engine systems diesel engine analyst - part 1

DIESEL ENGINE ANALYST

Engine Systems

Introductions:

Name: Address: College: ITM, Perú Dealer Name: Ferreyros S.A.

Agenda Engine Families Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics

Parts Differentiation REMAN Resources

Engine Families

This represents only a fraction of the engine offerings Caterpillar produces

3116/3126/C-7(86 - 313 kW)

3200 Family(93 - 336kW)

3300 Family(63 - 300 kW)

C-9/C-11/C-13(227 - 492 kW)

C-15/C18/3400 (186 - 1044 kW)

3500 Family(507 - 2500 kW)

3600 Family(1350 - 7200 kW)

M20(1020 -1710 kW)

M25(1800 -2700 kW)

M32(2880 -8000 kW)

M43 (5400 -16200 kW)

800 Series(39 - 60 kW)

1100 Series(49 - 186 kW)

400 Series(3.7 - 45 kW)

4000 Series(322 - 1886 kW)

3000 Series

Common Engine Terms

Bore Stroke Compression Ratio Displacement Horsepower

Bore Size

The diameter of the cylinder

Measured in inches or millimeters

Stroke

How far the piston moves from TDC to BDC

Equal to twice the crank radius

Compression Ratio

Ratio between the cylinder volume with the piston at BDC and the volume with the piston at TDC

Compression ratio of our engines are approximately a 16:1 (non-ACERT) and 18:1 (ACERT)

Displacement

Engine size is expressed in liters or cubic inches

Displacement = X Stroke X No. of Cyls. (3.14 X B 2 )

4

Horsepower is the rate of doing work (how quickly a force is applied through a distance)

Horsepower can be expressed in pound feet per second

1 horsepower = 550 lb/ft per second

= 33,000 lb/ft per minute

Horsepower

Engine Model Numbers

3208 Engine: 3200 = Engine Family & Relative Size

(3000, 3200, 3300, 3400, 3500, 3600)

08 = number of Cylinders

Depending on engine family, could

be 04, 06, 08, 12, 16, 18, or 24

3116 Engine 3100 = Engine Family

11 = 1.1 liters per cylinder, so:

3126 has 1.2 liters per cylinder

3176 has 1.7 liters per cylinder

6 = number of cylinders (4 or 6)

Engine Model Numbers

C-10, 10 liter truck engine 3176C is used in all other applications

C-12, 12 liter truck engine 3196C is used in all other applications

C7 replaced the 3126 engine C-9 replaced the 3306 engine

On-Highway & D6

Engine Model Numbers

3406 Engine

3406E was a 14.6 liter engine until 1998 In 1998, 3406E was 14.6 or 15.8 liter for truck 3456 was the 15.8 liter in any non-truck application In 2000, 14.6 liter and 15.8 liter became C-15 and

C-16 for truck, industrial applications In 2003, 15.2 liter truck is ACERT C15

Engine Model Numbers

3000/3100 Series Features

Dry Sleeve/Parent Bore Parent Bore – 3116/26, C7,3208 Dry Sleeve - 3054

One piece block assembly

Light weight with high horsepower to weight ratios

3126B

3054

3000 Series - Service Strategy Current Serviceability

Components only - 3003, 3013, 3024, 3034 Piece Parts - 3046, 3054, 3056, 3066 Reman as volume/need dictates

Rebuild Strategy 3003 - 3034, expected engine life equals machine life 3046 - 3066, limited rebuild opportunity

3013 3024 3034 3003

C6.6 Series Features using ACERT™ Technology

C6.6 Replaces the 3056E

• 1.1 Liter per Cylinder, Inline 6

• 4 valves per cylinder

• Cross Flow heads

• Fully Electronically Controlled

• Common Rail Fuel system

• Sculpted Block design reduced noise C6.6

Cross Flow Cylinder Heads

Cross flow design and refined port geometry

Improved breathing

Reduced pumping loss

Better combustion

C7 Series Features using ACERT™ Technology

C7

C7 Replaces the 3116, 3126

• ADEM A4 Electronic Control Module

• Cylinder block – increased tensile strength

• HEUI fuel system

• Cross Flow heads

• Turbocharged and Air to Air aftercooling

3100

3100 & C7 Series - Service Strategy

Current Serviceability Piece Parts For All

Rebuild Strategy Cost effective rebuild for all

models Reman components and

limited short blocks, bare blocks, and piston packs available

3300/3400 Series Features

One piece block One piece cylinder head Replaceable valve guides and seats Caterpillar fuel system Replaceable wet cylinder liners Roller cam followers and steel camshaft Totally hardened forged steel crankshaft

3400 HEUI

C9 Series Features using ACERT™ Technology

C9 Replaces the 3300

• ADEM A4 Electronic Control Module

• 8.8 liter (537 cu in)

• HEUI fuel system

• Cross Flow heads ( 4 valves per cylinder)

• Turbocharged and Air to Air aftercooling

• Improved block and head material strength

• Mid-supported liner

• Integral oil cooler • Reduced weight, leaks and engine width

C9

C11/C13 Series Features using ACERT™ Technology

C11 Replaces the 3176, C-10

C13 Replaces the 3196, C-12

• ADEM A4 Electronic Control Module

• MEUI fuel system

• Cross Flow heads

• Turbocharged and Air to Air aftercooling C13

C11

C15/C18 Series Features using ACERT™ Technology

C15 Replaces the 3406E, C-15

• ADEM A4 Electronic Control Module

•Variable injection timing•Controls quantity of fuel•Optimizes fuel pressure •Transient control for both speeds and loads

• MEUI fuel system

• Cross Flow heads

• Turbocharged and Air to Air aftercooling

C15

C27 replaces 3412 Two single overhead cams Gear-train for cams moved to back

Reduces noise & vibration Tight system tolerances - pistons & liners

More complete fuel combustion Reduced blow-by Fewer emissions

New block eliminates bends/turnsto improve airflow

Proven MEUI fuel system ADEM™A4 Controller Engine oil & filter changes

increased to 500 hours undermost operating conditions

C27 Series Features using ACERT™ Technology

Used on D10T, 773F, 775F

C32 Series Features using ACERT™ Technology

Used on 777F & D11T (fall 07)

C32 replaces 3508B Newly designed block adds

structural strength Cross flow cylinder head delivers

improved air flow Increased compression ratio

of 16.5:1 Proven MEUI fuel system ADEM™A4 Controller Engine oil & filter changes

increased to 500 hours undermost operating conditions

3300/3400 C7- C32 Series - Service Strategy

Current Serviceability Piece parts and sub-

components for all models.

Rebuild Strategy Cost effective rebuild for all

models Reman components, short

blocks, long blocks and engines available 3406

3500 Series Features One piece high strength cast engine block

Individual cylinder heads

Four valves per cylinder.

Self aligning roller cam followers.

Oil cooled pistons

Unit injectors at 20,000 psi

Caterpillar fuel system 3500B

3500 Series - Service Strategy

Current Serviceability Piece parts for all

Rebuild Strategy Cost effective rebuild for all models Reman components, short blocks,

long blocks and engines available

3500 Machine

Engine/Machine Usage Chart Series TTT TTL OHT HEX WL3000 D3C III - D5C III -- 301.5 - 320B 906 - 939CC6.6 D5N 953, 963 924 - 9383100 D5M - D6M -- 322B - 345B 924F - 962GC7 D6N 322, 325 950, 962

3300 D6R - D7R -- 330B - 350 L 966F - 980FC9 D6R 973 330DC11 725, 730 966C13 345 9723400 D8R - D10R 769 - 775 375 - 5080 980G - 990 IIC15 D8T 735,740 980HC18 D9T 771 385C 988HC27 D10T3500 D11R 777 - 797 5130 - 5230 992G - 994D

Engine Build Locations Build Location

Peterborough, England 3011 3013 3024 3034 3054 3056 C1.5 C2.2 C6.6

Sagami, Japan 3044 3046 3064 3066 3304 3306

Gosselies, Belgium 3116 3126 C7 C9

Greenville, South Carolina 3126 C7 C9

Griffen, Georgia 3408 3412 C27 C30 C32

Mossville, Illinois 3406 3456 C-10 C11 C-12 C13 C15 C-16 C18

Lafayette, Indiana 3508 3512 3516 3520 3524 C175-12 C175-16 C175-20 3606 3608 3612 3616

Keil, Germany CM20 CM25 CM32 CM43 GCM34 M20 M25 M32 M43

Engine Models

All Gas engines Produced in Lafayette Indiana

Electric Power Modules Packaged @ FG Wilson or Griffen Georgia

Agenda Engine Families Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics

Parts Differentiation REMAN Resources

Engine Wear

Definition of Wear Contact Pressure 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

Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

The Combustion Process – 4 Stroke Cycle

Compression Intake

The Combustion Process – 4 Stroke Cycle

Exhaust Power

The Combustion Process – 4 Stroke Cycle

Reciprocation & Rotation

Oil Consumption and Blow-by

Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

Internal Components

Valve Train

1. Cam lobe

2. Lifter

3. Pushrods

4. Rocker arms

5. Bridge (intake)

6. Valve spring

7. Exhaust valve

8. Intake valves

1

8

7

6

54

3

2

3126B/C7

Cylinder liner O-ring seals Piston Piston rings Piston pin and

retainer

Pistons, Rings, & Liners

Piston is one piece design

C15 Piston Assembly

Connecting Rod

A connecting rod connects the piston to the crankshaft

A cylinder head is installed on top of the block

The camshaft turns at ½ the speed of the crankshaft to control intake & exhaust operation

Cylinder Head & Cam Shaft

C15

Cat Compression Brake

Intake ValveActuation is part of the Caterpillar compression brake.

Crankshaft

Front Rear

Counterweights

Main Bearing Journals

Rod Bearing Journals

Web

There are 2 rotations of the crankshaft for each 4 stroke cycle!

The cylinder block is the central component of any engine

It houses the components that make up the “Serious Nucleus” of the engine

Cylinder Block

Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

An exhaust driven air compressor Impeller on the left Turbine on the right Connecting shaft, free floating bearings, oil lubricated center housing

Causes of Premature Wear or Failure Poor oil quality Dirt ingestion Hot engine shut down

Turbocharger

• The wastegate is opened by the high pressure boost in the compressor side of the turbo.

• Some of the exhaust gas then bypasses the turbine and escapes or ‘wastes’ to the exhaust stack.

Wastegate Actuator

Wastegate

Large turboNo wastegate

Small turbo, with wastegate

Engine Load

Bo

os

t

Small turbo, No wastegate

Waste Gate Turbocharger

Spins up quicker for good engine response Regulates turbo speed & prevents over-speeding

Heat exchanger for inlet air

Series of metal tubes through which hot inlet air flows

Heat from the air flowing from the tubes is absorbed through the tube walls and carried away

2 types Air to air (ATAAC) Jacket water (JWAC)

Aftercooling

Most common cause -- failure of the turbocharger compressor wheel

Damages aftercooler tubes Coolant leakage into inlet air stream

Poor coolant maintenance may cause pitting/corrosion of the aftercooler tubes

Results in water to air leakage Hydraulic lock on the engine

Causes of Premature Wearout & Failure of Aftercoolers

Flow of the coolant begins at the water pump

Pump impeller creates the flow

Water pumps are gear or belt driven

Water pump seals

Separates engine oil from coolant

Water Pump

Engine coolant flows from the water pump directly into the oil cooler

Oil carries heat away from critical engine parts

Heat is transferred from the oil to the engine coolant

Oil Cooler

Coolant flows through copper tubes in the oil cooler housing

Oil flows around the outside of the tubes

Scale build-up caused by improper cooling system maintenance can be cleaned out of tubes

Oil Cooler

Engine components

Air compressor

Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

Importance of Cooling System

40-60% Of All Engine Downtime Is Associated With 40-60% Of All Engine Downtime Is Associated With Cooling System ProblemsCooling System Problems

Important Customer Reminders:

Use proper start up procedures

Clean debris from the radiator and fan

Check radiator cap seal

Inspect the water pump for leaks

Select the right coolant

Function of Cooling System Maintain proper engine temperature

for optimum performance Dissipates excess heat from other

machine systems: Engine Transmission Hydraulic

Cools compressed inlet air to optimize combustion

Cooling System Components

1 Water Pump2 Oil Cooler3 Passages through

block and head4 Temp. Regulator &

Regulator Housing5 Radiator6 Pressure Cap7 Hoses & Pipes

Causes of Cooling System Wear & Failure Single most common problem – poor coolant quality

Due to… Not maintaining adequate levels of coolant additives Using coolant that does not meet Cat’s specifications Not keeping the cooling system topped off Using coolant past its useful life

Other problems include: Coolant to air leaks in the aftercooler

Causes hydraulic lock Radiator or hose failures

From reusing old radiators and hosing Failure to service the coolant relief valve

… most cooling system problems can be avoided with proper maintenance practices!

Cooling Systems

Coolant flows around cylinder liners

Absorbs heat from the combustion chamber

Prevents breakdown of oil film between pistons and liners

Cooling Systems

Coolant flows through passages in the cylinder block into the cylinder head

Water seals between the head and block prevent coolant leaks

Some engines have water ferrules to direct coolant to critical areas

Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

Importance Lubrication System

70-80% crank failures are due to oil contamination. 70-80% crank failures are due to oil contamination.

Function of Lubrication System

Cleans Parts Cylinder Walls

Cools Seals & Lubricates

Support Separate

Lubrication System Components

1 Oil Pump2 Relief Valve3 Oil Cooler4 Oil Filter5 Bypass Valves6 Oil Level Gauge

(Dipstick)7 Oil Pressure Gauge8 Oil Pan

Engine Lube System

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

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)

Methods to control soot levels in engine oil:

Soot particles agglomerating together

Barrier Filter

Centrifugal Filter