Cat Diesel Engines_basic
Transcript of Cat Diesel Engines_basic
-
5/20/2018 Cat Diesel Engines_basic
1/73
Service TrainingMALAGA
CAT Diesel Engines
ThorbenNovember 1997
-
5/20/2018 Cat Diesel Engines_basic
2/73
CHAPTER : Introduction
CAT DIESEL ENGINES
2Page:
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)
-
5/20/2018 Cat Diesel Engines_basic
3/73
CHAPTER : Introduction
CAT DIESEL ENGINES
3Page:
Caterpillar engines can be divided in two types:
IN-LINE ENGINES
VEE-
EN
GINES
Those two types of engines are running on two differenttypes of fuel:
GAS DIESEL
-
5/20/2018 Cat Diesel Engines_basic
4/73
CHAPTER : Introduction
CAT DIESEL ENGINES
4Page:
If you know one, you know them all !
The difference from one engine to another is the fuelsystem.
All other systems (cooling , lubrication , air) are fitted tothe different fuel systems.
The fuel system is the heart of an engine. It gives theengine its power.
-
5/20/2018 Cat Diesel Engines_basic
5/73
CHAPTER : Engine systems
CAT DIESEL ENGINES
5Page:
OIL
AIR INTAKE & EXHAUST
LUBRICATION
COOLING
FUEL
-
5/20/2018 Cat Diesel Engines_basic
6/73
CAT DIESEL ENGINES
6Page:
Air intake & exhaust
-
5/20/2018 Cat Diesel Engines_basic
7/73
CHAPTER : Air intake systems
CAT DIESEL ENGINES
7Page:
Natural Aspirated Turbocharged
Turbocharged Turbocharged Aftercooled
JWAC
-
5/20/2018 Cat Diesel Engines_basic
8/73
CHAPTER : T & TA
CAT DIESEL ENGINES
8Page:
-
5/20/2018 Cat Diesel Engines_basic
9/73
CHAPTER : NA & ATAAC
CAT DIESEL ENGINES
9Page:
-
5/20/2018 Cat Diesel Engines_basic
10/73
CHAPTER : JWAC & SCAC
CAT DIESEL ENGINES
10Page:
-
5/20/2018 Cat Diesel Engines_basic
11/73
CHAPTER : Air intake & exhaus
CAT DIESEL ENGINES
11Page:
The use of a turbocharger is to get more power out of anengine.
More air in the cylinder...
More fuel can be burned...
More horsepower output !
Aftercooling is an addition to turbocharging - this
increases the horsepower again !!
-
5/20/2018 Cat Diesel Engines_basic
12/73
CHAPTER : 4-stroke system
CAT DIESEL ENGINES
12Page:
-
5/20/2018 Cat Diesel Engines_basic
13/73
CAT DIESEL ENGINES
13Page:
OIL
Lubrication system
-
5/20/2018 Cat Diesel Engines_basic
14/73
CHAPTER : Lub. system functions
CAT DIESEL ENGINES
14Page:
An engine oil serves 5 vital functions in a modern dieselengine:
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
-
5/20/2018 Cat Diesel Engines_basic
15/73
CHAPTER : Lubrication
CAT DIESEL ENGINES
15Page:
ViscosityInternal resistance felt as one layer of liquid moves relativeto 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)
-
5/20/2018 Cat Diesel Engines_basic
16/73
CHAPTER : External & internal comp.
CAT DIESEL ENGINES
16Page:
-
5/20/2018 Cat Diesel Engines_basic
17/73
CHAPTER : Cross drillings & camshaft lub.
CAT DIESEL ENGINES
17Page:
-
5/20/2018 Cat Diesel Engines_basic
18/73
CHAPTER : Oil flow 3406 engine
CAT DIESEL ENGINES
18Page:
-
5/20/2018 Cat Diesel Engines_basic
19/73
CHAPTER : Oil pressure relief valve
CAT DIESEL ENGINES
19Page:
-
5/20/2018 Cat Diesel Engines_basic
20/73
CAT DIESEL ENGINES
20Page:
Cooling system
-
5/20/2018 Cat Diesel Engines_basic
21/73
CHAPTER : Heat transfer
CAT DIESEL ENGINES
21Page:
Fuel burning temperature can reach 1927C (3500F).
-
5/20/2018 Cat Diesel Engines_basic
22/73
CHAPTER : Heat sources
CAT DIESEL ENGINES
22Page:
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
-
5/20/2018 Cat Diesel Engines_basic
23/73
CHAPTER : Systems & components
CAT DIESEL ENGINES
23Page:
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
-
5/20/2018 Cat Diesel Engines_basic
24/73
CHAPTER : Keel/shunt/heat ex. system
CAT DIESEL ENGINES
24Page:
-
5/20/2018 Cat Diesel Engines_basic
25/73
CHAPTER : Coolant flow
CAT DIESEL ENGINES
25Page:
Coolant flow:
water pump
oil cooler
cylinder block
cylinder head
(radiator)
water pump
-
5/20/2018 Cat Diesel Engines_basic
26/73
CHAPTER : Pressure cap
CAT DIESEL ENGINES
26Page:
-
5/20/2018 Cat Diesel Engines_basic
27/73
CHAPTER : Altitude compensation
CAT DIESEL ENGINES
27Page:
-
5/20/2018 Cat Diesel Engines_basic
28/73
CAT DIESEL ENGINES
28Page:
Fuel system
-
5/20/2018 Cat Diesel Engines_basic
29/73
CHAPTER : CAT fuel systems
CAT DIESEL ENGINES
Pump & lines - Multiple plunger pump- High pressure fuel lines- Injection nozzles
- Limited injection pressure (18.000 PSI)*- Limited injection timing- Limited injection rate capabil it ies
MUI - Mainly used on large engines to eliminate the need for long high pressure lines and the related problems inherent with controllin g 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 injectionpressure in excess of 20.000 PSI and greater t iming flexibil ity.
PEEC (Programmable E lectronicEngineControl)
- ECM takes over of the functions of the mechanical governor.
- Fuel pump is still used.- Throttle l inkage replaced by electronic thrott le.- Air fuel ratio control electronically controlled.- Engine is equipped with various sensors for monitoring.
EUI / MEUI (MechanicalElectronicUnit 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 ElectronicUnit 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
-
5/20/2018 Cat Diesel Engines_basic
30/73
CHAPTER : Fuel pumps (pump & lines)
CAT DIESEL ENGINES
30Page:
-
5/20/2018 Cat Diesel Engines_basic
31/73
CHAPTER : System components
CAT DIESEL ENGINES
31Page:
-
5/20/2018 Cat Diesel Engines_basic
32/73
32
Page:
TRANSFER PUMP FUEL FILTER
LI
PRESSUREREGULATOR
ROTOR
DELIVERYVALVE
PLUNGERS
METERINGVALVE
AUTOMATICADVANCE
GOVERNOR
GOVERNORSPRING
RETURNCHECKVALVE
HOUSING LUBE
ORIFICECHECK VALVE
VENTWIRE
HEADPASSAGE
-
5/20/2018 Cat Diesel Engines_basic
33/73
CHAPTER : Lift pump
CAT DIESEL ENGINES
33Page:
-
5/20/2018 Cat Diesel Engines_basic
34/73
CHAPTER : Lift pump operation
CAT DIESEL ENGINES
34Page:
-
5/20/2018 Cat Diesel Engines_basic
35/73
35
Page:
CAM
FUEL RETURNCHECK VALVE
METERING V
FUEL O
DELVA
ROTOR
ORIFICE CHECKVALVE
SHOE
AUTOMATIC ADVANCEMECHANISM
GOVERNORWEIGHTS
PISTON
ROLLER
GOVERNORSPRING
-
5/20/2018 Cat Diesel Engines_basic
36/73
CHAPTER : Internal tranfer pump
CAT DIESEL ENGINES
36Page:
-
5/20/2018 Cat Diesel Engines_basic
37/73
CHAPTER : Metering valve
CAT DIESEL ENGINES
37Page:
-
5/20/2018 Cat Diesel Engines_basic
38/73
CHAPTER : Charging passages
CAT DIESEL ENGINES
38Page:
-
5/20/2018 Cat Diesel Engines_basic
39/73
CHAPTER : Pumping chambers
CAT DIESEL ENGINES
39Page:
-
5/20/2018 Cat Diesel Engines_basic
40/73
CHAPTER : Pumping chambers
CAT DIESEL ENGINES
40Page:
-
5/20/2018 Cat Diesel Engines_basic
41/73
CHAPTER : Fuel delivery to injectors
CAT DIESEL ENGINES
41Page:
-
5/20/2018 Cat Diesel Engines_basic
42/73
CHAPTER : Delivery valve
CAT DIESEL ENGINES
42Page:
-
5/20/2018 Cat Diesel Engines_basic
43/73
CHAPTER : Injection cycle review
CAT DIESEL ENGINES
43Page:
-
5/20/2018 Cat Diesel Engines_basic
44/73
CHAPTER : Timing advance
CAT DIESEL ENGINES
44Page:
-
5/20/2018 Cat Diesel Engines_basic
45/73
CHAPTER : Governor principle
CAT DIESEL ENGINES
45Page:
-
5/20/2018 Cat Diesel Engines_basic
46/73
CHAPTER : Plunger operation
CAT DIESEL ENGINES
46Page:
-
5/20/2018 Cat Diesel Engines_basic
47/73
CHAPTER : Standadyne governor
CAT DIESEL ENGINES
47Page:
-
5/20/2018 Cat Diesel Engines_basic
48/73
CHAPTER : Throttle lever operation
CAT DIESEL ENGINES
48Page:
-
5/20/2018 Cat Diesel Engines_basic
49/73
CHAPTER : Fuel Ratio Control (FRC)
CAT DIESEL ENGINES
49Page:
-
5/20/2018 Cat Diesel Engines_basic
50/73
CHAPTER : Shut off solenoid
CAT DIESEL ENGINES
50Page:
-
5/20/2018 Cat Diesel Engines_basic
51/73
Shut off solenoidCHAPTER :
CAT DIESEL ENGINES
51Page:
-
5/20/2018 Cat Diesel Engines_basic
52/73
CHAPTER : MUI fuel system
CAT DIESEL ENGINES
52Page:
Filterchangevalve
Relief valve
Handprimingpump
Checkvalve
Unitinjector
Pressurereliefvalve
Secondary
fuel filterelements
Secondaryfuel filterelements
Mainfuel
pump
Mainfuel tank
PrimaryFuel filters
Check
valve
Checkvalve
Checkvalve
Checkvalve
-
5/20/2018 Cat Diesel Engines_basic
53/73
CHAPTER : Mechanical Unit Injector
CAT DIESEL ENGINES
53Page:
-
5/20/2018 Cat Diesel Engines_basic
54/73
CHAPTER : MUI cylinder head
CAT DIESEL ENGINES
54Page:
-
5/20/2018 Cat Diesel Engines_basic
55/73
CHAPTER : Electronic engines
CAT DIESEL ENGINES
55Page:
InputCircuit
Power
Circuit
OutputCircuit
- From Battery
( 8vdc Minimum )- To Rack And Lamps- To Sensors
- Signals From Sensor
- Filter Electrical Noise
- Protect Voltage Levels
-
5/20/2018 Cat Diesel Engines_basic
56/73
CHAPTER : System components (PEEC)
CAT DIESEL ENGINES
56Page:
Eng Speed Sensor
Shutoff Solenoid
Rack Position Sensor
Rack BTM
Atmospheric Pressure
Sensor
Boost Pressure
Sensor
Oil Pressure
Sensor
Coolant Temp
Sensor
CoolantLevel
SensorCustomer
Connector
Eng Data Link
Connector
E C M
P7 J7
P15 J15
P8 J8
P9 J9
P12 J12
P17
P14 J14
J13
-
5/20/2018 Cat Diesel Engines_basic
57/73
57
Page:
BTM
FSOS
RPS
PRIMING
PUMP
ECM
TRANSFER PUMP
INJEC
T
PRIMARY
FILTER
CHECK
VALVE
SECONDARY
FILTER
-
5/20/2018 Cat Diesel Engines_basic
58/73
CHAPTER : PEEC fuel rack
CAT DIESEL ENGINES
58Page:
SHUTOFF SOLEINOID
B T M
FUEL RACK
SERVO
FUEL ON
PWM
RACK POSITION SENSOR
-
5/20/2018 Cat Diesel Engines_basic
59/73
59
Page:
ELECTRONICGOVERNOR
RACK POSITION SENSOR
RACKCONTROL
TORQUEMAPS
FRCMAPS
RACKBTM
SPEED SENSOR
BOOST PRESS. SENSOR
DESIRED SPEED
ACTUAL SPEED
RATEDRACKLIMIT
FRCRACKLIMIT
ACTUAL RACK POSITION
RACK POSITION SENSOR
-
5/20/2018 Cat Diesel Engines_basic
60/73
60
Page:
ELECTRONIC UNITINJECTOR
TIMING CALIBRATION SENSOR
ELECTRONICCONTROL MODULE
(ECM)
ENGINEHARNESS
SPEED/TIMING SENSOR
COOLANT TEMPERATURE SENSOR
TURBO OUTLET PRESSURE SENSOR
ATMOSPHERIC PRESSURE SENSOR
FUEL TEMPERATURE SENSOR
MACHINEHARNESS
GROUNDSTUD
MAINPOWER RELA
15 AMPBREAKER
DATA LINK
CONNECTORDATA LINK
THROTTLE POSITION SEN
CHECK ENGINE LAM
LAMP FLASH SWITCH
TRANSMISSION PRESSURE SWITCH
ADEM II
CONTROL
3176B EUI COMPON
CHALLENGE
J1 P1CONNECTOR
J2 P2
-
5/20/2018 Cat Diesel Engines_basic
61/73
CHAPTER : Fuel system (EUI)
CAT DIESEL ENGINES
61Page:
MECHANICALY ACTUATEDELECTRONICAL CONTROLED
ElectronicUnit
Injector
FILTER
E C M
PUMP
FUELTANK
RELIEFVALVE
-
5/20/2018 Cat Diesel Engines_basic
62/73
CHAPTER : Fuel injection
CAT DIESEL ENGINES
62Page:
1
2
3
45
6
7
8
9
10
11
12
1
2
3
45
6
7
8
9
10
11
12
1. Solenoid Connection2. Solenoid Valve Assem3. Spring4. Valve5. Plunger6. Barrel7. Seal8. Seal9. Spring10. Spacer11. Body12. Check
-
5/20/2018 Cat Diesel Engines_basic
63/73
63
Page:
High PressureOil Pump
HIGH PRESSURE OIL MA
Fuel Return Line
ECM
OilPump
OilSump
OilCooler
OilFilter
VehicleSystem
Engine System
RegulatorPressureControlValve
40 to 210 BAR
LOW PRESSURE 3 BAR
-
5/20/2018 Cat Diesel Engines_basic
64/73
CHAPTER : HEUI fuel system
CAT DIESEL ENGINES
64Page:
TO
LUBE
SY
STEM
FUEL
TRANSFER
PUMP
P
UMP
CO
NTROL
V
ALVE
OIL
FILTER O
IL
COOLER
HEUI
HEUI
O
IL
SU
MP
HYDRAULIC
PRESSURE
SENSOR
HYDRAULIC
TEMPERATURE
SENSOR
OILPRESSURE
SENSOR
HYDRAULIC
SUPPLY
PUMP
GROUP
COOLDOWN
CIRCUIT
FUEL
TEMPERATURE
SENSOR
ECM
FUELTANK
PRESSURE
REGULATING
VALVE
SECONDARY
FUEL
FILTER
PRIMARY
FUELFILTER
WATER
SEPARATOR
LUBEOIL
PUMP
COLDSTART
OIL
RESERVOIR
FLUIDMANIFOLD
HYDR
AULICPASSAGE
FL
UIDMANIFOLD
HYDR
AULICPASSAGE
-
5/20/2018 Cat Diesel Engines_basic
65/73
CHAPTER : HEUI injector
CAT DIESEL ENGINES
65Page:
BARREL
PISTON
VALVE
FUEL INLETCHECK VALVE
PIN
SPACER
SLEEVE
VALVE BODY
CHECK
SHIM
ADAPTER
SPACER
ARMATURE
SOLENOID
WASHER
PLUNGER
SLEEVE
LOWER FUEL SEAL
UPPER FUEL SEAL
NOZZLE
-
5/20/2018 Cat Diesel Engines_basic
66/73
CHAPTER : Injection
CAT DIESEL ENGINES
66Page:
-
5/20/2018 Cat Diesel Engines_basic
67/73
CHAPTER : Poppet valve open
CAT DIESEL ENGINES
67Page:
ARMATURESCREWPOPPETSPRING
-
5/20/2018 Cat Diesel Engines_basic
68/73
CHAPTER : Drain
CAT DIESEL ENGINES
68Page:
-
5/20/2018 Cat Diesel Engines_basic
69/73
CHAPTER : Poppet valve closed
CAT DIESEL ENGINES
69Page:
INLET
VALVE SEAT
SOLENOID
POPPET VALVE
ARMATURE
EXHAUST
VALVE SEAT
-
5/20/2018 Cat Diesel Engines_basic
70/73
CHAPTER : Nozzle group
CAT DIESEL ENGINES
70Page:
FUELATOMIZATION
NOZZLE GROUP
CHECK VALVE
REVERSE FLOWCHECK VALVE
-
5/20/2018 Cat Diesel Engines_basic
71/73
CHAPTER : Injection cycle
CAT DIESEL ENGINES
71Page:
CROSS SECTIONOF PLUNGER
START OF INJECTION PRESSURE DROP
INJECTIONRATE
START OF
INJECTION DURATION
FINALPRESSURE INCREASE
TIME (MILLISECONDS)
END OF
INJECTION
-
5/20/2018 Cat Diesel Engines_basic
72/73
72
Page:
PRIMING PORT
ORIFICE
RESERVOIR
SWASHPLATE
COMPENSATORVALVE
DRAIN PASSAGE
-
5/20/2018 Cat Diesel Engines_basic
73/73
CHAPTER : Injection pressure
CAT DIESEL ENGINES
73Page:
IDLE
INJECTIONPRESSURE
MECHANICALLY ACTUATEDFUEL SYSTEM
H E U I
ENGINE SPEED