Basic Knowledge of Enginebased on the textbook Truck Technology: The Facts You Need ()-Engine-for Indonesia KTB Area Coordinators

Self-introductionTAJIMA TAKASHI(Family name First name)MITSUBISHI FUSO TRUCK & BUS CORPORATIONREPRESENTATIVE OFFICE in Singapore

Major in UniversityMetallurgy

Career in Mitsubishi FUSO1987 Join Mitsubishi Motors Chassis design for Special purpose truck

1991 Chassis design for Heavy duty truck

1993 Product development for Domestic market

1996 Product development for Export market

2003 REPRESENTATIVE OFFICE in Singapore

Rep office member

General schedule

Contents

1-1. Indonesia current engine line-up

Engine model coding system [Text p10]

Indonesia current engine line-up [Text p10]

1-2. Classification of engine

Cylinder layout [Text p10]StraightStraight (6 cylinder)V (8 cylinder)Boxer (4 cylinder)Horizontal (6 cylinder)FUSO classColt dieselStraight4 cylinder

Combustion chamber [Text p18]All MFTBC enginefor KTB

Classification of combustion chamber [Text p19]

Classification of Valve mechanism [Text p21]TappetPistonPistonPistonValveValveCam-shaftTappetCamshaftPushrodCylinderheadCylinderheadValveCam-shaftRocker armRocker armOHVOHCDOHC4M50T3 (4valve)6M60T2 (4valve)All MFTBCenginefor KTB

1-3. Performance & Dimension

(Review) Drive line components [Text p8~9]Drive line components specifications determines the vehicle running performance.

(Review) Engine Performance Curves [Text p11]Output CurveBrake Specific Fuel Consumption Curve Fuel consumption of engine unit

Conversion between SI & current units [Text p11]

[PRACTICE] Conversion of output & torque [Text p11] Convert FE349 engine output &torque to SI.Refer spec comparison table Round off the figures after the decimal fractions.

How about DYNA 125LT?

Compression Ratio [Text p15]

Piston displacement [Text p20]

[PRACTICE] Piston displacement [Text p20] Calculate 4D34-2AT5 piston displacement.Bore x Stroke : 104mm x 115mm 1st digit of MFTBC engine model name shows number of cylinder. How about 6D16-3AT2 (118mm x 115mm)?

1-4. Stroke cycle

Theoretical 4 Stroke cycle (Savathe cycle) [Text p14~15]IntakeCompressionCombustionExhaustVolumePressureTDCBDCVolumePressureTDCBDCVolumePressureTDCBDCVolumePressureTDCBDCIgnition

VolumePressureTDCBDCIgnitionActual & theoretical 4 Stroke cycle [Text p14~15]TDCBDCPressureVolumeActual cycleTheoretical cycle

1-5. Comparison between Diesel & Gasoline

[PRACTICE] Whats the difference? [Text p14~15]Whats the difference between diesel & gasoline engine?

Comparison between Gasoline & Diesel [Text p14~15]

Merits & demerits of Diesel engine [Text p14~15]

Structure of Diesel & Gasoline [Text p14~15]Diesel engineGasoline engine

4 Stroke cycle of Diesel & Gasoline [Text p14~15]IntakeCompressionCombustionExhaustDieselengineGasolineengine

Theoretical cycle of Diesel & Gasoline [Text p12]Otto cycleDiesel cycleSavathe cycleVolumeVolumeVolumePressurePressurePressureCurrent Diesel engineGasoline engine

Combustion condition of diesel engine [Text p18]PressureCrank rotation angleIgnitiondelayRapidcombustionImmediatecombustionCombustionInjectionStart ofinjectionEnd ofinjectionIn case ofno ignition(kg/cm2)IgnitionCompressionExpansionTop dead centerIn case ofno ignition

Diesel knock [Text p18]When combustion pressure in a cylinder rises abnormally, it creates a shockwave that severely vibrates engine, resulting in a knocking noise.Measures to prevent diesel knock include improvements in fuel ignitability, shapes of combustion chambers, and injection systems.Possible causesIntake air temperature too lowInjection timing too earlyCompression pressure too lowFuel ignitability low (Use fuel with Cetane number of 50 or more.)

Gasoline knock [Text p18]

Diesel & Gasoline engine inventors [Text p15]Coffee breakRudolf Diesel1858 - 1913Diesel engineinvented in 1897Gottlieb Daimler1834 - 1900Gasoline engineinvented in 1885

2-1. General system of engine

Intake & exhaust system [Text p22]Inlet manifoldExhaustmanifoldExhaustpipeMufflerAir cleanerIntake systemExhaust system

Fuel, cooling, & electrical system [Text p22]

2-2. Main body

Main body structure [Text p20]ConnectingrodCrankshaftFlywheelPistonringsPistonCrankcase(cylinderblock)CylinderCylinder linerCylinder headOil pan

2-3. Lubrication

Engine oil flow in lubrication system [Text p32]Engine oil is necessary for lubricating moving parts& prevents wear or seizing.

Lubrication of piston & cylinder wall [Text p32]Engine oil has lubricating, cooling & cleansing function.

Oil cooler [Text p35]Engine oil must be cooled to keep its lubricating performance.(Engine oil deteriorates by being heated.)

Oil filter [Text p32]Replacement interval

2-4. Cooling system

Cooling system [Text p34]Hot coolant is cooled by radiator before further recirculation

Cooling device [Text p34~35]RadiatorWater pumpThermostatCooling fan

Replacing coolant [Text p34~35]Water to useUse soft water having the properties listed below. Do not use hard water taken from a well or river as it causes scale and rust.To prevent freezing and corrosion in the cooling system, be sure to addFUSO DIESEL LONG LIFE COOLANT(Ethylene glycol base antifreeze SAE J814-C) mixed with water

2-5. Fuel system

Basic fuel supply path [Text p25]Reduction of PMby converting towater & CO2Water separator

Injection pump [Text p25]TimerFuel feed pumpGovernorPump main bodyfor 6 cylinder engine

Structure of fuel injection pump [Text p25]Reduction of PMby converting towater & CO2

Pump element [Text p26]Reduction of PMby converting towater & CO2(In-out port)To pressurize fuelbefore delivery toinjection nozzles

Plunger operation [Text p26]Reduction of PMby converting towater & CO2

Control of fuel delivery quantity [Text p26]Reduction of PMby converting towater & CO2

Effective stroke [Text p26]Reduction of PMby converting towater & CO2Partial load

Governor [Text p28]Reduction of PMby converting towater & CO2Operating principleA device that automatically controls the fuel injection amount to stabilize the engine speed RevolutionCentrifugalforce

Basic structure of governor [Text p28]Reduction of PMby converting towater & CO2Injection decreaseControlrackFloating leverControl leverAcceleratorpedalFlyweightSlidingboltCamshaft

Flyweight working mechanism [Text p28]Reduction of PMby converting towater & CO2expansionSpringFloating leverControlrackIncreaseDecreaseDecreaseIncreaseGovernor springFlyweightFlyweight liftCamshaft

Classification of governor [Text p28]MechanicalgovernorMinimummaximumspeed governor(2-speed governor)All speed governorReduction of PMby converting towater & CO2Low idlecontrolHigh idlecontrolControlled by acceleratorFull acceleratorIdlingControl rack position (injection amount)IncreaseIncreaseControl rack position (injection amount)StartingPump rotation speedHighPump rotation speedHighHigh idle controlLow idle controlFull load controlPartial load controlAll MFTBCenginefor KTB

Structure of all speed governor [Text p28]Full load stopperStop camFloating armControl leverDamper springReturn springCam plateFloating leverFlyweight holderAdjusting lever shaftSupporting leverFlyweightStart springStop leverControl rackAdaptor screw

(Automatic) Timer [Text p28]A device that automatically controls the fuel injection timingDriven by engineDrives camshaftof injection pump

Operation of Automatic timer [Text p28]Reduction of PMby converting towater & CO2Timer advances injection timing as the engine speed increases.

Fuel feed pump [Text p25]Reduction of PMby converting towater & CO2Priming pumpGauze filterInletInletOutletOutlet

Operation of Fuel feed pump [Text p25]Reduction of PMby converting towater & CO2CamPressure chamberPistonSpring PreparationInlet valveOutlet valveHigh fuel pressureSuction chamber Suction / ejection Pausing

Cleaning feed pump gauze filter [Text p25]Remove the eyebolt 1 from the suction port side of the fuel feed pump.Remove the gauze filter 2 from the eyebolt 1.Clean the gauze filter 2.Refit the gauze filter 2 and eyebolt 1 in the opposite order to their removal.Bleed all air out of the fuel system.Start the engine and check for fuel leaks.

Construction of nozzle & nozzle holder [Text p25~26]Reduction of PMby converting towater & CO2

Construction & operation of nozzle [Text p25~26]for Direct injection engineforSwirl chamberengine

Variation of Hole type nozzle [Text p25~26]Reduction of PMby converting towater & CO2All MFTBCenginefor KTB

Water separator [Text p25]Reduction of PMby converting towater & CO2Check the condensate level in the water separator by examining the level of the float . If it has risen to the red line , drain the condensate.To remove, proceed as follows.1) Loosen the plug to discharge the condensate.2) After the float has come down, tighten the plug.3) Wipe & clean the water separator and surrounding parts.4) Check for fuel leaks.Inspection interval : every week

Structure of fuel filter [Text p25]for 4D33Fuel filter headFuel filter elementFrom feed pumpTo injection pump

Replacing fuel filter element [Text p25]1) Remove the element assembly by turning it counterclockwise. lf the assembly is hard to turn, use filter wrench.2) To install a new element, apply a light coat of engine oil to the gasket of the element assembly and screw the assembly into the filter head . After the gasket has come into contact with the filter head, screw in the assembly three quarters to one turn more for a tight fit.3) After opening the air plug , operate the fuel feed pump to feed fuel. Bleed air from the fuel system.4) Wipe clean any fuel spilt on engine parts.5) Start the engine and check for fuel leaks.CAUTIONWipe clean spilt diesel fuel, as it could start a fire.Replacement interval

Air bleeding (running out of gas) [Text p25]Reduction of PMby converting towater & CO2When the vehicle runs out of fuel, air becomes trapped in the fuel system and the engine cannot be started only by refueling. Perform the following procedures to bleed air from the system.1. Loosen the priming pump ofthe fuel injection pump by turning it counterclockwise.2. Loosen air plug of the fuel filter .3. Move the priming pump up and down by hand to feed fuel until no air bubbles come out from the air plug . During the procedure, keep the air plug covered with cloth.Primingpump

Air bleeding (running out of gas) [Text p25]Reduction of PMby converting towater & CO2When the vehicle runs out of fuel, air becomes trapped in the fuel system and the engine cannot be started only by refueling. Perform the following procedures to bleed air from the system.1. Loosen the priming pump ofthe fuel injection pump by turning it counterclockwise.2. Loosen air plug of the fuel filter .3. Move the priming pump up and down by hand to feed fuel until no air bubbles come out from the air plug . During the procedure, keep the air plug covered with cloth.

2-6. Intake & exhaust

Intake air & exhaust gas flow [Text p23 & 30]Forcedinduction

Air cleaner element (Colt Diesel) [Text p23]Reduction of PMby converting towater & CO21 ) Loosen the three hook bolt wing nuts and remove the dust pan .2 ) Remove the wing bolt tightening the element and withdraw the element .3 ) Clean the element by blowing air from the inside or by tapping it to loosen dust. Avoid applying excessive air pressure. Do not strike the element hard or hit it badly against other object.4 ) Remove the cover from the dust pan and clean dust collected in the dust pan. Clean the inside of air cleaner case, too5 ) Install by reversing order of the steps used for removal, making sure that arrow marks on the case and dust pan are aligned.

Air cleaner element (FUSO class) [Text p23]Check the dust indicator once a week.When the red mark appears at the window , the air cleaner element is clogged. Clean the element regardless of the distance driven.After cleaning, press the reset button to reset the red mark.Remove wing nut and draw the element straight out.Clean the element.Reinstall the element by reversing the above procedure.Do not remove the inner element unless it is to be replaced. It must be replaced simultaneously with the outer element. CAUTION!The element will not function properly if not installed securely, causing dust, etc. to be drawn into the engine .Dry paper single elementDry paper dual element

Air cleaner element (FUSO class) [Text p23]Cleaning a paper element1 . Blow clean compressed air evenly up and down from inside the element to remove the dust. Do not strike the element or hit it against another object. Make sure that the pressure of the compressed air used for cleaning does not exceed 7 kgf/cm2 ( 685 kPa )2 If the element is contaminated with oil smoke , soot or oil dust, replace the element regardless of the distance driven.Checks to make after cleaningCheck the filter paper for damage, pinholes and thin portions. If a defective portion or broken packing is evident, replace the element with a new one.

Turbocharger [Text p23]Reduction of PMby converting towater & CO2

Intercooler [Text p24]Reduction of PMby converting towater & CO2Used togetherHot airCooled airIntercooler increases the airs density for effective forced induction.

Exhaust brake [Text p31]Reduction of PMby converting towater & CO2A device that uses exhaust gases to boost the engine brake effectAll MFTBC enginefor KTB

Service brake ineffectiveness [Text p31]Reduction of PMby converting towater & CO2On long downhill roads, use both the engine braking &exhaust brake to prevent service brake ineffectivenesssuch as,Brake fade : Decrease of brake lining friction by overheatingVapor locking : Boiling of the brake fluid in the brake fluid hydraulic circuit.

2-7. Electrical system

Electricity supply & starting system [Text p36]Alternator charges batteries & generates electricity as engine runs.

3-1. Fuel & Engine oil

Comparison of fuel [Text p16]Flash point: the lowest temperature at which fuel catches fire when brought near source (fire, static electricity, and so on) Ignition point: the lowest temperature at which fuel spontaneously ignites as a result of its own heat

Classification of fuel [Text p16]Petroleum distillation curveDistilled volume (%)Distillation temperature ()Heavy oil AviationturbinefuelDiesel fuel KeroseneLP gas(Liquefied petroleum gas)GasolinePressurizedpetroleumVaporHeavy oil Tray NaphthaNaphthaKeroseneDiesel fuel GasolineCooling towerOil vaporLiquidsurfaceLiquefiedLPG Refinery gas

Indonesian diesel fuel [Text p16]

Cetane number (Diesel fuel) [Text p16]The higher the cetane number, the less likely the diesel fuel is to knock. The ignition quality (ignition lag) is expressed by the cetane number. The normal cetane (C6H34) which has the shortest ignition lag is assigned a cetane number of 100, whereas the alpha-methylnapthalene (C11H10) with the longest ignition lag, is assigened a cetane number of 0.The cetane number is defined as the percentage by volume of the normal cetane in a blend with alpha-methylnapthalene. The cetane number of a diesel fuel is determined by comparing its ignition quality, as measured by using a CFR (variable compression ratio) test engine, to the normal cetane and alpha-methylnapthalene blend with the same ignition quality as the test fuel; that is, the percentage of the normal cetane contained in the blend becomes the cetane number of the test fuel. The cetane numbers of diesel fuels currently available on the market range from 45 to 50.

Octane number (Gasoline) [Text p16]A number that indicates the antiknock quality of a gasoline. To determine the octane number of a gasoline the test results of that gasoline are compared with the quality of a standard fuel which is a blend of isooctane (assigned an octane number of 100) and normal heptane (assigned an octane number of 0).

Engine oil (Viscosity categories) [Text p33]

Engine oil (Performance classifications) [Text p33]

3-2. Indonesia EURO2 engine line-up

Indonesia EURO2 engine line-up [tentative]

3-3. Exhaust emission reduction

Exhaust gas generation mechanism [Text p17]Blow-by gas The compressed air-fuel mixture or the burned gases leaking from the combustion chamber past the piston rings and into the crankcase. Most of it is the unburned fuel (HC) with the remainder burned gases.CO: C+022CO (imperfect combustion) Diesel engine exhausts few CO.HC: unburned fuelNOx: N2+O2 2NO 2NO+O2 2NO2 (generated @ high temperature) PM: Particulate matter (unburned fuel & oil + soot mixture)Black smoke: Separated soot (originally carbon in fuel)

Toxic substances in exhaust gas [Text p17]CO (carbon monoxide) : Toxicity for the human body is extremely high. HC (hydrocarbon) : * Ultraviolet rays in sunlight changes HC to photochemical oxidant which causes photochemical smog. * Stimulation to mucous membranes such as respiratory organs * Bad influence to farm products. NOx (nitrogen oxides) : *A small amount of nitrogen oxides helps growth of a plant. *If its density is high, it causes air pollution, photochemical smog, acid rain. SPM (suspended particulate matter) : *Particulate matters (PM) equal to or less than a diameter of 10m that are harmful to the human body. *SPM which reached an alveolus cannot drained outside the body. *It is thought to be a cause of lung cancer. CO2 (Carbon dioxide) : *Carbon dioxide of the low density is essential to breathing and is not harmful. *It is thought to be a cause of global warming. SOx (Sulfur oxides, mainly sulfur dioxide SO2 and sulfur trioxide SO3) : *Generated by the combustion of insufficiently refined fuel includes sulfur. *One of the causes of air pollution and acid rain

(Review) Reduction of toxic substance [Text p17]Combustion temperature excessively lowCombustion temperature excessively high

(Review) Exhaust Emission Regulations [Text p17]70.15EURO2(nitrogen oxides)(particulatematter)Indonesia EURO2 : Jan 2007 ~

EURO2 testing method (GVW over 3.5ton) [Text p17]Test cycle : Steady 13 modeTime [min]RevolutionLoadHot startTesting time : 78min

Overview of Full Dilution Tunnel System [Text p17]

(Review) Improvement of fuel injection pump [Text p17]

(Review) Turbocharger [Text p17]

(Review) Intercooler [Text p17]

High pressure injection cuts PM generation [Text p29]Coffee breakReduction of PMby converting towater & CO2

Environmental measures in future (Image) [Text p29]Coffee breakReduction of PMby converting towater & CO2ImportanceYearAtmosphere environmentmeasuresAnti-global warmingmeasuresPetroleum independencemeasures

3-4. Introduction of low emission vehicle

CANTER & GUTS CNG [Text p37]CNG : Compressed Natural GasThree way catalystcombined mufflerCNG tank Fuel filler After muffler

CANTER & GUTS LPG [Text p37]LPG : Liquefied Petroleum GasLPG tank Fuel filler After muffler (only for long body) Three way catalystcombined muffler

Starting & low speed drivingAERO NONSTEP HEV [Text p37] Electronic controller Inverter Diesel engine Generator Propulsion motor Accessory drive motor Lithium-Ion battery Fuel tankMotorBatteryEngineInverterAcceleration & hill-climbingBraking

Terima Kasih!