Basic Structure and Functions

Basic Structure and Function

of SAA6D107-1 Engine
Engine Rebuild Training Course
 Basic Structure and Functions
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A. Engine Application

PC200-8
PC228-3E0

PC220-8 PC240-8

PC270-8 WA250-6 WA380-6

WA320-6

BR380JG-1E0 GD535-5 GD655-5

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B. Engine comparison (PC200-8 vs WA380-6)

Air inlet 1
connector Front view

1 Air inlet connector

PC200-8 WA380-6
Oil drain plug 2 2 Oil drain plug and hose

Muffler ass’y 3
3 Air cleaner
No Heat shields 4 Right-side view ass’y

Oil filter 5 6 Hanger

and hose
(attached
to machine Heat shields 4
5 Oil filter
body)
6 Hanger

Wider 7
PC200-8 flywheel housing
WA380-6
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Fuel filter 8
Oil level 10 9 Oil filler port
gauge 8 Fuel filter

9 Oil filler port

Oil level
gauge 10

PC200-8 Left-side view WA380-6

C. Engine comparison (Rated output and torque)

Rebuild Training component

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D. Diesel Engine

Diesel engine
Reciprocated
type
Gasoline Engine
Internal
combustion
Rotary Engine
Rotational type Thermo
Gas Turbine motor

External
Steam Turbine
combustion

Diesel Engine :
-One of the thermo-motor converting the thermal energy to the
kinetic energy.
-The heat is generated inside of cylinder.
-The combustion is Ignited by compressed air.
-Thermal energy is changed to kinetic energy by reciprocal
mechanism.

The Diesel engine is the converter

changing the chemical energy in fuel to the rotational energy.
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4-cycle diesel engine

Exhaust Intake
The gas after The fresh air is
combustion is charged to the
exhausted from the combustion chamber.
combustion chamber

Combustion Compression
(Power stroke)
Charged air is
The fuel is sprayed in compressed and
high temperature air. temperature is going
Explosive combustion up
occurs.

The diesel engine repeat 4 process in 2

rotation.
Output is generate in combustion stroke
(Power stroke).
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4-cycle diesel engine

Intake & Exhaust system

Intake Exhaust

Cylinder
Valve
Head System
Fuel Air Fuel System
Combustion
Combustion Chamber
Combustion Gas
( High Temp. &
Cooling
Press.) system

Cylinder
Block Piston

Connecting rod
Main Lubrication
Moving Crank shaft system
Parts
Flywheel

Output
( Torque X Speed)
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4-cycle diesel engine: Function of engine parts

Cylinder Block Main frame of the Engine

Main Moving
Convert the Combustion pressure to the Rotational force
Parts

Cylinder Head It composes the combustion chamber with the liner and the piston.

Valve system It controls valve opening/Closing and controls the gas flow.

Intake & Exhaust It supplies fresh air to the combustion chamber, and exhaust the gas after
system combustion.

Fuel system It supplies and injects the fuel to the combustion chamber

Lubrication
It lubricates all sliding surface in the engine and prevents seizing by cooling.
system

It cools the combustion chamber to prevent braking by seizing.

Cooling system It cools the lubrication oil to keep optimum temperature
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4-cycle diesel engine

Fuel Air Chemical Energy in fuel

Combustion

Combustion Gas
(High Press. &Temp. ) Thermal Energy

Mec
Piston hani
Kinetic energy
cal
Connecting rod loss

Crank shaft

Flywheel Kinetic
Mechanic Cooling
energy
al loss loss
(Rotational)

Not reacted
Output
(Torque X Speed)
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E. General structure of Engine

1 Crankshaft pulley 18 Fan

2 Crankshaft 19 Valve spring
3 Crankshaft gear 20 Head cover
4 Front seal 21 Rocker arm bracket
5 Connecting rod 22 Cylinder head
6 Front cover 23 Cylinder block
7 Cam gear 24 Push rod
8 Gear housing
25 Flywheel housing
9 Connecting rod bushing
26 Ring gear
10 Piston pin
27 Flywheel
11 Oil ring
28 Tappet
12 2nd ring
29 Thrust bearing
13 Top ring
14 Fan pulley 30 Main bearing
31 Rear seal
15 Piston
32 Oil pan
16 Intake valve
33 Cam shaft
17 Exhaust valve
34 Connecting rod cap
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E. General structure of Engine

35 Starting motor
36 Oil filter
37 Oil cooler
38 Exhaust manifold
39 Turbo charger
40 Fuel injection nozzle
41 Oil filler cap

42 Rocker cam
43 Electrical heater
(electrical intake air heater)

44 Fuel injection pump

45 Oil level gauge

46 Oil strainer

NOTE:
Engine illustration shown is for SAA4D102E-2
However, basic parts are almost the same.
Use this as reference only to familiarize the
Basic parts of engine.
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F. Main moving parts

1 Crankshaft 11 Second ring
2 Crankshaft gear 12 Oil ring
3 Main bearing
4 Connecting rod bearing 17 Thrust bearing
5 Connecting rod 18 Pin
6 Cylinder block (no liner) 19 Crankshaft pulley
7 Piston
d Piston cooling nozzle
8 Connecting rod bushing

9 Piston pin

10 Top ring

1 Piston ass’y

Con-rod 4 Flywheel
ass’y ass’y
2

Crank
shaft 3

NOTE:
Depending on the machine model,
the actual component may be different
Con-Rod cap
5 & metal from the diagram.

6 Damper
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F. Main moving parts

10 Top ring
11 Second ring
12 Oil ring
13 Connecting rod cap
14 Main cap
15 Main cap bolt
16 Connecting rod cap bolt

a Ring carrier

b Toroidal

c Re-entrant

Piston rings
Crankshaft
◆ Closed die forging, induction hardened journal

Piston
◆ Entrant combustion chamber for direct fuel
injection type
◆ Toroidal combustion chamber for direct fuel
injection type
◆ Aluminum piston
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G. Crankshaft and main bearing

Pin Journals
No. 6 upper -there are 6 pin journals
bearing In 6D107 series engine b -for lubricating camshaft
-the only Thrust
metal bearing

From oil main gallery a

-for lubricating crankshaft
Main Journals
-there are 7 main journals
In 6D107 series engine Lubrication oil flow

Crankshaft Lubrication oil flow

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H. Piston and connecting rod

Ni-resist
Insert cast
Free floating hollow
piston pin

Made of aluminum

Piston cooling nozzle

-lubricates piston pin

Bronze bushing
shaped in a tapered
form to obtain a wide
bearing surface

Metal
bearings
Con-rod
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I. Vibration damper
1 Vibration damper

2 Dowel pin

3 Mounting
4 Crankshaft pulley

5 Supply pump gear

6 Camshaft gear

7 Timing (crankshaft)

a Match marks

b Chamfered tooth

◆ The vibration damper absorbs the torsional

vibration that acts on the crankshaft and prevents
damage and abnormal wear of the crankshaft and gears.

8 Front seal

9 Front gear housing

10 Engine oil pressure switch

mounting hole
11 Bkup (camshaft) speed sensor
mounting hole
12 Ne (crankshaft) speed sensor
mounting hole
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J. Valve System

1 Exhaust valve 9 Adjustment screw

2 Intake valve
10 Locknut
3 Valve seal
11 Rocker arm
4 Valve spring
12 Push rod
5 Valve cotter
13 Tappet
6 Camshaft gear

7 Cam shaft

8 Thrust plate
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K. Camshaft, tappet, and push rod

a◆ The camshaft is driven by the crankshaft via gears.
a ◆ Cam bushings are used at the journal on both ends to support
the side load from the accessory drive.
◆ The other journals are supported by the cast iron bores in the
cylinder block, however, bushings can be installed to these bores
when the engine is sent to the repair shop for reconditioning.

b◆ The camshaft has cam lobes to operate intake and exhaust

valves. The cam lobes are in contact with the tappets which move
tappet the push rods up/down.

c◆ Mushroom head tappets are used. Since the surface of the tappet in
contact with the cam lobe is convex, the tappet rotates as it lifts the
Cam lobe
push rod.

Cam bushing Supported by cast iron bore

d◆ The spherical end at the bottom of the push rod is placed in the
ball socket of the tappet.
◆ The socket at the top of the push rod accepts the spherical end of the
rocker arm adjustment screw

c d
b tappet

convex

Cam lobe
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L. Systems of Engine

1. Air Intake and Exhaust System

Intake System
5 Intake valve
-From the intake manifold,
air is forced into the cylinders
and used for combustion.
Intake air inlet to 1
Turbocharger
-Air is drawn through the air
4 Intake manifold
cleaner into the compressor
-Air is taken to intake
side of the turbocharger
air heater (if applicable),
and into the intake manifold.

Turbocharger air to 2
charge air cooler
-Air is then forced through
the charge air cooler piping
to the charge air cooler
3 Charge air cooler
-also called After cooler.
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1. Air Intake and Exhaust System

Exhaust System 1 Exhaust valves
Exhaust manifold 2 -After combustion, exhaust gas escapes the
-exhaust gas is then Combustion chamber through the exhaust valves.
delivered to the exhaust
manifold.

Turbocharger 3
-gas is then delivered to
The turbo charger turbine 4 Turbocharger exhaust outlet
side. -the gas then exits the engine through
the Turbo charger exhaust outlet port
going to the muffler.

Turbo charger -from exhaust manifold

Exhaust
2 Impeller
-provides pressurized
Air to the engine for Exhaust Intake
Turbine 1 combustion
-rotated by
exhaust gas
energy. Turbine
drives impeller.

Intake
-to air after cooler
◆ The turbine and compressor wheels share a common shaft
(referred to as a rotor assembly), which is supported by two
rotating bearings in the bearing housing
Lubricating oil
◆ Passages in the bearing housing direct filtered, pressurized
engine oil to the shaft bearings and thrust bearings. The oil is
used to lubricate and cool the rotating components. Oil then
drains from the bearing housing to the engine sump through
the oil drain line.
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2. Lubricating oil system

11 General information

7 11 1. Gearotor lubricating oil pump

8
2. From lubricating oil pump
9 3. Pressure regulating valve closed
13
11 4. Pressure regulating valve open
14 14
5. To lubricating oil cooler
6. To oil pan
7. Lubricating oil cooler
13 8. Filter bypass valve
10 9. Filter bypass valve closed
10. Filter bypass valve open
3 4 11. To lubricating oil filter
2 5 14
12. Full-flow lubricating oil filter
12 13. From lubricating oil filter
2 14. Main lubricating oil rifle
5 1

Lubrication for the turbo charger

1. Turbocharger lubricating oil supply

2. Turbocharger lubricating oil drain
2
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2. Lubricating oil system

10
3 Lubrication for the power components
4
2 5 6 1. From lubricating oil cooler
4 2. Main lubricating oil rifle
6 3. To valve train
4. From main lubricating oil rifle
5. To piston-cooling nozzle
6. To camshaft
7 7. Crankshaft main journal
8. Oil supply to rod bearings
9. Directed piston-cooling nozzle
10. To internal lubrication of air compressor
9 8

4
2

5
2 1

3 Lubrication for the accessory drive

1
Lubrication for the overhead components 1. Oil feed from block
2. Oil supply to accessory drive
1. Main lubricating oil rifle 4. Rocker lever shaft NOTE:
2. Rocker lever support 5. Rocker lever bore Oil returns to pan through the gear housing
3. Transfer slot 6. Rocker lever
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3. Cooling system
Flow diagram

6 5
4 5 9 7

8
6

2 7 7

10
11 9
3 12 8
1

1. Coolant inlet 5. Coolant flow from cylinder block 9. Coolant flow back to radiator
2. Pump impeller to cylinder head 10. Bypass open
3. Coolant flow past lubricating 6. Coolant flow between cylinders 11. Coolant bypass in cylinder head
oil cooler 7. Coolant flow to thermostat housing 12. Coolant flow to water pump inlet
4. Coolant flow past cylinders 8. Coolant bypass passage
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4. Fuel system
1 Main filter

2 Injector

3 Inlet connector

4 Check valve

5 Supply pump

6 Common rail

7 High-pressure pipe

8 Pressure limiter valve

9 Feed pump

A From Pre-filter

B To oil cooler