Professional Documents
Culture Documents
METHOD OF OPERATION
INTRODUCTION
Service Training
MALAGA
Thorben
November 1997
CAT DIESEL ENGINES
CHAPTER : Introduction
EPG
MARINE
INDUSTRIAL
CAPTIVE
Page: 2
CAT DIESEL ENGINES
CHAPTER : Introduction
IN-LINE ENGINES
ES
VE
IN
E
G
-
EN
GAS DIESEL
Page: 3
CAT DIESEL ENGINES
CHAPTER : Introduction
Page: 4
CAT DIESEL ENGINES
CHAPTER : Engine systems
LUBRICATION
OIL
COOLING
FUEL
Page: 5
CAT DIESEL ENGINES
Page: 6
CAT DIESEL ENGINES
CHAPTER : Air intake systems
JWAC
Page: 7
CAT DIESEL ENGINES
CHAPTER : T & TA
Page: 8
CAT DIESEL ENGINES
CHAPTER : NA & ATAAC
Page: 9
CAT DIESEL ENGINES
CHAPTER : JWAC & SCAC
Page: 10
CAT DIESEL ENGINES
CHAPTER : Air intake & exhaus
Page: 11
CAT DIESEL ENGINES
CHAPTER : 4-stroke system
Page: 12
CAT DIESEL ENGINES
Lubrication system
OIL
Page: 13
CAT DIESEL ENGINES
CHAPTER : Lub. system functions
particles
deposits
Page: 14
CAT DIESEL ENGINES
CHAPTER : Lubrication
Viscosity
Internal resistance felt as one layer of liquid moves relative
to another layer - ie: internal liquid friction.
&
Page: 15
CAT DIESEL ENGINES
CHAPTER : External & internal comp.
Page: 16
CAT DIESEL ENGINES
CHAPTER : Cross drillings & camshaft lub.
Page: 17
CAT DIESEL ENGINES
CHAPTER : Oil flow 3406 engine
Page: 18
CAT DIESEL ENGINES
CHAPTER : Oil pressure relief valve
Page: 19
CAT DIESEL ENGINES
Cooling system
Page: 20
CAT DIESEL ENGINES
CHAPTER : Heat transfer
Page: 21
CAT DIESEL ENGINES
CHAPTER : Heat sources
- aftercoolers
housings
Page: 22
CAT DIESEL ENGINES
CHAPTER : Systems & components
Cooling systems:
- radiator
- keel cooler
- shunt cooling
Basic components:
- radiator
- fan
- coolant
- water pump
- pressure cap
Page: 23
CAT DIESEL ENGINES
CHAPTER : Keel/shunt/heat ex. system
Page: 24
CAT DIESEL ENGINES
CHAPTER : Coolant flow
Coolant flow:
water pump
oil cooler
cylinder block
cylinder head
(radiator)
water pump
Page: 25
CAT DIESEL ENGINES
CHAPTER : Pressure cap
Page: 26
CAT DIESEL ENGINES
CHAPTER : Altitude compensation
Page: 27
CAT DIESEL ENGINES
Fuel system
Page: 28
CAT DIESEL ENGINES
CHAPTER : CAT fuel systems
Page: 30
CAT DIESEL ENGINES
CHAPTER : System components
Page: 31
ORIFICE
CHECK VALVE TRANSFER PUMP FUEL FILTER
LIFT PUMP
VENT
WIRE
WATER
AUTOMATIC SEPARATOR
ADVANCE
GOVERNOR PRESSURE
SPRING REGULATOR
RETURN
INJECTOR
HOUSING LUBE
ROTOR
Page:
PLUNGERS
32
CAT DIESEL ENGINES
CHAPTER : Lift pump
Page: 33
CAT DIESEL ENGINES
CHAPTER : Lift pump operation
Page: 34
FUEL RETURN
CHECK VALVE CAM
GOVERNOR
SPRING
METERING VALVE
FUEL OUTLET
ROLLER
PRESSURE
REGULATOR
PISTON
Page: 36
CAT DIESEL ENGINES
CHAPTER : Metering valve
Page: 37
CAT DIESEL ENGINES
CHAPTER : Charging passages
Page: 38
CAT DIESEL ENGINES
CHAPTER : Pumping chambers
Page: 39
CAT DIESEL ENGINES
CHAPTER : Pumping chambers
Page: 40
CAT DIESEL ENGINES
CHAPTER : Fuel delivery to injectors
Page: 41
CAT DIESEL ENGINES
CHAPTER : Delivery valve
Page: 42
CAT DIESEL ENGINES
CHAPTER : Injection cycle review
Page: 43
CAT DIESEL ENGINES
CHAPTER : Timing advance
Page: 44
CAT DIESEL ENGINES
CHAPTER : Governor principle
Page: 45
CAT DIESEL ENGINES
CHAPTER : Plunger operation
Page: 46
CAT DIESEL ENGINES
CHAPTER : Standadyne governor
Page: 47
CAT DIESEL ENGINES
CHAPTER : Throttle lever operation
Page: 48
CAT DIESEL ENGINES
CHAPTER : Fuel Ratio Control (FRC)
Page: 49
CAT DIESEL ENGINES
CHAPTER : Shut off solenoid
Page: 50
CAT DIESEL ENGINES
Shut off solenoidCHAPTER :
Page: 51
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
Page: 52
CAT DIESEL ENGINES
CHAPTER : Mechanical Unit Injector
Page: 53
CAT DIESEL ENGINES
CHAPTER : MUI cylinder head
Page: 54
CAT DIESEL ENGINES
CHAPTER : Electronic engines
Page: 55
CAT DIESEL ENGINES
CHAPTER : System components (PEEC)
Shutoff Solenoid
J13
ECM
Rack BTM
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
Page: 56
BTM
FSOS
RPS
INJECTOR
PRIMING
PUMP
CHECK
VALVE
ECM
57
CAT DIESEL ENGINES
CHAPTER : PEEC fuel rack
SHUTOFF SOLEINOID
PWM
BTM
FUEL RACK
SERVO
FUEL ON
Page: 58
RACK POSITION SENSOR
RACK POSITION SENSOR
SPEED SENSOR
ACTUAL SPEED
DATA LINK
ET/ECAP
SPEED/TIMING SENSOR CONNECTOR
FILTER
RELIEF
VALVE
E C M
Electronic
Unit
Injector
PUMP
FUEL
TANK
Page: 61
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
Page: 62
HIGH PRESSURE OIL MANIFOLD
High Pressure
40 to 210 BAR
Oil Pump
ECM
Oi Fuel
lS Trans
Oil Oil u Vehicle Pump
Oil
Filter Cooler Pump
m System
p
Page:
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
CHAPTER :
PUMP
OIL
SUMP FUEL TANK
64
CAT DIESEL ENGINES
CHAPTER : HEUI injector
SPACER
SLEEVE
ARMATURE
VALVE
SHIM
BARREL
ADAPTER
PISTON WASHER
PLUNGER
FUEL INLET
CHECK VALVE
PIN
SLEEVE
SPACER
CHECK
NOZZLE
Page: 65
CAT DIESEL ENGINES
CHAPTER : Injection
Page: 66
CAT DIESEL ENGINES
CHAPTER : Poppet valve open
ARMATURE
SCREW
POPPET
SPRING
Page: 67
CAT DIESEL ENGINES
CHAPTER : Drain
Page: 68
CAT DIESEL ENGINES
CHAPTER : Poppet valve closed
POPPET VALVE
SOLENOID
ARMATURE
INLET EXHAUST
VALVE SEAT VALVE SEAT
Page: 69
CAT DIESEL ENGINES
CHAPTER : Nozzle group
NOZZLE GROUP
REVERSE FLOW
CHECK VALVE
CHECK VALVE
FUEL
ATOMIZATION
Page: 70
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)
Page: 71
PRIMING PORT COMPENSATOR
VALVE
DRAIN PASSAGE
TRANSFER PUMP
RESERVOIR
SWASHPLATE
72
CAT DIESEL ENGINES
INJECTION PRESSURE CHAPTER : Injection pressure
HEUI
MECHANICALLY ACTUATED
FUEL SYSTEM
IDLE
ENGINE SPEED
Page: 73
الشــــركة المصـــرية للصيانــــــة
Egyptian Maintenance Co.
METHOD OF OPERATION
BASIC PRINCIPLES OF THE DIESEL ENGINE
16 Basic principles of the diesel engine Method of operation
Fig. 1 7
1
11 Camshaft
12 Valves 2
13 Piston 8
14 Fuel-injection
system
3
15 Cylinder 43 6 9
16 Exhaust-gas
10 11 5
recirculation
17 Intake manifold 15
18 Turbocharger
19 Exhaust pipe
14
10 Cooling system
11 Connecting rod 12
æ SMM0608Y
13
12 Lubrication system
13 Cylinder block
14 Crankshaft
15 Flywheel
4
s
d 12 Fuel injector
5 13 Inlet valve
BDC
14 Exhaust valve
6
15 Combustion
7 chamber
æ UMM0013-3Y
8 16 Piston
9 α 17 Cylinder wall
M 18 Connecting rod
19 Crankshaft
10 Exhaust-valve
camshaft
Four-stroke cycle 3. Ignition stroke (c)
On a four-stroke diesel engine (Fig. 2), inlet After the ignition lag (a few degrees of α Crankshaft angle
crankshaft rotation) has elapsed, the igni- of rotation
and exhaust valves control the intake of air
d Bore
and expulsion of burned gases after com- tion stroke (working cycle) begins. The
M Turning force
bustion. They open and close the cylinder’s finely atomized and easily combustible
s Piston stroke
inlet and exhaust ports. Each inlet and ex- diesel fuel spontaneously ignites and burns Vc Compression
haust port may have one or two valves. due to the heat of the compressed air in the volume
combustion chamber (5). As a result, the Vh Swept volume
1. Induction stroke (a) cylinder charge heats up even more and the
pressure in the cylinder rises further as well. TDC Top dead center
Starting from Top Dead Center (TDC), the
The amount of energy released by combus- BDC Bottom dead
piston (6) moves downwards increasing the
center
capacity of the cylinder. At the same time tion is essentially determined by the mass
the inlet valve (3) is opened and air is drawn of fuel injected (quality-based control).
into the cylinder without restriction by a The pressure forces the piston downwards.
throttle valve. When the piston reaches The chemical energy released by combustion
Bottom Dead Center (BDC), the cylinder is thus converted into kinetic energy. The
capacity is at its greatest (Vh+Vc). crankshaft drive translates the piston’s
kinetic energy into a turning force (torque)
2. Compression stroke (b) available at the crankshaft.
The inlet and exhaust valves are now closed.
The piston moves upwards and compresses 4. Exhaust stroke (d)
the air trapped inside the cylinder to the de- Fractionally before the piston reaches bot-
gree determined by the engine’s compression tom dead center, the exhaust valve (4) opens.
ratio (this can vary from 6 : 1 in large-scale The hot, pressurized gases flow out of the
engines to 24 : 1 in car engines). In the pro- cylinder. As the piston moves upwards again,
cess, the air heats up to temperatures as high it forces the remaining exhaust gases out.
as 900°C. When the compression stroke is
almost complete, the fuel-injection system On completion of the exhaust stroke, the
injects fuel at high pressure (as much as crankshaft has completed two revolutions
2,000 bar in modern engines) into the hot, and the four-stroke operating cycle starts
compressed air. When the piston reaches again with the induction stroke.
top dead center, the cylinder capacity is at
its smallest (compression volume, Vc).