Ver.

1- 2010-03

Construction Machinery Ⅰ

Structure and Maintenance of

Internal Combustion Engine

Chapter 4
Structure of diesel engine

The Construction Equipment Training Center(CETC)

Japan International Cooperation Agency
1 1
© Employment and Human Resources Development Organization of Japan
 1-1 combustion of diesel engine

injection nozzle

intake valve
exhaust valve

intake compression explosion exhaust

Fig 4-1 4cycle engine

1-1 2
 1-1 combustion of diesel engine

absolute pressure

combustion

injection
TDC

Fig 4-2 combustion process of diesel engine

1-1 3
 1-1 combustion of diesel engine
(2) diesel knocking
① select fuel with good performance of
ignition
② raise pressure and temperature in a cylinder
by high compression ratio.
③ raise temperature of a chamber wall by high
temperature cooling water.
④ reduce fuel injection at the beginning.
⑤ increase whirls of air in a chamber.
(3) cetane number
performance of fuel ignition
1-1 4
 Section 2 structure and performance of engine

Systems of diesel engine

① engine body and main parts
② fuel system
③ lubrication system
④ cooling system
⑤ intake and exhaust system
⑥ electric system

1-1 5
Section 2 structure and performance of engine

Fig 4-3 structure

1-1 6
 2-1 engine body and main parts
cylinder block cylinder liner
O ring stud

main bearing cap

cap screw

Fig 4-4 cylinder block

Fig 4-5 cylinder head

1-1 7
 2-1 engine body and main parts

cylinder block cooling water Cylinder head

Head gas
cylinder liner
wet type dry type Cylinder blo
Cam Cylinder liner
Fig 4-6 cylinder liner shaft
water jacket
journal

Main gallery Rubber

Fig 4-7 inserted

1-1
cylinder liner 8
 2-1 engine body and main parts
piston
liner

piston pin
ring carrier

top ring
2 ring
3 ring
Connecting oil ring skirt
rod
piston
pin

Fig 4-8 cylinder liner,

piston, connection rod

Fig 4-9 piston

1-1 9
2-1 engine body and main parts

connecting rod
small-end

large-end

Crank pin metal

cap

Fig 4-10 connecting

1-1
rod 10
 2-1 engine body and main parts

Fig 4-11 crank shaft

Balance weight

Fig 4-12 ignition order of 4 cylinder engine main bearing part

crank arm
crank pin

Fig 4-14 balance weight

1-1 11
Fig 4-ignition order of 6 cylinder engine
 2-1 engine body and main parts
TDC

In. V. open Ex. V. close

In.
Cmp Exh. Exp.

In. V. close BDC Ex. V. open

Fig 4-15 valve timing

1-1
12
 2-1 engine body and main parts
Release shaft

Rocker arm

Push rod Exhaust

Valve clearance valve
adjust screw Rocker arm Tappet guide Intake
Valve valve
Cam shaft gear
Push rod clearance

valve
Tappet

Tappet Cam shaft

Cam Crank shaft gear

Fig 4-16 valve mechanism

13
1-1
 2-2 fuel system
nozzle

Air fled plug

spill pipe

Fuel filter

injection pipe
Air fled plug
Injection pump
Fuel supply pump Fuel
pump

Fuel tank

Fig 4-17 fuel system

1-1 14
 2-2 fuel system

Fig 4-18 priming pump

1-1 15
 2-2 fuel system
To fuel injection pump
Air fled plug

From feed pump

Air fled plug
Filter bracket
To fuel injection pump

cartridge
body
From feed pump
Filter element

drain plug
element type cartridge type

Fig 4-19 1-1fuel filter 16

 2-2 fuel system
Joint bolt
From injection pump

Nozzle holder cap Inlet connector

Adjust screw Fuel return To fuel tank
Rock nut
Nozzle spring Nozzle holder
Nozzle holder body
Inlet connector Nozzle cap Adjust shim

Bar filter Nozzle spring

Push rod
Nozzle cap

Nozzle Nozzle body

From injection pump
Nozzle body Nozzle

Combustion chamber

Fig 4-20 nozzle and nozzle holder

1-1 17
 2-2 fuel system

Single hole nozzle Multi hole nozzle

Fig 4-21 kind of nozzle (hole type)

pintle type Throttle nozle

Fig 4-22 kind of nozzle (pintle type)

1-1 18
 table 4-1 comparison of combustion method
item direct injection pre-chamber whirl chamber

nozzle hole nozzle pintle nozzle throttle nozzle

min fuel mostly around 160 g/PSh around 180 g/PSh, but the around 190 g/Pah, mostly used for
consumption ratio smaller engine, the worse small size engine

max explosion 8MPa(naturally aspirated) - 6MPa-8MPa the lowest of the the higher the speed, the higher
pressure 3MPa(super charged) relatively three the pressure
high
friction loss the lowest of the three. small big big
engine brake
cooling loss the lowest of the three. good for big big. good for hot water warming big
size vehicle due to small radiator of bus etc.

combustion noise big small mid. The bigger the noise, the
bigger output engine
starting in low temp the best in no aux starting device. little problem if glow plug is same as left
Intake air is preheated by intake equipped in susiidiary chamber
heater in cool area.
exhaust gas feature relatively more NOx. HC is also Nox is less than direct injection same as left
problem in small size engine. engine
heat load around small. the most suitable for highly big. Counter measures for big. But not so big, because it is
combustion chamber supercharged engine cylinder head, pre-chamber mainly used for small size engines.
1-1 ring etc.
mouth 19
 2-2 fuel system
To injection pump from fuel filter
Delivery valve holder

Delivery valve
Plunger sleeve
plunger
Pump housing
Plunger spring

Control rack

tappet from fuel tank

Cam shaft To fuel filter
in-line(Bosh) type

Fig 4-23 fuel injection pump (in-line(Bosh) type)

1-1 20
 2-2 fuel system

Adjusting lever

Feed pump
Fuel cut solenoid

Pump plunger

Face cam
To injection
nozzle
timer
Distributer type

Fig 4-23 fuel injection pump (distributer type)

1-1 21
 2-2 fuel system
delivery

Delivery spring
Delivery valve
Plunger sleeve
Fuel room
Plunger
Suction hole Pinion
Rack
Spring seat
Sleeve
groove Spring
Adjust screw
Tappet
Cam shaft

Fig 4-24 plunger and sleeve

1-1 22
 2-2 fuel system

Suction hole Leaning groove

sleeve

plunger

Injection start Injection end Injection start Injection start

Maximum load Light load No Injection

Fig 4-25 act of plunger

1-1 23
 2-2 fuel system
Injection pipe

stopper
valve

Retraction valve Valve shaft

open Close

Fig 4-26 delivery valve

1-1 24
 2-2 fuel system
Start spring
Control lever
Governor Floating lever
housing Governor cover
Tension lever
Guide lever
Swivel lever Stopper bolt
link
Control governor spring) Maximum speed stopper
rack
Idling sub
spring Adjusting stop full
Fly weight lever
holder
stopper

Gear shaft Idling spring

Full load stopper Hand lever
shifter
Cam shaft Guide bush
Stop full
Round nut Fly weight
gear
RSV governor(mechanical type)
Fig 4-27 governor1-1(mechanical type) 25
 2-2 fuel system
Pipe for negative pressure
Diaphragm
Cam lever
cam

rack

Stop arm

Stop lever
Auxiliary spring

Contact pin Main spring

Pneumatic type

Fig 4-27 governor1-1(pneumatic type) 26

 2-2 fuel system
Torque spring
output work range

Declared power

Governor
Work range

Rotation speed (min-1)

Fig 4-28 output diagram
1-1 27
 2-2 fuel system
O-ring Round nut Timer case
leg Oil seal
Bering pin Fly weight

Tooth flank
Timer spring Guide cap Flange
Fly weight
Adjusting washer These two pieces are welded
holder

Fig 4-29 automatic timer

s peed E
Leg of flange mum
Maxi
stop
curve

eg
5d
Cam shaft
gle
An

Bering pin Fly weight

stop Maximum speed
1-1 28
Fig 4-30 timer fly weight
 2.3 lubrication system

crank shaft crank pin

piston pin oil pan
main jounal journal
cam shaft
oil pan
bearing

valve gude
rocker arm
main gallary

shaft bearing tappet oil pan

timing gear
gear surface oil pan
bering

turbo charger oil pan

fuel injection
oil pan
pump

1-1 29
 2.3 lubrication system
Fuel injection
pump Rocker arm

in. ex.
valve
Turbo charger
Cam shaft piston

Piston cooling
Crank shaft nozzle

Oil filter element

Timing gear Oil cooler
Cooling water Safety valve
Regulator valve

Oil pump

Oil pan
Oil strainer

Fig 4-31 lubrication

1-1 system 30
 2.3 lubrication system

Port for oil pressure From oil pump

From oil pump
To engine
Filter element Filter bracket
To engine

cartridge

Oil
passage
Safety valve

By pass

Element type Cartridge type

Fig 4-oil filter

1-1 31
2.3 lubrication system
To engine

valve

To oil pan

Oil pump

Fig 4-33 regulator valve

1-1 32
 2.3 lubrication system
Oil filter

To
engine

Valve valve
conductor
spring
Oil
From pump

Caution lamp

Fig 4-34 safety valve

1-1 33
 2.3 lubrication system

From water pump

To engine

From oil pump

To oil filter
From oil filter

Fig 4-35 oil cooler

1-1 34
 2.3 lubrication system
To radiator Thermo stat
Water outlet pipe
From head To oil main
gallery
From oil filter
From radiator Oil cooler

Air breather
pipe

Water pump To crank case

Multi pipe cooler

Fig 4-36 type of oil cooler (multi pipe)

1-1 35
 2.3 lubrication system
Cooler cover Cooler element

To oil filter(oil)
From oil filter
(oil)

Cross section A-A From oil pump

Water drain port (oil)
To engine

Plate type oil cooler

Fig 4-36 type of oil cooler(plate type)
1-1 36
 2.4 cooling system
radiator fan Water pump Water manifold
thermostat Thermo
meter

Cylinder head

Cylinder liner

From main pump(oil)

Engine oil cooler
Fig 4-37 cooling
1-1
system 37
 2.4 cooling system
Feed water cap
Upper tank

tube

fin

Radiator core

Bottom tank
Fig 4-38 radiator
1-1 38
 2.4 cooling system

To radiator

sensor
wax
From
engine

To water pump

Fig 4-39 act of thermostat

1-1 39
 2.4 cooling system
housing

Pump shaft From

thermostat
Ball bearing
Water seal
From radiator
impeller
Fan pulley

fan

engine

Fig 4-40 water

1-1
pump 40
 2.5 intake and exhaust system

Dust indicator Exhaust pipe

Air cleaner muffler
Turbo charger

Vacuuater valve

Intake valve Exhaust valve

piston

Cylinder liner

Fig 4-41 intake and

1-1
exhaust system 41
 2.5 intake and exhaust system
Air cleaner body Outer element
Inner element

Dust case

Vacuuater valve

Fig 4-42 air cleaner

Fig 4-43 vacuuater valve

1-1 42
 2.5 intake and exhaust system

Fig 4-44 dust indicator

Fig 4-45 muffler

1-1 43
 2.5 intake and exhaust system
Air outlet
Thrust collar Turbine nozzle
Blower inpeller
Turbine housing
Blower housing
Turbine impeller

Oil inlet

Exhaust
Air inlet gas outlet

Oil
outlet

Thrust bearing Journal bearing

Impeller shaft sealing

Exhaust gas inlet
Fig 4-46 turbo
1-1
charger 44
 2.6 electric system
alternator

starter

Safety relay

Starter switch

①Starter switch ON Battery relay

②starter rotates.

③Alternator turns
Starter pinion breaks body
off battery

Fig 4-47 starting circuit

1-1 45
 2.6 electric system

alternator

Regulator

Starter switch

body
battery

Fig 4-48 charging system

1-1 46
 2.6 electric system
Electric heater
(ribbon heater)

To cylinder(intake)

From air cleaner

(intake)

To cylinder(intake)

battery

Fig 4-49 electric heater circuit

1-1 47
 2.6 electric system
heater

fuel

Fig 4-50 electric heater

1-1 48
 2.6 electric system
Heater signal

heater

Fig 4-51 glow plug

Fig 4-51 glow plug
insulator Heat coil

Holding pin Protection metal tube

Plug housing
1-1 49
Fig 4-52 structure of glow plug
mark

1-1 50