yesa 1102t (gasoline) 영문 (2 1) 워터마크

YES01, YOUNG-IL EDUCATION SYSTEM

Model: YESA-1102T

Version 2.1

#604, Samhwan Digital Venture Tower, 280-13, Seongsu-dong 2 ga, Seongdong-gu, Seoul 133-832, Korea TEL. 82-2-2024-0077 / FAX. 82-2-2024-0070 / E-mail : [email protected] / Web : http://www.yes01.co.kr

Engine and Transmission Structure Educational Equipment

(Gasoline)

Warning

Copyright of this educational material is owned by YES01,

YOUNG-IL EDUCATION SYSTEM.

Unauthorized reproduction or copying may cause civil or

criminal liability.

The Chief Director of YES01, YOUNG-IL EDUCATION

SYSTEM Co., Ltd.

Engine and Transmission Structure Educational Equipment (Gasoline)

Contents

Contents

Cautions 1 Equipment Overview 5 Exercise 11 1. Objectives 11 2. Operation Requirements 11 3. Theory 11 4. Operation Sequence 18


Contents


Cautions

1

1-1 Installation of education system

1. Please install the product at stable place.

2. Please avoid dust, humidity and sunray.

3. Please install at stable place for not missing the product.

4. Please be cautious for the number of person, shock, fracture and safety while

moving the product.

5. Please check caster before moving the product.

6. Please set caster to immovable position after installing the product.

7. Please be cautious for workers’ safety while moving the product with forklift or

other machines.

8. Please check tightening of bolts and nuts after installation.


Cautions

2

1-2 General cautions for safe use of educational system

1. Please make it sure to confirm cautions for installation and maintenance of

the product.

2. Please make it sure to notify the danger of the product to students before use.

3. Please dress up and keep the environment of the product clean and neat.

4. Please use proper tools and instruments for the product.

5. Please make it sure not to drop tools and parts.

6. Please check the operation of the product before starting education.

7. Please do not use your hand to pinpoint operating parts for safety.

8. Please make it sure to notify students to follow instructor’s order for educating

operating type educational system.

9. Please do not remove and rebuild cover and structure installed for safety.

10. Please follow safety rules of electricity for electric leakage, open circuit, and

over load.

11. Please do not fuel and do not wear glove for safety during operation.

12. Please keep away from the cross-sectioned part and operating part.

13. Please be cautious for rotating part and lever.


Cautions

3

14. In case of unusual sound, vibration, and overload are discovered, please stop

the operation and inspect the product.

15. Power has to be shut down for inspection and maintenance of the product.

16. Please follow usual safely rules of industrial machinery for unspecified items.

17. Manufacturer is not responsible for any accident incurred by not following the

above mentioned items.


Cautions

4

1-3 Cautions for maintenance of educational system

1. Please make it sure to explain theory, operating procedures, and safety to

students before practical training.

2. Please make it sure to keep educational system and its environment clean

and neat.

3. Please make it sure to check lubrication of major operating part before use.

4. Please avoid severe use and shock because product is manufactured for

education purpose.

5. In case unusual symptom and trouble of product are appeared during

operation, please inspect and fix it with given procedures.

6. Please do not use any parts for replacement except genuine parts for the

product.

7. Please do not disassemble, fix, and rebuild the product except specified use.

8. Please keep the product clean before and after using it and cover it with a

cover.

9. Please check regularly the operation, electric leak age, and safety of product.

10. Please disconnect and store the battery of battery-equipped system unless it

is regularly used. In addition, recharge the battery regularly.

11. Please store the product with a cover in dust free and humid free place for

long-term storage.


Equipment Overview

5

Equipment Overview

Figure 1 The Engine and Transmission Structure Educational Equipment (Gasoline)

(YESA-1102T)

Engine Manufacturer Hyundai Motor Company Vehicle Type SONATA Engine Type DOHC Gasoline

Engine Capacity 2000cc Transmission 5-Speed Manual Transmission

Table 1 Engine Specification


Equipment Overview

6

Figure 2 Front View

No. Name No. Name 1 Piston 7 Exhaust Manifold 2 Thermostat 8 Alternator 3 Camshaft 9 Oil Filter 4 Cylinder Head Cover 10 Clutch Pedal 5 Ignition Coil 11 Crankshaft 6 Camshaft Sprocket 12 Shift Lever

Table 2 Name of parts


Equipment Overview

7

Figure 3 Left View

No. Name No. Name 1 Water Pump Pulley 6 Intake Manifold 2 Power Steering Pump Pulley 7 Air-Conditioner Compressor Pulley 3 Camshaft Sprocket 8 Crankshaft Pulley 4 Timing Belt 9 Alternator Pulley 5 Throttle Position Sensor



Equipment Overview

8

Figure 4 Right View

No. Name No. Name 1 Transmission Housing 4 Exhaust Manifold 2 Intake Manifold 5 Ring Gear 3 Throttle Body (Valve)



Equipment Overview

9

Figure 5 Rear View

No. Name No. Name 1 Air-Conditioner Compressor 4 Starting Motor 2 Intake Manifold 5 Speed Gear 3 Throttle Body



Equipment Overview

10


Exercise

11

Objective a. Basic structure and principle of a gasoline engine may be understood

through a sectioned equipment. b. Names of main components of a gasoline engine may be known through a

sectioned equipment. c. Basic structure and principle of a transmission may be understood through a

sectioned equipment. d. Names of main components of a transmission may be known through a

sectioned equipment e. Correct methods for operating the equipment can be understood and

practiced.

Operation Requirements a. This equipment requires 220V of power supply. b. This equipment requires a flat floor so that the equipment may be fixed. c. This equipment requires to be operated after fully understanding this manual.

Theory

1. Gasoline Engine Construction Overview 1.1 Block All automotive and truck engines are constructed using a solid frame, called a block. A block is constructed of cast iron or aluminum and provides the foundation for most of the engine components and systems. The block is cast and then machined to very close tolerances to allow other parts to be installed. 1.2 Rotating Assembly Pistons are installed in the block and move up and down during engine operation. Pistons are connected to connecting rods, which connect the pistons to the crankshaft. The crankshaft converts the up-and-down motion of the piston to rotary motion, which is then transmitted to the drive wheels and propels the vehicle. SEE FIGURE 1-1.

1.3 Cylinder Heads All engines use a cylinder head to seal the top of the cylinders, which are in the engine block. The cylinder head also contains both intake valves that allow air and fuel into the cylinder and exhaust valves, which allow the hot gases left over to escape from the engine. Cylinder heads are constructed of cast iron or aluminum and are then machined for the valves and other valve-related components. SEE FIGURE 1-2.


Exercise

12

FIGURE 1-1 The rotating assembly for a V-8 engine that has eight pistons and

connecting rods and one crankshaft.

FIGURE 1-2 A cylinder head with four valves per cylinder, two intake valves

(larger) and two exhaust valves (smaller). 2. Engine Parts and Systems 2.1 Intake and Exhaust Manifolds Air and fuel enter the engine through an intake manifold and exit the engine through the exhaust manifold. Intake manifolds operate cooler than exhaust manifolds and are therefore constructed of nylon-reinforced plastic or aluminum. Exhaust manifolds must be able to withstand hot exhaust gases, so most are constructed from cast iron or steel tubing.

2.2 Cooling System All engines must have a cooling system to control engine temperatures. While some older engines were air cooled, all current production passenger vehicle engines are cooled by circulating antifreeze coolant through passages in the block and cylinder head. The coolant picks up the heat from the engine and after the thermostat opens, the water pump circulates the coolant through the radiator where the excess heat is released to the outside air, cooling the coolant. The coolant is continuously circulated through the cooling system and the temperature is controlled by the thermostat. SEE FIGURE 1-3.


Exercise

13

FIGURE 1-3 The coolant temperature is controlled by the thermostat, which

opens and allows coolant to flow to the radiator when the temperature reaches the rating temperature of the thermostat.

2.3 Lubrication System All engines contain moving and sliding parts that must be kept lubricated to reduce wear and friction. The oil pan, bolted to the bottom of the engine block, holds 4 to 7 quarts (4 to 7 liters) of oil. An oil pump, which is driven by the engine, forces the oil through the oil filter and then into passages in the crankshaft and block. These passages are called oil galleries. The oil is also forced up to the valves and then falls down through openings in the cylinder head and block, then back into the oil pan. SEE FIGURE 1-4.

FIGURE 1-4 A typical lubrication system, showing the oil pan, oil pump, oil filter,

and oil passages. 2.4 Fuel System and Ignition System All engines require both a fuel system to supply fuel to the cylinders and an ignition


Exercise

14

system to ignite the air-fuel mixture in the cylinders. The fuel system includes the following components.

∙ Fuel tank, where fuel is stored and where most fuel pumps are located

∙ Fuel filter and lines, which transfer the fuel for the fuel tank to the engine

∙ Fuel injectors, which spray fuel into the intake manifold or directly into the cylinder, depending on the type of system used

The ignition system is designed to take 12 volts from the battery and convert it to 5,000 to 40,000 volts needed to jump the gap of a spark plug. Spark plugs are threaded into the cylinder head of each cylinder, and when the spark occurs, it ignites the air-fuel mixture in the cylinder creating pressure and forcing the piston down in the cylinder. The following components are part of the ignition system.

∙ Spark plug - Provide an air gap inside the cylinder where a spark occurs to start combustion

∙ Sensor - Includes crankshaft position (CKP) and camshaft position (CMP) sensors, used by the power-train control module (PCM) to trigger the ignition coil(s) and the fuel injectors

∙ Ignition coil - Increase battery voltage to 5,000 to 40,000 volts

∙ Ignition control module (ICM) - Controls when the spark plug fires

∙ Associated wiring - Electrically connects the battery, ICM, coil, and spark plugs

3. Four- Stroke Cycle Operation 3.1 Principles The first four-stroke cycle engine was developed by a German engineer, Nickolaus Otto, in 1876. Most automotive engines use the four-stroke cycle of events. The process begins by the starter motor rotating the engine until combustion takes place. The four-stroke cycle is repeated for each cylinder of the engine. SEE FIGURE 1-5. A piston that moves up and down, or reciprocates, in a cylinder can be seen in FIGURE 1-5. The piston is attached to a crankshaft with a connecting rod. This arrangement allows the piston to reciprocate (move up and down) in the cylinder as the crankshaft rotates. SEE FIGURE 1-6.

3.2 Operation Engine cycles are identified by the number of piston strokes required to complete the


Exercise

15

cycle. A piston stroke is a one-way piston movement either from top to bottom or bottom to top of the cylinder. During one stroke, the crankshaft rotates 180 degrees (1/2 revolution). A cycle is a complete series of events that continually repeats. Most automobile engines use a four-stroke cycle. ∙ Intake stroke - The intake valve is open and the piston inside the cylinder travels downward, drawing a mixture of air and fuel into the cylinder. The crankshaft rotates 180 degrees from top dead center (TDC) to bottom dead center (BDC) and the camshaft rotates 90 degrees.

∙ Compression stroke - As the engine continues to rotate, the intake valve closes and the piston moves upward in the cylinder, compressing the air-fuel mixture. The crankshaft rotates 180 degrees from bottom dead center (BOG) to top dead center (TOC) and the camshaft rotates 90 degrees.

∙ Power stroke - When the piston gets near the top of the cylinder, the spark at the spark plug ignites the air-fuel mixture, which forces the piston downward. The crankshaft rotates 180 degrees from top dead center (TOG) to bottom dead center (BOG) and the camshaft rotates 90 degrees.

∙ Exhaust stroke - The engine continues to rotate, and the piston again moves upward in the cylinder. The exhaust valve opens, and the piston forces the residual burned gases out of the exhaust valve and into the exhaust manifold and exhaust system. The crankshaft rotates 180 degrees from bottom dead center (BOC) to top dead center (TOC) and the camshaft rotates 90 degrees.

This sequence repeats as the engine rotates. To stop the engine, the electricity to the ignition system is shut off by the ignition switch, which stops the spark to the spark plugs.

The combustion pressure developed in the combustion chamber at the correct time will push the piston downward to rotate the crankshaft.


Exercise

16

2. Manual Transmission 2.1 Basic Transmission Parts

FIGURE 6-1 The basic parts of a manual transmission

The basic parts of a manual transmission include: ∙ Transmission input shaft-a shaft, operated by the clutch that turns the gears inside the transmission. ∙ Transmission gears-provide a means of changing output torque and speed. ∙ Synchronizers-devices for meshing (locking) gears into engagement. ∙ Shift forks-pronged units for moving gears or synchronizers on their shafts for gear engagement. ∙ Shift linkage-arms or rods that connect the shift lever to the shift forks. ∙ Gear shift lever-lever allowing the driver to change transmission gears. ∙ Output shaft-shaft that transfers rotating power out of the transmission to drive shaft. ∙ Transmission case housing that encloses transmission shafts, gears and lubricating oil. 2.2 Purpose of a Manual Transmission A manual transmission is designed to change the vehicle's drive wheel speed and torque in relation to engine speed and torque. Without a transmission, the engine would not develop enough power to accelerate the vehicle from a standstill. The engine would stall as soon as the clutch was engaged. With a transmission in low (first) gear, the engine crankshaft must turn several times


Exercise

17

to make the drive shaft and wheels turn once. This increases the torque going to the wheels, but reduces vehicle speed. Then, as the transmission is shifted through the gears and into high, the engine and drive shaft begin to turn at approximately the same speed. Wheel and vehicle speed increases, while engine speed drops. A manual transmission in proper operating condition should: ∙ Be able to increase torque going to the drive wheels for quick acceleration. ∙ Supply different gear ratios to match different engine load conditions. ∙ Have a reverse gear for moving backwards. ∙ Provide the driver with an easy means of shifting transmission gears. ∙ Operate quietly, with minimum power loss.


Exercise

18

Operation Sequence 1. Connect 220VAC power cable at the left side of the equipment. 2. Operate the equipment in the following method.

① Turn POWER SW ON in the left lower side of the control panel.

② Check if POWER LAMP in the left upper side of the control panel is lighted up.

③ Set STOP/RUN Switch of speed control unit to RUN.

④ Rotate dial switch of speed control unit to adjust rotation speed of the equipment.

3. When the equipment operates, a LED indicating each stroke state will be lighted up, and the movement of pistons and valves of each stroke may be checked with your eyes through the colors of LED lamps.

Color Stroke

● Blue Intake

● Yellow Compression

● Red Explosion

● Green Exhaust


Exercise

19

4. By executing gear changing while pressing clutch pedal pressed with might and main, the condition of gear engagement may be checked with your eyes.

Caution ∙ At gear-changing, pay close attention so that a part of your body may not be inserted into rotational portion. Reference ∙ Performing gear-changing without pressing the clutch pedal, excessive load may be applied to the equipment, so perform gear-changing with the clutch pedal pressed to the maximum.

asd


Exercise

20

Engine and Transmission

Structure Educational Equipment (Gasoline)

Model: YESA-1102T Published by: YES01 U Learning Engineering Institute YES01, YOUNG-IL EDUCATION SYSTEM Co., Ltd Main Office and Factory, Technical Institute

#604, Samhwan Digital Venture Tower,

280-13, Seongsu-dong 2 ga,

Seongdong-gu, Seoul 133-832, Korea

TEL: 82-2-2024-0077

FAX: 82-2-2024-0070

URL: http://www.yes01.co.kr

Contact: If you have any question about equipments or materials,

please contact us:

Material Development: YES01 U Learning Engineering Institute

E-mail: [email protected]

If Part or all of this material is copied or reproduced

Without prior consent of YOUNG-IL EDUCATION SYSTEM

Co., Ltd such act will be in conflict with The Copyright Law.

yesa 1102t (gasoline) 영문 (2 1) 워터마크

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