Submitted by:

                Savant Panwar

Submitted to:
Gainwell Commosales Private limited
Acknowledgement
•First of all I would like to express my gratitude towards the almighty that made this golden opportunity possible and
made me successfully completed it. I would like to thank my parents as without their support I would have not been
able to keep the momentum up.

•I am courteous to Mr. Reindeer Kr. Pandita Sir, Head Facilities and Mr. Vikas Copra Sir, Workshop Facility Manager
who's blissful support and enlightening guidance help me shaped overall, I am able to broom at my fullest and reach
the pinnacle under his umbrella. Also, I am deeply indebted to Mr. Alok Dhoundiyal, Engineer-Engine Assembly. And
Mr. Mohd. Munis sir for their intellectual, insightful, and experienced guidance that led me complete my Internship
Training Program on "Engine Disassembly & Assembly" held in the esteemed organization "Gainwell Commosales
Private Limited".
•Through this Internship Training Program, I gained precious exposure to the crucial industrial training as well as gain
and polish important skills and I am confident about that it will lead to me a brighter future and will help me
outshine the carrier.
•Lastly, I would like to thanks all the staff members that at somewhere during this training helped me out and let me
achieve my goal.
Unnati Workshop
• Major machines, engines, transmission, torque converter, and other
components of heavy Caterpillar machines or rebuild here. 
• engine models ranging
•  C 2.2, C 4.4, C 6.4, C 7.1, C7, C9, C11, C13, C15, C16, C18, C27,
C32, 3116, 3126, 3306, 3512, 3406 and others are rebuild and tested
here.
• It is equipped with diesel and gas engine test bench.
Agenda

•Engine Families
•Engine works & wears
•      Engine Wear
•      Combustion process
•      External Components
•      Cooling System
•       Lube system
•       Fuel system 
•       Air System
•       Electronics
•      
•Parts Differentiation
Click to add text
Common Engine Terms

• Bore
• Stroke 
• Compression Ratio
• Displacement
• Horsepower
Bore Size

• Bore is the inner diameter of the

cylinder.

• Bore is measured in inches or

millimeters using Dial Bore Guage.
Stroke

• Stroke is the distance between

the TDC ( Top Dead Centre) and
BDC (Bottom Dead Centre) .

• Stroke is equal to twice the crank

radius.
Compression Ratio

• Compression Ratio is the ratio between the cylinder

volume with the piston at BDC and the volume with
the piston at TDC.

• Compression ratio of CAT engine are approximately

16:1 (non-ACERT) and 18:1 (ACERT).
Displacement

Engines size is expressed in liters or cubic

inches.
Horsepower

• Horsepower is the rate of doing work (how

quickly a force is applied through a distance.)

• Horsepower can be expressed in pound per

second.

• 1 horsepower = 550 lb./ft per second = 33.00

lb./ft per minute
Engine Model Numbers

• Engine model no. Is the code to tell

you the engine family, no. Of
cylinder, capacity, type of ignition
and so on.
• For example, 
•   3208 Engine:
•       3200 = Engine family & relative
size
•         (3000, 3200, 3400, 3500, 3600)
•         08 = no of Cylinders.
•Depending on Engine family, could be
04, 06, 08, 12, 16, 18   or 24
Engine Wear
• Definition of wear
•  1.  Contact
•  2.  Pressure
•  3.  Relative Motion
•   Normal & Abnormal wear
•   Major wear items
•   Cylinder liners
•   Seals & gaskets
•   Piston rings
•   Turbo bearings and seals 
•   Valves, guides, and seats
•   Main and rod bearings
Combustion Process- 4 Stroke Cycle
Combustion Process- 4 Stroke Cycle
Valve Train
1. Cam lobe
2. Lifter
3. Pushrods
4. Rocker arms
5. Bridge (intake)
6. Valve Spring
7. Exhaust valve
8. Intake valves
Pistons, Rings, &
Liners

•Cylinder liners 
•O-ring seals 
•Pistons 
•Piston rings 
•Piston pins and retainer 
Piston assembly &
Connecting rod

• A connecting rod connects the piston to the

crank shaft.

• The Dome Piston looks just like it sounds.

Instead of a flat top it has a dome that looks
like the top of a dome stadium. Piston
Dome refers to the amount of added
volume on top of the piston compared to a
flat top piston. 
Cylinder Head & Cam
shaft

• The cylinder head is installed on

the top of block

• The cam shaft turns at ½ the

speed of the crankshaft to control
intake & exhaust operation.
Cylinder Block

• This cylinder block is the central component

of an engine

• It houses the components that make up the

serious nucleus of the engine
Turbocharger
• An exhaust driven air compressor.
• Impeller on the left
• Turbine on right
• Connecting shaft, free floating bearings,
oil lubricated center housing

Causes of Premature wear or failure​

•  Poor oil quality​
•  Dirt injection ​
•  Hot engine shut down​
Aftercooler

• Heat exchange of inlet air

• Series of metal tubes
through which hot inlet air
flows
• Heat from the air flowing
from the tubes is absorbed
through the tubes valves and
carried away
• 2types
              Air to air (ATAAC)
             Jacket water (JWAC) 
Water Pump

• Flow of the coolant begins

at the water pump 
• Pump impeller creates the
flow 
• Water pump are gear or
belt driven
• Water pump seals
separates engine oil from
coolant
 Oil Pump
•Engine coolant flows from the water pump
directly into the oil cooler

•Oil carries heat away from the critical

engine parts

•Heat is transferred from the oil to the

engine coolant 
Oil Pump

• Oil coolant  flows through the copper

tubes in the oil cooler housing 

• Oil flows around outside of the tubes

• Scale build up caused by improper cooling

system maintenance can be cleaned out
of the tubes
Function of cooling system

Function of cooling system

• Maintain proper engine
temperature for optimum
performance.
• Dissipates excess
heat from other machine
system:
•              Engine
•              Transmission
•               Hydraulic
• Cools compressed inlet air to
optimize combustion.
Cooling System components
• Water pump
• Oil Cooler
• Passages through block and head
• Temp. Regulator Housing
• Radiator
• Pressure Cap
• Hoses & pipes
Cooling Systems

• Coolant flows around

cylinder liners

• Absorbs heat from

combustion chamber

• Prevents breakdown of  oil

film between piston and
liners
Function of Lubrication System

• Cleans
o      Parts 
o      Cylinder walls
• Cools
• Seals & Lubricates
o         Support
o         Separate
Lubrication System Components

1. Oil Pump
2. Relief Valve
3. Oil Cooler
4. Oil Filter
5. Bypass Valves
6. Oil Level Gauge (Dipstick)
7. Oil Pressure Gauge
8. Oil Pan
Causes of Lube System Wear & Failure
• Single largest problem is short engine life due to excessive
soot in the oil.
• Poor quality/low performance engine oil
• Extended oil change intervals
• Poor maintenance practices
• Fuel dilution 
• Wear (lube System Caused)
               Seals/Bearings
                       Turbo
                       Crank – Main/Rod
                       Valve, Guide
Methods to control soot levels in engine oil:

Methods to control soot levels in

engine oil:
• High quality engine oils contain
effective soot dispersant
additives
• High performance, full
flow, lube filter options
•     Standard,  Advanced, &                 
 Ultra-High 
• Bypass filtration devices:
centrifugal or  barrier filters
• Oil renewal systems (for large
mining machines)
Function of Fuel System

• Meters the amount of fuel to

achieve desired power

• Regulates engine speed and

timing sequence 

• Helps control emissions

Fuel Delivery – History
• Pre-Combustion (PC)
• Direct Injection (DI)
MUI System
• A unit injector is positioned above each cylinder
• A mechanically actuated governor controls fuel rate (scroll metered )
• With flyweights and springs
• Timing  is fixed
EUI Injector
• A unit injector is positioned above each
cylinder

• An Electronic Control Module (ECM)

controls fuel rate and timing

• Injectors are mechanically actuated by

a camshaft
EUI Injector 

• Without pressure from the

rocker arm, a spring keeps the
plunger retracted

• Fuel flows into the injector

through the fill / spill port, past
the solenoid valve and into the
barrel
EUI  - Injection 

• On a single from the ECM,

the solenoid closes the
fuel valve 

• Pressure elevates at the

tip to the 5,500 psi
needed to unseat the
valve 

• Injection begins
EUI – Injection 

• Fuel continues to inject until the

ECM signals the solenoid to open
the valve

• Injection timing and duration is

controlled by the ECM
HEUI System

• A unit injector is positioned above

each cylinder

• An Electric control module (ECM)

controls fuel rate , timing, and
injection position 

• The injector is hydraulically actuated

Air System Operation
•Flow
• Precleaner
• Air Filters
• Turbochargers
• Intake Manifold and cylinder
head
• Combustion chamber
• Exhaust Manifold
•Wear
•       Turbocharger
•             Bearings
•              seals
Electronics Control Module 
Caterpillar's Electronic Control Module (ECM)
And sensors control and monitor key engine
function, including:
• Fuel temperature.
• Engine oil temperature.
• Oil pressure.
• Atmospheric pressure.
• Coolant temperature 
• Injection actuation pressure
• Throttle position 
• Injection timing & duration logged faults
Features & Benefits of Electronics

Features
o Electronics Engine Control o Engine Monitoring
         Engine Speed Governing
         Torque Shaping       Fluid Level
         Fuel-air Ratio Control       Fluid Pressure
         Cold Mode Strategies       Fluid Temperature
         Altitude Derating
         Fuel Temperature
Compensation
o Information Management
         Accurate Tracking
         Storage result
Benefits
• Improved Emissions
• Increased Performance &
Reliability
• Improved Diagnostics
• Meet customer needs for
New Features / Advanced
Technology