER : Pump & lines fuel system

CHECK METERING
VALVE VALVE

CAT DIESEL ENGINES

FUEL TANK
GOVERNOR
HEAD
PASSAGE
DELIVERY
VALVE

INJECTOR

HOUSING LUBE

ROTOR
Page:

PLUNGERS
32
 CAT DIESEL ENGINES
CHAPTER : Lift pump

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 CAT DIESEL ENGINES
CHAPTER : Lift pump operation

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 FUEL RETURN
CHECK VALVE CAM
GOVERNOR
SPRING
METERING VALVE

FUEL OUTLET
ROLLER
PRESSURE
REGULATOR
PISTON

CHAPTER : Standadyne fuel pump

GOVERNOR
WEIGHTS

CAT DIESEL ENGINES

TRANSFER
PUMP
SHOE
ROTOR DELIVERY
AUTOMATIC ADVANCE VALVE
Page:

MECHANISM ORIFICE CHECK

VALVE
35
 CAT DIESEL ENGINES
CHAPTER : Internal tranfer pump

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 CAT DIESEL ENGINES
CHAPTER : Metering valve

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 CAT DIESEL ENGINES
CHAPTER : Charging passages

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 CAT DIESEL ENGINES
CHAPTER : Pumping chambers

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 CAT DIESEL ENGINES
CHAPTER : Pumping chambers

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 CAT DIESEL ENGINES
CHAPTER : Fuel delivery to injectors

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 CAT DIESEL ENGINES
CHAPTER : Delivery valve

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 CAT DIESEL ENGINES
CHAPTER : Injection cycle review

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 CAT DIESEL ENGINES
CHAPTER : Timing advance

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 CAT DIESEL ENGINES
CHAPTER : Governor principle

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 CAT DIESEL ENGINES
CHAPTER : Plunger operation

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 CAT DIESEL ENGINES
CHAPTER : Standadyne governor

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 CAT DIESEL ENGINES
CHAPTER : Throttle lever operation

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 CAT DIESEL ENGINES
CHAPTER : Fuel Ratio Control (FRC)

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 CAT DIESEL ENGINES
CHAPTER : Shut off solenoid

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 CAT DIESEL ENGINES
Shut off solenoidCHAPTER :

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 CAT DIESEL ENGINES
CHAPTER : MUI fuel system

Unit
injector

Pressure
relief Secondary
valve fuel filter
Check elements
valve
Filter
change
valve
Secondary
fuel filter
Check elements
valve

Relief valve

Main
fuel Check
pump valve
Check
valve

Hand
Check priming
valve pump

Main Primary
fuel tank Fuel filters

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 CAT DIESEL ENGINES
CHAPTER : Mechanical Unit Injector

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 CAT DIESEL ENGINES
CHAPTER : MUI cylinder head

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 CAT DIESEL ENGINES
CHAPTER : Electronic engines

Input Power Output

Circuit Circuit Circuit

- Signals From Sensor

- Filter Electrical Noise - From Battery - To Rack And Lamps
- To Sensors
- Protect Voltage Levels ( 8vdc Minimum )

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 CAT DIESEL ENGINES
CHAPTER : System components (PEEC)

Eng Data Link

Connector

Shutoff Solenoid
J13

Rack Position Sensor

P14 J14

ECM
Rack BTM

Eng Speed Sensor

P7 J7
Atmospheric Pressure P15 J15
Sensor

P17
Boost Pressure P8 J8
Sensor Coolant
Level
Customer
Sensor
Connector
Oil Pressure P9 J9
Sensor

Coolant Temp
Sensor P12 J12

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 BTM
FSOS
RPS

INJECTOR
PRIMING
PUMP

CHECK
VALVE

CHAPTER : PEEC fuel system

CAT DIESEL ENGINES
PRIMARY
SECONDARY
TRANSFER PUMP FILTER TANK
FILTER
Page:

ECM
57
 CAT DIESEL ENGINES
CHAPTER : PEEC fuel rack

SHUTOFF SOLEINOID

PWM
BTM

FUEL RACK
SERVO

FUEL ON

RACK POSITION SENSOR

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 RACK POSITION SENSOR
RACK POSITION SENSOR

ACTUAL RACK POSITION

RACK ELECTRONIC DESIRED SPEED THROTTLE

CONTROL GOVERNOR POSITION
SENSOR
RACK
BTM

CHAPTER : Control logic (PEEC)

FRC
RACK FRC
LIMIT MAPS RATED

CAT DIESEL ENGINES

TORQUE RACK
MAPS LIMIT

SPEED SENSOR
ACTUAL SPEED

BOOST PRESS. SENSOR

Page:
59
 CHALLENGER 75C/85C
3176B EUI COMPONENT DIAGRAM
ELECTRONIC ADEM II
CONTROL MODULE CONTROL
(ECM) GROUND
STUD
J2 P2 J1 P1 12V
TIMING CALIBRATION SENSOR CONNECTOR MAIN KEY
POWER RELAY SWITCH

ELECTRONIC UNIT ENGINE MACHINE

INJECTOR HARNESS HARNESS
15 AMP
BREAKER

DATA LINK
ET/ECAP
SPEED/TIMING SENSOR CONNECTOR

CHAPTER : EUI system components

DATA LINK

CAT DIESEL ENGINES

COOLANT TEMPERATURE SENSOR THROTTLE POSITION SENSOR

TURBO OUTLET PRESSURE SENSOR CHECK ENGINE LAMP

ATMOSPHERIC PRESSURE SENSOR LAMP FLASH SWITCH

TRANSMISSION PRESSURE SWITCHES

FUEL TEMPERATURE SENSOR
Page:
60
 CAT DIESEL ENGINES
CHAPTER : Fuel system (EUI)

ELECTRONICAL CONTROLED MECHANICALY ACTUATED

FILTER

RELIEF
VALVE

E C M

Electronic
Unit
Injector
PUMP

FUEL
TANK

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 CAT DIESEL ENGINES
CHAPTER : Fuel injection

5
4

9
1. Solenoid Connection
2. Solenoid Valve Assem 10
3. Spring 11
4. Valve
5. Plunger 12
6. Barrel
7. Seal
8. Seal
9. Spring
10. Spacer 1

11. Body
12. Check
2

5
4

10
11

12

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 HIGH PRESSURE OIL MANIFOLD
High Pressure
40 to 210 BAR
Oil Pump

CHAPTER : HEUI fuel system

Regulator Fuel Return Line
Pressure
Control

CAT DIESEL ENGINES

Valve
Engine System
Fuel
Filter

ECM
Oi Fuel
lS Trans
Oil Oil u Vehicle Pump
Oil
Filter Cooler Pump
m System
p
Page:

LOW PRESSURE 3 BAR Fuel Tank

63
 TO LUBE
SYSTEM HEUI

HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR

COOL DOWN FUEL HYDRAULIC

HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER FLUID MANIFOLD
HYDRAULIC PASSAGE

CHAPTER :
PUMP

CAT DIESEL ENGINES

CONTROL HEUI
VALVE ECM
OIL
COOLER

HEUI fuel system

FUEL
TRANSFER
SECONDARY PRESSURE
PUMP
FUEL REGULATING
LUBE OIL
FILTER VALVE
PUMP
PRIMARY
FUEL FILTER
WATER
SEPARATOR
Page:

OIL
SUMP FUEL TANK
64
 CAT DIESEL ENGINES
CHAPTER : HEUI injector

SPACER
SLEEVE
ARMATURE

VALVE

VALVE BODY SOLENOID

SHIM
BARREL
ADAPTER

PISTON WASHER

UPPER FUEL SEAL

PLUNGER

FUEL INLET
CHECK VALVE

PIN
SLEEVE
SPACER

LOWER FUEL SEAL

CHECK
NOZZLE

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 CAT DIESEL ENGINES
CHAPTER : Injection

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 CAT DIESEL ENGINES
CHAPTER : Poppet valve open

ARMATURE
SCREW
POPPET
SPRING

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 CAT DIESEL ENGINES
CHAPTER : Drain

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 CAT DIESEL ENGINES
CHAPTER : Poppet valve closed

POPPET VALVE

SOLENOID

ARMATURE

INLET EXHAUST
VALVE SEAT VALVE SEAT

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 CAT DIESEL ENGINES
CHAPTER : Nozzle group

NOZZLE GROUP

REVERSE FLOW
CHECK VALVE

CHECK VALVE

FUEL
ATOMIZATION

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 CAT DIESEL ENGINES
CHAPTER : Injection cycle

CROSS SECTION
OF PLUNGER

FINAL
START OF INJECTION PRESSURE DROP PRESSURE INCREASE

INJECTION
RATE

START OF END OF
INJECTION DURATION INJECTION

TIME (MILLISECONDS)

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 PRIMING PORT COMPENSATOR
VALVE

ORIFICE VALVE BASE

DRAIN PASSAGE
TRANSFER PUMP
RESERVOIR

CHAPTER : Variable displacement pump

CAT DIESEL ENGINES
Page:

SWASHPLATE
72
 CAT DIESEL ENGINES
INJECTION PRESSURE CHAPTER : Injection pressure

HEUI

MECHANICALLY ACTUATED
FUEL SYSTEM

IDLE
ENGINE SPEED

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