Cat Diesel Engines_basic

5/20/2018 Cat Diesel Engines_basic

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Service TrainingMALAGA

CAT Diesel Engines

ThorbenNovember 1997


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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)


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CAT DIESEL ENGINES

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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


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CAT DIESEL ENGINES

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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.


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CHAPTER : Engine systems

CAT DIESEL ENGINES

5Page:

OIL

AIR INTAKE & EXHAUST

LUBRICATION

COOLING

FUEL


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CAT DIESEL ENGINES

6Page:

Air intake & exhaust


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CHAPTER : Air intake systems

CAT DIESEL ENGINES

7Page:

Natural Aspirated Turbocharged

Turbocharged Turbocharged Aftercooled

JWAC


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CHAPTER : T & TA

CAT DIESEL ENGINES

8Page:


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CHAPTER : NA & ATAAC

CAT DIESEL ENGINES

9Page:


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CHAPTER : JWAC & SCAC

CAT DIESEL ENGINES

10Page:


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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 !!


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CHAPTER : 4-stroke system

CAT DIESEL ENGINES

12Page:


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CAT DIESEL ENGINES

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OIL

Lubrication system


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CHAPTER : Lub. system functions

CAT DIESEL ENGINES

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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


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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)


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CHAPTER : External & internal comp.

CAT DIESEL ENGINES

16Page:


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CHAPTER : Cross drillings & camshaft lub.

CAT DIESEL ENGINES

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CHAPTER : Oil flow 3406 engine

CAT DIESEL ENGINES

18Page:


19/73

CHAPTER : Oil pressure relief valve

CAT DIESEL ENGINES

19Page:


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CAT DIESEL ENGINES

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Cooling system


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CHAPTER : Heat transfer

CAT DIESEL ENGINES

21Page:

Fuel burning temperature can reach 1927C (3500F).


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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


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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


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CHAPTER : Keel/shunt/heat ex. system

CAT DIESEL ENGINES

24Page:


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CHAPTER : Coolant flow

CAT DIESEL ENGINES

25Page:

Coolant flow:

water pump

oil cooler

cylinder block

cylinder head

(radiator)

water pump


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CHAPTER : Pressure cap

CAT DIESEL ENGINES

26Page:


27/73

CHAPTER : Altitude compensation

CAT DIESEL ENGINES

27Page:


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CAT DIESEL ENGINES

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Fuel system


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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


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CHAPTER : Fuel pumps (pump & lines)

CAT DIESEL ENGINES

30Page:


31/73

CHAPTER : System components

CAT DIESEL ENGINES

31Page:


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32

Page:

TRANSFER PUMP FUEL FILTER

LI

PRESSUREREGULATOR

ROTOR

DELIVERYVALVE

PLUNGERS

METERINGVALVE

AUTOMATICADVANCE

GOVERNOR

GOVERNORSPRING

RETURNCHECKVALVE

HOUSING LUBE

ORIFICECHECK VALVE

VENTWIRE

HEADPASSAGE


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CHAPTER : Lift pump

CAT DIESEL ENGINES

33Page:


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CHAPTER : Lift pump operation

CAT DIESEL ENGINES

34Page:


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35

Page:

CAM

FUEL RETURNCHECK VALVE

METERING V

FUEL O

DELVA

ROTOR

ORIFICE CHECKVALVE

SHOE

AUTOMATIC ADVANCEMECHANISM

GOVERNORWEIGHTS

PISTON

ROLLER

GOVERNORSPRING


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CHAPTER : Internal tranfer pump

CAT DIESEL ENGINES

36Page:


37/73

CHAPTER : Metering valve

CAT DIESEL ENGINES

37Page:


38/73

CHAPTER : Charging passages

CAT DIESEL ENGINES

38Page:


39/73

CHAPTER : Pumping chambers

CAT DIESEL ENGINES

39Page:


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CHAPTER : Pumping chambers

CAT DIESEL ENGINES

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CHAPTER : Fuel delivery to injectors

CAT DIESEL ENGINES

41Page:


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CHAPTER : Delivery valve

CAT DIESEL ENGINES

42Page:


43/73

CHAPTER : Injection cycle review

CAT DIESEL ENGINES

43Page:


44/73

CHAPTER : Timing advance

CAT DIESEL ENGINES

44Page:


45/73

CHAPTER : Governor principle

CAT DIESEL ENGINES

45Page:


46/73

CHAPTER : Plunger operation

CAT DIESEL ENGINES

46Page:


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CHAPTER : Standadyne governor

CAT DIESEL ENGINES

47Page:


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CHAPTER : Throttle lever operation

CAT DIESEL ENGINES

48Page:


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CHAPTER : Fuel Ratio Control (FRC)

CAT DIESEL ENGINES

49Page:


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CHAPTER : Shut off solenoid

CAT DIESEL ENGINES

50Page:


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Shut off solenoidCHAPTER :

CAT DIESEL ENGINES

51Page:


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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


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CHAPTER : Mechanical Unit Injector

CAT DIESEL ENGINES

53Page:


54/73

CHAPTER : MUI cylinder head

CAT DIESEL ENGINES

54Page:


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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


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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


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Page:

BTM

FSOS

RPS

PRIMING

PUMP

ECM

TRANSFER PUMP

INJEC

T

PRIMARY

FILTER

CHECK

VALVE

SECONDARY

FILTER


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CHAPTER : PEEC fuel rack

CAT DIESEL ENGINES

58Page:

SHUTOFF SOLEINOID

B T M

FUEL RACK

SERVO

FUEL ON

PWM

RACK POSITION SENSOR


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59

Page:

ELECTRONICGOVERNOR


RACKCONTROL

TORQUEMAPS

FRCMAPS

RACKBTM

SPEED SENSOR

BOOST PRESS. SENSOR

DESIRED SPEED

ACTUAL SPEED

RATEDRACKLIMIT

FRCRACKLIMIT

ACTUAL RACK POSITION



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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


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CHAPTER : Fuel system (EUI)

CAT DIESEL ENGINES

61Page:

MECHANICALY ACTUATEDELECTRONICAL CONTROLED

ElectronicUnit

Injector

FILTER

E C M

PUMP

FUELTANK

RELIEFVALVE


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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


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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


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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


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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


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CHAPTER : Injection

CAT DIESEL ENGINES

66Page:


67/73

CHAPTER : Poppet valve open

CAT DIESEL ENGINES

67Page:

ARMATURESCREWPOPPETSPRING


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CHAPTER : Drain

CAT DIESEL ENGINES

68Page:


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CHAPTER : Poppet valve closed

CAT DIESEL ENGINES

69Page:

INLET

VALVE SEAT

SOLENOID

POPPET VALVE

ARMATURE

EXHAUST

VALVE SEAT


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CHAPTER : Nozzle group

CAT DIESEL ENGINES

70Page:

FUELATOMIZATION

NOZZLE GROUP

CHECK VALVE

REVERSE FLOWCHECK VALVE


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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


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72

Page:

PRIMING PORT

ORIFICE

RESERVOIR

SWASHPLATE

COMPENSATORVALVE

DRAIN PASSAGE


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CHAPTER : Injection pressure

CAT DIESEL ENGINES

73Page:

IDLE

INJECTIONPRESSURE

MECHANICALLY ACTUATEDFUEL SYSTEM

H E U I

ENGINE SPEED

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Cat Diesel Engines_basic